變速器綜合性能試驗(yàn)臺體系結(jié)構(gòu)及控制軟件開發(fā)

1、附錄A叭疔腐賚櫝門掎架矽撮矛變速器綜合性能試驗(yàn)臺體系結(jié)構(gòu)及控制軟件開發(fā)美頰崠蠹溫逍氪芹互奩謊玖南鶴軍偵反溘臚駝海講摘要：變速器是汽車系統(tǒng)中的關(guān)鍵設(shè)備，在同一試驗(yàn)臺上實(shí)現(xiàn)其綜合性能的在線檢測，在國內(nèi)尚沒有先例。本文介紹的新型試驗(yàn)臺系統(tǒng)，實(shí)現(xiàn)了變速器綜合性能的在線檢測。介紹了該試驗(yàn)臺系統(tǒng)的體系結(jié)構(gòu)及工作原理，并詳細(xì)敘述了其控制軟件的開發(fā)及實(shí)現(xiàn)。 悶飽鈑崢桿緝轢邑卅鏑灰關(guān)鍵詞：變速器試驗(yàn)臺體系結(jié)構(gòu)控制軟件 蜢涂涔圯瘓膂砩腳韜璀魂汽車變速器是汽車中的一個(gè)關(guān)鍵設(shè)備，其性能直接影響到汽車的動力性、經(jīng)濟(jì)性和可靠性。汽車變速器綜合性能的測試比較復(fù)雜，目前國內(nèi)的汽車變速器試驗(yàn)臺自動化程度低、機(jī)界面不友好、測試過

2、程依賴于測試者的經(jīng)驗(yàn)。因此，本試驗(yàn)臺系統(tǒng)自動程度高、測試項(xiàng)目多、實(shí)時(shí)性強(qiáng)且完全可靠。 哆感尋張噸圃薜掎提蚣鄯1 系統(tǒng)介紹 攀頗跳倫耜寮忖凸匾扼蓋具體說來，該試驗(yàn)臺系統(tǒng)具有以下優(yōu)點(diǎn)：可進(jìn)行五種不同型號變速器及其擴(kuò)展類型變速器的性能測試；自動測試過程可智能控制；短時(shí)間內(nèi)可完成綜合性能（換檔、加載、同步器）測試；運(yùn)行參數(shù)可實(shí)時(shí)顯示；可進(jìn)行故障的自動檢測、報(bào)警及處理等。 洶臏括彩檔璋柴衫櫧忪杞1.1 系統(tǒng)硬件介紹 漏猗慷俘壟窯副櫛鏤賚臁本系統(tǒng)采用雙變頻電機(jī)模擬汽車變速器實(shí)現(xiàn)工況，從而實(shí)現(xiàn)對變速器性能的真實(shí)檢測。電機(jī)的控制通過西門子6SE70系列變頻器來實(shí)現(xiàn)。該系統(tǒng)變頻器采用交流矢量控制技術(shù)，對大功率交

3、流電機(jī)實(shí)現(xiàn)了精確控制。因?yàn)樵撓到y(tǒng)中變頻器數(shù)量不多、數(shù)據(jù)傳輸量不大，采用RS485總線來實(shí)現(xiàn)工控機(jī)與變頻器之間的通訊，滿足了實(shí)時(shí)性要求。由于PLC控制穩(wěn)定、可靠，所以自動換檔執(zhí)行機(jī)構(gòu)（機(jī)械手）采用PLC控制器來實(shí)現(xiàn)不同型號變速器的自動換檔動作。瘟荀傲居刮淥窯簇己黨篁1.2 系統(tǒng)軟件開發(fā)環(huán)境 端蕪膿矚改蟲掮嵯拒豆勝工業(yè)過程控制軟件往往需要具有很強(qiáng)的通訊能力、現(xiàn)場數(shù)據(jù)的實(shí)時(shí)檢測能力及強(qiáng)大的數(shù)據(jù)庫、良好的圖形界面。組態(tài)王6.01采用全新中文Explorer界面并擁有豐富的繪圖工具和龐大的圖形庫（包括大量的工業(yè)標(biāo)準(zhǔn)元件），支持多媒體和ODBC數(shù)據(jù)庫提供的功能、具有強(qiáng)大的控件和控制語言，使用靈活、方便，提

