Gear position sensor automatic calibration test fixture

Abstract

The utility model provides a kind of gear position sensor automatic calibration test tool, including base, clamping platform, drive execution assembly, execution swing arm and floating coupling assembly, wherein:clamping platform is movably arranged in base;Drive execution assembly is set in base, including driving part, the reducer being connected with driving part, the angle detector being connected with the output end of reducer and the driving shaft being connected with the output end of angle detector;Execution swing arm, one end is connected with driving shaft;Floating coupling assembly is arranged at the end of execution swing arm away from driving shaft, for connecting the movable component of measured sensor.The utility model realizes the full automation and high precision of gear position sensor calibration test, ensures that test reference is stable and reliable by closed-loop drive and adjustable zero calibration, improves compatibility and operation safety using floating coupling and adjustable clamping, and makes test process efficient, consistent and intuitive by means of integrated electric control system optimization process control.

Description

Technical Field

[0001] This utility model relates to the field of testing fixtures, and in particular to an automatic calibration testing fixture for a gear position sensor. Background Technology

[0002] Gear position sensors are key electronic components used in automotive transmissions and industrial equipment for accurately detecting and controlling gear positions. The accuracy of their output signals directly affects the reliable operation and safety of the powertrain. In the sensor manufacturing and maintenance process, calibration testing is the core step in verifying its electrical performance and mechanical position matching accuracy, requiring testing equipment to provide stable, repeatable, and high-precision angle simulation and signal acquisition.

[0003] Traditional sensor calibration and testing methods often rely on manual operation or semi-automatic equipment, resulting in low testing efficiency and difficulty in ensuring consistency. The testing process typically requires operators to manually adjust the angle of the sensor input axis and record the corresponding output, which is prone to introducing errors due to human factors and makes rapid, batch testing difficult. Furthermore, existing testing fixtures often lack high-precision mechanical zero-point calibration mechanisms, leading to drift in the testing benchmark and affecting the reliability of results from different batches or multiple tests. In terms of sensor clamping, traditional methods can be cumbersome and lack automatic compensation for installation misalignment, easily subjecting the sensor to unnecessary lateral stress. In addition, moving parts are usually exposed during testing, posing certain safety risks, and the testing status lacks integrated monitoring and electronic control management. Utility Model Content

[0004] The technical problem to be solved by this utility model is to provide a test fixture for automatic calibration of gear position sensors that is stable and reliable, has good compatibility and a high safety factor, and optimizes process control with the help of an integrated electronic control system, so as to make the test process efficient, consistent and intuitive.

[0005] To solve the above-mentioned technical problems, this utility model adopts the following technical solution:

[0006] An automatic calibration test fixture for a gear position sensor includes a base, a clamping platform, a drive assembly, an actuation arm, and a floating coupling assembly. The clamping platform is movably mounted on the base. The drive assembly is mounted on the base and includes a drive component, a reducer connected to the drive component, an angle detector connected to the output end of the reducer, and a drive shaft connected to the output end of the angle detector. One end of the actuation arm is connected to the drive shaft. The floating coupling assembly is located at the end of the actuation arm away from the drive shaft and is used to connect the movable part of the sensor under test.

[0007] Preferably, the drive assembly further includes a zero-position calibration component, which includes a reference stop and a position detector disposed on the rotation path of the drive shaft.

[0008] Preferably, the reference block is mounted on the base via an adjustment mechanism, which enables the reference block to move in a direction parallel to the radial direction of the drive shaft.

[0009] Preferably, the adjustment mechanism includes a mounting base disposed on the base, an adjustment screw passing through the mounting base and threadedly connected to the reference stop, and a locking nut disposed on the adjustment screw and used to abut against the mounting base.

[0010] Preferably, the floating coupling assembly includes a ball head disposed at the end of the actuating swing arm and a connector for connecting the sensor under test, wherein the connector is provided with a ball socket that slides with the ball head.

[0011] Preferably, the connector further includes a locking sleeve for clamping the movable part of the sensor under test, and the locking sleeve is provided with a locking screw along its own radial direction.

[0012] Preferably, the bottom of the clamping platform is equipped with a slider, the base is provided with a guide rail that cooperates with the slider, and the clamping platform is also provided with a locking member for locking it to the guide rail.

[0013] Preferably, the clamping platform is further provided with a clamp, the clamp including a positioning base plate for supporting the sensor under test and a clamping member disposed above the positioning base plate.

