Article(id=1200070660924994390, tenantId=1146029695717560320, journalId=1189918454225211397, issueId=1200070646001664622, articleNumber=null, orderNo=null, doi=10.20104/j.cnki.1674-6546.20240259, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=null, receivedDateStr=null, revisedDate=1726848000000, revisedDateStr=2024-09-21, acceptedDate=null, acceptedDateStr=null, onlineDate=1764048741799, onlineDateStr=2025-11-25, pubDate=1734192000000, pubDateStr=2024-12-15, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1764048741799, onlineIssueDateStr=2025-11-25, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1764048741799, creator=13701087609, updateTime=1764048741799, updator=13701087609, issue=Issue{id=1200070646001664622, tenantId=1146029695717560320, journalId=1189918454225211397, year='2024', volume='', issue='12', pageStart='1', pageEnd='45', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1764048738241, creator=13701087609, updateTime=1764049472096, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1200073724071346316, tenantId=1146029695717560320, journalId=1189918454225211397, issueId=1200070646001664622, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1200073724071346317, tenantId=1146029695717560320, journalId=1189918454225211397, issueId=1200070646001664622, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=1, endPage=8, ext={EN=ArticleExt(id=1200070661315064706, articleId=1200070660924994390, tenantId=1146029695717560320, journalId=1189918454225211397, language=EN, title=Stick-Slip Vibration Analysis and Software Function Control Optimization of Steering Gear, columnId=null, journalTitle=Automotive Engineer, columnName=null, runingTitle=null, highlight=null, articleAbstract=

The steering system produces stick-slip vibration and noise due to the relative rotational friction between various components, resulting in unsmooth steering. To solve this problem, this paper studies the practical problems of stick-slip caused by worm gear deceleration mechanism of steering gear. The source of the problems are identified through tests, and the relevant influencing factors are determined by establishing a theoretical force model and CAE simulation analysis model. The torque anti-drop function MSP (Mechanical Stuck Prevention) of the steering gear is developed simultaneously. The software functional architecture and module interfaces are designed and the activation parameters are set through the debugging and optimization of the software functions. Finally, the output square wave signal of the motor torque 0.03 N·m is locked, which satisfies the software real-time control requirement, and improves the handing comfort of the vehicle.

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为解决转向系统各零部件间发生相对旋转摩擦而产生黏滑(Stick slip)振动及噪声,导致转向不够平滑的问题,针对转向机蜗轮蜗杆减速机构产生的黏滑实际问题,通过试验确定问题来源,建立理论受力模型和CAE仿真分析模型,确定相关影响因子,同步开发转向机的扭矩防跌落(MSP)功能,进行软件功能架构和各模块接口设计,通过软件功能调试优化并设定激活参数,最终锁定电机输出幅值为0.03 N·m的方波扭矩,满足软件层面的实时控制要求,提升了整车操纵舒适性。

