機械式前置汽車變速器實驗臺設(shè)計,機械式,前置,汽車,變速器,實驗,試驗,設(shè)計 機械設(shè)計簡介 設(shè)計過程 機器是機構(gòu)與其他零件的組合， 為了有益的用途而轉(zhuǎn)換，傳遞或利用能量，力或運動。實例有發(fā)動機，渦輪，車輛，卷揚機，印刷機，洗衣機和電影攝影機。 許多適用于機器設(shè)計的原理和方法也適用于不是真正機器的制成品，從輪轂蓋和檔案櫥柜到儀表和核壓力容器。“機械設(shè)計”這一術(shù)語比“機器設(shè)計”更為廣義，它包括機器設(shè)計。而對于某些儀器，如用以確定熱，流動線路和體積的熱力以及流體方面的問題要單獨考慮。但是，在機械設(shè)計時要考慮運動和結(jié)構(gòu)方面的問題以及保存和封裝的規(guī)定。在機械工程領(lǐng)域以及其他工程領(lǐng)域應(yīng)用機械設(shè)計，都需要諸如開關(guān)，凸輪，閥門，容器和攪拌器等機械裝置。 設(shè)計始于真正的或想象的需要?，F(xiàn)有的儀器可能需要在耐用性，效率，重量，速度或成本上加以改進。 可能需要新的儀器來完成以前由人做的功能，如計算，裝配或保養(yǎng)。目標全部或部分地確定后，設(shè)計的下一步就是構(gòu)思能夠完成所需功能的機構(gòu)及其布置。為此，徒手畫草圖價值極大，它不但作為一個人想法的記錄和其他人討論的輔助手段，而且尤其適于與自己的想法交流，作為創(chuàng)造性思路的興奮劑。還需要有關(guān)部件的廣泛知識，因為一臺新機器常常由熟知的各類零件重新安排或替換而成，也許改變了尺寸和材料。無論在構(gòu)思過程中還是之后，一個設(shè)計者都會進行快速或粗略的計算或分析以確定一般尺寸和可行性。當一些關(guān)于所需或可用空間量的想法確定后，可以按比例畫草圖。 當幾個零件的大致形狀和幾個尺寸出來時，分析可以真正開始了。分析的目的在于使其具有令人滿意的或者優(yōu)越的性能，以及在最小重量下的安全性和耐用性和有競爭力的成本。設(shè)計師將為每一個關(guān)鍵的承載截面尋找最佳的比例和尺寸，以及幾個零件強度的平衡。然后選擇材料和處理方法。這些重要的目標只有通過基于機械原理的分析才可以得到，如關(guān)于反作用力和摩擦的最優(yōu)利用的靜力學(xué)原理；關(guān)于慣性，加速度和能量的動力學(xué)原理；關(guān)于應(yīng)力和撓度的材料的彈性和強度原理；關(guān)于材料的物理行為原理；關(guān)于潤滑和水力驅(qū)動的流體力學(xué)原理。分析可以由構(gòu)思機械安排的同一個工程師來做，或者在大公司里由獨立的分析部門或研究組來做。分析的結(jié)果，可能需要新的安排和新的尺寸。不管是正式做的或非正式做的，設(shè)計是一個反復(fù)的和合作的過程，分析人員可以對所有階段起作用而不僅僅是他自己的階段。 最后，一項基于功能和可靠性的設(shè)計完成了，就可以制造樣機了。如果測試滿意，而且如果裝置要大量生產(chǎn)，就要對最初的設(shè)計進行一定的修改以確保以較低的成本大量生產(chǎn)。在隨后幾年的制造和使用期間，設(shè)計有可能因構(gòu)思了新想法或者基于測試和經(jīng)驗基礎(chǔ)上的進一步分析所顯示的改變而改變。銷售吸引力，客戶滿意度和制造成本都與設(shè)計有關(guān)，設(shè)計能力與工程投資的成功密切相關(guān)。 一些設(shè)計準則 在這一部分，有人建議運用創(chuàng)造性的態(tài)度進行的分析，這種分析可以引起重大改進以及對備用產(chǎn)品的構(gòu)思和完善，也許產(chǎn)品功能更多，更經(jīng)濟，更耐用。創(chuàng)造階段無需是最初和獨立的階段。雖然分析人員可能并不負責整個設(shè)計，但是他不僅僅是能從數(shù)字上提出要他解決的問題的正確答案，不僅僅是給出應(yīng)力值，尺寸或者工作限制。他可以提出更廣泛的見解，以便改進規(guī)范或方案。由于在分析前或分析過程中，他會熟悉裝置及其工作條件，他就處于一個構(gòu)思備選方案的有利位置。最好他能提出建議改變形狀來消除力矩或應(yīng)力集中，而不是允許構(gòu)建具有大截面和過多動態(tài)載荷的機構(gòu)。最好是他報廢他的細致的設(shè)計而不是后來看到的機械報廢。 為了激發(fā)創(chuàng)造性思維，建議設(shè)計人員和分析人員使用以下準則。前6條準則尤其適用于分析人員，雖然他可能涉及到所有這10項。 1. 創(chuàng)造性地利用所需的物理性能并控制不需要的。 2. 認識實用載荷及其重要性。 3. 預(yù)選考慮沒有作用的載荷。 4. 發(fā)明更有利的加載條件。 5. 提供最小重量的最有利的應(yīng)力分布和剛性。 6. 用基本方程計算比例并使尺寸最優(yōu)化。 7. 選取材料以獲得性能組合。 8. 在備件和集成零件間仔細選擇。 9. 修改功能設(shè)計以適應(yīng)生產(chǎn)過程和降低成本。 10.考慮裝配中使部件精確定位和互不干擾。 北京理工大學(xué)學(xué)報，1998，Vol.7,No.2 汽車變速器性能實驗臺自動控制 閻清東 項昌樂 馮永存 （北京理工大學(xué)車輛工程學(xué)院，北京 100081） 摘要 目的 實現(xiàn)汽車變速器性能實驗臺自動控制。 方法 采用了潤滑油油溫自動恒溫控制技術(shù)，微機控制變速器自動換檔，動力電機無級調(diào)速，加載電渦流測功機變載，試驗數(shù)據(jù)的自動采集與實時處理技術(shù)。 結(jié)果 潤滑油油溫控制在設(shè)定溫度℃；自動換檔簡單，可靠，準確 ；無級調(diào)速調(diào)載快速準確。加載轉(zhuǎn)矩偏差為r/min 。結(jié)論 將上述技術(shù)應(yīng)用于汽車變速器性能試驗臺，利用該試驗臺對某型變速器進行了微機程控性能試驗，效果良好。 關(guān)鍵詞 汽車變速器；性能試驗；計算機輔助測試；自動控制。 分類號 U463.212 ；U467.12 為提高民族產(chǎn)品性能而對汽車各部件進行試驗和理論的復(fù)雜研究是發(fā)展民族汽車工業(yè)的重要途徑。齒輪箱是汽車變速器的一個關(guān)鍵部分，其特性會直接影響到變速器的性能。主要的性能參數(shù)是：變速器效率，潤滑油，噪音等等。因此，對各性能進行快速而精確的測試是很必要的。 在本文中，汽車變速器性能多功能試驗臺應(yīng)用了自動控制技術(shù)，實現(xiàn)了潤滑油自動恒溫控制，可編程自動換檔，無級調(diào)速和負載調(diào)整，試驗數(shù)據(jù)的自動采集和處理，試驗報告和測試曲線的自動輸出，嚴格監(jiān)控了試驗環(huán)境，精度和速度。 1. 自動恒溫控制技術(shù) 性能測試中必須嚴格控制潤滑油的溫度，在整個試驗過程中油溫必須控制在設(shè)定溫度℃范圍內(nèi)。在本文中，采用了PID自動控制技術(shù)混合冷熱機油來實現(xiàn)潤滑油溫度恒定。該系統(tǒng)由潤滑油強制循環(huán)系統(tǒng)和帶有反饋的PID電子控制系統(tǒng)組成。圖1是潤滑油的強制循環(huán)系統(tǒng)圖，圖2是帶有反饋的PID電子控制系統(tǒng)圖。 圖1.潤滑油強制循環(huán)系統(tǒng) 1－電機 2－機油泵 3－壓力氣壓表 4－溢流閥 5－滑閥 6－過濾器 7－輔助油箱 8－截流閥 9－冷卻裝置 10－電子加熱器和熱機油箱 11－三通電子驅(qū)動閥 12－液壓油管 13－溫度傳感器 14－被測變速器 帶有反饋的PID自動控制系統(tǒng)用于控制三通電子可調(diào)閥的驅(qū)動電機。