CN114659792A - Belt tension control method and system - Google Patents
Belt tension control method and system Download PDFInfo
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- CN114659792A CN114659792A CN202210267800.4A CN202210267800A CN114659792A CN 114659792 A CN114659792 A CN 114659792A CN 202210267800 A CN202210267800 A CN 202210267800A CN 114659792 A CN114659792 A CN 114659792A
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- G01M15/00—Testing of engines
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- G—PHYSICS
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- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
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Abstract
The application relates to the technical field of engines, and provides a belt tension control method and a belt tension control system, wherein the belt tension control method comprises the following steps: tensioning the initial belt by using the initial tension value, performing a thermal test of fixed load and fixed rotating speed on the initial belt, and determining the initial tension value as an initial process tension value under the condition that the initial stable tension value of the initial belt meets a first preset condition; and (3) taking the initial process tension value as a retest initial tension value to initially stretch the retest belt, adjusting the retest initial tension value until the retest stable tension value of the retest belt meets a second preset condition, and determining the retest initial tension value as an installation tension value. The control method and the control system can continuously optimize the installation tension value, increase the success rate of subsequent belt installation, accelerate the production beat and improve the working efficiency.
Description
Technical Field
The application relates to the technical field of engines, in particular to a belt tension control method and system.
Background
In the related art, the belt tension of a fixed front end pulley system of an engine is a tensile force generated by belt elongation, and when each belt is pulled to a target tension, because the belt cannot completely fall into a wedge groove of a pulley in an initial stage, an actual stable tension value after the actual operation of the belt greatly deviates from a target tension value, and the operation of the belt is influenced.
Disclosure of Invention
In view of the above, embodiments of the present application are intended to provide a method and a system for controlling belt tension.
In order to achieve the above purpose, the technical solution of the embodiment of the present application is implemented as follows:
the embodiment of the application discloses a belt tension control method on one hand, which is used for fixing a front-end gear train and comprises the following steps:
tensioning an initial test belt by using an initial tension value, performing a thermal test of a fixed load and a fixed rotating speed on the initial test belt, and determining the initial tension value as an initial process tension value under the condition that the initial stable tension value of the initial test belt meets a first preset condition;
and taking the initial process tension value as a retest initial tension value to initially stretch the retest belt, adjusting the retest initial tension value until the retest stable tension value of the retest belt meets a second preset condition, and determining the retest initial tension value as an installation tension value.
In one embodiment, the number of retest belts is not greater than the number of initial belts.
In one embodiment, the step of taking the initial process tension value as a retest initial tension value to initially stretch the retest belt, adjusting the retest initial tension value until a retest stable tension value of the retest belt meets a second preset condition, and determining the retest initial tension value as an installation tension value includes:
selecting a part from a plurality of retest belts as a first retest belt, and primarily tensioning the first retest belt by taking the initial process tension value as a retest initial tension value;
and carrying out a thermal test of a fixed load and a fixed rotating speed on the first retesting belt, determining that the retest stable tension value of the first retesting belt meets the second preset condition, and determining that the first retest initial tension value is the installation tension value, wherein the number of the first retest belts is 3% -7% of the number of the initial test belts.
In one embodiment, the step of taking the initial process tension value as a retest initial tension value to initially stretch the retest belt, adjusting the retest initial tension value until a retest stable tension value of the retest belt meets a second preset condition, and determining the retest initial tension value as an installation tension value includes:
under the condition that the retest stable tension value of the first retest belt does not meet the second preset condition, selecting a part from the retest belts as an additional retest belt according to a preset proportion, and adjusting the retest initial tension value as an additional retest initial tension value to primarily stretch the additional retest belt;
and carrying out a thermal test of a fixed load and a fixed rotating speed on the added retest belt, determining that the retest stable tension value of the added retest belt meets the second preset condition, and determining that the added retest initial tension value is the installation tension value.
In one embodiment, the predetermined ratio is 50% to 100% of the number of the initial belts.
In one embodiment, an initial belt is tensioned according to an initial tension value, the initial belt is subjected to a thermal test with a fixed load and a fixed rotating speed, and the initial tension value is determined to be an initial process tension value when an initial stable tension value of the initial belt meets a first preset condition, wherein the control method comprises the following steps:
carrying out a thermal test of a test belt at a constant rotating speed and a constant load to obtain a target tension value of the test belt in a stable period; the first preset condition comprises the steps of determining that the absolute value of the difference between the initial stable tension value and the target tension value is smaller than a target tolerance, and determining that the process capacity index of the initial belt is larger than or equal to a threshold value.