[0014] Preferably, it also includes an electrical control box, which contains a controller and a signal acquisition module. The controller is electrically connected to the drive unit and the angle detector, and the signal acquisition module is provided with a test interface for connecting the sensor under test.

[0015] Preferably, the base is further provided with a protective cover and a mounting bracket, the mounting bracket being disposed on the base and surrounding the movement area of ​​the swing arm, and the protective cover being disposed on the mounting bracket.

[0016] The present invention adopts the above technical solution and has the following technical effects compared with the prior art:

[0017] (1) Achieve automated high-precision testing: Through closed-loop drive and electronic control system, automatically simulate angle changes and collect signals, replacing manual operation and significantly improving testing efficiency and accuracy.

[0018] (2) Ensure the stability of the test benchmark: The zero-point calibration component provides an adjustable and repeatable mechanical zero point, eliminates accumulated errors, and ensures the long-term consistency and reliability of test results.

[0019] (3) Improved compatibility and safety: The floating coupling component adapts to the alignment deviation to protect the sensor; the movable clamping platform and protective cover design make installation convenient and operation safe. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of an automatic calibration test fixture for a gear position sensor according to the present invention;

[0021] Figure 2 This is a schematic diagram of a protective cover for an automatic calibration test fixture for a gear position sensor according to the present invention.

[0022] Figure 3 This is a schematic diagram of the clamping platform for an automatic calibration test fixture for a gear position sensor according to the present invention;

[0023] Figure 4 This is a schematic diagram showing the positions of the drive actuation assembly and the zero-position calibration component of an automatic calibration test fixture for a gear position sensor according to this utility model.

[0024] Figure 5 This is a schematic diagram of the zero-position calibration component of an automatic calibration test fixture for a gear position sensor according to this utility model;

[0025] Figure 6 This is a schematic diagram of the floating coupling component of an automatic calibration test fixture for a gear position sensor according to this utility model.

[0026] The accompanying figures are labeled as follows:

[0027] 1-Base;

[0028] 2-Clamping platform; 201-Slider; 202-Guide rail; 203-Locking component; 204-Clamp; 2041-Positioning base plate; 2042-Pressure component;

[0029] 3-Drive actuator assembly; 301-Drive component; 302-Reducer; 303-Angle detector; 304-Drive shaft;

[0030] 4- Execute the swing arm;

[0031] 5-Floating coupling assembly; 501-Ball head; 502-Connector; 5021-Ball socket; 5022-Locking sleeve; 5023-Locking screw;

[0032] 6-Zero-position calibration component; 601-Reference stop; 602-Position detector; 603-Adjustment mechanism; 6031-Mounting base; 6032-Adjusting screw; 6033-Lock nut;

[0033] 7-Electrical control box; 701-Controller; 702-Signal acquisition module; 7021-Test interface;

[0034] 8-Protective cover; 801-Mounting bracket. Detailed Implementation

[0035] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0036] Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0037] Example 1

[0038] As attached Figures 1 to 6 As shown, an automatic calibration test fixture for a gear position sensor is provided, mainly including a base 1, a clamping platform 2, a drive actuation assembly 3, an actuation swing arm 4, and a floating coupling assembly 5. The base 1 forms the supporting foundation of the entire fixture, and its table surface is precision machined to provide a flat reference mounting surface; the clamping platform 2 forms a sliding engagement with the guide rail 202 provided on the base 1 through the slider 201 at its bottom, so that the clamping platform 2 can carry the clamp 204 on it and move smoothly along the extension direction of the guide rail 202 to adjust the distance with the driven end.

[0039] The locking component 203 adopts a handle screw structure. When a fixed position is required, rotating the handle of the locking component 203 can press its end against the side of the guide rail 202 or the slider 201, thereby generating friction to prevent sliding. The positioning base plate 2041 in the fixture 204 is machined with a positioning groove or positioning pin that matches the contour of a common sensor housing. The clamping component 2042 adopts a quick-pressing rod or screw structure. Its pressing arm can rotate around the axis. When pressing down, the sensor housing is pressed tightly onto the positioning base plate 2041 through the pressing head, realizing quick mounting and releasing.