4、供給用戶一方便的集成開發(fā)環(huán)境，使開發(fā)者可快速構(gòu)造應(yīng)用系統(tǒng)。它還具有強(qiáng)大的通訊能力和良好的開放性。本系統(tǒng)控制軟件基于組態(tài)王6.01二次開發(fā)，實(shí)現(xiàn)了測試過程的控制、測試數(shù)據(jù)的實(shí)時(shí)顯示，而且縮短了開發(fā)時(shí)間。 寶佃札飛橢繽停娜閑碾2 系統(tǒng)體系結(jié)構(gòu) 詹鋅燒樽莩樟佗剝劃匡正2.1 系統(tǒng)要求 慍壢啕酴畀甯棹畫醬棧又廠方要求試驗(yàn)臺系統(tǒng)能夠在線檢測變速器的綜合性能，包括以下試驗(yàn)：各檔換檔試驗(yàn)；變速器加載能力測試；變速器操縱（同步器）性能的測試；變檔檢測；變速器的疲勞壽命試驗(yàn)；傳動效率試驗(yàn)。 薔侈舟軍昭哈伺瓠杌齏乾工作性能要求為： 鄧霾鄶愿滋串笈紲濃亓捅(1)系統(tǒng)運(yùn)行穩(wěn)定、安全可靠； 撂繳犯驢賈蔬圇姑盂忖姿（2）

5、測試數(shù)據(jù)報(bào)表和測試及故障診斷的界面友好； 搔氦鎊瘛癜萁歲洹羥論愜（3）臺架試驗(yàn)方法科室、規(guī)范，達(dá)到汽車機(jī)械式變速器臺架試驗(yàn)方法國家標(biāo)準(zhǔn)； 凼螳氨韋坌漆咨菌磁祜淆（4）在同一臺架上對不同種變速器完成測試功能。 悅鲼己熱簦杲詈閱礫償倡2.2 系統(tǒng)體系結(jié)構(gòu) 佤匣棗肷臍邱喵愀隉葺亮系統(tǒng)整體結(jié)構(gòu) 檑稅摯褰耦舢斑舐泠抹晡系統(tǒng)分為三大模塊：控制部分；換檔機(jī)械手部分；試驗(yàn)臺機(jī)電部分?？刂撇糠忠杂?jì)算機(jī)為中心，控制軟件根據(jù)現(xiàn)場數(shù)據(jù)和當(dāng)前工作狀態(tài)控制系統(tǒng)的流程、指令發(fā)送、故障檢測等；通過板卡通訊向PLC機(jī)械手發(fā)送換檔控制指令、通過RS485總線變頻器發(fā)送測試所需的轉(zhuǎn)速和加載扭矩信號?？刂撇糠诌€包括變頻器、現(xiàn)場數(shù)據(jù)采

6、集卡（PCL818L）、PLC控制器。變頻器可以實(shí)現(xiàn)三相交流異步電動機(jī)的無級調(diào)速。變頻器選用西門子6SE70系列變頻器，該系列變頻器采用交流電機(jī)的矢量控制技術(shù)對電機(jī)進(jìn)行控制。矢量控制也叫磁場定向控制。它的基本思路是利用d-q旋轉(zhuǎn)坐標(biāo)變換，將定子電流分成勵(lì)磁電流id1和轉(zhuǎn)矩電流，在調(diào)速過程中保持轉(zhuǎn)子磁鏈不變，即id1為常數(shù)，此時(shí)交流電機(jī)調(diào)速原理與直流電機(jī)相同?，F(xiàn)場數(shù)據(jù)采集卡將現(xiàn)場采集的數(shù)據(jù)傳輸?shù)接?jì)算機(jī)。PLD控制器根據(jù)計(jì)算機(jī)發(fā)送的指令完成將換檔信號轉(zhuǎn)換為換機(jī)械手的執(zhí)行命令。蓼鞋巹假紉勖傷酮吒罩廁河橙砂斫黜哞愚烏鋦玷脘餒尺氓隊(duì)鉬戔通矸鞍碌扉昔罩投辭嬉涼煳蓑力海芏換檔機(jī)械手部分是控制部分的執(zhí)行機(jī)構(gòu)，

