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CN115727124A - Heavy full-time full-drive transfer case electric control system - Google Patents

Heavy full-time full-drive transfer case electric control system Download PDF

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CN115727124A
CN115727124A CN202111011116.1A CN202111011116A CN115727124A CN 115727124 A CN115727124 A CN 115727124A CN 202111011116 A CN202111011116 A CN 202111011116A CN 115727124 A CN115727124 A CN 115727124A
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full
gear
transfer case
switch
drive
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周元豪
高锦
陈利东
杜浪东
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Shaanxi Heavy Duty Automobile Co Ltd
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Shaanxi Heavy Duty Automobile Co Ltd
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Abstract

本发明提供一种重型全时全驱分动器电控系统,系统控制器具备开关控制和外部指令控制两种方式,根据开关状态或外部指令信号,并判断输入与输出轴转速大小,控制对应电磁阀动作,实现相应功能,满足分动器基础功能;控制取力器时,可实现取力器在不同工况运行时的多模式切换功能;电控系统能够对分动器齿轮油进行保护,使其处于合适的工作温度。控制器通过油温大小控制电动油泵与油冷器进行热交换,确保分动器不会因为油温过高或过低导致损坏;主控制器根据输出轴转速值和车辆传动系数计算实际车速,并与输入轴转速和挡位状态进行检验,确保车速的有效性。本发明在满足基础功能的同时可实时反馈运行状态,具备安全冗余措施及故障诊断机制。

Figure 202111011116

The invention provides an electronic control system for a heavy-duty full-time full-drive transfer case. The system controller has two modes of switch control and external command control. The solenoid valve operates to realize the corresponding functions and meet the basic functions of the transfer case; when controlling the power take-off, it can realize the multi-mode switching function of the power take-off under different working conditions; the electronic control system can protect the transfer case gear oil , so that it is at a suitable working temperature. The controller controls the heat exchange between the electric oil pump and the oil cooler through the oil temperature to ensure that the transfer box will not be damaged due to too high or too low oil temperature; the main controller calculates the actual vehicle speed according to the output shaft speed value and the vehicle transmission coefficient, And check with the input shaft speed and gear state to ensure the validity of the vehicle speed. The present invention can feed back the operating state in real time while satisfying basic functions, and has safety redundancy measures and a fault diagnosis mechanism.

Figure 202111011116

Description

一种重型全时全驱分动器电控系统An electronic control system of a heavy-duty full-time full-drive transfer

技术领域technical field

本发明属于全时全驱分动器技术领域,尤其涉及一种重型全时全驱分动器电控系统。The invention belongs to the technical field of full-time full-drive transfers, in particular to an electric control system for heavy-duty full-time full-drive transfers.

背景技术Background technique

分动器是由齿轮组成的动力传动装置,能够将变速器输出的动力按一定的扭矩比例分配到各驱动桥,并进一步实现增速或增扭,常用于多轴驱动的车辆上。分动器输入轴直接通过万向传动装置与变速器输出轴相连,输出轴分前后两个方向,分别经万向传动装置与各驱动桥连接。The transfer case is a power transmission device composed of gears, which can distribute the power output by the transmission to each drive axle according to a certain torque ratio, and further realize speed increase or torque increase. It is often used in vehicles driven by multiple shafts. The input shaft of the transfer box is directly connected with the output shaft of the transmission through the universal transmission device, and the output shaft is divided into two directions, front and rear, and connected with each drive axle through the universal transmission device respectively.

对于目前广泛应用于国内重型车辆的全时全驱分动器而言,其额定输入扭矩能够达到10000Nm,额定转速超过2000r/min,基本功能包括可实现高、空、低三种挡位,高、低挡之间切换可以实现增速或增扭,空挡时不传递动力;其次是具有差速锁,能够同步前后输出轴转速,满足全轮驱动的功能;再者拥有至少一个取力接口,通过万向传动装置连接,以满足上装系统的取力需求。上述各功能均采用气控的方式,通过气缸推动活塞,使拔叉或啮合套动作,进而实现相对应功能。对于这种纯齿轮组合的结构,为防止齿轮啮合时打齿损坏分动器,在操作时,需确保车辆处于静止,变速器处于空挡状态。For the full-time all-drive transfer box widely used in domestic heavy-duty vehicles, its rated input torque can reach 10000Nm, and its rated speed exceeds 2000r/min. Switching between low gears and low gears can achieve speed increase or torque increase, and no power is transmitted in neutral gear; secondly, it has a differential lock, which can synchronize the speed of the front and rear output shafts to meet the function of all-wheel drive; moreover, it has at least one power take-off interface, It is connected through a universal transmission to meet the power take-off requirements of the bodywork system. The above-mentioned functions are all controlled by air, and the piston is pushed by the cylinder to make the fork or the engaging sleeve move, and then realize the corresponding function. For this pure gear combination structure, in order to prevent the teeth from being damaged by the gears when the gears mesh, it is necessary to ensure that the vehicle is stationary and the transmission is in neutral during operation.