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Stick-Slip Vibration Noise Analysis and Control of Vehicle under Starting Condition[D]. Chongqing: Chongqing University, 2019., articleTitle=null, refAbstract=null), Reference(id=1200407205607501835, tenantId=1146029695717560320, journalId=1189918454225211397, articleId=1200070660924994390, doi=null, pmid=null, pmcid=null, year=1990, volume=332, issue=1624, pageStart=89, pageEnd=105, url=null, language=null, rfNumber=[7], rfOrder=8, authorNames=POPP K, STELTER P, journalName=Philosophical Transactions of the Royal Society: Physical and Engineering Sciences, refType=null, unstructuredReference=POPP K, STELTER P. Stick-Slip Vibrations and Chaos[J]. Philosophical Transactions of the Royal Society: Physical and Engineering Sciences, 1990, 332(1624): 89-105., articleTitle=Stick-Slip Vibrations and Chaos, refAbstract=null), Reference(id=1200407205695582220, tenantId=1146029695717560320, journalId=1189918454225211397, articleId=1200070660924994390, doi=null, pmid=null, pmcid=null, year=2021, volume=null, issue=null, pageStart=null, pageEnd=null, url=null, language=null, rfNumber=[8], rfOrder=9, authorNames=王润兰, journalName=考虑时变法向载荷的摩擦系统stick-slip振动分析, refType=null, unstructuredReference=王润兰. 考虑时变法向载荷的摩擦系统stick-slip振动分析[D]. 成都: 西南交通大学, 2021., articleTitle=null, refAbstract=null), Reference(id=1200407205796245518, tenantId=1146029695717560320, journalId=1189918454225211397, articleId=1200070660924994390, doi=null, pmid=null, pmcid=null, year=2021, volume=null, issue=null, pageStart=null, pageEnd=null, url=null, language=null, rfNumber=[8], rfOrder=10, authorNames=WANG R L, journalName=Stick-Slip Vibration Analysis of Friction System Considering Time-Varying Normal Load, refType=null, unstructuredReference=WANG R L. Stick-Slip Vibration Analysis of Friction System Considering Time-Varying Normal Load[D]. Chengdu: Southwest Jiaotong University, 2021., articleTitle=null, refAbstract=null), Reference(id=1200407205884325904, tenantId=1146029695717560320, journalId=1189918454225211397, articleId=1200070660924994390, doi=null, pmid=null, pmcid=null, year=2022, volume=null, issue=null, pageStart=null, pageEnd=null, url=null, language=null, rfNumber=[9], rfOrder=11, authorNames=童静, journalName=EPS蜗轮蜗杆啮合性能有限元分析, refType=null, unstructuredReference=童静. 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1.扭矩转向盘 2.扭矩传感器 3.角度传感器 4.磁座 5.底板工装 6.CAN信号线 7.驱动头 8.某转向机总成(DP-EPS) 9.传感器总成 10.电机 11.蜗轮蜗杆减速机构

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1.调节螺钉 2.蜗杆 3.蜗轮 4.联轴器 5.调整螺母 6.壳体

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车速/km·h-1 转向盘转角/(°) 手力跌落值/N·m
89.9 1.3 0.67
80.0 ±5.0 0.62
66.7 1.0 0.76
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某车型出现黏滑现象的工况

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车速/km·h-1 转向盘转角/(°) 手力跌落值/N·m
89.9 1.3 0.67
80.0 ±5.0 0.62
66.7 1.0 0.76
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方向 扭矩跌落值
试验1 试验2 试验3 试验4
顺时针 0.15 1.03 0.94 0.24
逆时针 0.18 1.11 1.13 0.20
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蜗轮蜗杆减速机构互换性测试结果 N·m

