Research On The Testing System Of The Synchronizer's Capability And Life Span

1,Introduction If the auto has a synchronizer, it will ride smoothly, handle easily and decrease the driver's exhaustion. In order to test the synchronizer's capability and the life span, we should have a testing system. This task had developed the testing system that testing the synchronizer's capability and the life span. The system drive the manipulator with the hydraulic pressure for simulate the process of changing shaft. And it collect signals from all kinds of sensors, how to analyze them for evaluate the ability and reliability of the testing synchronizer. This system is a typical example that simulate the robot with the machine,electrons and hydraulic pressure. According to the demand, this system should test some parameters including the force for choose shaft,the shaft's locomotive route,the synchronizer's torsion,the synchronizer's rotational speed,the lubricant temperature,the synchronizer's life-span and the capability etc. 2,The structure of the system Chart1 thesystem principle chart This system include the testing machine,the synchronizer,the changeable electromotor,the system that driving the hydraulic pressure,the force pump,the box for controlling temperature,the manipulator,some sensors,the converter and the industrial computer etc. 三,The controlling principle of the system The controlling principle of the mechanism: The system include the manual form and the automatic form. When the system test the parameters for the synchronizer's capability, it usually uses the manual form. When testing the parameters for the synchronizer's life span, it usually uses the automatic form. At the same time, the manipulator that having the location controlling capability simulate the people's hand. The controlling principle of the hydraulic pressure: this system uses the servo-system. When the microcomputer is send out a voltage, this voltage is transformed electricity through D/A transducer and driver the manipulator with the hydraulic pressure. The process of testing system include some steps. At first, the electromotor rotated according to the demand. Secondly, the hydraulic pressure drive the manipulator to change shaft. Meanwhile, the microcomputer record the experiment's number and the signal that the sensors send out. The signal export through the chart form or the digital form. When finishing all demanding circulation, electromotor will stop, the manipulator regain original location and the test finish. 四,The software of the system The system use C++ Builder as the computer language and the program is consisted of some units. The system require some functions which can control the signal directly, but C++ Builder hasn't this function, it use the Windriver to compile the driver's program. The hardware has a unit for controlling the manipulator's change. The manipulator make the shaft move randomly. From the flow chart, we can easily see it. For making the manipulator resemble the people's hands, the controlling part of the hydraulic pressure is of great importance to the program. This part consists of two steps. One is an analog's PID of the hydraulic pressure. From changing the voltage, the hydraulic pressure change so adjusting the whole system's press. The other is a digital PID of the computer. From changing the PID'S parameter, the computer can control the manipulator's speed. The hardware has a unit for the system's communication. This system require RS-485's protocol which control the converter and RS-232's protocol which control the noise processor. This function is achieved by the MSCOMM32 of the Activex. The hardware has a unit for the digital initialization and record. The system require a database that administer the manipulator situation, the parameter and the collection data. We use the ACCESS database to fulfill this function. First, the executive parameter initializations and record to the ACCESS database. Then, the system executive the program and the data are read from the database. According to the data, the manipulator begin to move. Meanwhile, the database will collect the new data automatically which can be analyzed in future.