7、機(jī)械手根據(jù)PLD發(fā)送的換檔指令完成指公平的換檔動作。佝鶴霸兜仕忙舨髻柱纘郴試驗(yàn)臺機(jī)電部分是本系統(tǒng)是最終執(zhí)行機(jī)構(gòu)，完成將變速器驅(qū)動到相應(yīng)轉(zhuǎn)速和加載扭矩，以達(dá)到特定測試工況。機(jī)械部分包括兩個(gè)功率比較大的變頻電機(jī)和試驗(yàn)臺架。本系統(tǒng)中電機(jī)的性能對整體性能影響很大，因而選用交流變頻電機(jī)。該電機(jī)能滿足高精度的扭矩、轉(zhuǎn)速控制，而且功率足夠大，可以滿足本系統(tǒng)試驗(yàn)工況要求。工作時(shí)，加載電機(jī)工作在發(fā)電狀態(tài)下，能量回饋到電網(wǎng)，大大節(jié)約了能源。試驗(yàn)臺架包括離合器、傳動機(jī)構(gòu)和汽車變速器。因?yàn)樵囼?yàn)時(shí)要達(dá)到高轉(zhuǎn)速、高扭矩的工作狀態(tài)，所以機(jī)械部分加精度要高。汽車變速器是本系統(tǒng)測試對象，為了使裝卸變速器的時(shí)間短，本試驗(yàn)臺變速器

8、的夾緊松開操作是通過油缸4軸連動壓板來實(shí)現(xiàn)的。鵠愿啵些捕蚨誓昆港靈俺2.3 系統(tǒng)工作原理锍挨瓞襤揶牾蔭苧嬸足戮系統(tǒng)采用雙電機(jī)模擬汽車工況，其中驅(qū)動電機(jī)通過變頻器的速度閉環(huán)控制模擬汽車的驅(qū)動機(jī)構(gòu)，加載電機(jī)通過變頻器的扭矩閉環(huán)控制模擬汽車加載。機(jī)械手根據(jù)計(jì)算機(jī)發(fā)出的指令信號完成對不同型號變速器的換檔動作，從而能控制變速器換檔到指定檔位。在測試過程中，控制軟件對系統(tǒng)的運(yùn)行參數(shù)實(shí)時(shí)記錄顯示，并對溫度、轉(zhuǎn)速、扭矩、電流、完全罩到位信號等實(shí)時(shí)監(jiān)控，遇到故障自動報(bào)警、自動分析。抿狽燕奎晏湍慘噫舳僮寓3 系統(tǒng)軟件的開發(fā)與實(shí)現(xiàn)資繾澈此別僵噌幽宰軍闖本系統(tǒng)控制軟件是基于組態(tài)王6.01二次開發(fā)的、功能結(jié)構(gòu)如圖2所示

9、。跗鏤吉裁橇囂曷搿哭娥枕本系統(tǒng)從功能上完成了自動試驗(yàn)、手動試驗(yàn)、單獨(dú)換檔試驗(yàn)、疲勞試驗(yàn)和效率試驗(yàn)。計(jì)算機(jī)自動試驗(yàn)是本系統(tǒng)的主要部分，在這種狀態(tài)下計(jì)算機(jī)控制變速器的測試過程，包括：試驗(yàn)流程、試驗(yàn)過程中換檔順序、各個(gè)檔位的轉(zhuǎn)速給定、加載扭矩給定、系統(tǒng)協(xié)調(diào)、信號檢測及處理等。在自動試驗(yàn)控制下，完成從空檔到最高檔位的換檔和加載交替過程，接著完成從最高檔位降低到最低檔位的降檔換檔，最后完成倒檔測試。手動試驗(yàn)是由人操作手動操作臺的扭鈕完成的，其程序主要完成監(jiān)測、報(bào)警功能。單獨(dú)換檔是應(yīng)廠家要求對某一指定檔位進(jìn)行試驗(yàn)。疲勞試驗(yàn)和效率試驗(yàn)分別對變速器的耐久性和傳動效率進(jìn)行測試。組態(tài)王6.01有豐富的畫面制作系統(tǒng)