对于车辆操作人员而言,为了更方便、更安全的控制分动器,目前常采用在车辆仪表台上安装分动器挡位开关、全驱开关及取力器开关,通过硬线与继电器配合,并附加一定的保护措施,控制对应的电磁阀动作。电磁阀出气口接分动器本体对应的气口,控制气口的通断气进而实现各功能。各功能的工作状态则是通过点动开关的通断信号反馈至仪表,提示驾驶员。除此之外,通过安装在分动器后输出轴尾部的车速传感器输出方波信号,连接至仪表做完处理后,才能正常显示车速。For vehicle operators, in order to control the transfer case more conveniently and safely, it is often used to install the transfer case gear switch, full drive switch and power take-off switch on the vehicle instrument panel, and cooperate with the relay through hard wires , and add certain protective measures to control the corresponding solenoid valve action. The air outlet of the solenoid valve is connected to the corresponding air port of the transfer case body, and the air opening and closing of the air port are controlled to realize various functions. The working state of each function is fed back to the instrument through the on-off signal of the jog switch to prompt the driver. In addition, the vehicle speed sensor installed at the rear of the output shaft of the transfer box outputs a square wave signal, and the vehicle speed can only be displayed normally after it is connected to the instrument for processing.

分动器通过内部齿轮旋转带动齿轮油进行润滑,以保证齿轮正常运转,若油位不合适,过多或过少则会导致润滑不畅,分动器油温变高,同时又不能及时反馈给驾驶员,导致分动器处于过热状态,影响分动器使用寿命,更严重者会烧毁分动器。The transfer case drives the gear oil to lubricate through the rotation of the internal gears to ensure the normal operation of the gears. If the oil level is not suitable, too much or too little will lead to poor lubrication, high temperature of the transfer case oil, and no timely feedback For the driver, the transfer case will be overheated, which will affect the service life of the transfer case, and in more serious cases, the transfer case will be burned.

分动器在低温环境下运行时,由于齿轮油粘滞,在进行功能切换,特别是挂取力器时,经常出现取力器齿啮合不牢靠,当变速器挂挡后,出现取力器齿轮打齿现象,直接损坏分动器。When the transfer case is running in a low temperature environment, due to the viscosity of the gear oil, when the function is switched, especially when the power take-off is engaged, the teeth of the power take-off often do not mesh reliably. When the transmission is in gear, the gear of the power take-off appears Tooth hitting phenomenon will directly damage the transfer case.

采用传统的控制方式,系统结构复杂,装配难度大,不利于维修。对于操作人员而言,需要注意事项过多,无误操作保护机制,由于人员的疏忽,会导致分动器意外损坏。每个功能的控制及反馈信号只能通过硬线传递,控制方式及线束系统过于复杂,电控化程度低,不利于故障检测。对于分动器出现油位低、油温高的情况,不能及时告知驾驶员,会造成故障越来越严重,直至损坏分动器,导致车辆无法正常运行。With the traditional control method, the system structure is complicated, the assembly is difficult, and it is not conducive to maintenance. For the operator, there are too many matters to be paid attention to, and the protection mechanism is not misoperated. Due to the negligence of the personnel, the transfer case will be accidentally damaged. The control and feedback signals of each function can only be transmitted through hard wires. The control method and wiring harness system are too complicated, and the degree of electronic control is low, which is not conducive to fault detection. If the oil level is low and the oil temperature is high in the transfer case, if the driver cannot be notified in time, the fault will become more and more serious, until the transfer case is damaged, resulting in the failure of the vehicle to operate normally.

因此设计一种既能实现分动器常规功能又能实时监控分动器运行状态,并具有安全冗余措施及故障诊断机制的电控系统是解决上述问题的最有效途径。Therefore, it is the most effective way to solve the above problems to design an electronic control system that can realize the conventional functions of the transfer case and monitor the operation status of the transfer case in real time, and has safety redundancy measures and fault diagnosis mechanism.

发明内容Contents of the invention

为解决上述背景技术中存在的问题,本发明提供了一种重型全时全驱分动器电控系统,既满足基础功能的控制需求又能实时反馈分动器运行状态,且具备安全冗余措施和故障诊断机制。In order to solve the problems existing in the above-mentioned background technology, the present invention provides a heavy-duty full-time full-drive transfer case electronic control system, which not only meets the control requirements of basic functions but also can provide real-time feedback on the operation status of the transfer case, and has safety redundancy measures and fault diagnosis mechanisms.

具体的,本发明提供一种重型全时全驱分动器电控系统,包括分动器总成、电动油泵、集成式油冷器、集成式电磁阀组、分动器挡位开关、全驱开关、取力器开关及系统控制器;Specifically, the present invention provides a heavy-duty full-time full-drive transfer case electric control system, including a transfer case assembly, an electric oil pump, an integrated oil cooler, an integrated solenoid valve group, a transfer case gear switch, a full Drive switch, power take-off switch and system controller;

所述分动器总成、所述电动油泵、所述集成式电磁阀组、所述分动器挡位开关、所述全驱开关及所述取力器开关均与所述系统控制器电连接;所述集成式电磁阀组与所述分动器总成之间气路连接,所述集成式油冷器与所述分动器总成之间油路连接;The transfer case assembly, the electric oil pump, the integrated solenoid valve group, the transfer case gear switch, the all-wheel drive switch and the power take-off switch are all electrically connected to the system controller. Connection; the air circuit connection between the integrated solenoid valve group and the transfer case assembly, and the oil circuit connection between the integrated oil cooler and the transfer case assembly;

所述分动器总成包括输入轴转速传感器、高挡信号开关、低挡信号开关、全驱信号开关、油温传感器、输出轴转速传感器、油位传感器和取力器信号开关;The transfer case assembly includes an input shaft speed sensor, a high gear signal switch, a low gear signal switch, an all-drive signal switch, an oil temperature sensor, an output shaft speed sensor, an oil level sensor and a power take-off signal switch;

所述集成式电磁阀组包括高挡电磁阀、空挡电磁阀、低挡电磁阀、取力器电磁阀和全驱电磁阀;The integrated solenoid valve group includes a high gear solenoid valve, a neutral gear solenoid valve, a low gear solenoid valve, a power take-off solenoid valve and a full drive solenoid valve;

