QC/T 291-2023 PDF English
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Performance requirements and bench test method for automotive mechanical transfer case
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| QC/T 291-1999 | English | 279 |
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(Automotive mechanical performance requirements of actuator)
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QC/T 291-2023: Performance requirements and bench test method for automotive mechanical transfer case
---This is an excerpt. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/QCT291-2023
QC
AUTOMOTIVE INDUSTRY STANDARD
ICS 43.040.50
CCS T 21
Replacing QC/T 291-1999, QC/T 292-1999
Automotive Mechanical Transfer Case Assembly
Performance Requirements and Bench Test Methods
Issued on. DECEMBER 20, 2023
Implemented on. JULY 1, 2024
Issued by. Ministry of Industry and Information Technology of the People’s
Republic of China
Table of Contents
Foreword... 7
1 Scope... 10
2 Normative References... 10
3 Terms and Definitions... 10
4 Technical Requirements... 11
5 Test Methods... 13
1 Scope
This Document specifies the performance requirements and bench test methods for automotive
mechanical transfer case assemblies (hereinafter referred to as “transfer cases”).
This Document applies to mechanical transfer cases used for non-operational purposes in
vehicles with a maximum mass not exceeding 31,000 kg.
Transfer cases for non-road vehicles can be implemented as a reference.
2 Normative References
The provisions in following documents become the essential provisions of this Document
through reference in this Document. For the dated documents, only the versions with the dates
indicated are applicable to this Document; for the undated documents, only the latest version
(including all the amendments) is applicable to this Document.
GB/T 6461 Methods for corrosion testing of metallic and other inorganic coatings on
metallic substrates - Rating of test specimens and manufactured articles subjected to
corrosion tests
GB/T 10125 Corrosion tests in artificial atmospheres - Salt spray tests
GB/T 30512 Requirements for Prohibited Substances on Automobiles
QC/T 983 Measuring method of cleanliness of automobile manual transmission assembly
3 Terms and Definitions
For the purposes of this Document, the following terms and definitions apply.
3.1 Static shift force
Shifting is performed without the transfer case running, and the axial force acting on the gear
sleeve during the shifting process.
3.2 Dynamic shift force
Shifting is performed with the transfer case running, and the axial force acting on the gear
sleeve during the shifting process.
3.3 Shifting time
The time that is taken to shift from transfer case neutral to the transfer case target gear.
3.4 Maximum test torque of transfer case assembly
The maximum test torque of the transfer case assembly is the smaller OF the product of the
maximum torque of the engine and the first gear ratio of the transmission that matches the
transfer case AND the maximum wheel adhesion torque converted to the input shaft of the
transfer case. The force direction is the same as the forward direction of the actual vehicle.
When the transfer case has only one gear, the maximum test torque of the transfer case assembly
is expressed by Mmax. When the transfer case has two gears, high and low, the maximum test
torque of the high gear of the transfer case is expressed by MHmax, and the maximum test torque
of the low gear of the transfer case is expressed by MLmax.
4 Technical Requirements
4.1 Static shift force and static shifting time
The test shall be conducted according to the method specified in 5.1.The static shift force and
static shifting time indicators shall meet the product technical requirements.
4.2 Dynamic shift force and dynamic shifting time
The test shall be conducted according to the method specified in 5.2.The dynamic shift force
and dynamic shifting time indicators of the transfer case shall meet the product technical
requirements.
4.3 Fatigue life of the shift actuator bench
The test shall be conducted according to the method specified in 5.3.The minimum fatigue life
of the transfer case shift actuator bench shall be no less than 1×104 times.
4.4 Transmission efficiency of the transfer case
The test shall be conducted according to the method specified in 5.4.The transfer case
transmission efficiency shall meet the product technical requirements.
4.5 Lubrication of the transfer case
The test shall be conducted according to the method specified in 5.5.The components involved
in the transmission shall have obvious lubricating oil infiltration.
4.6 Sealing of the transfer case
The test shall be conducted according to the method specified in 5.6.During the test, there shall
be no oil seepage or oil leakage in the transfer case.
4.7 Temperature rise of the transfer case
The test shall be carried out according to the method specified in 5.7.During the test, the
maximum oil temperature of the lubricant shall meet the requirements of the product technical
conditions; and the lubricant temperature-time curve shall be smooth without mutation.
4.8 Noise of the transfer case
The test shall be carried out according to the method specified in 5.8.The maximum allowable
noise sound pressure level of the gear transfer case (a transfer case that mainly uses a gear pair
as a power transmission device between the input shaft and the output shaft) is 91dB (A). The
maximum allowable noise sound pressure level of the chain transfer case (a transfer case that
mainly uses a sprocket chain pair as a power transmission device between the input shaft and
the output shaft) is 93dB (A).
4.9 Static torsional strength of the transfer case
The test shall be completed according to the method specified in 5.9.The static torsional reserve
coefficient of the transfer case shall meet the requirements of the product technical conditions,
but the minimum value shall be no less than 1.8.
