Testing device for cooling system of large-torque automotive automatic transmission

Abstract

The utility model discloses a large-torque automotive automatic transmission cooling system testing device, and belongs to the technical field of transmission testing. The driving motor is connected with the automatic transmission; an output shaft of the automatic transmission is connected with the load motor; the movable cooler test device is connected with an automatic transmission oil pipe through connection, and the cooling-water machine is connected with the movable cooler test device through a water pipe; and the rack industrial personal computer controls the on-off of the driving motor. Different from a previous rack cooler, the cooler test device adopts a constant-flow highly-integrated movable cooler test device, internal variables are integrated into a rack industrial personal computer, operation is simple, and heat dissipation of a constant-flow fan can better simulate the heat dissipation form of a transmission in a real vehicle. According to the utility model, various heat dissipation requirements of the automatic transmission for the large-torque windmill in the actual use process can be truly simulated by setting various complex test working conditions, such as rapid acceleration, long-time climbing and heavy-load driving, so that the test result has more practical guiding significance.

Description

Technical Field

[0001] This utility model belongs to the field of transmission testing technology, and in particular relates to a testing device for a high-torque automotive automatic transmission cooling system. Background Technology

[0002] With the development of the automotive industry, high-torque automatic transmissions play a crucial role in vehicle power transmission. Automatic transmissions generate a significant amount of heat during operation; if the cooling system is inadequate, it can lead to excessively high transmission oil temperatures, causing shift delays, reduced efficiency, and even damage to transmission components, severely impacting vehicle reliability and lifespan. Therefore, conducting comprehensive and accurate testing of the cooling system of high-torque automatic transmissions to evaluate its cooling performance has become a critical step in automotive research and development and production.

[0003] Current testing equipment and methods for automatic transmission cooling systems have several problems. ① Cooler testing equipment is limited to a single test condition. High-torque transmissions generate more heat, and current equipment often has low and inconsistent water flow rates, mostly simulating heat dissipation under normal driving conditions. Bench tests can only measure parameters like transmission flow rate and temperature, making it impossible to determine the minimum flow rate for the cooler testing equipment. ② Traditional cooler testing equipment has poor integration, with numerous temperature and pressure measurement points, and complex and inconvenient communication signal integration. ③ The testing methods lack comprehensive test conditions, failing to cover the extreme operating conditions faced by the cooling system of high-torque automatic transmissions under complex conditions (long-term hill climbing, frequent rapid acceleration, heavy-load driving), resulting in test results that do not accurately reflect the actual performance of the cooling system, are unadjustable, and cannot fully simulate real-world heat dissipation. ④ Traditional testing methods are relatively simple in data processing and analysis, lacking systematic data mining and failing to evaluate the cooling system's capabilities.

[0004] Therefore, developing a test device that can be adapted to a high-torque cooling system on a test bench, and a test method for a high-torque automotive automatic transmission cooling system that can simulate various complex working conditions, comprehensively monitor test parameters, and scientifically analyze test data, is of great practical significance. Summary of the Invention

[0005] The purpose of this invention is to provide a test device for the cooling system of a high-torque automotive automatic transmission. By simulating various complex working conditions, it comprehensively monitors the relevant parameters of the cooling system and uses scientific data processing and analysis methods to accurately evaluate the performance of the cooling system, providing a reliable basis for the optimized design and quality improvement of the cooling system of a high-torque automotive automatic transmission.

[0006] The technical solution adopted by this utility model is:

[0007] A test device for a high-torque automotive automatic transmission cooling system includes a drive motor, an automatic transmission, a load motor, a movable cooler test device, a chiller, and a benchtop industrial control computer. The drive motor is connected to the automatic transmission, and the output shaft of the automatic transmission is connected to the load motor. The movable cooler test device is connected to the automatic transmission oil pipe via an adapter, and the chiller is connected to the movable cooler test device via a water pipe. The benchtop industrial control computer controls the on / off state of the drive motor.

[0008] Compared with the prior art, the present invention has the following advantages:

[0009] 1. The cooler test device of this utility model is different from the previous bench cooler. This time, a highly integrated movable cooler test device with constant flow is adopted. The internal variables are integrated into the bench industrial control computer, which is simple to operate. The constant flow fan heat dissipation can better simulate the heat dissipation of the transmission in the real vehicle.

