Digital management and control system and method for bogie axle drive maintenance line

Abstract

The invention provides a digital management and control system and method for a bogie axle drive maintenance line, and relates to the field of rail traffic component maintenance, and the system comprises a maintenance execution system which is used for basic data management, work order management, plan management, complete set management, production execution, quality management and equipment point inspection in a wheel drive maintenance process; the digital twinning system is used for realizing digital twinning in the maintenance process through a twinning large screen of a production dispatching center; the IOT equipment system is used for the Internet of Things to construct an overall interconnected and intercommunicated data exchange environment of the maintenance line through non-inductive identification, maintenance equipment interaction, tool interaction and two-dimensional code identification; the hardware facility comprises a twin large screen, a station machine, an area board, a hand-held terminal and a weak current private network laying device. According to the invention, the accuracy, authenticity and traceability of the overhaul data of each process and link are ensured through real-time dynamic capture of the data of the whole overhaul process of the axle drive of the bogie, and the precision error caused by factors such as manual measurement, filling and reporting is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of rail transit component maintenance, and more specifically, to a digital control system and method for a bogie axle drive maintenance line. Background Art

[0002] The maintenance of bogie axle drive includes wheelset disassembly, wheelset maintenance, wheelset assembly, axle maintenance, wheel maintenance, brake disc maintenance, bearing maintenance, traction motor maintenance, coil spring maintenance, shock absorber maintenance, grounding device maintenance, axle box gearbox axle box maintenance and small parts maintenance, etc., with high process complexity. Maintenance data is mostly measured manually, which is labor-intensive and cannot automatically upload measurement data, and there is a risk of manual error; the bearing press-fitting process estimates the bearing press-fitting pressure by visually observing the pressure gauge value, and there is a large dimensional error in manual judgment, which makes it impossible to call maintenance data and trace quality, and the bearing assembly accuracy cannot be guaranteed; the axle box assembly station uses manual handheld pneumatic triggers to tighten the operation, and the torque value cannot be automatically uploaded and managed, and quality control cannot be achieved. In addition, the operator frequently bends over the operation, which is labor-intensive; the equipment status is unknown, and regular inspection and maintenance are required; the management personnel do not understand the on-site conditions well and cannot effectively supervise the maintenance progress. Summary of the invention

[0003] In view of the technical problems existing in the prior art, the present invention provides a digital control system and method for a bogie axle drive maintenance line. In order to realize the digital control of the bogie axle drive maintenance, the maintenance execution system starts from the maintenance data collection and control during the operation process, and should collect as much data as possible, summarize, analyze and count the data to realize quality card control and work order equipment management.

[0004] According to a first aspect of the present invention, a digital control system for a bogie axle drive maintenance line is provided, comprising: a maintenance execution system, a digital twin system, an IOT equipment system and hardware facilities; wherein:

[0005] The maintenance execution system is used to realize basic data management, work order management, plan management, complete set management, production execution, quality management and equipment inspection in the process of wheel drive maintenance;

[0006] The digital twin system is used to monitor and analyze the maintenance process based on the collected real-time data;

[0007] The IOT equipment system is used for the Internet of Things to build an overall interconnected data exchange environment for the maintenance line;

[0008] The hardware facilities include twin large screens, workstation machines, area billboards, handheld terminals and weak-current dedicated network laying equipment.

[0009] Based on the above technical solution, the present invention can also make the following improvements.

[0010] Optionally, the maintenance execution system includes a data acquisition module, a quality control module and a work order management module; wherein,

[0011] The data acquisition module acquires key data of bogie axle drive maintenance in real time through integration with the IOT equipment system;

[0012] The quality control module analyzes and compiles statistics on the collected data to ensure that various quality requirements during the maintenance process are met;

[0013] The work order management module is used to manage and track the execution status of maintenance tasks.

[0014] Optionally, the maintenance execution system also includes a plan management module for managing monthly plans, daily plans, emergency repair plans and work order plans, and supporting real-time feedback on task progress and completion status.

[0015] Optionally, the maintenance execution system also includes a quality management module, which is used to collect quality data during the maintenance process in real time, and display the maintenance quality status and early warning information on a large screen to ensure that the maintenance quality is controlled within a specified range.

