A three-axle test bench for special vehicles

Abstract

The utility model discloses a kind of for special vehicle three-axle test bench, it includes mechanical part and electrical part;Mechanical part is by base welding assembly, front middle axle fixed seat, rear axle fixed seat, speed-regulating motor, belt drive assembly etc. The electrical part adopts ModbusRTU communication protocol, uses Kunlun Tongtai touch screen as master station, controls frequency converter and each function module to realize stepless frequency conversion speed regulation and data monitoring;The application can display shaft speed, lock state and other information in real time, support differential lock control, stepless speed regulation and multiple protection functions, improve detection accuracy, operation convenience and maintenance efficiency, suitable for performance check of front axle, middle axle and rear axle for special vehicle overhaul and intermediate repair enterprise.

Description

Technical Field

[0001] This utility model relates to the technical field of special vehicle testing, and in particular to a three-axle test bench for special vehicles. Background Technology

[0002] Special vehicles, such as wheeled armored vehicles, play a crucial role in specialized fields. Their front, middle, and rear axles are key components, and their performance directly impacts the overall reliability and safety of the vehicle. During major or intermediate vehicle overhauls, conducting sealing tests, no-load running-in tests, temperature rise tests, differential lock clutch tests, and functional tests on these three axles is essential to ensuring vehicle repair quality. However, traditional testing methods typically rely on manual operation or simple mechanical devices, resulting in low efficiency, poor accuracy, and incomplete data monitoring, failing to meet the demands of modern repair workshops for efficient and precise testing. Current technology lacks a testing device capable of simulating the actual operating conditions of the three axles of special vehicles and achieving multi-functional integrated testing, leading to significant rework, high repair costs, and inconsistent repair quality. Furthermore, the electrical control systems of traditional testing equipment often use independent control modules, lacking unified communication protocols and real-time monitoring capabilities. This makes it difficult to achieve precise control and dynamic feedback of parameters such as motor speed, current, and voltage, further limiting the improvement of testing efficiency and accuracy. Therefore, developing a test bench that can simulate the three-axle operation principle of special vehicles, has multi-functional testing capabilities, and is easy to operate has become an urgent technical challenge. Utility Model Content

[0003] The purpose of this invention is to provide a three-axle test bench for special vehicles to overcome the shortcomings of the existing technology.

[0004] To achieve the above objectives, this utility model provides the following technical solution:

[0005] A three-axle test bench for special vehicles includes mechanical and electrical components. Among them:

[0006] The mechanical components consist of a base welding assembly, front and middle axle mounting brackets, a rear axle mounting bracket, a speed-regulating motor, a belt drive assembly, a pulley bracket, a drive shaft, bearing housings, a protective cover, a motor base plate, and a support plate. Furthermore, the base welding assembly serves as the foundation structure of the entire test bench, on which the rear axle mounting bracket and the front and middle axle mounting bracket are fixedly installed for mounting the front, middle, and rear axles of the armored vehicle and ensuring the stable fixation of the three axles during testing. The speed-regulating motor is mounted on the base welding assembly and connected to the three axles via the belt drive assembly, thereby achieving stepless frequency conversion speed regulation. The pulley bracket is arranged between the rear axle mounting bracket and the front and middle axle mounting bracket, on which the belt drive assembly is mounted to transmit power from the speed-regulating motor to the three axles. Specifically, both ends of the drive shaft are fixed by bearing housings to ensure smooth and reliable transmission, while the protective cover covers the transmission components to improve safety.

[0007] Furthermore, the electrical components include an electrical control cabinet, a Kunlun Tongtai touchscreen, a frequency converter, RS485 digital input modules, RS485 digital output modules, analog speed-to-current modules, current-to-current modules, pneumatic solenoid directional valves, RS232-to-485 converters, circuit breakers, relays, air pipes, and cables. The electrical control cabinet is installed independently of the operating platform to reduce vibration interference from platform operation on the electrical control system. The Kunlun Tongtai touchscreen acts as the master station, communicating with each slave module via an RS485 bus, using the Modbus RTU communication protocol to send and receive data frames. The frequency converter, as one of the slave stations, is responsible for controlling the starting, speed regulation, and protection functions of the speed-regulating motor. The RS485 digital input and output modules are used to process the input and output control of digital signals, respectively. The analog speed-to-current and current-to-current modules are used for signal conversion and processing to ensure the accuracy of data transmission.

