换挡机构卡滞示意图The shift stagnation diagram of planetary gears20140410 v05

1、 1浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司2022-7-5RNDRND换挡试验简报换挡试验简报RND shifting Tests Report SummaryBy：KeBing, Zhang BinBin, Zhang GuanBinCheck：Hu JianhuaDate:24 Apr. 2014 目录目录 Contents1.总结总结 Summary2.背景介绍背景介绍 Background Introduction3.2013/11试验总结试验总结 Test 1 Dated on 2013.113.1 布置图布置图 The layout drawing 3.2 失效模

2、式失效模式 Failure 3.2.1 N档到档到D档档 N to D 3.2.2 N档到档到R档档 N to R4.2014/04试验总结试验总结 Test 2 Dated on 2014.044.1 布置图布置图 The layout drawing 4.2 时序图时序图 Sequence chart4.3 失效模式失效模式 Failure 4.3.1 转速转速50rpm input shaft speed:50rpm 4.3.2 100rpm 及及200rpm input shaft speed :100rpm/200rpm浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司 1、总

3、结总结 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浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司 第一描述：GRC反馈（反馈单号：TIR-Testbench-P1-001）TM001样箱在R档和D档时有无法挂入现象，偶尔强行挂入后，同步机构出现锁死现象，无法退出；DFL在TM003样箱测试时也发现类似问题。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：经确认，故障模式属静态挂档困难，经故障再现

6、，R档/D档确存在无法挂入现象，表现为同步器齿套无法越过同步环，但加大挂档力时，齿套可勉强完成挂档动作，未出现锁死现象；拆箱后，行星机构零件无明显磨损和撞击痕迹。静态下，手工推动拨叉挂档10次，由N档挂入D档时，试验10次，有4次齿套无法越过同步环现象，初步统计，挂不入故障率为40%。R档未试验（R档需合箱试验）。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、背景介绍背景介绍 Background Introduction浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司 RND机构RND actuator输入锥Input cone同步器Planetary gear浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司3、 2013/11试验总结试验总结 Test 1 dated on 2013.113.1 静态手动换挡布置图静态

9、手动换挡布置图 The layout drawing of the shift stagnation testmanual shift 3.2、失效模式说明、失效模式说明 Failure3.2.1 N to D 挂档成功挂档成功OK 挂档失败挂档失败NG说明说明Failure Position illustrate:1、大部分失效卡滞发生在齿套越过同步环，与结合齿结合过程中；、大部分失效卡滞发生在齿套越过同步环，与结合齿结合过程中；Most of failures occur when the sleeve pass the synchronous rings, engaging with t

10、he tooth of planetary carrier.2、部分失效发生在齿套与同步环齿结合过程中；、部分失效发生在齿套与同步环齿结合过程中；Some failures occur when the sleeve engage the tooth of the synchronous rings.浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司Neutral PositionD PositionNeutral PositionFailure Position4.6mm8.5mm 3.2、失效模式说明、失效模式说明 Failure3.2.1 N to D 浙江德孚力汽车变速器有限公司

11、浙江德孚力汽车变速器有限公司D Position(959 inc)D Failure(741 inc)Duty cycleN position(481 inc)3、据图可知，换挡卡滞时的脉冲为、据图可知，换挡卡滞时的脉冲为741inc，D档脉冲为档脉冲为959inc，N档脉冲为档脉冲为481inc，则卡滞行，则卡滞行程为（程为（741-481)/(959-481)X100%=54.4%,即齿套行程为即齿套行程为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. 电机示意图电机示意图 The motor diagram of D failure 挂档成功挂档成功OK 挂档失败挂档失败NGNeutral PositionR PositionFailure Position 1Neutral Position3.2.2、N to R 浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司说明说明Failure P

13、osition illustrate :1、卡滞发生在齿套越过同步环，与结合齿结合过程中。、卡滞发生在齿套越过同步环，与结合齿结合过程中。Some failures occur when the sleeve pass the synchronous rings, engaging with the tooth of pivot plate.2、部分失效发生在齿套与同步环齿结合过程中；、部分失效发生在齿套与同步环齿结合过程中；Some failures occur when the sleeve engage the tooth of the synchronous rings.Failure

14、 Position 28.5mm6.2mm 浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司3.2.2、N to R N Position(487 inc)R Position(0 inc)R Failure(129 inc)Required positionDuty cycle3、据图可知，换挡卡滞时的脉冲为、据图可知，换挡卡滞时的脉冲为129 inc，R档脉冲为档脉冲为0 inc，N档脉冲为档脉冲为487 inc，则卡滞行，则卡滞行程为（程为（487-0)/(487-129)X100%=73.5%,即齿套行程为即齿套行程为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. 电机示意图电机示意图 The motor diagram of D failure 4、 2014/04试验总结试验总结 Test 2 dated on 2014.44.1 动态换挡试验布置图动态换挡试验布置图 The layout d

16、rawing of the shift stagnation test输入锥Input cone同步器Planetary gear离合器Clutch离合执行机构Clutch actuatorRND机构RND actuator电机Motor此处固定Confirm浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司 4.2 时序图时序图 Sequence charta cycleEngine idling speedengageddisengagedmotorclutchpositionInput shaft浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司 4.3、失效模式、失效模式

17、Failure4.3.1转速转速50rpm input shaft speed:50rpm 1）N to DD Failure PositionNeutral Position浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司Input speed Duty cycle 70%Required positionD failure position773 inc说明说明Failure Position illustrate :1、卡滞发生在齿套越过同步环，与结合齿结合过程中。此时电机脉冲信号为、卡滞发生在齿套越过同步环，与结合齿结合过程中。此时电机脉冲信号为773inc，卡滞行程，卡滞行程

18、为为(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转速转速50rpm input shaft speed:50rpm 2）N to R浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司说明说明Failure Position illustrate :1、卡滞发生在齿套越过同步环，与结合齿结合过程中。此时电机脉冲信号为、卡滞发生在齿套越过同步环，与结合齿结合过程中。此时电机脉冲信号为154inc，卡滞行程，卡滞行程为为(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 浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司D Failure PositionNeutral PositionD Failure PositionNeutral PositionSpeed:100rpm Duty cycle:70% Speed:200rpm Duty cycle:70%说明说明Failure Position illustrate :1、100rpm时，卡滞发生在齿套越过同步环，与结合齿结合过程中。此时电机脉冲信号为时，卡滞发生在齿套越过同步环，与结合齿结合过程中。此时电机脉冲信号为930

22、inc。齿套行程约为齿套行程约为75%，即卡滞行程为，即卡滞行程为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时，卡滞发生时电机已完成，即脉冲信号为时，卡滞发生时电机已完成，即脉冲信号为1000in

23、c，实际齿套行程约为，实际齿套行程约为90%，即卡滞行，即卡滞行程为程为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 浙江德孚力汽车变速器有限公司浙江德孚力汽车变速器有限公司Speed:100rpm Duty cycle:70% Speed:200rpm Duty cycle:70%说明说明Failure Position illustrate :1、100rpm时，卡滞发生在齿套越过同步环，与结合齿结合过程中。此时电机脉冲信号为时，卡滞发生在齿套越过同步环，与结合齿结合过程中。此时电机脉冲信号为140inc。齿套行程为齿套行程为(500-140)/500X100%=72%，即卡滞行程为，即卡滞