Structural Design of High Speed ​​Impact Durability Test System for Automotive Alternator

6 Structural design of high-speed impact durability test system for automotive alternator Zhou Hongcuo. Zhou Chenping, Yang Songqing, Hubei Jingzhou High-tech Institute of Technology, Hubei Jingzhou 434000, the structural design of the durability test system. Described in. The characteristics of the multi-threaded operation mode implemented on the 98 platform; at the same time, the various interferences and solutions in the development and debugging are introduced.

i Overview The rapid development of the automotive industry will lead the mountain, and various auto parts manufacturers will increase the technological transformation and development of new products. The performance improvement of automotive alternator products is particularly prominent. In order to verify the performance of the continuously improved alternator, the demand for the AC hairpin test equipment in one field is very urgent. Can accelerate the pace of new product development. Enable enterprises to seize the opportunities in the fierce competition.

The test system consists of less than 5 sets of 1 computer and 5 test sets. At the same time, 5 alternators can be driven at high speed. Humanity test. The set test bench is turbulent under the monitoring of the computer. The embedded combination of temperature and other parameters makes the tested alternator accept the demanding simulation test.

2 system control structure design The main control computer of the system and the control unit of each test bed between the mountains, 6485 communication connected to the local area network. The endurance test was completed by communication 1. Calling the set test data of each test stand. For the impact test computer to pass, the interface into, 1 Yue 485 communication, network and other operating test unit control unit to achieve real-time monitoring and monitoring.

Each set of test benches is an independent combination of electromechanical systems. In the front body of the test bench, the changes of the relevant parameters such as the test environment temperature of the alternator, the rotational speed and the dynamic load of the alternator are simulated. Complete the various test computer control of the alternator, the high-speed impact durability test bench control principle of the car alternator.

The temperature control unit controls the space temperature inside the test bench, and the temperature difference is built. The controllable temperature rise slope and other adjustments are intelligent. The system with high precision is still included in the system. The 10 dual-channel regulator is matched with the type 1 thermocouple sampling. More than feather output. The road is positively depleted. Only the solid state relay controls the heating of the heater, and the adjustment of the equalizing fan and the inlet and outlet vents reaches the constant temperature cycle in the box or completes the high temperature impact. The other side reversely adjusts the spray dry ice refrigeration for low temperature test or impact. The temperature control range is 40, 15, and the speed is in the middle; the brake is single. The fire power of the braking resistor is frequency-converted, the motive is smashed into the steam, and the engine is operated. The maximum speed of the alternator is up to 25kimiii, and the mountain is accelerated. During the cycle test. The speed drawing can be set to open and close the two modes of operation. When the ring is opened, the 4 high-speed impact test is the same. In the closed loop, the regulator 2 is made into a choke generator, and the speed imitation is converted to the feedback input of the inverter. In addition to the given parameters of the communication transmission, the speed regulator is closed by the 10 regulators. During high speed impact test. The speed open loop control speed is calculated from the gear ratio to the corresponding frequency. Communication with the frequency converter to transmit frequency parameters; development of testing and testing equipment for the addition and subtraction of motor electrical equipment.

The test equipment speed time value is written to the inverter by communication. Control the slope acceleration parameter speed segment, 1 overclocking machine 0 to 1 fast anti-change. Complete the impact process. The key to the trial step drive is the high-speed acceleration and deceleration performance of the load-finding unit to test the output of the alternator. The battery load box is connected in parallel using the constant-current and constant-voltage load mode to test the output capacity of the alternator; The performance of the system, the system constant current range of 20, 4 to adjust the output current in the case of emotional flow. Due to the regulator's operation, the output voltage of the alternator is basically constant; the constant voltage range of the system is less than 1028, and the constant load of the constant voltage type is less than the output voltage of the alternator regulator. The regulator does not work. The alternator output current is rated maximum less than 200.

The temperature acquisition module module provides monitoring of the alternator temperature 485 communication network to collect internal temperature data in the operation of the alternator, which is important for the performance analysis of the alternator.

In the analog control box of each test bed of the system, the high-performance Hall sensing element is used to isolate the current and voltage of the circuit such as the excitation of the main circuit load battery of the alternator output, and the phase line or neutral line output from the alternator is isolated. The taken-out frequency confidence is converted into a violation analog signal by the converter and converted into a standard current signal transmission. From the computer bus, the interface directly collects relevant data. Among them, the speed signal is sent to the feedback input of the inverter.

The temperature of the inverter on the test bench is adjusted to only the load box. The temperature acquisition module is a separate station on the 3485 communication network. The computer follows the communication protocol data format of each device site, and the constant current and constant voltage control of each control single redundant box of the data exchange and coordination system is simulated. Quantity control. Battery switch, segmentation control of the regulator, external control mode of the inverter, etc. Direct operation control is performed by the computer 10 interface.

