Design of Microcomputer Control Test System for Automobile Alternator Performance Tan Qing 1 Hu Zhiming. Zhongnan Industry People's Electromechanical Research Institute. Lake 1. Changsha 41083 design requires the overall structure and design method of its mechanical and electronic control hardware system function software modules. Discuss this, debugging and features of the test system. After the test system is put into trial operation, it has been tested by the quality inspection department of the relevant manufacturer. The results of the test show that its technical performance indicators can be comparable with imported equipment, and the accuracy and low efficiency of the traditional test methods for automobile generator performance are solved. The data is not currently the vast majority of automotive generator manufacturers in the performance test of automotive generators are using the traditional test method, its test accuracy is low, high efficiency and low data can not be stored. Bringing a lot of quality to the product quality test, and the automobile generator manufacturers in developed countries have introduced the microcomputer to the city of the city. Several large auto electric appliance companies have also introduced such equipment. However, it is expensive, so in China, we have developed a computer-based test system for the performance of automotive hair dryers with high performance and stable test accuracy. It is a meaningful and cutting-edge work. Wood Wen introduces the design example of the abbreviation system. The new system no longer needs to manually adjust the load, no longer use visually coordinated operation methods, and the switching of inspection items no longer depends on labor; secondly, the test accuracy must reach an advanced level. Speed ​​is also greatly shortened the test cycle. To meet the requirements of productivity, the latest system should be applied to the main technical indicators and functions of a variety of + different models of hairpin design new system, including the different types of integrated automotive alternator; the system should have parameter setting performance test sampling Coefficient proofreading record query and operation help and other functions; start charging, zero current speed, must measure, load characteristics must be measured, up to file can be set, the regulator adjusts the voltage characteristics must be measured; the final detection accuracy level of the device is. The voltage is 0.5; the current is 5; the speed is 1. The level test requires continuous completion, during which the load adjustment and the test item 1 are switched to ensure the test speed; the test results are displayed on the screen, and there are Light refers to the test results to be saved, and can be easily inquired and printed afterwards. 2 system design 2.1 system overall knot factory according to 1 requirements, and reference 1. We designed a system structure hardware is mainly divided into six parts Input and output interface data acquisition card and related interface terminal board; measurement unit sensor and its signal conversion, execution unit inverter relay electronic load; record display unit display hard disk. printer. 2.2 System mechanical design This system requires convenient loading and unloading. Therefore, the fixed clamping of the generator is pneumatic, and the clamping and electrode wiring of the generator are automatically completed. In order to ensure the accuracy of the test, the contact of the contact is good, the electrode material is made of copper, the position of the generator is set by the generator mounting hole and the convex position is set into the disk and the pressure head is detached to adapt to different vertical requirements. The generator shaft is connected to the drive shaft through a 1-axis coupling to avoid damage to the motor bearing by the eccentric force. 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 stable motor speed and easy control. The drive shaft and the drive motor are placed in the bed through sound insulation to reduce the impact of mechanical noise on the environment. The speed of the drive shaft is very high, and the design also adopts noise reduction measures. 2.3 system electric screw hardware set 2.3.1 system main test circuit according to the domestic steam electrical standards standards test requirements. The designed test circuit hardware mainly consists of a whole consisting of a generator and a rectifier circuit and a regulator, and outputs a direct current; 2 current sensors 1 and 1 and 2, respectively, are used to detect the charging current and the load current; The sensor 8 detects the controlled object of the automobile alternator; the speed of the generator is detected by a rotational speed sensor, and the frequency bit number is passed through the frequency rolling converter and then enters the computer controlled electronic load to make the load current change satisfy. Performance testing requirements. 2.3.2 System Control Principle 3 It can be seen from 1 that the control core of the system is the industrial computer of the station 586, and its function is to provide a human-computer interaction interface. Control the progress of the entire test process. After completing the connection of the system related to the external system, the 818 data acquisition card is thrown, the current voltage and the reverse sampling signal are converted into a digital input computer through the 8181; the operation button of the console passes the switch of 88. Input port, 1 input computer; computer output control signal through 818 switch output port 00 to the finger buzzer relay, etc. The generator is driven by the Taiwan phase asynchronous motor. The motor is screwed by the inverter. The inverter can pass the 1. and 0 of the machine, and the speed and acceleration and deceleration process. 2.4 System function software shuttle block 14 wood system application The software consists of 5 function blocks. The functional blocks of each station are independent of each other, connected to each other, and become a whole. The overall structure of the cabinet 2. The following is a brief introduction of each functional module. System application software module structure box 2.4.1 parameter setting module 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 system's parameter setting module saves 20 kinds of generator model parameters, and each model's parameters are set to exit the parameter setting module. The last changed or set model becomes the current test model. The module also has settings for items such as test date and product start number. 