[0016] Optionally, the digital twin system builds a virtual model of the bogie axle drive through real-time data interaction with the maintenance execution system, simulates key steps and operating status in the maintenance process, supports visualization of equipment status and process flow, and facilitates maintenance personnel to make maintenance decisions and remote monitoring.

[0017] Optionally, the digital twin system includes a data-driven module, a real-time status mapping module and a three-screen interactive module, which are used to realize the digital twin of the maintenance process through the twin large screen of the production scheduling center, and realize the synchronous update and display of work order BOM, process and complete set management.

[0018] Optionally, the digital twin system includes an interactive design module, which simulates the maintenance environment through scene modeling and 3D virtual reality technology, and supports users to remotely view and control every link in the maintenance process.

[0019] Optionally, the IOT equipment system includes a non-contact recognition module, a maintenance equipment interaction module, a tool interaction module, and a QR code recognition module, and realizes automatic recognition and data upload of maintenance equipment and tools through non-contact recognition, maintenance equipment interaction, tool interaction and QR code recognition.

[0020] Optionally, the IOT device system includes a sensor network and an edge computing device, wherein the sensor network can collect temperature, vibration, and stress parameters of the bogie wheel axle drive, and perform preliminary data processing through the edge computing device.

[0021] Optionally, the system also includes a job backtracking function, which allows selection of a specific job plan or time period for backtracking, and acquisition of detailed information on each link in the job process through 3D animation playback.

[0022] According to a second aspect of the present invention, a digital management and control method for a bogie axle drive maintenance line is provided, comprising:

[0023] Conduct visual research on the maintenance object, analyze the function, structure and maintenance requirements of the maintenance components, determine the maintenance capacity through demand analysis, evaluate the implementation conditions and control factors, refine the maintenance process and compare the overall layout plan;

[0024] Establish standardized process flow for warehousing, disassembly, cleaning, inspection and testing, maintenance, assembly, testing, and delivery, digitally express the relationship between personnel, equipment, tools, materials, and operating standards involved in each process, and use IOT technology to complete the collection, analysis, and decision-making of equipment status data and test result data during the maintenance process;

[0025] Establish a centralized monitoring center to monitor the entire maintenance process and status in real time, coordinate the formulation of project progress plans, use twin large screens to intuitively guide construction, and promptly discover on-site problems.

[0026] Technical effects and advantages of the present invention:

[0027] The present invention provides a digital control system and method for the bogie axle drive maintenance line, which ensures the accuracy, authenticity and traceability of the maintenance data of each process and link through real-time dynamic capture of the data of the entire process of bogie axle drive maintenance, and reduces the precision error caused by factors such as manual measurement and reporting. Through big data analysis and intelligent interaction, the technical barriers between the maintenance section and the information systems at the section level are broken, so that each key maintenance data can be uploaded to the section level in real time, improving the quality control and supervision of the maintenance process.

[0028] Other features and advantages of the present invention will be described in the following description, and partly become apparent from the description, or understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures pointed out in the description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 An architecture diagram of a digital management and control system for a bogie axle drive maintenance line provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0030] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0031] It is understandable that, based on the defects in the background technology, the embodiment of the present invention proposes a digital control system for the bogie axle drive maintenance line, specifically as follows: Figure 1 As shown, the system includes a maintenance execution system, a digital twin system, an IOT equipment system and hardware facilities; wherein,

[0032] The maintenance execution system is used to realize basic data management, work order management, plan management, complete set management, production execution, quality management and equipment inspection in the process of wheel drive maintenance;

[0033] The digital twin system is used to monitor and analyze the maintenance process based on the collected real-time data;

[0034] The IOT equipment system is used for the Internet of Things to build an overall interconnected data exchange environment for the maintenance line;

[0035] The hardware facilities include twin large screens, workstation machines, area billboards, handheld terminals and weak-current dedicated network laying equipment.

[0036] Furthermore, the maintenance execution system is used to realize basic data management, monthly plan, work orders in process, temporary repair plan, work order plan, work order BOM, process, set management, daily plan management, task feedback, quality management and progress management in the wheel drive maintenance process.

[0037] The maintenance execution system includes a data acquisition module, a quality control module and a work order management module; wherein,

[0038] The data acquisition module acquires key data of bogie axle drive maintenance in real time through integration with the IOT equipment system;

[0039] The quality control module analyzes and compiles statistics on the collected data to ensure that various quality requirements during the maintenance process are met;

[0040] The work order management module is used to manage and track the execution of maintenance tasks. The work order management module includes monthly plan issuance, work order formulation and annual completion number archiving management.