如果反饋溫度值低于設(shè)定溫度值，驅(qū)動電機將順時針轉(zhuǎn)動，熱機油流量增加，否則，驅(qū)動電機將逆時針轉(zhuǎn)動，冷機油流量增加。冷潤滑油來自于冷卻裝置 ，熱潤滑油來自裝有電子加熱器的熱潤滑油油箱，溫度計用于監(jiān)測變速箱機油溫度為PID溫度控制器提供了基本的設(shè)定數(shù)。輔助溫度控制器用于控制熱潤滑油箱中油溫保持在PID設(shè)定溫度的一定范圍內(nèi)。 圖2.PID自動控制原理圖 1－PID溫度控制器 2－溫度計 3－輔助溫度控制器 4－電子加熱器 5－熱機油箱溫度傳感器 6－變速器油溫傳感器 7－反饋溫度傳感器 8－三通電子可調(diào)閥驅(qū)動電機 2. 計算機控制系統(tǒng) 圖3是計算機自動控制流程圖 系統(tǒng)功能如下： 1. 監(jiān)測性能參數(shù)；輸入轉(zhuǎn)速和扭矩，輸出轉(zhuǎn)速和扭矩，潤滑油溫度，檔位。 2. 調(diào)整主可變頻率電機的轉(zhuǎn)速和電渦流電力測功機的負載。 圖3.計算機自動控制流程圖 2.1換檔控制 換檔桿的運動是由用于換檔和位置控制的汽缸活塞曲柄機構(gòu)控制的，活塞行程是由電磁開關(guān)控制的。換檔過程完全是由單片機上的CPU控制的。圖4是換檔氣動系統(tǒng)，圖5是換檔控制電路布置圖，CPU通過向單片機上的CPU發(fā)送換檔指令以閉合相應(yīng)的繼電器來控制電磁滑閥的動作，同時不同的氣動電路接通來實現(xiàn)不同的換檔和位置動作。 圖4.氣動換檔示意圖 1－油水分離器 2－儲氣筒 3－氣壓表 4，5，10，11－ 電磁滑閥 6－單向閥 7－換檔控制氣缸 8－電磁開關(guān) 9－位置控制氣缸 圖5.換檔控制電路示意圖 1，2，3，4－整體式繼電器 5，6，7，8－滑閥控制電磁鐵 9－主CPU 10－單片機上的CPU 11－位置開關(guān) 2.2 轉(zhuǎn)速和負載的控制 液晶示波器的頻率是1.832MHZ。第一級分離頻率的時間常數(shù)是2.頻率分離器的頻率是921.6KHZ，而后，系統(tǒng)控制軟件為下級頻率分離器設(shè)定連續(xù)的時間常數(shù)以獲得連續(xù)的電壓。時間常數(shù)和頻率之間的關(guān)系是：時間常數(shù)=921.6/頻率。 控制轉(zhuǎn)速和負載的自動控制器帶有與計算機連接的電壓通道端口。再通過F/D（頻率/電壓）轉(zhuǎn)換器可以獲得控制電壓。輸入頻率，輸出電壓，驅(qū)動電機轉(zhuǎn)速和測功機。磁化電流之間的相應(yīng)關(guān)系如下表： 表1. 對應(yīng)關(guān)系 輸入頻率/KHZ 輸出電壓/V 驅(qū)動電機轉(zhuǎn)速/（r/min） 測功機磁化電流/A 0 0 0 0 5 5 6000 5 3.計算機數(shù)據(jù)實時采集和處理 3.1數(shù)據(jù)實時采集 傳感器的信號在傳送到計算機以前，被高精度的V/F（電壓/頻率）和I/F轉(zhuǎn)換器轉(zhuǎn)變成類似的線性頻率信號。通過8253時間計數(shù)器和相應(yīng)的計算，可以得出被測工程的可變值。對應(yīng)關(guān)系：A=CN，A是工程值，N是時間計數(shù)器的脈沖值，C為轉(zhuǎn)換器的校對系數(shù)。 3.2數(shù)據(jù)實時處理 從傳感器獲取的原始數(shù)據(jù)的基礎(chǔ)上，輸入功率，輸出功率，比例，效率會直接計算出來。同時，計算機屏幕上會顯示出效率曲線。 4. 實驗臺的結(jié)構(gòu) 性能實驗臺是一臺動力開環(huán)測試臺，由機械框架，電控系統(tǒng)，計算機系統(tǒng)，潤滑油自動恒溫控制系統(tǒng)和可編程控制自動換檔系統(tǒng)組成。圖6是實驗臺的框架圖。動力組是55KW的高轉(zhuǎn)速可變頻電機，可以實現(xiàn)0-6000r/min范圍內(nèi)的連續(xù)可變調(diào)速。因此，變速器輸入可以省去一臺調(diào)速器，在很大范圍內(nèi)降低了實驗臺的噪音。負載組是一臺160KW的電渦流電力測功機，動力可以單邊或雙邊輸入，以達到配有差速齒輪或無差速齒輪的變速器的要求。在變速器的輸出端采用了同步帶，可以簡化實驗臺的結(jié)構(gòu)和降低噪音。 圖6.實驗臺框架結(jié)構(gòu)圖 1－55KW可變頻電機 2－輸入扭矩，轉(zhuǎn)速傳感器 3－被測變速器 4－輸出扭矩，轉(zhuǎn)速傳感器 5－同步帶 6－160KW電渦流電力測功機 7－潤滑油泵工作臺 8－換檔機構(gòu)系統(tǒng) 5.試驗舉例 在實驗臺上對ALTO變速器進行性能測試，通過原始數(shù)據(jù)處理，效率曲線如圖7所示。試驗過程中，檢測參數(shù)被控制在實驗臺許可范圍內(nèi)。試驗數(shù)據(jù)如下圖： 圖7.效率曲線 輸入轉(zhuǎn)速：（（1000，2000，3000）5）r/min； 輸入扭矩：（（28，56）1）N·m； 潤滑油溫度：（802）℃。 6.總結(jié) 1. 冷熱機油混合技術(shù)的采用，可以實現(xiàn)潤滑油恒溫控制。 2. 可編程自動換檔，可調(diào)轉(zhuǎn)速負載，和數(shù)據(jù)實時采集和處理技術(shù)的采用，變速器特性測試可以自動完成。 3. 試驗報告和測試結(jié)果曲線可以通過計算機顯示獲取。 參考文獻 Lu J F.傳感器端口通道和試驗裝置電路（中文版）。北京 北京航空工業(yè)出版社，1994 （收錄于1997.11.26） 8 大 學(xué) 畢業(yè)設(shè)計任務(wù)書 學(xué) 院、系： 專 業(yè)： 機械設(shè)計制造及其自動化 學(xué) 生 姓 名： 學(xué) 號： 設(shè) 計 題 目： 機械式汽車前置變速器實驗臺 起 迄 日 期: 指 導(dǎo) 教 師: 系 主 任: 發(fā)任務(wù)書日期: 年 月 日  任務(wù)書填寫要求 1．畢業(yè)設(shè)計任務(wù)書由指導(dǎo)教師根據(jù)各課題的具體情況填寫，經(jīng)學(xué)生所在系的負責人審查、簽字后生效。此任務(wù)書應(yīng)在畢業(yè)設(shè)計開始前一周內(nèi)填好并發(fā)給學(xué)生； 2．任務(wù)書內(nèi)容必須用黑筆工整書寫或按教務(wù)處統(tǒng)一設(shè)計的電子文檔標準格式（可從教務(wù)處網(wǎng)頁上下載）打印，不得隨便涂改或潦草書寫，禁止打印在其它紙上后剪貼； 3．任務(wù)書內(nèi)填寫的內(nèi)容，必須和學(xué)生畢業(yè)設(shè)計完成的情況相一致，若有變更，應(yīng)當經(jīng)過所在專業(yè)及系主管領(lǐng)導(dǎo)審批后方可重新填寫； 4．任務(wù)書內(nèi)有關(guān)“學(xué)院、系”、“專業(yè)”等名稱的填寫，應(yīng)寫中文全稱，不能寫數(shù)字代碼。學(xué)生的“學(xué)號”要寫全號（如0201140102），不能只寫最后2位或1位數(shù)字； 5．有關(guān)年月日等日期的填寫，應(yīng)當按照國標GB/T 7408—94《數(shù)據(jù)元和交換格式、信息交換、日期和時間表示法》規(guī)定的要求，一律用阿拉伯數(shù)字書寫。如“20011年3月15日”或“20011-03-15”。 畢 業(yè) 設(shè) 計 任 務(wù) 書 1．畢業(yè)設(shè)計的任務(wù)和要求： 任務(wù)：設(shè)計機械式前置汽車變速器實驗臺。 