1. A real-time monitoring method for service life of a commercial vehicle synchronizer is characterized by comprising the following steps:

calibrating the gear shifting impulse of the synchronizer before the transmission leaves a factory, and calibrating a plurality of different preset gear shifting impulses and gear shifting times under each preset gear shifting impulse;

accumulating the products of the preset gear shifting impulses and the gear shifting times under the preset gear shifting impulses to obtain the total gear shifting impulse service life of the synchronizer;

after the gearbox actually runs to a set mileage, collecting and calculating the product of each gear shifting impulse used by the synchronizer and the gear shifting times under each gear shifting impulse, and accumulating to obtain the used gear shifting impulse life of the synchronizer;

and obtaining the remaining shift impulse life of the synchronizer according to the difference between the total shift impulse life and the used shift impulse life, and accumulating the shift times under each shift impulse in the remaining shift impulse life to obtain the remaining shift life times of the synchronizer.

2. The method for monitoring the service life of the synchronizer of the commercial vehicle according to claim 1, is characterized in that:

the method further comprises the step of taking the proportional relation of the gear shifting times under each gear shifting impulse in the used gear shifting impulse life as an actual gear shifting rule of the gearbox when the ratio of the used gear shifting impulse life to the total gear shifting impulse life is larger than a set judgment coefficient;

and calculating the remaining shift impulse life of the synchronizer by utilizing the proportional relation of the shift times under each shift impulse in the used shift impulse life, and calculating the remaining shift life times of the synchronizer according to the remaining shift impulse life.

3. The method for monitoring the service life of the synchronizer of the commercial vehicle according to claim 2, is characterized in that:

the method also comprises the steps of dividing the traveled mileage of the gearbox into a plurality of interval mileage sections, and respectively calculating the number of the remaining shift life of the synchronizer according to the actual shift schedule of the gearbox in each interval mileage section;

and weighting the remaining shift life times of the synchronizer calculated by the mileage sections of each section, and accumulating to obtain the corrected remaining shift life times of the synchronizer.

4. The method for monitoring the service life of the synchronizer of the commercial vehicle according to claim 3, wherein the method comprises the following steps:

the method also comprises the steps of selecting partial interval mileage sections from the multiple interval mileage sections, weighting the calculated number of the remaining shift life of the synchronizer according to the mileage sections of the partial intervals, and accumulating to obtain an absolute value of the difference value between the number of the remaining shift life of the synchronizer and the corrected number of the remaining shift life of the synchronizer;

and if the absolute value is larger than a set judgment threshold value, readjusting the weighting coefficient of the weighting process, or replacing the actual gear shifting schedule with the initial gear shifting schedule, and recalculating the remaining gear shifting life time of the synchronizer.

5. The method for monitoring the service life of the synchronizer of the commercial vehicle according to claim 3, wherein the method comprises the following steps:

the method further comprises the steps of selecting an interval mileage section closest to the current mileage from the interval mileage sections, and calculating the difference value between the residual shift life times of the synchronizer and the corrected residual shift life times of the synchronizer according to the actual shift rule of the selected interval mileage section gearbox to obtain an absolute value;

and if the absolute value is greater than the set judgment coefficient, readjusting the weighting coefficient of the weighting process, or replacing the actual gear shifting schedule with the initial gear shifting schedule, and recalculating the remaining gear shifting life time of the synchronizer.

6. A real-time monitoring device of commercial car synchronizer life-span, its characterized in that, the device includes:

the calibration module (101) is used for calibrating the gear shifting impulse of the synchronizer before the transmission leaves a factory, and calibrating a plurality of different preset gear shifting impulses and gear shifting times under each preset gear shifting impulse;

a first calculation module (102) for accumulating products of the preset shift impulses and the number of shifts at the preset shift impulses to obtain a total shift impulse life of the synchronizer;

the acquisition module (103) is used for acquiring and calculating the products of the used gear shifting impulses of the synchronizer and the gear shifting times under the gear shifting impulses to accumulate to obtain the used gear shifting impulse life of the synchronizer after the gearbox actually runs to a set mileage;

and the second calculation module (105) is used for obtaining the remaining shift impulse life of the synchronizer according to the difference value of the total shift impulse life and the used shift impulse life, and accumulating the gear shifting times under each shift impulse in the remaining shift impulse life to obtain the remaining shift life times of the synchronizer.

7. The device for real-time monitoring of the service life of the synchronizer of the commercial vehicle according to claim 6, wherein:

the gear shifting control system further comprises a judging module (104) which is used for judging that when the ratio of the used gear shifting impulse life to the total gear shifting impulse life is larger than a set judging coefficient, the proportional relation of the gear shifting times under each gear shifting impulse in the used gear shifting impulse life is used as an actual gear shifting rule of the gearbox;

the second calculation module (105) is further used for calculating the remaining shift impulse life of the synchronizer according to the proportional relation of the shift times under each shift impulse in the used shift impulse life, and calculating the remaining shift impulse life times of the synchronizer according to the remaining shift impulse life.

