Side reducer no-load test detection system

Abstract

The utility model provides a side reducer no-load test detection system, and belongs to the field of reducer performance test equipment. The system comprises an electric control cabinet, a variable-frequency and variable-speed motor, a torque sensor, a vibration sensor, a temperature sensor, a test bed, a touch screen, a start button, a stop button, a PLC, a switching power supply, a frequency converter, a circuit breaker, a relay, an analog quantity acquisition module and a double-path signal conversion module. According to the utility model, automatic control and real-time data acquisition and display of side reducer no-load test detection are realized, the efficiency and precision of side reducer test can be improved, the reliability of test results is ensured, and the requirements of special vehicle related industries for high-precision and intelligent detection equipment are met; safety protection measures, such as a three-phase indicating lamp, an over-torque alarm indicating lamp and an emergency stop button, are specially added in the design, so that the safety of equipment and operators is ensured.

Description

Technical Field

[0001] The utility model belongs to the field of speed reducer performance test equipment, in particular to a side speed reducer no-load test detection system. Background Art

[0002] The side reducer is a core component of the powertrain of special vehicles, used to transmit torque from the engine and transmission, transferring power to the vehicle's motion system and providing speed regulation and shift control. Located on the left and right sides of the front end of the special vehicle, the side reducer is composed of a large number of parts, including a housing, driven shaft, planetary gears, planetary axles, and numerous rolling bearings. Its speed regulation and shift control functions are accomplished through the coordination of numerous parts and the movement between them. Strict requirements are imposed on the dimensional accuracy and fit of each part to ensure the proper operation of the side reducer and the proper performance of its transmission, thus maintaining the stability and reliability of the special vehicle's transmission function.

[0003] Traditional side reducer test benches primarily rely on manual control, which is cumbersome and inefficient, making it difficult to accurately record and analyze the test process. Test data is also difficult to accurately acquire and analyze, and automatic electromechanical data collection and statistics cannot be implemented. The lack of safety protection features poses a safety hazard. Summary of the Invention

[0004] The utility model aims to solve the problems existing in the prior art in the above background technology and provides a side speed reducer no-load test detection system.

[0005] In order to achieve the above purpose, the technical solution adopted by the present utility model is as follows:

[0006] The utility model provides a side reducer no-load test detection system, including an electric control cabinet, a variable frequency speed regulation motor, a torque sensor, a vibration sensor, and a temperature sensor. The variable frequency speed regulation motor and the torque sensor are both installed on an independently set test bench. The variable frequency speed regulation motor is coaxially connected to the torque sensor through a first coupling. The torque sensor is coaxially connected to the reducer on the side to be detected through a second coupling. The temperature sensor is installed at the bottom of the reducer on the side to be detected, and the detection end of the temperature sensor extends into the oil pool of the reducer on the side to be detected. The vibration sensor is installed on the housing of the reducer on the side to be detected. The electric control cabinet includes a cabinet body and a cabinet. The cabinet door is hinged on the front side of the cabinet body, and a touch screen, start button and stop button are installed on the cabinet door. A PLC controller, switching power supply, frequency converter, circuit breaker, relay, analog quantity acquisition module and dual-channel signal conversion module are installed inside the cabinet body; the input end of the circuit breaker is connected to the external AC power grid, and the output end of the circuit breaker is connected to the switching power supply. The switching power supply, torque sensor, touch screen, start button and stop button are all electrically connected to the PLC controller. The frequency converter, temperature sensor and vibration sensor are electrically connected to the PLC controller through relays, analog quantity acquisition module and dual-channel signal conversion module respectively, and the output end of the frequency converter is connected to the variable frequency speed regulation motor.

[0007] According to one embodiment of the present invention, a three-phase indicator light, an over-torque alarm indicator light, and an emergency stop button are provided on the cabinet door, and the three-phase indicator light, the over-torque alarm indicator light, and the emergency stop button are electrically connected to the PLC controller respectively.

[0008] According to one embodiment of the present invention, the PLC controller adopts Siemens S7-200 SMART PLC.

[0009] According to one embodiment of the present invention, the variable frequency speed regulating motor is a YVP series three-phase variable frequency speed regulating motor.

[0010] According to one embodiment of the present invention, the torque sensor is a Haibohua HCNJ-101 dynamic torque sensor.

[0011] According to one embodiment of the present invention, the vibration sensor is Chaorui CRZ-401, and the temperature sensor is PT100 temperature sensor.

[0012] According to one embodiment of the present invention, the inverter is a Sanling heavy-duty 90KW FR-A800 series inverter equipped with an integrated braking unit.

