发动机及变速器测控实验教学系统的研究与开发
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摘要
本课题在原汽车测控实验教学系统的基础上，通过软、硬件的设计与开发，研制了发动机及变速器测控实验教学系统。该系统以90款日产Maxima VG30E电控发动机及RE4F02型自动变速器为基础，在不影响电控发动机及自动变速器各种性能的前提下，对电控系统进行改造，最终设计了一套可进行实验、教学、科研及实际故障检测的平台。
通过系统的信号显示及检测板、信号模拟台、故障设置台及基于虚拟仪器技术的软件平台，可实现电控发动机及自动变速器电控系统各信号的动态显示及检测，主控信号的模拟，常见故障的设置，信号波形及参数的显示、存储、再现及与标准波形的对比，数据流分析等功能，从而也具有故障检测功能。本课题的主要内容为：
1)发动机及变速器台架的设计。使发动机、变速器、变速杆、加速踏板、制动踏板、燃油箱、蓄电池及各种仪表协调有序且可靠地布置在一可移动的台架内，并在熟悉系统电路的基础上对系统进行重新布线。设计后的台架具有布局合理，美观大方，灵活性、可靠性高、可操作性强，实验、教学效果好的优点；同时台架还能脱离系统其它部分单独运行，独立性强；
2)测控台架的设计。设计了可进行电压变换、信号隔离、信号整形、信号放大、限压稳压、电路切换等功能的信号调理电路；通过优化发动机及变速器线路，设计出了信号显示及检测电路，实现了信号动态显示及检测功能；利用单刀双掷开关的切换、电位计的调节，可对4个主控信号进行模拟；设计了故障设置模块电路，利用AT89C51单片机及74LS154、74LS249等芯片扫描故障设置按键的状态，进而对操作终端的继电器进行控制，实现对常见36个故障进行设置；
3)基于虚拟仪器技术的测控软件的设计。根据测试要求选择合适的计算机和数据采集卡，根据软件开发平台的特点选择LabVIEW软件作为系统的开发平台，设计了主控模块、参数设置、虚拟仪表、起动测试、波形测试、变速器测试、数据处理等10个软件模块，实现了系统的登陆、参数设置、虚拟仪表、测试各种工况下发动机及变速器各信号波形或变化趋势、测试波形与标准波形对比、数据流分析、波形打印、波形存储、数据事后处理、系统帮助等功能；
4)系统软、硬件的调试及试验分析。对软硬件各模块进行现场调试，系统运行正常可靠、达到系统设计的要求；分别在起动、怠速、加速工况下进行原机试验、信号模拟试验、故障设置试验，使用Fluke98汽车万用示波器、万用表和软件平台的相关模块对信号的数据及波形进行测试，对比现实仪表与虚拟仪表的实验结果。通过试验结果的分析，表明系统能真实反映发动机及变速器的工作参数及信号波形，充分实现信号的动态显示及检测、信号模拟、故障设置等功能，使用软件平台能准确可靠地进行信号的采集、参数及波形的测试、数据及波形的保存、处理，系统达到了设计的目标。
经实验室试用，结果表明，该系统具有人机界面友好、操作方便、可靠性高的优点，可同时服务于实验、教学、科研及故障诊断，具有较高的实用价值及应用前景。
Based on the previous automotive testing-control experimental and teaching system, this thesis, has introduced the engine-transmission testing-control experimental and teaching system through the design and development of software and hardware. The system is based on the Nissan Maxima VG30E electronic controlled engine and the RE4F02 automatic transmission. It aims to complete rebuilding its electronic control system, at last designed a set of the experimental, teaching, researching and fault detecting bench without affecting all the electronic controlled engine and automatic transmission performances.
Through the signal display and measuring board, signal simulating bench, faults setting bench, and the software platform which is based on the virtual instrumental technology, this system can realize the display and check of the signals from the electronic controlled engine and automatic transmission, the simulation of master signals, the settlement of some usual faults, the display, store, analysis, and reappearance of the waveform and parameter of the signals, the comparison with the standard waveform and the analytical functions of the data stream. And hence, it offers a diagnosing function on the faults. The thesis includes 4 parts, which are as follows:
1) Design of the engine and transmission bench. Carefully place the engine, transmission, gear shift lever, accelerator pedal, brake pedal, fuel tank, battery and other instruments into a movable bench in a sequential manner. Be familiar with the system circuit and rewires it.. The designed bench owns great advantages: suitable layout, beautiful sight, flexibility, good dependability, easy ways to operate, effective in experiment and teaching; moreover, it has good independence for it can run alone when disengaging other parts of the system.