[0008] Specifically, this utility model achieves the function of the test bench through the following specific technical solutions:

[0009] S1: The master station sends data frames via the RS485 bus, and each slave station performs corresponding operations based on the content of the data frame. For example, when the master station touchscreen sends a data frame to start a three-phase motor, the frequency converter recognizes and executes the data frame, starting the speed-regulating motor to run at a specific frequency.

[0010] S2: When the master station needs to read relevant data from the inverter, the master station sends a request data frame to the touch screen. After the inverter recognizes the request, it returns a useful data frame, which is then displayed on the screen by the master station.

[0011] S3: Switch output and switch input control follow the same logic, but the data frame content is different, including slave address, register address and function code, etc.

[0012] Furthermore, this invention achieves stepless frequency conversion speed regulation of the three-phase drive motor through an external speed control knob and touch screen. The touch screen displays the shaft speed, lock status, voltage, current, and frequency values ​​in real time, facilitating operator monitoring of the test process. In addition, the three-phase drive motor has emergency stop power-off protection, overload protection, and forward / reverse rotation functions to improve the safety and reliability of the test.

[0013] In particular, the innovative point of this utility model is:

[0014] The Modbus RTU communication protocol is used as the main line, and various functional modules are connected via an RS485 bus to achieve efficient communication between the master station and slave stations. The master station controls the slave station to perform operations by sending data frames and receives data frames returned by the slave station to complete data interaction.

[0015] The independent electrical control cabinet design separates the electrical control system from the operating platform, reducing the vibration impact of platform operation on the electrical control system and extending the service life of the equipment.

[0016] By combining the belt drive assembly with the speed-regulating motor, stepless frequency conversion speed regulation of the three bridges is achieved to meet the testing requirements under different working conditions.

[0017] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0018] The touchscreen displays the shaft speed and lock status in real time, and supports controlling the connection and disconnection of the differential locks on each bridge, improving operational convenience. Both the external speed control knob and the touchscreen enable stepless frequency conversion speed regulation of the three-phase drive motor, real-time monitoring of voltage, current, and frequency values, improving testing accuracy. The three-phase drive motor features emergency stop power-off protection, overload protection, and forward / reverse rotation functions, enhancing the safety and reliability of the testing process. The independent electrical control cabinet design effectively reduces the vibration impact of the test bench operation on the electrical control system, lowering equipment maintenance costs and extending service life. This test bench facilitates testing and maintenance in the workshop, reducing rework, lowering repair costs, and improving product repair quality.

[0019] Specifically, this utility model is applicable to repair enterprises specializing in major and intermediate repairs of special vehicles, and is used for comprehensive inspection of the performance of the front, middle, and rear axles of vehicles, meeting the needs of the special vehicle repair industry for efficient and accurate testing equipment. The above-described technical solution of this utility model, through a detailed description of the mechanical structure, electrical system, and control logic of the test bench, ensures that those skilled in the art can implement the technical solution of this utility model based on the described content. Attached Figure Description

[0020] Figure 1 This is a schematic front view of the test bench of this utility model;

[0021] Figure 2This is a three-dimensional schematic diagram of the test bench of this utility model.

[0022] The attached figures are labeled as follows:

[0023] 1. Base welding assembly;

[0024] 2. Speed-regulating motor;

[0025] 3. Pulley bracket;

[0026] 4. Rear axle mounting bracket;

[0027] 5. Front and middle axle mounting brackets;

[0028] 6. Belt drive assembly;

[0029] 7. Electrical control cabinet. Detailed Implementation

[0030] To make the above-mentioned objects, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a full understanding of this utility model. However, this utility model can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed below.

