硕士学位毕业论文

硕士研究生：李进

指导教师：沈斌 教授

答辩时间：2013.06

摘要

随着每一代车型的更替，乘客对车辆舒适度有着更高的期待。其中车厢内部的宁静度是非常重要的一方面，因此噪声级别已经有了很大的改善。在此背景下，变速箱由于距离乘客很近，当其发生噪声故障时，很容易被发觉。变速箱噪声对客户满意度有着非常负面的影响，必须在生产和检测环节中及时地检测出来。这对现有的变速箱加工流程提出了更高的要求。因此对现有的与变速箱噪声有关的流程进行研究与分析，并提出相应的改进建议，显得十分迫切与必要。

本文完成了如下内容的工作：

首先对德国某汽车企业的车辆总装工厂的与变速箱噪声相关的车辆终检过程进行了研究分析与总结。从中选取了一台具有故障噪声的DQ200型双离合器变速箱进行分析研究，找到了导致其噪声的机械加工错误。

与此同时对噪声故障变速箱从车辆总装厂到变速箱工厂的反馈流程进行了总结和描述。并对变速箱厂内的噪声故障分析流程进行了描述和分析。然后总结与评价了在变速箱生产过程中的噪声检测环节。

在此基础上对双离合器变速箱故障噪声的分析流程进行了详细的研究和总结，并找到了造成案例变速箱故障噪声的原因以及在生产过程中产生加工缺陷的原因。定位了加工及检测工艺中的薄弱环节，定义了消除该工艺缺陷的措施，并对措施的有效性进行了检验。

关键字：变速箱噪声，噪声分析，EOL检测，噪声检测工艺流程

Abstract

With each generation of vehicle, the passengers also have higher expectations on vehicle comfort. Quiet passenger compartment is a very important aspect, so the noise level has been greatly improved. In this background due to close distance of the gearbox from the passengers the noises are easy to be found when they occur. Gearbox noises have a very negative impact on customer satisfaction, therefore they must be promptly detected in the production and testing processes. This has higher requirements on the existing gearbox manufacturing processes. Therefore, the existing processes and gearbox noise-related research and analysis, and propose recommendations for improvement, it is urgent and necessary.

Following tasks are finished in this work:

First, the transmission-noise-related vehicle final test process in vehicle assembly plant of a German automobile company were studied, analyzed and summarized. In the meantime is DQ200 dual-clutch gearbox with noise fault analyzed and studied, and machining errors, which cause of the noises, are found.

At the same time are the feedbacks processes of the gearbox with noise fault from the vehicle assembly plant to the transmission factory are summarized and described. Also the analysis process of noise failure of Transmission has been described and analyzed. Then are the noise testing processes in transmission production summarized and evaluated.

On this basis, the analysis processes on the noise of dual-clutch gearbox failure are detail studied and summarized, and the causes of gearbox failure in the production process are as well processed. Then the weaknesses in the machining and testing processes are located, and the measures to eliminate defects in the process are also definited, the effectiveness of which has been tested.

Keywords: transmissionnoise, noiseanalyse, EOL-Testing, testprocess.