Train coupler correcting system

Abstract

The invention discloses a train coupler correcting system, which relates to the technical field of railway freight equipment, and comprises a positioning driving module, a three-point positioning assembly comprising a 1.5 kW servo motor, a gear rack mechanism and an eccentric depended wheel, and a depended wheel is attached to a rack to eliminate a gap and limit the shaking of a lower box body; the overturning positioning module is composed of a 0.75 kW stepping motor, a high-precision encoder and an electromagnetic brake, and is used for controlling the upper box body to overturn by 90 degrees and immediately locking the upper box body; the coupler righting execution module comprises a push plate driving motor and a flexible touch plate assembly; the induction detection module is provided with a coupler feeler lever and a push plate induction device; the cable protection module and the double guide rods are used for separately arranging power and network cables and spring wires for preventing twisting; and the cooperative control module and the PLC are linked with all the modules to pre-store operation and reset processes. According to the invention, the positioning and overturning precision is improved, the working efficiency is optimized, the dust resistance and cable protection capability are enhanced, the device is adaptive to multiple vehicle types, and the fault and operation and maintenance cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of railway freight equipment technology, and in particular to a train coupler positive coupler system. Background Technology

[0002] As a core mode of bulk commodity transportation, railway freight's operational efficiency and safety directly impact logistics efficiency. The tippler system, a key piece of equipment for unloading bulk cargo, relies on the coupler alignment device to achieve precise docking between the wagon and the tippler. The alignment device must disconnect the couplers of adjacent wagons before the tippler tipps overturns, fix the couplers during the overturning process to prevent displacement, and re-couple the couplers after overturning. This entire process directly determines the continuity of unloading operations and the service life of the couplers. In bulk cargo transportation scenarios such as coal deliveries to thermal power plants and bulk cargo at ports, if the coupler shifts due to positioning deviation or fixing failure, it can not only lead to coupling failure but also cause collision damage to the coupler, requiring shutdown for repairs in severe cases and affecting transportation turnaround efficiency.

[0003] Existing straightening equipment has significant shortcomings in mechanical positioning and structural protection. In the positioning process, traditional equipment often uses a single gear and rack drive, lacking an effective backlash elimination mechanism. When the lower housing moves along the track, it is prone to wobbling due to transmission backlash, causing the coupler contact rod and push plate to fail to accurately align with the coupler position, with alignment deviations often reaching several millimeters. Regarding tilting control, the 90-degree tilting of the upper housing relies heavily on motor start-stop control, lacking high-precision angle detection and real-time locking devices, resulting in a low tilting accuracy rate and a large alignment error between the push plate centerline and the coupler axis, further reducing the straightening effect. Furthermore, during equipment movement, cables are often arranged in a single, dragged configuration without effective isolation or telescopic protection structures, making them highly susceptible to kinking during movement, leading to power and signal transmission interruptions and becoming one of the main causes of equipment failure.

[0004] Insufficient adaptability to different operations and environments further restricts the efficiency of the equipment. Different freight scenarios utilize various types of couplers, such as No. 13 and No. 16, in train carriages. Existing positive coupler equipment often has fixed push plate strokes and contact plate dimensions, failing to flexibly adapt to the structural differences of different couplers. Frequent component replacements are necessary to meet operational requirements, increasing maintenance costs. Simultaneously, the high dust concentration in the tipper's operating environment, where dust easily adheres to the surfaces of gears, racks, rails, and sensing elements, exacerbating equipment wear and jamming. This leads to problems such as lower carriage movement obstruction and false triggering of limit switches, resulting in frequent downtime due to malfunctions. These combined issues result in low coupling success rates, high coupler damage rates, and limited operational efficiency for traditional positive coupler equipment, making it difficult to meet the high-efficiency, continuous, and multi-car compatibility requirements of modern railway freight operations. Summary of the Invention

[0005] The present invention proposes a train coupler positive coupling system to solve the problems mentioned in the prior art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a train coupler positive coupling system, comprising:

[0007] The positioning drive module, as the core execution unit for equipment movement and positioning, consists of a drive motor, a gear and rack transmission mechanism, and an eccentric wheel three-point positioning assembly. The drive motor is a 1.5kW AC servo motor. The gear and rack are made of 40Cr material. The eccentric wheel three-point positioning assembly includes an eccentric wheel, double wheels, and an M8 internal hexagon lock screw.

[0008] The flip positioning module enables precise 90° flipping and locking of the upper housing. It consists of a flip motor, an angle detection unit, and an electromagnetic brake device. The flip motor is a 0.75kW two-phase stepper motor driven by a harmonic reducer. The angle detection unit is equipped with a 16-bit incremental encoder.

[0009] The coupler straightening execution module is responsible for the coupler clamping and fixing as well as flexible buffering. It consists of a push plate drive unit, a flexible contact plate assembly, and a guide rail. The push plate drive unit uses a 0.75kW servo motor, which drives the push plate to move through a ball screw pair. The flexible contact plate assembly includes a nylon PA6 contact plate, a cylindrical helical spring, and a limit shaft structure.

[0010] The sensing and detection module enables precise sensing and status feedback of the coupler position. It consists of a coupler contact rod device, a push plate sensing device, and a signal processing unit. The coupler contact rod device is installed at the front end of the lower housing. The contact rod is made of 45# steel with heat treatment and a travel limit switch is installed at the top. The push plate sensing device integrates a travel switch and a pressure sensor. The signal processing unit uses a signal isolator.

[0011] The cable protection module ensures stable cable transmission by employing a combination of a double cable guide rod device and a spring wire design. The double cable guide rods are made of extruded aluminum alloy with a double-groove structure for arranging power cables and network cables. The spring wires are sheathed with polyurethane and wrapped with an outer tinned copper mesh shielding layer.

[0012] The collaborative control module, as the central hub of the system, adopts a Siemens S7-1200 series PLC controller, expands analog and digital modules, and connects each module through the PROFINET bus.

[0013] Furthermore, it also includes a dynamic positioning accuracy calibration module, which is connected to the encoder and eccentric wheel assembly of the positioning drive module respectively. It collects the actual movement distance of the lower housing and the preset theoretical movement distance in real time and calculates the positioning deviation. The calculation method is P = DL, where P is the positioning deviation, D is the actual movement distance of the lower housing, and L is the theoretical movement distance of the lower housing. When P > 0.5mm, the controller outputs a pulse signal to drive the eccentric wheel fine-tuning motor to rotate in 0.5° steps, pushing the wheel to further tighten the rack.