要求：設(shè)計零號圖紙（裝配圖）一張，部件圖三張（輸入傳動、輸出傳動、軸承座組件），零件圖三張（輸出軸、多楔帶輪、花鍵軸）。 設(shè)計說明書一份。 刻錄光盤一張。 2．畢業(yè)設(shè)計的具體工作內(nèi)容： 原始數(shù)據(jù)：1）適用5T07汽車變速器。 2）輸入扭矩：85N.m。 3）輸入轉(zhuǎn)速：0~3000r/min。 4）反拖電機功率：3kw。 5）輸出扭矩：<1000N.m。 6）工件移動距離：180~200mm。 技術(shù)要求：1）輸入軸跳動<0.03mm。 2）輸出軸跳動<0.02mm。 3）工件夾緊力≥150N。 4）工作效率：2~3min/件。 工作要求：1）學(xué)習AutoCAD軟件。 2）結(jié)構(gòu)設(shè)計合理。 3）撰寫設(shè)計說明書。 4）翻譯英文資料一份。 畢 業(yè) 設(shè) 計 任 務(wù) 書 3．對畢業(yè)設(shè)計成果的要求： 設(shè)計零號圖紙（裝配圖）一張，部件圖三張（輸入傳動、輸出傳動、軸承座組件），零件圖三張（輸出軸、多楔帶輪、花鍵軸）。 設(shè)計說明書一份。 刻錄光盤一張。 4．畢業(yè)設(shè)計工作進度計劃： 起 迄 日 期 工 作 內(nèi) 容 2011年 3月 1 日 ~3月10日 3月11日 ~3月20日 3月21日 ~4月15日 4月16日 ~5月15日 5月16日 ~6月10日 6月10日~ 6月15日 查閱有關(guān)帶式輸送機自動張緊裝置的資料，準備開題； 完成開題報告； 機械式變速器實驗臺設(shè)計的理論分析； 機械式變速器實驗臺的總體和結(jié)構(gòu)設(shè)計； 完成畢業(yè)設(shè)計說明書的撰寫，翻譯英文資料； 論文答辯 學(xué)生所在系審查意見： 系主任： 年 月 日 大學(xué) 屆本科畢業(yè)設(shè)計說明書 機械式前置汽車變速器實驗臺的設(shè)計 摘要 根據(jù)5T07汽車變速器性能試驗的要求，提出了FF式機械式變速器試驗臺的整體方案，介紹了各部分的結(jié)構(gòu)和工作原理，并給出了整個機械結(jié)構(gòu)系統(tǒng)的功能，說明了試驗臺的特點，使用情況，它集機械，變頻調(diào)速，傳感器等技術(shù)為一體，通過對機械式變速器的結(jié)構(gòu)原理以及相關(guān)測試診斷技術(shù)的分析，總結(jié)出機械式變速器臺架的試驗方法，在此基礎(chǔ)上對試驗臺的驅(qū)動設(shè)備和負載設(shè)備進行的選型和匹配，檢測臺主要由驅(qū)動系統(tǒng)，負載系統(tǒng)，臺架系統(tǒng)，控制臺及一些附屬設(shè)備組成。臺架系統(tǒng)可以利用定位板實現(xiàn)變速器的夾緊定位，一臺交流異步電動機以變頻方式調(diào)速實現(xiàn)模擬發(fā)動機，采用磁粉制動器作為負載裝置實現(xiàn)對路況的模擬，以滿足檢測的需要，監(jiān)控系統(tǒng)實現(xiàn)檢測模式的選擇，檢測過程的控制及顯示變速器運行狀態(tài)等功能，附屬設(shè)備主要是提供變速器運行所必需的及方便檢測工作的外部環(huán)境。該臺架系統(tǒng)實用性強，具有很高的推廣價值。 關(guān)鍵字： 機械式變速器，性能測試，實驗裝置 Design of the Mechanical automobile transmission performance test stand Abstract Based on the requirement of the 5T07 transmission performance test stand, the article shows the overall layout the FF type automobile transmission test performance, both the function of Mechanical structure system and the Features，the use condition of the stand. It consists of the mechanical system, data Acquisition system, and sensor and so on. By the Analysis of the mechanical structure Principle and related test Technology, it is used to get the test method. The test stand includes driver equipment and load equipment, stands system, control system and auxiliary equipment. The stand uses positioning board to realize the clamping of the tested transmission, and an AC asynchronous motor to realize the Simulation of the drive engine, and use a magnetic braker to simulate the traffic condition. Monitoring System can realize the choice of the monitoring model, and the control of the monitoring processing, and the function to put out the test results. Auxiliary equipment is to offer the external environment during the test process. The test stand is of big Practicability, and has strong value. Keyword: mechanical transmission, performance test, the test Equipments 畢業(yè)設(shè)計說明書 機械式前置汽車變速器實驗臺設(shè)計 高洪宇 0702014425 學(xué)生姓名： 學(xué)號： 學(xué) 院： 專 業(yè)： 機械設(shè)計制造及其自動化 指導(dǎo)教師： 機械工程與自動化學(xué)院 年 月 大 學(xué) 畢業(yè)設(shè)計說明書評語 學(xué)院： 專業(yè)： 機械設(shè)計制造及其自動化 姓名： 學(xué) 號： 題目： 機械式前置汽車變速器實驗臺設(shè)計 指導(dǎo)教師評語： 同學(xué)在規(guī)定的時間內(nèi)完成了畢業(yè)設(shè)計任務(wù)書的要求。該同學(xué)所設(shè)計的機械式手動變速器試驗臺，設(shè)計方案合理，試驗過程可行，數(shù)據(jù)符合實際設(shè)計情況。其中，反拖機構(gòu)的設(shè)計，結(jié)構(gòu)緊湊，具有一定創(chuàng)新性。 該同學(xué)在設(shè)計過程中勤于思考，對設(shè)計方案反復(fù)推敲，并與指導(dǎo)老師多次討論，力爭使設(shè)計更趨于合理，并獨立運用CAD軟件完成了整個臺體的設(shè)計，表現(xiàn)出了較強的自學(xué)能力和扎實的設(shè)計基礎(chǔ)。 