CN-116499737-B - Device and method for testing strength of gear of electric drive axle assembly

CN116499737BCN 116499737 BCN116499737 BCN 116499737BCN-116499737-B

Abstract

The invention discloses a device and a method for testing the strength of an electric drive axle assembly gear, wherein the device comprises a high-voltage power distribution cabinet, a low-voltage power supply, a whole vehicle controller VCU, an upper computer, an output motor controller, a gearbox controller, a tested motor controller, a tested motor gear shifting mechanism, a plurality of high-voltage connectors, a plurality of low-voltage connectors and the like, and the detection of the strength of the electric drive axle gear is realized through testing the maximum bearing torque of an input shaft, an intermediate shaft and an output shaft of the tested motor. The invention has the advantages of convenient installation and operation, various gear combinations, different torque distribution, various torque experiments on the gears, precise experiment guarantee, time saving and debugging, no need of fine adjustment on the stress of the electric drive axle, and direct adjustment on the strength of the electric drive axle according to the experimental scheme result.

Inventors

LI YUNFENG
WU DONGDONG
GAO CHAO
ZENG QINGHUA
Guo Yuanchi

Assignees

南京司凯奇汽车科技有限公司

Dates

Publication Date: 20260505
Application Date: 20230216

Claims (7)

1. The utility model provides a testing arrangement of electric drive axle assembly gear strength, its characterized in that includes high-voltage distribution cabinet (5), low-voltage power supply (16), whole car controller VCU (15) and host computer (14), and: The high-voltage transformer comprises an output motor (1), an output motor controller (22), an output motor high-voltage connector (21) and an output motor high-voltage connector (20), wherein the output motor (1) is provided with an output motor high-voltage harness terminal (26); The automatic transmission comprises a transmission (2), a transmission controller (19), a transmission controller pressure connector (28) and a transmission electromagnetic valve assembly (3), wherein the transmission electromagnetic valve assembly (3) integrates a gear shifting electromagnetic valve, a gear sensor and a gas circuit interface; The device comprises a tested motor (6), a tested motor controller (8), a tested motor high-voltage plug-in connector (7), a tested motor compression connector (9) and a tested motor gear shifting mechanism (10), wherein the tested motor (6) comprises an input shaft, an intermediate shaft and an output shaft which are connected through gears, the strength of the gears is tested by the testing device, the tested motor (6) is provided with a tested motor high-voltage wire harness terminal (27), the output shaft, the input shaft and the intermediate shaft of the tested motor (6) are made of the same materials, the input shaft, the intermediate shaft and the output shaft work in a mutually matched mode through the gears, and the strength of the input shaft, the intermediate shaft and the output shaft is higher than that of the gears; The output motor (1) is connected with the gearbox (2), and a transmission shaft (4) connected with the motor (6) to be tested is arranged at the output end of the output motor (1) and is used for transmitting the rotation torque of the output motor to an input shaft of the motor (6) to be tested; Two groups of high-voltage wire harnesses are led out from the output end of the high-voltage power distribution cabinet (5), are respectively connected with the input ends of the output motor high-voltage connector (21) and the tested motor high-voltage connector (7), and the output ends of the output motor high-voltage connector (21) and the tested motor high-voltage connector (7) are respectively connected with the high-voltage wire harness wiring ends of the output motor (1) and the tested motor (6) and are used for providing high-voltage working power supplies for the output motor (1) and the tested motor (6); The output end of the low-voltage power supply (16) is provided with an emergency stop switch (17) and a safe box (18), a plurality of high-voltage wire harnesses are led out from the output end of the low-voltage power supply (16), and the high-voltage wire harnesses are respectively connected with an output motor low-voltage connector (20), a gearbox controller low-voltage connector (28) and a tested motor low-voltage connector (9) and used for providing low-voltage working power supplies for the output motor (1), the gearbox (2) and the tested motor (6).
2. The device for testing the gear strength of the electric drive axle assembly according to claim 1, wherein the bottom of the tested motor (6) is provided with a fixing mechanism, the fixing mechanism comprises a differential lock (13), a group of locking points (11) and a group of half shafts (12) which are positioned at two sides of the differential lock (13), and two ends of the half shafts (12) are respectively connected with the differential lock (13) and the locking points (11).