In one embodiment, the method for performing a constant-speed and constant-load thermal test on a test belt to obtain a target tension value of the test belt during a stabilization period comprises the following steps:
carrying out a thermal test of a test belt at a fixed rotating speed and a fixed load, and recording a tension value of the test belt along with time to obtain a damping curve of the tension value of the test belt along with the change of time;
and according to the attenuation curve of the test belt, the tension value of the test belt in the stable period is a target tension value.
In one embodiment, the second preset condition includes:
the second preset condition comprises that the absolute value of the difference between the retest stable tension value and the target tension value is smaller than the target tolerance;
determining that a process capability index of the retest belt is greater than or equal to the threshold.
Another aspect of the embodiments of the present application discloses a belt tension control system, including:
mounting an actuator;
a control device capable of controlling the mounting actuator mounting belt to realize the control method according to any one of claims 1 to 8.
In one embodiment, the control system comprises:
and the alarm device is electrically connected with the control device, and the control device can control the alarm device to send out an alarm signal under the condition that the retest stable tension value of the retest belt does not meet the second preset condition.
The embodiment of the application discloses a control method and a control system for belt tension, an initial test belt is stretched by an initial tension value in the early stage, the initial stable tension value after stabilization meets the preset conditions so as to determine the initial test process tension value, then the initial test process tension value is used as a retest tension value to stretch the retest belt, the process tension value is determined after the retest stable tension value after stabilization meets the preset conditions, the process tension value is continuously optimized so that when a large batch of belts are subsequently installed, the installation tension value can be directly adjusted to the process tension value, the measurement times are reduced, and the production tact is accelerated.
Drawings
Fig. 1 is a schematic flow chart of a method for controlling a belt tension according to an aspect of the present disclosure;
FIG. 2 is a schematic structural diagram of a pulley of the generator adjusted by an adjusting lever in a fixed front-end gear train, wherein a dotted line is an initial position of the pulley of the generator;
FIG. 3 is a schematic view of the belt fully dropped into the pulley wedge groove;
fig. 4 is a schematic view of a structure in which the belt does not completely fall into the pulley wedge groove.
Description of the reference numerals
A fixed front end wheel train 1; a belt 11; a generator pulley 12; a water pump pulley 13; an idler pulley 14; a compressor pulley 15; a crankshaft pulley 16; the rod 2 is adjusted.
Detailed Description
It should be noted that, in the present application, technical features in examples and embodiments may be combined with each other without conflict, and the detailed description in the specific embodiment should be understood as an explanation of the gist of the present application and should not be construed as an improper limitation to the present application.
The present application will be described in further detail with reference to the following drawings and specific embodiments. The descriptions of "first," "second," etc. in the embodiments of the present application are for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly including at least one feature. In the description of the embodiments of the present application, "a plurality" means at least two, e.g., two, three, etc., unless specifically limited otherwise.
Before describing a method and a system for controlling belt tension provided by the embodiments of the present application, in order to make the embodiments of the present application clearer, a fixed front-end gear train of an engine is described:
referring to fig. 2, a fixed front wheel train 1 of an engine includes: the belt 11, the generator belt wheel 12, the water pump belt wheel 13, the idler wheel 14, the compressor belt wheel 15 and the crankshaft belt wheel 16, and the belt 11 sequentially bypasses the generator belt wheel 12, the water pump belt wheel 13, the idler wheel 14, the compressor belt wheel 15 and the crankshaft belt wheel 16. Tension is generated by extending the belt 11, so that the belt 11 is tightened, and when the engine is in operation, the belt 11 can drive each belt wheel to rotate. After the belt 11 is installed, the positions of the respective pulleys are not substantially moved again by the change in the load or the like.
In the related art, when the belt 11 is installed in a workshop and the belt 11 is driven to move by manually rotating the crankshaft pulley 16 for three circles, because each accessory (compressor and generator) has no load, the tension of the belt 11 is low in the operation process of the belt 11, the belt 11 cannot well fall into the corresponding wedge groove, and meanwhile, the speed of rotating the crankshaft also influences the depth of the belt 11 falling into the wedge groove. The belt 11 is completely dropped into the wedge groove as shown in fig. 3, and the belt 11 is not completely dropped into the wedge groove as shown in fig. 4. Because the belt 11 does not completely fall into the wedge groove, if the measured tension of the belt 11 is (example 500N), in the subsequent operation process, the dynamic tension of the belt 11 is greatly increased (for example, 1500N at the maximum) due to the dynamic operation (the load of the compressor and the generator is increased, and the rotating speed of the engine is increased), the belt 11 will quickly fall into the wedge groove in a short time, so that the initial tension of the belt 11 is rapidly attenuated in a large proportion (for example, the operation is attenuated to 350N in a short time) to reach an actual stable tension value, and the actual stable tension value and a target tension value generate a large deviation. From the wheel system, the problem of abnormal slipping noise can be caused by an excessively small actual stable tension value; an excessive actual steady tension value will affect the life of the belt 11 and the bearings in the vicinity, while an excessive actual steady tension value will also lead to excessive fuel consumption problems.