[0010] 2. Comprehensive operating condition simulation: This utility model can simulate the various heat dissipation requirements of high-torque automatic transmissions in actual use by setting a variety of complex test conditions, such as rapid acceleration, long-term uphill climbing, and heavy-load driving, making the test results more practically instructive.

[0011] 3. Comprehensive parameter monitoring: This utility model comprehensively monitors multiple key parameters such as transmission oil temperature, heat exchanger inlet and outlet temperatures, coolant flow rate, pressure, and cooling fan speed. At the same time, the variables inside the cooler test device are recorded at the same frequency as the operating conditions collected by the test piece, which can fit curves in real time. It can gain a deep understanding of the working characteristics of the cooling system under different real vehicle test conditions, and provide rich data support for analyzing the performance of the cooling system.

[0012] 4. High application value: This utility model helps to improve the research and development efficiency and quality of cooling systems for high-torque automotive automatic transmissions, reduces the risk of vehicle failures caused by cooling system problems, and plays an important role in improving the reliability and market competitiveness of automobiles. Attached Figure Description

[0013] Figure 1 This is a system diagram of this utility model;

[0014] Figure 2 This is a schematic diagram of the test device for the cooler of this utility model;

[0015] The components include: 1. Drive motor; 2. Automatic transmission; 3. Load motor; 4. Portable cooler test device; 5. Chiller; 6. Benchtop industrial computer; 7. High-precision electromagnetic flowmeter; 8. Pressure stabilizing tank; 9. Temperature measuring point; 10. Heat exchanger; 11. Fan; 12. Main circulation pump; 13. Pressure measuring point; 14. Flowmeter. Detailed Implementation

[0016] To better understand the purpose, structure, and function of this utility model, a more detailed description of this utility model will be provided below with reference to the accompanying drawings.

[0017] like Figure 1 As shown, this utility model provides a test device for a high-torque automotive automatic transmission cooling system, including a drive motor 1, an automatic transmission 2, a load motor 3, a movable cooler test device 4, a chiller 5, and a benchtop industrial control computer 6; the drive motor 1 is connected to the automatic transmission 2 via a coupling, and the output shaft of the automatic transmission 2 is connected to the load motor 3 via a transmission shaft; the movable cooler test device 4 is connected to the automatic transmission 2 via an oil pipe adapter, and the chiller 5 is connected to the movable cooler test device 4 via a water pipe; the benchtop industrial control computer 6 controls the on / off state of the drive motor 1.

[0018] like Figure 2 As shown, the portable cooler test device 4 includes a heat exchanger 10, a high-precision electromagnetic flowmeter 7, a fan 11, a main circulation pump 12, and a flowmeter 14.

[0019] The left side of the heat exchanger 10 is circulated to the chiller 5 via a coolant circulation loop. Temperature measuring points 9 are installed on both the inlet and outlet coolant circulation loops of the heat exchanger 10. A high-precision electromagnetic flow meter 7 is connected in series in the coolant circulation loop at the inlet of the heat exchanger 10. The flow data from the high-precision electromagnetic flow meter 7 is transmitted back to the control system in real time to provide feedback on the operating status and achieve closed-loop constant flow control.

[0020] The right side of the heat exchanger 10 is circulatedly connected to the automatic transmission 2 through the test piece circulation loop. Temperature measuring points 9 and pressure measuring points 13 are provided on the test piece circulation loop at both the oil inlet and outlet ends of the heat exchanger 10, and flow meters 14 are installed on both. A fan 11 is located next to the test piece circulation loop, and a main circulation pump 12 is provided on the test piece circulation loop.

[0021] like Figure 2 As shown, a pressure stabilizing tank 8 is connected in series in the coolant circulation loop, and the pressure stabilizing tank 8 is located at the outlet end of the heat exchanger 10.

[0022] The portable cooler test device 4 is highly integrated and easy to move. It has a large and constant cooling flow rate and can accurately test the speed of the cooling fan 11, the inlet and outlet temperatures of the heat exchanger 10, the flow rate and pressure of the coolant, and the flow rate and pressure of the test piece. It can also communicate directly with the benchtop industrial control computer to meet the heat dissipation and monitoring requirements under complex working conditions.