[0040] The drive assembly 3 is securely fixed to a specific area of ​​the base 1 via its mounting plate. The drive component 301 is preferably a servo motor, whose output shaft is directly connected to the input shaft of the reducer 302 via a coupling. The reducer 302 is a precision planetary gear structure used to reduce speed and increase output torque. The angle detector 303 is a high-precision absolute encoder, whose housing is connected to the output flange of the reducer 302, and whose sensing shaft is coaxially connected to the drive shaft 304, thereby directly detecting the real-time rotation angle of the drive shaft 304. The drive shaft 304 is supported in a bearing housing by a pair of angular contact ball bearings to ensure rotational accuracy and rigidity. When the drive component 301 receives a command from the controller 701 and rotates, the torque is amplified by the reducer 302 and transmitted to the drive shaft 304. The rotational motion of the drive shaft 304 is monitored and fed back in real time by the angle detector 303, forming a closed-loop position control system.

[0041] The actuator arm 4 is fixedly installed at the extended end of the drive shaft 304 via a key connection or expansion sleeve connection. Its arm body is a rigid structure to reduce swing deformation. The ball head 501 in the floating coupling assembly 5 is fixed to the center of the distal end face of the actuator arm 4 by thread or welding. The main body of the connector 502 is cylindrical, with a ball socket 5021 machined at one end. The ball socket 5021 opens upward, and its inner spherical surface mates with the outer spherical surface of the ball head 501 to form a universal joint structure, allowing the connector 502 to swing at a small angle in any direction. The locking sleeve 5022 is connected to the other end of the connector 502 by thread to form an integral unit. Its side wall has a slit and a locking screw 5023 is installed radially. When the input shaft of the sensor under test is inserted into the inner hole of the locking sleeve 5022, tightening the locking screw 5023 can cause the locking sleeve 5022 to elastically deform and thus hold the input shaft.

[0042] In the zero-point calibration assembly 6, the mounting base 6031 of the adjusting mechanism 603 is fixed to the base 1 by screws, and a guide hole is machined on its upper part; the adjusting screw 6032 passes through the guide hole, one end of which is connected to the reference stop 601 by a thread, and the other end is equipped with a handwheel; the locking nut 6033 is paired and installed on the adjusting screw 6032 and located on both sides of the mounting base 6031; the position detector 602 is a proximity switch, and its sensing head is facing the side trigger area of ​​the reference stop 601; when zero-point calibration is required, the locking nut 6033 is loosened, and the handwheel is turned to drive the adjusting screw 6032 to rotate, which can drive the reference stop 601 to move precisely to adjust the mechanical zero point. After the adjustment is completed, the locking nut 6033 is tightened to lock it.

[0043] The electrical control box 7 is a vertical cabinet structure. The controller 701 is a programmable logic controller or industrial computer, which is connected to the driver of the drive unit 301 and the angle detector 303 through a multi-core cable. The signal acquisition module 702 is a multi-channel data acquisition card with multiple test interfaces 7021 on the front panel. The interface types include analog voltage interface, resistance interface and digital signal interface, which are connected to the output terminal of the sensor under test through test cables. When the test process starts, the controller 701 controls the drive shaft 304 to move to each calibration point according to the preset program. At the same time, it instructs the signal acquisition module 702 to synchronously acquire the output signal of the sensor and compare it with the feedback value of the angle detector 303 to automatically complete the calibration and judgment.

[0044] The protective cover 8 is a split transparent acrylic sheet or a mesh metal sheet, which is installed on the mounting frame 801 by hinges and buckles for easy opening and closing. The mounting frame 801 is spliced ​​from aluminum profiles or steel square tubes, and its column is fixed to the edge of the base 1 by a flange. The overall frame completely surrounds the movement range of the actuator arm 4 and the floating coupling component 5, forming a safe isolation area to prevent the operator's limbs from accidentally entering the movement area, while blocking external dust.

[0045] Example 2

[0046] Based on Embodiment 1, the solution in Embodiment 1 will be further described in detail below with reference to the specific working method, such as... Figures 1 to 6 As shown below, see details:

[0047] The zero-position calibration component 6 is used to provide a mechanical zero-position reference for the rotation of the drive shaft 304; the sensing end of the position detector 602 has a specific sensing area shape and is set facing the predetermined trigger surface of the reference block 601; the reference block 601 has a specific shape that contacts the trigger surface, and this shape is designed to form a stable and repeatable contact with the rotating drive shaft 304 or its linkage component; when the drive shaft 304 rotates and drives its linkage component to contact the specific shape of the reference block 601, the reference block 601 triggers the sensing area of ​​the position detector 602, and the position detector 602 then generates a jumping electrical signal, which indicates that the drive shaft 304 has reached a predefined absolute mechanical position.

