A portable device for heavy truck axle housing level measurement

Abstract

The application relates to the technical field of new energy vehicles and vehicle detection equipment, and discloses a portable device for heavy truck axle housing liquid level measurement, which is suitable for electric drive axle and traditional drive axle. The device comprises a shell support structure, an electronic control assembly, a posture adjusting execution mechanism, a quick locking connection mechanism and a liquid level measurement assembly; the shell support structure is used for supporting the device and stretching and retracting the measurement assembly; the electronic control assembly is used for power supply, control and result display; the posture adjusting execution mechanism is used for adjusting the posture of the measurement assembly to keep it vertical; the quick locking connection mechanism is used for quickly fixing the device and the oil filling hole of the axle housing; and the liquid level measurement assembly realizes liquid level detection by cooperating a magnetic float and a Hall sensor. The application takes into account the application requirements of the electric drive axle and the traditional drive axle, and can especially meet the requirements of the electric drive axle on liquid level detection precision and reliability.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicles and vehicle testing equipment technology, specifically to a portable device for measuring the liquid level in the axle housing of heavy-duty trucks. Background Technology

[0002] During operation, the drive axle housing of heavy-duty trucks is usually filled with lubricating gear oil to lubricate and cool the gears and bearings inside the axle housing. Therefore, it is necessary to check the oil level in the axle housing regularly to ensure that the lubrication system is in normal working condition and to avoid wear or even damage to the transmission system due to insufficient lubrication.

[0003] Currently, the fluid level inside the axle housing of heavy-duty trucks is mostly measured manually by inserting a thin iron wire into the oil filler hole. The fluid level is determined by observing the position of the oil adhering to the wire's surface. However, this method has certain shortcomings in practical use: Firstly, a small amount of oil may remain on the edge or inner wall of the oil filler hole, and the thin iron wire can easily come into contact with this residual oil during insertion, affecting the judgment of the true fluid level. Secondly, it is difficult to keep the thin iron wire perpendicular to the fluid surface inside the axle housing, resulting in a large measurement error. In addition, this method is not convenient to operate, has low detection efficiency, and poor measurement repeatability, making it difficult to meet the needs of rapid and accurate fluid level detection during vehicle maintenance.

[0004] With the development of new energy vehicle technology, heavy-duty trucks are gradually moving towards electric drive. As a crucial assembly in new energy vehicles, the electric drive axle integrates a motor, reduction gear, and lubrication system. Compared to traditional drive axles, the electric drive axle's motor and reduction gear typically share a lubrication system. The fluid level directly affects the motor's heat dissipation performance and the reliability of the transmission system, placing higher demands on the stability and reliability of the lubricating oil level and cooling medium. However, the electric drive axle has a more compact structure and limited detection space, requiring higher sealing and detection accuracy. Traditional fluid level detection methods are inconvenient to operate and prone to large errors under these conditions, making them unsuitable for the structural characteristics of electric drive axles.

[0005] Existing liquid level detection methods mostly rely on keeping the measuring element in a vertical position to ensure measurement accuracy. However, in heavy-duty truck drive axles, especially electric drive axle structures, the small space in the axle housing, the limited installation angle, and the irregular position of the oil filling hole make it difficult to keep the measuring device in a vertical position, which causes liquid level measurement errors and affects the accuracy of lubrication and heat dissipation performance evaluation.

[0006] Therefore, there is an urgent need for a liquid level detection device that can adapt to the structural characteristics of ordinary vehicle axles and electric drive axles, is easy to operate, and has high measurement accuracy. Summary of the Invention

[0007] The purpose of this invention is to provide a portable device for measuring the liquid level in heavy-duty truck axle housings, applicable to both traditional fuel-powered heavy-duty truck drive axle housings and new energy heavy-duty truck electric drive axle housings. This device addresses the problems of inconvenient operation, low measurement accuracy, and poor adaptability in existing liquid level measurement technologies, thereby achieving rapid, accurate, and reliable liquid level detection.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] A portable device for measuring the liquid level in a heavy-duty truck axle housing includes a housing support structure, an electronic control component, an attitude adjustment actuator, a quick-locking connection mechanism, and a liquid level measuring component. The housing support structure supports and stores the entire device and allows for the extension and retraction of the liquid level measuring component. The electronic control component provides power, control, and displays the measurement results. The attitude adjustment actuator adjusts the attitude of the liquid level measuring component to maintain its perpendicularity to the horizontal plane during measurement. The quick-locking connection mechanism quickly secures the device to the oil filler hole of the drive axle housing. The liquid level measuring component detects the level of lubricating oil inside the axle housing.