[0041] The maintenance execution system also includes a basic data management module, a plan management module, a complete set management module, a production execution module, a quality management module and an equipment inspection management module;

[0042] The basic data management module is the underlying logical source of data for the maintenance execution system. By configuring the process route and various parameters, a standard data source is formed for calling, thereby realizing digital and unified management of process data.

[0043] The plan management module is used to formulate maintenance plans, including monthly plans, daily plans, emergency maintenance plans and work order plans, and supports real-time feedback on task progress and completion. The plan management module is detailed to the planned tasks of each process and step, and tasks are assigned to specific dates and equipment. The completion status of the plan in each time period and the current maintenance information can be viewed, and the progress is automatically alarmed to assist decision-making.

[0044] The complete set management module is used to ensure that the types and quantities of components assembled during the assembly process are complete and the traceability information is complete.

[0045] The production execution module uses the maintenance process guidance at the process level to guide work reporting, prompt key information, and control the maintenance quality.

[0046] The quality management module is used to collect quality data during the maintenance process in real time, and display the maintenance quality status and early warning information on a large screen to ensure that the maintenance quality is controlled within the specified range, including reporting of abnormalities during the maintenance process and status control of maintenance quality data, forming abnormal order numbers and classifying and summarizing them in the background, and assigning the processing progress to the responsible person until the problem is resolved, thus achieving closed-loop quality management.

[0047] The equipment inspection management module presets equipment inspection operation steps and details, implements the equipment inspection process, ensures normal equipment operation, and reduces maintenance quality problems caused by equipment problems.

[0048] The maintenance execution system also includes a process management module, which can query the process flow and real-time operation progress through the work order number, and can change the operation flow and quality parameters to perform maintenance flexibly.

[0049] Furthermore, the digital twin system includes a data-driven module, a real-time status mapping module and a three-screen interactive module, which is used to realize the digital twin of the maintenance process through the twin large screen of the production scheduling center, and the synchronous update and display of the work order BOM, process and complete set management.

[0050] The digital twin system obtains data from the maintenance execution management system, connects with it through the twin large screen, regional dashboard, workstation machine, and three-screen interaction, realizes real-time status mapping through data-driven, and displays the real-time status of the workshop in terms of plan progress, production statistics, equipment status, quality alarms, etc.

[0051] The twin large-screen display business dimensions include seven parts: section area, production line, workshop overview, work order management, equipment management, personnel management and safety monitoring.

[0052] The business dimensions displayed on the regional dashboard include information such as regional plans, work order progress, machine operators, and equipment disassembly animation guidance.

[0053] The workstation machine is used for data uploading and work reporting at the maintenance station.

[0054] The three-screen interaction simulates the maintenance environment through scene modeling and 3D virtual reality technology, supporting users to remotely view and control every link in the maintenance process. The three-screen interaction is used to assist management personnel in maintenance management, including maintenance execution management, process routes, and digital twin interfaces. The maintenance execution management interface provides data, the process route provides a query entry, and the digital twin interface presents detailed work orders and equipment information management.

[0055] The digital twin system described above builds a virtual model of the bogie axle drive through real-time data interaction with the maintenance execution system, simulates the key steps and operating status in the maintenance process, supports the visualization of equipment status and process flow, and facilitates maintenance personnel to make maintenance decisions and remote monitoring.

[0056] Furthermore, the IOT device system, which is fully called the Internet of Things Device Management System (IOT), significantly improves the operational capabilities of enterprises and organizations by centrally managing and monitoring devices, improving efficiency, and enhancing security. In terms of detailed description, centralized management and monitoring of devices is one of the core advantages of the Internet of Things Device Management System, which can integrate scattered device information onto one platform for easy management and real-time monitoring. For example, a smart factory can monitor the operating status of all devices in real time through the Internet of Things Device Management System, promptly discover and deal with potential problems, thereby reducing downtime and improving production efficiency. In this way, the Internet of Things Device Management System not only improves the management efficiency of the equipment, but also enhances the overall security of the equipment.