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方向 扭矩跌落值
试验1 试验2 试验3 试验4
顺时针 0.15 1.03 0.94 0.24
逆时针 0.18 1.11 1.13 0.20
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方向 扭矩跌落值
试验5 试验6
顺时针 1.17 0.17
逆时针 1.06 0.24
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故障件与正常件的复装测试结果 N·m

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方向 扭矩跌落值
试验5 试验6
顺时针 1.17 0.17
逆时针 1.06 0.24
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参数 范围 最小手力跌落 最大手力跌落
蜗轮蜗杆预紧力Fpre-load/N 0~80 0 80
蜗杆分度圆直径d1/mm 16.1±0.1 16.2 16.0
蜗轮分度圆半径r2/mm 40.0±0.1 39.9 40.1
蜗杆螺旋角β/(°) 75.0±0.2 75.2 74.8
蜗杆压力角α/(°) 20.0±0.2 20.2 19.8
手力跌落ΔTtbt/N·m 0.76 1.10
), ArticleFig(id=1200407204722504703, tenantId=1146029695717560320, journalId=1189918454225211397, articleId=1200070660924994390, language=CN, label=表4, caption=

手力跌落范围

, figureFileSmall=null, figureFileBig=null, tableContent=
参数 范围 最小手力跌落 最大手力跌落
蜗轮蜗杆预紧力Fpre-load/N 0~80 0 80
蜗杆分度圆直径d1/mm 16.1±0.1 16.2 16.0
蜗轮分度圆半径r2/mm 40.0±0.1 39.9 40.1
蜗杆螺旋角β/(°) 75.0±0.2 75.2 74.8
蜗杆压力角α/(°) 20.0±0.2 20.2 19.8
手力跌落ΔTtbt/N·m 0.76 1.10
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转向机黏滑分析与控制优化研究
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漆胜 , 黄银银 , 杜杰 , 万锐 , 丁俊琰 , 汪家林
汽车工程师 | 2024,(12): 1-8
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汽车工程师 | 2024, (12): 1-8
转向机黏滑分析与控制优化研究
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漆胜, 黄银银, 杜杰, 万锐, 丁俊琰, 汪家林
作者信息
  • 博世华域转向系统(武汉)有限公司, 武汉 430200
Stick-Slip Vibration Analysis and Software Function Control Optimization of Steering Gear
Sheng Qi, Yinyin Huang, Jie Du, Rui Wan, Junyan Ding, Jialin Wang
Affiliations
  • Bosch Huayu Steering System (Wuhan) Co., Ltd., Wuhan 430200
出版时间: 2024-12-15 doi: 10.20104/j.cnki.1674-6546.20240259
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为解决转向系统各零部件间发生相对旋转摩擦而产生黏滑(Stick slip)振动及噪声,导致转向不够平滑的问题,针对转向机蜗轮蜗杆减速机构产生的黏滑实际问题,通过试验确定问题来源,建立理论受力模型和CAE仿真分析模型,确定相关影响因子,同步开发转向机的扭矩防跌落(MSP)功能,进行软件功能架构和各模块接口设计,通过软件功能调试优化并设定激活参数,最终锁定电机输出幅值为0.03 N·m的方波扭矩,满足软件层面的实时控制要求,提升了整车操纵舒适性。

转向机  /  NVH  /  黏滑  /  理论受力  /  扭矩防跌落  /  方波扭矩

The steering system produces stick-slip vibration and noise due to the relative rotational friction between various components, resulting in unsmooth steering. To solve this problem, this paper studies the practical problems of stick-slip caused by worm gear deceleration mechanism of steering gear. The source of the problems are identified through tests, and the relevant influencing factors are determined by establishing a theoretical force model and CAE simulation analysis model. The torque anti-drop function MSP (Mechanical Stuck Prevention) of the steering gear is developed simultaneously. The software functional architecture and module interfaces are designed and the activation parameters are set through the debugging and optimization of the software functions. Finally, the output square wave signal of the motor torque 0.03 N·m is locked, which satisfies the software real-time control requirement, and improves the handing comfort of the vehicle.

