A load device for AMT shift control unit durability test

Abstract

The utility model discloses a load device for AMT gear shift control unit endurance test, specifically relates to the field of automobile parts testing equipment, including the protection cover and base, the protection cover covers above base formation test space, install gear selection cylinder load mechanism, gear shift cylinder load mechanism, differential gear cylinder load mechanism and range gear cylinder load mechanism on the base, wherein, four kinds of load mechanism structure are same and symmetrical arrangement, can carry out synchronous endurance test to four executing cylinders of AMT gear shift control unit simultaneously. The utility model adopts mechanical spring load mode, saves complicated hydraulic or pneumatic system, and the overall structure is simplified, and it is convenient to install and maintain, does not need hydraulic pump, air source processing unit and so on expensive parts, and the manufacturing cost is greatly reduced, through the adjustment spring pre -tightening force, can adapt to the test demand of different models AMT gear shift control unit, accurately simulates the switching process of self -lock force and gear shift force, and the test result is more close to actual working condition.

Description

Technical Field

[0001] This utility model relates to the technical field of automotive parts testing equipment, and more specifically, to a load device for durability testing of an AMT shift control unit. Background Technology

[0002] As a core component of the vehicle's transmission system, the AMT (Automated Manual Transmission) shift control unit's durability and reliability directly affect the vehicle's transmission efficiency and service life. Therefore, rigorous durability testing must be conducted during the research and development and quality control of the AMT control unit to simulate the long-term mechanical loads and fatigue impacts caused by frequent gear shifts in real-world operating environments.

[0003] Currently, the commonly used durability testing load mechanisms in the industry mainly include two types: hydraulic mechanical and pneumatic mechanical. While hydraulic load mechanisms can provide a large load force, their system structure is complex, costly, and difficult to maintain, and they pose a risk of hydraulic oil leakage, creating potential threats to the environment and testing safety. Pneumatic load mechanisms, although relatively simple in structure, suffer from poor load force stability, slow response speed, and are greatly affected by the quality of the air source, resulting in poor versatility and test repeatability.

[0004] Furthermore, traditional load mechanisms typically only simulate loads in a single direction, making it difficult to realistically reproduce the dual-stage force changes (i.e., the switching between locking force and shifting force) during AMT gear shifting, resulting in significant deviations between test results and actual operating conditions. Simultaneously, existing equipment often only allows testing of a single cylinder, failing to achieve simultaneous load testing of multiple cylinders (such as gear selection, shifting, differential gearing, and range gearing), leading to low testing efficiency and failing to meet the integrated testing requirements of modern AMT systems. Utility Model Content

[0005] In order to overcome the above-mentioned defects of the prior art, the embodiments of this utility model provide a load device for endurance testing of AMT shift control unit. The technical problem to be solved by this utility model is: how to provide a load device that is compact in structure, low in cost, versatile, has a low failure rate, can simulate real two-stage load force and can simultaneously perform endurance testing of four cylinders (gear selection, shifting, differential gear, and range gear).

[0006] To achieve the above objectives, this utility model provides the following technical solution: a load device for endurance testing of an AMT shift control unit, comprising a protective cover and a base, wherein the protective cover covers the base to form a test space; The base is equipped with a gear selection cylinder load mechanism, a shift cylinder load mechanism, a differential gear cylinder load mechanism, and a range gear cylinder load mechanism. The four load mechanisms have the same structure and are arranged symmetrically, which can simultaneously perform synchronous durability tests on the four actuator cylinders of the AMT shift control unit.

[0007] In a preferred embodiment, the base is configured as a rigid platform made of high-strength cast iron or alloy steel, and the base is provided with a precision-machined positioning surface and an array of multiple threaded holes for precise installation of different models of AMT shift control units. The protective cover is made of transparent polycarbonate material and has an openable observation window.

[0008] In a preferred embodiment, the gear selection cylinder load mechanism includes a gear selection connector, a gear selection position sensor, a gear selection load rod, a gear selection rod chamber, a gear selection rodless chamber, a gear selection positioning block, and a gear selection load spring preload adjustment bolt. The gear selection connector is connected to the gear selection load rod, and the gear selection connector is threadedly connected to the gear selection cylinder. The gear selection cylinder load mechanism pushes the gear selection cylinder to move through the gear selection rodless chamber. The rodless chamber provides load resistance, which is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. After the gear selection rodless chamber pushes the gear selection cylinder to its position, the gear selection position sensor detects the position and transmits the position signal to the control cabinet. After receiving the signal, the control cabinet's solenoid valve reverses, and the gear selection rod chamber pulls the gear selection cylinder to move. The gear selection rod chamber provides load resistance, which is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork.