[0014] Furthermore, it also includes a multi-model coupler adaptation module, which communicates with the collaborative control module and the coupler straightening execution module. It has a built-in mainstream coupler parameter database that stores key parameters such as coupler head size, contact reference position, and maximum permissible collision force. It is equipped with a laser rangefinder sensor installed at the front end of the lower housing to measure the actual position of the coupler before coupler search. After the measurement data is transmitted to the collaborative control module, it automatically corrects the theoretical moving distance of the lower housing and the push plate tightening stroke.

[0015] Furthermore, it also includes a push plate spring parameter adaptation module, which is connected to the coupler straightening execution module and the multi-model coupler adaptation module. Based on the maximum allowable collision force of the currently adapted coupler and the set spring compression stroke, it calculates the required spring stiffness. The calculation method is K = F / S, where K is the spring stiffness, F is the maximum allowable collision force of the coupler, and S is the set spring compression stroke. Based on the calculation results, the spring replacement prompt function guides maintenance personnel to select a spring with the corresponding stiffness.

[0016] Furthermore, it also includes a coupler dynamic offset compensation module, which works in conjunction with the collaborative control module, the sensing and detection module, and the positioning and driving module; the encoder collects the position data of the lower housing, the pressure sensor of the push plate sensing device provides feedback on the change of contact force of the contact plate, and the collaborative control module integrates the two types of data to determine the direction and magnitude of the coupler offset.

[0017] Furthermore, it also includes a dust protection module that works in conjunction with the positioning drive module, cable protection module, and running track to adapt to the high-dust operating environment of the tipper; a stainless steel dust cover is added to the outside of the gear and rack mechanism of the positioning drive module, and the inside of the dust cover is sealed with rubber to fit tightly against the surface of the rack; polyurethane dust scrapers are installed at both ends of the running track to remove dust and debris from the track surface in real time as the lower box moves; a polytetrafluoroethylene dust cap is added to the top of the double guide rods of the cable protection module, and a drainage hole is set at the bottom of the guide rod.

[0018] Furthermore, it also includes an intelligent fault early warning module, which connects to the collaborative control module and the status monitoring module to collect real-time statistics on equipment operation data and calculate the frequency of fault shutdowns. The calculation method is Q = N / T, where Q is the frequency of fault shutdowns, N is the number of fault shutdowns in that shift, and T is the total working time in that shift. When Q exceeds the threshold, a three-color indicator light (red, yellow, and green) will issue a graded warning, a buzzer will emit an intermittent alarm sound, and the touch screen will simultaneously display the fault point, the cause of the fault, and the troubleshooting steps to guide maintenance personnel in handling the situation.

[0019] Furthermore, it also includes a full-parameter status monitoring and recording module, which establishes data connections with each functional module to collect 12 key operating parameters in real time, such as: motor operating current, motor temperature, lower housing positioning deviation, upper housing flipping angle, push plate spring compression, and contact plate contact force; the parameter data is stored on an industrial-grade SD card, and supports multi-dimensional querying of historical data by time, module type, and parameter name.

[0020] Furthermore, it also includes a manual emergency operation module, which works independently in parallel with the collaborative control module. It is equipped with a wall-mounted manual operation panel, which integrates an emergency stop button, a manual and automatic switching switch, forward and reverse buttons for the lower housing, flip and reset buttons for the upper housing, and push plate extension and retraction buttons. When the automatic control system malfunctions or is under maintenance, it switches to manual mode, and the actions of each mechanism can be controlled individually via buttons. During operation, the travel limit switches still maintain their protective function and automatically stop when the mechanism reaches its limit position.

[0021] Furthermore, it also includes a remote operation and maintenance and diagnostic module, which is connected to the collaborative control module and the full-parameter status monitoring module via Ethernet and equipped with a 4G / 5G dual-mode communication module. It encrypts and uploads real-time operating parameters, fault warning information, and historical report data of the equipment to the remote operation and maintenance platform. Operation and maintenance personnel can log in to the platform via PC or mobile terminal to view the equipment operating status curve, download historical data, and issue parameter adjustment commands. When the equipment triggers a red emergency warning, it automatically pushes a fault snapshot to the operation and maintenance terminal, and supports remotely starting fault simulation through the platform to reproduce the fault scenario and formulate a repair plan.

[0022] Compared with existing technologies, the beneficial effects of this invention are:

[0023] In terms of positioning and alignment accuracy, this invention achieves a breakthrough from "rough alignment" to "precise locking." The design of the eccentric wheel three-point positioning component in the positioning drive module, by rotating the eccentric wheel to ensure the wheel is tightly fitted against the back of the rack, effectively eliminates the backlash problem of traditional gear and rack transmissions, significantly reducing the swaying amplitude during the movement of the lower housing, and laying a stable benchmark for subsequent hook finding and tightening. The high-precision encoder and fast-response braking device in the flip positioning module ensure that the upper housing can be locked instantly when flipped to 90 degrees, greatly improving the alignment accuracy between the push plate and the coupler axis, fundamentally reducing the risk of coupler collisions caused by alignment deviations. This precise mechanical positioning design directly improves the stability of the coupler fixation and avoids damage to the coupler caused by displacement during rollover.

[0024] Coupler protection and operational safety are fundamentally enhanced. The flexible contact plate assembly of the coupler straightening actuator module uses a spring-buffered structure to create a flexible collision when the contact plate comes into contact with the coupler, rather than the rigid contact of traditional equipment. This provides sufficient clamping force to fix the coupler while effectively absorbing collision energy, protecting the coupler structure from damage. The dual feedback mechanism of limit switches and pressure signals in the sensing detection module ensures that the push plate stops immediately after contacting the coupler, avoiding deformation caused by excessive clamping and further improving operational safety. At the same time, the dust protection module reduces the impact of dust on gears, racks, tracks, and sensing elements through structures such as dust covers and scrapers, lowering the risk of equipment failure caused by dust jamming and extending the equipment's service life.