8. The device for real-time monitoring of the service life of the synchronizer of the commercial vehicle according to claim 7, wherein:

the second calculation module (105) is also used for dividing the traveled mileage of the gearbox into a plurality of interval mileage sections, and calculating the remaining shift life times of the synchronizer according to the actual shift schedule of the gearbox in each interval mileage section;

and the second calculation module (105) weights the remaining shift life times of the synchronizer calculated by the mileage segments of each interval and then accumulates the weighted remaining shift life times to obtain the corrected remaining shift life times of the synchronizer.

9. The device for monitoring the service life of the synchronizer of the commercial vehicle according to claim 8, wherein:

a second calculation module (105) selects partial interval mileage sections from the multiple interval mileage sections, weights the remaining shift life times of the synchronizer calculated according to the interval mileage sections of each part, and then accumulates the weighted remaining shift life times to obtain an absolute value of the difference value between the remaining shift life times of the synchronizer and the corrected remaining shift life times of the synchronizer;

the calibration module (101) takes the proportional relation of the gear shifting times under each preset gear shifting impulse as an initial gear shifting rule of the gearbox, and when the judgment module (104) judges that the absolute value is larger than the set judgment threshold value, the second calculation module (105) readjusts the weighting coefficient of the weighting processing, or replaces the actual gear shifting rule with the initial gear shifting rule and recalculates the remaining gear shifting life time of the synchronizer.

10. The device for monitoring the service life of the synchronizer of the commercial vehicle according to claim 8, wherein:

the second calculation module (105) selects an interval mileage section closest to the current mileage from the interval mileage sections, and calculates the difference value between the remaining shift life times of the synchronizer and the corrected remaining shift life times of the synchronizer according to the actual shift rule of the selected interval mileage section gearbox to obtain an absolute value;

the calibration module (101) takes the proportional relation of the gear shifting times under each preset gear shifting impulse as an initial gear shifting rule of the gearbox, and if the judgment module (104) judges that the absolute value is larger than the set judgment threshold value, the second calculation module (105) readjusts the weighting coefficient of weighting processing, or replaces the actual gear shifting rule with the initial gear shifting rule and recalculates the remaining gear shifting life time of the synchronizer.

Background

In the field of automatic transmissions for commercial vehicles, in particular in the field of automatic transmissions for heavy trucks, AMT automatic transmissions gradually become the main form of automatic transmissions for commercial vehicles. In foreign countries, the technology of the AMT gearbox of the commercial vehicle is mature, and various automobile manufacturers successively release the AMT gearbox products. In China, automobile manufacturers also take steps to accelerate the research and development of AMT gearbox products, and strive to break through the key research and development technology of commercial vehicle AMT products. The AMT gearbox has the characteristics of high transmission efficiency, low manufacturing cost and easiness in maintenance of the traditional manual gearbox. Because the AMT gearbox is accomplished at the process of shifting gears automatically, can reduce the impact of shifting gears, improve the travelling comfort of shifting gears, further reduce advantages such as driver intensity of labour, AMT gearbox possesses better development prospect in commercial car automatic gearbox field.

For automatic transmissions, shift comfort directly affects overall vehicle comfort. The synchronizer is used as a main component of gear shifting, and the design, manufacturing precision and fatigue life of the synchronizer directly influence the gear shifting performance of the transmission. If the synchronizer fails in the gear shifting process, the phenomenon of gear shifting impact abnormal sound can occur, and even the automatic gearbox cannot shift gears in serious conditions. Therefore, the fatigue life of the synchronizer directly affects the life of the transmission, so that the fatigue life detection of the synchronizer is indispensable in the design and development process of the synchronizer of the automatic transmission.

In the related technology, the service life of a synchronizer of an AMT (automated mechanical transmission) is not monitored and early warned in the field of the AMT of commercial vehicles. In the use process of the AMT, the synchronizer of the AMT is gradually worn to be damaged, the process is accompanied with accidents, the accidents are inevitable, and once the synchronizer is out of order, the loss of human bodies and property is brought. When the synchronizer is not in fault, the overhaul frequency is judged only through the experience of a driver, and potential safety hazards exist.

Disclosure of Invention

The embodiment of the application provides a real-time monitoring method and a monitoring device for the service life of a synchronizer of a commercial vehicle, and aims to solve the problems that monitoring and early warning for the service life of the synchronizer of an AMT (automated mechanical transmission) are lacked in the field of AMT automatic transmissions of commercial vehicles in the related technology, and potential safety hazards exist.

The first aspect of the embodiment of the application provides a method for monitoring the service life of a synchronizer of a commercial vehicle in real time, which comprises the following steps:

calibrating the gear shifting impulse of the synchronizer before the transmission leaves a factory, and calibrating a plurality of different preset gear shifting impulses and gear shifting times under each preset gear shifting impulse;

accumulating the products of the preset gear shifting impulses and the gear shifting times under the preset gear shifting impulses to obtain the total gear shifting impulse service life of the synchronizer;

after the gearbox actually runs to a set mileage, collecting and calculating the product of each gear shifting impulse used by the synchronizer and the gear shifting times under each gear shifting impulse, and accumulating to obtain the used gear shifting impulse life of the synchronizer;

and obtaining the remaining shift impulse life of the synchronizer according to the difference between the total shift impulse life and the used shift impulse life, and accumulating the shift times under each shift impulse in the remaining shift impulse life to obtain the remaining shift life times of the synchronizer.