[0057] In this embodiment, the IOT equipment system includes a senseless recognition module, a maintenance equipment interaction module, a tool tool interaction module and a QR code recognition module. The IOT equipment system interconnects a large number of maintenance equipment in the maintenance line through senseless recognition, maintenance equipment interaction, tool tool interaction, QR code recognition and other means, and realizes more effective connection and better information flow between all data production and data consumption equipment, systems, processes and personnel in the workshop, eliminating information islands.

[0058] In addition, the IOT device system also includes a sensor network and an edge computing device. The sensor network can collect the temperature, vibration, and stress parameters of the bogie axle drive and perform preliminary data processing through the edge computing device.

[0059] From the above, it can be seen that the IOT equipment system uses non-contact recognition technology to realize automatic recognition and data upload of maintenance equipment and tools through QR code recognition, equipment interaction, tool interaction, etc.

[0060] In this embodiment, the management and control system also includes an operation backtracking function, which allows the selection of a specific operation plan or time period for backtracking, and obtains detailed information on each link in the operation process through 3D animation playback.

[0061] In summary, the digital control system for the bogie axle drive maintenance line described in the embodiment of the present invention ensures the accuracy, authenticity and traceability of the maintenance data of each process and link by real-time dynamic capture of the data of the entire process of bogie axle drive maintenance, and reduces the precision errors caused by factors such as manual measurement and reporting. Through big data analysis and intelligent interaction, the technical barriers between the maintenance section and the various information systems at the section level are broken, so that each key maintenance data can be uploaded to the section level in real time, improving the quality control and supervision of the maintenance process.

[0062] According to a second aspect of the present invention, a method for digital management and control of a bogie axle drive maintenance line is provided, the method comprising the following steps:

[0063] At the initial stage of maintenance, visual research is conducted on the maintenance object, the function, structure and maintenance requirements of the components are analyzed, the maintenance capacity is determined through demand analysis, and the implementation conditions and control factors are analyzed, the maintenance process flow is refined and the overall layout plan is compared to ensure the rationality of the maintenance line layout and efficient operation;

[0064] Before maintenance, a standardized process flow of warehousing, disassembly, cleaning, inspection and testing, maintenance, assembly, testing, and delivery is established. The relationship between personnel, equipment, tools, materials, and operating standards involved in each process is expressed in a digital way. The equipment status data and test result data are collected, analyzed, and decided through IOT technology during the maintenance process.

[0065] During maintenance, a centralized monitoring center is established to monitor the entire maintenance process and status in real time, coordinate the formulation of the project progress plan, use the twin large screen to intuitively guide the construction, and promptly discover on-site problems.

[0066] The digital control method for a bogie axle drive maintenance line provided by an embodiment of the present invention has the following technical effects:

[0067] Visualization of research objects: A comprehensive visualization study of the maintenance objects was conducted to ensure a deep understanding of the components through detailed analysis of their functions, structures and maintenance requirements. This comprehensive visualization laid the foundation for the formulation of accurate maintenance plans;

[0068] Rationalization of overall layout: The maintenance capacity was determined through demand analysis, and the implementation conditions and control factors were studied in depth. By refining the maintenance process and comparing the overall layout plan, the rationality and efficient operation of the maintenance line layout were ensured, providing a scientific planning basis for subsequent steps;

[0069] Digitalization of maintenance process: Establish standardized process flow of warehousing, disassembly, cleaning, inspection and testing, maintenance, assembly, testing, and delivery, and express the relationship between personnel, equipment, tools, materials, and operating standards involved in each process in a digital way to achieve the effect of digitalization of process, standardization of process, and numericalization of results;

[0070] Digitalization of maintenance equipment: Equipment is the key carrier of the digital component maintenance line. IOT technology is used to collect, analyze and make decisions on equipment status data and test result data during the maintenance process. For key and complex equipment, virtual prototype technology is used to display and optimize the equipment operation process in advance, and to ensure the connection between equipment to ensure that the assembly line is busy but not chaotic;

[0071] Centralized control and integration: By establishing a centralized monitoring center to monitor the entire maintenance process and status in real time, the maintenance efficiency can be improved. Through data accumulation, production organization can be guided, resource allocation can be optimized, management efficiency can be brought into play, and maintenance costs can be saved;

[0072] Refined on-site management: Coordinate the formulation of project progress plans, carry out safety training, establish regular meeting systems and coordination mechanisms. Use virtual simulation technology to intuitively guide construction, discover on-site problems in a timely manner, and avoid on-site rework.