当进行挡位切换、全驱控制和取力器控制时,所述系统控制器根据控制需求和所述输入轴转速传感器与所述输出轴转速传感器采集的转速大小,判断是否处于安全转速范围内;若是,则控制所述集成式电磁阀组对应的电磁阀工作;所述系统控制器同时采集所述高挡信号开关、所述低挡信号开关、所述全驱信号开关、所述取力器信号开关状态信号进行处理后,以CAN信号的方式发送至数字仪表;When performing gear switching, full drive control and power take-off control, the system controller judges whether it is within a safe speed range according to the control requirements and the speed collected by the input shaft speed sensor and the output shaft speed sensor ; If so, control the solenoid valve corresponding to the integrated solenoid valve group to work; the system controller simultaneously collects the high gear signal switch, the low gear signal switch, the full drive signal switch, the power take After processing the switch state signal of the instrument signal, it is sent to the digital instrument in the form of a CAN signal;

当进行分动器齿轮油保护控制时,所述系统控制器采集所述油温传感器电流值做换算处理后,输出油温大小,并根据所述油温大小控制所述电动油泵转速,使齿轮油在所述集成式油冷器中充分循环,与冷却液进行热交换,形成闭环控制;When performing transfer gear oil protection control, the system controller collects the current value of the oil temperature sensor for conversion processing, outputs the oil temperature, and controls the speed of the electric oil pump according to the oil temperature, so that the gear The oil fully circulates in the integrated oil cooler and exchanges heat with the cooling liquid to form a closed-loop control;

当进行车速信号采集处理时,所述系统控制器采集所述输出轴转速传感器频率信号,根据车辆发送的传动系数,换算实际车速;所述系统控制器根据所述输入轴转速传感器频率信号大小与分动器当前挡位状态,实时校验车速大小,将有效的车速值以CAN报文方式发送至数字仪表。When performing vehicle speed signal collection and processing, the system controller collects the frequency signal of the output shaft speed sensor, and converts the actual vehicle speed according to the transmission coefficient sent by the vehicle; The current gear status of the transfer box, the real-time verification of the vehicle speed, and the effective vehicle speed value are sent to the digital instrument in the form of CAN messages.

作为本发明的进一步说明,所述集成式电磁阀组还包括一路输入气源接口,所述高挡电磁阀、所述空挡电磁阀、所述低挡电磁阀、所述取力器电磁阀和所述全驱电磁阀均为电控气电磁阀;所述电控气电磁阀的输出接口分别接所述分动器总成的相应各功能(高挡、空挡、低挡、全驱、取力器)的控制气口;且所述高挡电磁阀为断电常通气电磁阀,所述空挡电磁阀、所述低挡电磁阀、所述取力器电磁阀和所述全驱电磁阀均为断电常断气电磁阀。As a further description of the present invention, the integrated solenoid valve group also includes an input air source interface, the high gear solenoid valve, the neutral gear solenoid valve, the low gear solenoid valve, the power take-off solenoid valve and The all-drive solenoid valves are all electric-controlled air solenoid valves; the output interfaces of the electric-controlled air solenoid valves are respectively connected to the corresponding functions of the transfer case assembly (high gear, neutral gear, low gear, full drive, take-off, etc.) and the control air port of the power device); and the high gear solenoid valve is a power-off normally ventilated solenoid valve, and the neutral gear solenoid valve, the low gear solenoid valve, the power take-off solenoid valve and the full drive solenoid valve are all It is a gas solenoid valve that normally shuts off when the power is off.

作为本发明的进一步说明,所述高挡信号开关、所述低挡信号开关、所述全驱信号开关和所述取力器信号开关均为接触式点动开关;所述分动器挡位开关具有高、空、低三个挡位,默认为高挡状态;所述全驱开关和所述取力器开关具有关闭和打开两个挡位,默认为关闭状态。As a further description of the present invention, the high gear signal switch, the low gear signal switch, the full drive signal switch and the power take-off signal switch are all contact type jog switches; The switch has three gears of high, empty and low, and is in the high gear state by default; the full drive switch and the power take-off switch have two gears of off and on, and is in the off state by default.

作为本发明的进一步说明,所述输入轴转速传感器和所述输出轴转速传感器均为高精度电磁式传感器,所述系统控制器采集所述高精度电磁式传感器频率值后转换为对应转速大小,以CAN信号方式发送至数字仪表。As a further description of the present invention, the input shaft speed sensor and the output shaft speed sensor are both high-precision electromagnetic sensors, and the system controller collects the frequency value of the high-precision electromagnetic sensor and converts it into a corresponding speed value, Send to the digital instrument in the form of CAN signal.

作为本发明的进一步说明,所述油温传感器和所述油位传感器均为电流型传感器,所述系统控制器采集所述电流型传感器电流值后转换为对应液位高度和温度大小,当油液高度和油温大小超出设定的安全阈值时,则将故障状态以CAN信号方式发送至数字仪表。As a further description of the present invention, the oil temperature sensor and the oil level sensor are current sensors, and the system controller collects the current value of the current sensor and converts it into the corresponding liquid level height and temperature. When the liquid height and oil temperature exceed the set safety threshold, the fault status will be sent to the digital instrument in the form of CAN signal.

作为本发明的进一步说明,所述集成式油冷器包括齿轮油腔、冷却液腔和散热片,通过循环散热,实现热交换;通过所述散热片实现降温。As a further description of the present invention, the integrated oil cooler includes a gear oil chamber, a cooling liquid chamber and cooling fins, and realizes heat exchange through circulating heat dissipation; cooling is realized through the cooling fins.