In some embodiments: the method further comprises the step of taking the proportional relation of the gear shifting times under each gear shifting impulse in the used gear shifting impulse life as an actual gear shifting rule of the gearbox when the ratio of the used gear shifting impulse life to the total gear shifting impulse life is larger than a set judgment coefficient;

and calculating the remaining shift impulse life of the synchronizer by utilizing the proportional relation of the shift times under each shift impulse in the used shift impulse life, and calculating the remaining shift life times of the synchronizer according to the remaining shift impulse life.

In some embodiments: the method also comprises the steps of dividing the traveled mileage of the gearbox into a plurality of interval mileage sections, and respectively calculating the number of the remaining shift life of the synchronizer according to the actual shift schedule of the gearbox in each interval mileage section;

and weighting the remaining shift life times of the synchronizer calculated by the mileage sections of each section, and accumulating to obtain the corrected remaining shift life times of the synchronizer.

In some embodiments: the method also comprises the steps of selecting partial interval mileage sections from the multiple interval mileage sections, weighting the calculated number of the remaining shift life of the synchronizer according to the mileage sections of the partial intervals, and accumulating to obtain an absolute value of the difference value between the number of the remaining shift life of the synchronizer and the corrected number of the remaining shift life of the synchronizer;

and if the absolute value is larger than a set judgment threshold value, readjusting the weighting coefficient of the weighting process, or replacing the actual gear shifting schedule with the initial gear shifting schedule, and recalculating the remaining gear shifting life time of the synchronizer.

In some embodiments: the method further comprises the steps of selecting an interval mileage section closest to the current mileage from the interval mileage sections, and calculating the difference value between the residual shift life times of the synchronizer and the corrected residual shift life times of the synchronizer according to the actual shift rule of the selected interval mileage section gearbox to obtain an absolute value;

and if the absolute value is greater than the set judgment coefficient, readjusting the weighting coefficient of the weighting process, or replacing the actual gear shifting schedule with the initial gear shifting schedule, and recalculating the remaining gear shifting life time of the synchronizer.

The embodiment of the application provides in a second aspect a real-time supervision device in commercial car synchronizer life-span, the device includes:

the calibration module is used for calibrating the gear shifting impulse of the synchronizer before the transmission leaves a factory, and calibrating a plurality of different preset gear shifting impulses and gear shifting times under each preset gear shifting impulse;

the first calculation module is used for accumulating the products of the preset gear shifting impulses and the gear shifting times under the preset gear shifting impulses to obtain the total gear shifting impulse service life of the synchronizer;

the acquisition module is used for acquiring and calculating the products of the used gear shifting impulse of the synchronizer and the gear shifting times under the gear shifting impulses to accumulate to obtain the used gear shifting impulse service life of the synchronizer after the gearbox actually runs to a set mileage;

and the second calculation module is used for obtaining the remaining shift impulse life of the synchronizer according to the difference value between the total shift impulse life and the used shift impulse life, and accumulating the shift times under each shift impulse in the remaining shift impulse life to obtain the remaining shift life times of the synchronizer.

In some embodiments: the gear shifting control system further comprises a judging module, wherein the judging module is used for judging that the ratio of the used gear shifting impulse life to the total gear shifting impulse life is larger than a set judgment coefficient, and taking the proportional relation of the gear shifting times under each gear shifting impulse in the used gear shifting impulse life as the actual gear shifting rule of the gearbox;

the second calculating module is also used for calculating the remaining shift impulse life of the synchronizer according to the proportional relation of the shift times under each shift impulse in the used shift impulse life, and calculating the remaining shift life times of the synchronizer according to the remaining shift impulse life.

In some embodiments: the second calculation module is also used for dividing the traveled mileage of the gearbox into a plurality of interval mileage sections and respectively calculating the number of the remaining shift life of the synchronizer according to the actual shift schedule of the gearbox in each interval mileage section;

and the second calculation module performs weighting processing on the remaining shift life times of the synchronizer calculated by the mileage sections in each interval and then accumulates the weighted number to obtain the corrected remaining shift life times of the synchronizer.

In some embodiments: the second calculation module selects partial interval mileage sections from the multiple interval mileage sections, and the residual shift life times of the synchronizer calculated according to the interval mileage sections are weighted and accumulated to obtain a difference absolute value of the residual shift life times of the synchronizer and the corrected residual shift life times of the synchronizer;

the calibration module takes the proportional relation of the gear shifting times under each preset gear shifting impulse as an initial gear shifting rule of the gearbox, and when the judgment module judges that the absolute value is larger than the set judgment threshold value, the second calculation module readjusts the weighting coefficient of the weighting processing, or replaces the actual gear shifting rule with the initial gear shifting rule and recalculates the remaining gear shifting life time of the synchronizer.

In some embodiments: the second calculation module selects an interval mileage section closest to the current mileage from the interval mileage sections, and an absolute value is obtained according to a difference value between the residual shift life times of the synchronizer and the corrected residual shift life times of the synchronizer calculated according to an actual shift rule of the selected interval mileage section gearbox;

the calibration module takes the proportional relation of the gear shifting times under each preset gear shifting impulse as an initial gear shifting rule of the gearbox, and if the judgment module judges that the absolute value is larger than the set judgment threshold value, the second calculation module readjusts the weighting coefficient of the weighting processing, or replaces the actual gear shifting rule with the initial gear shifting rule and recalculates the remaining gear shifting life time of the synchronizer.