[0025] Operational efficiency and adaptability are significantly optimized, and maintenance costs are greatly reduced. The collaborative control module's pre-stored "operation-reset" full-process logic automates the linkage of actions such as lower box movement, upper box flipping, and push plate tightening. The entire process can be completed without manual intervention, reducing the time spent on manual confirmation in traditional equipment and greatly improving operational continuity and efficiency. The multi-model coupler adaptation module has a built-in database of mainstream coupler parameters. Combined with real-time position correction via laser ranging, the equipment can adapt to different coupler models without replacing parts, solving the problem of limited adaptability in traditional equipment. The intelligent fault warning and remote maintenance module can monitor the equipment's operating status in real time, provide early warnings of faults and troubleshooting suggestions. Combined with the full parameter recording function, it facilitates quick problem location for maintenance personnel, shortening fault handling time and reducing maintenance costs.

[0026] Furthermore, the cable protection module's dual-guide rod and spring wire combination design effectively prevents cable kinking and signal interference, ensuring the stability of power and data transmission. The manual emergency module provides safe operation during equipment failure or maintenance, further enhancing equipment reliability. Overall, this invention, through the collaborative innovation of multiple modules, achieves precision, automation, and high adaptability in hook-and-line operations, meeting the demands of modern railway freight transport for high efficiency, safety, and low maintenance. Attached Figure Description

[0027] Figure 1 This is a schematic block diagram of a train coupler positive coupler system proposed in this invention;

[0028] Figure 2 This is a comparison chart of the key performance characteristics of the conventional coupler system and the coupler system of this invention.

[0029] Figure 3 A comparison chart of system failure downtime frequency under different dust concentrations;

[0030] Figure 4 Comparison chart of coupler performance for multiple vehicle models;

[0031] Figure 5 This is a diagram illustrating the dynamic calibration process for the positioning accuracy of the lower housing. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0034] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a mechanical connection or an electrical connection; they may refer to a direct connection or an indirect connection through an intermediate medium; and they may refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. The invention will now be described in further detail with reference to the accompanying drawings.

[0035] Reference Figures 1 to 5 A train coupler system, comprising:

[0036] The positioning drive module, as the core execution unit for equipment movement and positioning, consists of a drive motor, a gear and rack transmission mechanism, and an eccentric guide wheel three-point positioning component. The drive motor is a 1.5kW AC servo motor equipped with a planetary reducer with a reduction ratio of 1:20, outputting a rated torque of 180N·m and supporting stepless speed regulation from 0-0.5m / s. The gears in the gear and rack transmission mechanism are made of 40Cr material, with a module of 2.5 and 40 teeth. The tooth surfaces are carburized and quenched to a hardness of HRC55. The rack length is adapted to the span of the tippler track, and the installation parallelism error is ≤0.2mm / m. The eccentric wheel three-point positioning assembly includes an eccentric wheel (5mm eccentricity, forged from 45# steel), double wheels (polyurethane material, 50mm diameter, Shore hardness 75D), and M8 hex socket head cap screws. By rotating the eccentric wheel with a special wrench, the wheels can be driven to rotate 0-30° along the eccentric shaft until they are tightly fitted against the back of the rack, eliminating the 0.5-1mm transmission gap and limiting the movement and sway of the lower housing to ≤0.5mm.

[0037] The flipping positioning module enables precise 90° flipping and locking of the upper housing. It consists of a flipping motor, an angle detection unit, and an electromagnetic brake. The flipping motor is a 0.75kW two-phase stepper motor with a step angle of 1.8°, which drives the upper housing to rotate around the hinge axis via a harmonic reducer (reduction ratio 1:50). The angle detection unit is equipped with a 16-bit incremental encoder with a sampling frequency of 500Hz and an angle measurement accuracy of ±0.1°, providing real-time feedback of the flipping angle data. The electromagnetic brake is a power-off braking type with a braking torque of 20N·m and a response time of ≤0.1s. It locks immediately when the upper housing flips to 90°±0.5°, maintaining a perpendicular state to the lower housing and ensuring that the alignment deviation between the push plate centerline and the coupler axis is ≤1mm.

[0038] The coupler straightening execution module, responsible for both coupler clamping and flexible buffering, consists of a push plate drive unit, a flexible contact plate assembly, and a guide rail. The push plate drive unit uses a 0.75kW servo motor, which drives the push plate vertically along the T-shaped guide rail via a ball screw pair (5mm lead, positioning accuracy ±0.02mm). The moving speed is adjustable from 0.05-0.2m / s. The flexible contact plate assembly includes a nylon PA6 contact plate (20mm thickness), a cylindrical helical spring (3mm wire diameter, 25mm outer diameter, stiffness 30-40N / mm), and a limiting shaft structure. The contact plate rotates around a stainless steel rotating shaft (10mm diameter). The limiting shaft restricts the contact plate's movement range through a waist-shaped hole (30mm long diameter). The spring compression stroke is set to 15mm to ensure an effective contact area of ​​≥95% between the contact plate and the coupler, avoiding rigid collision damage.

[0039] The sensing and detection module enables precise sensing and status feedback of the coupler position. It consists of a coupler contact rod device, a push plate sensing device, and a signal processing unit. The coupler contact rod device is installed at the front of the lower housing. The contact rod is made of 45# steel with heat treatment, is 180mm long and 20mm in diameter, and has a travel limit switch (IP67 waterproof rating, trigger accuracy 0.1mm) installed at the top. The response time after touching the coupler is ≤0.2s. The push plate sensing device is integrated inside the contact plate and includes a travel switch and a pressure sensor (range 0-1000N, resolution 1N). When the contact plate contacts the coupler and the spring is compressed to the set travel, the switch signal and pressure signal are triggered simultaneously. The signal processing unit uses a signal isolator to convert the collected signal into a 4-20mA standard signal for transmission to the control module, with an anti-interference voltage ≥2kV.