10、，支持無限色和二十四種過濾色，并具有豐富的圖庫和圖庫精靈、豐富的動畫連接向?qū)?。利用組態(tài)王6.01界面開發(fā)系統(tǒng)可給各種控制模式開發(fā)生動的界面，非常形象、美觀。由于自動試驗(yàn)過程是本軟件系統(tǒng)的關(guān)鍵，故以下僅對自動試驗(yàn)進(jìn)行討論。躍苓米靶胎狠霆炔聳歟煤3.1 接口通訊參數(shù)麥杏駐苦索偎螄井誥橛打組態(tài)王與I/O設(shè)備之間的通訊很方便，主要通過以下幾種方式進(jìn)行通訊：串口通訊方式、DDE方式、板卡方式、網(wǎng)絡(luò)節(jié)點(diǎn)方式、人機(jī)接口方式。組態(tài)王有豐富的數(shù)據(jù)類型，使用起來特別方便。反縭葬菇我鉈甬袼郅乞?qū)⒔涌谕ㄓ崊?shù)如圖2所示。澤斬老撓味乞履趴蜚眶岡舌省鑾敗嗽塢奔甾究被貧 計(jì)算機(jī)通過檢測現(xiàn)場數(shù)據(jù)，根據(jù)任務(wù)規(guī)劃狀態(tài)向PLC和變

11、頻器發(fā)送相應(yīng)的控制指令。是釹慎絮嗜餮剄溢斃燔賒現(xiàn)場數(shù)據(jù)包括：變速器當(dāng)前檔位、轉(zhuǎn)速、扭矩、通過拉壓力傳感所測得的掛檔力、離合器開關(guān)信號、變速器夾緊信號、軸承溫度等。其中與PLC的通訊利用組態(tài)王的板卡通訊方式，組態(tài)王與變頻器通訊采用組態(tài)王的串口通訊方式，組態(tài)王與現(xiàn)場數(shù)據(jù)通訊通過PCL818L擴(kuò)展板卡來實(shí)現(xiàn)?，F(xiàn)場數(shù)據(jù)用于檢測工作狀態(tài)是否到位和故障報(bào)警等，如機(jī)械手是否換檔到位是根據(jù)現(xiàn)場采集的速度之比和配方中的速比是否一致來判斷的，而溫度、轉(zhuǎn)速等指標(biāo)又是故障報(bào)警的依據(jù)。飛右譴閬敢幛昊帑筒蟲程計(jì)算機(jī)通過檢測現(xiàn)場數(shù)據(jù)，根據(jù)任務(wù)規(guī)劃狀態(tài)向PLC和變頻器發(fā)送相應(yīng)的控制指令。 氵灄斤乍書鄲黏端類鱧賂現(xiàn)場數(shù)據(jù)包括：

12、變速器當(dāng)前檔位、轉(zhuǎn)速、扭矩、通過拉壓力傳感所測得的掛檔力、離合器開關(guān)信號、變速器夾緊信號、軸承溫度等。其中與PLC的通訊利用組態(tài)王的板卡通訊方式，組態(tài)王與變頻器通訊采用組態(tài)王的串口通訊方式，組態(tài)王與現(xiàn)場數(shù)據(jù)通訊通過PCL818L擴(kuò)展板卡來實(shí)現(xiàn)。現(xiàn)場數(shù)據(jù)用于檢測工作狀態(tài)是否到位和故障報(bào)警等，如機(jī)械手是否換檔到位是根據(jù)現(xiàn)場采集的速度之比和配方中的速比是否一致來判斷的，而溫度、轉(zhuǎn)速等指標(biāo)又是故障報(bào)警的依據(jù)。 遜小瞢赧寅熔貳岑磺餐鴝3.2 自動換檔過程的實(shí)現(xiàn) 偈擐筱埯戴霜啦五信桴說3.2.1 自動換檔過程流程圖 鷗萊羞哺著汪由鵓櫓琺拋?zhàn)詣訐Q檔過程流程圖如圖4所示輇青蝤毽馇榆粒怡躺銪熟自動換檔過程要完成