該同學(xué)在書寫設(shè)計說明書的過程中，嚴格按照學(xué)校規(guī)定的說明書格式書寫，說明書整體結(jié)構(gòu)緊湊、書寫規(guī)范、文筆較流暢，翻譯也比較正確。 由于實踐經(jīng)驗不足，在設(shè)計中還存在不足之處：如：結(jié)構(gòu)不太緊湊，這還有待于進一步完善。 綜觀畢業(yè)設(shè)計整個過程，都說明付曉強同學(xué)提交的答辯材料符合要求，可以提交答辯。 建議成績： 指導(dǎo)教師(簽字)： 年 月 日  大學(xué) 屆本科畢業(yè)設(shè)計說明書 目 錄 1 緒論 1 1.1 汽車變速器試驗臺簡介 1 1.2 變速器的分類及特點 2 1.3 機械式變速器的基本要求 3 1.4 機械式變速器換檔規(guī)律 4 1.5 本文的主要內(nèi)容及其重點 4 2 變速器試驗臺的結(jié)構(gòu)和工作原理 5 2.1 試驗臺設(shè)計依據(jù) 6 2.2 試驗工藝流程 7 2.3 實驗臺工作原理和組成 7 2.4 臺體機械結(jié)構(gòu)形式 8 2.5 動力設(shè)備的選擇 9 2.6 本章小結(jié) 9 3 電機的選擇 10 3.1 選擇電動機類型和結(jié)構(gòu)形式 10 3.2 選擇電動機的容量 10 3.3 確定電動機的轉(zhuǎn)速 12 3.4 主電機轉(zhuǎn)速控制 13 3.5 本章小結(jié) 13 4 輸入部件的設(shè)計 14 4.1 輸入軸設(shè)計準則 14 4.2 皮帶型號的選擇 15 4.3 皮帶的設(shè)計 17 4.4 帶輪型號的選擇 18 4.5 摩擦離合器型號的選擇 19 4.6 鍵的選擇計算 21 4.7 本章小結(jié) 21 5 輸出部件的設(shè)計 22 5.1 軸承類型的選擇 22 5.2 上傳輸軸的設(shè)計 23 5.3 左移動滑臺驅(qū)動液壓缸的選擇 27 5.4 輸入軸的設(shè)計 29 5.5 鍵的選擇計算和校核 30 5.6 聯(lián)軸器的選擇與校核 30 5.7 本章小結(jié) 32 6 其他零部件的設(shè)計 33 6.1 箱體及安裝滾筒的設(shè)計 33 6.2 導(dǎo)軌的設(shè)計 33 6.3 左，右輸出部分單片式離合器的選用 36 6.4 定位板的設(shè)計 37 6.5 傳感器的選擇 37 6.6 加載器的選擇 40 6.7 螺釘?shù)葏?shù) 40 6.8 本章小結(jié) 41 7 計算機數(shù)據(jù)采集分析系統(tǒng) 42 7.1 數(shù)據(jù)采集卡的選擇 42 7.2 試驗臺控制系統(tǒng)主要部分及功能 44 7.3 試驗臺測試系統(tǒng) 44 7.4 試驗臺造型設(shè)計 45 7.4 本章小結(jié) 46 結(jié) 論 47 參考文獻 48 致 謝 49 第II頁 共Ⅱ頁 畢業(yè)設(shè)計中英文翻譯 高洪宇 0702014425 學(xué)生姓名： 學(xué)號： 學(xué) 院： 專 業(yè)： 機械設(shè)計制造及其自動化 指導(dǎo)教師： 機械工程與自動化學(xué)院 年 月 Introduction to Mechanical Design The Design Process A machine is a combination of mechanism and other components which transforms, transmits ,or utilizes energy, force ,or motion for a useful purpose .Examples are engines ,turbines ,vehicle ,hoists, printing presses, washing machines ,and movie cameras. Many of the principle and methods of design that apply to machines also apply to manufactured articles that are not true machines, from hub caps and filing cabinets to instruments and nuclear pressure vessels. The term “mechanical design” is used in a broader sense than “mechanical design” to include their design. For some apparatus, the thermal and fluid aspects that determine the requirements of heat, flow path, and volume are separately considered. However, the motion and structural aspects and the provisions for retention and enclosure are considerations in mechanical design. Applications occur in the field of mechanical engineering, and in other engineering fields as well, all of which require mechanical devices, such as switches, cams, valves, vessels, and mixers. Designing starts with a need, real or imagined. Existing apparatus may need improvements in durability, efficiency, weight, speed, or cost. New apparatus may be needed to perform a function previously done by men, such as computation, assembly, or servicing. With the objective wholly or partly defined, the next step in design is the conception of mechanisms and their arrangements that will perform the needed functions. For this, freehand sketching is of great valve, not only as record of one’s thoughts and as an aid in discussion with others, but particularly for communication with one’s own mind, as a stimulant for creative ideas. Also, a broad knowledge of components is desirable ,because a new machine usually consists of a new arrangement or substitution of well-known types of components ,perhaps with changes in size and material .Either during or following this conceptual process, one will make quick or rough calculations or analyses to determine general size and feasibility. When some idea as to the amount of space that is needed or available has been obtained, to-scale layout drawing may be started. When the general shape and a few dimensions of the several components become apparent, analysis can begin in earnest. The analysis will have as its objective satisfactory or superior performance, plus safety and durability with minimum weight, and a competitive cost. Optimum proportions and dimensions will be sought for each critically loaded section, together with a balance between the strengths of the several components. Materials and their treatment will be chosen. These important objectives can be attained only by analysis based upon the principles of mechanics, such as those of static’s for reactions forces and for the optimum utilization of friction; of dynamics for inertia, acceleration, and energy; of elasticity and strength of materials for stress and deflection; of physical behavior of materials; and of fluid mechanics for lubrication and hydrodynamic drives. The analyses may be made by the same engineer who conceived the arrangement of mechanisms, or, in a large company, they may be made by a separate analysis division or research group. As a result of the analyses, new arrangements and new dimensions may be required .Design is reiterative and cooperative process, whether done formally or informally, and the analyst can contribute to phases other than his own. Finally, a design based upon function and reliability will be completed, and a prototype may be built. If its tests are satisfactory, and if the device is to be produced in quantity, the initial design will undergo certain modifications that enable it to be manufactured in quantity at a lower cost. During subsequent years of manufacture and service, the design is likely to undergo changes as new ideas are conceived or as further analyses based upon tests and experience indicate alterations . Sales appeal, customer satisfaction, and manufacturing cost are all related to design, and ability in design is intimately involved in the success of an engineering venture. Some rule for design In the section it is suggested that, applied with a creative attitude, analyses can lead to important improvements and to the conception and perfection of alternate, perhaps more functional, economical, and durable products. The creative phase need not be an initial and separate one. Although he may not be responsible for the whole design, an analyst can contribute more than the numerically correct answer to a problem that he is asked to solve- more than the values of stress, dimensions, or limitations of operation. He can take the broader view that the specifications or the arrangements may be improved. Since he will become familiar with device and its conditions of operation before or during hid analysis, he is in a good position to conceive of alternatives. It is better that he suggest a change in shape that will eliminate a moment or a stress concentration than to allow construction of a mechanism with heavy sections and excessive dynamic loads. It is better that he scrap his fine analysis, rather than that he later see the mechanism scrapped. To stimulate creative thought, the following rules are suggested for the designer and analyst. The first six rules are particularly applicable for the analyst, although he may become involved with all ten rules. 