[0013] Beneficial technical effects of the utility model:

[0014] This utility model utilizes a touch screen, start and stop buttons, a PLC controller, a frequency converter, a circuit breaker, relays, an analog acquisition module, and a dual-channel signal conversion module integrated into the electrical control cabinet to achieve automated control, real-time data acquisition, and display. Safety precautions, such as a three-phase indicator light, an over-torque warning indicator, and an emergency stop button, are incorporated into the design to ensure the safety of both the equipment and the operator. This series of technical optimizations is expected to significantly improve the efficiency and accuracy of side reducer testing, ensuring the reliability of test results and meeting the demand for high-precision, intelligent testing equipment in the special vehicle industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 This is a structural diagram of a no-load test detection system for a side reducer of the utility model;

[0016] Figure 2 yes Figure 1 Schematic diagram of the structure inside the middle cabinet;

[0017] Figure 3 This is a control principle block diagram of a side reducer no-load test detection system of the utility model;

[0018] Figure numerals: 1. Electric control cabinet; 101. Cabinet door; 102. Cabinet body; 2. Touch screen; 3. Variable frequency speed regulation motor; 4. First coupling; 5. Torque sensor; 6. Second coupling; 7. Reducer on the side to be tested; 8. Temperature sensor; 9. Vibration sensor; 10. PLC controller; 11. Frequency converter; 12. Circuit breaker; 13. Switching power supply; 14. Relay; 15. Analog acquisition module; 16. Dual-channel signal conversion module; 17. Emergency stop button; 18. Three-phase indicator light; 19. Start button; 20. Stop button; 21. Over-torque alarm indicator light; 22. Test bench. DETAILED DESCRIPTION

[0019] To make the purpose, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention. Example

[0020] Please see the attached Figure 1-3As shown, a side reducer no-load test detection system of this embodiment includes an electric control cabinet 1, a variable frequency speed regulation motor 3, a torque sensor 5, a vibration sensor 9, and a temperature sensor 8. The variable frequency speed regulation motor 3 and the torque sensor 5 are both installed on an independently set test bench 22. The variable frequency speed regulation motor 3 is coaxially connected to the torque sensor 5 through a first coupling 4. The torque sensor 5 is coaxially connected to the reducer 7 on the side to be detected through a second coupling 6. The temperature sensor 8 is installed at the bottom of the reducer 7 on the side to be detected, and the detection end of the temperature sensor 8 extends into the oil pool of the reducer 7 on the side to be detected. The vibration sensor 9 is installed on the shell of the reducer 7 on the side to be detected. The electric control cabinet 1 includes a cabinet body 102 and a cabinet door 101 hinged on the front side of the cabinet body 102. The cabinet door 1 A touch screen 2, a start button 19, and a stop button 20 are installed on 01, and a PLC controller 10, a switching power supply 13, a frequency converter 11, a circuit breaker 12, a relay 14, an analog quantity acquisition module 15, and a dual-channel signal conversion module 16 are installed in the cabinet 102; the input end of the circuit breaker 12 is connected to the external AC power grid, and the output end of the circuit breaker 12 is connected to the switching power supply 13. The switching power supply 13, the torque sensor 5, the touch screen 2, the start button 19, and the stop button 20 are all electrically connected to the PLC controller 10. The frequency converter 11, the temperature sensor 8, and the vibration sensor 9 are electrically connected to the PLC controller 10 through the relay 14, the analog quantity acquisition module 15, and the dual-channel signal conversion module 16 respectively. The output end of the frequency converter 11 is connected to the variable frequency speed regulation motor 3.

[0021] In this embodiment, the touch screen 2 is model TPC7022Ew, a high-performance, embedded, integrated touch screen equipped with a Cortex-A7 processor and a main frequency of up to 800MHz. This product uses a 7-inch TFT LCD with a resolution of 800x480. It is a four-wire resistive touch screen that supports multi-touch and is highly responsive. It comes pre-installed with McgsPro configuration software, enabling rapid development and deployment of industrial automation projects. It features Ethernet, USB, and RS232 / RS485 ports for easy connection to various peripherals and devices. Its display brightness reaches up to 250cd / m², ensuring clear display in all lighting conditions. It can meet multi-point control, automatic process control, computer data acquisition and display functions, and can also save and export experimental data.

[0022] In this embodiment, the PLC controller 10 uses the Siemens S7-200 SMART PLC, which is a high-performance, highly integrated, simpler, and cost-effective small PLC product. It provides CPU modules of different types and rich I / O points. The single I / O points can reach up to 60 points, which can meet the control needs of most small automation equipment. In addition, the CPU module is equipped with standard and economical options for users to choose from. For different application requirements, the product configuration is more flexible and the cost is controlled to the maximum extent. The S7-200SMART PLC is equipped with a Siemens dedicated high-speed processor chip, and the basic instruction execution time can reach 0.15us. The S7-200 SMARTPLC integrates 1 Ethernet interface and 1 RS485 interface, supports multiple communication protocols, such as PPI, Modbus RTU, etc., and is convenient for connection and data exchange with touch screens, inverters, various sensors and other equipment.