13、松開離合器、換檔、閉合離合器的動作和定時(shí)加載以及檔位的自動更替。由于松開離合器、換檔、閉合離合器都是在電機(jī)運(yùn)轉(zhuǎn)的情況下工作的，因而每一動作命令的發(fā)出都要先檢驗(yàn)其條件是否嚴(yán)格滿足以保證安全。離合器松開的條件為：電機(jī)的轉(zhuǎn)速必須在預(yù)設(shè)的范圍內(nèi)；檔檔的條件為：必須檢測到離合器已松開；離合器閉合條件為：換檔到位。如果條件不滿足就等待條件滿足，但是等待時(shí)間也是有限制的，故采用定時(shí)器計(jì)時(shí)的方法來控制順序動作等待時(shí)間。當(dāng)檔位換到位時(shí)，按該檔位的測試參數(shù)加載，加載一段時(shí)間就可以測得變速器的加載能力，因而加載的定時(shí)也采用定時(shí)器來完成。加載計(jì)時(shí)完畢，將進(jìn)行下一檔位的測試，在程序中進(jìn)入換檔準(zhǔn)備過程。在換檔準(zhǔn)備過程中，

14、當(dāng)前檔位標(biāo)志更替為下一個(gè)測試檔位的標(biāo)志，檔位參數(shù)（變比、檔位、加載扭矩、加載轉(zhuǎn)速）更改為下一測試檔位的參數(shù)?？僚展ム手走獙页粗B釣懂箍腔梢裸憩掠熙邳 自動換檔命令語言可以規(guī)定在事件發(fā)生、存在和消失時(shí)分別執(zhí)行的程序。離散變量名或表達(dá)式都可以作為事件。當(dāng)該事件剛剛發(fā)生時(shí)，該單元的程序只執(zhí)行一次；當(dāng)該事件存在時(shí)，按照設(shè)定的時(shí)間間隔反復(fù)執(zhí)行該單元程序；當(dāng)該事件消失時(shí)，該單元程序只執(zhí)行一次。事件命令語言存在時(shí)的循環(huán)執(zhí)行程序與普通程序的while循環(huán)類似，但不完全相同。事件命令語言在事件存在條件下可以控制和調(diào)節(jié)系統(tǒng)循環(huán)執(zhí)行的時(shí)間，因而有利于過程控制的定時(shí)操作。事件命令語言可以完成普通程序的if、whi

15、le條件，同時(shí)可以達(dá)到定時(shí)功能。而且工業(yè)控制中很多都是通過離散狀態(tài)變更來激發(fā)程序的流程。組態(tài)王命令語言形式很適合開發(fā)這種過程。 圄紹啖劈豈嶇好旺源宜萇自動換檔過程建立了多種工作狀態(tài)：“換檔準(zhǔn)備”、“換檔開始”、“換檔成功”、“加載”、“運(yùn)行”、“試驗(yàn)完成”等。以這些工作狀態(tài)和計(jì)算機(jī)檢測到的現(xiàn)場數(shù)據(jù)組合構(gòu)成不同的事件，再以這些不同的事件之間相互激發(fā)、轉(zhuǎn)換的邏輯關(guān)系實(shí)現(xiàn)自動換檔過程的邏輯關(guān)系。 彐瀅蝕賬歸慕娃漚褸夾缽這里采用了自動換檔命令語言中事件存在時(shí)循環(huán)的定時(shí)功能。當(dāng)程序進(jìn)入定時(shí)器狀態(tài)時(shí)，采用計(jì)數(shù)器進(jìn)行倒計(jì)時(shí)，事件存在時(shí)命令語言其它的程序都處于不被激發(fā)狀態(tài)。在這種狀態(tài)下，通過設(shè)定計(jì)數(shù)器起始計(jì)數(shù)

16、值n和事件命令語言存在時(shí)循環(huán)執(zhí)行一次的時(shí)間t，可以設(shè)定定時(shí)器的定時(shí)T（T=nt）。 站萏齋滑焙萋絡(luò)斐疤成酴組態(tài)王還具有配方功能。在制造領(lǐng)域，配方用來描述生產(chǎn)一件產(chǎn)品所用的不同配料之間的比例關(guān)系，具生產(chǎn)過程中一些變量對應(yīng)的參數(shù)設(shè)定值的集合。不同型號變速器和不同檔位的測試參數(shù)（轉(zhuǎn)速、加載扭矩等）數(shù)據(jù)結(jié)構(gòu)類型是一致的，只是比例關(guān)系不同，因而采用配方功能比例方便。 逶笞纛花獫饔查暮呂扭鶯該軟件系統(tǒng)具有連網(wǎng)功能，可以遠(yuǎn)程檢測現(xiàn)場工作狀態(tài)，可并入企業(yè)的CIMS系統(tǒng)。 客蔗綃菇僭緄襯樟隘釵弊本試驗(yàn)臺系統(tǒng)綜合了計(jì)算機(jī)、通訊、自動化、電子、電氣、機(jī)械等方面知識，是一個(gè)智能化的變速器綜合性能在線檢測機(jī)電一體化試驗(yàn)

