Torque test of the drive shaft is the main means to disassemble the resistance of the vehicle chassis (including tires) and analyze the energy flow. Aiming at the demand of quick test of vehicle drive shaft torque, a test system which could be applied to different vehicle types was developed. Firstly, the overall architecture of the drive shaft torque test system was designed, which included sensing assembly, wireless acquisition assembly and calibration bench, and key hardware was selected; secondly, a sensing component that could achieve wide temperature compensation and axial moment decoupling was designed using biaxial patch bridge technology, and a rechargeable shaft sleeve that could adapt to narrow spaces was developed, which was made by 3D printing technology, and could support testing endurance requirements of over 20 hours and meet the layout, power supply, and thermal radiation resistance requirements of sensing components; then, a fast calibration test bench suitable for large axial angle deformation of the driving shaft after loading was designed; finally, the developed torque test system was calibrated, and road test and drum test were conducted. The results showed that the linearity of the drive shaft torque calibration reached 99.811%, and the test system had good performance and high test accuracy. The designed vehicle drive shaft torque test system has the advantages of fast calibration and test, portability and reusability of key sensing modules, and has high practical application value.
Yu TANG,Liang TAO,Yi XU,Heng WANG,Bin CHEN,Xiaolong ZHANG. Development and test of vehicle drive shaft torque test system. Chinese Journal of Engineering Design, 2023, 30(6): 789-796.
Fig.1 Structural block diagram of drive shaft torque test system
元件
厂地/型号
性能参数
供电形式
传感模块
德国/ datatel dt 1001T-ST
输出：±2 V，输入：±50 mV，阻值≥350 Ω
工作温度：-40~125 ℃
DC 5.1~9 V
RF无线接收器
德国/ datatel dt 1001R2-S
模拟输出：±10 V，工作温度：0~40 ℃
DC 10~32 V
模数采集模块
英国/ Influx
8路差分16位模数通道，精度：±0.001 5%
采样率：1 kHz
DC 4~36 V
应变片
日本/ KFGS-2-120-D31-11
硬化后工作温度：-196~120 ℃
自动补偿温度：10~100 ℃，电阻：350 Ω
线性膨胀系数：11×10-6/℃
Table 1Performance parameters of each component of drive shaft torque test system
Fig.2 Full bridge connection schematic and physical arrangement of strain gauges
Fig.3 Schematic of shaft sleeve assembly
Fig.4 Comparison of internal and external temperature of shaft sleeve at speed of 10 km/h
Fig.5 Calibration bench assembly
部件
材料
密度/
（kg/mm3）
弹性模量/Pa
泊松比
传力板
40 Cr
7.82×10-9
2.06×1011
0.29
横臂
45号钢
7.85×10-9
2.06×1011
0.27
Table 2Material parameters of transmission plate and cross arm
Fig.6 Stress nephogram of assembly of transmission plate and cross arm
Fig.7 Displacement nephogram of assembly of transmission plate and cross arm
序号
砝码质量
m/ kg
传感总成输出
电压Us/ mV
T40B扭矩传感器
输出电压Ul / mV
1
28.0
1 355.12
-1 740.20
2
66.0
3 179.00
-4 080.15
3
34.0
1 642.29
-2 107.30
4
49.4
2 379.27
-3 056.29
5
36.5
1 762.22
-2 262.67
6
10.5
514.18
-660.16
7
15.0
-696.61
898.82
8
74.0
-3 515.96
4 486.43
9
53.5
-2 543.20
3 241.73
10
21.0
-1 001.11
1 263.44
11
9.0
-431.85
535.27
12
40.0
-1 903.68
2 421.85
13
29.4
-1 396.24
1 773.02
Table 3Data of calibration test of sensing assembly
Fig.8 Calibration curve of sensing assembly
Fig.9 Installation diagram of sensing assembly
Fig.10 Test results of sensing assembly torque and wheel rim torque under variable vehicle speed
Fig.12 Relationship curve between sensing assembly torque and wheel rim torque under constant vehicle speed
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