The beneficial effect that technical scheme that this application provided brought includes:

the embodiment of the application provides a real-time monitoring method and a monitoring device for the service life of a synchronizer of a commercial vehicle, and the monitoring method firstly calibrates the gear shifting impulse of the synchronizer before a gearbox leaves a factory, and calibrates a plurality of different preset gear shifting impulses and gear shifting times under each preset gear shifting impulse; then, accumulating the products of the preset gear shifting impulses and the gear shifting times under the preset gear shifting impulses to obtain the total gear shifting impulse service life of the synchronizer; then, after the gearbox actually runs to a set mileage, collecting and calculating the product of each gear shifting impulse used by the synchronizer and the gear shifting times under each gear shifting impulse, and accumulating to obtain the used gear shifting impulse service life of the synchronizer; and finally, obtaining the remaining shift impulse life of the synchronizer according to the difference between the total shift impulse life and the used shift impulse life, and accumulating the shift times under each shift impulse in the remaining shift impulse life to obtain the remaining shift life times of the synchronizer.

Therefore, according to the monitoring method, before the transmission leaves a factory, the gear shifting impulse of the synchronizer is calibrated, and the total gear shifting impulse service life of the synchronizer is calculated by calibrating a plurality of different preset gear shifting impulses of the synchronizer and the gear shifting times under each preset gear shifting impulse. After the gearbox actually runs to a set mileage, the used gear shifting impulse life of the synchronizer is calculated by collecting and calculating the used gear shifting impulse of the synchronizer and the gear shifting times under the gear shifting impulses. And finally, obtaining the remaining shift impulse life of the synchronizer according to the difference value of the total shift impulse life and the used shift impulse life, and accumulating the shift times under each shift impulse in the remaining shift impulse life to obtain the remaining shift life times of the synchronizer to display the remaining shift life times of the synchronizer to a user. According to the method and the device, the service life of the synchronizer is judged by monitoring the gear shifting impulse of the synchronizer, the judgment result is more objective and accurate, the possibility of misjudgment is reduced, the safety of the gearbox is guaranteed, the remaining gear shifting service life of the synchronizer can be predicted, and the user experience is improved.

Drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present application, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.

FIG. 1 is a flow chart illustrating steps of a monitoring method according to an embodiment of the present application;

fig. 2 is a block diagram of a monitoring device according to an embodiment of the present application. (ii) a

Reference numerals:

101. a calibration module; 102. a first calculation module; 103. an acquisition module; 104. a judgment module; 105. and a second calculation module.

Detailed Description

In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are some embodiments of the present application, but not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.

The embodiment of the application provides a real-time monitoring method and a monitoring device for the service life of a synchronizer of a commercial vehicle, and can solve the problems that monitoring and early warning for the service life of the synchronizer of an AMT (automated mechanical transmission) are lacked in the field of AMT automatic transmissions of commercial vehicles in the related technology, and potential safety hazards exist.

Referring to fig. 1, a first aspect of the embodiments of the present application provides a method for monitoring the service life of a synchronizer of a commercial vehicle in real time, where the method includes the following steps:

step 1, shifting impulse I of synchronizer before gearbox leaves factory_iCalibrating to obtain multiple different preset gear shifting impulses I_iAnd each preset gear shifting impulse I_iNumber of shifts alpha_iEach preset gear shifting impulse I_iNumber of shifts alpha_iAs the initial gear shift schedule a of the gearbox.

For example, before a certain type of gearbox leaves factory, a gearbox manufacturer obtains a plurality of different preset gear shifting impulses I through tests and market research_iThe number of shifts alpha at a preset shift stroke is 75N · s, 250N · s and 400N · s, 75N · s, respectively_iThe number of the gear shifting is 30 ten thousand, the number of the gear shifting times under the 250N & s preset gear shifting impulse is 10 ten thousand, the number of the gear shifting times under the 400N & s preset gear shifting impulse is 2 ten thousand, and the initial gear shifting rule of the gearbox is 30: 10: 2.

step 2, presetting gear shifting impulse I_iWith each preset gear shift impulse I_iNumber of shifts alpha_iThe products of the two are accumulated to obtain the total shift impulse life L of the synchronizer₀；

In the formula:

I_ito prepareSetting gear shifting impulse;

α_ifor each preset gear shift impulse I_iThe number of shifts.

Monitoring the actual gear shifting impulse I of the synchronizer in real time in the actual operation of the gearbox;

the actual shift impulse I is calculated as follows:

I＝∫Fdt (2)

in the formula:

f is the shift force and dt is the shift time.

And 3, after the gearbox actually runs to a set mileage, acquiring and calculating the product of each gear shifting impulse used by the synchronizer and the gear shifting times under each gear shifting impulse, and accumulating to obtain the used gear shifting impulse service life L of the synchronizer₁；

In the formula:

β_ithe number of shifts for each shift stroke that has been used.