1. Apply ingenuity to utilize desired physical properties and to control undesired ones. 2. Recognize functional loads and their significance. 3. Anticipate unintentional loads. 4. Devise more favorable loading conditions. 5. Provide for favorable stress distribution and stiffness with minimum weight. 6. Use basic equations to proportion and optimize dimensions. 7. Choose materials for a combination of properties. 8. Select carefully between stock and integral components. 9. Modify a functional design to fit the manufacturing process and reduce cost. 10. Provide for accurate location and noninterference of parts in assembly. Journal of Beijing Institute of Technology, 1998, Vol.7, No.2 Automatic Control of Automobile Transmission Performance Test Stand Abstract Aim to realize automatic control of automobile transmission performance test stand. Methods The automatic control technique of the lubricant temperature, the program-controlled automatic shifting of the transmission, the continuous adjusting of revolution speed and load, data –acquisition and data real-time processing were adopted. Results The lubricant temperature was controlled at the set temperature .The automatic shifting of the transmission is simple, reliable and accurate. The automatic adjusting of load and rotation speed is rapid and accurate, the torque divergence is, and the rotation speed divergence is. Conclusion The four kinds of techniques are applied into the automobile transmission performance test stand successfully. The profound study of test and theory about every part of automobile for improving the performances of national products is of very important meaning for developing the national automobile industry. Gear box is a key part of automobile transmission systems. Its properties have effects on the performance directly. The main performance parameters are: the transmission efficiency, the lubricant, the noise and so on. So it is necessary to do the performance test rapidly and accurately. In this paper, automatic-control techniques are applied to the multifunction test stand of the automobile transmission performance. Lubricant automatic constant temperature control, program-controlled automatic shifting, infinitely variable adjusting rotation speed and load, automatic acquisition and processing of the test data, and automatic outputting test reports and curves are fulfilled. The test conditions, accuracy and speed are provided strictly. 1 AUTOMATIC CONSTANT TEMPERATURE CONTROL TECHNIQUE The lubricant temperature should be controlled strictly under the performance test. In the whole process of the test, the temperature should be guaranteed at the set temperature. Otherwise, the test of the gear box performance would be affected. In this paper, mixing cool oil and hot oil by PID automatic-control technique is used to realize the lubricant constant temperature. The system consists of the lubricant force-circulating system and the PID electric automatic-control with feedback system. Fig.1 shows the lubricant force-circulating system. Fig.2 illustrates the PID electric automatic-control