[0040] The cable protection module ensures stable cable transmission during equipment movement, employing a combination of a double cable guide rod device and spring wires. The double cable guide rods are made of extruded aluminum alloy with a double-groove structure (groove width 22mm, groove depth 15mm), respectively accommodating power cables and network cables. The power cable specification is 4×1.5mm. 2 The copper core wire (temperature resistance rating 105℃) and the network cable are Category 5e shielded twisted pair (shielding layer coverage 90%). The spring wire is made of polyurethane sheath material with a 200% elongation rate. The maximum elongation length is adapted to the lower cabinet movement distance (≤5m). The outer layer is wrapped with a tin-plated copper mesh shielding layer with a shielding effectiveness ≥85dB. The two ends of the guide rod are equipped with cable fixing clamps to prevent the cable from twisting or pulling when moving with the equipment.

[0041] The collaborative control module, serving as the central hub of the system, employs a Siemens S7-1200 series PLC controller (CPU1214C), expanding with analog input / output and digital input / output modules. It connects to various functional modules via a PROFINET bus with a communication rate of 100Mbps. A pre-stored "operation-reset" full-process logic program is included. During operation, the modules are linked in the sequence of "lower housing movement → upper housing tilting → hook positioning → push plate tightening → tipping trigger." During reset, the process of "push plate disengaging → upper housing returning to position → lower housing returning to position" is executed. The signal transmission delay between each step is ≤50ms. A built-in fault diagnosis program monitors eight common faults, including motor overload and switch malfunctions, and supports manual reset and emergency stop operations.

[0042] According to claim 1, a train coupler system is characterized by further including a dynamic positioning accuracy calibration module, which is connected to the encoder and eccentric wheel assembly of the positioning drive module respectively, to collect the actual movement distance of the lower box and the preset theoretical movement distance in real time, and calculate the positioning deviation. The calculation method is P = DL. Where P is the positioning deviation in mm; D is the actual movement distance of the lower box in mm, obtained by conversion from the encoder pulse signal; L is the theoretical movement distance of the lower box in mm, preset by the control program. When P > 0.5 mm, the controller outputs a pulse signal to drive the eccentric wheel fine-tuning motor (0.1 kW stepper motor) to rotate in 0.5° steps, pushing the wheel to further tighten the rack. After each adjustment, the P value is re-collected and calculated until P ≤ 0.5 mm, ensuring that the positioning accuracy of the lower box is not affected by rack wear or installation errors.

[0043] This invention also includes a multi-model coupler adaptation module, which communicates with the collaborative control module and the coupler straightening execution module. It has a built-in database of parameters for mainstream couplers such as No. 13, No. 16, and No. 25, storing key parameters such as coupler head size (length 80-150mm), contact reference position, and maximum permissible collision force (400-600N). Equipped with a laser rangefinder (range 0-500mm, accuracy ±0.1mm), installed at the front end of the lower housing, it measures the actual position of the coupler before hook finding. After the measurement data is transmitted to the collaborative control module, it automatically corrects the theoretical moving distance of the lower housing and the pusher plate's clamping stroke. The pusher plate's moving speed can be adaptively adjusted within the range of 0.03-0.05m / s to adapt to the different coupler positions of different car models, with a positioning accuracy ≤±0.8mm.

[0044] This invention also includes a push plate spring parameter adaptation module, connected to the coupler straightening execution module and the multi-model coupler adaptation module. Based on the maximum permissible collision force of the currently adapted coupler and the set spring compression stroke, the required spring stiffness is calculated. The calculation method is K = F / S. Where K is the spring stiffness, in N / mm; F ​​is the maximum permissible collision force of the coupler, in N, taken from a multi-model parameter database; and S is the set spring compression stroke, in mm, with a default value of 15mm. Based on the calculation results, a spring replacement prompt function guides maintenance personnel to select a spring with the corresponding stiffness, ensuring that the contact plate provides both flexible buffering and stable clamping force when contacting the coupler, avoiding damage to the coupler structure or clamping failure.

[0045] This invention also includes a coupler dynamic offset compensation module, which works in conjunction with the collaborative control module, sensing and detection module, and positioning drive module to function during the 165° tilting of the tipper. The encoder collects the lower housing position data at a frequency of 100Hz, and the pressure sensor of the push plate sensing device provides feedback on changes in the contact force of the contact plate at a frequency of 50Hz. The collaborative control module integrates these two types of data to determine the direction and magnitude of the coupler offset. When the contact force fluctuates by ±50N (corresponding to an offset >1mm), the push plate motor micro-adjustment is automatically activated, adjusting the push plate position in 0.1mm steps, compensating for the offset through changes in spring compression. Simultaneously, a micro-adjustment signal is sent to the lower housing drive motor to correct the lower housing position by ±0.5mm, suppressing the coupler dynamic offset within ±1mm and ensuring the stability of the coupler posture during the tipping process.

[0046] This invention also includes a dust protection module, which works in conjunction with the positioning drive module, cable protection module, and running track to adapt to the high-dust operating environment of the tipper. A stainless steel dust cover is added to the outside of the gear and rack mechanism of the positioning drive module. The inner side of the dust cover uses a rubber sealing edge (Shore hardness 60A) to tightly fit the rack surface with a gap ≤0.3mm. Polyurethane dust scrapers (5mm thick, width matching the track) are installed at both ends of the running track, with a gap ≤0.2mm between the dust scraper and the track surface, to remove dust and debris from the track surface in real time as the lower housing moves. A polytetrafluoroethylene dust cap is added to the top of the double guide rods of the cable protection module, and drainage holes are provided at the bottom of the guide rods to prevent dust and water from entering the guide rods, reducing the risk of equipment jamming and cable wear.

[0047] This invention also includes an intelligent fault early warning module, connected to the collaborative control module and the status monitoring module, which collects real-time equipment operation data and calculates the frequency of fault downtime. The calculation method is Q = N / T. Where Q is the frequency of fault downtime, in times / shift; N is the number of fault downtimes in that shift, automatically recorded by the collaborative control module; and T is the total working time of that shift, in hours, with a value of 8 hours / standard shift. A pre-stored early warning threshold of 0.2 times / shift is used. When Q exceeds the threshold, a three-color indicator light (yellow for alert, orange for alarm, and red for emergency) issues a tiered warning, a buzzer emits an intermittent alarm sound, and the touchscreen simultaneously displays the fault point (such as worn dust scraper, stuck spring wire), the cause of the fault, and troubleshooting steps to guide maintenance personnel in accurate handling.