Step 4, obtaining the residual gear shifting impulse life L of the synchronizer according to the difference value of the total gear shifting impulse life and the used gear shifting impulse life₂For the remaining shift momentum life L₂Accumulating the gear shifting times under each gear shifting impulse to obtain the remaining gear shifting life time t of the synchronizer, wherein the remaining gear shifting life time t of the synchronizer is the remaining gear shifting impulse life L₂The accumulated value of the gear shifting times under each gear shifting impulse is obtained;

in the embodiment of the application, the similarity is similar to alpha_iAnd beta_iIntroducing a set of unknowns gamma_i，γ_iIndicating remaining shift momentum life L₂The number of gear shifts under each preset gear shift impulse can be obtained as follows:

the number of the remaining shift life time t of the synchronizer is gamma_iAccumulation of (c):

according to the monitoring method, before the transmission leaves a factory, the gear shifting impulse of the synchronizer is calibrated, and the total gear shifting impulse service life of the synchronizer is calculated by calibrating a plurality of different preset gear shifting impulses of the synchronizer and the gear shifting times under each preset gear shifting impulse.

After the gearbox actually runs to a set mileage, the used gear shifting impulse life of the synchronizer is calculated by collecting and calculating the used gear shifting impulse of the synchronizer and the gear shifting times under the gear shifting impulses.

And finally, obtaining the remaining shift impulse life of the synchronizer according to the difference value of the total shift impulse life and the used shift impulse life, and accumulating the shift times under each shift impulse in the remaining shift impulse life to obtain the remaining shift life times of the synchronizer to display the remaining shift life times of the synchronizer to a user.

According to the method and the device, the service life of the synchronizer is judged by monitoring the gear shifting impulse of the synchronizer, the judgment result is more objective and accurate, the possibility of misjudgment is reduced, the safety of the gearbox is guaranteed, the remaining gear shifting service life of the synchronizer can be predicted, and the user experience is improved.

In some alternative embodiments: the embodiment of the application provides a real-time monitoring method for the service life of a synchronizer of a commercial vehicle, and the method further comprises the step of monitoring the service life L of the used gear shifting impulse₁And total shift momentum life L₀When the ratio epsilon% is larger than the set judgment coefficient delta%, the used shift impulse life L is ensured₁And taking the proportional relation of the gear shifting times under each gear shifting impulse as the actual gear shifting rule of the gearbox.

Calculating the remaining shift momentum life L of the synchronizer using the proportional relationship of the shift times at each shift momentum over the used shift momentum life₂And through the remaining shift stroke life L₂And calculating the number t of the remaining shifting service life of the synchronizer.

When the gearbox is actually used, even the same type of gearbox is used, the service life of the synchronizer is different due to different gear shifting rules of drivers. The average gear shifting rule of all factory-leaving vehicles collected by a manufacturer is used for calculating the number t of the remaining gear shifting life of the synchronizer, so that the result is easy to be inaccurate, and therefore, the gear shifting rules of different drivers need to be independently learned.

Therefore, when epsilon% < delta%, the embodiment of the application judges that the driving mileage of the gearbox of the vehicle is insufficient and beta is not enough_i/β_jThe stability is not available, so that the gear shifting rule of a driver is consistent with the gear shifting rule set by a factory in the following driving process; when epsilon% is more than or equal to delta%, the driving mileage of the gearbox of the vehicle is judged to be enough, in the following driving process, the gear shifting rule of the driver is approximate to the gear shifting rule in the driving course, and gamma can be obtained_i/γ_jThe values of (A) are as follows:

β_i/β_jis the proportion of the number of gear shifts at each gear shift stroke that the driver has used;

γ_i/γ_jis a proportion of the number of shifts at each shift stroke that is not used by the driver.

And (3) obtaining the number t of the remaining shift life of the synchronizer through the formulas (4), (5), (6), (7) and (8):

as can be seen from equations (9) and (10), the number of remaining shift life times t of the synchronizer is a function of the actual shift schedule β of the transmission, which is expressed as:

t＝f(β) (11)

in the formula:

beta is the actual gear shifting law of the gearbox.

It can be considered that t (β) is the number of remaining shift life times t of the synchronizer that is predicted with reference to the actual shift schedule β of the transmission.

In some alternative embodiments: the embodiment of the application provides a real-time monitoring method for the service life of a synchronizer of a commercial vehicle, and the method further comprises the steps of dividing the traveled mileage of a gearbox into a plurality of interval mileage sections, respectively calculating the number of the remaining shift service life of the synchronizer according to the actual shift rule of the gearbox in each interval mileage section, weighting the number of the remaining shift service life of the synchronizer calculated in each interval mileage section, and accumulating the weighted number to obtain the corrected number t of the remaining shift service life of the synchronizer.

In the formula:

x_jfor the weight coefficient of the number of remaining shift life times of the synchronizer in the mileage section corresponding to the interval of 1 to m, f_j(beta) the number of remaining shift life of the synchronizer calculated for the shift schedule of the mileage section in different intervals;

x_jthe number and the numerical value of the (C) are determined according to the research of manufacturers on the market.

For example, a vehicle travels 2 kilometers, travels along a straight line at 0 to 1 kilometer, travels along a circular track at 1 to 2 kilometers, and travels along the circular track in the course of subsequent travel. Then, it can be considered that the actual shift schedule of 0-1 km has no reference value, and the actual shift schedule of 1-2 km should be all included in the calculation range.