作为本发明的进一步说明,所述电动油泵为PWM电流控制方式,根据控制电流大小改变油泵转速,进而控制齿轮油流速。As a further description of the present invention, the electric oil pump adopts a PWM current control method, and the rotation speed of the oil pump is changed according to the magnitude of the control current, thereby controlling the flow rate of the gear oil.

作为本发明的进一步说明,所述系统控制器预留取力器运行模式外部选择接口,且所述外部选择接口与所述挡位开关、所述全驱开关及所述取力器开关的控制逻辑一致,所述系统控制器采集所述挡位开关、所述全驱开关及所述取力器开关状态,并通过CAN总线发送控制条件。As a further description of the present invention, the system controller reserves an external selection interface for the operation mode of the power take-off, and the external selection interface is connected with the control of the gear switch, the full drive switch and the power take-off switch. The logic is consistent, the system controller collects the status of the gear switch, the full drive switch and the power take-off switch, and sends the control conditions through the CAN bus.

作为本发明的进一步说明,所述系统控制器为电子控制器,具有数字量输入、频率值输入及电流模拟输入接口;具有数字驱动接口和PWM驱动接口;具备两路CAN通讯接口,支持CAN总线刷写和标定功能,CAN报文满足SAEJ1939标准。As a further description of the present invention, the system controller is an electronic controller with digital input, frequency value input and current analog input interface; with digital drive interface and PWM drive interface; with two CAN communication interfaces, supporting CAN bus Flashing and calibration functions, CAN messages meet the SAEJ1939 standard.

作为本发明的进一步说明,当进行系统故障诊断时,所述系统控制器实时监控、判断各传感器与执行机构是否有开短路故障,输入信号值是否处于合理范围,CAN信号是否通讯错误及总线节点是否掉线等故障;当发生故障时,将故障代码以CAN报文的方式发送至数字仪表,故障诊断满足SAEJ1939标准中DM1报文规定。As a further illustration of the present invention, when performing system fault diagnosis, the system controller monitors in real time and judges whether each sensor and actuator has an open-short fault, whether the input signal value is within a reasonable range, whether the CAN signal has a communication error and the bus node Whether there are faults such as disconnection; when a fault occurs, the fault code is sent to the digital instrument in the form of a CAN message, and the fault diagnosis meets the requirements of the DM1 message in the SAEJ1939 standard.

与现有技术相比,本发明具有以下有益的技术效果:Compared with the prior art, the present invention has the following beneficial technical effects:

与原有分动器相比,加装电控系统后,满足基础功能的同时可实时反馈运行状态,具备安全冗余措施及故障诊断机制,系统结构简单、操作便捷,方便故障维修。操作与使用过程中,能够有效防止误操作,提高了分动器使用效率,减小了分动器损坏风险。主控制器能够与车辆其它电控系统通过CAN总线互通互联,提高车辆整体电控化程度。Compared with the original transfer case, after installing the electronic control system, it can provide real-time feedback on the operating status while satisfying the basic functions. It has safety redundancy measures and a fault diagnosis mechanism. The system structure is simple, easy to operate, and convenient for fault maintenance. In the process of operation and use, it can effectively prevent misoperation, improve the use efficiency of the transfer case, and reduce the risk of damage to the transfer case. The main controller can communicate with other electronic control systems of the vehicle through the CAN bus to improve the overall electronic control of the vehicle.

附图说明Description of drawings

图1为本发明提供的重型全时全驱分动器电控系统原理图;Fig. 1 is the schematic diagram of the electric control system of the heavy-duty full-time full-drive transfer box provided by the present invention;

图2为本发明提供的重型全时全驱分动器电控系统中集成式电磁阀组结构图;Fig. 2 is the structural diagram of the integrated electromagnetic valve group in the electronic control system of the heavy-duty full-time full-drive transfer provided by the present invention;

图3为本发明提供的重型全时全驱分动器电控系统的框图。Fig. 3 is a block diagram of the electronic control system of the heavy-duty full-time full-drive transfer provided by the present invention.

附图标记说明Explanation of reference signs

分动器总成1、输入轴转速传感器11、高挡信号开关12、低挡信号开关13、全驱信号开关14、油温传感器15、输出轴转速传感器16、油位传感器17、取力器信号开关18、电动油泵2、集成式油冷器3、集成式电磁阀组4、高挡电磁阀41、空挡电磁阀42、低挡电磁阀43、取力器电磁阀44、全驱电磁阀45、分动器挡位开关5、全驱开关6、取力器开关7、系统控制器8。Transfer case assembly 1, input shaft speed sensor 11, high gear signal switch 12, low gear signal switch 13, full drive signal switch 14, oil temperature sensor 15, output shaft speed sensor 16, oil level sensor 17, power take-off Signal switch 18, electric oil pump 2, integrated oil cooler 3, integrated solenoid valve group 4, high gear solenoid valve 41, neutral gear solenoid valve 42, low gear solenoid valve 43, PTO solenoid valve 44, full drive solenoid valve 45. Transfer gear switch 5, full drive switch 6, power take-off switch 7, system controller 8.

具体实施方式Detailed ways

为使本发明实施例的目的、技术方案和优点更加清楚,下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例是本发明一部分实施例,而不是全部的实施例。通常在此处附图中描述和示出的本发明实施例的组件可以以各种不同的配置来布置和设计。In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments It is a part of embodiments of the present invention, but not all embodiments. The components of the embodiments of the invention generally described and illustrated in the figures herein may be arranged and designed in a variety of different configurations.

