Research On The Synchronizer Test Bench With Single Chip Microcomputer

Synchronizer is the one of the most important apartments of the transmission,which determines the performance of transmission shift quality, as well as the lifespan of the transmission. As is widely recognized, the automotive is a verycomplicated production, which is hardly studied through theoretical arithmetic orsimulation, so it’s essential to build testbench to research the performance and the lifespan of the synchronizer.The main content of this topic was to develop a testbench to do some research onthe performance and span of the synchronizer, using which, too many experimentswere done to evaluate the transmission.First of all,in this paper, both the domestic and the foreign testbench forsynchronizers was studied and compared. The working principle of the synchronizerswas presented, at the same time, the dynamic characteristic and mathematical modelof which was analyzed.Then, based on the study above, the whole design process of the synchronizertestbench was introduced, including the mechanical structure design, the electric andelectronic control system design, etc.After that, the electric and electronic control system design, based on the singlechip microcomputer, which was one of the technological difficulties, was introducedin detail. The electric and electronic control system included the hardware design, thesoftware design, and reliability measures. The hardware system, including thecontroller, the IO and the communication, etc, was based on the Infineon XC2785XMCU. The software system mainly included the main function, the data collectionsystem and the auxiliary program, etc. At the same time, some reliability solution wastake to help the testbench run well.At last, the experiment process, including the previous preparation, and theresults were presented. During the analysis of the results, a evaluation method of the performance of the synchronizer was introduced.Using the synchronizer testbench, several mechanical transmissions were tested,and a lot of experimental data about the synchronizers’ performance and life-span wasgot, which prove the feasibility of the testbench.