17、系統(tǒng)，自動化程序度、檢測時(shí)間縮短，大大降低了運(yùn)行成本、提高了生產(chǎn)效率。制動電機(jī)采用回饋制動，節(jié)約能源。系統(tǒng)控制方法精確，檢測傳感器精度高，達(dá)到了很高的精度。應(yīng)用組通訊和過程控制能力，減少了控制程序的開發(fā)時(shí)間。試驗(yàn)臺已經(jīng)通過廠方驗(yàn)收，即將投入生產(chǎn)一線，并將被廣泛推廣。罰沂右厄棼蹦市圜鋇驕苔譜詣懂綮猜遭剔苞芪伲辟逅塬悅辟摶撬橐攻嗡鈺腴櫧煨錕镲颮兩髹遙轍刮麥迎素吝儀衽埔邗閉縮瓔杪蚱釃瓶頏氵顱鉚通晏紋督附錄B鏘梗賈慈飫?chuàng)尨坨枞⒆繥earbox the comprehensive function experiment the set system structure and control soft

18、ware a development扁逅隕崧箍絨藪黏菪捋詆釋忿霍誰氏整煙弛臘袤希Summary:The gearbox is the key equipments in the automobile system, at same on-line examination that experiment on the stage to carry out it to synthesize function, has no precedent still in the domestic.This text is introductive new experiment the pedestal sy

19、stem, carry out gearbox the on-line examination of the comprehensive function.Introduce should experiment the system structure and the work principle of the pedestal system, and describe it a control software in detail of the development and the realization. 垃哈蕾端縫瘭蚓縮暖揞乳Keyword:The gearbox experiment

20、s the set system structure control software并磐腐嬉犧陡獬葛荒迮笥The automobile gearbox is a key equipments in the automobile, its function influences to the motive,economy and credibility of the automobile directly.The test of the automobile gearbox comprehensive function is more complicated, the local automo

21、bile gearbox experiments the set automation degree currently low,the machine interface is not friendly,test the process depend on in experience of the tester.Experiment the pedestal system auto degree therefore and originally high,the test item many,solid the hour is strong and completely dependable

22、. 悛躊礻閂杏潘哈伲烴鑫瓠1 systems introduce驄傈葺咱蜚嘰弁椰砹戌壹Concretely say that come, should experiment the pedestal system to have a following advantage:Can carry on five kinds of different model number gearboxes and it expands the performance test of the type gearbox;Automatic test process can intelligence control

23、;The in a short time can complete a comprehensive function(shift gear,add to carry,synchronous machine) test;The movement parameter can actually the hour show;Can carry on the auto examination of the breakdown,report to the police and handle.etc. 傭蟠沃列璐賄獎虍壘卉墩1.1 system hardwares introduce參鷲鼎賑冰錚泡堪攛幘虜T

24、his system adoption double changes the electrical engineering emulation automobile gearbox to carry out the work condition, carrying out the true examination toward the gearbox function thus.The control of the electrical engineering changes the machine through Siemens 6 SE70 serieses to carry out.Th

25、at system changes the machine adoption exchanges vector control technique, to big power exchanges the electrical engineering carried out a precision a control.Because in that system change the machine quantity not much,the data deliver quantity not big, adoption RS485 total line to carry out work to

26、 control machine and change the communication of the machine, satisfy solid the hour request.Because of PLC control stability,credibility, so shift gear the performance organization(the machine hand) adoption PLC controller automatically to carry out different model number gearbox to shift gear acti

27、on automatically.藍(lán)鳳胳餼鏇恿敦孓鷹驀倌1.2 system software development environments鲞浩沫褥朗撻蠢鳶楝觳鍶The industrial process control software usually needs to have a very strong communication ability,the spot data of solid hour examine the ability and strong database,good sketch interface.Set king 6.01 adopt the all n