因此,以下对在附图中提供的本发明的实施例的详细描述并非旨在限制要求保护的本发明的范围,而是仅仅表示本发明的选定实施例。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。Accordingly, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the invention. Based on the embodiments of the present invention, all other embodiments obtained by persons of ordinary skill in the art without creative efforts fall within the protection scope of the present invention.

应注意到:相似的标号和字母在下面的附图中表示类似项,因此,一旦某一项在一个附图中被定义,则在随后的附图中不需要对其进行进一步定义和解释。It should be noted that like numerals and letters denote similar items in the following figures, therefore, once an item is defined in one figure, it does not require further definition and explanation in subsequent figures.

在本发明的描述中,还需要说明的是,除非另有明确的规定和限定,术语“设置”、“安装”、“相连”、“连接”应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或一体地连接;可以是机械连接,也可以是电连接;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通。对于本领域的普通技术人员而言,可以具体情况理解上述术语在本发明中的具体含义。In the description of the present invention, it should also be noted that, unless otherwise clearly specified and limited, the terms "installation", "installation", "connection" and "connection" should be understood in a broad sense, for example, it may be a fixed connection, It can also be a detachable connection or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediary, and it can be the internal communication of two components. Those of ordinary skill in the art can understand the specific meanings of the above terms in the present invention in specific situations.

下面将结合具体实施例对本发明的技术方案加以解释。The technical solutions of the present invention will be explained below in conjunction with specific embodiments.

如图1-3所示,提供一种重型全时全驱分动器电控系统,包括分动器总成1、电动油泵2、集成式油冷器3、集成式电磁阀组4、分动器挡位开关5、全驱开关6、取力器开关7及系统控制器8;As shown in Figure 1-3, an electronic control system for a heavy-duty full-time full-drive transfer case is provided, including a transfer case assembly 1, an electric oil pump 2, an integrated oil cooler 3, an integrated solenoid valve group 4, a Actuator gear switch 5, full drive switch 6, power take-off switch 7 and system controller 8;

所述分动器总成1、所述电动油泵2、所述集成式电磁阀组4、所述分动器挡位开关5、所述全驱开关6及所述取力器开关7均与所述系统控制器8电连接;所述集成式电磁阀组4与所述分动器总成1之间气路连接,所述集成式油冷器3与所述分动器总成1之间油路连接;The transfer case assembly 1, the electric oil pump 2, the integrated solenoid valve group 4, the transfer case gear switch 5, the full drive switch 6 and the power take-off switch 7 are all connected with The system controller 8 is electrically connected; the integrated solenoid valve group 4 is connected to the transfer case assembly 1 through an air circuit, and the integrated oil cooler 3 is connected to the transfer case assembly 1 Inter-oil connection;

所述分动器总成1包括输入轴转速传感器11、高挡信号开关12、低挡信号开关13、全驱信号开关14、油温传感器15、输出轴转速传感器16、油位传感器17和取力器信号开关18;The transfer case assembly 1 includes an input shaft speed sensor 11, a high gear signal switch 12, a low gear signal switch 13, an all-drive signal switch 14, an oil temperature sensor 15, an output shaft speed sensor 16, an oil level sensor 17 and a Force signal switch 18;

所述集成式电磁阀组4包括高挡电磁阀41、空挡电磁阀42、低挡电磁阀43、取力器电磁阀44和全驱电磁阀45;The integrated solenoid valve group 4 includes a high gear solenoid valve 41, a neutral gear solenoid valve 42, a low gear solenoid valve 43, a power take-off solenoid valve 44 and a full drive solenoid valve 45;

分动器总成1为传统重型大功率分动器,采用齿轮油对齿轮进行润滑,可实现高、空、低三种挡位,高、低挡之间切换可以实现增速或增扭,空挡时不传递动力;具有差速锁,能够同步前后输出轴转速,满足全轮驱动的功能;拥有至少一个取力接口,通过万向传动装置连接,满足上装系统的取力需求。各功能均采用电控气的方式,通过气缸推动活塞,使拔叉或啮合套动作,进而实现相对应功能。The transfer case assembly 1 is a traditional heavy-duty high-power transfer case, which uses gear oil to lubricate the gears, which can realize three gears: high, empty and low. Switching between high and low gears can realize speed increase or torque increase. No power is transmitted in neutral; it has a differential lock, which can synchronize the speed of the front and rear output shafts to meet the function of all-wheel drive; it has at least one power take-off interface, which is connected through a universal transmission to meet the power take-off requirements of the bodywork system. Each function adopts the way of electronically controlled gas, and the piston is pushed by the cylinder to make the fork or the engaging sleeve move, and then realize the corresponding function.

进一步的,所述系统控制器8为电子控制器,具有数字量输入、频率值输入及电流模拟输入接口;具有数字驱动接口和PWM驱动接口;具备两路CAN通讯接口,支持CAN总线刷写和标定功能,CAN报文满足SAEJ1939标准。Further, the system controller 8 is an electronic controller, which has digital input, frequency value input and current analog input interfaces; has a digital drive interface and a PWM drive interface; has two CAN communication interfaces, supports CAN bus brushing and Calibration function, CAN message meets SAEJ1939 standard.