[0048] This invention also includes a full-parameter status monitoring and recording module, which establishes data connections with each functional module to collect 12 key operating parameters in real time, including motor operating current (0-5A), motor temperature (0-150℃), lower housing positioning deviation (0-2mm), upper housing tilting angle (0-90°), push plate spring compression (0-20mm), and contact plate contact force (0-1000N), with a sampling interval of ≤100ms. Parameter data is stored on an industrial-grade SD card (64GB capacity, read / write speed ≥10MB / s), supporting multi-dimensional querying of historical data by time (accurate to the second), module type, and parameter name. It automatically generates daily / weekly operation reports, recording equipment operating status, fault information, and processing results, with a storage period of ≥1 year, facilitating maintenance traceability and performance analysis.

[0049] This invention also includes a manual emergency operation module, which works independently in parallel with the collaborative control module. It is equipped with a wall-mounted manual operation panel, integrating an emergency stop button (red mushroom head, forcibly disconnecting the motor power), a manual / automatic switch, a lower housing forward / reverse button, an upper housing flip / reset button, and a push plate extension / retraction button. When the automatic control system malfunctions or requires maintenance, switching to manual mode allows individual control of each mechanism's actions via buttons. During operation, the travel limit switches maintain their protective function, automatically stopping when the mechanism reaches its limit position to prevent overtravel and mechanical damage, thus improving equipment safety and maintenance convenience.

[0050] This invention also includes a remote operation and maintenance (O&M) and diagnostic module, which is connected to the collaborative control module and the full-parameter status monitoring module via Ethernet. Equipped with a 4G / 5G dual-mode communication module (supporting full network compatibility, upload speed ≥10Mbps), it encrypts and uploads real-time equipment operating parameters, fault warning information, and historical report data to the remote O&M platform. O&M personnel can log in to the platform via PC or mobile terminal to view equipment operating status curves, download historical data, and issue parameter adjustment commands (such as correcting positioning deviation thresholds and updating coupler parameters). When the equipment triggers a red emergency warning, a fault snapshot (including abnormal parameters, equipment attitude, and timestamp) is automatically pushed to the O&M terminal. The platform supports remotely initiating fault simulation, reproducing fault scenarios, and developing repair plans, reducing fault handling time by ≥40%.

[0051] The following two examples further illustrate the specific implementation of this system:

[0052] Example 1: 3000t / h thermal power plant freight tippler with matching hook system (application scenario of a thermal power plant in Datong, Shanxi)

[0053] This embodiment addresses the need for upgrading a 3000t / h tippler system at a thermal power plant in Datong, Shanxi. The original system used a traditional gear and rack drive, with a lower housing sway of ±3mm, an 8% damage rate to the No. 13 coupler, a single operation cycle of 110 seconds, and a failure downtime frequency of 1.5 times per shift. The solution of this invention achieves precise hook alignment and automated operation. The specific implementation process is as follows.

[0054] 1. System module selection, installation, and debugging

[0055] The positioning drive module uses a 1.5kW Siemens V90 servo motor, equipped with a 1:20 planetary reducer, with an output torque of 180 N·m. The gears are made of 40Cr material, with a module of 2.5, 40 teeth, and the tooth surface is carburized and quenched to HRC55. The rack is 5m long, and the installation parallelism error is 0.15mm / m. The eccentric wheel assembly has an eccentricity of 5mm. The double wheels are made of polyurethane (Shore hardness 75D), with a diameter of 50mm. The eccentric wheel is rotated using a 24mm open-end wrench to make the wheel fit against the back of the rack, and then secured with M8 hex socket screws.

[0056] The flip positioning module is equipped with a 0.75kW Leadshine two-phase stepper motor with a step angle of 1.8° and a 1:50 harmonic reducer; a 16-bit incremental encoder with a sampling frequency of 500Hz and an angle accuracy of ±0.1°; an electromagnetic brake with a braking torque of 20N·m and a response time of 0.08 seconds; during debugging, the flip positioning angle is set to 90°±0.5°.

[0057] The push plate drive motor of the coupler straightening execution module is a 0.75kW Delta servo motor with a ball screw lead of 5mm and a positioning accuracy of ±0.02mm. The push plate moves along a T-shaped track at an adjustable speed of 0.05-0.2m / s. The flexible contact plate assembly has a 20mm thick nylon PA6 contact plate, a 3mm diameter cylindrical helical spring with an outer diameter of 25mm, a stiffness of 35N / mm, and a compression stroke set to 15mm. The contact plate rotates around a 10mm diameter stainless steel shaft, and the movement range is limited by a 30mm long oblong hole.

[0058] The coupler contact rod of the sensing detection module is made of 45 steel with heat treatment, with a length of 180mm and a diameter of 20mm. The top travel limit switch has a waterproof rating of IP67, a trigger accuracy of 0.1mm, and a response time of 0.15 seconds. The pressure sensor of the push plate sensing device has a range of 0-1000N and a resolution of 1N. The signal is converted into a 4-20mA standard signal by an isolator.

[0059] The cable protection module's dual guide rods are made of aluminum alloy, with double slots 22mm wide, each containing 4 x 1.5mm rods. 2Power cable (temperature resistant 105℃) and Category 5e shielded network cable, spring wire elongation rate 200%, maximum elongation length 5m, outer tin-plated copper mesh shielding layer with shielding effectiveness of 85dB, and cable fixed at both ends of the guide rod with clamps.

[0060] The collaborative control module uses Siemens S7-1200CPU1214C, expands analog and digital modules, connects each module through PROFINET bus, pre-stores operation and reset procedures, and has a signal transmission delay of 45ms.

[0061] 2. Core Functionality Testing and Formula Application

[0062] Dynamic calibration test for positioning accuracy: The lower housing needs to be moved 2000mm to the far end of the tipper. The encoder collects the actual distance D = 2000.6mm, the theoretical distance L = 2000mm, and P = 0.6mm > 0.5mm according to P = DL. The controller drives the 0.1kW eccentric wheel fine-tuning motor to rotate 0.5°, and the wheel further tightens the rack. D = 2000.4mm is collected again, P = 0.4mm ≤ 0.5mm, and the calibration is complete.

[0063] Push plate spring parameter matching: The maximum allowable collision force of the No. 13 coupler is 525N. The compression stroke is set to 15mm. According to K=F / S, K=525 / 15=35N / mm. Select the spring with the corresponding stiffness. After installation, when the contact plate contacts the coupler, the spring is compressed by 15mm and the pressure is 520N, which meets the requirements.

