手动变速系统优化及换档质量评价研究
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摘要
手动变速器目前仍然占据着相当大的市场,进一步开展手动变速系统优化及换档质量评价的研究,无论对于消费者还是对于变速器生产厂商以及整车厂都将具有重大意义。
以微型车换档操纵机构作为研究对象,基于人机工程学原理进行了驾驶员坐姿舒适性分析和驾驶员操纵舒适性分析,并对原型车和改型车做了对比。通过对换档操纵机构的运动分析和静力学分析,构建了换档操纵机构的数学模型。基于带精英策略的非支配排序遗传算法,在MATLAB平台上进行了软件编程。用该程序对换档操纵机构的数学模型进行优化计算。数据对比表明,优化结果达到了设定的目标。
分析了手动变速器的结构,建立了手动变速器齿轮系的数学模型,应用机械可靠性设计方法选取了相关的约束条件,在MATLAB中基于NSGA-II算法进行手动变速器齿轮系的优化设计,选取一组优化数据,与齿轮系原始数据进行对比,结果表明：优化目标均有不同程度的改善。
开发了变速器综合性能测试系统,能够完成手动变速器换档性能测试、离合器性能测试和变速器的同步性能测试等测试项目。该测试系统,基于虚拟仪器技术,借助于一系列的传感器、运动控制卡、数据采集卡等相关设备,利用LabVIEW软件开发平台进行了数据采集模块、信号处理、步进电机控制、图形曲线的显示及数据存储等部分的软件编写,使得变速器性能测试系统能够自动进行数据采样、传输存储、处理加工、动态显示等操作。根据相关试验标准,对变速器换档性能测试进行了研究。结合车辆在路面行驶时的换档时机,制定了测试台架上变频电机转速的控制方案。根据变速器同步时间测试方案,设计了变速器输入端转速测量装置,基于同步器的结构、工作原理设置了试验参数,分析了同步器同步时间的影响因素。根据测试结果,分析了锁环式同步器同步过程的各个阶段及测试曲线的变化情况。
介绍了传统换档质量概念及传统的换档质量评价方法,分析了其不足之处,结合变速器性能测试系统的测试数据,基于人机工程学理论,完善了换档质量的评价指标；根据测试数据对变速器进行了评价指标数值计算及综合评价,参照评价标准,对变速器换档质量做出了相应评价。
The manual transmission still takes up a large market presently, therefore the further research on the optimization of the manual transmission system and the evaluation of the gear shift quality is of great significance to the consumer, the vehicle factories and the manufacturers of the manual transmission as well.
Taking the minivan's shift operating mechanism as the research object, the thesis analyzes the comfort level of the driver's sitting postures and the driving comfort level based on the principle of ergonomics, and the thesis also compares the sitting postures comfort level and the driving comfort level between the original vehicle and the improved vehicle. In the research, the optimal model of the shift operating mechanism has been established through the kinematic analysis and statics analysis of the shift operating mechanism. And based on the NSGA-Ⅱ, software programming has been undertaken on the MATLAB platform. Then this software program is used to optimize the mathematical model of the shift operating mechanism. The comparison of the data shows that the result of optimization has achieved the set objectives.
The thesis has analyzed the construction of the manual transmission, set up the mathematical model of the manual transmission gears, chosen the relevant constraint conditions by use of the designing method of mechanical reliability, and carried out the optimal designing on the manual transmission gears in the MATLAB, based on the calculating method of NSGA-Ⅱ. Then a group of optimal data is picked out and compared with the original data of the gears. The result demonstrates that the optimal objectives have been improved in various degrees.
The thesis has developed the manual transmission comprehensive performance testing system, which can undertake the tests of the gear shift performance, the clutch performance, and the synchronizer performance. Based on the Virtual instrument technology and by means of a series of sensors、motion control card、data acquisition card and some concerning equipments, the testing system writes the software of data acquisition module signal processing、stepped motor controlling、graphical display、 data storage and so on, which enables the manual transmission performance testing system to accomplish the operations of data sampling, transportation and saving, processing and dynamic displaying automatically by use of the Lab VIEW software developing platform. According to the concerning criteria, the thesis has a research on the test of the gear shift performance of the manual transmission. Take into consideration of the timing of gear shift when the vehicle running on the road, the thesis formulates the rotational speed controlling scheme of the variable frequency motor on the testing bench. The thesis designs the rotational speed of the transmission input shaft measuring device, according to the synchronization time test plan of the manual transmission. Based on the structure of the lock ring synchronizer and its working principles, the thesis sets the test parameters and analyzes the influencing factors of the synchronization time. According to the testing result, the thesis analyzes the different stages in the synchronizing process of the lock ring synchronizer, and the changes of the testing curves.
The thesis introduces the conventional concepts of the gear shift quality and the methods of evaluation on the gear shift quality, analyzes its deficiencies, and combined with the test data of the manual transmission performance testing system, perfects the evaluation indicators of the gear shift quality, based on the theory of ergonomics. According to the test data, the thesis also calculate the value of the evaluation indicators of the manual transmission, appraises it in an all-around way and evaluates the gear shift quality of the manual transmission referring to the evaluation standards.