[0009] In a preferred embodiment, the shift cylinder load mechanism includes a shift connector, a shift load rod, a shift rod chamber, a shift rodless chamber, a shift positioning block, a shift position sensor, and a shift load spring preload adjustment bolt. The shift connector is connected to the shift load rod, and the shift connector is threadedly connected to a shift cylinder. The shift rod chamber and the shift rodless chamber are respectively located on both sides of the shift positioning block. The shift rod chamber, the shift rodless chamber, and the shift positioning block together form a shift load spring assembly. The shift leverless chamber pushes the shift cylinder to move, and the shift leverless chamber provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. After the shift leverless chamber pushes the shift cylinder to its position, the shift position sensor detects the position and transmits the position signal to the control cabinet. After receiving the signal, the control cabinet's solenoid valve reverses, and the shift lever chamber pulls the shift cylinder to move. The shift lever chamber provides load resistance, which is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork.

[0010] In a preferred embodiment, the differential gear cylinder load mechanism includes a differential gear connector, a differential gear load rod, a differential gear rodless cavity, a differential gear rod cavity, a differential gear positioning block, a differential position sensor, and a differential load spring preload adjustment bolt. The differential gear connector is connected to the differential gear load rod, and the differential gear connector is threadedly connected to the differential gear cylinder. The differential gear rodless cavity and the differential gear rod cavity are respectively located on both sides of the differential gear positioning block. The differential gear rodless cavity, the differential gear rod cavity, and the differential gear positioning block together form a differential load spring assembly. The differential gear rodless chamber pushes the differential gear cylinder to move, and the differential gear rodless chamber provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. After the differential gear leverless chamber pushes the differential gear cylinder to its position, the differential position sensor detects the position and transmits the position signal to the control cabinet. After receiving the signal, the control cabinet's solenoid valve reverses, and the differential gear lever-type chamber pulls the differential gear cylinder to move. The differential gear lever-type chamber provides load resistance, which is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork.

[0011] In a preferred embodiment, the range-limiting cylinder load mechanism includes a range-limiting connector, a range-limiting load rod, a range-limiting rodless cavity, a range-limiting rod cavity, a range-limiting positioning block, a range position sensor, and a range-limiting load spring preload adjustment bolt. The range-limiting connector is connected to the range-limiting load rod, and the range-limiting connector is threadedly connected to the range-limiting cylinder. The range-limiting rodless cavity and the range-limiting rod cavity are respectively located on both sides of the range-limiting positioning block. The range-limiting rodless cavity, the range-limiting rod cavity, and the range-limiting positioning block together form a range-limiting load spring assembly. The range gear rodless chamber pushes the range gear cylinder to move, and the range gear rodless chamber provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. After the range gear leverless chamber pushes the range gear cylinder to its position, the range position sensor detects the position and transmits the position signal to the control cabinet. After receiving the signal, the control cabinet's solenoid valve reverses, and the range gear lever with a rod chamber pulls the range gear cylinder to move. The range gear lever with a rod chamber provides load resistance, which is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork.

[0012] In a preferred embodiment, the shift load spring assembly, the selector load spring assembly, and the range load spring assembly all include a rod-type butterfly spring, a rod-type guide post, a rod-type cylindrical helical compression spring, a rodless butterfly spring, a rodless guide post, a rodless cylindrical helical compression spring, and a positioning rod. The load force can be precisely adjusted by the load spring preload adjustment bolt.

[0013] The technical effects and advantages of this utility model are as follows: This invention uses a mechanical spring load method, eliminating the need for complex hydraulic or pneumatic systems. The overall structure is simplified and compact, with a small footprint, making it easy to install and maintain. It also eliminates the need for expensive components such as hydraulic pumps and air source processing units, significantly reducing manufacturing costs. This invention can adapt to the testing requirements of different models of AMT shift control units by adjusting the spring preload; it has a purely mechanical structure, with no leakage or pollution, and stable and reliable operation; through the design and arrangement of the spring assembly, it accurately simulates the switching process of self-locking force and shifting force, and the test results are closer to the actual working conditions.

[0014] This invention can simultaneously perform durability tests on four cylinders: gear selection, gear shifting, differential gear, and range gear, greatly improving testing efficiency; the spring preload is adjustable, and sensor feedback control ensures the consistency of the testing process and the reliability of the data. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure and appearance of this utility model.

