Pedal assembly durability test equipment

Abstract

The invention discloses durability testing equipment for a pedal assembly, and belongs to the technical field of automobile part testing. The equipment comprises a test bench, a treading execution mechanism, a sensing detection system and an integrated closed-loop control system. The control system is configured to execute a multi-stage test sequence at least comprising a loading stage and a pressure maintaining stage, and perform real-time pressure closed-loop control on the execution mechanism based on feedback of the pressure sensor in the loading stage or the pressure maintaining stage. A built-in fault diagnosis module of the system monitors pressure and displacement data in real time, and when a pressure deviation target value exceeds a set threshold value or a displacement change rate exceeds a limit, test is immediately interrupted and an alarm is given. According to the invention, high-fidelity and high-consistency load simulation is realized through closed-loop control, the safety and reliability of the test process are guaranteed in combination with intelligent diagnosis, and the problems of simulation distortion and poor safety in the traditional open-loop test are solved.

Description

Technical Field

[0001] This invention belongs to the field of automotive component testing technology, specifically relating to a pedal assembly durability testing device. Background Technology

[0002] With the development of the automotive industry, the vehicle pedal assembly, as a key human-machine interface and safety component, directly affects the driving experience and road safety in terms of durability and reliability. Therefore, conducting durability tests on the pedal assembly under simulated real-world usage conditions before installation is a necessary step to ensure product quality.

[0003] Currently, common pedal durability testing methods in the industry mainly rely on semi-automatic or open-loop control testing equipment. These devices typically use cylinders or motors to perform periodic pedaling actions, with the start and stop of the test controlled manually or by a simple timer. However, this approach has significant shortcomings: First, the applied force during the test is often preset by adjusting air pressure or current, constituting open-loop control. This makes it impossible to dynamically adjust based on real-time pedal deformation or resistance changes, leading to deviations between the simulated pedaling force curve and actual operating conditions, making it difficult to guarantee the accuracy and consistency of the test. Second, existing equipment generally lacks intelligent monitoring of the health status of the testing process. When force sensor drift, mechanical loosening, or abnormal specimen failure occurs, the equipment often fails to immediately identify and stop, potentially resulting in invalid test data, atypical product damage, or even safety hazards due to equipment overload. The safety and reliability of the testing process need to be improved.

[0004] Therefore, the present invention proposes a pedal assembly durability testing device to at least partially solve the above-mentioned problems. Summary of the Invention

[0005] To address the aforementioned problems in the prior art, this invention provides a pedal assembly durability testing device, which solves the problem that existing pedal durability testing devices, which use open-loop control, cannot dynamically adjust the pedaling force according to the real-time deformation or resistance changes of the pedal, resulting in insufficient test accuracy and consistency.

[0006] The objective of this invention can be achieved through the following technical solution: a pedal assembly durability testing device, comprising: Test bench, used to mount the pedal assembly under test; At least one pedal actuator is mounted on the test bench for applying a mechanical load to the pedal assembly under test; The sensing and detection system includes a pressure sensor for detecting the mechanical load and a displacement sensor for detecting the deformation of the tested pedal assembly; An integrated closed-loop control system is electrically connected to the pedal actuator and the sensing and detection system. The integrated closed-loop control system is configured to execute a multi-stage test sequence, which includes at least a loading stage and a pressure holding stage, and in the loading stage or the pressure holding stage, real-time pressure closed-loop control is performed on the pedal actuator based on feedback from the pressure sensor. The integrated closed-loop control system also has a built-in fault diagnosis module. The fault diagnosis module monitors pressure and displacement data in real time during the test and is configured to interrupt the test sequence and trigger an alarm when the real-time pressure value deviates from the target value of the stage by more than a set threshold, or the displacement change rate exceeds a preset threshold.

[0007] As a preferred embodiment of the present invention, the test bench includes at least one set of test stations arranged along a transverse track, each test station is equipped with an independent pedaling actuator and a sensing detection system, and the spacing between the test stations is adjustable.

[0008] As a preferred embodiment of the present invention, the pedal actuator includes a pedal fixing bracket, which is detachably connected to the pedal assembly under test via an interface.

[0009] As a preferred embodiment of the present invention, the pressure sensor is a spoke-type pressure sensor integrated into the force transmission path of the pedal actuator; the displacement sensor is a linear displacement sensor.

[0010] As a preferred embodiment of the present invention, the integrated closed-loop control system includes a servo driver and a proportional valve. The servo driver is used to control the movement speed of the pedal actuator, and the proportional valve is used to adjust the output pressure of the pedal actuator according to the feedback of the pressure sensor.

