A vehicle's actual application conditions, such as startup, idle park, low speed or high speed driving, speed increase, speed decrease, climbing, and reversing are extremely complex. They require the vehicle's driving force and speed to change within a large range. The range of output torque and speed change produced by the piston engines that are widely adopted at present is smaller. In order to adapt to the constantly changing driving conditions and to enable the engine to work under favorable conditions (higher power with lower fuel consumption), a gearbox is added into the transmission system. The automobile gearbox is one of the highest-tech products among the components for a vehicle. One of its more crucial aspects is online testing, which aims to simulate the car's actual operating conditions while on the production line to test for transmission related indicators.
At present, the automotive transmission detection scheme primarily comprises using a generator analog engine and generator analog load methods to achieve the online testing functions. The specific procedures are as follows: Use two AC motors to simulate vehicle conditions and detect the transmission's integrated indicators online. During each stage of the shift change process, the load capacity can be used to instantly monitor the system's operating parameters and plot out the system performance curve. The robotic arm automatically completes the different gear shift actions for different types of transmissions. Control the software's system operating parameters and record them immediately, provide real-time monitoring for temperature, speed, torque, and current, and provide automatic alarm and analyses when fails are encountered. The core of the control department is the computers. The control software is used to control the system's process, task allocation, instruction transmission, fault detections, etc., according to the field data and current operating conditions.
The automobile transmission detection system requirements are:
- The machine will remain in a long-term vibrating state because of the engine running tests. Therefore, the computer must have an excellent shock resistance platform.
- High I/O expansion flexibility.
- Must be able to achieve instant control of the temperature, rotation speed, torque, noise, speed, and other status parameters.
- The system must be able to adapt to the plant's stringent requirements such as vibration, oil, dust, and continuous production.
The system adopts Advantech's rugged 7-slot modular industrial computer MIC-3111. Its MIC-3716 high-speed multifunction data acquisition card, 16-bit high-resolution, and 250 Ks/S ultra-high sampling rate can fully capture the transmission's operating parameters. Data such as temperature, rotation speed, torque, and noise are instantly displayed by the FPM-2150 industrial-grade touch screen display in the control room. In addition, MIC-3716 can be used to output the control parameters and achieve the gearbox loading, shift, and other operations. Meanwhile, the WebAccess configuration software can perform data logging and real-time monitoring on the operations of the entire test system, and can perform automatic alarm and analyses when faults are encountered.