[0016] Figure 2 This is a schematic diagram of the overall internal structure of this utility model.

[0017] Figure 3 This is a schematic diagram of the overall cross-sectional structure of this utility model.

[0018] Figure 4 For the present utility model Figure 3 Enlarged view of the structure in section A.

[0019] The attached diagram is labeled: 100 Protective cover, 101 Base; 103 Differential gear connector, 104 Gear shift connector, 105 Range gear connector, 106 Gear selection connector, 107 Differential position sensor, 108 Gear shift position sensor, 109 Range position sensor, 110 Gear selection position sensor, 111 Differential gear load bar, 112 Gear shift load bar, 113 Range gear load bar, 114 Gear selection load bar, 115 Differential gear rodless cavity, 116 Differential gear rod cavity, 117 Gear shift rodless cavity, 11 8. Shift lever chamber; 119. Range gear leverless chamber; 120. Range gear lever chamber; 121. Selective gear lever chamber; 122. Selective gear leverless chamber; 123. Differential gear positioning block; 124. Shift positioning block; 125. Range gear positioning block; 126. Selective gear positioning block; 127. Differential load spring preload adjustment bolt; 128. Shift load spring preload adjustment bolt; 129. Range load spring preload adjustment bolt; 130. Selective gear load spring preload adjustment bolt. 150 Rod-type butterfly spring, 151 Rod-type guide post, 152 Rod-type cylindrical helical compression spring, 153 Rodless cylindrical helical compression spring, 154 Rodless guide post, 155 Rodless butterfly spring, 156 Positioning rod. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] This utility model provides, for example Figure 1 The load device shown is used for endurance testing of an AMT shift control unit. It includes a protective cover 100 and a base 101. The device has a clean appearance and is easy to integrate into a test bench. The protective cover 100 covers the base 101 to form a test space. The protective cover 100 is made of transparent polycarbonate material and has an openable observation window. The protective cover 100 can effectively prevent external interference and misoperation, and improve test safety. The base 101 is equipped with a gear selection cylinder load mechanism, a shift cylinder load mechanism, a differential gear cylinder load mechanism, and a range gear cylinder load mechanism. The base 101 is a rigid platform made of high-strength cast iron or alloy steel. The base 101 has a precision-machined positioning surface and an array of multiple threaded holes for accurately installing different models of AMT shift control units. The four load mechanisms have the same structure and are symmetrically arranged, which can simultaneously perform synchronous endurance testing on the four actuator cylinders of the AMT shift control unit. Through the symmetrical layout design, each load mechanism can maintain the consistency of output characteristics during operation, while avoiding load deviation problems caused by spatial asymmetry. The design of the gear selection cylinder load mechanism, gear shifting cylinder load mechanism, differential gear cylinder load mechanism, and range gear cylinder load mechanism must meet the requirements of modularity and symmetry to achieve the function of synchronous testing of multiple cylinders. Among them, the load mechanism can provide load resistance through mechanical spring assembly. For example, the mechanical spring assembly can be composed of disc spring, cylindrical helical compression spring and its guide post, and the load characteristics can be precisely controlled by adjusting the preload. In practical applications, the protective cover 100 is used to isolate the test environment from the external space. Its main function is to prevent external interference factors from affecting the test process. Specifically, the protective cover 100 can be made of transparent materials, such as tempered glass or acrylic sheets, to facilitate observation of the internal test status, while also possessing a certain degree of impact resistance to ensure test safety. Furthermore, the protective cover 100 can be opened and closed via sliding rails, hinges, or magnetic attraction, thus facilitating installation before testing and disassembly after testing. The base 101, as the basic platform supporting the test equipment, must be designed to meet the requirements of high rigidity and high stability. Specifically, the base 101 can be made of cast iron, steel, or other high-strength composite materials, and its surface is precision-machined to ensure flatness and assembly accuracy. For example, the base 101... The upper part can be equipped with structures such as positioning pin holes, threaded hole arrays, or guide rail grooves to fix different models of AMT shift control units and their matching load mechanisms, thereby adapting to various testing needs; the precision-machined positioning surface refers to a high-flatness surface formed by precision machining, which can be achieved by grinding, lapping, etc., with the aim of providing a precise installation reference for the AMT shift control unit; the threaded hole array refers to multiple threaded holes arranged in a specific layout, which can be machined in one go by CNC machine tools, with the aim of adapting to the installation requirements of different models of AMT shift control units; transparent polycarbonate material is an engineering plastic with good light transmittance and impact resistance, which can be manufactured by injection molding or extrusion molding processes, with the aim of realizing visual monitoring of the testing process; The four identical load mechanisms integrated on the base 101 are arranged symmetrically. Their synchronous operation mechanism can simultaneously simulate the mechanical load of four actuators during gear shifting, solving the problem that traditional single-cylinder test equipment cannot reflect system-level interactive effects. This not only improves test efficiency but also reduces the complexity of equipment maintenance and debugging, thus effectively addressing the problems of complex equipment structure, difficult maintenance, and low test efficiency in existing technologies. Four load mechanisms can simultaneously perform synchronous durability tests on the four actuator cylinders of the AMT shift control unit. This synchronous operation mechanism not only improves testing efficiency but also realistically reproduces the actual working conditions of multiple cylinders working together, solving the problem that traditional single-cylinder testing equipment cannot reflect system-level