[0064] Coupler dynamic offset compensation: When the tipper rotates 165°, the encoder collects the position of the lower box at 100Hz, and the pressure sensor feeds back the contact force at 50Hz. When the coupler offsets by 1.2mm, the pressure drops to 470N. The push plate motor makes a fine adjustment in 0.1mm steps. After compensation, the pressure rises back to 500N, and the offset is suppressed to 0.8mm.

[0065] Intelligent fault warning: Each shift operates for 8 hours, completing 60 operations. There are 2 fault shutdowns. According to Q=N / T, Q=2 / 8=0.25 times / shift. This exceeds the threshold of 0.2 times / shift, so the system triggers an orange alarm, indicating "dust scraper wear". Inspection revealed that the dust scraper was worn by 2mm. After replacement, the system returned to normal.

[0066] 3. Full-process operation and reset verification

[0067] Operating Procedure: The equipment is placed at the initial position, the motor is locked, and the dust scraper removes dust from the track; the lower box moves to the far end at 0.2 m / s, is aligned, and then locked; the upper box rotates 90°, is braked and locked, with an alignment deviation of 0.8 mm; the lower box moves in the opposite direction at 0.05 m / s, the contact rod touches the coupler, and the switch is triggered to lock after 0.15 seconds; the push plate moves at 0.1 m / s, the contact plate touches the coupler, the spring is compressed 15 mm, and the switch is triggered to lock; a start signal is sent to the tipper, and the offset is dynamically compensated during the tipping process; after the tipper returns to the correct position, the push plate disengages and locks, the upper box resets to 0°, the lower box returns to its original position, the motor is powered off, and the reset takes 13 seconds.

[0068] 4. Performance Data Representation

[0069] Table 1: Performance Comparison between Traditional System and Invention

[0070] Performance indicators Traditional system This invention system Lower housing positioning deviation ±3mm ±0.4mm Upper box flip alignment deviation ±2mm ±0.8mm Coupler damage rate 8％ 0.5％ Single operation cycle 110 seconds 68 seconds Frequency of downtime due to malfunction 1.5 times / shift 0.25 times / shift

[0071] Table 1 shows the data from one month of operation after the upgrade. Traditional systems suffer from large gear and rack transmission clearances, resulting in a lower housing positioning deviation of ±3mm, inaccurate upper housing rotation alignment, and an 8% coupler damage rate due to rigid contact. Manual intervention extends the operation cycle to 110 seconds, and cable kinks and dust jamming cause frequent malfunctions. This invention eliminates clearances through eccentric guide wheels and achieves high-precision rotation control, significantly improving positioning and alignment accuracy. The spring buffer design reduces the coupler damage rate to 0.5%; the automated process shortens the cycle to 68 seconds; and the dust-resistant and cable protection design reduces malfunctions. Although occasional warnings are triggered by scraper wear, the overall performance far surpasses that of traditional systems, solving the pain points of inaccurate positioning, low efficiency, and frequent malfunctions.

[0072] Example 2: 5000t / h Port Bulk Cargo Tipper Hook System (Application Scenario of a Bulk Cargo Terminal in Ningbo Port)

[0073] This example illustrates a new 5000t / h tippler project at Ningbo Port, where the dust concentration in the operating environment reaches 50mg / m³. 3 It needs to be compatible with No. 13 and No. 16 couplers and requires continuous operation without failure. The specific implementation process is as follows.

[0074] 1. Building and debugging a highly adaptable system

[0075] The gear and rack surfaces of the positioning drive module are coated with a wear-resistant coating, and the dust cover uses a rubber sealing edge (Shore hardness 60A) with a gap of 0.2mm. The eccentric guide wheel assembly has an automatic fine-tuning function, which is controlled by the collaborative control module. The encoder and electromagnetic brake of the flip positioning module are linked and tested, with a flip-in locking response time of 0.07 seconds and an alignment deviation of 0.7mm.

[0076] The spring stiffness of the coupler straightening actuator module is adjustable from 30-40 N / mm and comes with a spring replacement kit. The contact plate size of the flexible contact plate assembly is compatible with No. 13 and No. 16 couplers, and the contact area is ≥95%.

[0077] The sensing and detection module is equipped with a laser rangefinder (range range 0-500mm, accuracy ±0.1mm), which is cross-calibrated with the limit switch and has a trigger accuracy of 0.08mm; the range of the push plate pressure sensor is extended to 0-1200N to adapt to different coupler collision force requirements.

[0078] The cable protection module has a PTFE dust cap on the top of the double guide rods, a drainage hole at the bottom, and the spring wire sheath is made of wear-resistant polyurethane. The telescopic length is 6m, and the maximum moving distance of the lower enclosure is 5.5m.

[0079] The dust protection module is equipped with polyurethane dust scrapers (5mm thick, 0.1mm gap from the track) at both ends of the track, and the gear and rack mechanism is equipped with an automatic lubrication device that sprays oil every 2 hours to reduce dust adhesion.

[0080] The multi-model coupler adaptation module has a built-in database of coupler parameters for No. 13 and No. 16 couplers. The No. 13 coupler allows a collision force of 525N, and the No. 16 coupler allows 580N. The laser rangefinder sensor measures the coupler position before searching for the coupler and automatically corrects the movement distance of the lower box body.

[0081] 2. Core Functionality and Formula Implementation Testing

[0082] Multi-vehicle compatibility test: When switching to No. 16 coupler operation, the laser rangefinder measured the coupler position as 1800.6mm. The theoretical movement distance was corrected to 1800.6mm. The push plate clamping stroke was calculated according to K=F / S, K=580 / 15≈38.67N / mm. A 39N / mm spring was selected. When the spring was compressed to 14.9mm, the switch was triggered with a pressure of 581N, indicating successful compatibility.

[0083] Dust resistance test: simulated dust concentration 10-70 mg / m³ 3 The system operated continuously for 8 hours without gear or rack jamming, limit switches triggered without error, and cable transmission was stable.

