自动变速箱最终测试原理中英文培训材料

1、u FT简要介绍 General Description u FT设备 FT Equipmentu 测试机信息 TEST Machine Informationu 测试顺序与功能 General Test Sequence and FunctionFinal test Introduction2冷却油压传感器主油压传感器润滑油压传感器输入轴扭矩传感器输入轴速度编码器输出轴扭矩传感器输出轴速度编码器换档扭矩传感器换档角度传感器油位传感器温度传感器Final test 测试机通过：General Description采集数据，将采集到的数据、命令值，以及利用采集的数据和命令值得到的计算值绘制曲线

2、，在统计分析的基础上，保证所有制造的变速箱处于相似稳定状态。General DescriptionFT用于:FT Machine are used for: u 设备自动调整模拟发动机输出扭矩，模拟实际整车工况，测试变速箱功能。These tests will resemble the conditions when Trans are installed in the vehicle, adjust automatically to multiple engine torque.u 适用于不同型号的变速箱。Can be adapted to product changes with mino

3、r modifications.u 测试节拍/步骤：250s/17stepsu 程序逻辑控制器控制FT测试系统所有部件的动作。Programmable Logic Controller (PLC) controls all system tooling motions.u 人机界面装置与PLC联机，监控/控制设备操作或手动操作。Human-Machine Interface (HMI) allows the operator to monitor and control system operation both in automatic and manual modes. It is con

4、nected to PLC.操作面板u 测试机收集处理测试的变速箱数据，并与PLC联机传递接受命令。The test computer controls transmission test data. It interfaces with the stand PLC, transmitting and receiving commands.(计算、发指令、采集数据)FT Equipment-ControllerPallet-mounted TransPreload conveyor sectionRF antenna readstest computer for test setuptest

5、standRF antenna readslocated, clamped, engaged and sealedAcceptedRejected*2/Abortunload arearepair areatestedPart informationPLCTest computerCommands and feedbackHMIFT Equipment-Trans LocationThe pallet/transmission lift将托盘从运输轨道上升起/从托盘上升起待测变速箱 Raises the pallet off the test conveyor section then rai

6、ses the transmission off the pallet.cylinderlift platecylinderlocating pinThe headstocku 夹紧保持变扭器壳体。Engages and secures the transmission housing. u 位于测试机变扭器壳体边。The headstock assembly is mounted below housing side of the test stand. u 所有定位夹紧设备移动精度均在0.5mm以内,测试结束后自动返回原位。Be able to consistently hold posi

7、tion within a tolerance of 0.5mm. The device must be returned to the normal position by the test machine at the end of the test. FT Equipment-Trans LocationFT Equipment-Trans LocationThe torque converter driveru 夹紧TC，在测试过程中随输入轴旋转。 Engages the torque converter to rotate the input shaft during testing

8、.u 安装在输入轴尾部。在测试中，会从headstock中伸出夹紧TC输出扭矩。Is bolted to the output shaft of the spindle assembly on the input drive and advances through a circular opening in the headstock platespring-loaded fingersFT Equipment-Trans LocationThe TC retainer release assembly u 保持变速箱固定。Stability the transmissionu 安装在测试机

9、桥夹下壳体端。Is mounted below the bridge on the case side of the test stand. pneumatic cylinderrodlock unitspring-loaded pressure feetFT Equipment Input Drive AssemblyThe input drive and slide assembly u 在测试过程中旋转变速箱输入轴输入扭矩. Rotates the transmission input shaft during testing.u 安装在测试机变扭器壳体边。Located on the

10、housing side of the test stand base.1 Motor2 Flex Coupling3 Chain box4 Speed Encoder5 Torque Transducer6 Flex Coupling6 Spindle Assembly1234567FT Equipment Output Drive AssemblyThe output assembliesu 模拟变速箱输出负载，即自动模拟车轮状态。The output drives simulate a load on the transmission, acting as the wheels of a

11、n automobile.u 输出轴总成位于变速器变扭器壳体总成/变速箱壳体总成边各一个。There are two sets of output drives and slides, one located on the case side of the test stand base and the other located on the housing side. Tool changeru 具变速箱型号自动选择输出工具。Automatically select the slave adaptor for the output drive assembly based on the m

12、odel being tested. u 工具更换装置能够防止变速箱密封/衬套损伤。The tooling be designed to prevent damage to the transmission oil seals or bushings during automatic engagement and testing.FT Equipment Tool ChangerFT Equipment ProbesThe Noise Vibration and Harshness (NVH) probes measure transmission vibration during the t

13、est cycle.NVH探针-探测测试中的变速箱振动The Cooler Out probe seals the transmission cooler out port during testing and allows for test oil flow through the port.冷却油孔探针-密封冷却油出口，使测试油安全通过，同时检测压力The Shifter actuates the transmission gearing by rotating the manual shaft during the test cycle and measures the torque r

14、equired to actuate the manual shaft.换档探针-测试过程中转动手动轴调整变速箱档位输出，同时测量换档扭矩The cooler line in and line pressure probes seal the transmission cooler in and line pressure ports, respectively, during testing. This allows for test oil flow and transmission pump pressure, respectively, to be measured through t