[0073] Although the preferred embodiments of the present invention have been described, those skilled in the art may make other changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present invention.

[0074] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

[0075] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A digital control system for a bogie axle drive maintenance line, characterized in that: include: Maintenance execution system, digital twin system, IOT equipment system and hardware facilities; among them, The maintenance execution system is used for basic data management, work order management, plan management, complete set management, production execution, quality management and equipment inspection during the wheel drive maintenance process; The digital twin system is used to monitor and analyze the maintenance process based on the collected real-time data; The IOT equipment system is used to build a data exchange environment for overall interconnection of the maintenance line; The hardware facilities include twin large screens, workstation machines, area billboards, handheld terminals and weak-current dedicated network laying equipment.

2. A digital control system for a bogie axle drive maintenance line according to claim 1, characterized in that: The maintenance execution system includes a data acquisition module, a quality control module and a work order management module; wherein, The data acquisition module acquires key data of bogie axle drive maintenance in real time through integration with the IOT equipment system; The quality control module analyzes and compiles statistics on the collected data to ensure that various quality requirements during the maintenance process are met; The work order management module is used to manage and track the execution status of maintenance tasks.

3. A digital control system for a bogie axle drive maintenance line according to claim 2, characterized in that: The maintenance execution system also includes a plan management module for managing monthly plans, daily plans, emergency repair plans and work order plans, and supports real-time feedback on task progress and completion status.

4. A digital control system for a bogie axle drive maintenance line according to claim 3, characterized in that: The maintenance execution system also includes a quality management module, which is used to collect quality data during the maintenance process in real time, and display the maintenance quality status and early warning information on a large screen to ensure that the maintenance quality is controlled within the specified range.

5. The digital control system for the bogie axle drive maintenance line according to claim 1 is characterized in that: The digital twin system interacts with the maintenance execution system in real time to build a virtual model of the bogie axle drive, simulates key steps and operating conditions in the maintenance process, supports visual display of equipment status and process flow, and facilitates maintenance personnel to make maintenance decisions and remote monitoring.

6. A digital control system for a bogie axle drive maintenance line according to claim 5, characterized in that: The digital twin system includes a data-driven module, a real-time status mapping module and a three-screen interactive module, which is used to realize the digital twin of the maintenance process through the twin large screen of the production scheduling center, and the synchronous update and display of the work order BOM, process and complete set management.

7. A digital control system for a bogie axle drive maintenance line according to claim 6, characterized in that: The digital twin system also includes an interactive design module, which simulates the maintenance environment through scene modeling and 3D virtual reality technology, and supports users to remotely view and control every link in the maintenance process.

8. The digital control system for the bogie axle drive maintenance line according to claim 1 is characterized in that: The IOT equipment system includes a non-sensing recognition module, a maintenance equipment interaction module, a tool interaction module and a QR code recognition module. The IOT equipment system completes automatic recognition and data upload of maintenance equipment and tools through non-sensing recognition, maintenance equipment interaction, tool interaction and QR code recognition.

9. A digital control system for a bogie axle drive maintenance line according to claim 8, characterized in that: The IOT device system also includes a sensor network and an edge computing device. The sensor network collects temperature, vibration, and stress parameters of the bogie wheel axle drive and performs data processing through the edge computing device.

10. A digital control method for a bogie axle drive maintenance line, applied to a digital control system for a bogie axle drive maintenance line according to any one of claims 1 to 9, characterized in that: The method comprises: Conduct visual research on the maintenance object, analyze the function, structure and maintenance requirements of the maintenance components, determine the maintenance capacity through demand analysis, evaluate the implementation conditions and control factors, refine the maintenance process and compare the overall layout plan; Establish standardized process flow for warehousing, disassembly, cleaning, inspection and testing, maintenance, assembly, testing, and delivery, digitally express the relationship between personnel, equipment, tools, materials, and operating standards involved in each process, and use IOT technology to complete the collection, analysis, and decision-making of equipment status data and test result data during the maintenance process; Establish a centralized monitoring center to monitor the entire maintenance process and status in real time, coordinate the formulation of project progress plans, use twin large screens to intuitively guide construction, and promptly discover on-site problems.

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