5 Test Methods
5.1 Test on static shift force and static shifting time
5.1.1 Test sample
5.1.1.1 The test sample is a transfer case with high and low gears.
5.1.1.2 The test sample shall meet the requirements of the design drawings and the number shall
be no less than 2.
5.1.2 Test equipment and devices
5.1.2.1 The test equipment can perform the shift action of the transfer case and measure the
shift force, shifting time, gear position and other information during the shift process. Thereof,
the sampling frequency of the shift force, shifting time and gear position information shall be
no less than 100 Hz.
5.1.2.2 The test device can simulate the moments of inertia on the input end and the output end
of the transfer case.
5.1.2.3 The measuring device of the test equipment can measure the static shift force. The
maximum allowable error of measuring the static shift force shall be within the range of ±5%.
NOTE. The shift force can be measured by attaching a strain gauge to the shift fork, or by other methods
such as using a force sensor to measure the force acting on the shift rocker arm, and then converting the
transmission lever ratio between the shift sleeve and the shift rocker arm force measuring point to the
shift sleeve to calculate the shift force.
5.1.3 Test methods
5.1.3.1 Install the sample on the test bench, and the posture after installation shall be consistent
with the design posture.
5.1.3.2 Adjust the moments of inertia on the input end and output end of the transfer case so
that the moment of inertia on the input end of the transfer case is equivalent to the moment of
inertia between the input shaft of the transfer case and the neutral gear of the transmission; and
the moment of inertia on the output end of the transfer case is equivalent to the moment of
inertia of the whole vehicle converted to the output end of the transfer case.
5.1.3.3 Put the transfer case in neutral and randomly rotate the input shaft or output shaft for
several turns before shifting.
5.1.3.4 When the input and output ends of the transfer case are stationary, the target test gear
shall be connected; and the relationship curve between the shift force and the shifting time
during the shifting process shall be recorded.
5.1.3.5 The target test gear is connected to the neutral gear.
5.1.3.6 When the input and output ends of the transfer case are stationary, another target test
gear shall be connected; and the static shift test is carried out in the order of 5.1.3.3 to 5.1.3.5.
The shifting process can be tested by alternating shifting or unidirectional shifting.
5.1.3.7 Record the relationship curve between the shift force and the shifting time during the
shifting process.
5.1.3.8 The static shift test of each gear shall be no less than 3 times.
5.1.4 Processing of test results
5.1.4.1 The maximum shift force in the relationship curve between the shift force and the
shifting time is taken as the maximum static shift force of the gear.
5.1.4.2 The maximum shifting time in the relationship curve between shift force and shifting
time is taken as the maximum static shifting time; and the minimum shifting time in the
relationship curve between shift force and shifting time is taken as the minimum static shifting time.
5.2 Test on dynamic shift force and dynamic shifting time
5.2.1 Test sample
5.2.1.1 The test sample is a transfer case with high and low gears.
5.2.1.2 The test sample shall meet the requirements of the design drawings and the number shall
be no less than 2.
5.2.2 Test equipment and devices
5.2.2.1 The test equipment can perform the shift action of the transfer case; and can measure
the shift force, shifting time, gear information, input shaft and output shaft speed of the transfer
case and other information during the shifting process. Thereof, the sampling frequency of the
shift force, shifting time and gear information shall be no less than 100Hz.
5.2.2.2 The maximum allowable error of measuring dynamic shift force shall be within ±5%.
NOTE. The shift force can be measured by attaching a strain gauge to the shift fork; or by other methods
such as using a force sensor to measure the force acting on the shift rocker arm; and then converting the
transmission lever ratio between the shift sleeve and the shift rocker arm force measuring point to the
shift sleeve to calculate the shift force.
5.2.2.3 The test equipment can determine whether the transfer case shift is successful.
5.2.2.4 The test equipment can simulate the moments of inertia on the input end and the output
end of the transfer case.
5.2.2.5 The test equipment can drive the output end of the transfer case to operate; and the
maximum control error of the speed of the driving device shall be within the range of ±5 r/min.
5.2.2.6 The maximum allowable error of the speed measuring device of the test equipment shall
be within the range of ±1 r/min.
5.2.3 Test methods
5.2.3.1 Install the sample on the test bench. The posture after installation shall be consistent
with the design posture.
5.2.3.2 Adjust the rotational moments of inertia on the input end and output end of the transfer
case so that the moment of inertia on the input end of the transfer case is equivalent to the
rotational moment of inertia between the input shaft of the transfer case and the neutral gear of
the transmission; and the rotational moment of inertia on the output end of the transfer case is
equivalent to the moment of inertia of the whole vehicle converted to the output end of the
transfer case.
5.2.3.3 When the input end and output end of the transfer case are stationary, the target test gear
shall be connected.
5.2.3.4 Adjust the output speed of the transfer case so that the output speed of the transfer case
is equal to the minimum design speed corresponding to the target test gear and run for at least 3s.