[0010] Furthermore, the housing support structure includes a housing (101) and a push rod (102). The push rod (102) can extend and retract inside the housing (101), and the push rod (102) can be locked and released through a self-locking structure, thereby driving the attitude adjustment actuator and the liquid level measurement component to move between the inside and outside of the housing (101).

[0011] Furthermore, the attitude adjustment actuator includes a rotary drive mechanism for adjusting the horizontal tilt angle of the liquid level measuring component and a linear drive mechanism for adjusting the pitch angle of the liquid level measuring component. Through attitude adjustment with two degrees of freedom, the liquid level measuring component can automatically adjust its attitude and maintain its perpendicularity to the horizontal plane.

[0012] Furthermore, the liquid level measuring assembly includes a measuring assembly protective shell (502), a magnetic float (503), a magnetic float guide rod (505), and a measuring PCB (507). The magnetic float (503) is sleeved on the outside of the magnetic float guide rod (505) and can slide up and down along the guide rod axis. The measuring PCB (507) is provided inside the magnetic float guide rod (505). Multiple Hall sensors (508) are arranged on the measuring PCB (507). The measurement of the lubricating oil level in the bridge housing is realized by detecting the position of the magnetic float (503).

[0013] Furthermore, a gravity sensor (509) is also provided on the measurement PCB (507) to detect the attitude information of the liquid level measurement component in real time and feed the detection result back to the control unit (205), thereby driving the attitude adjustment actuator to automatically adjust the attitude of the liquid level measurement component.

[0014] Furthermore, the quick-locking connection mechanism is located at the front end of the housing support structure. It forms a radial tensioning structure by cooperating with the tensioning ring (404) and the wedge block (418), which enables the device to be quickly inserted into the oil injection hole of the drive axle housing and achieve reliable locking. At the same time, it enables quick unlocking and disassembly through the release mechanism.

[0015] The core of this invention lies in the coordinated design of the attitude adjustment actuator and the liquid level measurement component, which ensures that the measurement component remains aligned with the direction of gravity under complex installation conditions, thereby significantly improving the accuracy of liquid level measurement under non-vertical working conditions.

[0016] The portable device for measuring liquid level in heavy-duty truck axle housings proposed in this invention has at least the following beneficial effects:

[0017] This invention achieves direct detection of the lubricating oil level inside the drive axle housing by setting up a liquid level measurement component and a magnetic float detection structure, thereby improving the accuracy of liquid level measurement.

[0018] By setting up an attitude adjustment actuator and combining it with a gravity sensor for attitude feedback control, the liquid level measuring component is kept perpendicular to the horizontal plane during the measurement process, thereby effectively reducing errors caused by measurement attitude deviation.

[0019] By setting up a quick-locking connection mechanism, the device can be quickly installed at the oil injection hole of the drive axle housing and reliably fixed, improving testing efficiency and ease of use.

[0020] This invention features a compact overall structure, facilitating rapid on-site testing without disassembling the axle housing. It offers high measurement accuracy, enabling rapid and accurate detection of fluid levels in the axle housing of heavy-duty trucks. This invention helps improve the operational reliability of key components in both fuel-powered and new energy heavy-duty trucks, reducing the risk of failure. It is particularly suitable for applications where the motor and reduction mechanism share a lubrication system in electric drive axles, ensuring motor heat dissipation and system operational reliability, and possesses significant engineering application value. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the working state of the portable device for measuring the liquid level in the bridge housing according to the present invention.