2) Design of testing-control bench. Design a signal process circuit which can transform the voltage, isolate the signals, shape the form of the signals, magnify the transmitted signals, limit and stabilize the voltage, and switch the circuit; by optimizing the circuitry of the engine and the transmission, it designs a circuit of signal display and check, which realizes the dynamic display and check of the signals; making use of the switch of single-pole double throw switch and the regulation of the potentiometer, it can simulate 4 master signals; designing the modular circuit of the settlement of faults and using AT89C51 SCM, 74LS154 and 74LS249 chip to scan the state of the keystroke of the settlement of faults, it can control the relay of terminal operation, so realizes the settlement of 36 usual faults;
3) Design of software which is based on the virtual instrumental technology. Selecting appropriate computer and data acquisition card according to the testing requirement and choosing LabVIEW in reference to the features of the platform of software development, it designs main control module, parameter setting, virtual instruments, start testing, waveform testing, transmission testing, and data processing etc, and realizes the functions of the log-in of the system, the setting of the parameter, virtual instruments, test of the waveforms and the changing trends of the signals from the engine and the transmission in different kinds of working conditions, the comparison between the testing waveform and the standard waveform, the analyses of the data stream, the print of the waveform, the store of the waveform, the process of data after testing and assistance from the system;
4) Debugging of the system and the analysis of the tests. Debug each module of software and hardware of the system on the spot which indicates that it has fulfilled the demand of the designed system. Carry on the test of the normal test, the test of simulating signals, the test of settling the faults in the working condition of start, idle speed and acceleration respectively, using the Fluke98 car oscilloscope, the multimeter and related module of the software platform to test data and the waveforms and compare the results of the real instrument and the virtual instrument. The analysis of the result indicates that the system truly reflects the working parameter and the signal waveforms. It fully realizes the dynamic display and check of the signals, the simulation of the signals, the settlement of the faults. The use of the software platform can help a lot in gathering the signals, testing the parameter and the waveforms, and storing and processing of data and the waveforms. Thus, the system fulfills its designed objectives.
The result of the trial in the laboratory proves that the system owns great advantages: friendly man-machine interface, easy ways to operate and good dependability, etc. Being able to be applied on different occasions, like experiment, teaching, researching and diagnosing, it turns out to have wide practical value and prospects.
通过系统的信号显示及检测板、信号模拟台、故障设置台及基于虚拟仪器技术的软件平台，可实现电控发动机及自动变速器电控系统各信号的动态显示及检测，主控信号的模拟，常见故障的设置，信号波形及参数的显示、存储、再现及与标准波形的对比，数据流分析等功能，从而也具有故障检测功能。本课题的主要内容为：
1)发动机及变速器台架的设计。使发动机、变速器、变速杆、加速踏板、制动踏板、燃油箱、蓄电池及各种仪表协调有序且可靠地布置在一可移动的台架内，并在熟悉系统电路的基础上对系统进行重新布线。设计后的台架具有布局合理，美观大方，灵活性、可靠性高、可操作性强，实验、教学效果好的优点；同时台架还能脱离系统其它部分单独运行，独立性强；
2)测控台架的设计。设计了可进行电压变换、信号隔离、信号整形、信号放大、限压稳压、电路切换等功能的信号调理电路；通过优化发动机及变速器线路，设计出了信号显示及检测电路，实现了信号动态显示及检测功能；利用单刀双掷开关的切换、电位计的调节，可对4个主控信号进行模拟；设计了故障设置模块电路，利用AT89C51单片机及74LS154、74LS249等芯片扫描故障设置按键的状态，进而对操作终端的继电器进行控制，实现对常见36个故障进行设置；
3)基于虚拟仪器技术的测控软件的设计。根据测试要求选择合适的计算机和数据采集卡，根据软件开发平台的特点选择LabVIEW软件作为系统的开发平台，设计了主控模块、参数设置、虚拟仪表、起动测试、波形测试、变速器测试、数据处理等10个软件模块，实现了系统的登陆、参数设置、虚拟仪表、测试各种工况下发动机及变速器各信号波形或变化趋势、测试波形与标准波形对比、数据流分析、波形打印、波形存储、数据事后处理、系统帮助等功能；
4)系统软、硬件的调试及试验分析。对软硬件各模块进行现场调试，系统运行正常可靠、达到系统设计的要求；分别在起动、怠速、加速工况下进行原机试验、信号模拟试验、故障设置试验，使用Fluke98汽车万用示波器、万用表和软件平台的相关模块对信号的数据及波形进行测试，对比现实仪表与虚拟仪表的实验结果。通过试验结果的分析，表明系统能真实反映发动机及变速器的工作参数及信号波形，充分实现信号的动态显示及检测、信号模拟、故障设置等功能，使用软件平台能准确可靠地进行信号的采集、参数及波形的测试、数据及波形的保存、处理，系统达到了设计的目标。
经实验室试用，结果表明，该系统具有人机界面友好、操作方便、可靠性高的优点，可同时服务于实验、教学、科研及故障诊断，具有较高的实用价值及应用前景。
Based on the previous automotive testing-control experimental and teaching system, this thesis, has introduced the engine-transmission testing-control experimental and teaching system through the design and development of software and hardware. The system is based on the Nissan Maxima VG30E electronic controlled engine and the RE4F02 automatic transmission. It aims to complete rebuilding its electronic control system, at last designed a set of the experimental, teaching, researching and fault detecting bench without affecting all the electronic controlled engine and automatic transmission performances.