28、ew Chinese Explorer interface and own abundant painting tool with the huge sketch database(include a great deal of industrial standard component), the support multimedia and the ODBC database provide of function,have to control the piece and the control language strongly, use vivid,convenience, prov

29、ide one convenience to the customer of integrated development environment, can make the developer construct applied system quickly.It still has a strong communication ability with open sex goodly.This system controls software is kings 6.01 two developments according to the set, carry out to test pro

30、cess of control,the test data of solid hour show, and shorten development time. 倩飆滌蜷砷扭被刮墟鏟啐2 system structure霹僮曳柱魃侈煥杭菽樗笱2.1 systems request愉褥淄曹湍源嗡危唇羹棣Factory the square request experiment the pedestal system to can be on-line examination gearbox of comprehensive function, include the following exper

31、iment:Each file of shifts gear to experiment;The gearbox adds to carry an ability test;The gearbox manipulate(synchronous machine) the test of the function;The jumps a file examination;The tired 功 life span of the gearbox experiment;The spreads to move an efficiency to experiment. 磬必董籽處鑿篚王汰嗶臥Work th

32、e function request is: 村鱺踢湮胨紡躬汲褓移蔞(1)The system circulates a stability,safe credibility; 嬈巛耙付酯峒濠蕕浴鑾坦(2)The test data statement and test and break down examine a patient of interface amity; 蔚腿瘵熔倆魴甸厥隴賀婪(3)The pedestal experiments method section room,norm, attaining the automobile machine type gearbox

33、pedestal to experiment national standard of method; 剛惟帑懊納纊皎爸礓債桉(4)Grow the gearbox completion test function to the dissimilarity at same top. 瑰蕊嘈兆鞋誒躥憧嘉釋惰2.2 system structure襁撤汁歲嵇俘墮筏函釷赦System whole structure,such as figure,1 show. 瀆尖苔獯楂作啶傅呔嗾鈉The system is divided into three major mold piece:The contr

34、ol part;The shifts gear the machine hand for cent;The experiments the pedestal machine electricity part.Control the part takes calculator as center, controling software according to the spot data and current work appearance control system of process,allow to harm an allotment,the instruction send ou

35、t and break down examination etc.;Pass the plank card communication toward the PLC machine hand to send out to shift gear the control instruction and change the machine to send out what test need to turn through a total line of RS485 soon with add to carry to twist signal.Control part to still inclu

36、de to change a machine,the spot data to collect card(the PCL818 Ls),PLC controller.Change the machine can carry out three communicate mutually the difference step electric motor of without the class adjust soon.Change the machine chooses to change the machine with Siemens 6 SE70 serieses, that serie

37、s changes the vector of the machine adoption exchanges electrical engineering control technique to carry on a control to the electrical engineering.The vector control also calls the magnetic field definite direction control.Its basic way of thinking makes use of d-q to revolve to sit the mark transf

38、ormation, will settle sub- electric current to be divided into the magnetoelectricity to flow id 1 with turn the electric current iq 1, keep to turn the son chain during the period of adjusting soon constant, namely id 1 is a constant, communicate at this time the electrical engineering adjusts soon

39、 the principle and direct current electrical engineering homology.The spot data collect the data that the card will collect on the scene to deliver to the calculator.The instruction completion that the PLD controller sends out according to the calculator will shift gear the signal conversion for cha

40、nge the machine hand to execute an order.邳慣瘕衲蜈燕切鷺匱諺潰Shift gear the machine hand is the performance organization that controls part for cent, the machine hand sends out according to the PLD of shift gear the instruction completion to point fair of shift gear action.詢咎臬丨埴蕩淝鳘苯愿本Experimenting the pedest

41、al machine electricity part is this system is end performance organization, complete to drive the gearbox to correspond to turn soon and add to carry to twist to attain particular test work condition.The machine part includes two power a ratio bigger change the electrical engineering with experiment

42、 a pedestal.The function of the electrical engineering influences to the whole function very greatly in this system, as a result choose to change electrical engineering with the exchanges.That electrical engineering can satisfy high accuracy to twist and turn to control soon, and the power is enough

43、 big, can satisfy this system to experiment the work condition request.Add to carry the electrical engineering work while generate electricity the appearance while work, the energy gives something back to the charged barbed wire net, economizing energy consumedly.Experiment the pedestal includes a c

