Design of Microcomputer Control Test System for Automotive Alternator Performance
Design of Microcomputer Control Test System for Automotive Alternator Performance Tan Qing 1 . The South China Institute of Electrical and Mechanical Technology 1 Institute. Hu 1.Changsha 41083 Design Requirements The design method of the overall structure and functional software modules of mechanical and electronic control hardware systems. Discuss the debugging and features of the test system. After the test system was put into trial operation, the performance of the relevant quality inspection department of the manufacturer confirmed the result of the test. The technical performance indicators of the test system were comparable to those of imported equipment, and the traditional test methods for the performance of the automotive generator were solved with low accuracy and low efficiency. The data is not present in the vast majority of automotive generator manufacturers on the performance testing of automotive generators are followed by the traditional test methods, the test accuracy is low error, high efficiency and low data can not be stored. Traceable to the quality test of the product brings great + but the auto generator manufacturers in foreign developed countries have introduced the micro-computer to the city's stomach, and recently several large-scale automotive electronics companies have also introduced such equipment. , But the price is expensive, therefore, in our country to develop a high-precision and stable automotive performance test computer performance test system.
It is a piece of work that makes sense and ends. The introduction of the abbreviation system in the wooden text is a design example.
The new system no longer needs to manually adjust the load, and no longer adopts a visually coordinated operation method. The switching of test items does not depend on labor. Second, the test accuracy must reach the advanced level. The test cycle is also greatly reduced in speed. In order to meet the requirements of productivity, the latest system should be applied to the major technical indicators and functions of a new system for designing multiple inverters, including various types of monolithic automotive alternators; the system should have parameters to set performance test sampling. The function of the calibration is to record the query and operation help; the initial charge and turn, zero current speed, must be measured, the load characteristic must be measured, the maximum can be set, the voltage characteristic of the regulator must be measured; the final detection accuracy grade of the equipment is. The voltage is 0.5; 1. The current is 5; The rotational speed is 1., The test requirement of the grade is finished continuously, among them the load is adjusted and the test item 1 is changed and shaken, guarantee the rapidity of the test; Test result should reveal on the screen, and have Lights means that the test results should be saved and can be easily searched and printed afterwards. 2 System Design 2.1 The overall system of the system is based on 1 requirements, and the reference is 1. We have designed a system structure hardware is mainly divided into six major parts Input and output interface data acquisition card and related interface terminal board; measurement unit sensor and signal conversion, execution unit inverter relay electronic load; record display unit display hard drive. printer.
2.2 System Mechanical Design This system requires the degree of automation to facilitate loading and unloading. Therefore, pneumatic clamping is used for the fixed clamping of the generator, and the clamping of the generator and the electrode connection times are automatically completed. For the accuracy of the test, to ensure good contact with the contact, the electrode material is made of copper, and the positioning of the generator adopts the generator mounting hole and the convex positioning plate and the indenter to move and disassemble to meet the requirements of different species. The generator shaft is connected to the drive shaft through a one-step shaft section to avoid damage to the motor bearings due to eccentric forces.
The power of the drive shaft is connected to the asynchronous motor controlled by the constant torque vector inverter through the timing belt to ensure the stable motor speed and easy control. The drive shaft and the drive motor are placed in the bed through the sound insulation device to reduce the impact of mechanical noise on the environment. The rotational speed of the drive shaft is 5, and noise reduction measures are also adopted in the design.
2.3 The system electric screw hardware set juice 2.3.1 system main test loop According to the domestic Kir appliances standards test requirements. The designed test circuit hardware mainly consists of a cabinet consisting of a generator, a rectifier circuit, and a regulator as a whole, which outputs a direct current; 2 current sensors 1 and 1 and 2, respectively, for detecting the charging current and the load current; voltages The sensor 8 detects the subject vehicle alternator; the frequency of the generator is detected by a rotational speed sensor. The frequency number is transmitted to the computer via the frequency converter and the electronic load controlled by the computer enables the change of the load current to be satisfied. Performance test requirements. 2.3.2 System Control Principle 3 From 1 we can see that the control core of the system is the industrial computer of the Taiwan 586. Its role is to provide the human-computer interaction interface. Control the entire testing process. Complete the system related to an external system, then, by the 818 data capture card toss, the current and voltage conversion and other violations of the sampling signal by 8181, 1 converted to a digital input computer; console operation button through 88, the amount of switch Input port, 1 input computer; computer output control signal through the 818 switch output port 00 to reach the buzzer of the signal lamp relay control circuit to control the amount of output through 818, 0, port to the electronic load.
The generator is driven by the phase-phase asynchronous motor. The motor is screwed by a frequency converter. The frequency converter can pass the 1. and 0 of the counter and the screw twists the speed and acceleration/deceleration process. 2.4 System Function Software Shuttle Block 14 Wood System Application The software is made up of 5 function blocks. The functional blocks of each station are independent, interconnected, and integrated. The general structure of the blocks is described below.
System application software module structure block 2.4.1 Parameter setting module The generator model is not 1. Its parameters and test conditions are also different, so when the model changes, the test parameters and conditions must be changed accordingly. The parameter setting module of the system saves 20 kinds of generator model parameters, and each type of parameter is used to set parameters and exit the parameter setting module. The last changed or set model becomes the current test model. The module also has setting functions for items such as test date and product start number.