In view of the above, an aspect of the embodiment of the present invention provides a method for controlling a belt tension, for fixing a front-end gear train 1, with reference to fig. 1, the method includes:
s1, tensioning the initial belt by the initial tension value, carrying out a thermal test of a fixed load and a fixed rotating speed on the initial belt, and determining the initial tension value as an initial process tension value under the condition that the initial stable tension value of the initial belt meets a first preset condition.
Specifically, the initial tension value refers to a tension value when the initial belt is initially tensioned after the initial belt is wound on the fixed front-end wheel train 1. The initial stable tension value refers to the tension value of the initial belt when the tension state of the initial belt reaches basic stability after the initial belt is subjected to a thermal test.
It is understood that the condition that the tension of the initial belt is substantially stable means that the tension of the initial belt is attenuated to enter a stable attenuation period, and the tension value of the initial belt in the stable attenuation period may have small fluctuation, but the fluctuation of the stable attenuation period is small relative to the tension attenuation in the rapid attenuation period of the initial belt.
Here, the number of the initial belts is plural. For example, in the case of installation of the workshop belt 11, the planned production capacity of the day may be taken as the whole capacity, and at least a part of the whole capacity, such as 95% or 100%, may be taken as the initial belt. For example, when 200 machines are planned for production on the same day, 190 or 200 machines may be taken for initial belt installation.
On the one hand, through the measurement of preliminary examination belt and carry out the collection analysis, can acquire preliminary examination technology tension value comparatively accurately, can reduce follow-up belt 11 and measure the number of times, improve work efficiency.
On the other hand, the constant rotational speed means that the engine rotates the crankshaft pulley 16 at a constant rotational speed. The constant load means that the fuel injection quantity of the engine is constant by controlling the throttle opening. By adopting a thermal test with constant rotating speed and constant load, the belt 11 can be effectively embedded into the wedge grooves in each belt wheel, the mounting precision of the belt 11 is improved, the uncertainty of tension measurement of the belt 11 is reduced, and the production quality is improved.
S2, taking the initial process tension value as a retest initial tension value to initially stretch the retest belt, adjusting the retest initial tension value until the retest stable tension value of the retest belt meets a second preset condition, and determining the retest initial tension value as an installation tension value.
Specifically, the retest initial tension value is a tension value when the retest belt is initially tensioned after the retest belt is wound on the fixed front-end wheel train 1. The retest stable tension value refers to the tension value when the tension state of the retest belt reaches basic stability after the retest belt is subjected to a thermal test.
The installation tension value may be used for subsequent batch installations of the belt 11. The installation tension value is the tension value when the belt 11 is initially tensioned after the belt 11 is wound on the fixed front-end wheel train 1.
It is understood that the condition of the retest belt being substantially stable is defined as the tension of the retest belt decaying into a steady decay period, wherein the tension of the retest belt may fluctuate less during the steady decay period, but less during the steady decay period relative to the tension decay period during which the retest belt decays rapidly.
Illustratively, in some embodiments, the number of retest belts is no greater than the number of pretest belts. Therefore, the preliminary test process tension value preliminarily determined in the early stage can be verified and adjusted through a proper amount of retesting belts, and the efficiency and the accuracy are both considered. The initial process tension value can be optimized on the premise of not reducing the working efficiency so as to increase the success rate of the subsequent belt 11 installation.
The mode of adjusting the retest initial tension value is not limited, for example, referring to fig. 2, the retest initial tension value can be adjusted by moving the position of any one pulley of the front-end wheel train 1, and after the position of the pulley is moved, the adjusted pulley can be locked by a fastener such as a bolt or a screw. Illustratively, taking the adjustment of the generator pulley 12 as an example, the generator pulley 12 is disposed in a preset track, the preset track may be linear, curved, or in other shapes, and one end of the preset track is an initial end, and when the generator pulley 12 is at the initial end, the preset track is closer to the other pulleys, so that the retest belt is easily mounted on each pulley in the front-end train, after the retest belt is mounted, the adjusting rod 2 is pulled to drive the generator pulley 12 to move away from the initial end in the preset track, at this time, the retest belt is slowly tightened, and the retest initial tension value is gradually increased, thereby achieving the purpose of adjusting the retest initial tension value.