At this time, the process of the present invention,equation (12) can be expressed as: t is 0 f_0～1(β)+1*f_1～2(β)。

In some alternative embodiments: the embodiment of the application provides a real-time monitoring method for the service life of a synchronizer of a commercial vehicle, and the method further comprises the steps of selecting partial interval mileage sections from a plurality of interval mileage sections, weighting the remaining shift life times of the synchronizer calculated according to the partial interval mileage sections, and accumulating the weighted remaining shift life times to obtain the remaining shift life times t of the synchronizer₁Taking an absolute value of the difference value of the number t of the corrected remaining gear-shifting life times of the synchronizer;

and if the absolute value is greater than the set judgment threshold value tau, the weighting coefficient of the weighting processing is readjusted, or the actual gear shifting rule is replaced by the initial gear shifting rule, and then the remaining gear shifting life time of the synchronizer is recalculated.

The remaining shift life times of the synchronizer calculated by the mileage section among all the parts are as follows:

number of remaining shift life t of synchronizer₁The absolute value of the difference value of the remaining shift life times t of the corrected synchronizer is as follows:

Δt＝|t₁-t| (14)

the manufacturer may determine the determination threshold τ of Δ t (e.g., 1000 times, 2000 times) according to market research, and when Δ t is greater than τ, the result of calculating the lifetime by equation (12) is considered to have no accuracy, and the lifetime calculation is performed again. For example, change x_jOr replacing the actual gear shifting rule beta with the initial gear shifting rule alpha by a manufacturer, and then entering a formula (12) to calculate the number of the remaining service life of the synchronizer in real time.

In some alternative embodiments: the embodiment of the application provides a real-time monitoring method for the service life of a synchronizer of a commercial vehicle, and the method further comprises the steps of selecting an interval mileage section closest to the current mileage from a plurality of interval mileage sections, and taking an absolute value of the difference value between the number of the remaining shift life times of the synchronizer and the corrected number of the remaining shift life times of the synchronizer calculated according to the actual shift schedule of a gearbox of the selected interval mileage section;

and if the absolute value is greater than the set judgment threshold value tau, the weighting coefficient of the weighting processing is readjusted, or the actual gear shifting rule is replaced by the initial gear shifting rule, and then the remaining gear shifting life time of the synchronizer is recalculated.

The calculated number of the remaining shift life of the synchronizer in the section mileage section closest to the current mileage is as follows:

t₁＝f_m(β) (15)

number of remaining shift life t of synchronizer₁The absolute value of the difference value of the remaining shift life times t of the corrected synchronizer is as follows:

Δt＝|t₁-t| (14)

the manufacturer may determine the determination threshold τ of Δ t (e.g., 1000 times, 2000 times) according to market research, and when Δ t is greater than τ, the result of calculating the lifetime by equation (12) is considered to have no accuracy, and the lifetime calculation is performed again. For example, change x_jOr replacing the actual gear shifting rule beta with the initial gear shifting rule alpha by a manufacturer, and then entering a formula (12) to calculate the number of the remaining service life of the synchronizer in real time.

Referring to fig. 2, a second aspect of the embodiment of the present application provides a device for monitoring the service life of a synchronizer of a commercial vehicle in real time, where the device includes:

a calibration module 101, the calibration module 101 being used for the shift impulse I of the synchronizer before the gearbox leaves the factory_iCalibrating to obtain multiple different preset gear shifting impulses I_iAnd each preset gear shifting impulse I_iNumber of shifts alpha_iEach preset gear shifting impulse I_iNumber of shifts alpha_iAs the initial gear shift schedule a of the gearbox.

For example, before a certain type of gearbox leaves factory, a gearbox manufacturer obtains a plurality of different preset gear shifting impulses I through tests and market research_iThe number of shifts alpha at a preset shift stroke is 75N · s, 250N · s and 400N · s, 75N · s, respectively_iThe number of the gear shifting is 30 ten thousand, the number of the gear shifting times under the 250N & s preset gear shifting impulse is 10 ten thousand, the number of the gear shifting times under the 400N & s preset gear shifting impulse is 2 ten thousand, and the initial gear shifting rule of the gearbox is 30: 10: 2

A first calculating module 102, the first calculating module 102 being configured to calculate each preset shift impulse I and each preset shift impulse I_iNumber of shifts alpha_iThe products of the two are accumulated to obtain the total shift impulse life L of the synchronizer₀；

In the formula:

I_ipresetting a gear shifting impulse;

α_ifor each preset gear shift impulse I_iThe number of shifts.

Monitoring the actual gear shifting impulse I of the synchronizer in real time in the actual operation of the gearbox;

the actual shift impulse I is calculated as follows:

I＝∫Fdt (2)

in the formula:

f is the shift force and dt is the shift time.

An acquisition module 103, wherein the acquisition module 103 is configured to acquire and calculate a product of each shift impulse used by the synchronizer and a shift order under each shift impulse to accumulate to obtain a used shift impulse life L of the synchronizer after the transmission actually runs to a set mileage₁；

In the formula:

β_ithe number of shifts for each shift stroke that has been used.