[0022] Figure 2 This is a schematic diagram of the locking process of the self-locking mechanism of the shell support structure of the present invention;

[0023] Figure 3 This is a schematic diagram of the self-locking mechanism of the shell support structure of the present invention;

[0024] Figure 4 This is a schematic diagram of the overall structure of the portable device for measuring the liquid level in the bridge housing according to the present invention.

[0025] Figure 5 This is a schematic diagram of the internal structure of the device of the present invention in its initial state;

[0026] Figure 6 This is a schematic diagram of the structure and installation of the electronic control component of the present invention;

[0027] Figure 7 This is a cross-sectional structural diagram of the quick-locking connection mechanism of the present invention;

[0028] Figure 8 This is an exploded view of the structure of the attitude adjustment actuator of the present invention;

[0029] Figure 9 This is an exploded view of the structure of the quick-locking connection mechanism of the present invention;

[0030] Figure 10 This is a schematic diagram of the liquid level height measurement reference of the present invention.

[0031] Figure 11 This is an exploded view of the liquid level measuring component of the present invention;

[0032] Figure 12 This is a schematic diagram illustrating the working process and liquid level detection principle of the device of the present invention.

[0033] Part number description in the image:

[0034] 101. Housing, 102. Push rod, 103. Self-locking buckle, 104. Pin seat, 105. Tension spring a, 106. Tension spring b, 107. Slider a, 108. Slide rod a, 109. Housing fixing seat, 110. Housing tension spring seat, 201. LED display, 202. Measuring button, 203. Power button, 204. Battery, 205. Control unit, 206. Charging interface, 301. Stepper motor a, 302. Reducer, 303. Rotary disk, 304. Stepper motor b, 305. Lead screw, 306. Slider b, 307. Pull rod, 308. Connector, 309. Pin, 310. U-shaped part, 401. Quick-release flange, 402. Compression spring a, 403. Pressure ring, 404. Tensioner 405. Ring, 406. Limit seat, 407. Pawl block, 408. Release button, 409. Slide bar b, 410. Rubber pad, 411. Lever, 412. Lever support, 413. Roller pin, 414. Groove, 415. Small ball, 416. Compression spring b, 417. Slide bar c, 418. Wedge block, 419. Guide seat, 420. Limit hole, 421. Wedge block guide groove, 422. Tension spring c, 423. Slide bar d, 501. Sealing ring, 502. Measuring component protective shell, 503. Magnetic float, 504. Oil guide groove, 505. Magnetic float guide rod, 506. Plug, 507. Measuring PCB, 508. Hall sensor, 509. Gravity sensor, 510. Oil passage hole. Detailed Implementation

[0035] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings, but the scope of protection of the present invention is not limited to the following embodiments.

[0036] like Figures 1 to 12 As shown, a portable device for measuring liquid level in heavy-duty truck axle housings includes a housing support structure, an electronic control assembly, an attitude adjustment actuator, a quick-locking connection mechanism, and a liquid level measuring assembly.

[0037] 1. The housing support structure includes a housing (101) and a push rod (102), the push rod (102) being slidably disposed along the axial direction of the housing (101). The push rod (102) is provided with a self-locking buckle (103), the housing (101) is provided with a pin seat (104), a slider a (107) and a sliding rod a (108), and the push rod (102) is locked with the self-locking buckle (103) when pushed to a designated position by the elastic action of the tension spring a (105) and the tension spring b (106), thereby maintaining the extended state of the push rod (102).

[0038] When it is necessary to retract the push rod (102), by pressing the push rod (102) again, the slider a (107) is disengaged from the self-locking buckle (103), and the push rod (102) automatically retracts into the housing (101) under the action of the tension spring a (105).

[0039] The outer casing (101) is also provided with an outer casing fixing seat (109) and an outer casing tension spring seat (110) for installing relevant elastic elements and supporting and fixing the internal mechanism.

[0040] 2. The electronic control component is located inside the housing (101), such as... Figure 6 As shown, it includes an LED display screen (201), a measurement button (202), a power button (203), a battery (204), a control unit (205), and a charging interface (206).