15、hese ports.主油压探针-密封冷却/主油压出口，分别测试油泵泵油压力及测试油压。NVH probeCooler outcooler line in and line pressureShifterThe Bubbler probe measures the test oil level inside the transmission during the fill, test and evacuation step of the test sequence.油位探针-在充油，测试，放油步骤中测量变速箱内油位。The electrical connector is the physica

16、l interface between the transmission electrical circuits and the test stand.线路连接探针-变速箱电路循环与测试机接口。The Oil Fill/Vent probe seals the transmission vent cap opening during testing and allows for test oil flow through the opening.加油口充/放油探针-密封充/放油孔，保持测试油通过。The Part marker stamps a character in the surface

17、 of the transmission housing if the test sequence was completed and the transmission passed the test. 打印机-变速箱完成并通过测试时，在变速箱表面打印测试机号码。FT Equipment Probesoil fill/ventBubblerpart markerelectrical connectorFT Equipment Test oil system变速箱油由滤油中心提供至测试机。Automatic Transmission Fluid (ATF) is supplied from th

18、e plant central supply to the test stand test oil system. FT Equipment Test oil system回用变速箱油脏油箱粗过滤20micron精过滤10micron脱水出油口（Sediment取油处）过滤器（滤芯）60MESH过滤器（滤芯）20micron金属网粗滤经管道进入FT设备油道，进入测试变速箱前过滤测试循环中过滤精炼室ATW设备ATW设备管道，油泵测试变速箱管道，油泵的过滤滤芯装有压力传感器，对其滤口进出油压进行监测，如出现问题会及时报警。净油箱FT Oil filter FT系统用油过滤：Test Machine

19、 Information-PCSPCS系统同时配有分析FT测试数值的工具Data analysis tools. PCS is equipped with a powerful set of tools for viewing and analyzing the data collected at the test station. Data Analysis Tools:Type of analysisType of analysisCorrelation相关性Histogram柱状图Limit Evaluation界限评估Statistical Summary统计概括Summary概括To

20、p N RejectedTest points Top N 拒绝故障码Top N Reject CodesTop N Repair CodesTop N Pallet NumbersX-YCorrelationX-YTop N Reject CodesSummaryTest point valuesTest records numberHistogramPCS(PC Control Stream)是多任务实时控制系统，能高速处理分析数据。PCS is a multi-tasking, real-time control system designed for manufacturing and

21、 process control solutions that require high-speed data acquisition and data analysis.Test Machine Information-PCSTest pointSingle Sample Peak Displays the test point value, description, low limit value, and high limit value for y-axis test points.Single Sample Location Displays the Test point value

22、, description, low limit value, and high limit value for x-axis test points. Single Sample Peak and Location Displays test point values, low limit values, and high limit values for x-axis and y-axis test points.Test Machine Information-PCSPeak Threshold Test point Displays the high threshold limit a

23、nd description and the low threshold limit and description. The limits are shown as horizontal bars, typically for the entire duration of the trace.Test pointFinal Test目前共有300个左右的测点，其中约100个是重要测点。所有测点的控制限均由统计分析得出，重要测点的控制限一般设置在3.5，非重要测点的控制限一般设置在5或更多。对于重要测点参数控制限的更改，需要测试工程师召集QE、PE等相关部门开协调会讨论是否需要Drive Au

24、dit验证，再决定如何更改。19StepDescription1Electrical Check2Park Check3Pump Prime with Shifter Sweep4Launch Pressure Cycling5Clutch Fill and Defuzz6Line Pressure Characterization7Stall Check8Pump Capacity9Leak Check10TCC11Clutch 1 (C1234) Performance Characterization12Clutch 2 (CBR1) Performance Characterizati

25、on13Clutch 2 (C35R) Performance Characterization14Clutch 2 (CB26) Performance Characterization15Clutch 2 (C456) Performance Characterization16Final Oil Level17SweepGeneral Test Sequence and FunctionSTEP 1: ELECTRICAL CHECKdescription: Use GMLAN commands and feedback to verify TEHCM communication and

26、 electrical integrity of components in the TEHCM.purpose: To do the following: Verify communication with the TEHCM. Detect electrical opens/shorts. Detect missing electrical devices. Record TEHCM version information.duration: 3-4 secondsTest point range: 100-199NOTE:This step does not collect a reco

27、rding.21STEP 2: PARK CHECKdescription: Test the park mechanism.purpose: To verify that the park pawl stops the output and holds with negative torque and positive torque (optional) applied.duration: 4-5 secondsTest point range: 400-40922STEP 3: PUMP PRIME WITH SHIFTER SWEEPdescription: Fill the trans

28、mission with enough fluid for the pump to supply line pressure and test the shifter mechanism. This is the first step in which the transmission is spinning.purpose: To do the following: Ensure that the pump can supply pressure to the transmission and to measure spin loss. Measure shifter torque and

29、ensure that the force required to move the manual shaft is nominal.duration: 4-5 secondsTest point range: 200-499PUMP_PRIME23STEP 4: LAUNCH PRESSURE CYCLINGdescription: Exercise VBS solenoids, switches, snap rings, regulator valves, and clutch seals.purpose: To excecise CB1234, CBR1, C35R, CB26, and