[0031] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly attached to the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. When the number of elements is referred to as "multiple," it can be any number of two or more. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0032] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0033] The present invention will now be described in detail with reference to the embodiments shown in the accompanying drawings:

[0034] Appendix Figure 1 and attached Figure 2 A detailed explanation is provided, including the attached... Figure 1This is a schematic diagram of the front view of the test bench, attached. Figure 2 This is a three-dimensional schematic diagram of the test bench. The component numbers marked in the attached diagram include: 1. Base welding assembly; 2. Speed ​​regulating motor; 3. Pulley bracket; 4. Rear axle mounting base; 5. Front and middle axle mounting base; 6. Belt drive assembly; and 7. Electrical control cabinet. The following detailed description of this utility model will illustrate its specific structural composition, operating principle, and operational process.

[0035] The mechanical components of the test bench are based on a base welded assembly 1, upon which a rear axle mounting bracket 4 and a front and middle axle mounting bracket 5 are fixed. These two mounting brackets are used to install the rear and front and middle axles of the armored vehicle, respectively, ensuring the stability of all three axles during testing. The base welded assembly 1 is constructed of high-strength steel, possessing sufficient rigidity and load-bearing capacity to withstand potential vibrations and load variations during testing. A speed-regulating motor 2 is mounted on one side of the base welded assembly 1, and its output shaft is connected to the three axles of the armored vehicle via a belt drive assembly 6. The belt drive assembly 6 is mounted on a pulley bracket 3, which is positioned between the rear axle mounting bracket 4 and the front and middle axle mounting bracket 5. This layout ensures smoother power transmission and higher space utilization. The drive shaft is fixed at both ends by bearing seats to ensure stability during transmission, while a protective cover covers the transmission components to prevent foreign objects from entering or personnel from contacting hazardous areas.

[0036] The core components of the electrical system include the electrical control cabinet 7, the Kunlun Tongtai touchscreen, the frequency converter, RS485 digital input modules, RS485 digital output modules, analog speed-to-current modules, current-to-current modules, and other auxiliary components. The electrical control cabinet 7 is independently located on one side of the base welding assembly 1, away from the operating platform, thus reducing the vibration impact on the electrical control system during platform operation. The electrical control cabinet 7 integrates circuit breakers, relays, and other protective components to ensure the safety of the entire electrical system. The Kunlun Tongtai touchscreen, acting as the master station, communicates with each slave module via an RS485 bus, using the Modbus RTU communication protocol for data exchange. The frequency converter, as one of the slave stations, is responsible for controlling the starting, speed regulation, and protection functions of the speed-regulating motor 2. The RS485 digital input and output modules handle the input and output control of digital signals, such as controlling the operation of pneumatic solenoid directional valves. The analog speed-to-current and current-to-current modules perform signal conversion tasks, transforming the analog signals collected by sensors into data formats suitable for transmission and display.

[0037] The operation process of the test bench is as follows: S1: When the operator needs to start the speed-regulating motor 2, a start command is sent through the Kunlun Tongtai touch screen. The master station touch screen generates a data frame containing the start command and sends it to each slave station via the RS485 bus. Only the frequency converter in the slave station recognizes the data frame and is related to it, so it executes the start operation and runs the speed-regulating motor 2 at the set frequency. S2: If the master station needs to read relevant parameters of the frequency converter, such as the operating current value, the master station touch screen generates a request data frame and sends it to the bus. After receiving the data frame, the frequency converter parses it and returns a data frame containing the required parameters. The master station receives the data frame and displays the parameters on the screen in real time. S3: For switch input and output control, such as controlling the state switching of the differential lock, the master station also achieves this by sending a specific data frame. The data frame content includes information such as the slave station address, register address, and function code to ensure that the command is accurately transmitted to the target device.

[0038] The test bench's functionality relies on efficient collaboration between its modules. For example, during a sealing test, the speed-regulating motor 2 drives the armored vehicle's three axles via the belt drive assembly 6, while the Kunlun Tongtai touchscreen displays the shaft speed and lock status in real time. Operators can control the engagement and disengagement of the differential locks on each axle via the touchscreen to verify their functionality. When adjusting the motor speed using an external speed control knob or the touchscreen, the frequency converter adjusts the output frequency according to the input signal, achieving stepless speed regulation of the three-phase drive motor. The touchscreen simultaneously monitors voltage, current, and frequency values ​​to ensure that all parameters remain within reasonable ranges during the test. Furthermore, the three-phase drive motor features emergency stop protection, immediately cutting off power when an abnormality is detected; overload protection triggers an alarm and stops operation when the motor load exceeds the rated value; and forward / reverse rotation is achieved by changing the motor phase sequence to meet the needs of different operating conditions.