Steering Gear  /  NVH  /  Stick slip  /  Theoretical stress  /  Mechanical Stuck Prevention (MSP)  /  Square wave torque
漆胜, 黄银银, 杜杰, 万锐, 丁俊琰, 汪家林. 转向机黏滑分析与控制优化研究. 汽车工程师, 2024 , (12) : 1 -8 . DOI: 10.20104/j.cnki.1674-6546.20240259
Sheng Qi, Yinyin Huang, Jie Du, Rui Wan, Junyan Ding, Jialin Wang. Stick-Slip Vibration Analysis and Software Function Control Optimization of Steering Gear[J]. Automotive Engineer, 2024 , (12) : 1 -8 . DOI: 10.20104/j.cnki.1674-6546.20240259
电动助力转向(Electrical Power Steering,EPS)系统蜗轮蜗杆减速机构中,蜗轮蜗杆啮合过程受啮合力、传动误差和摩擦等因素影响,会产生黏滑振动现象,影响驾驶员的转向手感,造成转向过程中的扭矩跌落,降低驾驶舒适性。黏滑摩擦振动的相关研究始于1939年,Bowden和Leben[1]首次提出黏滑(Stick slip)的概念,并进行了静、动摩擦因数为常量时,系统的黏滑摩擦振动特性试验分析,结果显示,黏滑摩擦振动的振幅与静、动摩擦因数的差值成正比例关系。Lozia[2]通过建立摩擦模型仿真分析了转向系统中的黏滑问题,蜗轮蜗杆从静止到运动过程中会出现扭矩跌落的现象。Zuleeg[3]通过建立带-质量块模型研究了不同摩擦因数及斯特里贝克(Stribeck)系数对黏滑的影响,并分析了润滑脂在黏滑抑制方面的作用原理,摩擦因数的变化能够不同程度地影响此现象。Pasternak[4]等通过数值模拟发现,在没有动、静摩擦因数差值的情况下,施加的法向力振荡与滑动振荡同步时,系统会产生类似的黏滑运动。
本文主要针对EPS系统中蜗轮蜗杆啮合的受力情况,研究相关零部件的精度对黏滑振动现象的影响,并采用软件控制的方式,通过逻辑信号对电机的输出扭矩进行调控,以消除该现象造成的转向手感变化,提升整车的操控性能。
某轿车开发过程中,在高速工况下,转向时出现黏滑振动现象。失效形式表现为,以60 km/h以上的中高车速行驶时,变道过程中小角度转向时存在扭矩波动,力矩跌落约0.5 N·m,转向手感与预期不一致,易导致转向过度、偏离车道。
现代摩擦学认为,摩擦存在于有相对运动趋势(静摩擦)或相对运动(滑动摩擦)的两物体间,当两物体发生相对滑动,接触面间的摩擦因数因低速区间存在非线性负斜率效应,可能会引发系统的黏滑振动、纯滑动、多稳态现象,降低系统的稳定性[5]
为描述黏滑振动,引入如图1所示的无阻尼单自由度滑块-传送带模型,滑块的位移为0时对应弹簧的无应力状态,并认为摩擦力是块和传送带间相对速度的函数。因此,系统的运动微分方程为:
$m\ddot{x}-{F}_{f}(\dot{x}-v)+kx=0$
式中:m为滑块的质量;x为滑块的位移;k为弹簧的弹性系数;v为传送带速度;Ff($\dot{x}-v$)为摩擦力,由Stribeck曲线描述[6]
当传送带的速度v保持不变,滑块以相同的运动速度以弹簧自由状态置于传送带上时,滑块与传送带保持相对静止,系统处于黏滞(Stick)状态。
随着滑块切向位移从P1增加到P2点,弹簧产生的切向力大于最大静摩擦力,相对速度不为0,黏滞状态变为滑动(Slip)状态。
