Research And Implementation Of A Testing System For Comprehensive Performance Of Gearbox

Gearbox as the main components of the car, in the event of failure at worst affectthe car's dynamic performance, serious may not be driving, there may even place avariety of traffic accidents, endangering life. Gearbox to maintain a good workingstate, it is necessary to pay attention to routine maintenance, but also need to ensurethat when its loading is a qualified product. So the test after the gearbox assembly iscrucial. But how to design a stable and reliable test bed to detect gearbox products, ithas been a problem to explore for a vast number of research institutions andenterprises.The launching of this subject was under the support of the manual gearboxcomprehensive performance test bed project commissioned by a well-knownautomotive group in Anhui, combined with the Outstanding Youth Fund of AnhuiProvince: auto gearbox Universal energy-efficient intelligent detection system(2008JQL085). In accordance with relevant standards, a test bed was designed to testvarious types of manual gearbox. The comprehensive application of the science ofcontrol, signal processing, sensor technology and artificial intelligence theory, wasused to study the key issues such as the variable loading, shift controlling, noisefiltering, product classification and fault diagnosis.The main contents of this article and made innovative achievements are asfollows:1. The structure and working principle of the manual gearbox was studied, andthe types, advantages and disadvantages of the automatic gearbox were analyzed. Onthis basis, the test items and test methods of the gearbox test was summarized, as afoundation for further research.2. In the working environment of the test bed, the measured signal wassusceptible to a variety of noise. By studying non-stationary random signal and thefrequency analysis method, the use of biorthogonal wavelet filter noise reductiongearbox test bed signal was proposed based on wavelet analysis. The practice hasshown that the noise reduction effect is very obvious.3. An integrated test bed which could carry out both a shift performance testand load performance test was designed. Load capacity could be adjusted according toneed, and thus it was able to simulate a vehicle traveling a variety of conditions. Thetest bed was also capable of a variety of other test items, such as gearbox efficiencytesting, fatigue testing, noise testing, the oil temperature testing, and it could be extended to other test items by manually test. In addition, the test bed through thereplacement of the couplings could be applied to different structures of the five typesof gearbox.4. The AC motor speed control technology was used by the test bed. At loadtime, the output motor act as a generator changed the mechanical kinetic energy bythe drive motor passed into electricity. Electrical energy could be returned to the gridthrough the inverter, saving a lot of energy. Power consumption of the test bed wasonly one tenth of the total power when the actual working.5. Precise control of clutch and input motor speed in the shift process greatlyimproved the shift quality. This control basically eliminated the impact of the shiftingprocess of the test bed; at the same time minimized the impact of the gearboxstructure. Non-destructive testing of products could be achieved.6. A classification and fault diagnosis system for unreleased new gearbox wasdesigned by wavelet neural network and expert system. The system was used for thegearbox classification of quality level, and a preliminary diagnosis of the faultgearbox.The gearbox comprehensive performance test bed developed in this subject haspassed through the corporate acceptance, and put into practical operation. Theperformance of the test bed has achieved the design requirements and better testresults. The test bed received the Award of the Chinese Academy of Sciences andAnhui to build. Developed test bed system and the results of the work for the furtherstudy of the gearbox test has laid a good foundation, and also has a certain role inpromoting the development of China's automobile industry.