The installation tension value of the follow-up belt 11 is determined under the condition that the stable retest stable tension value meets the second preset condition. Like this, through the large batch preliminary examination belt in earlier stage to preliminary examination process tension value acquire with preliminary optimization after, then verify and further optimize the retest belt of the less quantity of preliminary examination process tension value tensioning that will acquire to reduce follow-up belt 11 installation tension value uncertainty, increase the success rate of installation, can accomplish belt 11's batch installation high-efficiently, effectively accelerate the production beat, improve production efficiency.
In one embodiment, S1, a preliminary belt is tensioned according to an initial tension value, the preliminary belt is subjected to a thermal test with a constant load and a constant rotation speed, and when an initial stable tension value of the preliminary belt satisfies a first preset condition, the initial tension value is determined to be an initial process tension value, and the control method includes:
s11, carrying out thermal test of a test belt at a constant rotating speed and a constant load to obtain a target tension value of the test belt in a stable period; the first preset condition comprises the steps of determining that the absolute value of the difference between the initial stable tension value and the target tension value is smaller than a target tolerance, and determining that the process capacity index of the initial belt is larger than or equal to a threshold value.
Exemplarily, 2-5 belts 11 are taken as test belts to carry out a thermal test with a fixed rotating speed and a fixed load, and the tension value after the test belts are stable is obtained as a target tension value. The target tolerance is a preset value, and the operator can determine the target tolerance as required, for example, the target tolerance can be between 5N (newton) and 10N, for example, the target tolerance can be 10N; the target tolerance can also be obtained through corresponding calculation by obtaining the target tension values of a plurality of stable test belts. And then ensuring that the initial stable tension value falls into the range of the target tension value by the absolute value of the difference between the initial stable tension value and the target tension value after the initial belt is stabilized and the target tolerance. The target tolerance can also be optimized according to the actual engineering capability.
Here, the process capability index (Cpk) as used herein refers to the degree to which the process capability meets the requirements of the product quality standards, such as specification ranges and the like. The calculation formula is as follows: CPK ═ Min [ (USL-Mu)/3 σ, (Mu-LSL)/3 σ ], USL denotes the upper specification limit, LSL denotes the lower specification limit, Mu denotes the average value, and σ denotes the standard deviation.
Illustratively, the threshold is 1.33. Whether the process capability coefficient is larger than or equal to 1.33 is judged by calculating the process capability coefficient between the initial stable tension value of the initial belt and the target tension value range of the test belt, and the initial stable tension value is ensured to meet the requirement of yield. Note that, when Cpk.gtoreq.1.33, the expression ability was good, the state was stable, and the initial stable tension value was close to the target tension value. In the embodiment, the absolute value of the difference between the initial stable tension value and the target tension value is determined to be smaller than the target tension, and if the absolute value does not meet the requirement, the initial tension value can be adjusted until the absolute value meets the requirement; after the requirements are met, calculating the process capability index of the initial belt to be greater than or equal to the threshold, if Cpk is less than the threshold, indicating that the initial stable tension value deviates from the target tension value, and if the initial stable tension value is greater than or less than the target tension value, if the initial stable tension value is greater than the target tension value, correspondingly reducing the initial tension value, if the initial stable tension value is less than the target tension value, correspondingly increasing the initial tension value until the process capability index of each initial belt is greater than or equal to the threshold. The accuracy of the tension value of the initial test process can be improved, the number of measurement times is reduced for the verification of the follow-up retest belt, and the production efficiency is improved. Of course, the threshold value can also be 1.67, and the accuracy of the initial process tension value is further improved.
In one embodiment, the step S11 of performing a constant-speed and constant-load thermal test on the test belt to obtain a target tension value of the test belt during a stabilization period includes:
s111, carrying out a thermal test of a fixed rotating speed and a fixed load on a test belt, and recording a tension value of the test belt along with time to obtain an attenuation curve of the tension value of the test belt along with time variation;
and S112, according to the attenuation curve of the test belt, setting the tension value of the test belt in the stable period as a target tension value.