滑块受到弹簧拉力和动摩擦力,正向位移达到最大值P3点,速度降为0,开始反向运动,弹簧由伸长变为压缩,反向达到最大值P4点,正向移动。
滑块受到弹簧的推力和摩擦力作用,将正向加速到v,系统由滑动状态变为黏滞状态,进入新一轮黏滑振动[8]
在EPS系统蜗轮蜗杆减速机构扭矩跌落中,黏滑运动是重要因素。黏滑运动作为一种典型的摩擦自激振动,是滑动物体之间的一种自激跳跃运动,通常由动、静摩擦间的间歇性变化引起。蜗轮蜗杆相对运动时,由静摩擦转换为滑动摩擦,蜗杆和蜗轮的材料分别是金属和塑料,钢与塑料的静摩擦因数为0.1~0.3,滑动摩擦因数为0.05~0.15。库伦(Coulomb)总结了摩擦定律中的如下结果:
Fk=μkN
Fs=μsN
式中:Fk为动摩擦力,Fs为静摩擦力,N为法向力,μk为动摩擦因数,μs为静摩擦因数。
此外,两个固体接触的静止时间长度会影响粘附力,从而影响静摩擦因数。因此,蜗轮、蜗杆之间的静摩擦因数大于动摩擦因数,在转向从静到动的瞬间,会出现摩擦力由大到小的突变,产生扭矩跌落,造成在转向手感上的振动或形成瞬态噪声。
基于电动助力转向机的工作原理,当驾驶员在转向盘上施加手力时,扭矩传感器开始工作,将中间轴和转向齿轮在扭杆作用下产生的相对转角转变成电信号发送到转向电子控制单元(Electronic Control Unit,ECU),ECU根据车速传感器和扭矩传感器的信号决定电机的旋转方向和提供的助力大小。但由于系统存在摩擦,电机转子(电机输出轴)在初期并未跟随转动,只有当手力与电机助力的合力增大到一定程度后,EPS系统才能克服系统最大静摩擦力,电机转子开始转动,此时蜗轮蜗杆机构才会发生相对运动,即静摩擦变为滑动摩擦,此现象会造成手力跌落,转向手感表现为有黏滑感。根据经验,手力跌落超过0.4 N·m时,易被驾驶员感知。目前,转向机黏滑问题有两种常用的复现方式,即整车测试和台架试验。
整车测试包括驾驶员主观评价和整车数据采集两部分,根据车辆售后表现,转向机黏滑问题常发生在高速公路上长时间行驶,第一次小角度转动转向盘时。这是因为高速行驶长时间未进行转向时,蜗轮、蜗杆之间的润滑油因重力作用等原因堆积在局部,导致蜗轮、蜗杆啮合处油脂较少,二者间摩擦因数较大,进而引起较大的力矩跌落,同时根据助力转向特性,高速行驶时电机助力较小,转向机摩擦补偿扭矩也较小,故高速时力矩跌落更易被感知。因此,高速小角度转动转向盘通常作为考核转向机是否存在黏滑振动问题的重要工况。表1所示为某车型售后出现黏滑现象的工况,图2所示为整车采集的实时数据。
基于整车数据分析,需进一步进行台架测试复现问题,锁定黏滑振动发生的源头。经测试发现,故障件转向机在进行顺时针与逆时针转动时,均出现了黏滑振动现象。台架测试如图3所示,主要测试步骤为:
a. 将转向机切换到工厂模式;
b. 找中位,使转向机的齿条处于中间位置;
c. 触发车速信号,设定为80 km/h;
d. 输入轴安装带有力矩传感器的转向盘,逆时针缓慢转动;
e. 获得稳定的转向扭矩,停止3 s;
f. 重复步骤d~步骤e,将转向机回到中间位置;
g. 静置5 min;
h. 顺时针缓慢转动,重复步骤e~步骤f;
i. 完成测试,记录数据。
根据经验,转向扭矩跌落超过0.4 N·m会产生明显的黏滑振动现象。基于台架的测试结果如图4图5所示,故障件顺时针与逆时针旋转时扭矩跌落均为1.0 N·m左右,而且转向手感上存在明显的黏滑振动感,确认故障件存在黏滑现象。
基于上述分析可以初步确认黏滑振动发生在转向机的蜗轮蜗杆减速机构和齿轮齿条传动机构。而蜗轮、蜗杆的材料分别为塑料和金属,其静摩擦因数明显大于滑动摩擦因数,黏滑振动现象出现的可能性更大。同时,为了进一步锁定该问题的源头,按照台架测试的步骤进行了蜗轮蜗杆减速机构的互换测试。试验设计如下:
试验1,使用齿轮齿条机构和蜗轮蜗杆减速机构正常件进行测试;