A second calculation module 105, the second calculation module 105 for calculating a total shift impulse lifeObtaining a remaining shift impulse life L of the synchronizer using a difference in shift impulse life₂For the remaining shift momentum life L₂Accumulating the gear shifting times under each gear shifting impulse to obtain the remaining gear shifting life time t of the synchronizer, wherein the remaining gear shifting life time t of the synchronizer is the remaining gear shifting impulse life L₂The accumulated value of the gear shifting times under each gear shifting impulse is obtained;

in the embodiment of the application, the similarity is similar to alpha_iAnd beta_iIntroducing a set of unknowns gamma_i，γ_iIndicating remaining shift momentum life L₂The number of gear shifts under each preset gear shift impulse can be obtained as follows:

the number of the remaining shift life time t of the synchronizer is gamma_iAccumulation of (c):

in some alternative embodiments: referring to fig. 2, the embodiment of the present application provides a device for monitoring the service life of a synchronizer of a commercial vehicle in real time, and the device further includes a determining module 104 for determining the service life L of the shift impulse when used₁And total shift momentum life L₀When the ratio epsilon% is larger than the set judgment coefficient delta%, the used shift impulse life L is ensured₁And taking the proportional relation of the gear shifting times under each gear shifting impulse as the actual gear shifting rule of the gearbox.

The second calculation module is further used for calculating the remaining shift impulse life L of the synchronizer according to the proportion relation of the shift times under each shift impulse in the used shift impulse life₂And through the remaining shift stroke life L₂And calculating the number t of the remaining shifting service life of the synchronizer.

When the gearbox is actually used, even the same type of gearbox is used, the service life of the synchronizer is different due to different gear shifting rules of drivers. The average gear shifting rule of all factory-leaving vehicles collected by a manufacturer is used for calculating the number t of the remaining gear shifting life of the synchronizer, so that the result is easy to be inaccurate, and therefore, the gear shifting rules of different drivers need to be independently learned.

Therefore, when epsilon% < delta%, the embodiment of the application judges that the driving mileage of the gearbox of the vehicle is insufficient and beta is not enough_i/β_jThe stability is not available, so that the gear shifting rule of a driver is consistent with the gear shifting rule set by a factory in the following driving process; when epsilon% is more than or equal to delta%, the driving mileage of the gearbox of the vehicle is judged to be enough, in the following driving process, the gear shifting rule of the driver is approximate to the gear shifting rule in the driving course, and gamma can be obtained_i/γ_jThe values of (A) are as follows:

β_i/β_jis the proportion of the number of gear shifts at each gear shift stroke that the driver has used;

γ_i/γ_jis a proportion of the number of shifts at each shift stroke that is not used by the driver.

And (3) obtaining the number t of the remaining shift life of the synchronizer through the formulas (4), (5), (6), (7) and (8):

as can be seen from equations (9) and (10), the number of remaining shift life times t of the synchronizer is a function of the actual shift schedule β of the transmission, which is expressed as:

t＝f(β) (11)

in the formula:

beta is the actual gear shifting law of the gearbox.

It can be considered that t (β) is the number of remaining shift life times t of the synchronizer that is predicted with reference to the actual shift schedule β of the transmission.

In some alternative embodiments: referring to fig. 2, the embodiment of the present application provides a device for monitoring the service life of a synchronizer of a commercial vehicle in real time, a second calculating module 105 of the device is further configured to divide the traveled mileage of a transmission into a plurality of interval mileage sections, respectively calculate the remaining shift life times of the synchronizer according to the actual shift schedule of the transmission in each interval mileage section, and perform weighting processing on the remaining shift life times of the synchronizer calculated in each interval mileage section by using the second calculating module 105, and then perform accumulation to obtain the corrected remaining shift life times t of the synchronizer.

In the formula:

x_jfor the weight coefficient of the number of remaining shift life times of the synchronizer in the mileage section corresponding to the interval of 1 to m, f_j(beta) the number of remaining shift life of the synchronizer calculated for the shift schedule of the mileage section in different intervals;

x_jthe number and the numerical value of the (C) are determined according to the research of manufacturers on the market.

For example, a vehicle travels 2 kilometers, travels along a straight line at 0 to 1 kilometer, travels along a circular track at 1 to 2 kilometers, and travels along the circular track in the course of subsequent travel. Then, it can be considered that the actual shift schedule of 0-1 km has no reference value, and the actual shift schedule of 1-2 km should be all included in the calculation range.

At this time, equation (12) may be expressed as:t＝0*f_0～1(β)+1*f_1～2(β)。

referring to fig. 2, in the embodiment of the present application, a real-time monitoring device for the service life of a synchronizer of a commercial vehicle is provided, where a second calculation module 105 of the monitoring device selects a part of interval mileage sections from a plurality of interval mileage sections, weights the remaining shift life times of the synchronizer calculated according to the interval mileage sections, and then accumulates the weighted values to obtain an absolute value of a difference between the remaining shift life times of the synchronizer and the corrected remaining shift life times t of the synchronizer;

the calibration module 101 uses the proportional relationship of the shift times under each preset shift impulse as the initial shift schedule of the transmission, and the judgment module 104 determines that if the absolute value is greater than the set judgment threshold, the second calculation module 105 readjusts the weighting coefficient of the weighting process, or replaces the actual shift schedule with the initial shift schedule, and recalculates the remaining shift life time of the synchronizer.