2.4.2 Parametric Proofing Module In the system design, many anti-jamming measures are used. These measures are described in more detail below.
The function of the parameter proofing module is mainly to overcome the disturbance of certain DC properties of the system error in the sampling process of the human 0 and the nonlinear characteristics of the sensor itself, and to make the detection value faithfully reflect the actual value. The parameters were adjusted and the system was sampled. The test values ​​and actual positions were obtained respectively. The method of linear regression was used to fit the test values ​​to the actual values ​​and the proof factor was obtained. In order to make the proofreading meaningful, the actual value is obtained by a high-precision measuring instrument. 2.4.3 Test Module The function of the test module is to perform computer control of the generator test process, and test the generator model parameter test conditions and test items and sequence. Both are taken from the last parameter setting. After pressing the start button, the computer will automatically perform the system test process according to the set parameters and the order of the items, and automatically fully test. The result is significant. Accumulation of records and numbering.
2.4.4 Record query and system help module The record query module provides the date and time according to the model according to the current date, such as the random number, etc., to record and query the printer for printing.
The system help module provides on-line help for detailed explanations of system functions and operating methods, which helps operators to operate correctly and for beginners to learn and train.
3 System debugging When putting the theoretically designed system solutions into reality, there will always be many questions. The system's debugging sequence is from the local to the entire system; from hardware to software; from the mechanical line, where the detection system signal sampling channel debugging and interference suppression electronic load debugging current closed-loop control is the key to the entire debugging.
Because the system has a frequency converter and the working current of the generator, there is a very large magnetic interference, and the polar people's milk rang the accuracy of the sampling signal. Therefore, the debugging of the sampling channel not only includes routine work such as zero point and span calibration, but more importantly, the system's interference must be eliminated. In order to suppress the harmonic noise during the operation of the inverter into the system and enter the system, a phase-in line filter is added between the inverter and the grid. In addition, the signal line is shielded to minimize the length of the trace and reduce the node. In particular, it is necessary to avoid the situation in which large current conductors are surrounded in the signal line routing.
The electronic load can be debugged in the test software of 818 cards. The duty-paying plant must ensure stable performance and good linearity, which brings greater convenience to software control. The design of electronic load should consider over-current over-voltage protection in order to adapt to the different testing requirements.
Current closed loop, system adopted, segmented control, 0 system accurate test quickly.
4 System Features 4 The wood system's juice design and software programming strive to reflect the following special features that make this system has a good automatic continuity and intelligence accuracy and rapidity and reliability.
Automatic Continuity Intelligence This system is controlled by the Taiwan 586 IPC to test the entire performance of the automotive alternator. It is possible to set 1 parameter for the +4 generator. When you enter the test state, you can change the product code automatically. After each test, the number of products automatically added to the number of test items can be arbitrarily set. The test can be arranged freely.
Accuracy The system mainly considers the main factors that influence the detection accuracy in the design and debugging, such as the sensor detection accuracy. The frequency converter electromagnetic signal interferes with the voltage and current of the generator after rectification to reach the predetermined requirements. Voltage is 0.5, current is 5, and rapidity is in load performance. During the test, the initial value is given first, so that the actual current value given value is very close, thereby shortening the adjustment. The closed-loop regulation of the turbulent flow is adopted when the segmented 0 control algorithm has a large error, and the control is used to reduce the overshoot; Hours are used to control and maintain the control speed and eliminate the steady-state error; when the computer enters within the given value error limit, the last screwing scene is maintained to avoid the occurrence of limit cycles or adjustments. The benefits of doing so are stability and stability. The convergence of the test results.
The high security 3 start button must work after the fixture is clamped; when the speed is less than 3 mountains, the release of the key is valid, and the excitation excitation and the fan machine number do not correspond, and the system can not be tested because the system cannot enter the test state. Tested to damage the product under test.
5 Conclusions The system has been put into trial operation in several large-scale automobile electrical appliances factories such as Changsha Hitachi Steamer Electric Appliance Factory. Its quality inspection department has tested its performance. The system is reliable and the operation is convenient and flexible. Both meet and exceed the requirements for juice design, the test cycle can be controlled within 2,5, the results of repeated testing with the same generator is very good, the system is put into operation, solve the traditional test method error large results poor reliability data recording time-consuming The tedious and other questions, which greatly improve the test accuracy, thus ensuring the product quality; due to the flexibility of software programming, and the entire test has achieved 0 mobilization, thereby reducing the labor intensity and improve the efficiency. The technical performance indicators can be comparable to the access devices, referenced by the Automotive Technology Research Center Standardization Institute. 2.5161.
2 Li Zhizhong, Wang Jiayu. The data acquisition and monitoring of the computer application elbow. Beijing Tsinghua University Press, 1998.3 Qi Zhiping. Electromechanical system software technology. Beijing Zhongji Liu Enyi Computer Technology System System Analysis and Design Assistant, Wuhan Huazhong University of Science and Technology Press. 1993.680.
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