[0011] As a preferred embodiment of the present invention, it further includes a human-computer interaction unit, which provides a graphical interface for configuring the parameters of the multi-stage test sequence and displaying the pressure-displacement curve and alarm information in real time.

[0012] As a preferred embodiment of the present invention, it further includes a safety and power management unit, which interlocks the emergency stop button with the safety circuit of the control system to cut off the power source of the moving parts when an alarm is triggered or a manual emergency stop is performed.

[0013] As a preferred embodiment of the present invention, the control system is further configured with a data traceability module, which is used to record the pressure peak, displacement change and fault code of each test cycle, and generate a structured test report.

[0014] As a preferred embodiment of the present invention, in the fault diagnosis module, the set threshold is ±5% of the stage target pressure value; the fault diagnosis module generates a fault code when an alarm is triggered.

[0015] As a preferred embodiment of the present invention, the multi-stage test sequence further includes a rapid approach stage and a rapid return stage, and the speed parameters of the rapid approach stage, loading stage, pressure holding stage and rapid return stage can be configured independently.

[0016] The beneficial effects of this invention are as follows: By setting a pressure sensor to monitor the pedaling force value in real time and configuring the upper and lower limit alarm functions of the fault diagnosis module, abnormal test conditions can be detected in a timely manner and the test can be stopped automatically. Compared with the prior art, this improves the safety and reliability of the test and avoids equipment damage or test data distortion caused by abnormal force values. By accurately detecting changes in pedal height through a displacement sensor and checking the records at intervals through a data traceability module, the deformation of the pedal during the durability test can be accurately evaluated. Compared with the prior art, this provides reliable data support for product quality assessment. The integrated closed-loop control system enables flexible configuration of multi-stage test sequences, which can meet different test requirements and improve the applicability and testing efficiency of the equipment compared with the prior art. The data traceability module automatically records test data and generates structured test reports and curve analysis, realizing digital management of the test process. Compared with the traditional manual recording method, this has higher data processing efficiency, test result traceability, accuracy, and convenience. Attached Figure Description

[0017] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0018] Figure 1 This is a schematic diagram of the overall structure of a pedal assembly durability testing device according to the present invention.

[0019] Figure 2 This is a front view structural schematic diagram of a pedal assembly durability testing device according to the present invention.

[0020] Figure 3 This is a schematic diagram of the human-computer interaction structure of a pedal assembly durability testing device according to the present invention.

[0021] Explanation of main component symbols In the diagram: 100, test bench; 200, pedal actuator; 201, pedal fixing bracket; 211, pedal assembly under test; 300, pressure sensor; 301, displacement sensor; 400, human-machine interaction unit. Detailed Implementation

[0022] To further illustrate the technical means and effects adopted by the present invention to achieve the intended purpose, the following detailed description of the specific implementation methods, structures, features and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided.

[0023] Please see Figures 1-3 This invention provides a pedal assembly durability testing device, which includes a test bench 100, at least one pedal actuator 200 mounted on the test bench 100, a sensing and detection system for real-time data acquisition, and an integrated closed-loop control system as the core of the device control. The sensing and detection system mainly consists of a pressure sensor 300 and a displacement sensor 301. The device is also equipped with a human-machine interface unit 400 for parameter setting and status monitoring.

[0024] Specifically, the test bench 100 serves as the base of the entire device, providing a stable mounting platform for the test piece and various functional modules. In this embodiment, the test bench 100 includes at least one set of test stations arranged along a transverse track. Each test station is equipped with an independent pedal actuator 200 and a sensing detection system, and the spacing between the test stations is adjustable.

[0025] The pedal actuator 200 is the core component for applying load to the pedal. This actuator 200 includes a pedal mounting bracket 201 and a pedal assembly under test 211. The pedal mounting bracket 201 is detachably connected to the pedal assembly under test 211 via an interface and is used to mount the pedal assembly under test 211. Operators can flexibly fix the driven arm bracket and the active arm bracket of the pedal under test according to the actual mounting holes of the pedal assembly under test 211, ensuring consistency between the test state and the actual use state, and exhibiting good versatility. The pedal actuator 200 is driven by a servo motor, enabling precise control of its movement speed and position. Simultaneously, its output force is adjusted via a pneumatic system. Before testing, the horizontal position of the pedal actuator 200 can be adjusted manually to ensure it accurately applies the preset pedal position on the pedal assembly under test 211, such as, but not limited to, a single pedal position, an active arm pedal position, or a driven arm pedal position.

