換擋機(jī)構(gòu)卡滯示意圖The shift stagnation diagram of planetary gears20140410 v05

1、 1浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司2022-7-5RNDRND換擋試驗(yàn)簡(jiǎn)報(bào)換擋試驗(yàn)簡(jiǎn)報(bào)RND shifting Tests Report SummaryBy：KeBing, Zhang BinBin, Zhang GuanBinCheck：Hu JianhuaDate:24 Apr. 2014 目錄目錄 Contents1.總結(jié)總結(jié) Summary2.背景介紹背景介紹 Background Introduction3.2013/11試驗(yàn)總結(jié)試驗(yàn)總結(jié) Test 1 Dated on 2013.113.1 布置圖布置圖 The layout drawing 3.2 失效模

2、式失效模式 Failure 3.2.1 N檔到檔到D檔檔 N to D 3.2.2 N檔到檔到R檔檔 N to R4.2014/04試驗(yàn)總結(jié)試驗(yàn)總結(jié) Test 2 Dated on 2014.044.1 布置圖布置圖 The layout drawing 4.2 時(shí)序圖時(shí)序圖 Sequence chart4.3 失效模式失效模式 Failure 4.3.1 轉(zhuǎn)速轉(zhuǎn)速50rpm input shaft speed:50rpm 4.3.2 100rpm 及及200rpm input shaft speed :100rpm/200rpm浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司 1、總

3、結(jié)總結(jié) SummaryDateDesign Version / Change DescriptionTesting ProceduresTesting ResultPage20140422V0Input Shaft Speed: 50rpmInput Cone Speed: 0rpmMotor PWM :70% N-D: Stuck 4.6mm (54.6%) N-R: Stuck 5.9mm (69.2%)1213Input Shaft Speed: 100rpm/200rpmInput Cone Speed: 0rpmMotor PWM : 70%100rpm: N-D:Stuck 6.4

4、mm (75%) N-R:Stuck 6.1mm(72%)200rpm:N-D: Stuck 7.65mm (90%) N-R:Stuck 6.1mm(72%)141520131130V0Manual shift N-D: Stuck 4.6mm (54.4%)N-R: Stuck 6.2mm(73.5%)79浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司 第一描述：GRC反饋（反饋單號(hào)：TIR-Testbench-P1-001）TM001樣箱在R檔和D檔時(shí)有無法掛入現(xiàn)象，偶爾強(qiáng)行掛入后，同步機(jī)構(gòu)出現(xiàn)鎖死現(xiàn)象，無法退出；DFL在TM003樣箱測(cè)試時(shí)也發(fā)現(xiàn)類似問題。First desc

5、ription：The sample TM001 tested in GRC(TIR-Testbench-P1-001) was found the R range and D range couldnt shift occasionally. Though it can be forced to shift successfully sometimes, the planetary gears will be locked.DFL also find this stagnation occurred on the sample TM003.第二描述：經(jīng)確認(rèn)，故障模式屬靜態(tài)掛檔困難，經(jīng)故障再現(xiàn)

6、，R檔/D檔確存在無法掛入現(xiàn)象，表現(xiàn)為同步器齒套無法越過同步環(huán)，但加大掛檔力時(shí)，齒套可勉強(qiáng)完成掛檔動(dòng)作，未出現(xiàn)鎖死現(xiàn)象；拆箱后，行星機(jī)構(gòu)零件無明顯磨損和撞擊痕跡。靜態(tài)下，手工推動(dòng)撥叉掛檔10次，由N檔掛入D檔時(shí)，試驗(yàn)10次，有4次齒套無法越過同步環(huán)現(xiàn)象，初步統(tǒng)計(jì)，掛不入故障率為40%。R檔未試驗(yàn)（R檔需合箱試驗(yàn)）。Second description: The stagnation is the static shift difficult through verified. With the reappearance of the stagnation, we found the gear

7、sleeve couldnt pass the ring. If we increase the shift force, the gear sleeve can pass the ring narrowly and successfully. After unpacking the sample, there is no hitting mark on planetary gears.Under the static state, we did the manual test 10 times only with the planetary gears and the gear sleeve

8、 , there were 4 four times failure when N to D. The failure rate is 40%. We dont do the test with N to R.2、背景介紹背景介紹 Background Introduction浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司 RND機(jī)構(gòu)RND actuator輸入錐Input cone同步器Planetary gear浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司3、 2013/11試驗(yàn)總結(jié)試驗(yàn)總結(jié) Test 1 dated on 2013.113.1 靜態(tài)手動(dòng)換擋布置圖靜態(tài)