3. The device for testing the gear strength of the electric drive axle assembly according to claim 1, wherein the whole vehicle controller VCU (15), the upper computer (14), the output motor controller (22), the gearbox controller (19) and the tested motor controller (8) are in communication connection, The vehicle control unit VCU (15) is used for receiving real-time data of the output motor (1), the tested motor (6), the gearbox (2) and the tested motor gear shifting mechanism (10), processing the data and feeding back the data to the upper computer (14), receiving an instruction of the upper computer (14) and issuing the received instruction to each controller; the upper computer (14) is used for inputting control signals by an operator to control the testing device, and comprises the step of calibrating the output torque of the output motor; The output motor controller (22) is used for controlling the torque and the rotating speed of the output motor (1) and acquiring information including the torque, the rotating speed, the temperature and the fault condition of the output motor (1); The input end of the gearbox controller (19) is provided with an electromagnetic valve assembly, an input shaft rotating speed sensor, a rotating shaft rotating speed sensor and an air passage interface, wherein the electromagnetic valve assembly is used for simulating gear switching of the gearbox, and the input shaft rotating speed sensor and the rotating shaft rotating speed sensor are used for simulating rotating states of an input shaft and an output shaft of the gearbox and outputting rotating speed signals; the detected motor controller (8) is used for controlling the torque and the rotating speed of the detected motor (6) and acquiring information including the torque, the rotating speed, the temperature and the fault condition of the detected motor (6).
4. The device for testing the gear strength of the electric drive axle assembly according to claim 1, wherein the output motor high-voltage connector (21) and the tested motor high-voltage connector (7) are provided with functional modules for converting direct-current power sources into alternating-current power sources.
5. The device for testing the gear strength of the electric drive axle assembly according to claim 1, wherein the gearbox (2) is provided with two gears and two speed ratios, the gearbox electromagnetic valve assembly (3) comprises a first electromagnetic valve, a second electromagnetic valve, a first electromagnetic valve sensor and a second electromagnetic valve sensor, the first electromagnetic valve and the second electromagnetic valve are respectively used for simulating the two gears of the gearbox, namely, when an upper computer (14) gives an instruction that the gearbox (2) is in a first gear, the first electromagnetic valve executes the instruction, the first electromagnetic valve sensor monitors whether the current gear is in the first gear position, if the current gear is in the first gear position, the upper computer (14) is fed back to be successfully in gear, and otherwise, the upper computer (14) is fed back to be failed in gear.
6. The device for testing the gear strength of the electric drive axle assembly according to claim 1, wherein the tested motor (6) is provided with two gears and two speed ratios, a rotating speed sensor and a temperature sensor are arranged on the tested motor (6), the tested motor gear shifting mechanism (10) is provided with a tested motor gear shifting motor position sensor, namely when an upper computer (14) gives an instruction that the tested motor (6) is in a first gear, the tested motor gear shifting mechanism (10) executes the instruction, the tested motor gear shifting motor position sensor detects whether the current gear is in the first gear position or not, if the current gear is in the first gear position, the upper computer (14) is fed back to be successfully in gear shifting, and if the current gear is not in the first gear position, the upper computer (14) is fed back to be successfully in gear shifting.
7. A method for testing the strength of a gear of an electric drive axle assembly, applied to the testing device of any one of claims 1 and 6, comprising the steps of: s1, testing a large speed ratio combination which is obtained by adjusting a gearbox (2) and a tested motor (6) to the maximum gear, wherein the speed ratio of the gearbox is as follows The speed ratio of the motor to be tested is ; S2, adjusting the output torque of the output motor (1) through the upper computer (14), and when the output torque of the output motor (1) is When the intermediate shaft of the tested motor (6) is damaged, judging the maximum bearing torque of the intermediate shaft of the tested motor ; S3, manually rotating to adjust the meshing angles among an input shaft, an intermediate shaft and an output shaft of the tested motor (6) to 120 degrees, and performing other speed ratio combination tests; S4, testing the input shaft and the output shaft of the motor (6) to be tested by using the methods from S1 to S3, and judging the maximum bearing torque of the input shaft of the motor to be tested And maximum bearing torque of output shaft ; S5, comparing the maximum bearing torque of the intermediate shaft of the tested motor (6) Maximum bearing torque of input shaft And maximum bearing torque of output shaft And taking the maximum value of the three as the bearable maximum torque C of the motor to be tested.