interactive effects. Specifically, through the modular design of the load mechanism, it is possible to simulate the two-stage load changes of the gearbox shift fork lever self-locking force and shifting force during the test, thus more closely reflecting actual usage scenarios. The modular load mechanism design makes maintenance and replacement more convenient, and the optimization of the overall structure effectively solves the problems of high complexity and difficult maintenance of traditional equipment. The rigid platform design of the base 101, combined with the visualization structure of the protective cover 100, effectively solves the problems of deformation affecting accuracy, poor adaptability, and inability to observe in real time during the testing process. At the same time, it provides a reliable support foundation for the synchronous testing of various load mechanisms such as the gear selection cylinder load mechanism and the gear shift cylinder load mechanism. like Figure 2 As shown, the gear selection cylinder load mechanism includes a gear selection connector 106, a gear selection position sensor 110, a gear selection load rod 114, a gear selection rod chamber 121, a gear selection rodless chamber 122, a gear selection positioning block 126, and a gear selection load spring preload adjusting bolt 130. The gear selection connector 106 is connected to the gear selection load rod 114, and the gear selection connector 106 is threadedly connected to the gear selection cylinder. The gear selection rodless chamber 122 of the gear selection cylinder load mechanism pushes the gear selection cylinder to move. The rodless chamber 122 provides load resistance, which is divided into two stages. The first stage of the force simulates the self-locking force of the gearbox shift fork, and the second stage of the force simulates the shifting force of the gearbox shift fork. After the shift leverless chamber 122 pushes the shift cylinder into place, the shift position sensor 110 detects the position and transmits the position signal to the control cabinet. After the control cabinet receives the signal, the solenoid valve of the control cabinet reverses, and the shift lever chamber 121 pulls the shift cylinder to move. The shift lever chamber 121 provides load resistance, which is divided into two stages. The first stage of the force simulates the self-locking force of the gearbox shift fork, and the second stage of the force simulates the shifting force of the gearbox shift fork. The gear selection connector 106 is a mechanical connector made of high-strength alloy steel, ensuring the stability and reliability of force transmission; the gear selection position sensor 110 uses a Hall effect sensor or photoelectric encoder to monitor the cylinder position in real time and feed it back to the control system; the gear selection load rod 114 is a rigid transmission component that evenly transmits the load force to the cylinder end; the gear selection rod cavity 121 and the gear selection rodless cavity 122 are cavity structures formed on both sides of the gear selection positioning block 126, and their inner walls can be specially coated to reduce the coefficient of friction and improve the stability of the load output; the gear selection positioning block 126 can change its stroke range by adjusting its installation position to adapt to the testing requirements of different models of AMT control units; Specifically, this solution achieves accurate load simulation by constructing a bidirectional load chamber and a segmented resistance adjustment system; the gear selection connector 106 and the gear selection load rod 114 form a stable mechanical linkage structure to ensure the reliability of the force transmission path; the gear selection rodless chamber 122 provides low resistance in the initial stage to simulate the friction force of the shift fork in the self-locking state; when the cylinder moves to the predetermined position, the gear selection position sensor 110 triggers a signal, and the control cabinet then switches the solenoid valve state, causing the gear selection rod chamber 121 to start working; this symmetrical arrangement of the dual chambers achieves bidirectional motion load simulation. This design breaks through the limitations of traditional unidirectional loads. The load force can be precisely adjusted in two stages via the gear selection load spring preload adjustment bolt 130. The first stage, with low resistance, corresponds to a self-locking state, while the second stage, with high resistance, simulates the mechanical deformation resistance during actual gear shifting. Notably, this mechanism works collaboratively with three other load mechanisms through a standardized interface, significantly improving equipment versatility and solving the adaptation problem of multi-cylinder synchronous testing. This integrated bidirectional load simulation architecture balances testing efficiency and operational condition fidelity, providing a reliable hardware foundation for the durability assessment of the AMT control unit. The shift cylinder load mechanism includes a shift connector 104, a shift load rod 112, a shift rod chamber 118, a shift rodless chamber 117, a shift positioning block 124, a shift position sensor 108, and a shift load spring preload adjustment bolt 128. The shift connector 104 is connected to the shift load rod 112, and a shift cylinder is threaded onto the shift connector 104. The shift rod chamber 118 and the shift rodless chamber 117 are located on opposite sides of the shift positioning block 124. The shift rod chamber 118, the shift rodless chamber 117, and the shift positioning block 124 together form a shift load spring assembly. The shift rodless chamber 117 pushes the shifter to shift gears. When the cylinder moves, the shift leverless chamber 117 provides load resistance, which is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. After the shift leverless chamber 117 pushes the shift cylinder into place, the shift position sensor 108 detects the position and transmits the position signal to the control cabinet. After receiving the signal, the solenoid valve of the control cabinet reverses, and the shift rod chamber 118 pulls the shift cylinder to move. The shift rod chamber 118 provides load resistance, which is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. The shift cylinder load mechanism, through the threaded connection structure between the shift connector 104 and the shift load rod 112, ensures the mechanical coupling stability between the cylinder and the test unit, laying the foundation for dual-stage load transfer. The