2.4.2 Parameter Calibration Module In the system design, many anti-interference measures are adopted. For these measures, the following will be introduced in more detail. The function of the parameter proofing module is mainly to overcome the interference of some DC characteristics of the systematic error in the process of human 0 sampling and the nonlinear characteristics of the sensor itself, and to make the detected value reflect the actual value. The parameters are checked and paid, and the system is sampled successively, and the detected value and the real private position are respectively obtained. The method of linear regression of the claws fits the detected value to the actual value to obtain the proofreading coefficient. In order to make the proofreading meaningful, the actual value is obtained by a high-precision testing instrument. The function of the 2.4.3 test module test module is to perform computer control on the generator test process, the test model parameters of the test, and the test items and sequence. Both are taken from the last parameter setting. After pressing the start button, the computer automatically performs the system test process according to the set parameter conditions and the order of the items, and automatically tests completely. The result is obvious. The accumulation of record saves and numbers. 2.4.4 Record Query and System Help Module Record Query Module provides the ability to record and query the printer for printing according to the model by month according to the current date. The system help module provides online help for detailed descriptions of the system functions and how to operate them, helping the operator to operate correctly and learn from the novice. 3 system debugging When the theoretical design of the system plan is put into the reality of the factory, there will always be a lot of questions. The debugging sequence of the system is from partial to the whole system; from hardware to software; from the mechanical line, which detects the debugging of the system signal sampling channel and the suppression of the interference of the electronic load debugging current is the key to the whole debugging. Because the system has a frequency converter and the working current of the generator, there is a large 屯 magnetic disturbance, and the extreme human milk rang the accuracy of the sampling signal. Therefore, the debugging of the sampling channel not only includes the routine work such as the calibration of the zero point and the span, but more importantly, the interference of the system must be excluded. In order to prevent the harmonic noise entering the system when the inverter is running, 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 junction. In particular, it is necessary to avoid the situation in which a large current wire is enclosed in the signal line routing path. The debugging of the electronic load can be carried out in the test software of the 818 card. The production of sputum must ensure stable performance and good linearity, which brings greater convenience to software control. The design of electronic load should consider over-current and over-voltage protection to adapt to the test of different hairpins. Current closed loop, system adoption, segmentation control, 0 system accurate test fast. 4 System Features 4 Wood system's juice design and software compilation strive to reflect the following special features to make the system with better automatic continuity, intelligent accuracy, speed and reliability. Automatic continuity intelligence The system is controlled by the 586 industrial computer for the whole performance test process of the automotive alternator. It can set the parameter of the +4 generator. When entering the test state, the product number is changed. After the test, the number of the product number can be arbitrarily set. The test can be arranged arbitrarily. Accuracy The system considers the main factors affecting the detection accuracy in the design and debugging. For example, the sensor detection accuracy, the inverter electromagnetic signal interferes with the rectified voltage and current of the generator to reach the predetermined required voltage of 0.5, the current is 5, and the rapidity is in the load performance. When testing, first give the initial value, so that the actual current value is very close, thus shortening the adjustment. The closed-loop adjustment of the turbulence is adopted when the segmentation is 0. The control algorithm is used when the error is large, and the control is used to reduce the overshoot; The hour is adopted, the control is kept to maintain the control speed and the steady-state error is eliminated; when the computer enters the set value error limit, the last twisting scene is maintained, and the limit ring or adjustment is avoided, and the advantage of being too long is stability and The convergence of the test results. The high safety 3 start button must be activated after the clamp is clamped; the release button is valid only when the speed is less than 3 mountains 14 , and the excitation pressure does not correspond to the hair extension machine, and the test state cannot be entered. The system can guarantee no cause. The test damages the product under test. 5 Conclusion The system has been put into trial operation in several large-scale automobile and electric appliance factories such as Changsha Hitachi Automobile Electric Appliance Factory. The quality inspection department has tested the performance. The system is reliable in operation, convenient and flexible in operation, and the test accuracy is stable. Both meet and exceed the juice requirements, the test cycle can be controlled within 2,5, the results of repeated tests of the same generator are very good. The system is put into operation, solving 7 traditional test methods, large error results, poor reliability, data recording time-consuming The cumbersome and so on, the test accuracy is greatly improved, thus ensuring the product quality; due to the flexible software programming, and the entire test has achieved 0 mobilization, thereby reducing the labor intensity and improving the efficiency. The technical performance indicators can be published with the entry control equipment comparable to the Automotive Technology Research Center Standardization Institute. 2.5161. 2 Li Zhizhong, Wang Jiaxuan. The microcomputer application in data acquisition and monitoring is elbow. Beijing Tsinghua University Press, 1998.3 Qi Zhiping. Software technology for electromechanical systems. Beijing Zhongjin Liu Enzhen Computer Technology System Analysis and Designer, Wuhan Huazhong University of Science and Technology Press. 1993.680.
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Design of Microcomputer Control Test System for Automobile Alternator Performance