with feedback system. Fig. 1 lubricant force-circulating system 1-motor 2-oil pump 3-pressure manometer 4-discharge valve 5-slide valve 6-filter 7-auxiliary oil tank 8. Stop-valve 9-cooling apparatus 10-electric heater and hot oil tank 11.three-port electric-drive valve 12-hydraulic tube The PID automatic control with feedback system is used to control the motor of the three-port electric-adjusting valve. If the feedback temperature valve is lower than the set temperature valve, the valve’s motor will rotate clockwise, and then the hot oil flow will rise. Otherwise, the valve’s motor will rotate counter-clockwise, and then the cool oil flow will rise. The cool lubricant comes from the cooling apparatus. The hot lubricant comes from the hot-lubricant tank with electric heaters. The temperature meter monitors the box’s oil temperature, and provides the basic set number for the PID temperature controller. The auxiliary temperature controller keeps the temperature of the oil in the hot lubricant tank in some range of the PID set temperature. Fig.2 PID automatic-control principle diagram 1-PID temperature controller 2- temperature meter 3- Auxiliary temperature controller 4-electric heater 5-hot oil case temperature transducer 6- transmission oil temperature transducer 7-feedback temperature transducer 8- the motor of the three-port electric-adjusting valve 2. COMPUTER-CONTROL SYSTEM Fig.3 illustrates the computer automatic control flow chat. System functions are as follows: 1. Monitoring performance parameters: the input rotation speed and torque, the output rotation speed and torque, the lubricant temperature, the position of shifting. 2. Adjusting main variable frequency motor’s rotation speed and eddy current electro-dynamometer’s load. 3. Automatic selecting shift position. Fig.3 Computer automatic control flow chart 2.1 Shifting Control The cylinder position crank mechanism of shifting and positioning controls the shifter lever’s motion. Piston stroke is controlled by magnetic switches. Shifting steps are completed by 1-oil-water dividing filter 2-gas source 3- gas manometer 4, 5, 10, 11-magnetic slide valve 6-one-way valve 7-shifting cylinder 8- magnetic switch 9- positioning cylinder Fig.4 shifting pneumatics system schematic diagram 1, 2, 3, 4-solid relay 5, 6, 7, 8-slide valve magnet 9- main computer 10-computer on slice 11-position switch Fig.5 Shifting control electric circuit schematic diagram the computer on slice. The shifting pneumatics system is shown as Fig.4 .The shifting control electric circuit demonstrating chart is shown as Fig.5. The computer sends shifting commands to the computer on slide for switching-on corresponding relay to control the magnetic slide valve. The different pneumatics circuits are switched on to realize different shifting and positioning motion. 