[0041] Among them, the battery (204) is used to provide power to the device; the power button (203) is used to control the power on and off of the device; the measurement button (202) is used to start the liquid level measurement; the control unit (205) adjusts the actuator in real time according to the attitude information fed back by the gravity sensor (509) to realize closed-loop control; the LED display screen (201) is used to display the measured liquid level height data; and the charging interface (206) is used to charge the battery (204).

[0042] 3. The attitude adjustment actuator is located at the front end of the push rod (102) and is used to automatically adjust the attitude of the liquid level measuring component during the measurement process so that it remains in a vertical state.

[0043] like Figure 5 and Figure 8 As shown, the attitude adjustment actuator includes a stepper motor a (301), a reducer (302), a rotary disk (303), a stepper motor b (304), a lead screw (305), a slider b (306), a pull rod (307), a connector (308), a pin (309), and a U-shaped part (310).

[0044] Stepper motor a (301) drives the rotary disk (303) to rotate via reducer (302) to adjust the horizontal tilt angle of the liquid level measuring component; stepper motor b (304) drives slider b (306) to move via drive screw (305), and adjusts the pitch angle of the liquid level measuring component via pull rod (307), connector (308) and U-shaped part (310). Through the above two-degree-of-freedom adjustment mechanism, the liquid level measuring component is kept in a vertical state during measurement.

[0045] 4. For example Figure 4 , Figure 7 and Figure 9As shown, the quick-locking connection mechanism is located at the front end of the device and is used to quickly fix the device to the oil injection hole of the axle housing.

[0046] The quick-locking connection mechanism includes a quick-release flange (401), a compression spring a (402), a pressure ring (403), a tension ring (404), a limit seat (405), a pawl block (406), a release button (407), a slide bar b (408), a rubber pad block (409), a lever (410), a lever support (411), a roller pin (412), a groove (413), a small ball (414), a compression spring b (415), a slide bar c (416), a limit bolt (417), a wedge block (418), a guide seat (419), a limit hole (420), a wedge block guide groove (421), a tension spring c (422), and a slide bar d (423).

[0047] When the device is inserted into the oil injection hole of the axle housing, the pressure ring (403) compresses the compression spring a (402) under the action of axial thrust, which drives the tension ring (404) to expand radially outward, so that the tension ring (404) forms a tight fit with the inner wall of the oil injection hole, thereby realizing the rapid locking and fixing of the device.

[0048] When the release button (407) is pressed, the pawl block (406) is released from its locked state, and the tension ring (404) contracts under the action of the elastic element, allowing the device to be removed from the oil injection hole. The rubber pad (409) is used to improve the sealing performance and prevent damage to the surface of the axle housing.

[0049] 5. For example Figure 10 As shown, the liquid level height measured by this invention is the vertical distance h between the lubricating oil surface inside the bridge housing and the lower edge of the oil injection hole in the bridge housing. By detecting the height position of the magnetic float (503) and combining it with the structural parameters of the device, the control unit (205) can calculate the distance h from the liquid surface to the lower edge of the oil injection hole and display the measurement result through the LED display screen (201).

[0050] 6. For example Figure 11 As shown, the liquid level measuring component includes a sealing ring (501), a measuring component protective shell (502), a magnetic float (503), an oil guide groove (504), a magnetic float guide rod (505), a plug (506), a measuring PCB (507), a Hall sensor (508), a gravity sensor (509), and an oil passage hole (510).

[0051] The measuring component protective housing (502) is equipped with a magnetic float guide rod (505), and the magnetic float (503) can slide up and down along the guide rod. The protective housing (502) is provided with an oil passage hole (510) and an oil guide groove (504) to allow the lubricating oil inside the bridge housing to enter the protective housing.

[0052] When lubricating oil enters the protective shell (502), the magnetic float (503) moves up and down with the change in liquid level under the action of buoyancy. Hall sensors (508) are arranged along the measurement PCB (507) array. By detecting the change signal of the magnetic field generated by the magnetic float (503), the control unit (205) calculates the position of the magnetic float (503), thereby obtaining the liquid level information. Gravity sensor (509) is used to detect the attitude of the liquid level measuring component and feeds back the detection signal to the control unit (205) to realize automatic attitude adjustment.