[0084] Fault warning and remote operation and maintenance: In a certain shift, there are 100 operations, 3 downtimes due to faults, and a total operation time of 8 hours. According to Q=N / T, Q=3 / 8=0.375 times / shift. The system issues a red warning, and the remote platform pushes a fault snapshot showing "spring wire stuck". After the operation and maintenance personnel replace the spring wire on-site, the problem is resolved, and the processing time is reduced by 45%.

[0085] 3. Full-process operation adaptation verification

[0086] Operation of coupler No. 13: The lower box body moves 2200mm, and after calibration, P=0.3mm; the upper box body rotates 90°, with an alignment deviation of 0.7mm; the push plate tightening pressure is 520N, and after offset compensation, the deviation is 0.6mm; the operation cycle is 70 seconds.

[0087] Coupler operation for car #16: Laser ranging corrected movement distance of 1800.6mm, after calibration P=0.35mm; flipping alignment deviation of 0.75mm; push plate pressure of 580N, after offset compensation deviation of 0.7mm; operation cycle of 72 seconds.

[0088] Reset process: The push plate disengages, the upper housing resets, and the lower housing returns to its original position, taking 14 seconds. The motor is then powered off and locked, and the dust fan starts to remove internal dust.

[0089] 4. Performance Data Representation

[0090] Table 2: System operating performance under different dust concentrations

[0091]

[0092] Table 2 shows data from tests conducted during the commissioning phase at different dust concentrations, with the traditional system at 30 mg / m³. 3 The frequency of malfunctions has reached 1.8 times per shift, 50mg / m³ 3 Continuous operation is not possible at this time. This invention, through a dust cover, dust scraper, and automatic lubrication design, achieves 50mg / m³... 3 In high-dust environments, the failure frequency is only 0.22 times per shift, the positioning deviation is ≤ ±0.4mm, the operation cycle is consistently within 72 seconds, and the coupler damage rate is ≤ 0.5%. Even at 70mg / m³ 3 Even in extreme environments, it can still maintain basic operations, with only a slight increase in the frequency of malfunctions. At the same time, the multi-model compatibility design makes the No. 13 and No. 16 couplers perform similarly without the need to replace parts, demonstrating strong environmental adaptability and multi-scenario adaptability, perfectly meeting the port's high dust and multi-model operation requirements.

[0093] Reference Figure 2This diagram visually demonstrates the groundbreaking improvements in mechanical positioning and operational efficiency achieved by this invention. Traditional systems suffer from large gear and rack transmission backlash and low tilting control precision, resulting in positioning deviations of ±3mm and ±2mm between the lower and upper housings, respectively. Rigid contact leads to a coupler damage rate as high as 8%. Manual intervention and frequent malfunctions extend the work cycle to 110 seconds, with a failure frequency of 1.5 times per shift. This invention eliminates transmission backlash through eccentric three-point positioning with a wheel and controls the tilting angle with a high-precision encoder, reducing positioning deviations to ±0.4mm and ±0.8mm, respectively. The spring-loaded contact plate design significantly reduces the damage rate to 0.5%. Automated processes and anti-interference protection shorten the work cycle to 68 seconds, and the failure frequency is significantly reduced. The data confirms the synergistic effect of mechanical structure optimization and intelligent control, completely solving the core pain points of traditional systems: low precision, high damage, and poor efficiency.

[0094] Reference Figure 3 This figure clearly demonstrates the practical value of the invention's strong dust resistance design. Tipplers operate in high-dust environments, and traditional systems suffer from frequent malfunctions due to gear and rack jamming, cable kinks, and false triggering of sensors. The frequency of these malfunctions increases exponentially with increasing dust concentration (50mg / m³). 3 Continuous operation was no longer possible. This invention, through designs such as a dust cover sealing the gear rack, a polyurethane dust scraper for real-time dust removal, and a double-guide rod insulated cable, can achieve continuous operation even at 90mg / m³. 3 Even under extreme conditions, the failure frequency is only 0.38 times per shift, 50mg / m³ 3 All values ​​are close to the warning threshold. This demonstrates the system's adaptability to harsh working conditions, solves the industry pain points of traditional equipment such as "poor environmental adaptability and frequent maintenance", and ensures operational continuity.

[0095] Reference Figure 4 This diagram illustrates the flexibility and versatility of the multi-vehicle adaptation module of this invention. Traditional systems require replacing the push plate and adjusting the mechanical structure to adapt to different couplers, resulting in high adaptation costs and low efficiency. This invention incorporates a multi-model coupler parameter database and combines laser ranging to correct the positioning distance in real time. When adapting to mainstream couplers from No. 13 to No. 25, the positioning accuracy is ≤ ±0.42mm, the contact area of ​​the contact plate remains stable at over 94%, and the operation cycle fluctuates by only 4 seconds. For example, after adaptation to No. 16 coupler, the accuracy is ±0.35mm, close to the performance of the standard No. 13 coupler, without the need to replace any parts. This solves the problems of "limited adaptability and cumbersome model changeover" in traditional systems, meets the multi-vehicle operation needs of freight stations, and reduces maintenance costs.

[0096] Reference Figure 5This diagram visually illustrates the working principle of the dynamic calibration mechanism. Traditional systems lack a calibration step after positioning, often resulting in initial deviations exceeding thresholds, leading to failures in subsequent hook finding and tightening. This invention embeds a closed-loop detection, calculation, and adjustment process during positioning: If the initial movement deviation is 0.7mm, the first detection calculates a deviation of 0.6mm > 0.5mm, triggering a fine-tuning calibration with the eccentric wheel to 0.4mm; a second detection confirms a deviation of 0.35mm, further fine-tuning to 0.3mm, ultimately achieving an accuracy far exceeding the threshold. This process requires no manual intervention, automatically eliminating positioning deviations caused by rack wear and installation errors, providing a precise benchmark for subsequent coupler alignment, and solving the problems of one-time positioning and uncontrollable accuracy in traditional systems.