Through the signal display and measuring board, signal simulating bench, faults setting bench, and the software platform which is based on the virtual instrumental technology, this system can realize the display and check of the signals from the electronic controlled engine and automatic transmission, the simulation of master signals, the settlement of some usual faults, the display, store, analysis, and reappearance of the waveform and parameter of the signals, the comparison with the standard waveform and the analytical functions of the data stream. And hence, it offers a diagnosing function on the faults. The thesis includes 4 parts, which are as follows:
1) Design of the engine and transmission bench. Carefully place the engine, transmission, gear shift lever, accelerator pedal, brake pedal, fuel tank, battery and other instruments into a movable bench in a sequential manner. Be familiar with the system circuit and rewires it.. The designed bench owns great advantages: suitable layout, beautiful sight, flexibility, good dependability, easy ways to operate, effective in experiment and teaching; moreover, it has good independence for it can run alone when disengaging other parts of the system.
2) Design of testing-control bench. Design a signal process circuit which can transform the voltage, isolate the signals, shape the form of the signals, magnify the transmitted signals, limit and stabilize the voltage, and switch the circuit; by optimizing the circuitry of the engine and the transmission, it designs a circuit of signal display and check, which realizes the dynamic display and check of the signals; making use of the switch of single-pole double throw switch and the regulation of the potentiometer, it can simulate 4 master signals; designing the modular circuit of the settlement of faults and using AT89C51 SCM, 74LS154 and 74LS249 chip to scan the state of the keystroke of the settlement of faults, it can control the relay of terminal operation, so realizes the settlement of 36 usual faults;
3) Design of software which is based on the virtual instrumental technology. Selecting appropriate computer and data acquisition card according to the testing requirement and choosing LabVIEW in reference to the features of the platform of software development, it designs main control module, parameter setting, virtual instruments, start testing, waveform testing, transmission testing, and data processing etc, and realizes the functions of the log-in of the system, the setting of the parameter, virtual instruments, test of the waveforms and the changing trends of the signals from the engine and the transmission in different kinds of working conditions, the comparison between the testing waveform and the standard waveform, the analyses of the data stream, the print of the waveform, the store of the waveform, the process of data after testing and assistance from the system;
4) Debugging of the system and the analysis of the tests. Debug each module of software and hardware of the system on the spot which indicates that it has fulfilled the demand of the designed system. Carry on the test of the normal test, the test of simulating signals, the test of settling the faults in the working condition of start, idle speed and acceleration respectively, using the Fluke98 car oscilloscope, the multimeter and related module of the software platform to test data and the waveforms and compare the results of the real instrument and the virtual instrument. The analysis of the result indicates that the system truly reflects the working parameter and the signal waveforms. It fully realizes the dynamic display and check of the signals, the simulation of the signals, the settlement of the faults. The use of the software platform can help a lot in gathering the signals, testing the parameter and the waveforms, and storing and processing of data and the waveforms. Thus, the system fulfills its designed objectives.
The result of the trial in the laboratory proves that the system owns great advantages: friendly man-machine interface, easy ways to operate and good dependability, etc. Being able to be applied on different occasions, like experiment, teaching, researching and diagnosing, it turns out to have wide practical value and prospects.
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