[0053] 7. For example Figure 12 As shown, the liquid level measurement process of the device of the present invention is as follows:

[0054] ① First, insert the device into the oil injection hole of the axle housing. Under the action of axial thrust, the pressure ring (403) is stressed and drives the tension ring (404) to expand outward, so that the device and the inner wall of the oil injection hole form a tight fit, thereby realizing the rapid locking and fixing of the device.

[0055] ② Then push the push rod (102) to the self-locking position to allow the liquid level measuring component to enter the bridge housing.

[0056] ③ After pressing the measurement button (202), the gravity sensor (509) detects the current attitude information of the liquid level measuring component and sends the detection signal to the control unit (205). The control unit (205) drives the stepper motor a (301) and the stepper motor b (304) respectively according to the attitude deviation to adjust the horizontal tilt angle and pitch angle of the liquid level measuring component so that it gradually reaches the vertical state.

[0057] ④ When the liquid level measuring component is kept vertical, the lubricating oil inside the bridge housing enters the protective shell (502) of the measuring component through the oil passage (510), and the magnetic float (503) floats to the corresponding liquid level position under the action of buoyancy. The Hall sensor (508) detects the magnetic field change signal, and the control unit (205) calculates the liquid level height h, and then outputs the liquid level measurement result through the LED display (201).

[0058] ⑤ After the measurement is completed, press the release button (407) to release the locking mechanism and cause the tension ring (404) to contract. Press the push rod (102) again to separate the self-locking buckle (103) from the slider a (107). Under the action of the tension spring a (105), the push rod (102) retracts into the housing (101). Finally, pull the device out of the bridge housing oil injection hole to complete one liquid level measurement process.

[0059] The improvement of this invention does not lie in the liquid level detection principle itself, but in the adaptive adjustment of the liquid level measurement posture under non-vertical installation conditions, thereby ensuring detection accuracy.

[0060] This invention can be applied to both traditional fuel vehicle drive axles and electric drive axles for new energy vehicles, and is especially suitable for scenarios such as heavy-duty truck electric drive axles where high accuracy of liquid level detection and ease of operation are required.

Claims

1. A portable device for heavy truck axle housing level measurement, characterized in that, The system includes a housing support structure, an electronic control component, an attitude adjustment actuator, a quick-locking connection mechanism, and a liquid level measurement component. The housing support structure includes a housing (101) and a push rod (102). The attitude adjustment actuator is located at the front end of the push rod (102), and its output end is connected to the liquid level measurement component. The liquid level measurement component is detachably connected to the oil filling hole of the drive axle housing via the quick-locking connection mechanism. The electronic control component is located inside the housing (101) and is electrically connected to both the attitude adjustment actuator and the liquid level measurement component. It is used to receive liquid level measurement signals and control the action of the attitude adjustment actuator. The attitude adjustment actuator... The device is used to adjust the spatial orientation of the liquid level measuring component, so that the liquid level measuring component remains vertical during the measurement process; the liquid level measuring component is used to insert into the drive axle housing and detect the lubricating oil level in the housing based on the change in the position of the magnetic float; the quick-locking connection mechanism is set at the front end of the housing (101) and is used to quickly position and lock the device to the oil filling hole of the axle housing; the device is used for liquid level measurement of the drive axle housing of heavy trucks, and is suitable for electric drive axles and traditional drive axles, especially for liquid level detection of the shared lubrication system of the motor and reduction mechanism in electric drive axles, so as to meet the requirements of the electric drive system for the accuracy and reliability of liquid level detection related to lubrication and heat dissipation.

2. The portable device for measuring the liquid level in a heavy-duty truck axle housing according to claim 1, characterized in that: The housing support structure also includes a self-locking buckle (103), a pin seat (104), a tension spring a (105), a tension spring b (106), a slider a (107), a sliding rod a (108), a housing fixing seat (109), and a housing tension spring seat (110). The pin seat (104) is fixed on the housing (101), the sliding rod a (108) is fixed on the pin seat (104), and the slider a (107) can slide along the sliding rod a (108). The self-locking buckle (103) is set on the push rod (102), and the slider a (107) is connected to the pin seat (104) through the tension spring b (106). The housing (101) is connected to the push rod (102) through the tension spring a (105) to form a self-locking telescopic structure of the push rod.