[0023] The test method for the cooling system of a high-torque automotive automatic transmission includes the following steps:

[0024] S1. Test preparation: Install and debug the equipment, and set the test parameters;

[0025] Equipment Installation and Commissioning: Install the high-torque automatic transmission 2 and the movable cooler test device 4 on the test bench, ensuring a secure installation and leak-free sealing of all pipe connections. Connect the cooler circulation device, temperature sensors, pressure sensors, flow sensors, speed sensors, and other test equipment, and commission the equipment to ensure normal operation. Specifically, temperature sensors are installed in the transmission oil pan, the inlet and outlet of the heat exchanger 10, and at key locations in the coolant piping; pressure sensors are installed in the test specimen's circulation piping; flow meters (high-precision electromagnetic flow meter 7 and flow meter 14) are installed in both the coolant circulation loop and the test specimen's circulation loop.

[0026] Test parameters were set: Based on the actual operating conditions and design requirements of the high-torque automatic transmission 2, the initial test parameters were set, including a constant coolant temperature of 30±3°C, an initial oil temperature of 30±3°C for the automatic transmission 2, an ambient temperature of 30±3°C, and an initial coolant flow rate of 30L / min. The flow rate was adjusted in steps, with a minimum adjustment of 5L / min.

[0027] Three test conditions were designed to simulate real vehicle conditions: ① Long-term hill climbing condition (maintaining high and stable torque output for 1 hour), ② Simulated rapid vehicle acceleration condition (rapidly increasing the transmission input torque to the rated torque and then reducing the torque to 0 in a short period of time, repeating the above operation for 1 hour), and ③ Heavy-load driving condition (setting the road slope resistance to full load, adjusting the uphill and downhill slopes, 1 hour for each slope).

[0028] S2. Preliminary test: Start the movable cooler test device 4 and the automatic transmission 2 to check the operating status;

[0029] Start the portable cooler test device 4 and automatic transmission 2, and run them at 750 rpm for 10 minutes. Observe the working status of each component of the cooling system, check whether there is any leakage in the coolant pipeline, whether the cooling fan 11 is operating normally, and whether the data of each sensor is stable and within a reasonable range, to ensure that there are no abnormalities in the test equipment and cooling system.

[0030] S3. Formal Experiment:

[0031] Operating condition simulation and parameter monitoring: Conduct the test sequentially according to the set test conditions;

[0032] The first method simulates a long-term hill climb using a high-torque automatic transmission 2. A prolonged hill climb condition is set, with the automatic transmission 2 having a total of 8 gears. Within 60±3 seconds (preferably 60 seconds), the torque of the automatic transmission 2 reaches 1400±300 Nm (preferably 1400 Nm), and the speed reaches 2200±300 rpm (preferably 2200 rpm), remaining stable for 1±0.3 hours (preferably 1 hour). Internal variables of the test apparatus are monitored and recorded in real time: transmission oil temperature, heat exchanger inlet and outlet temperatures, coolant temperature, coolant flow rate, coolant pressure, and cooling fan speed. Data is recorded every 30 seconds.

[0033] The second method involves setting up a simulated rapid acceleration condition. Drive motor 1 simulates the external characteristics of an engine. Once the torque reaches its maximum value in the shortest time, the drive side is released. The operation is repeated until the torque drops to 0. The parameter data is recorded every 30 seconds. The operation lasts for 1 ± 0.3 hours (preferably 1 hour).

[0034] The third method involves setting up a heavy-load driving condition, setting the test equipment to run under full load, setting the initial road slope to 0, adjusting the road's uphill and downhill slopes to a maximum of 30%, and recording the data of each parameter every 30 seconds for a duration of 1 ± 0.3 hours (preferably 1 hour).

[0035] Under the three test conditions described above, the initial water temperature was 30±3°C, the transmission oil temperature was 30±3°C, the indoor ambient temperature was 30±3°C, and the transmission had eight gears (D1-D8). The movable cooler test device 4 maintained a constant flow control with a preset initial flow rate of 30L / min, and the fan 11 had a constant power. The internal variables of the test device were monitored and recorded in real time, including the automatic transmission 2 oil temperature, the inlet and outlet temperatures of the heat exchanger 10, the coolant temperature, the coolant flow rate, the coolant pressure, and the speed of the cooling fan 11. Data was recorded every 30 seconds. During this period, the transmission was judged to have reached thermal equilibrium based on the measured temperature data and other parameters. Note that if the coolant temperature is greater than 118°C or the automatic transmission 2 oil temperature is greater than 130°C, the test must be stopped immediately. At this time, the movable cooler test device 4 was adjusted, and the preset flow rate was set sequentially from 30L / min up to 100L / min, with a minimum interval of 5L / min. Finally, the performance of the transmission cooling system was evaluated based on the test results to confirm the minimum cooling flow rate of the transmission cooling system.

