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The limitations of traditional testing methods for power steering hydraulic pumps have been identified, prompting the development of a more effective and accurate approach. This new method has been validated through practical application in production, proving to be user-friendly and capable of delivering reliable results that accurately reflect the performance of the steering hydraulic pump. The corresponding test equipment has also been designed to support this improved methodology.
1. Introduction
The power steering hydraulic pump is a critical component of the vehicle's steering system, significantly influencing the overall performance, handling, and stability of the car. As automotive technology continues to evolve, with the introduction of advanced materials, manufacturing processes, and high-speed hydraulic pumps for passenger vehicles, there is an increasing need to thoroughly evaluate the performance of these components. Therefore, it is essential to refine and enhance existing testing methods, ensuring they are both effective and comprehensive in assessing the characteristics of power steering hydraulic pumps.
During the testing process, several key parameters must be measured, including temperature, flow rate, pressure, speed, and torque. However, due to the unique structure and operational requirements of power steering hydraulic pumps, accurately and efficiently measuring their performance remains a significant challenge. This necessitates the development of a more suitable and precise testing approach.
2. Power Steering Pump Testing Method
In 1984, the standard "ZBT 23002: Vehicle Power Steering Hydraulic Pump Bench Test Method" was established and implemented in 1987. At the time, most domestic power steering pumps were gear-type, and the testing procedures were sufficient for the products available. However, as the automotive industry has advanced, especially with the widespread adoption of vane-type pumps and imported technologies, the original testing methods have become outdated and inadequate for modern applications.
By the first quarter of 1997, the Chongqing Automobile Research Institute discovered that the existing test method failed to meet current requirements, making it difficult to conduct accurate quality assessments. This led to the need for a more advanced and reliable testing procedure.
2.1. 0.85pmax Pressure Concept
The previous method required testing under maximum operating pressure (pmax), which often caused the safety valve to open, leading to inaccurate or incomplete results. To address this, the concept of testing at 0.85 times pmax was introduced. This approach ensures the safety valve remains closed during testing, allowing for more accurate and realistic performance evaluation.
2.2. Air Tightness Test
The original method did not include an air tightness test. However, extensive testing has shown that this test can effectively assess the sealing performance and assembly quality of the pump. It is simple, cost-effective, and easy to implement, making it a valuable addition to the testing protocol.
2.3. Oil Temperature for Reliability Testing
Power steering pumps operate under more complex conditions than general-purpose pumps, with frequent changes in speed, pressure, and oil temperature. Additionally, their placement near the engine and limited fluid volume contribute to higher heat generation. To simulate real-world conditions, the test oil temperature should be maintained around 70°C for more accurate reliability assessment.
2.4. Cut-off Test
The original method included a cut-off test, but due to the presence of unloading valves and internal leakage, such tests are no longer necessary. This has been eliminated to avoid unnecessary complexity and improve test accuracy.
2.5. Variable Speed Impact Test
Unlike continuous overload testing, the variable speed impact test better reflects actual driving conditions, where the pump experiences fluctuating loads and impacts. This change improves the correlation between test results and real-world performance.
3. Test Rig Structure
The drive system uses AC frequency conversion for speed control, allowing flexibility for different pump configurations. The fuel tank, equipped with a 3 kW heater, maintains optimal oil temperature, while quick-change connectors ensure ease of use and prevent oil spillage.
4. Hydraulic System
The test rig features a proportional relief valve controlled by a computer, enabling precise and automated loading. High-pressure filters and a water-cooled system ensure clean oil and stable temperature, enhancing the accuracy of flow measurements.
5. Test System
The system measures speed, flow, pressure, and temperature. Signal conditioning and proper grounding are crucial to minimize interference and ensure accurate data collection.
6. Computer System
The control software is based on MS-DOS, offering a user-friendly interface with full Chinese prompts. It supports both manual and automatic operations, providing reliable and efficient testing capabilities.
7. Conclusion
After extensive trials and improvements, a practical and effective testing method for power steering hydraulic pumps has been developed. This method has proven to be easy to use, accurate, and highly reliable, with the ZYBT-â…¡ test bench demonstrating excellent performance in real-world applications. It offers significant improvements in efficiency and accuracy, making it a valuable tool for the automotive industry.