试验2,使用齿轮齿条机构和蜗轮蜗杆减速机构故障件进行测试;
试验3,使用齿轮齿条机构正常件和蜗轮蜗杆减速机构故障件进行测试;
试验4,使用齿轮齿条机构故障件和蜗轮蜗杆减速机构正常件进行测试;
试验5,使用齿轮齿条机构和蜗轮蜗杆减速机构故障件复装进行测试;
试验6,使用齿轮齿条机构和蜗轮蜗杆减速机构正常件复装进行测试。
测试结果如表2表3所示。
根据互换测试结果,故障现象跟随蜗轮蜗杆减速机构,故可以确定该问题是由蜗轮蜗杆从静止状态到相对滑动状态导致的黏滑振动现象。
图6所示为某转向机蜗轮蜗杆结构减速机构。蜗杆2与2个轴承过盈配合,蜗杆小端由调节螺钉1限位,如图7所示。蜗杆轴线具有一定的倾斜角度,通过弹簧垫片的形变和调整螺钉为蜗轮蜗杆提供适当的预紧力。调节螺钉预紧力FLBS_z图8所示,其中z为橡胶块的形变量,阶段Ⅰ为调整螺钉橡胶块与轴承支架柔性接触,阶段Ⅱ为调整螺钉金属螺钉与小端轴承刚性接触,此时橡胶块达到最大形变量z0
根据整体结构可知,调节螺钉预紧力会直接影响蜗轮蜗杆的受力,因此需要在产线上进行调试来控制其预紧力,结合对调节螺钉刚度的研究,定义调节螺钉的压缩量范围为0.2 mm±0.08 mm,其产生的预紧力为20 N左右。
蜗轮蜗杆减速机构的整体结构较为复杂,组件较多,其中蜗杆、蜗轮、伺服壳体、支架轴承等零件的精度和调节螺钉预紧力设置的大小会直接影响蜗轮、蜗杆之间的接触应力[9]。由摩擦理论可知,蜗轮、蜗杆接触时正压力与产生的摩擦力正相关,正压力越大,其静摩擦力转化为滑动摩擦力的差值也越大,反映到转向盘上的手力跌落也就越大。
为了研究零件尺寸在极限状态下蜗轮、蜗杆接触应力的变化,以分析零件精度对黏滑振动现象的贡献,同时使CAE仿真结果与理论计算结果达到一定程度的吻合,本文对蜗轮、蜗杆间正压力变化的影响因子进行研究。
由于整体模型的复杂性,在有限元建模中将伺服壳体的模型简化为约束,主要建立蜗轮、蜗杆及其两端轴承的模型。同时,蜗轮、蜗杆模型装配时的中心距为48.92 mm,支架轴承的偏心量为0.5 mm,蜗杆小端预紧力为20 N。装配模型如图9所示。
理论状态下的接触应力如图10所示,蜗杆、蜗轮的跨棒距分别为21.732 mm、88.196 mm,壳体中心距为48.92 mm;仿真计算可得蜗杆的接触应力为72.4 MPa,蜗轮的接触应力为81.6 MPa。
极限状态下的接触应力如图11所示,蜗杆、蜗轮的跨棒距分别为21.686 mm、88.296 mm,壳体中心距为48.87 mm;仿真计算可得蜗杆的接触应力为83.61 MPa,蜗轮的接触应力为92.44 MPa。
提高预紧力后,接触应力如图12所示,预紧力为50 N;仿真计算可得蜗杆的接触应力为119.5 MPa,蜗轮的接触应力为126.8 MPa。
由仿真分析结果可知,不同状态的零件和预紧力都会影响蜗轮、蜗杆的正压力,结合摩擦定律,摩擦力也与正压力成正比。其中蜗轮、蜗杆和壳体三者之间的配合尺寸对正压力的贡献较大。其次,蜗杆小端预紧力过大也会明显改变正压力。
蜗轮蜗杆啮合受力情况如图13所示,其中合力F即为蜗轮、蜗杆间的正压力N
蜗轮蜗杆的受力计算公式如下:
Fx=2 000Mm/d1
Fy=Fx cot β
${F}_{z}=\frac{{F}_{x}}{\mathrm{s}\mathrm{i}\mathrm{n} \beta }·\mathrm{t}\mathrm{a}\mathrm{n}\alpha +{F}_{pre-load}$
$F=\frac{{F}_{z}}{\mathrm{s}\mathrm{i}\mathrm{n} \alpha }=\frac{2 000{M}_{m}}{{d}_{1}·\mathrm{s}\mathrm{i}\mathrm{n}\beta ·cos \alpha }+\frac{{F}_{pre\_load}}{\mathrm{s}\mathrm{i}\mathrm{n} \alpha }$
