Drive Train Testing System Torque Synchronization

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Solution Overview

Problem

Conventional drive train testing systems struggle to accurately reproduce torque variations in synchronization with the mechanical phase of an actual engine, leading to phase displacement errors and inadequate evaluation of drive train components.

Innovation Solution

A drive train testing system that includes a motor connected to the drive train, a torque command generation device, and a machine angle acquisition means using absolute or incremental encoders to generate a torque command signal synchronized with the motor's machine angle, ensuring accurate torque variation simulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the rotation speed is integrated to calculate the phase of the motor, then the torque command signal can be generated, but phase displacement errors occur due to integration starting position and sensor errors

Engineering Contradiction:

Improvetorque command signal generationVSAvoidphase accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical integration method (which accumulates errors) with an electrical signal detection method. Instead of integrating rotation speed to obtain phase information, the system directly detects the machine angle signal from an encoder, eliminating integration errors and providing accurate phase synchronization for torque command generation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a machine angle signal as an intermediary between the rotation detection and torque command generation. This intermediate signal provides direct phase information without the error accumulation inherent in integration methods, enabling precise torque application synchronized with the mechanical phase.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the torque command signal is generated based on integrated rotation speed, then the testing system can operate, but phase displacement occurs leading to inaccurate engine simulation

Engineering Contradiction:

Improvetesting operation capabilityVSAvoidengine simulation accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces the unreliable mechanical integration approach with direct electrical signal detection. By using a machine angle signal from an encoder instead of integrating rotation speed, the system maintains operational capability while eliminating phase displacement errors that compromise simulation accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements feedback by continuously monitoring the machine angle signal and using it to generate the torque command signal. This closed-loop approach ensures that torque application remains synchronized with the actual mechanical phase, improving both operational reliability and simulation accuracy.

Inventive Principle:

Principle #23Feedback

3Ease of manufacture

If conventional testing methods are used, then the drive train can be tested, but components requiring mechanical phase synchronization cannot achieve optimal performance evaluation

Engineering Contradiction:

Improvetesting system operationVSAvoidperformance evaluation accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces conventional integration-based torque command generation with direct machine angle signal utilization. This substitution maintains system operational simplicity while dramatically improving the accuracy of performance evaluation for components that require precise mechanical phase synchronization.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10444116B2Drive train testing system and drive train testing method

Publication Date: 2019.10.15 MEIDENSHA CORP

AI summary

The purpose of the present invention is to provide a drive train testing system whereby torque fluctuation in a real engine can be reproduced with good precision. A drive train testing system is provided with an input-side dynamometer connected to an input shaft WI of a test piece W which is a vehicle drive train, a torque command generation device for generating a torque command signal for causing a torque resembling that of a vehicle engine to be generated by the input-side dynamometer, and a rotation detector for detecting a motor machine angle corresponding to an absolute position from a reference position of a rotary shaft of the input-side dynamometer. Using the motor machine angle detected by the rotation detector, the torque command generation device generates a torque command signal fluctuating in synchrony with a signal having a period that is a predetermined degree multiple of the motor machine angle.