9、手動(dòng)換擋布置圖 The layout drawing of the shift stagnation testmanual shift 3.2、失效模式說明、失效模式說明 Failure3.2.1 N to D 掛檔成功掛檔成功OK 掛檔失敗掛檔失敗NG說明說明Failure Position illustrate:1、大部分失效卡滯發(fā)生在齒套越過同步環(huán)，與結(jié)合齒結(jié)合過程中；、大部分失效卡滯發(fā)生在齒套越過同步環(huán)，與結(jié)合齒結(jié)合過程中；Most of failures occur when the sleeve pass the synchronous rings, engaging with t

10、he tooth of planetary carrier.2、部分失效發(fā)生在齒套與同步環(huán)齒結(jié)合過程中；、部分失效發(fā)生在齒套與同步環(huán)齒結(jié)合過程中；Some failures occur when the sleeve engage the tooth of the synchronous rings.浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司Neutral PositionD PositionNeutral PositionFailure Position4.6mm8.5mm 3.2、失效模式說明、失效模式說明 Failure3.2.1 N to D 浙江德孚力汽車變速器有限公司

11、浙江德孚力汽車變速器有限公司D Position(959 inc)D Failure(741 inc)Duty cycleN position(481 inc)3、據(jù)圖可知，換擋卡滯時(shí)的脈沖為、據(jù)圖可知，換擋卡滯時(shí)的脈沖為741inc，D檔脈沖為檔脈沖為959inc，N檔脈沖為檔脈沖為481inc，則卡滯行，則卡滯行程為（程為（741-481)/(959-481)X100%=54.4%,即齒套行程為即齒套行程為54.4%X8.5mm=4.6mm。According to the picture, the pulse of shift failure is 741 inc ,D position

12、 is 959 inc ,N position is 481 inc ,i.e. the failure travel is (741-481)/(959-481)X100%=54.4%, the sleeve travel is 4.6mm. 電機(jī)示意圖電機(jī)示意圖 The motor diagram of D failure 掛檔成功掛檔成功OK 掛檔失敗掛檔失敗NGNeutral PositionR PositionFailure Position 1Neutral Position3.2.2、N to R 浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司說明說明Failure P

13、osition illustrate :1、卡滯發(fā)生在齒套越過同步環(huán)，與結(jié)合齒結(jié)合過程中。、卡滯發(fā)生在齒套越過同步環(huán)，與結(jié)合齒結(jié)合過程中。Some failures occur when the sleeve pass the synchronous rings, engaging with the tooth of pivot plate.2、部分失效發(fā)生在齒套與同步環(huán)齒結(jié)合過程中；、部分失效發(fā)生在齒套與同步環(huán)齒結(jié)合過程中；Some failures occur when the sleeve engage the tooth of the synchronous rings.Failure

14、 Position 28.5mm6.2mm 浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司3.2.2、N to R N Position(487 inc)R Position(0 inc)R Failure(129 inc)Required positionDuty cycle3、據(jù)圖可知，換擋卡滯時(shí)的脈沖為、據(jù)圖可知，換擋卡滯時(shí)的脈沖為129 inc，R檔脈沖為檔脈沖為0 inc，N檔脈沖為檔脈沖為487 inc，則卡滯行，則卡滯行程為（程為（487-0)/(487-129)X100%=73.5%,即齒套行程為即齒套行程為73.5%X8.5mm=6.2mm。According to

15、 the picture, the pulse of shift failure is 129 inc ,R position is 0 inc ,N position is 487 inc ,i.e. the failure travel is (487-0)/(487-129)X100%=73.5%, the sleeve travel is 6.2mm. 電機(jī)示意圖電機(jī)示意圖 The motor diagram of D failure 4、 2014/04試驗(yàn)總結(jié)試驗(yàn)總結(jié) Test 2 dated on 2014.44.1 動(dòng)態(tài)換擋試驗(yàn)布置圖動(dòng)態(tài)換擋試驗(yàn)布置圖 The layout d

16、rawing of the shift stagnation test輸入錐Input cone同步器Planetary gear離合器Clutch離合執(zhí)行機(jī)構(gòu)Clutch actuatorRND機(jī)構(gòu)RND actuator電機(jī)Motor此處固定Confirm浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司 4.2 時(shí)序圖時(shí)序圖 Sequence charta cycleEngine idling speedengageddisengagedmotorclutchpositionInput shaft浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司 4.3、失效模式、失效模式