shift load spring assembly adopts a design where the shift rod chamber 118 and the shift rodless chamber 117 are symmetrically distributed on both sides of the shift positioning block 124. By controlling the chamber pressure changes in stages, the load resistance exhibits a stepped switching between self-locking force and shifting force, thereby accurately replicating the mechanical characteristic changes of the gearbox shift fork rod under actual working conditions. The shift position sensor 108 uses a Hall effect sensor or a photoelectric sensor. When the shift rodless chamber 117 is pushed into place, the sensor triggers the solenoid valve to shift. The shift lever chamber 118 immediately engages to apply reverse load, and this dynamic response mechanism effectively solves the test deviation problem caused by the response lag of traditional pneumatic mechanisms. The shift load spring preload adjustment bolt 128 is used to adjust the initial preload of the spring assembly. The load parameters can be flexibly adjusted by rotating the bolt to change the spring compression, adapting to the test requirements of different AMT control units. This shift cylinder load mechanism not only realizes the independent dual-stage load simulation of each actuator in multi-cylinder synchronous testing, but also effectively bridges the technical gap between laboratory testing and actual working conditions, providing a more accurate and efficient solution for the durability testing of AMT shift control units. The differential gear cylinder load mechanism includes a differential gear connector 103, a differential gear load rod 111, a differential gear rodless chamber 115, a differential gear rod chamber 116, a differential gear positioning block 123, a differential position sensor 107, and a differential load spring preload adjustment bolt 127. The differential gear connector 103 is connected to the differential gear load rod 111, and the differential gear connector 103 is threadedly connected to the differential gear cylinder. The differential gear rodless chamber 115 and the differential gear rod chamber 116 are respectively located on both sides of the differential gear positioning block 123. The differential gear rodless chamber 115, the differential gear rod chamber 116, and the differential gear positioning block 123 together form a differential load spring assembly; the differential gear rodless chamber 115... 5. The differential gear cylinder is moved by pushing the differential gear rodless chamber 115, which provides load resistance. The load resistance is divided into two stages: the first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. After the differential gear rodless chamber 115 pushes the differential gear cylinder into place, the differential position sensor 107 detects the position and transmits the position signal to the control cabinet. After receiving the signal, the solenoid valve of the control cabinet reverses, and the differential gear rod chamber 116 pulls the differential gear cylinder to move. The differential gear rod chamber 116 provides load resistance, which is divided into two stages: the first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. The differential gear connector 103 is made of high-strength alloy steel. The differential gear cylinder load mechanism ensures the stability of mechanical transmission through the rigid connection structure between the differential gear connector 103 and the differential gear load rod 111. The differential gear rodless cavity 115 and the differential gear rod cavity 116 are located on both sides of the differential gear positioning block 123, forming a symmetrical spring assembly structure. This design achieves bidirectional controllable loading of force through the differential principle, which shortens the switching response time between the self-locking force and the shifting force. The differential gear positioning block 123 is a key structure for fixing and supporting the spring assembly. It can adopt a modular design to adapt to different models of AMT systems. The design is based on specific requirements and aims to achieve flexible configuration. The differential position sensor 107 uses magnetostriction or photoelectric encoding technology to achieve micron-level detection accuracy, ensuring the timing accuracy of load switching. The differential load spring preload adjustment bolt 127 is used to adjust the compression of the disc spring assembly. It can be precisely adjusted through multi-level scale markings, aiming to control the self-locking force threshold and shifting force peak value in segments. The differential gear cylinder load mechanism establishes a dynamic load model that highly matches the actual working conditions at the differential gear position through the synergistic action of the hydraulic chamber and mechanical spring, effectively solving the problem that traditional unidirectional load mechanisms cannot reproduce complex mechanical interactions. The range-shift cylinder load mechanism includes a range-shift connector 105, a range-shift load rod 113, a range-shift rodless cavity 119, a range-shift rod cavity 120, a range-shift positioning block 125, a range position sensor 109, and a range load spring preload adjustment bolt 129. The range-shift connector 105 is connected to the range-shift load rod 113, and the range-shift cylinder is threaded onto the range-shift connector 105. The range-shift rodless cavity 119 and the range-shift rod cavity 120 are located on opposite sides of the range-shift positioning block 125. The range-shift rodless cavity 119, the range-shift rod cavity 120, and the range-shift positioning block 125 together form the range-shift load spring assembly. The range-shift rodless cavity 119, the range-shift rod cavity 120, and the range-shift positioning block 125 together form the range-shift load spring assembly. 