Description

Device and method for testing strength of gear of electric drive axle assembly Technical Field The invention relates to a device and a method for testing the strength of an electric drive axle assembly gear, and belongs to the technical field of automobile manufacturing. Background At present, an electric drive axle is a high-integration transmission system integrating an electric control, a motor, a speed reducer and a drive axle, and the electric drive axle is composed of three parts, namely, a motor, an inverter and an electric drive speed changer. In the existing drive axle torque experiment bench, only the torsional rigidity and static torsion strength of a half shaft can be tested, a special test bench is lacked for separately testing the rigidity and torque of an electric drive axle output shaft, an intermediate shaft and the like, and experimental data and analysis of an electric drive axle assembly are lacked. Disclosure of Invention In order to solve the defects in the prior art, the invention aims to provide a device and a method for testing the strength of a gear of an electric drive axle assembly, which can rapidly realize the strength detection of an input shaft, an output shaft and an intermediate shaft of the electric drive axle. In order to achieve the above purpose, the present invention adopts the following technical scheme: the utility model provides a testing arrangement of electric drive axle assembly gear strength, its characterized in that includes high-voltage distribution cabinet, low-voltage power supply, whole car controller VCU and host computer to and: The device comprises an output motor, an output motor controller, an output motor high-voltage connector and an output motor high-voltage connector, wherein the output motor is provided with an output motor high-voltage wire harness terminal; the gearbox comprises a gearbox, a gearbox controller low-voltage connector and a gearbox electromagnetic valve assembly, wherein the gearbox electromagnetic valve assembly integrates a gear shifting electromagnetic valve, a gear sensor and a gas circuit interface; the device comprises a tested motor, a tested motor controller, a tested motor high-voltage plug connector, a tested motor compression connector and a tested motor gear shifting mechanism, wherein the tested motor comprises an input shaft, an intermediate shaft and an output shaft which are connected through gears, the strength of the gears is tested by the testing device, and the tested motor is provided with a tested motor high-voltage wire harness terminal; The output motor is connected with the gearbox, and the output end of the output motor is provided with a transmission shaft connected with the motor to be tested and used for transmitting the rotation torque of the output motor to the input shaft of the motor to be tested; The output end of the high-voltage power distribution cabinet is led out of two groups of high-voltage wire harnesses, the two groups of high-voltage wire harnesses are respectively connected with the input ends of the high-voltage connector of the output motor and the high-voltage connector of the tested motor, and the output ends of the high-voltage connector of the output motor and the high-voltage connector of the tested motor are respectively connected with high-voltage wire harness wiring ends of the output motor and the tested motor and are used for providing high-voltage working power supplies for the output motor and the tested motor; The output end of the low-voltage power supply is provided with an emergency stop switch and a safe box, a plurality of high-voltage wire harnesses are led out from the output end of the low-voltage power supply, and the high-voltage wire harnesses are respectively connected with an output motor low-voltage connector, a gearbox controller low-voltage connector and a tested motor low-voltage connector for providing low-voltage working power supply for the output motor, the gearbox and the tested motor. Preferably, the bottom of the tested motor is provided with a fixing mechanism, the fixing mechanism comprises a differential lock, a group of locking points and a group of half shafts, the locking points and the half shafts are positioned on two sides of the differential lock, and two ends of the half shafts are respectively connected with the differential lock and the locking points. Preferably, the whole vehicle controller VCU, the upper computer, the output motor controller, the gearbox controller and the tested motor controller are in communication connection, wherein, The whole vehicle controller VCU is used for receiving real-time data of the output motor, the tested motor, the gearbox and the tested motor gear shifting mechanism, processing the data and feeding back the data to the upper computer, receiving an instruction of the upper computer and issuing the received instruction to each controller; the upper computer is used for inputting control signals by an