式中:FxFyFz分别为F沿xyz方向的分力,α为蜗杆的压力角,β为蜗杆的螺旋角,d1为蜗杆的分度圆直径,Fpre-load为预紧力,Mm=5 N·m为电机扭矩。
以某车型为例,相关参数为α=20°、β=75°、Fpre-load=20 N、d1=16.1 mm,则F≈742 N,钢与塑料的静摩擦因数为μk=0.1~0.3(基于零件的材料本文取0.2),滑动摩擦因数为μs=0.05~0.15(本文取0.1),则蜗轮蜗杆啮合由静摩擦转化为滑动摩擦,正压力变化为:
ΔF=F(μk-μs)=74.2 N
转换至蜗轮的切向的力变化为:
ΔFyF·cos α·cos β≈19.5 N
齿条力的传递公式为:
$\Delta {{F}_{c}}=\Delta {{T}_{tbt}}\cdot \left( 2\pi /{{i}_{2}} \right)\cdot {{\eta }_{2}}+\Delta {{F}_{y}}{{r}_{2}}\cdot \left( 2\pi /{{i}_{1}} \right)\cdot {{\eta }_{1}}$
由静到动的瞬间,克服伺服端力矩的变化,ΔFc为0,将切向力转化至手力矩的变化:
$\Delta {T}_{tbt}=\frac{\Delta {F}_{y}{r}_{2}{i}_{2}{\eta }_{1}}{{\eta }_{2}{i}_{1}}=\left(\frac{2 000{M}_{m}}{{d}_{1}·sin\beta ·cos\alpha }+\frac{{F}_{pre\_load}}{sin\alpha }\right)\left({\mu }_{k}-{\mu }_{s}\right)·{r}_{2}{i}_{2}·{\eta }_{1}/({\eta }_{2}·{i}_{1})$
式中:ΔFc为齿条力的变化量,i1=55为传感器端转向齿轮与齿条的传动比,i2=47为伺服端驱动齿轮与齿条的传动比,η1为转向齿轮与齿条传动的机械效率,η2为驱动齿轮与齿条传动的机械效率,r2=40 mm为蜗轮的分度圆直径,ΔTtbt为手力跌落。
计算可得蜗轮输出扭矩约为0.78 N·m,ΔTtbt≈0.85 N·m。即该车型转向机蜗轮蜗杆的理论力矩跌落值为0.85 N·m。
该车型参数选取如表4所示,由式(11)计算得到ΔTtbt的范围约为0.76~1.10 N·m。
以上计算均采用理论值,但实际情况下,零件尺寸存在一定公差。此外,上述计算是在纯机械状态下进行的受力分析,暂未考虑介质的影响,在实际装配过程中,会在蜗轮、蜗杆的啮合处增加高性能油脂,以改善蜗轮、蜗杆之间的啮合,降低摩擦因数,改善手力矩的跌落。故黏滑是客观存在的物理现象,只能改善,无法完全消除。
对于新车型,可参考式(11)通过合理选择相关参数尽量减小蜗轮、蜗杆间的力矩跌落。但对于本文车辆,因其在售后阶段出现黏滑问题,更改零件尺寸影响较大,且验证周期较长,因此从软件层面进行优化。
EPS系统采用控制器局域网(Controller Area Network,CAN)通信,连接到整车底盘网络,基于CAN总线的通信矩阵,EPS系统可获取车速、轮速、发动机状态等信息,如图14所示。扭矩和位置传感器提供驾驶员手力和电机转子位置信号,本文研究的转向机采用扭矩转角传感器(Torque Angle Sensor,TAS),能够同时提供扭矩信息和转向盘的转角信号。EPS系统控制电机输出用于实现助力转向,ECU通过整车和内部传感器的信号计算获得所需助力,控制电机的输出力矩。在实际运行过程中,使用多个软件功能模块计算,最后将每个功能输出叠加,使电机精确提供助力。为了消除蜗轮蜗杆减速机构造成的扭矩跌落,开发了扭矩防跌落(Mechanical Stuck Prevention,MSP)功能,在整车信号达到一定条件时,激发MSP功能,提供补偿扭矩,解决转向机的黏滑振动问题。
