Research On The Control System Of The Intelligent Pneumatic Synchronizer Test Bench

Pneumatic synchronizer test bench is a test facilities that driven the transmission shifts bygas pressure to simulate actual synchronizer working conditions. It has a lot of significantadvantages such as simple structure, low cost, non-polluting, prompt action，good cushioningproperties, operating characteristics agree well with the palm shifting, but its main drawbackis the low shift position control accuracy.The control systemis the core of the synchronizer test rig, and its performance determinesthe reliabilityand conveniences of thetestrigdirectly. This paper had developed the intelligentcontrol systems to solve the problem of low precision pneumatic position control. Thepneumatic synchronizer test bench with this system can full play to their strengths. This studymade great contribution to the test and research of synchronizer.First of all, in this paper, the working principle and test requirements of the synchronizerwas presented. Both the domestic and the foreign test bench for synchronizer and pneumaticposition control system was studied and compared. The structure of the pneumaticsynchronizer test bench was Introduction and the shift actuator drive by the high-speedswitching valve controlled cylinder wad designed.Then, This paper describes the structure of the test bed control system, selection and useof sensors and actuators, and the hardware and software design of Synchronizer Test-benchControl Unit (STCU) with embedded microcontrollers as its core. The bench with this controlsystem has the following features: Monitoring parameters of the transmission such as shiftforce and displacement, shaft speed, temperature, generating PWM driving signal,rememberinggearpositiondata,automaticshiftingcontinuously, communicating with the hostcomputer.After that, the fuzzy adaptive PID controller which can adjust continuously the duty cycleof PWM generated by microcontroller, according to the position error and its change rate, was designed. The controller together with linear decomposition algorithm of PWM can controlthe position of servo-pneumatic actuator based on PWM fast, accurate and without overshoot.The simulation model which verified that the system is feasible and effective, was built withMATLAB/Simulink andAMESim.At last, the function, accuracy and repeatability of the control system were tested in thepneumatic synchronizer test rig. The experiment of synchronizer was presented and theperformance and life-span were evaluated according to the analysis of the experiment result.The Control System of the Intelligent Pneumatic Synchronizer Test Bench whichComposed by pneumatic system, embedded microcontroller and fuzzy adaptive PID controllerovercomes the disadvantages of low precision pneumatic position control, gives full play tothe advantages of the pneumatic system, and provides the most economical and practicalsolution for the test and research of synchronizer.