30、 C456 clutch rod movement.duration: 2-3 secondsTest point range: 14000-14049LT_PRS_CYCLING24STEP 5: CLUTCH FILL AND DEFUZZdescription: Fill and break-in each of the five (5) clutches and perform static NVH testing for first, second, third, and fifth gears.purpose: To do the following: Fill the clutc

31、h housings. Get the clutches wet. Verify clutch pressure switch operation. Verify the default and boost clutch valves. Verify the input and output speed sensors. Verify torque converter clutch (TCC) actuation. Verify first, second, third, and fifth gear ratios. Perform a static NVH test for first, s

32、econd, third, and fifth gears.duration: 12-15 secondsTest point range: 500-599CLUTCH_DEFUZZ25STEP 6: LINE PRESSURE CHARACTERIZATIONdescription: Test the line pressure solenoid and circuits.purpose: To do the following: Verify that the line pressure control circuit produces stable pressure. Character

33、ize the relationship between the commanded line pressure and the actual measured line pressure. Determine hysteresis.duration: 3-5 secondsTest point range: 700-799LINE_PRESS26STEP 7: STALL CHECKdescription: Verify that the torque converter performs properly in a stall condition?purpose: To do the fo

34、llowing: Verify fourth gear ratio and spin loss. Calculate and verify the TCC K-factor. Perform a static NVH test for fourth gear.The K-factor is written to the TEHCM as a calibration at the end of the test sequence.duration: 7-8 secondsTest point range:800-899STALL_CHECK27STEP 8: PUMP CAPACITYdescr

35、iption: Test the ability of the pump to produce pressure at a given input speed.purpose: To verify that the pump is functioning adequately and to determine the input speed at which the hydraulic system changes priority from the cooler circuit to the more critical line pressure circuit.duration: 5-6

36、secondsTest point range: 300-309PUMP_CAPACITY28STEP 9: LEAK CHECKdescription: Check for any leaks in the clutches.purpose: To verify the seal integrity of the clutches by measuring cooler and line pressure at a speed specific to each clutch.The speed for each clutch is based on the input speed deter

37、mined in the Pump Capacity test step and the speed atwhich cooler pressure drops for a good transmission. Each clutch must be actuated individually in a sequence thatensures the full fill time is represented.duration: 14-18 seconds Test point range:600-699LEAK_CHECK29STEP 10: TCCdescription: Test th

38、e torque converter clutch (TCC) apply and release time and verify the sixth gear ratio.purpose: To determine that the TCC functions properly and to verify the sixth gear ratio.duration: 7-8 secondsTest point range: 14050-1409930STEP 11: CLUTCH 1 (CB1234) PERFORMANCE CHARACTERIZATIONdescription: Do t

39、he following: Measure clutch fill time. Get clutch offset pressure by gradually increasing clutch 1 pressure until the ratio changes. Get capacity pressure and capacity torque at First Axis by setting a high ramp pressure at clutch 1 and rampingdown the pressure while applying capacity torque at the

40、 output drive until the ratio changes. Calculate clutch gain with capacity torque, capacity pressure, and offset pressure.purpose: To determine the clutch gain (slope) and return spring pressure (offset) and to verify first gear ratio. The slope andoffset are written to the TEHCM as a calibration at

41、 the end of the test sequence.duration: 10-15 secondsTest point range: 14150-14349CB123431STEP 12: CLUTCH 2 (CBR1) PERFORMANCE CHARACTERIZATIONdescription: Do the following: Measure clutch fill time. Get clutch offset pressure by gradually increasing C2 pressure until the ratio changes. Get capacity

42、 pressure and capacity torque First Axis by setting a high ramp start pressure at C2 and rampingdown the pressure while applying capacity torque at output drive until the ratio changes. Calculate clutch gain with capacity torque, pressure, and offset pressure.purpose: To determine the clutch gain (s

43、lope) and return spring pressure (offset) and to verify reverse gear ratio. The slope andoffset will be written to the TEHCM as a calibration at the end of the test sequence.duration: 10-15 secondsTest point range: 14350-14549CBR132STEP 13: CLUTCH 3 (C35R) PERFORMANCE CHARACTERIZATIONdescription: Do

44、 the following: Measure clutch fill time. Get clutch offset pressure by gradually increasing C3 pressure until the ratio changes. Get capacity pressure and capacity torque?at First Axis by setting a high ramp start pressure at C3 and rampingdown pressure while applying capacity torque at output driv

45、e until the ratio changes. Calculate clutch gain with capacity torque, pressure, and offset pressure.purpose: To determine the clutch gain (slope) and return spring pressure (offset) and to verify third gear ratio. The slope andoffset ?will be written to the TEHCM as a calibration at the end of the test sequence.duration: 10-15 secondsTest point range: 14550-1474933STEP 14: CLUTCH 4 (CB26) PERFORMANCE CHARACTERIZATIONdescription: Do the following: Measure clutch fill time. Get clutch offset pressure by gradually increasing C4 pressure until the ratio changes. Get capacity pressu