[0048] The adjustment mechanism 603 is connected to the base 1, and the reference block 601 is mounted on the adjustment mechanism 603. The adjustment mechanism 603 includes a guide component, a drive component, and a locking component. The guide component constrains the reference block 601 to move linearly only in a direction parallel to the radial direction of the drive shaft 304. The drive component is used to drive the reference block 601 to move along the guide component when needed. After the reference block 601 is adjusted to the target position by the drive component, the locking component can be used to fix its position.

[0049] Mounting base 6031 is fixedly mounted on base 1. Adjusting screw 6032 passes through the through hole on mounting base 6031 and forms a threaded connection with reference block 601. Locking nut 6033 is fitted onto adjusting screw 6032. When adjusting screw 6032 is rotated, its threaded engagement with reference block 601 converts the rotational motion into linear movement of reference block 601 along the radial direction of drive shaft 304. When reference block 601 moves to the target position, locking nut 6033 is tightened so that its end face abuts tightly against the surface of mounting base 6031. The resulting friction locks the axial and circumferential positions of adjusting screw 6032, thereby fixing reference block 601.

[0050] The ball head 501 is fixedly mounted on the end of the swing arm 4, and the connector 502 is fitted onto the ball head 501 through its ball socket 5021. Together, they form a spherical sliding pair. When the swing arm 4 is driven by the drive shaft 304 to swing, the ball head 501 moves accordingly and drives the connector 502 to follow the movement through spherical contact with the ball socket 5021. The inner spherical surface of the ball socket 5021 slides with the outer spherical surface of the ball head 501, so that the connector 502 can swing slightly in multiple directions relative to the ball head 501 during the driving process of the swing arm 4, thereby compensating for possible installation alignment deviations between the movable part of the sensor under test and the drive shaft 304.

[0051] As part of the connector 502, the locking sleeve 5022 has a through hole inside for accommodating and clamping the movable part of the sensor under test. The locking screw 5023 is screwed in radially along the locking sleeve 5022. When the locking screw 5023 is tightened, its end moves toward the center of the through hole of the locking sleeve 5022 and presses against the movable part of the sensor under test. The radial pressure generated makes the inner wall of the locking sleeve 5022 tightly hug the movable part, thereby achieving reliable connection and torque transmission. When the locking screw 5023 is loosened, its end retracts, and the clamping force of the locking sleeve 5022 on the movable part is released, allowing for disassembly.

[0052] The slider 201 is fixedly installed at the bottom of the clamping platform 2, and the guide rail 202 is fixedly installed on the base 1. The slider 201 and the guide rail 202 are interlocked to form a sliding connection, so that the clamping platform 2 can move linearly relative to the base 1 along the extension direction of the guide rail 202. The locking member 203 is installed on the clamping platform 2, and its locking end acts on the slider 201 or the guide rail 202. When the locking member 203 is tightened or pressed, its locking end generates and applies a locking force. This locking force is transmitted directly or through the intermediate structure to the mating interface between the slider 201 and the guide rail 202, thereby increasing the friction between the two to prevent relative sliding and thus fixing the position of the clamping platform 2. When the locking member 203 is released, the locking force disappears, and the clamping platform 2 returns to a sliding state.

[0053] The positioning base plate 2041 is fixedly installed on the clamping platform 2, and its top plane is used to support and position the housing of the sensor under test. The clamping member 2042 is installed above the positioning base plate 2041, and its clamping end faces the positioning base plate 2041. When the clamping member 2042 is operated to be in the clamping state, its clamping end moves downward and presses against the upper surface of the housing of the sensor under test directly or through the intermediate pressure block, thereby pressing the sensor under test tightly onto the positioning base plate 2041. When the clamping member 2042 is operated to be in the release state, its clamping end moves upward and releases the pressure on the sensor under test, at which time the sensor can be picked up and put down.

[0054] The electrical control box 7 is located on the side of the base 1 or placed independently. Inside, a controller 701 and a signal acquisition module 702 are fixedly installed by a mounting bracket. The controller 701 is electrically connected to the drive unit 301 and the angle detector 303 via cables, and is used to send motion commands to the drive unit 301 and receive real-time angle signals fed back by the angle detector 303. The signal acquisition module 702 is connected to the signal output terminal of the sensor under test via a cable through a test interface 7021 on its panel, and is used to acquire the electrical signals of the sensor under test at different settings. The type of the test interface 7021 is set to match the interface specifications of the sensor under test. When the controller 701 controls the drive unit 301 to move, the feedback signal of the angle detector 303 and the sensor signal acquired by the signal acquisition module 702 are processed synchronously to complete the calibration and testing process of the sensor.