Exemplarily, 5 belts 11 are taken as test belts to be subjected to a thermal test with a constant rotation speed and a constant load, tension values of the test belts along with time are recorded at regular intervals, for example, 10min, a decay curve of the tension values of the test belts along with time is drawn, and according to the decay curve of the tension values of the test belts along with time, the tension values after a stable decay period, for example, 20min, are taken as target tension values. It can be understood that in the tension decay curve with time, the tension decay is roughly divided into two periods, the period of time when the tension is rapidly reduced is the rapid decay period, the period of time when the tension is basically stable is the stable decay period, and the time when the stable decay period is carried out from the rapid decay period is the turning time, so that the turning time corresponds to the situation that the tension value of the test belt enters the stable period, and the tension value of the stable period is the target tension value.
Therefore, the target tension value can be quickly obtained within limited times by adopting fewer test belts, and the working efficiency is improved.
In some embodiments, the time-dependent attenuation curve of the tension of the test belt can be output to a computer screen or output to paper, so that an operator can visually observe the time-dependent attenuation curve of the tension of the test belt, search the turning time of the tension of the test belt from the rapid attenuation period to the stable attenuation period according to the time-dependent attenuation curve of the tension of the test belt, and determine the target tension value through the turning time. Of course, it is also possible to directly output the target tension value without outputting the tension decay curve of the test belt with time. In practice, the operator makes a selection according to the requirements of the belt 11. In some embodiments, the target tension value may not be directly output to a computer screen or a paper sheet, and may be buffered in a detection device or a processor as long as the target tension value can be used for performing the next processing.
Exemplary ways to determine the stationary phase by the turn-over time are: can be determined according to the slope of the decay curve corresponding to the time point. For example, the time point corresponding to the initial 0 slope of the decay curve is the inflection time, indicating that the tension value has entered the stationary phase.
In one embodiment, S2, primarily tensioning the retest belt by using the initial process tension value as a retest initial tension value, adjusting the retest initial tension value until a retest stable tension value of the retest belt meets a second preset condition, and determining the retest initial tension value as an installation tension value includes:
s21, selecting a part from the plurality of retest belts as a first retest belt, and primarily tensioning the first retest belt by taking the initial process tension value as a retest initial tension value;
s22, performing a thermal test of a fixed load and a fixed rotating speed on the first retesting belt, determining that the retesting stable tension value of the first retesting belt meets the second preset condition, and determining that the first retesting initial tension value is the installation tension value, wherein the number of the first retesting belts is 3% -7% of the number of the first retesting belts.
Illustratively, 5 retest belts are selected from the retest belts to serve as first retest belts, the first retest belts are initially tensioned by taking the initial process tension value as the retest initial tension value, then a thermal test with constant rotation degree and constant load is carried out, the tension value of the first retest belts along with time is recorded every 10min, a decay curve of the tension value of the first retest belts along with time is drawn, a corresponding tension value is obtained as a retest stable tension value according to the decay curve of the tension of the first retest belts along with time and a stabilization period after the turning time is 20min, and then whether the retest stable tension value meets a second preset condition is judged to determine that the retest initial tension value is an installation tension value. This application embodiment is through getting a plurality of retest belts in the part as first retest belt to the initial tension value of pretesting process carries out the stretch-draw for the initial tension value of retest, can verify the initial tension value of process that obtains earlier stage to and carry out further optimization and adjustment to it, for follow-up in batches 11 installation of belt provide accurate value and increase the installation success rate, reduce follow-up installation time, accelerate the production beat, improve production efficiency.
In some embodiments, the attenuation curve of the tension of the first retest belt with time can be output to a computer screen or to paper, so that an operator can visually observe the attenuation curve of the tension of the first retest belt with time, find the turning time when the tension of the first retest belt enters the stable attenuation period from the rapid attenuation period according to the attenuation curve of the tension of the first retest belt with time, and determine the retest stable tension value through the turning time. Of course, the tension of the test belt can be directly output to the retest stable tension value instead of outputting the attenuation curve of the tension of the test belt along with the time. In actual operation, the operator makes a selection according to the requirements of the belt 11. In some embodiments, the retest stable tension value may not be directly output to a computer screen or paper, and may be buffered in a detection device or a processor as long as it can be used for performing the next processing.
In one embodiment, the second preset condition includes:
s23, the second preset condition comprises that the absolute value of the difference between the retest stable tension value and the target tension value is smaller than the target tolerance;
and S24, determining that the process capability index of the retesting belt is larger than or equal to the threshold value.