44、lutch and spreads to move the organization and automobile gearbox.Experiment to attain to be high to turn soon,high twist the work appearance of the , so the machine part adds accuracy to want high.The automobile gearbox is this system test object, for making to pack time of unload the gearbox short

45、, experiment the set gearbox to clip originally to loosen to open an operation tightly is pass the oil urn 4 stalks to connect to move to press plank to carry out.鐘寇彎肉浚泱撇堯襻閥儲2.3 The system work principle噔喙菇謖夢媚鈳腋量鞲揲The system adoption double the electrical engineering imitate the automobile work cond

46、ition, driving electrical engineering among them through a speed of change the machine to shut the wreath control to imitate an automobile of drive organization, add to carry electrical engineering to pass to change the machine to twist to shut the wreath control emulation automobile to add to carry

47、.The instruction signal completion that the machine hand sends out according to the calculator shifts gear action to the different model number gearbox, can control gearbox to shift gear to the appointed file thus.During the period of test control software is solid to the movement parameter of the s

48、ystem record a manifestation, and to the temperature,turn soon and twist ,electric current and cover to signal etc. completely actually supervision, meet to break down auto report to the police,auto analysis.咐奄諛裂徠洧詵似鹿鵲旎3 The development and the realization of the system software哄焊綈肘磐龐氡哏淥凹畦This syste

49、m control software is according to set kings 6.01 two developments, the function structure, such as figure,2 show.鶴酮吒琬森嘌植應(yīng)叉瞥斂This system completes an au to experiment, move to experiment from the function, alone shift gear experiment, the fatigue test and efficiency experiment. The calculator autos

50、experiment is the main part of this system, the test process of the calculator control gearbox under this kind of appearance, include: Experiment process, experiment to shift gear in the process in proper order, each file turn soon give settle, add to carry to twist to give settle, system moderate,

51、signal examination and handle etc.Be experimenting a control automatically under, the completion shifts gear and adds to carry alternative process from blank on schedule to the tallest file, completing immediately after to be as low as the lowest file to decline file to shift gear from the tallest f

52、ile, the end completion pours a file test. Move to experiment is operate by the person to move an operation a pedestal to twist the knob completion of, its procedure mainly completes a monitor and reports to the police function. Shifting gear alone carries on experiment to some one appointed file at

53、 the request of the factory house. The fatigue test and efficiency experiment a difference to the durable of the gearbox with spread to move an efficiency to carry on a test. Set king 6.01 have abundant appearance creation system, support the infinite color and 24 kinds of percolation colors, and ha

54、ve abundant of the diagram database and diagram database spirit, abundant of animation conjunction guide. Make use of a set of kings 6.01 interface development systems can develop vivid interface for various control mode, very image,beauty.Because experiment process automatically is the key of this

55、software system, past the following only to experiment to carry on a discussion automatically.替圍累烙豎統(tǒng)詵潺粢朋閡3.1 Connect a peoples communication parameter什蘇披屎茲諦璐檁髭罷癰The calculator passes an examination the spot a data, according to mission programming appearance to PLC and change the machine to send out

56、 correspond of control instruction. 舛隼彩鑫潑猴恕嘵蘿房杷The spot data include: Gearbox current file, turn soon and twist and pass to pull pressure to spread feeling measure of hang file dint, clutch switch signal, gearbox to clip tight signal, bearings temperature etc.Make use of a set of kings plank card co

57、mmunication method with PLC communication among them, set king with change the machine communication adoption set the kings string communication method, set the king expand the plank card with the spot data communication through the PCL818 Ls to carry out. The spot data used for examining whether th

58、e work appearance arrive and breakdown to report to the police or not etc., such as the machine hand whether shift gear to is according to collect on the scene of the ratio and formulation of the speed in of compare soon whether consistent to judge of, but temperature,turn soon etc., the index sign

59、is the basis that breaks down to report to the police again. 魎亦腠鲅睫授褥儼衫汩讠3.2 shift gear the realization of the process automatically蟪胨片措栽攢輩右芡訇嘲3.2.1 shift gear process flow chart automatically旒圾鈀善氪優(yōu)纟槳偵謅鋏Shift gear process and complete to loosen to open a clutch and shift gear,shut action of match the clutch automatically with add to carry in fixed tim