17、Failure4.3.1轉(zhuǎn)速轉(zhuǎn)速50rpm input shaft speed:50rpm 1）N to DD Failure PositionNeutral Position浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司Input speed Duty cycle 70%Required positionD failure position773 inc說明說明Failure Position illustrate :1、卡滯發(fā)生在齒套越過同步環(huán)，與結(jié)合齒結(jié)合過程中。此時(shí)電機(jī)脈沖信號(hào)為、卡滯發(fā)生在齒套越過同步環(huán)，與結(jié)合齒結(jié)合過程中。此時(shí)電機(jī)脈沖信號(hào)為773inc，卡滯行程，卡滯行程

18、為為(773-500)/(1000-500)X100%=54.6%，即，即8.5X54.6%=4.6mm。Some failures occur when the sleeve pass the synchronous rings, engaging with the tooth of pivot plate. The pulse signal of motor was 773inc now. i.e. the failure travel is (773-500) /(1000-500)X100%=54.6%, the sleeve travel is 4.6mmD position1000

19、 incN position500 inc4.6mm 4.3.1轉(zhuǎn)速轉(zhuǎn)速50rpm input shaft speed:50rpm 2）N to R浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司說明說明Failure Position illustrate :1、卡滯發(fā)生在齒套越過同步環(huán)，與結(jié)合齒結(jié)合過程中。此時(shí)電機(jī)脈沖信號(hào)為、卡滯發(fā)生在齒套越過同步環(huán)，與結(jié)合齒結(jié)合過程中。此時(shí)電機(jī)脈沖信號(hào)為154inc，卡滯行程，卡滯行程為為(500-154)/500X100%=69.2%，即，即8.5X69.2%=5.9mm。Some failures occur when the sleeve

20、pass the synchronous rings, engaging with the tooth of pivot plate. The pulse signal of motor was 154 inc now. i.e. the failure travel is (500-154) /500X100%=69.2%, the sleeve travel is 5.9 mm.Input speed Duty cycle 70%Required positionR failure position154 incD position1000 incN position500 incR Fa

21、ilure Position Neutral Position5.9mm 浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司D Failure PositionNeutral PositionD Failure PositionNeutral PositionSpeed:100rpm Duty cycle:70% Speed:200rpm Duty cycle:70%說明說明Failure Position illustrate :1、100rpm時(shí)，卡滯發(fā)生在齒套越過同步環(huán)，與結(jié)合齒結(jié)合過程中。此時(shí)電機(jī)脈沖信號(hào)為時(shí)，卡滯發(fā)生在齒套越過同步環(huán)，與結(jié)合齒結(jié)合過程中。此時(shí)電機(jī)脈沖信號(hào)為930

22、inc。齒套行程約為齒套行程約為75%，即卡滯行程為，即卡滯行程為8.5X75%=6.4mm。When the input speed is 100rpm,the failure occurred when the sleeve pass the synchronous rings, engaging with the tooth of pivot plate. The pulse is 930inc now , and the sleeve travel is 8.5X75%=6.4mm。2、200rpm時(shí)，卡滯發(fā)生時(shí)電機(jī)已完成，即脈沖信號(hào)為時(shí)，卡滯發(fā)生時(shí)電機(jī)已完成，即脈沖信號(hào)為1000in

23、c，實(shí)際齒套行程約為，實(shí)際齒套行程約為90%，即卡滯行，即卡滯行程為程為8.5X90%=7.65mm。When the input speed is 100rpm,when the failure occurred, the motor has completed its travel. i.e. the pulse is 1000inc, and the sleeve travel is 8.5X90%=7.65mm。4.3.2 100rpm 及及200rpm input shaft speed :100rpm/200rpm1）N to D6.4mm7.65mm 浙江德孚力汽車變速器有限公司浙江德孚力汽車變速器有限公司Speed:100rpm Duty cycle:70% Speed:200rpm Duty cycle:70%說明說明Failure Position illustrate :1、100rpm時(shí)，卡滯發(fā)生在齒套越過同步環(huán)，與結(jié)合齒結(jié)合過程中。此時(shí)電機(jī)脈沖信號(hào)為時(shí)，卡滯發(fā)生在齒套越過同步環(huán)，與結(jié)合齒結(jié)合過程中。此時(shí)電機(jī)脈沖信號(hào)為140inc。齒套行程為齒套行程為(500-140)/500X100%=72%，即卡滯行程為，即卡滯