[0055] Mounting bracket 801 is fixedly mounted on the platform of base 1. Its structure is set as a frame that surrounds the movement area of ​​the actuator arm 4. The outline of the frame is larger than the maximum movement envelope of the actuator arm 4. The protective cover 8 is installed on the side and top of mounting bracket 801 by means of hinges, buckles or screws. Its material is set to transparent or semi-transparent. When the actuator arm 4 is driven by drive shaft 304 to swing, its entire movement trajectory is restricted within the space enclosed by mounting bracket 801. Mounting bracket 801 plays the role of physical isolation and safety protection. The protective cover 8 further isolates the movement area from the external environment, which can prevent personnel from accidentally touching the moving parts and also block the entry of foreign objects.

[0056] 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.

[0057] 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.

[0058] 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. An automatic calibration and testing fixture for a gear position sensor, characterized in that, The device includes a base (1), a clamping platform (2), a drive actuation assembly (3), an actuation arm (4), and a floating coupling assembly (5), wherein: the clamping platform (2) is movably disposed on the base (1); the drive actuation assembly (3) is disposed on the base (1), and includes a drive component (301), a reducer (302) connected to the drive component (301), an angle detector (303) connected to the output end of the reducer (302), and a drive shaft (304) connected to the output end of the angle detector (303); one end of the actuation arm (4) is connected to the drive shaft (304); the floating coupling assembly (5) is disposed at the end of the actuation arm (4) away from the drive shaft (304), and is used to connect the movable part of the sensor under test.

2. The automatic calibration test fixture for the gear position sensor according to claim 1, characterized in that, The drive assembly (3) further includes a zero-position calibration component (6), which includes a reference stop (601) and a position detector (602) disposed on the rotation path of the drive shaft (304).

3. The automatic calibration test fixture for the gear position sensor according to claim 2, characterized in that, The reference stop (601) is mounted on the base (1) via an adjustment mechanism (603), which enables the reference stop (601) to move in a direction parallel to the radial direction of the drive shaft (304).

4. The automatic calibration test fixture for the gear position sensor according to claim 3, characterized in that, The adjustment mechanism (603) includes a mounting base (6031) disposed on the base (1), an adjustment screw (6032) passing through the mounting base (6031) and threadedly connected to the reference stop (601), and a locking nut (6033) disposed on the adjustment screw (6032) and used to abut against the mounting base (6031).

5. The automatic calibration test fixture for the gear position sensor according to claim 1, characterized in that, The floating coupling assembly (5) includes a ball head (501) disposed at the end of the actuating swing arm (4) and a connector (502) for connecting the sensor under test. The connector (502) is provided with a ball socket (5021) that slides with the ball head (501).

6. The automatic calibration test fixture for the gear position sensor according to claim 5, characterized in that, The connector (502) also includes a locking sleeve (5022) for clamping the movable part of the sensor under test, and the locking sleeve (5022) is provided with a locking screw (5023) in its radial direction.

7. The automatic calibration test fixture for the gear position sensor according to claim 4, characterized in that, The bottom of the clamping platform (2) is equipped with a slider (201), the base (1) is provided with a guide rail (202) that cooperates with the slider (201), and the clamping platform (2) is also provided with a locking member (203) for locking it to the guide rail (202).

8. The automatic calibration test fixture for the gear position sensor according to claim 7, characterized in that, The clamping platform (2) is also provided with a clamp (204), which includes a positioning base plate (2041) for supporting the sensor under test and a clamping member (2042) provided above the positioning base plate (2041).

9. The automatic calibration test fixture for the gear position sensor according to claim 1, characterized in that, It also includes an electrical control box (7), which is equipped with a controller (701) and a signal acquisition module (702). The controller (701) is electrically connected to the drive unit (301) and the angle detector (303). The signal acquisition module (702) is equipped with a test interface (7021) for connecting the sensor under test.

10. The automatic calibration test fixture for the gear position sensor according to claim 1, characterized in that, The base (1) is also provided with a protective cover (8) and a mounting bracket (801). The mounting bracket (801) is disposed on the base (1) and surrounds the movement area of ​​the swing arm (4). The protective cover (8) is disposed on the mounting bracket (801).

Images