[0026] The sensing and detection system is used to accurately quantify key physical parameters during the testing process. This system includes a pressure sensor 300, preferably a spoke-type pressure sensor 300, such as the Ocean Wheel spoke-type pressure sensor 300, with a measuring range of 300 kg. This sensor is integrated into the force transmission path of the pedal actuator 200 to detect the mechanical load applied to the tested pedal assembly 211, i.e., the pedaling force, in real time and accurately. Simultaneously, the system also includes a displacement sensor 301, preferably a high-precision linear displacement sensor 301, such as the GEERT-M200 series high and low temperature displacement sensor 301. Its measuring probe is configured to contact the bottom of the pedal under test to monitor the displacement, deformation, or height change of the pedal during the force application process in real time.

[0027] An integrated closed-loop control system is key to achieving high-precision, intelligent testing in this invention. The core hardware of this system includes a programmable logic controller (PLC), such as the ESAY-320 series, which acts as the main controller, coordinating the operation of all components. The PLC is electrically connected to a servo drive (e.g., SV600EP-5R5I) and a proportional valve (e.g., an SNS proportional valve). The servo drive precisely controls the speed and stroke of the pedal actuator 200 according to the PLC's instructions, while the proportional valve dynamically adjusts the air pressure of the pneumatic system according to the PLC's instructions. During testing, the PLC collects force feedback signals from the pressure sensor 300 in real time and compares them with a preset target pressure value. Through control logic such as PID algorithms, it adjusts the opening of the proportional valve in real time, thereby achieving precise closed-loop control of the output pressure of the pedal actuator 200. This control method ensures highly stable and accurate force values ​​during the loading and holding phases, realistically replicating the target working conditions.

[0028] The human-machine interface unit 400, preferably a touch-screen integrated industrial computer in this embodiment, provides operators with an intuitive and convenient equipment control interface. Through this graphical interface, users can perform the following operations: 1) Parameter configuration: Set the test name, target number of cycles, treading mode (such as single-sided treading, double-sided treading or only opening and closing life test), speed and time of each test stage (such as rapid approach, loading, pressure holding, rapid return), target pressure value, upper and lower limit thresholds of pressure alarm, and the interval number of displacement sampling, etc.

[0029] 2) Mode Switching: Switches between manual mode for equipment debugging and product clamping and automatic mode for performing durability tests. In manual mode, the action of each actuator cylinder can be controlled individually, and the pedal position and initial force value can be fine-tuned.

[0030] 3) Status Monitoring: Real-time display of current cycle count, real-time pedal force, real-time pedal height, hardware connection status (such as PLC connection status), and system operation logs. Pressure-displacement curves can also be plotted and displayed in real time.

[0031] 4) Data Management: After testing, the recorded test data can be saved as a structured data table with one click. The recorded test data includes the peak force value for each cycle, the height value of the interval sampling, etc., and supports custom file storage path and name. A data clearing function is also provided, along with a two-factor authentication mechanism to prevent data loss due to accidental operation.

[0032] The workflow of the device of this invention is as follows: First, the operator prepares for power-on, confirming that the power and air supply are stably connected. Then, the test pedal assembly 211 is installed onto the test bench 100 via the pedal fixing bracket 201, and the test pedal is secured with screws. Next, the operator enters manual mode through the human-machine interface unit 400, adjusts the pedal actuator 200 and displacement sensor 301 to appropriate initial positions, and calibrates the displacement sensor 301 to ensure stable initial readings. After debugging, the operator inputs or retrieves the preset test formula on the parameter setting page and sets all test parameters. Finally, the system is switched to automatic mode, the start button is pressed, and the device begins to automatically execute cyclic pedaling tests according to the set multi-stage test sequence.

[0033] During automated testing, the fault diagnosis module built into the integrated closed-loop control system plays a crucial role. This module monitors data from pressure sensor 300 and displacement sensor 301 in real time. On one hand, it compares the real-time pressure value with the set upper and lower limits of the target pressure, for example, ±5% of the target value. Once the real-time pressure value exceeds this range, the system determines that the pressure is abnormal, immediately interrupts the test sequence, issues an audible and visual alarm through the human-machine interface unit 400, and records the corresponding fault code. On the other hand, it monitors the rate of change of displacement data. If a sudden change in pedal displacement is detected, such as a sharp drop which may indicate breakage, or no change for a long time which may indicate jamming, a shutdown alarm will also be triggered. This intelligent diagnostic mechanism greatly improves the safety and reliability of the testing process, effectively avoiding invalid testing and potential safety risks caused by abnormal failure of the test specimen or equipment malfunction.

[0034] Furthermore, this invention also includes a safety and power management unit. This unit integrates the physical emergency stop button on the control panel and interlocks it with the safety circuit of the control system. In any emergency, whether the operator manually presses the emergency stop button or the fault diagnosis module automatically triggers an alarm, this unit will immediately cut off the power source to all moving parts to ensure the safety of the equipment and personnel. Testing can only be restarted after the fault has been cleared and the equipment has been reset.