[0023] In this embodiment, the torque sensor 5 is the Haibohua HCNJ-101 dynamic torque sensor, which is a precision measuring instrument specifically used to measure various torques, rotational speeds, and mechanical powers. This series of torque sensors uses strain bridge electrical measurement technology, uses a set of toroidal transformers to provide power contactlessly, and uses a micro-power signal coupler instead of the toroidal transformer for contactless signal transmission. It effectively overcomes the high-order harmonic self-interference caused by the inductive coupling signal and the mutual interference of the energy toroidal transformer with the signal toroidal transformer. At the same time, it changes the output spike pulse into an equal square wave signal. Therefore, this series of torque sensors can operate for a long time at a high speed. This series of torque sensors can be used for both static and dynamic measurements, and a variety of installation forms are designed, which brings great convenience to users. The vibration sensor 9 uses the Chaorui CRZ-401 integrated vibration transmitter, and the temperature sensor 8 uses the PT100 temperature sensor 8.

[0024] In this embodiment, inverter 11 uses the Sanling heavy-duty 90kW FR-A800 series inverter equipped with an integrated brake unit. This product offers a variety of control methods, including V / F control (initial setting), advanced flux vector control, real-time sensorless control, vector control, and PM sensorless vector control. This inverter features advanced flux vector control. Using vector calculation, the inverter's output current is divided into excitation current and torque current. Frequency and voltage compensation are performed to match the VFD motor's current to the load torque, improving low-speed torque. Output frequency compensation (slip compensation) is also implemented, bringing the VFD motor's actual speed closer to the commanded speed. This is effective under conditions of drastic load fluctuations. Real-time sensorless vector control is available, inferring the VFD motor's speed to achieve speed and torque control with high current control capabilities. When high-precision, high-response control is required, real-time sensorless vector control is selected for offline automatic tuning. It is suitable for situations where the load changes are more intense but the speed changes are minimized to the maximum extent, low-speed torque is required, and mechanical damage caused by excessive torque (torque limitation) is avoided. The installation of an integrated braking unit can consume the energy during the speed reduction process of the variable frequency speed regulating motor, ensuring the stable operation of the variable frequency speed regulating motor 3 controlled by the inverter 11.

[0025] In this embodiment, the variable frequency speed regulating motor 3 uses a YVP series three-phase variable frequency speed regulating motor. The internal coil of the motor adopts a full copper wire coil and is equipped with an independent fan. It has low heat generation and fast heat dissipation. It can run continuously at 100% of the rated load within 10%-100% of the rated speed, which can meet the 12 constant speed 3-5min experimental requirements during the experiment.

[0026] In this embodiment, analog acquisition module 15 is AM06, and dual-channel signal conversion module 16 is a Haibohua brand product. Haibohua's dual-channel signal conversion module 16 typically uses a high-precision A / D converter, capable of accurately converting analog signals to digital signals, meeting various high-precision measurement and control requirements. It supports multiple analog signal inputs, such as 0-20mA, 0-10V, and 0-5V, to meet the signal conversion requirements of various sensors and devices. The electrical control cabinet 1 can optionally use an XL21 power cabinet. The cabinet body 102 and cabinet door 101 are painted with blue nitrocellulose enamel, and the test bench 22 is sprayed with gray-white paint.

[0027] Specifically, to ensure the safety of the equipment and operators, the cabinet door 101 is provided with a three-phase indicator light 18, an over-torque alarm indicator light 21, and an emergency stop button 17. The three-phase indicator light 18, the over-torque alarm indicator light 21, and the emergency stop button 17 are electrically connected to the PLC controller 10. The start button 19 and the stop button 20 are used to start and stop the system normally. When the torque value detected by the torque sensor 5 is too large and exceeds a preset threshold, the over-torque alarm indicator light 21 illuminates, and the operator presses the emergency stop button 17 to manually stop the variable frequency speed control motor 3.

[0028] The system utilizes modern industrial control principles and is developed through a human-machine interface and PLC system with mature market technology to achieve automatic equipment control. The speed and torque are transmitted to the touch screen 2 in a timely manner through the torque sensor 5, which can realize automatic control of the operation process. It can realize fixed-speed timing experiments, as well as manual input of arbitrary speed experiments. It can modulate the speed upper limit and torque upper limit, and perform overspeed and over-torque alarm emergency stop. It has the function of collecting and reading input speed, input torque, and rotation parameters, which can realize the recording of the entire operation data and the viewing of speed and torque curves.