The remaining shift life times of the synchronizer calculated by the mileage section among all the parts are as follows:

number of remaining shift life t of synchronizer₁The absolute value of the difference value of the remaining shift life times t of the corrected synchronizer is as follows:

Δt＝|t₁-t| (14)

the manufacturer may determine the determination threshold τ of Δ t (e.g., 1000 times, 2000 times) according to market research, and when Δ t is greater than τ, the result of calculating the lifetime by equation (12) is considered to have no accuracy, and the lifetime calculation is performed again. For example, change x_jOr replacing the actual gear shifting rule beta with the initial gear shifting rule alpha by a manufacturer, and then entering a formula (12) to calculate the number of the remaining service life of the synchronizer in real time.

In some alternative embodiments: referring to fig. 2, in the embodiment of the present application, a real-time monitoring device for the service life of a synchronizer of a commercial vehicle is provided, where a second calculating module 105 of the monitoring device selects an interval mileage segment closest to a current mileage from a plurality of interval mileage segments, and obtains an absolute value from a difference between a remaining shift life time of the synchronizer and a remaining shift life time of the modified synchronizer, which is calculated according to an actual shift schedule of a transmission with the selected interval mileage segment.

The calibration module 101 uses the proportional relationship of the shift times under each preset shift impulse as the initial shift schedule of the transmission, and the judgment module 104 determines that if the absolute value is greater than the set judgment threshold, the second calculation module 105 readjusts the weighting coefficient of the weighting process, or replaces the actual shift schedule with the initial shift schedule, and recalculates the remaining shift life time of the synchronizer.

The calculated number of the remaining shift life of the synchronizer in the section mileage section closest to the current mileage is as follows:

t₁＝f_m(β) (15)

number of remaining shift life t of synchronizer₁The absolute value of the difference value of the remaining shift life times t of the corrected synchronizer is as follows:

Δt＝|t₁-t| (14)

the manufacturer may determine the determination threshold τ of Δ t (e.g., 1000 times, 2000 times) according to market research, and when Δ t is greater than τ, the result of calculating the lifetime by equation (12) is considered to have no accuracy, and the lifetime calculation is performed again. For example, change x_jOr replacing the actual gear shifting rule beta with the initial gear shifting rule alpha by a manufacturer, and then entering a formula (12) to calculate the number of the remaining service life of the synchronizer in real time.

The calculation process of equation (9) is as follows:

let j equal 1 be given by equation (7):

and (3) pushing out:

and (3) pushing out:

substituting equation (16) into equation (6) yields:

namely:

equation (4) and equation (5) are combined to obtain:

substituting equation (16) into the above equation, we obtain:

namely:

substituting equation (17) into the above equation, we obtain:

obtaining by solution:

the calculation process of equation (10) is as follows:

let j equal 1 be given by equation (8):

substituting equation (18) into equation (6) yields:

namely:

equation (4) and equation (5) are combined to obtain:

substituting equation (18) into the above equation yields:

namely:

substituting equation (19) into the above equation yields:

obtaining by solution:

principle of operation

The embodiment of the application provides a real-time monitoring method and a monitoring device for the service life of a synchronizer of a commercial vehicle.

Then, accumulating the products of the preset gear shifting impulses and the gear shifting times under the preset gear shifting impulses to obtain the total gear shifting impulse service life of the synchronizer; and then, after the gearbox actually runs to a set mileage, acquiring and calculating the product of each gear shifting impulse used by the synchronizer and the gear shifting times under each gear shifting impulse, and accumulating to obtain the used gear shifting impulse service life of the synchronizer.

And finally, obtaining the remaining shift impulse life of the synchronizer according to the difference between the total shift impulse life and the used shift impulse life, and accumulating the shift times under each shift impulse in the remaining shift impulse life to obtain the remaining shift life times of the synchronizer.

Therefore, according to the monitoring method, before the transmission leaves a factory, the gear shifting impulse of the synchronizer is calibrated, and the total gear shifting impulse service life of the synchronizer is calculated by calibrating a plurality of different preset gear shifting impulses of the synchronizer and the gear shifting times under each preset gear shifting impulse.

After the gearbox actually runs to a set mileage, the used gear shifting impulse life of the synchronizer is calculated by collecting and calculating the used gear shifting impulse of the synchronizer and the gear shifting times under the gear shifting impulses. And finally, obtaining the remaining shift impulse life of the synchronizer according to the difference value of the total shift impulse life and the used shift impulse life, and accumulating the shift times under each shift impulse in the remaining shift impulse life to obtain the remaining shift life times of the synchronizer to display the remaining shift life times of the synchronizer to a user.

According to the method and the device, the service life of the synchronizer is judged by monitoring the gear shifting impulse of the synchronizer, the judgment result is more objective and accurate, the possibility of misjudgment is reduced, the safety of the gearbox is guaranteed, the remaining gear shifting service life of the synchronizer can be predicted, and the user experience is improved.

In the description of the present application, it should be noted that the terms "upper", "lower", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, which are only for convenience in describing the present application and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and operate, and thus, should not be construed as limiting the present application. Unless expressly stated or limited otherwise, the terms "mounted," "connected," and "connected" are intended to be inclusive and mean, for example, that they may be fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present application can be understood by those of ordinary skill in the art as appropriate.

It is noted that, in the present application, relational terms such as "first" and "second", and the like, are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in a process, method, article, or apparatus that comprises the element.

The above description is merely exemplary of the present application and is presented to enable those skilled in the art to understand and practice the present application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the application. Thus, the present application is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.