3. The portable device for measuring the liquid level in a heavy-duty truck axle housing according to claim 1, characterized in that: The electronic control component includes an LED display screen (201), a measurement button (202), a power button (203), a battery (204), a control unit (205), and a charging interface (206); the LED display screen (201), the measurement button (202), and the power button (203) are disposed on the outer surface of the housing (101), and the battery (204), the control unit (205), and the charging interface (206) are disposed inside the housing (101).

4. The portable device for measuring the liquid level in a heavy-duty truck axle housing according to claim 1, characterized in that: The attitude adjustment actuator includes a stepper motor a (301), a reducer (302), a rotary disk (303), a stepper motor b (304), a lead screw (305), a slider b (306), a pull rod (307), a connector (308), a pin (309), and a U-shaped component (310). The stepper motor a (301) is connected to the rotary disk (303) through the reducer (302) and is used to adjust the horizontal angle of the liquid level measuring component. The stepper motor b (304) drives the slider b (306) to move along the U-shaped component (310) through the lead screw (305) and drives the connector (308) to rotate through the pull rod (307) to adjust the pitch angle of the liquid level measuring component.

5. A portable device for measuring the liquid level in a heavy-duty truck axle housing according to claim 4, characterized in that: The measurement PCB (507) is equipped with a gravity sensor (509) for detecting the attitude information of the liquid level measuring component; the control unit (205) controls the stepper motor a (301) and stepper motor b (304) to operate according to the detection signal of the gravity sensor (509) in order to adjust the attitude of the liquid level measuring component.

6. A portable device for measuring the liquid level in a heavy-duty truck axle housing according to claim 1, characterized in that: The quick-locking connection mechanism includes: a quick-release flange (401), a compression spring a (402), a pressure ring (403), a tensioning ring (404), and a limiting seat (405). Under the action of axial thrust, the pressure ring (403) pushes the limiting seat (405) to move, and drives the tensioning ring (404) to expand outward through the wedge block structure, thereby achieving a locking connection with the oil injection hole of the drive axle housing.

7. A portable device for measuring liquid level in a heavy-duty truck axle housing according to claim 6, characterized in that: The quick-locking connection mechanism also includes a pawl block (406), a release button (407), a slide bar c (416), a compression spring b (415), and a limiting hole (420); the pawl block (406) can slide along the slide bar c (416) and cooperate with the limiting hole (420) under the action of the compression spring b (415) to maintain the locked state; when the release button (407) is pressed, the pawl block (406) disengages from the limiting hole (420), thereby releasing the tension ring (404).

8. A portable device for measuring liquid level in heavy-duty truck axle housings according to claim 1, characterized in that: The liquid level measurement assembly includes a measurement assembly protective shell (502), a magnetic float (503), a magnetic float guide rod (505), a plug (506), and a measurement PCB (507); the magnetic float (503) is sleeved on the magnetic float guide rod (505) and can move up and down along the magnetic float guide rod (505); the measurement PCB (507) is disposed inside the magnetic float guide rod (505).

9. A portable device for measuring the liquid level in a heavy-duty truck axle housing according to claim 8, characterized in that: Multiple Hall sensors (508) are arranged on the measuring PCB (507) along the axial direction of the magnetic float guide rod (505). The magnetic sensing direction of the Hall sensors (508) is consistent with the axial magnetization direction of the magnetic float (503) to form an axisymmetric magnetic detection structure.

10. A portable device for measuring liquid level in a heavy-duty truck axle housing according to claim 8, characterized in that: The magnetic float (503) has an oil guide groove (504) on its inner side, and the plug (506) has multiple oil passage holes (510) to allow the lubricating oil in the bridge housing to enter the measuring component protective shell (502) and drive the magnetic float (503) to move along the magnetic float guide rod (505).

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