[0029] Left / right side reducer no-load test

[0030] The maximum output speed of the variable frequency speed regulating motor 3 is 2800 rpm, the power is 90 kW, and the power consumption is AC 380 V. When overcurrent or torque exceeds the limit, the over-torque alarm indicator 21 lights up, and the emergency stop button 17 is pressed to power off the variable frequency speed regulating motor 3.

[0031] Check the working temperature: During the test, under the input speed (1400, 1600, 1800, 2000, 2200, 2400, 2600) r / min working conditions, stabilize at each working point for 3-5 minutes, the system works normally without abnormal noise, measure the lubricating oil temperature ≤80℃, and record the corresponding temperature value.

[0032] Check the no-load loss: At the specified input speed (1400, 1600, 1800, 2000, 2200, 2400, 2600) r / min and no-load conditions, record the input torque after it stabilizes at the operating point for 3-5 minutes, and use this to calculate the no-load loss. After the torque stabilizes, it should be ≤30N·m.

[0033] In the no-load loss test, when the maximum input speed of the full-disc brake is 2580r / min±10 / min, its no-load power is ≤13kw; the test is carried out according to the brake disc input speed (r / min) of 800±10, 1100±10, 1300±10, 1500±10, 1800±10, 2000±10, 2200±10, 2400±10, the stable working time at each point is 3-4min, and the speed is gradually increased from low speed to high speed for a total of 5 times, and the average value is taken as the no-load loss power of the full-disc brake.

[0034] During the test, the following data should be collected and recorded: brake disc input speed np (r / min), brake disc input torque Mp (N·m), and the results should be derived. At the same time, the no-load power (kW) should be calculated.

[0035] The above description is intended to illustrate the preferred embodiments of the present invention and is provided to illustrate the technical solutions of the present invention. Those skilled in the art may make routine modifications, equivalent substitutions, and improvements within the spirit and principles of the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art and may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments described herein.

Claims

1. A side reducer no-load test detection system, characterized in that: The invention comprises an electric control cabinet (1), a variable frequency speed regulating motor (3), a torque sensor (5), a vibration sensor (9), and a temperature sensor (8). The variable frequency speed regulating motor (3) and the torque sensor (5) are both installed on an independently provided test bench (22). The variable frequency speed regulating motor (3) is coaxially connected to the torque sensor (5) through a first coupling (4). The torque sensor (5) is coaxially connected to the reducer (7) on the side to be detected through a second coupling (6). The temperature sensor (8) is installed at the bottom of the reducer (7) on the side to be detected, and the detection end of the temperature sensor (8) extends into the oil pool of the reducer (7) on the side to be detected. The vibration sensor (9) is installed on the housing of the reducer (7) on the side to be detected. The electric control cabinet (1) comprises a cabinet body (102) and a cabinet door (101) hinged on the front side of the cabinet body (102). The cabinet door (101) is provided with a touch screen (2), a start button A start button (19), a stop button (20), a PLC controller (10), a switching power supply (13), a frequency converter (11), a circuit breaker (12), a relay (14), an analog quantity acquisition module (15), and a dual-channel signal conversion module (16) are installed in the cabinet (102); the input end of the circuit breaker (12) is connected to the external AC power grid, and the output end of the circuit breaker (12) is connected to the switching power supply (13); the switching power supply (13), the torque sensor (5), the touch screen (2), the start button (19), and the stop button (20) are all electrically connected to the PLC controller (10); the frequency converter (11), the temperature sensor (8), and the vibration sensor (9) are electrically connected to the PLC controller (10) through the relay (14), the analog quantity acquisition module (15), and the dual-channel signal conversion module (16), respectively; and the output end of the frequency converter (11) is connected to the variable frequency speed regulating motor (3).

2. The side reducer no-load test detection system according to claim 1, characterized in that: A three-phase indicator light (18), an over-torque alarm indicator light (21), and an emergency stop button (17) are provided on the cabinet door (101), and the three-phase indicator light (18), the over-torque alarm indicator light (21), and the emergency stop button (17) are electrically connected to the PLC controller (10), respectively.

3. The side reducer no-load test detection system according to claim 1, characterized in that: The PLC controller (10) adopts Siemens S7-200 SMART PLC.

4. The side reducer no-load test detection system according to claim 1, characterized in that: The variable frequency speed regulating motor (3) is a YVP series three-phase variable frequency speed regulating motor.

5. The side reducer no-load test detection system according to claim 1, characterized in that: The torque sensor (5) is a Haibohua HCNJ-101 dynamic torque sensor.

6. The side reducer no-load test detection system according to claim 1, characterized in that: The vibration sensor (9) is selected from Chaorui CRZ-401, and the temperature sensor (8) is selected from PT100 temperature sensor.

7. The side reducer no-load test detection system according to claim 1, characterized in that: The inverter (11) is a Sanling heavy-duty 90KW FR-A800 series inverter equipped with an integrated braking unit.

Images