扭矩防跌落功能可以控制助力电机输出方波扭矩周期信号,电机输出的扭矩作用到蜗杆上,方向与蜗轮、蜗杆间的正压力平行:
$f\left(t\right)=A·sgn\left(sin\left(\frac{2\pi t}{T}\right)\right)$
式中:AT分别为方波扭矩信号的幅值、周期,根据车辆当前的行驶状态、转向盘角度、车速等实时变化。
扭矩防跌落功能主要由助力电机扭矩计算模块和扭矩安全校验模块组成,如图15所示,助力电机扭矩计算模块根据输入车速和实际转向盘角度信号,通过查表可以计算出当前车辆状态下的期望振动力矩,如果车速和实际转向盘角度信号中任意一个无效,方波扭矩输出直接为0,待信号有效时,再次计算扭矩。
将扭矩计算得到的方波扭矩信号输入到转向机的助力电机,这种方波扭矩实质上是一种可控的振动,激烈的电机振动会引起转向盘振动,影响转向的力矩和精度,造成车辆的整体驾驶体验不佳。在理想状态下,转向系统希望不存在振动或者振动很微弱,不足以产生影响。因此,扭矩防跌落功能输出的扭矩幅值和频率设置为可标定的,不同车型的实际值可以通过整车试验得到,在不同车速和小角度转向条件下,不断增大振动幅值和频率,找到影响驾驶员手感的临界值。
如果转向机没有发生黏滑振动,扭矩防跌落功能的输出即为0,因此在电机扭矩计算模块中加入了最小转子速度的计算,如图16所示,最小转子速度根据有效力矩、转向盘角度和手力梯度取最大值得到。当实际电机转子速度大于计算的最小转子速度时,说明蜗轮蜗杆机构没有发生黏滑振动现象,能够正常运转,反之,则判断转向机的蜗轮蜗杆处发生黏滑振动,扭矩防跌落功能输出振动力矩克服黏滑振动现象。
为了满足功能安全需求,设计安全校验模块,对期望的方波扭矩的频率和幅值进行安全限制,避免因系统失稳导致扭矩突变,从而引起手感不适或者重大安全事故。
针对本文研究的故障件,开启了MSP功能,设定其激发的条件,当实际转子速度小于最小转子速度时,MSP功能可以激活,同时车速大于30 km/h时,MSP能够输出电机扭矩,调试MSP的输出参数,基于输出的不同方波扭矩信号,进行了黏滑测试,结果如图17所示,MSP在激活后输出幅值为0.03 N·m的方波力矩。
锁定最优的扭矩输出值后,在整车上进行验证,并采集整车数据,未发生明显的扭矩跌落现象,如图18所示。
本文通过对EPS系统的结构设计、理论受力和软件功能进行研究,结合试验和整车测试数据分析,量化了最终的软件参数,并验证了该功能对转向机的优化效果。经过多轮MSP功能调试,锁定该车型的MSP参数,并形成推荐参数值,完成标准化。
致谢 感谢博世华域转向系统(武汉)有限公司的郑敏、胡冲等对本文研究的支持。
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doi: 10.20104/j.cnki.1674-6546.20240259
  • 首发时间:2025-11-25
  • 出版时间:2024-12-15
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    博世华域转向系统(武汉)有限公司, 武汉 430200
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genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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