9. The range gear cylinder is moved by pushing the range gear cylinder. The range gear rodless chamber 119 provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. After the range gear rodless chamber 119 pushes the range gear cylinder into place, the range position sensor 109 detects the position and transmits the position signal to the control cabinet. After receiving the signal, the control cabinet's solenoid valve reverses, and the range gear rod chamber 120 pulls the range gear cylinder to move. The range gear rod chamber 120 provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. The range switch connector 105 is made of high-strength alloy steel, and its rigid connection structure with the range switch load rod 113 ensures axial alignment during cylinder movement, avoiding test errors caused by off-center loading. The layout design of the range switch rodless cavity 119 and the range switch rod cavity 120, located on both sides of the range switch positioning block 125, ensures that the spring assembly maintains force balance during reciprocating motion. The range position sensor 109 uses a magnetostrictive or photoelectric sensor to achieve real-time acquisition of position signals. When the range switch rodless cavity 119 pushes the cylinder to move, the first... In the first stage, the self-locking force threshold is controlled by the spring compression. In the second stage, the shifting force amplitude is adjusted by the coordinated adjustment of the cavity pressure and spring stiffness. The linkage mechanism between the range position sensor 109 and the solenoid valve constructs a closed-loop feedback system to ensure the timing accuracy of the load switching in the two stages. This dual-cavity spring assembly structure not only inherits the response advantages of the pneumatic system, but also compensates for the load instability caused by air pressure fluctuations through mechanical limits and elastic elements. At the same time, the standardized modular design enables the mechanism to operate in parallel with other cylinder load mechanisms to achieve synchronous testing of multiple actuators. The four cylinders of the shift control unit are connected to the corresponding load rods (111-114) via connectors (103-106). Positioning blocks (123-126) are installed on the load rods to fix the load spring assemblies. The load spring assemblies of the rodless chamber and the rod chamber are respectively arranged on both sides of the positioning blocks (123-126). The compression of the springs can be adjusted by the load spring preload adjusting bolt, thereby precisely controlling the magnitude of the load force. like Figure 3-4 As shown, the shift load spring assembly, gear selection load spring assembly, and range gear load spring assembly all include a rod-type butterfly spring 150, a rod-type guide post 151, a rod-type cylindrical helical compression spring 152, a rodless butterfly spring 155, a rodless guide post 154, a rodless cylindrical helical compression spring 153, and a positioning rod 156. The butterfly spring has the characteristics of high stiffness, small space occupation, and stable load force, and is suitable for simulating the self-locking force of the first stage; the cylindrical helical compression spring is used to simulate the shifting force of the second stage; the guide post is used to ensure the coaxiality of the spring movement and avoid uneven load; in actual testing, different specifications of springs or adjustments to the preload can be made to adapt to different models of AMT control units; the position sensor detects the cylinder position in real time and feeds the signal back to the control cabinet, which controls the solenoid valve to switch directions, realizing automatic cyclic testing; The rod-type butterfly spring 150 and the rodless butterfly spring 155 are elastic elements with a conical structure, made of metal sheets of different materials or thicknesses to achieve varying stiffness. The butterfly spring provides low stiffness in its initial stage to simulate the self-locking force of a gearbox shift fork, while its stiffness increases sharply during compression to simulate the leap in shifting force. Dynamic switching of the two-stage force is achieved through a single element, improving the stability and adjustability of the load force. The rod-type cylindrical helical compression spring 152 and the rodless cylindrical helical compression spring 153 are auxiliary energy storage elements, employing helical spring designs with different wire diameters or coil numbers to meet specific load requirements. These springs... The spring intervenes after the disc spring reaches its critical deformation, achieving a staged superposition of load force through a combination of different parameters; enhancing the adjustment accuracy of the load force and ensuring a smooth transition during the load process; the rod-type guide post 151 and the rodless guide post 154 are guiding components used to constrain the axial movement trajectory of the spring assembly; the design of the guide post can effectively prevent the spring assembly from shifting or becoming unstable during the force process, thereby improving the reliability of the overall structure; the positioning rod 156 achieves precise adjustment through threaded connection or sliding fit; by changing the pre-compression amount, the position of the dual-stage force switching point is controlled, thereby adapting to the testing requirements of different models of AMT shift control units; A composite spring assembly structure consisting of a butterfly spring, a cylindrical helical compression spring, and a guide post was constructed to solve the stability and adjustability issues of the load spring assembly in two-stage force simulation. The rod-type butterfly spring 150 and the rodless butterfly spring 155 provide low stiffness in the initial stage to simulate self-locking force, while their stiffness increases sharply during compression to simulate the leap in shifting force. The rod-type cylindrical helical compression spring 152 and the rodless cylindrical helical compression spring 153 serve as auxiliary energy storage elements, intervening after the butterfly spring reaches critical deformation, achieving a staged superposition effect of load force through combinations of different parameters. The rod-type guide post 151 and the rodless guide post 154 not only constrain the axial movement trajectory of the spring assembly but also achieve precise adjustment of the spring pre-compression amount through the positioning rod 156, thereby ensuring the controllability of the two-stage force switching point. This composite structure design enables the spring assembly to meet high load requirements while possessing good dynamic response characteristics, and also allows for adaptive adjustment under different test conditions through modular component configuration. In summary, the shift load spring assembly, the gear selection load spring assembly, and the range gear load spring assembly can accurately simulate the dynamic switching process between the self-locking force and the shifting force of the gearbox shift fork, significantly improving the stability and adjustment accuracy of the load force, while enhancing the reliability of the structure and meeting the requirements of multi-cylinder synchronous durability testing.