[0039] The test bench design also fully considers convenience and reliability in practical application scenarios. For example, the independent electrical control cabinet 7 not only reduces vibration interference to the electrical system during bench operation but also facilitates daily maintenance and repair. The selection of the belt drive assembly 6 makes power transmission smoother and easier to adjust, adapting to the testing requirements of different types of armored vehicle three-axle systems. The Kunlun Tongtai touchscreen interface is intuitive and easy to use, allowing operators to quickly get started without complex training. The introduction of analog speed-to-current and current-to-current modules improves the accuracy of signal transmission and avoids misjudgments caused by signal distortion.

[0040] Through the above technical solutions, this test bench can comprehensively test the performance of the three axles of armored vehicles. In the sealing test, the sealing effect is judged by observing lubricating oil leakage; in the no-load running-in test, the operating status of the three axles at different speeds is recorded; in the temperature rise test, the temperature changes of key components of the three axles are monitored; in the differential lock clutch test, the sensitivity and reliability of the differential lock's operation are verified; and in the functional test, the overall working performance of the three axles is checked to ensure it meets requirements. These testing items effectively improve workshop maintenance efficiency, reduce rework, lower repair costs, and simultaneously improve product repair quality.

[0041] In summary, this utility model achieves efficient testing of the three axles of special vehicles through optimized mechanical structure design and electronic control system configuration. The test bench not only meets the actual needs of overhaul and intermediate repair businesses but also provides a reliable testing method for the special vehicle repair industry. Detailed descriptions of the embodiments clarify the assembly method, operating principle, and operation steps of the test bench, ensuring that those skilled in the art can completely reproduce the technical solution of this utility model based on the described content.

[0042] The technical features of the above embodiments can be combined arbitrarily. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as the combination of these technical features does not contradict each other, it should be considered within the scope of this specification. For those skilled in the art, several modifications and improvements can be made without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A tri-axle test bed for specialty vehicles, characterized by: It includes mechanical and electrical components. The mechanical components consist of a base welding assembly (1), a speed-regulating motor (2), a pulley bracket (3), a rear axle mounting base (4), a front and middle axle mounting base (5), and a belt drive assembly (6). The electrical components include an electrical control cabinet (7), a Kunlun Tongtai touch screen, a frequency converter, an RS485 digital input module, an RS485 digital output module, an analog speed-to-current module, a current-to-current module, a pneumatic solenoid directional valve, an RS232 to 485 converter, a circuit breaker, a relay, air pipes, and cables.

2. The three axle test bed for special vehicles as claimed in claim 1 wherein: The rear axle mounting base (4) and the front middle axle mounting base (5) are fixedly mounted on the base welding assembly (1). The rear axle mounting base (4) and the front middle axle mounting base (5) are used to install the rear axle and the front middle axle of the armored vehicle, respectively.

3. The three axle test bed for special vehicles as claimed in claim 2 wherein: The speed-regulating motor (2) is connected to the three axles of the armored vehicle via a belt drive assembly (6). The belt drive assembly (6) is mounted on a pulley bracket (3), which is located between the rear axle mounting base (4) and the front middle axle mounting base (5).

4. The three axle test stand for specialty vehicles of claim 1, wherein: The Kunlun Tongtai touch screen, as the master station, communicates with each slave station module via RS485 bus and uses Modbus RTU communication protocol to send and receive data frames. The frequency converter, as one of the slave stations, controls the starting, speed regulation and protection functions of the speed-regulating motor (2).

5. The three axle test stand for specialty vehicles of claim 4, wherein: The RS485 digital input module and RS485 digital output module respectively handle the input and output control of digital signals, while the analog speed-to-current module and current-to-current module complete the signal conversion task.

6. The three axle test stand for specialty vehicles of claim 1, wherein: The electrical control cabinet (7) is independently set on one side of the base welding assembly (1), away from the operating platform to reduce the vibration impact of the platform operation on the electrical control system.

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