进一步的,所述集成式电磁阀组4还包括一路输入气源接口,所述高挡电磁阀41、所述空挡电磁阀42、所述低挡电磁阀43、所述取力器电磁阀44和所述全驱电磁阀45均为电控气电磁阀;所述电控气电磁阀的输出接口分别接所述分动器总成1的相应各功能(高挡、空挡、低挡、全驱、取力器)的控制气口;由于分动器长时间工作在高挡状态,为避免高挡电磁阀长时间通电过热,则所述高挡电磁阀41为断电常通气电磁阀,所述空挡电磁阀42、所述低挡电磁阀43、所述取力器电磁阀44和所述全驱电磁阀45均为断电常断气电磁阀。Further, the integrated solenoid valve group 4 also includes an input air source interface, the high gear solenoid valve 41, the neutral gear solenoid valve 42, the low gear solenoid valve 43, the power take-off solenoid valve 44 and the full-drive electromagnetic valve 45 are electrically controlled air electromagnetic valves; the output interfaces of the electrically controlled air electromagnetic valves are respectively connected to the corresponding functions of the transfer case assembly 1 (high gear, neutral gear, low gear, full gear, etc.) drive, power take-off) control air port; because the transfer case works in the high gear state for a long time, in order to avoid the high gear solenoid valve being energized and overheated for a long time, the high gear solenoid valve 41 is a normally ventilated solenoid valve when the power is off, so The neutral solenoid valve 42, the low gear solenoid valve 43, the power take-off solenoid valve 44 and the full drive solenoid valve 45 are all power-off and air-off solenoid valves.

进一步的,所述高挡信号开关12、所述低挡信号开关13、所述全驱信号开关14和所述取力器信号开关18均为接触式点动开关,功能有效时,两个触点闭合;所述分动器挡位开关5具有高、空、低三个挡位,默认为高挡状态;所述全驱开关6和所述取力器开关7具有关闭和打开两个挡位,默认为关闭状态。Further, the high gear signal switch 12, the low gear signal switch 13, the all-drive signal switch 14 and the power take-off signal switch 18 are all contact type jog switches. The point is closed; the transfer gear switch 5 has three gears: high, empty and low, and is in the high gear state by default; the full drive switch 6 and the power take-off switch 7 have two gears: closing and opening bit, the default is off.

进一步的,所述输入轴转速传感器11和所述输出轴转速传感器16均为高精度电磁式传感器,所述系统控制器8采集所述高精度电磁式传感器频率值后转换为对应转速大小,以CAN信号方式发送至数字仪表。Further, the input shaft speed sensor 11 and the output shaft speed sensor 16 are high-precision electromagnetic sensors, and the system controller 8 collects the frequency value of the high-precision electromagnetic sensor and converts it into a corresponding speed value, so as to The CAN signal is sent to the digital instrument.

进一步的,所述油温传感器15和所述油位传感器17均为电流型传感器,所述系统控制器8采集所述电流型传感器电流值后转换为对应液位高度和温度大小,当油液高度和油温大小超出设定的安全阈值时,则将故障状态以CAN信号方式发送至数字仪表。Further, the oil temperature sensor 15 and the oil level sensor 17 are current-type sensors, and the system controller 8 collects the current value of the current-type sensor and converts it into the corresponding liquid level height and temperature. When the altitude and oil temperature exceed the set safety threshold, the fault status will be sent to the digital instrument in the form of CAN signal.

进一步的,所述集成式油冷器3包括齿轮油腔、冷却液腔和散热片,通过循环散热,实现热交换;通过所述散热片实现降温。Further, the integrated oil cooler 3 includes a gear oil chamber, a cooling liquid chamber and cooling fins, and heat exchange is realized through circulation of heat dissipation; cooling is achieved through the cooling fins.

进一步的,所述电动油泵2为PWM电流控制方式,根据控制电流大小改变油泵转速,进而控制齿轮油流速。Further, the electric oil pump 2 adopts a PWM current control mode, and the oil pump speed is changed according to the magnitude of the control current, thereby controlling the gear oil flow rate.

分动器电控系统主要功能实现方式:Main functions of transfer case electronic control system:

分动器基础功能:当进行挡位切换、全驱控制和取力器控制时,所述系统控制器8根据控制需求和所述输入轴转速传感器11与所述输出轴转速传感器16采集的转速大小,判断是否处于安全转速范围内;若是,则控制所述集成式电磁阀组4对应的电磁阀工作;所述系统控制器8同时采集所述高挡信号开关12、所述低挡信号开关13、所述全驱信号开关14、所述取力器信号开关18状态信号进行处理后,以CAN信号的方式发送至数字仪表。Basic functions of the transfer case: when performing gear shifting, all-wheel drive control and power take-off control, the system controller 8 according to the control requirements and the rotational speed collected by the input shaft rotational speed sensor 11 and the output shaft rotational speed sensor 16 size, to determine whether it is within the safe speed range; if so, control the operation of the electromagnetic valve corresponding to the integrated electromagnetic valve group 4; the system controller 8 simultaneously collects the high gear signal switch 12, the low gear signal switch 13. After the state signals of the all-wheel drive signal switch 14 and the power take-off signal switch 18 are processed, they are sent to digital instruments in the form of CAN signals.

取力器多状态控制功能:由于车辆上装使用环境不同,经常出现多种运行工况,如停车取力、行车取力或定转速控制等,系统设计时,所述系统控制器8预留取力器运行模式外部选择接口,且所述外部选择接口与所述挡位开关5、所述全驱开关6及所述取力器开关7的控制逻辑一致,所述系统控制器8采集所述挡位开关5、所述全驱开关6及所述取力器开关7状态,并通过CAN总线发送控制条件,实现不同的工作方式。Multi-state control function of power take-off: Due to the different operating environments of vehicles, various operating conditions often appear, such as parking power take-off, driving power take-off or constant speed control, etc. When the system is designed, the system controller 8 reserves The external selection interface of the power device operation mode, and the external selection interface is consistent with the control logic of the gear switch 5, the full drive switch 6 and the power take-off switch 7, and the system controller 8 collects the The gear switch 5, the full drive switch 6 and the power take-off switch 7 states, and control conditions are sent through the CAN bus to realize different working modes.