[0022] Finally, the following points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, and can be mechanical or electrical connections, or internal connections between two components, or direct connections. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may change. Secondly: The accompanying drawings of the embodiments disclosed in this utility model only involve the structures involved in the embodiments disclosed in this utility model. Other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of this utility model can be combined with each other. Finally: The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A load device for endurance testing of an AMT shift control unit, characterized in that: It includes a protective cover (100) and a base (101), wherein the protective cover (100) covers the base (101) to form a test space; The base (101) is equipped with a gear selection cylinder load mechanism, a shift cylinder load mechanism, a differential gear cylinder load mechanism, and a range gear cylinder load mechanism. The four load mechanisms have the same structure and are arranged symmetrically, which can simultaneously perform synchronous durability tests on the four actuator cylinders of the AMT shift control unit.

2. The load device for endurance testing of an AMT shift control unit according to claim 1, characterized in that: The base (101) is a rigid platform made of high-strength cast iron or alloy steel. The base (101) is provided with a precision-machined positioning surface and an array of multiple threaded holes for the precise installation of different models of AMT shift control units. The protective cover (100) is made of transparent polycarbonate material and has an openable observation window.

3. The load device for endurance testing of an AMT shift control unit according to claim 1, characterized in that: The gear selection cylinder load mechanism includes a gear selection connector (106), a gear selection position sensor (110), a gear selection load rod (114), a gear selection rod chamber (121), a gear selection rodless chamber (122), a gear selection positioning block (126), and a gear selection load spring preload adjustment bolt (130). The gear selection connector (106) is connected to the gear selection load rod (114), and the gear selection connector (106) is threadedly connected to the gear selection cylinder. The gear selection cylinder load mechanism has a gear selection rodless chamber (122) that pushes the gear selection cylinder to move. The rodless chamber (122) provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. After the gear selection rodless chamber (122) pushes the gear selection cylinder to the position, the gear selection position sensor (110) detects the position and transmits the position signal to the control cabinet. After the control cabinet receives the signal, the solenoid valve of the control cabinet reverses, and the gear selection rod chamber (121) pulls the gear selection cylinder to move. The gear selection rod chamber (121) provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork.