The test system computer data acquisition real-time control has 2 channels, only 8485 communication network and computer bus 1., interface. In the real-time multi-task control system, its functions complement each other, and it is more perfect to adapt to complex control requirements; billion-related meal number transfer data exchange loose-quantity conversion data mining distance from transmission input and output control constitutes the test bench The reliability and safety of data communication in the core system of the technology core is the focus of technical indicators. The computer is controlled by multiple sets of test benches. The parallel operation software multi-line operation of the transfer hall is the technical key of the system.

3 software function and multi-thread coordinated operation mechanism system software small function test set test control data acquisition failure loose monitoring equipment test and other completion of the endurance and impact two types of test tasks.

Alternator durability test. The temperature and speed load are set to be nested by the boundaries. The alternator is tested according to the set time, and the test interface setting of the punch 1 is recorded with constant current or constant voltage, and the speed and temperature are repeatedly raised and lowered according to the determined slope.

Compared with durability test conditions. The impact test has strict acceleration and deceleration test equipment requirements, and the real-time control requirements are higher.

The debugging function consists of debugging ADDAi, fT5tjUliftM test Chongshan curve and other investment blocks to form multiple blood coexistence and running flexible debugging of each part of the combined function, with the completion of manual test = a large amount of data collected in the test according to the failure mode of the alternator and the amnesty tax redundancy The software is inferior to the data processing, and the results are immediately returned to the control system for use or output. Part of the test data can be transferred to software 1 for performance analysis. Multiple test benches perform multiple test computers at the same time. The computer operation is very busy. The contradiction of multi-task conflict is the primary question of software security.

The development of the 98 platform makes full use of the multi-threading and message-driven mechanism of the operating system, which reduces the busyness of the system and improves the sensitivity of the program response, so that the complex tasks of the computer to control multiple test beds can be realized. At the same time, his program error correction is very fast in the test run. Only the state monitoring thread is always running off. Analyze whether it should be alarmed or interrupted according to the collected data. In addition to this process is concentrated in the message processing program, error location is very easy to need, in the face of the time when the data is only required to send a message can be processed to simplify the tracking operation through the timer. The thread message 1 does 1. The thread does not have to actively pull the ring to passively call the operating system to this passive to passive metamorphosis. Try to take advantage of the features that the operating system promotes. Minimize the waste of processor time to complete intensive parallel tasks. This can be said to be the green 4 security reliability analysis of multi-task real-time control. The domestically developed electromechanical equipment is compared with the similar equipment imported from abroad. equipment. The cost varies greatly; the new control technology such as the control machine batch control 10 is used in the same claw flat 1 mechanical manufacturing process. There is a difference in the quality of electronic components. Ask the mechanical structure above. Electronic components are designed and manufactured to improve quality. Try to use imported good equipment to carefully select domestic cooperative manufacturers, and make good development of the process 1. To achieve safe, reliable and stable long-term operation. Other threads are only suspended when the output needs to be adjusted to wake up. The timer thread message cooperation relationship 2 is not occupied by the cell. Instant 1 corresponding processing.

Remember the time. Thread. Eliminate collaboration in a variety of ways. Compared with the traditional control of the city's 1 mountain line, it is not a one-to-one ratio.

There are obvious advantages.

3 threads do not have to consider looping out the processor time until the timeout of the timing structure so that the processor time is not wasted in the empty loop 1. Raise the response violation of other worker threads. Multiple tasks get timely response when they are processed in parallel. There is no delay to refresh the face due to the crowded task. The thread is running. It must pass the same formula to make the boundary record. In addition, the message is used to call the public data object to play, the code inside the thread is concise, the interaction between the thread and the external program is Xian 1 Luo, the first +, the new technology should be done to automatically control the performance of security and reliability, It is very important for each electrical component to resist external interference and to suppress self-radiation interference. The excitation source of the system is the exciter of the freighter alternator, and the second is the main corpse of the metering device. The electric power of the river power modulates the electric current. The most susceptible to sub-interference is the amplifier circuit load ç­˜ amplifier circuit IO port and analog conversion circuit communication line. The main anti-interference strategy of this system is as follows: The electrical components are separated from each other.

Good grounding. Reduce each ring for analog circuit co-calibration, number and digital circuit ground resistance Y source sensor electromagnetic isolation analog conversion AIVDA, digital and computer optical isolation only 3485 communication network between the optical isolation of each site. These are the most effective methods for system anti-interference. Lottery; when the test bench is running. Each alternator has a potential difference between the high-current load box circuit and the ground in the common ground state due to the grounding of the iron. This dynamic potential difference will affect the surrounding load box. The normal work is to eliminate the impact. It is necessary to connect the ground potential sampling ends of all load boxes in parallel. The system can work normally. This is the most serious lateral interference during the parallel operation of multiple test stands.

1 Kunzang. Than the Xu 1 microcomputer interface technology. Beijing Tsinghua University Press. 1991 2 Wang servant programming. Fingering. North Ke Beijing Academy is responsible for editing the village

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