[0035] Finally, the data traceability module configured in this invention, as part of the integrated closed-loop control system software, is responsible for automatically recording key data throughout the entire testing process. It not only records the pressure peak and displacement change for each test cycle, but also records the fault code and occurrence time when a fault occurs. After the test, the system can automatically generate structured test reports and height variation curves based on this massive amount of data, providing detailed, reliable, and traceable data support for product performance degradation analysis and quality assessment, thus achieving comprehensive digital management of the testing process.

[0036] This invention, by setting a pressure sensor 300 to monitor the pedaling force value in real time and configuring an upper and lower limit alarm function of the fault diagnosis module, can promptly detect abnormal test conditions and automatically stop the test. Compared with existing technologies, this improves the safety and reliability of the test and avoids equipment damage or test data distortion caused by abnormal force values. By accurately detecting changes in pedal height through a displacement sensor 301 and checking the records at intervals through a data traceability module, the deformation of the pedal during the durability test can be accurately assessed, providing reliable data support for product quality assessment compared with existing technologies. The integrated closed-loop control system enables flexible configuration of multi-stage test sequences to meet different test requirements, improving the applicability and testing efficiency of the equipment compared with existing technologies. The data traceability module automatically records test data and generates structured test reports and curve analyses, realizing digital management of the testing process. Compared with traditional manual recording methods, this has higher data processing efficiency, test result traceability, accuracy, and convenience.

[0037] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A pedal assembly durability test apparatus, characterized by, include: Test bench, used to mount the pedal assembly under test; At least one pedal actuator is mounted on the test bench for applying a mechanical load to the pedal assembly under test; The sensing and detection system includes a pressure sensor for detecting the mechanical load and a displacement sensor for detecting the deformation of the tested pedal assembly; An integrated closed-loop control system is electrically connected to the pedal actuator and the sensing and detection system; The integrated closed-loop control system is configured to execute a multi-stage test sequence, which includes at least a loading stage and a pressure holding stage, and in the loading stage or the pressure holding stage, real-time pressure closed-loop control is performed on the pedal actuator based on feedback from the pressure sensor. The integrated closed-loop control system also has a built-in fault diagnosis module. The fault diagnosis module monitors pressure and displacement data in real time during the test and is configured to interrupt the test sequence and trigger an alarm when the real-time pressure value deviates from the target value of the stage by more than a set threshold or the displacement change rate exceeds a preset threshold.

2. A pedal assembly durability test apparatus according to claim 1, wherein The test bench includes at least one set of test stations arranged along a transverse track. Each test station is equipped with an independent pedaling actuator and a sensing detection system, and the spacing between the test stations is adjustable.

3. A pedal assembly durability testing apparatus according to claim 1, wherein The pedal actuator includes a pedal fixing bracket, which is detachably connected to the pedal assembly under test via an interface.

4. A pedal assembly durability test apparatus according to claim 1, wherein The pressure sensor is a spoke-type pressure sensor integrated into the force transmission path of the pedal actuator; the displacement sensor is a linear displacement sensor.

5. A pedal assembly durability testing apparatus according to claim 1, wherein The integrated closed-loop control system includes a servo driver and a proportional valve. The servo driver is used to control the movement speed of the pedal actuator, and the proportional valve is used to adjust the output pressure of the pedal actuator based on the feedback from the pressure sensor.

6. The pedal assembly durability testing equipment according to claim 1, characterized in that, It also includes a human-machine interaction unit, which provides a graphical interface for configuring the parameters of the multi-stage test sequence and displaying the pressure-displacement curve and alarm information in real time.

7. The pedal assembly durability testing equipment according to claim 1, characterized in that, It also includes a safety and power management unit, which interlocks the emergency stop button with the safety circuit of the control system to cut off the power source of the moving parts when an alarm is triggered or a manual emergency stop is required.

8. The pedal assembly durability testing equipment according to claim 1, characterized in that, The control system is also equipped with a data traceability module, which records the pressure peak, displacement change and fault code for each test cycle, and generates a structured test report.

9. The pedal assembly durability testing equipment according to claim 1, characterized in that, In the fault diagnosis module, the set threshold is ±5% of the stage target pressure value; the fault diagnosis module generates a fault code when an alarm is triggered.

10. The pedal assembly durability testing equipment according to claim 1, characterized in that, The multi-stage test sequence also includes a rapid approach stage and a rapid return stage, and the speed parameters of the rapid approach stage, loading stage, pressure holding stage and rapid return stage can be configured independently.

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