以微型车换档操纵机构作为研究对象,基于人机工程学原理进行了驾驶员坐姿舒适性分析和驾驶员操纵舒适性分析,并对原型车和改型车做了对比。通过对换档操纵机构的运动分析和静力学分析,构建了换档操纵机构的数学模型。基于带精英策略的非支配排序遗传算法,在MATLAB平台上进行了软件编程。用该程序对换档操纵机构的数学模型进行优化计算。数据对比表明,优化结果达到了设定的目标。
分析了手动变速器的结构,建立了手动变速器齿轮系的数学模型,应用机械可靠性设计方法选取了相关的约束条件,在MATLAB中基于NSGA-II算法进行手动变速器齿轮系的优化设计,选取一组优化数据,与齿轮系原始数据进行对比,结果表明：优化目标均有不同程度的改善。
开发了变速器综合性能测试系统,能够完成手动变速器换档性能测试、离合器性能测试和变速器的同步性能测试等测试项目。该测试系统,基于虚拟仪器技术,借助于一系列的传感器、运动控制卡、数据采集卡等相关设备,利用LabVIEW软件开发平台进行了数据采集模块、信号处理、步进电机控制、图形曲线的显示及数据存储等部分的软件编写,使得变速器性能测试系统能够自动进行数据采样、传输存储、处理加工、动态显示等操作。根据相关试验标准,对变速器换档性能测试进行了研究。结合车辆在路面行驶时的换档时机,制定了测试台架上变频电机转速的控制方案。根据变速器同步时间测试方案,设计了变速器输入端转速测量装置,基于同步器的结构、工作原理设置了试验参数,分析了同步器同步时间的影响因素。根据测试结果,分析了锁环式同步器同步过程的各个阶段及测试曲线的变化情况。
介绍了传统换档质量概念及传统的换档质量评价方法,分析了其不足之处,结合变速器性能测试系统的测试数据,基于人机工程学理论,完善了换档质量的评价指标；根据测试数据对变速器进行了评价指标数值计算及综合评价,参照评价标准,对变速器换档质量做出了相应评价。
The manual transmission still takes up a large market presently, therefore the further research on the optimization of the manual transmission system and the evaluation of the gear shift quality is of great significance to the consumer, the vehicle factories and the manufacturers of the manual transmission as well.
Taking the minivan's shift operating mechanism as the research object, the thesis analyzes the comfort level of the driver's sitting postures and the driving comfort level based on the principle of ergonomics, and the thesis also compares the sitting postures comfort level and the driving comfort level between the original vehicle and the improved vehicle. In the research, the optimal model of the shift operating mechanism has been established through the kinematic analysis and statics analysis of the shift operating mechanism. And based on the NSGA-Ⅱ, software programming has been undertaken on the MATLAB platform. Then this software program is used to optimize the mathematical model of the shift operating mechanism. The comparison of the data shows that the result of optimization has achieved the set objectives.
The thesis has analyzed the construction of the manual transmission, set up the mathematical model of the manual transmission gears, chosen the relevant constraint conditions by use of the designing method of mechanical reliability, and carried out the optimal designing on the manual transmission gears in the MATLAB, based on the calculating method of NSGA-Ⅱ. Then a group of optimal data is picked out and compared with the original data of the gears. The result demonstrates that the optimal objectives have been improved in various degrees.
The thesis has developed the manual transmission comprehensive performance testing system, which can undertake the tests of the gear shift performance, the clutch performance, and the synchronizer performance. Based on the Virtual instrument technology and by means of a series of sensors、motion control card、data acquisition card and some concerning equipments, the testing system writes the software of data acquisition module signal processing、stepped motor controlling、graphical display、 data storage and so on, which enables the manual transmission performance testing system to accomplish the operations of data sampling, transportation and saving, processing and dynamic displaying automatically by use of the Lab VIEW software developing platform. According to the concerning criteria, the thesis has a research on the test of the gear shift performance of the manual transmission. Take into consideration of the timing of gear shift when the vehicle running on the road, the thesis formulates the rotational speed controlling scheme of the variable frequency motor on the testing bench. The thesis designs the rotational speed of the transmission input shaft measuring device, according to the synchronization time test plan of the manual transmission. Based on the structure of the lock ring synchronizer and its working principles, the thesis sets the test parameters and analyzes the influencing factors of the synchronization time. According to the testing result, the thesis analyzes the different stages in the synchronizing process of the lock ring synchronizer, and the changes of the testing curves.
The thesis introduces the conventional concepts of the gear shift quality and the methods of evaluation on the gear shift quality, analyzes its deficiencies, and combined with the test data of the manual transmission performance testing system, perfects the evaluation indicators of the gear shift quality, based on the theory of ergonomics. According to the test data, the thesis also calculate the value of the evaluation indicators of the manual transmission, appraises it in an all-around way and evaluates the gear shift quality of the manual transmission referring to the evaluation standards.
引文
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