4. The load device for endurance testing of an AMT shift control unit according to claim 1, characterized in that: The shift cylinder load mechanism includes a shift connector (104), a shift load rod (112), a shift rod chamber (118), a shift rodless chamber (117), a shift positioning block (124), a shift position sensor (108), and a shift load spring preload adjustment bolt (128). The shift connector (104) is connected to the shift load rod (112), and the shift connector (104) is threadedly connected to the shift cylinder. The shift rod chamber (118) and the shift rodless chamber (117) are respectively located on both sides of the shift positioning block (124). The shift rod chamber (118), the shift rodless chamber (117), and the shift positioning block (124) together form a shift load spring assembly. The shift leverless chamber (117) pushes the shift cylinder to move. The shift leverless chamber (117) provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. After the shift leverless chamber (117) pushes the shift cylinder to the position, the shift position sensor (108) detects the position and transmits the position signal to the control cabinet. After the control cabinet receives the signal, the solenoid valve of the control cabinet reverses, and the shift lever chamber (118) pulls the shift cylinder to move. The shift lever chamber (118) provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork.

5. The load device for endurance testing of an AMT shift control unit according to claim 4, characterized in that: The differential gear cylinder load mechanism includes a differential gear connector (103), a differential gear load rod (111), a differential gear rodless cavity (115), a differential gear rod cavity (116), a differential gear positioning block (123), a differential position sensor (107), and a differential load spring preload adjustment bolt (127). The differential gear connector (103) is connected to the differential gear load rod (111), and the differential gear connector (103) is threadedly connected to the differential gear cylinder. The differential gear rodless cavity (115) and the differential gear rod cavity (116) are respectively located on both sides of the differential gear positioning block (123). The differential gear rodless cavity (115), the differential gear rod cavity (116), and the differential gear positioning block (123) together form a differential load spring assembly. The differential gear rodless chamber (115) pushes the differential gear cylinder to move. The differential gear rodless chamber (115) provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. After the differential gear rodless chamber (115) pushes the differential gear cylinder to the position, the differential position sensor (107) detects the position and transmits the position signal to the control cabinet. After the control cabinet receives the signal, the solenoid valve of the control cabinet reverses, and the differential gear rod chamber (116) pulls the differential gear cylinder to move. The differential gear rod chamber (116) provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork.

6. The load device for endurance testing of an AMT shift control unit according to claim 5, characterized in that: The range gear cylinder load mechanism includes a range gear connector (105), a range gear load rod (113), a range gear rodless cavity (119), a range gear rod cavity (120), a range gear positioning block (125), a range position sensor (109), and a range load spring preload adjustment bolt (129). The range gear connector (105) is connected to the range gear load rod (113), and the range gear connector (105) is threadedly connected to the range gear cylinder. The range gear rodless cavity (119) and the range gear rod cavity (120) are respectively located on both sides of the range gear positioning block (125). The range gear rodless cavity (119), the range gear rod cavity (120), and the range gear positioning block (125) together form a range gear load spring assembly. The range gear rodless chamber (119) pushes the range gear cylinder to move. The range gear rodless chamber (119) provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork. After the range gear rodless chamber (119) pushes the range gear cylinder to the position, the range position sensor (109) detects the position and transmits the position signal to the control cabinet. After the control cabinet receives the signal, the solenoid valve of the control cabinet reverses, and the range gear rod chamber (120) pulls the range gear cylinder to move. The range gear rod chamber (120) provides load resistance. The load resistance is divided into two stages. The first stage force simulates the self-locking force of the gearbox shift fork, and the second stage force simulates the shifting force of the gearbox shift fork.

7. The load device for endurance testing of an AMT shift control unit according to claim 6, characterized in that: The shift load spring assembly, the selector load spring assembly, and the range load spring assembly all include a rod-type butterfly spring (150), a rod-type guide post (151), a rod-type cylindrical helical compression spring (152), a rodless butterfly spring (155), a rodless guide post (154), a rodless cylindrical helical compression spring (153), and a positioning rod (156).

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