For example, the target tolerance is a preset value, and the operator can determine the target tolerance as required, for example, the target tolerance may be between 5N (newton) and 10N, for example, the target tolerance may be 10N; the target tolerance can also be obtained through corresponding calculation by obtaining target tension values determined by the attenuation curves of the tension of a plurality of test belts along with time. And then judging the difference between the retest stable tension value and the target tension value, and ensuring that the retest stable tension value falls into the range of the target tension value. The target tolerance can also be optimized appropriately according to the actual engineering capability.
The threshold may be 1.33. And judging whether the process capability index is greater than or equal to 1.33 or not by calculating the process capability index between the process capability index of the retest belt and the range of the target tension value of the test belt, so as to ensure that the retest stable tension value meets the requirement of yield.
In the embodiment, the absolute value of the difference between the retest stable tension value and the target tension value is determined to be smaller than the target tension, and if the absolute value does not meet the requirement, the initial tension value can be adjusted until the absolute value meets the requirement; after the requirement is met, calculating the process capability index of the retest belt to be greater than or equal to the threshold, if the Cpk is less than the threshold, indicating that the retest stable tension value deviates from the target tension value, and if the retest stable tension value is greater than the target tension value, correspondingly reducing the retest initial tension value, and if the retest stable tension value is less than the target tension value, correspondingly increasing the retest initial tension value until the process capability index of each pretest belt is greater than or equal to the threshold. Through further optimization, the accuracy of the installation tension value can be improved, time for subsequent batches of the belts 11 is saved, and the production efficiency is improved. Of course, the threshold value may also be 1.67, improving the accuracy of the installation tension value.
In one embodiment, S2, primarily tensioning the retest belt by using the initial process tension value as a retest initial tension value, adjusting the retest initial tension value until a retest stable tension value of the retest belt meets a second preset condition, and determining the retest initial tension value as an installation tension value includes:
s25, under the condition that the retest stable tension value of the first retest belt does not meet the second preset condition, selecting a part from the retest belt as an additional retest belt according to a preset proportion, and adjusting the retest initial tension value as the additional retest initial tension value to initially stretch the additional retest belt;
s26, carrying out a thermal test of fixed load and fixed rotating speed on the additional retest belt, determining that the retest stable tension value of the additional retest belt meets the second preset condition, and determining that the initial tension value of the additional retest belt is the installation tension value.
Illustratively, a minimum requirement that a retest stable tension value is smaller than a target tension value occurs in a first retest belt, a part of the retest belts is selected as an additional retest belt according to a preset proportion, for example, 100 retest belts are selected from the retest belts, the additional retest belts are tensioned by taking the retest initial tension value as the additional retest initial tension value, then a thermal test with a fixed rotation speed and a fixed load is performed, the tension value of the additional retest belts along with time is recorded every 10min, an attenuation curve of the tension value of the additional retest belts along with time is drawn, a corresponding tension value is obtained as the retest stable tension value according to the attenuation curve of the additional retest belts along with time, a stable period is obtained after a turning time such as 20min, then whether the retest stable tension value meets a second preset condition is judged, and the retest initial tension value is determined as an installation tension value. It is understood that the minimum requirement of the target tension value herein refers to a minimum limit size of the target tension value obtained by calculating the target tension value and the target tolerance.
For example, in some embodiments, the preset ratio is 50% to 100% of the number of the initial test belts, for example, when the number of the initial test belts is 200, in the case that the retest stable tension value of the first retest belt does not satisfy the second preset condition, 50% of the number of the initial test belts, that is, 100 additional retest belts may be taken as the additional retest belts for testing; and if the retest stable tension value of the additional retest belt does not meet the second preset condition, continuously taking 100 percent of the number of the initial test belts, namely 200 retests, and readjusting the retest initial tension value. After the problem belt 11 can be corrected and adjusted in time, the retest initial tension value is further optimized, the rejection rate is reduced, and the qualification rate of subsequent belt 11 installation is improved.
It will be appreciated that the process capability index is greater than or equal to 1.33 and corresponds to a PPM (scrap per million) of 66.07, i.e., as throughput increases, although the stabilized tension of the belt 11 approaches the target tension, it will always deviate from the target tension, and therefore, the installation tension needs to be continually optimized and adjusted to reduce the scrap rate.
In one embodiment, after the installation tension value is determined, 5000 belts are produced in a fixed production period, for example, the belts can be tensioned through the determined installation tension value, so that a hot test for each batch of belts 11 is not required, the production rhythm is accelerated, and the production efficiency is improved.
In an embodiment, when the batch-installed belts 11 are subjected to spot inspection or a short-range slip abnormal sound fault occurs after sale, part of the batch-installed belts 11 are selected as retests, the retest initial tension value is optimized and adjusted, and the installation tension value is determined again.