分动器齿轮油保护机制:分动器齿轮油保护机制主要是防止齿轮油温过高或过低造成分动器烧毁或出现打齿现象,影响分动器使用寿命;当进行分动器齿轮油保护控制时,所述系统控制器8采集所述油温传感器15电流值做换算处理后,输出油温大小,并根据所述油温大小控制所述电动油泵2转速,使齿轮油在所述集成式油冷器3中充分循环,与冷却液进行热交换,形成闭环控制;油温过高或过低时,增大齿轮油流速,确保齿轮油处于合适的工作温度。Transfer case gear oil protection mechanism: The transfer case gear oil protection mechanism is mainly to prevent the transfer case from being burned or toothed due to too high or too low temperature of the gear oil, which will affect the service life of the transfer case; During oil protection control, the system controller 8 collects the current value of the oil temperature sensor 15 for conversion processing, outputs the oil temperature, and controls the speed of the electric oil pump 2 according to the oil temperature, so that the gear oil The above-mentioned integrated oil cooler 3 fully circulates and exchanges heat with the coolant to form a closed-loop control; when the oil temperature is too high or too low, increase the flow rate of the gear oil to ensure that the gear oil is at a suitable working temperature.

车速信号采集处理功能:车速信号采集处理主要是通过分动器电控系统向车辆仪表提供有效的车速信息;当进行车速信号采集处理时,所述系统控制器8采集所述输出轴转速传感器16频率信号,根据车辆发送的传动系数,换算实际车速;所述系统控制器8根据所述输入轴转速传感器11频率信号大小与分动器当前挡位状态,实时校验车速大小,将有效的车速值以CAN报文方式发送至数字仪表。Acquisition and processing function of vehicle speed signal: Acquisition and processing of vehicle speed signal mainly provides effective vehicle speed information to the vehicle instrument through the electronic control system of the transfer case; The frequency signal is converted to the actual vehicle speed according to the transmission coefficient sent by the vehicle; the system controller 8 checks the vehicle speed in real time according to the frequency signal of the input shaft speed sensor 11 and the current gear state of the transfer case, and converts the effective vehicle speed The values are sent to the digital instrument in CAN messages.

故障诊断功能:当进行系统故障诊断时,所述系统控制器8实时监控、判断各传感器与执行机构是否有开短路故障,输入信号值是否处于合理范围,CAN信号是否通讯错误及总线节点是否掉线等故障;当发生故障时,将故障代码以CAN报文的方式发送至数字仪表,故障诊断满足SAEJ1939标准中DM1报文规定。Fault diagnosis function: when performing system fault diagnosis, the system controller 8 monitors in real time and judges whether each sensor and actuator has an open-short fault, whether the input signal value is within a reasonable range, whether the CAN signal has a communication error and whether the bus node is disconnected. Line and other faults; when a fault occurs, the fault code is sent to the digital instrument in the form of a CAN message, and the fault diagnosis meets the DM1 message regulations in the SAEJ1939 standard.

以上给出的实施例是实现本发明较优的例子,本发明不限于上述实施例。本领域的技术人员根据本发明技术方案的技术特征所做出的任何非本质的添加、替换,均属于本发明的保护范围。The above-mentioned embodiments are preferred examples for realizing the present invention, and the present invention is not limited to the above-mentioned embodiments. Any non-essential additions and substitutions made by those skilled in the art according to the technical features of the technical solution of the present invention shall fall within the protection scope of the present invention.

Claims (10)