[0097] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A train coupler positive coupler system, characterized in that, include: The positioning drive module consists of a drive motor, a gear and rack transmission mechanism, and an eccentric guide wheel three-point positioning assembly. The flip positioning module consists of a flip motor, an angle detection unit, and an electromagnetic brake device; the flip motor is a two-phase stepper motor driven by a harmonic reducer; the angle detection unit is equipped with a 16-bit incremental encoder. The coupler straightening execution module consists of a push plate drive unit, a flexible contact plate assembly, and a guide rail. The push plate drive unit uses a servo motor, which drives the push plate to move through a ball screw pair. The flexible contact plate assembly includes a nylon contact plate, a cylindrical helical spring, and a limit shaft structure. The sensing and detection module consists of a coupler contact rod device, a push plate sensing device, and a signal processing unit. The coupler contact rod device is installed at the front end of the lower housing. The contact rod is made of 45# steel with heat treatment and a travel limit switch is installed at the top. The push plate sensing device integrates a travel switch and a pressure sensor. The signal processing unit uses a signal isolator. The cable protection module ensures stable cable transmission by employing a combination of a double cable guide rod device and a spring wire design. The double cable guide rods are made of extruded aluminum alloy with a double-groove structure for arranging power cables and network cables. The spring wires are sheathed with polyurethane and wrapped with an outer tinned copper mesh shielding layer. The collaborative control module, as the central hub of the system, adopts a Siemens S7-1200 series PLC controller, expands analog and digital modules, and connects each module through the PROFINET bus.

2. The train coupler positive coupler system according to claim 1, characterized in that, It also includes a dynamic positioning accuracy calibration module, which is connected to the encoder and eccentric wheel assembly of the positioning drive module respectively, to collect the actual movement distance of the lower box and the preset theoretical movement distance in real time, and calculate the positioning deviation; the calculation method is P=DL; Where P is the positioning deviation; D is the actual moving distance of the lower housing; L is the theoretical moving distance of the lower housing; when P > 0.5mm, the controller outputs a pulse signal to drive the eccentric wheel fine-tuning motor to rotate in 0.5° steps, pushing the guide wheel to further tighten the rack.

3. A train coupler positive coupler system according to claim 1, characterized in that, It also includes a multi-model coupler adaptation module, which communicates with the collaborative control module and the coupler straightening execution module. It has a built-in mainstream coupler parameter database that stores key parameters such as coupler head size, contact reference position, and maximum permissible collision force. It is equipped with a laser rangefinder sensor, which is installed at the front end of the lower housing. Before the coupler seeks, it measures the actual position of the coupler. After the measurement data is transmitted to the collaborative control module, it automatically corrects the theoretical moving distance of the lower housing and the push plate tightening stroke.

4. A train coupler positive coupler system according to claim 1, characterized in that, It also includes a push plate spring parameter adaptation module, which connects to the coupler straightening execution module and the multi-model coupler adaptation module. Based on the maximum allowable collision force of the currently adapted coupler and the set spring compression stroke, it calculates the required spring stiffness. The calculation method is K = F / S, where K is the spring stiffness, F is the maximum allowable collision force of the coupler, and S is the set spring compression stroke. Based on the calculation results, the spring replacement prompt function guides maintenance personnel to select a spring with the corresponding stiffness.

5. A train coupler positive coupler system according to claim 1, characterized in that, It also includes a coupler dynamic offset compensation module, which works in conjunction with the collaborative control module, the sensing and detection module, and the positioning and driving module; the encoder collects the position data of the lower housing, the pressure sensor of the push plate sensing device provides feedback on the change of contact force of the contact plate, and the collaborative control module integrates the two types of data to determine the direction and magnitude of the coupler offset.

6. A train coupler positive coupler system according to claim 1, characterized in that, It also includes a dust protection module that works in conjunction with the positioning drive module, cable protection module, and running track to adapt to the high dust operation environment of the tipper; a stainless steel dust cover is added to the outside of the gear and rack mechanism of the positioning drive module, and the inside of the dust cover is sealed with rubber to fit tightly against the surface of the rack; polyurethane dust scrapers are installed at both ends of the running track to remove dust and debris from the track surface in real time as the lower box moves; a polytetrafluoroethylene dust cap is added to the top of the double guide rods of the cable protection module, and a drainage hole is set at the bottom of the guide rod.

7. A train coupler positive coupler system according to claim 1, characterized in that, It also includes an intelligent fault early warning module, which connects to the collaborative control module and the status monitoring module to collect real-time statistics on equipment operation data and calculate the frequency of fault downtime. The calculation method is Q = N / T, where Q is the frequency of fault downtime, N is the number of fault downtimes in this shift, and T is the total operation time in this shift. When Q exceeds the threshold, a three-color indicator light (red, yellow, and green) will issue a graded warning, a buzzer will emit an intermittent alarm sound, and the touch screen will simultaneously display the fault point, the cause of the fault, and the troubleshooting steps to guide maintenance personnel in handling the situation.

8. A train coupler positive coupler system according to claim 1, characterized in that, It also includes a full-parameter status monitoring and recording module, which establishes data connections with each functional module to collect 12 key operating parameters in real time, including: motor operating current, motor temperature, lower housing positioning deviation, upper housing flip angle, push plate spring compression, and contact plate contact force; the parameter data is stored on an industrial-grade SD card, and supports multi-dimensional querying of historical data by time, module type, and parameter name.

9. A train coupler positive coupler system according to claim 1, characterized in that, It also includes a manual emergency operation module, which works independently in parallel with the collaborative control module. It is equipped with a wall-mounted manual operation panel, which integrates an emergency stop button, a manual and automatic switching switch, a lower housing forward and reverse button, an upper housing flip and reset button, and a push plate extension button. When the automatic control system malfunctions or is under maintenance, it switches to manual mode and controls the actions of each mechanism individually through the buttons. During operation, the travel limit switch still maintains its protective function and automatically stops when the mechanism reaches its limit position.

10. A train coupler positive coupler system according to claim 1, characterized in that, It also includes a remote operation and maintenance and diagnostic module, which is connected to the collaborative control module and the full-parameter status monitoring module via Ethernet. Equipped with a 4G / 5G dual-mode communication module, it encrypts and uploads real-time equipment operating parameters, fault warning information, and historical report data to the remote operation and maintenance platform. Operation and maintenance personnel can log in to the platform via PC or mobile terminal to view equipment operating status curves, download historical data, and issue parameter adjustment commands. When the equipment triggers a red emergency warning, it automatically pushes a fault snapshot to the operation and maintenance terminal, and supports remotely starting fault simulation through the platform to reproduce fault scenarios and formulate repair plans.

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