In another aspect, the present embodiment provides a system for controlling tension of a belt 11, which includes a mounting actuator and a control device. The control device can control the mounting actuator mounting belt 11 to implement the control method described above. For example, taking a preliminary test belt as an example, the installation actuator can automatically assemble the preliminary test belt according to the initial tension value, and control the engine to rotate the crankshaft at a certain rotation speed, for example, at a rotation speed of 1r/min for 3 turns, and after the preliminary test belt enters the wedge groove of each belt wheel, then perform a thermal test at a fixed rotation speed and a fixed load; the control device is electrically connected with the installation actuator, can record an initial stable tension value of the initial belt in a stable period, calculates a process capability index of the initial belt, can adjust the initial tension value according to the size relation between the process capability index and a threshold value, and correspondingly controls the installation actuator to increase or decrease the initial tension value until Cpk is greater than or equal to 1.33 if Cpk is less than 1.33, so that the initial tension value is determined to be an initial process tension value.
In one embodiment, taking a retest belt as an example, the installation actuator can automatically assemble an initial test belt according to a retest initial tension value, control the engine to rotate the crankshaft at a certain rotation speed, for example, at a rotation speed of 1r/min for 3 circles, and perform a thermal test at a fixed rotation speed and a fixed load after the retest belt enters the wedge groove of each belt wheel; the control device is electrically connected with the installation actuator, can record a retest stable tension value of the retest belt in a stable period, calculates a process capability index of the retest belt, can adjust the retest initial tension value according to the size relation between the process capability index and a threshold value, and correspondingly controls the installation actuator to increase or decrease the retest initial tension value until Cpk is greater than or equal to 1.33 if Cpk is less than 1.33, so that the retest initial tension value is determined to be the installation tension value.
In the prior art, the tension detection of the belt 11 after assembly, hot test and stabilization of the hot test is not at the same station, and meanwhile, the excessively low stable tension value needs to be reworked again, so that a large amount of manpower needs to be coordinated, centralized and coordinated, the normal operation of a production line is influenced, and the production beat is seriously slowed down.
The control system in this embodiment installs executor and controlling means through the installation, concentrates on a station with the tension detection after assembly, heat examination and the heat examination is stable, can in time adjust it in the testing process, when there is the tension value of stabilizing unsatisfied preset condition, can adjust initial tension value automatically, uses manpower sparingly for the production beat, improves production efficiency.
In one embodiment, the control system comprises an alarm system, the alarm system is electrically connected with the control device, and the control device can control the alarm device to send out an alarm signal under the condition that the initial stable tension value of the initial belt does not meet the first preset condition and/or the retest tension value of the retest belt does not meet the second preset condition. The alarm signal can be light, sound or other means.
Illustratively, taking a preliminary test belt as an example, when the preliminary stable tension value of the preliminary test belt after stabilization is smaller than the minimum requirement of the target tension value, the control system controls the alarm device to send an alarm signal that a red light is normally on, so as to remind the preliminary test belt of being required to be reassembled and adjust the initial tension value; when the process capability index of the initial belt is smaller than the threshold value, the control device controls the alarm device to send a red light flashing alarm signal to remind that the initial tension value needs to be adjusted.
In one embodiment, taking a retest belt as an example, when the retest stable tension value of the retest belt after stabilization is smaller than the minimum requirement of the target tension value, the control system controls the alarm device to send an alarm signal that a red light is normally on, so as to remind the retest belt of being required to be reassembled and adjust the retest initial tension value; when the process capability index of the retest belt is smaller than the threshold value, the control device controls the alarm device to send out an alarm signal with red light flickering to remind that the retest initial tension value needs to be adjusted.
This embodiment is through installation alarm system, and under the condition that the tension value is unsatisfied first preset condition in the preliminary examination of preliminary examination belt, and/or the retest tension value of retest belt is unsatisfied the second preset condition, send alarm signal through controlling means control alarm device, be convenient for look over and data statistics to belt 11, improve work efficiency.
In one embodiment, the control device can control the alarm device to send out a qualified signal when the initial stable tension value of the initial belt meets the first preset condition and/or when the retest stable tension value of the retest belt meets the second preset condition. The qualified signal can be light, sound or other means. For example, when the process capability index of the initial belt is greater than or equal to the threshold value, the alarm device sends a signal of green light flashing to prompt that the initial belt is installed successfully. And data statistics can be conveniently carried out.
In one embodiment, when the process capability index of the retest belt is greater than or equal to the threshold value, the alarm device sends a signal of green light flickering to prompt that the retest belt is installed in a qualified mode.