[0036] This method allows automakers to fully verify the cooling performance of the automatic transmission 2 on the bench during the prototype development stage of the high-torque transmission. During the vehicle modification stage, the corresponding heat exchanger 10 can be matched according to the bench test data, eliminating problems such as powertrain torque limitation and overheating alarm caused by insufficient cooling performance during vehicle use, thereby improving product quality and prototype development efficiency.

[0037] S4. Data Processing and Analysis:

[0038] Data processing: After the experiment, all collected data were processed, and outliers were removed. The data were then categorized and stored according to different operating conditions for easy subsequent analysis.

[0039] Performance index calculation: Based on the processed data, calculate various performance indicators of the cooling system. Calculate the heat dissipation efficiency of heat exchanger 10 (calculate the heat exchange capacity based on the coolant temperature and flow rate at the inlet and outlet of heat exchanger 10, and calculate the heat dissipation efficiency in conjunction with the heat generated by automatic transmission 2), the average rate of temperature rise of automatic transmission 2 oil, etc.

[0040] Data Analysis and Charting: Data analysis software is used for in-depth analysis. Charts such as transmission oil temperature-time curves, heat exchanger inlet and outlet temperature-time curves, and coolant flow rate-time curves are generated to visually display the changing trends of various cooling system parameters under different operating conditions. This is achieved by comparing experimental data under different operating conditions.

[0041] Results Evaluation: Based on the calculated performance indicators and data analysis results, the performance of the cooling system was evaluated against the design requirements and industry standards for high-torque automotive automatic transmission cooling systems. By simulating actual operating conditions, it was determined whether the cooling system could meet the heat dissipation requirements under different operating conditions and whether there were problems such as excessive temperature or insufficient coolant flow. The performance of the cooling system under various operating conditions was analyzed to identify its weaknesses and performance bottlenecks.

[0042] It is understood that this utility model has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of this utility model. Furthermore, under the teachings of this utility model, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of this utility model.

Claims

1. A test apparatus for a high-torque automotive automatic transmission cooling system, characterized in that: It includes a drive motor (1), an automatic transmission (2), a load motor (3), a portable cooler test device (4), a chiller (5), and a benchtop industrial control computer (6); the drive motor (1) is connected to the automatic transmission (2), and the output shaft of the automatic transmission (2) is connected to the load motor (3); the portable cooler test device (4) is connected to the automatic transmission (2) by an oil pipe adapter, and the chiller (5) is connected to the portable cooler test device (4) through a water pipe; the benchtop industrial control computer (6) controls the on / off state of the drive motor (1).

2. The testing apparatus for a high-torque automotive automatic transmission cooling system according to claim 1, characterized in that: The portable cooler test device (4) includes a heat exchanger (10), a high-precision electromagnetic flowmeter (7), a fan (11), a main circulation pump (12), and a flowmeter (14). The left side of the heat exchanger (10) is connected to the chiller (5) through a coolant circulation loop. Temperature measuring points (9) are set on the coolant circulation loops at both the inlet and outlet of the heat exchanger (10). A high-precision electromagnetic flowmeter (7) is connected in series on the coolant circulation loop at the inlet of the heat exchanger (10). The right side of the heat exchanger (10) is connected to the automatic transmission (2) through the test piece circulation loop. Temperature measuring point (9), pressure measuring point (13), flow meter (14), and fan (11) are installed on the test piece circulation loop at the oil inlet and oil outlet of the heat exchanger (10). A main circulation pump (12) is also installed on the test piece circulation loop.

3. The testing apparatus for a high-torque automotive automatic transmission cooling system according to claim 2, characterized in that: A pressure stabilizing tank (8) is connected in series in the coolant circulation loop, and the pressure stabilizing tank (8) is located at the outlet of the heat exchanger (10).

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