2.2 Controlling of Rotation Speed and Load The frequency of crystal oscillator is 1.8432MHz. The first grade dividing frequency time constant is 2. Then the frequency divider’s freq2uency is 921.6 kHz. Later, the system control software sets sequential time constant for next frequency divider to get sequential voltage. The relation between time constant and frequency is time constant=921.6frequency. The automatic controllers of rotation speed and load have voltage access ports with computer. By F/V transducer control voltage is obtained. Corresponding relations among the input frequency, the output voltage, the motor rotation speed and the electrodynamometer magnetizing current are as follows: Input frequency/kHz Output voltage/V Motor-rotation speed(r/min) electrodynamometer magnetizing current/A 0 0 0 0 5 5 6000 5 3. COMPUTER DATA REAL-ACQUISITION AND PROCESSING 3.1 Data Real-Acquisition The signals of transducers are changed into the same signal – the linear frequency signal by high precision V/F and I/F transducers before they transmitted to the computer. Then by 8253 time-counter and corresponding calculations, the valve of the tested engineering variable is obtained. Corresponding relation is A=cN, A is the engineering valve, N is the number of pulses of time-counter, and c is the calibrated coefficient of transducer. 3.2 Data Real-Time Processing On the basic of original data acquired from transducers, the input power, the output power, the ratio and the efficiency are calculated immediately. At the same time, the efficiency curves are showed on the computer screen. 4. THE CONSTRUCTION OF THE TEST STAND This performance test stand is a power open-circuit test stand, and consists of the frame, the electric control system, the computer system, the lubricant automatic constant temperature system, and the program-controlled automatic shifting system. Fig.6 shows the frame of the test stand. The power set is a high rotation speed frequency-changing motor of 55KW, and able to realize infinitely variable speed adjusting from 0-6000r/min, thus, the transmission input doesn’t need a speeder, the noise of the test stand itself id lowered on a large scale .The loading set is an eddy current electrodynamometer of 160KW, the power could be input from one side or double sides, so as to meet the requirements of the transmission with a differential gear or without a differential gear. The synchronous belt is adopted at the transmission output side, thus, the construction id very simple and the noise is low. 1-55KW frequency changing motor 2-input torque, rotation speed transducer 3- tested transducer 4-output torque, rotation speed transducer 5- synchronous belt 6-160KW eddy current electrodynamometer 7-lubricant pump station 8-shifting mechanical system Fig.6 The construction of the test stand frame 5. THE EXAMPLE OF THE TEST The performance test of ALTO transmission is done on the test stand. By original data processing, the efficiency curves are shown as Fig.7 During the test process, monitor parameters are controlled in the range of the test stand, the data are as follows: Fig.7 Efficiency curve Input rotation speed :(( 1000, 2000, 3000)) r/min Input torque ((28, 56)) Nm Lubricant temperature (80) 6. CONCLUSIONS (1) By the technique of mixing the cool and the hot oil, the transmission lubricant constant temperature control could be realized. (2) By the technique of program-control automatic shifting, adjusting rotation speed and load, and data real-time acquisition and processing, the automobile transmission property test could be completed automatically. (3) Computer gives test report and curves. REFERENCE 1. Lu J F Transducer port and test apparatus circuit (in China). Beijing: Beijing institute of Aero-technics Publishing House, 1994 12