Another aspect of the embodiments of the present application provides a storage medium on which a computer program is stored, where the computer program is executed by a processor to implement the steps in the control method in any one of the embodiments of the present application.
The above description is only a preferred embodiment of the present application, and is not intended to limit the present application, and various modifications and changes may be made to the present application by those skilled in the art. All changes, equivalents, modifications and the like which come within the spirit and principle of the application are intended to be embraced therein.
Claims (10)
1. A method of controlling belt tension for a fixed front wheel train, the method comprising:
tensioning an initial test belt by using an initial tension value, performing a thermal test of a fixed load and a fixed rotating speed on the initial test belt, and determining the initial tension value as an initial process tension value under the condition that the initial stable tension value of the initial test belt meets a first preset condition;
and taking the initial process tension value as a retest initial tension value to initially stretch the retest belt, adjusting the retest initial tension value until the retest stable tension value of the retest belt meets a second preset condition, and determining the retest initial tension value as an installation tension value.
2. The control method according to claim 1, wherein the number of the retest belts is not greater than the number of the initial belts.
3. The control method according to claim 1, wherein the step of primarily tensioning the retest belt by taking the initial process tension value as a retest initial tension value, the step of adjusting the retest initial tension value until the retest stable tension value of the retest belt meets a second preset condition, and the step of determining the retest initial tension value as an installation tension value comprises the steps of:
selecting a part from a plurality of retest belts as a first retest belt, and primarily tensioning the first retest belt by taking the initial process tension value as a retest initial tension value;
and carrying out a thermal test of a fixed load and a fixed rotating speed on the first retesting belt, determining that the retest stable tension value of the first retesting belt meets the second preset condition, and determining that the first retest initial tension value is the installation tension value, wherein the number of the first retest belts is 3% -7% of the number of the initial test belts.
4. The control method according to claim 3, wherein the step of primarily tensioning the retest belt by taking the initial process tension value as a retest initial tension value, the step of adjusting the retest initial tension value until the retest stable tension value of the retest belt meets a second preset condition, and the step of determining the retest initial tension value as an installation tension value comprises the steps of:
under the condition that the retest stable tension value of the first retest belt does not meet the second preset condition, selecting a part from the retest belts as an additional retest belt according to a preset proportion, and adjusting the retest initial tension value as an additional retest initial tension value to primarily stretch the additional retest belt;
and carrying out a thermal test of a fixed load and a fixed rotating speed on the added retest belt, determining that the retest stable tension value of the added retest belt meets the second preset condition, and determining that the added retest initial tension value is the installation tension value.
5. The control method according to claim 4, wherein the preset ratio is 50% to 100% of the number of the preliminary belts.
6. The control method according to claim 1, wherein an initial belt is tensioned at an initial tension value, the initial belt is subjected to a thermal test at a constant load and a constant rotation speed, and the initial tension value is determined as an initial process tension value in the case where an initial steady tension value of the initial belt satisfies a first preset condition, the control method comprising:
carrying out a thermal test of a test belt at a constant rotating speed and a constant load to obtain a target tension value of the test belt in a stable period; the first preset condition comprises the steps of determining that the absolute value of the difference between the initial stable tension value and the target tension value is smaller than a target tolerance, and determining that the process capacity index of the initial belt is larger than or equal to a threshold value.
7. The control method according to claim 6, wherein the step of subjecting the test belt to a constant-speed and constant-load hot test to obtain a target tension value for a stabilization period of the test belt comprises:
carrying out a thermal test of a test belt at a fixed rotating speed and a fixed load, and recording a tension value of the test belt along with time to obtain a damping curve of the tension value of the test belt along with the change of time;
and according to the attenuation curve of the test belt, taking the tension value of the test belt in the stable period as a target tension value.
8. The control method according to claim 6, characterized in that the second preset condition includes:
the second preset condition comprises that the absolute value of the difference between the retest stable tension value and the target tension value is smaller than the target tolerance;
determining that a process capability index of the retest belt is greater than or equal to the threshold.
9. A belt tension control system, comprising:
mounting an actuator;
a control device capable of controlling the mounting actuator mounting belt to realize the control method according to any one of claims 1 to 8.
10. The control system of claim 9, comprising:
the alarm device is electrically connected with the control device, the initial stable tension value of the initial belt is not met under the condition of the first preset condition, and/or the retest stable tension value of the retest belt is not met under the condition of the second preset condition, and the control device can control the alarm device to send out an alarm signal.
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