1. A heavy full-time full-drive transfer case electric control system is characterized by comprising a transfer case assembly, an electric oil pump, an integrated oil cooler, an integrated electromagnetic valve bank, a transfer case gear switch, a full-drive switch, a power takeoff switch and a system controller;
the transfer case assembly, the electric oil pump, the integrated electromagnetic valve bank, the transfer case gear switch, the full-drive switch and the power takeoff switch are all electrically connected with the system controller; the integrated electromagnetic valve bank is connected with the transfer case assembly through a gas circuit, and the integrated oil cooler is connected with the transfer case assembly through an oil circuit;
the transfer case assembly comprises an input shaft rotating speed sensor, a high gear signal switch, a low gear signal switch, a full-drive signal switch, an oil temperature sensor, an output shaft rotating speed sensor, an oil level sensor and a power takeoff signal switch;
the integrated electromagnetic valve group comprises a high-gear electromagnetic valve, a neutral-gear electromagnetic valve, a low-gear electromagnetic valve, a power takeoff electromagnetic valve and a full-drive electromagnetic valve;
when gear switching, full-drive control and power takeoff control are carried out, the system controller judges whether the system is in a safe rotating speed range or not according to control requirements and rotating speeds acquired by the input shaft rotating speed sensor and the output shaft rotating speed sensor; if yes, controlling the electromagnetic valve corresponding to the integrated electromagnetic valve group to work; the system controller simultaneously collects state signals of the high-gear signal switch, the low-gear signal switch, the full-drive signal switch and the power takeoff signal switch, processes the state signals and sends the processed state signals to a digital instrument in a CAN (controller area network) signal mode;
when the transfer case gear oil protection control is carried out, the system controller collects the current value of the oil temperature sensor to carry out conversion processing, then outputs the oil temperature, controls the rotating speed of the electric oil pump according to the oil temperature, and enables the gear oil to be fully circulated in the integrated oil cooler to exchange heat with the cooling liquid to form closed-loop control;
when vehicle speed signal acquisition processing is carried out, the system controller acquires frequency signals of the output shaft rotating speed sensor and converts the actual vehicle speed according to a transmission coefficient sent by a vehicle; and the system controller checks the speed of the vehicle in real time according to the frequency signal of the input shaft rotation speed sensor and the current gear state of the transfer case, and sends an effective speed value to the digital instrument in a CAN message mode.
2. The electric control system of the heavy-duty full-time full-drive transfer case according to claim 1, wherein the integrated solenoid valve set further comprises an input air source interface, and the high-gear solenoid valve, the neutral-gear solenoid valve, the low-gear solenoid valve, the power take-off solenoid valve and the full-drive solenoid valve are all electric control solenoid valves; the output interface of the electric control gas electromagnetic valve is respectively connected with the control gas port of each corresponding function of the transfer case assembly; and the high-gear electromagnetic valve is a power-off normally-on electromagnetic valve, and the neutral electromagnetic valve, the low-gear electromagnetic valve, the power takeoff electromagnetic valve and the full-drive electromagnetic valve are all power-off normally-off electromagnetic valves.
3. The heavy duty full time full drive transfer case electrical control system of claim 1, wherein said high range signal switch, said low range signal switch, said full drive signal switch and said power take off signal switch are contact jog switches; the transfer case gear switch is provided with three gears of high, idle and low, and defaults to a high gear state; the full-drive switch and the power takeoff switch have two gears of closing and opening and are in a closing state by default.
4. The electric control system of the heavy full-time full-drive transfer case according to claim 1, wherein the input shaft rotation speed sensor and the output shaft rotation speed sensor are both high-precision electromagnetic sensors, and the system controller collects frequency values of the high-precision electromagnetic sensors, converts the frequency values into corresponding rotation speeds, and sends the rotation speeds to the digital instrument in a CAN signal mode.
5. The heavy full-time full-drive transfer case electric control system according to claim 1, wherein the oil temperature sensor and the oil level sensor are all current type sensors, the system controller collects current values of the current type sensors and converts the current values into corresponding liquid level heights and temperature magnitudes, and when the liquid level heights and the oil temperature magnitudes exceed set safety threshold values, a fault state is sent to a digital instrument in a CAN signal mode.
6. The electric control system of the heavy full-time full-drive transfer case according to claim 1, wherein the integrated oil cooler comprises a gear oil cavity, a cooling liquid cavity and a cooling fin, and heat exchange is realized through circulation heat dissipation; the cooling is realized through the cooling fins.
7. The electric control system of the heavy full-time full-drive transfer case according to claim 1, wherein the electric oil pump is in a PWM current control mode, and the rotation speed of the electric oil pump is changed according to the control current, so that the flow rate of gear oil is controlled.
8. The electric control system of the heavy full-time full-drive transfer case according to claim 1, wherein the system controller reserves an external selection interface of a power takeoff operation mode, the external selection interface is consistent with control logics of the gear switch, the full-drive switch and the power takeoff switch, and the system controller collects states of the gear switch, the full-drive switch and the power takeoff switch and sends control conditions through a CAN bus.
9. The electric control system of the heavy-duty full-time full-drive transfer case according to claim 1, wherein the system controller 8 is an electronic controller having digital quantity input, frequency value input and current analog input interfaces; the digital driving interface and the PWM driving interface are provided; the CAN bus flash and calibration system has two CAN communication interfaces, supports CAN bus flash and calibration functions, and CAN messages meet SAEJ1939 standards.
10. The electric control system of the heavy full-time full-drive transfer case according to claim 9, wherein when performing system fault diagnosis, the system controller 8 monitors and judges whether or not there are open/short circuit faults between each sensor and the actuator, whether or not the input signal value is in a reasonable range, whether or not the CAN signal is in communication error, whether or not the bus node is disconnected, and other faults in real time; when a fault occurs, the fault code is sent to the digital instrument in a CAN message mode, and fault diagnosis meets the DM1 message regulation in the SAEJ1939 standard.
CN202111011116.1A 2021-08-31 2021-08-31 Heavy full-time full-drive transfer case electric control system Pending CN115727124A (en)

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Citations (5)

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Publication number Priority date Publication date Assignee Title
US20080318726A1 (en) * 2007-06-21 2008-12-25 Toyota Jidosha Kabushiki Kaisha Control apparatus for vehicular power transmitting system
CN203637579U (en) * 2013-12-27 2014-06-11 陕西重型汽车有限公司 Controller for controlling transfer case and power take-off of vehicle
DE102019102907A1 (en) * 2019-02-06 2020-08-06 Voith Patent Gmbh Wheelset gear
CN111817503A (en) * 2019-04-11 2020-10-23 上海汽车集团股份有限公司 A hybrid gearbox drive motor cooling system and control method
CN113007343A (en) * 2021-03-22 2021-06-22 东风越野车有限公司 Power distributor-based anti-misoperation method for amphibious vehicle

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080318726A1 (en) * 2007-06-21 2008-12-25 Toyota Jidosha Kabushiki Kaisha Control apparatus for vehicular power transmitting system
CN203637579U (en) * 2013-12-27 2014-06-11 陕西重型汽车有限公司 Controller for controlling transfer case and power take-off of vehicle
DE102019102907A1 (en) * 2019-02-06 2020-08-06 Voith Patent Gmbh Wheelset gear
CN111817503A (en) * 2019-04-11 2020-10-23 上海汽车集团股份有限公司 A hybrid gearbox drive motor cooling system and control method
CN113007343A (en) * 2021-03-22 2021-06-22 东风越野车有限公司 Power distributor-based anti-misoperation method for amphibious vehicle

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