5.2.3.5 Switch from the target test gear to the neutral gear.
5.2.3.6 Switch from the neutral gear to another target test gear after running for at least 1s.
5.2.3.7 Carry out the shift test in the order of 5.2.3.4 to 5.2.3.6.The shifting process can be
tested by alternating shift or unidirectional shift.
5.2.3.8 Repeat 5.2.3.4 to 5.2.3.6 at least 3 times.
5.2.3.9 Record the relationship curve between the shift force and the shifting time during the shifting process.
5.2.4 Processing of test results
5.2.4.1 The maximum shift force in the relationship curve between the shift force and the
shifting time is taken as the maximum dynamic shift force of the gear.
5.2.4.2 The maximum shifting time in the relationship curve between the shift force and the
shifting time is taken as the maximum dynamic shifting time of the gear; and the minimum
shifting time in the relationship curve between the shift force and the shifting time is taken as
the minimum dynamic shifting time of the gear.
5.3 Test on fatigue life of the shift actuator bench
5.3.1 Test sample
5.3.1.1 The test sample is a transfer case with high and low gears.
5.3.1.2 The test sample shall meet the requirements of the design drawings, and the number of
samples shall be no less than 2.
5.3.2 Test equipment and devices
5.3.2.1 The test equipment can complete the shifting action of the transfer case and determine
whether the transfer case shifting is successful.
5.3.2.2 The test equipment can drive the transfer case output end to operate after the transfer
case shifts; and the maximum speed control error of the driving device shall be within the range
of ±5 r/min.
5.3.2.3 The oil temperature control device of the test equipment can ensure that the lubricant
temperature is maintained in the range of 60 ℃~90 ℃ during the shifting process of the transfer
case. During a single test, the lubricant temperature fluctuation range is ±5 ℃.
5.3.2.4 The maximum allowable error of the oil temperature measuring device shall be within
the range of ±1 ℃.
5.3.2.5 The test equipment can simulate the moments of inertia on the input end and the output
end of the transfer case.
5.3.2.6 The maximum allowable error of the speed measuring device shall be within the range
of ±1 r/min.
5.3.2.7 The lubrication system of the test equipment can ensure that the gears, shafts, bearings
and other parts inside the transfer case are fully lubricated during the shifting process.
5.3.3 Test methods
5.3.3.1 Test methods for fatigue life of the shift actuator bench of the transfer case with
synchronizer
5.3.3.1.1 Fill lubricant according to product technical requirements and install the temperature
sensor on the drain plug.
5.3.3.1.2 Install the sample on the test bench. The posture after installation shall be consistent
with the design posture.
5.3.3.2 Test method for fatigue life of the shift actuator bench of the electronically
controlled and pneumatic mechanical transfer case
5.3.3.2.1 Add lubricant according to the technical requirements of electronically controlled and
pneumatic mechanical transfer cases and install the temperature sensor on the drain plug.
NOTE. The electronically controlled mechanical transfer case is a transfer case that changes the gear
meshing position in the transfer case through the electronically controlled actuator, thereby changing the
transmission ratio or transmission mode to achieve the purpose of speed change. Pneumatic mechanical
transfer case is a transfer case that changes the gear meshing position in the transfer case through a
pneumatic actuator, thereby changing the transmission ratio or transmission mode to achieve the purpose
of speed change.
5.3.3.2.2 Install the sample on the test bench; and the posture after installation shall be
consistent with the design posture.
5.3.3.2.3 Adjust the rotational moment of inertia on the input end and output end of the transfer
case so that the moment of inertia on the input end of the transfer case is equivalent to the
rotational moment of inertia between the input shaft of the transfer case and the neutral gear of
the transmission; and the rotational moment of inertia on the output end of the transfer case is
equivalent to the moment of inertia of the whole vehicle converted to the moment of inertia on
the output end of the transfer case.
5.3.4 Processing of test results
5.3.4.1 When the number of shifting cycles reaches the number of cycles specified in the
technical requirements, the shift actuator of the transfer case shall not appear the damage that
affects the shifting performance.
5.3.4.2 For the shift actuator of the transfer case with synchronizer, the synchronizer shall not
fail in any form; and the synchronizer ring axial clearance shall be no less than the designed
limit value.
5.4 Test on transmission efficiency of the transfer case
5.4.1 Test sample
The test sample shall meet the requirements of the design drawing and the number shall be no
less than 1.
5.4.2 Test equipment and devices
5.4.2.1 The transfer case transmission efficiency test bench or similar device, the maximum
allowable error of the equipment speed control shall be within the range of ±5 r/min; and the
maximum allowable error of the torque control shall be within the range of ±2%.
5.4.2.2 There is a lubricant temperature controlling device, which can ensure that the
5.4.3 Test methods
5.4.3.1 Fill the specified lubricant according to the product technical requirements and install
the temperature sensor on the drain plug.
5.4.3.2 Install the sample on the test bench; and the posture after installation shall be consistent
with the design posture.
5.4.3.3 When the transfer case has two gears, high and low, the transfer case is connected to high gear.
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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