LED signal and method of use

Abstract

This invention relates to the field of rail transit signaling equipment technology, specifically disclosing an LED signal controller and its usage method. The LED signal controller of this invention includes a base and at least two light boxes. All the light boxes are stacked and connected sequentially from top to bottom, with the center of all the light boxes aligned on a central line. The connection between each pair of adjacent light boxes is a square sleeve structure. A rubber ring is interference-fitted between the upper and lower light box connection parts. Spring washers are disposed on the top of the base. By using a square sleeve structure with interference-fitted rubber rings between adjacent light boxes, the center of all the light boxes is aligned on a central line, completely solving the problem of easy turning with circular sleeves, while simultaneously achieving waterproofing, dustproofing, and vibration resistance. The spring washers between the base and the light boxes effectively absorb vibration, preventing bolt loosening, and the self-locking latch ensures a tight lock on the door cover, further improving overall sealing and vibration resistance.

Description

Technical Field

[0001] This invention relates to the field of rail transit signaling equipment technology, specifically to an LED signal controller and its usage method. Background Technology

[0002] Railway signal lights are core terminal equipment for rail transit safety. Their signal lights directly control the train's operating status, requiring the equipment to operate 24 hours a day with high stability. With the rapid development of rail transit, traditional incandescent bulb signal lights have been gradually replaced by LED signal lights, which have advantages such as energy saving, long lifespan, and stable light intensity.

[0003] However, in the high-frequency vibration environment of railways, the nuts of existing LED signal lights are prone to loosening and falling off, the light box is prone to turning and causing the light to deviate, and the rubber sealing gasket is prone to aging, causing water and dust ingress problems. Summary of the Invention

[0004] This invention provides an LED signal controller and its usage method, aiming to solve the technical problems of poor structural stability, easy water and dust ingress, and easy light deviation in traditional LED signal controllers.

[0005] The present invention provides an LED signal controller and its method of use, comprising: Base; At least two light boxes are provided, and all the light boxes are stacked and connected from top to bottom. The center of all the light boxes is on a central line. The connection between each pair of adjacent light boxes is a square sleeve structure. The connection between the upper light box is a square sleeve shape, and the connection between the lower light box is a square core shape. The length and width gap between the upper light box connection and the lower light box connection are both 0.1-0.5mm. A rubber ring is interference-fitted in the gap between the upper light box connecting part and the lower light box connecting part; A spring washer, which is made of elastic rubber, is located on the top of the base and is fixedly connected to the light box at the bottom. The lens assembly is fixedly installed at the light-transmitting end of the lamp chamber of the lamp box.

[0006] Preferably, the bottom of the base has at least two mounting holes.

[0007] Preferably, the square sleeve-shaped connecting part of the upper light box has a length and width of 70mm-80mm.

[0008] Preferably, the light box is equipped with an eaves, which are made of aluminum alloy and have an arc-shaped structure.

[0009] Preferably, the mounting end of the awning has four screw holes, and the awning is fixed to the light box by four screws.

[0010] Preferably, a door cover is hinged to one side of the light box, and the free end of the door cover is equipped with a self-locking latch. Tightening the self-locking latch can press the door cover firmly onto the light box.

[0011] Preferably, the lens assembly includes an LED lens, multiple LED beads, a light-emitting disk housing, a substrate, LED color identification pins, a mounting bracket, LED color markings, a programming socket, a power off test button, universal terminals, heat dissipation holes, and a control circuit. The mounting bracket is fixed to the lens assembly, the light-emitting disk housing is mounted on the mounting bracket, the substrate is disposed inside the light-emitting disk housing, and the multiple LED beads are evenly distributed on the substrate plane. Each LED bead is covered by an LED lens. The light-emitting disk housing is provided with LED color identification pins, LED color markings, a programming socket, a power off test button, universal terminals, and heat dissipation holes. The LED color markings are set for different colored LED areas, the universal terminals are power input terminals, and the heat dissipation holes are opened on the side wall of the light-emitting disk housing.

[0012] Preferably, the control circuit is integrated on a PCB circuit board, and various electronic components and circuits inside the solid-state relay are mounted on the PCB circuit board in a distributed manner, with the substrate electrically connected to the control circuit.

[0013] The specific steps for using an LED signal controller are as follows: S1: Fix the base to the signal pole at the railway site with expansion bolts, and use a level to calibrate it to ensure that the tilt of the base is ≤0.5°; S2: Attach the bottom edge of the lightbox to the top edge of the base and tighten with bolts to a torque of 30N. m, ensuring no connection gaps; S3: Install and press each light box from bottom to top to ensure a precise fit of the square joint parts with no circumferential gaps; S4: Install the lens assembly into the light-transmitting end of the lamp chamber of the light box. According to the on-site pre-aiming requirements, rotate the lens assembly to adjust the distance between the inner and outer lenses and fix it initially. S5: Attach the mounting end of the awning to the light box and tighten the four screws in a crisscross pattern, with a tightening torque of 15N. m, ensuring that the eaves and light box fit together without any looseness; S6: Hinge the hinge end of the door cover to the hinge seat of the light box, and fix the self-locking lock nose to the free side of the door cover, aligning it with the lock of the light box; S7: Fasten the door cover to the outside of the light box, rotate the self-locking lock lug to the locked position, and lock the free side of the door cover; S8: Detect the light intensity of the signal lights using a light intensity tester. Based on the on-site observation conditions, rotate the lens group again to adjust the spacing until the light intensity reaches the required value on site, thus completing the overall assembly.

[0014] The beneficial effects of this invention are: the adjacent light boxes adopt a square sleeve structure and an interference fit rubber ring, and the center of all the light boxes is on the same center line, which completely solves the problem of easy turning of the circular sleeve, and at the same time achieves waterproof, dustproof and vibration-proof; the spring washer between the base and the light box effectively absorbs the vibration force and prevents the bolts from loosening, and the self-locking lock nose makes the door cover tightly locked, further improving the overall sealing and vibration resistance performance. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of a specific embodiment of the present invention.

[0016] Figure 2 This is another structural schematic diagram of a specific embodiment of the present invention.

[0017] Figure 3 This is a schematic diagram of the lens group in this invention.

[0018] Figure 4 This is another schematic diagram of the lens group in this invention.

[0019] Figure label: 1. Lightbox; 2. Canopy; 3. Base; 301. Mounting hole; 4. Door cover; 5. Self-locking latch; 6. Spring washer; 7. Lens assembly; 71. LED lens; 72. LED beads; 73. Light-emitting disk housing; 74. Substrate; 75. LED color identification pin; 76. Mounting bracket; 77. LED color marking; 78. Programming socket; 79. Light-off test button; 710. WATER terminal; 711. Heat dissipation hole. Detailed Implementation

[0020] 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention. The specific implementation methods of the LED signal controller will be described in detail below with reference to the accompanying drawings and technical solutions of the present invention.

[0021] like Figure 1-4As shown, the LED signal controller of this embodiment is preferably made of 6061 aluminum alloy precision die casting, which is suitable for the ground signal display requirements of railway high-speed rail lines. The LED signal controller mainly includes a base 3 and three light boxes 1. The three light boxes 1 are connected from top to bottom. It should be noted that the number of light boxes 1 can also be two, four or more. The number of light boxes 1 can be adjusted according to the usage. This embodiment does not limit the number of light boxes 1. The base 3 is die-cast and has at least two mounting holes 301 at the bottom. The entire signal controller can be installed in the working position by bolt fasteners on the mounting holes 301. A spring washer 6 is fixedly connected to the top of the base 3. The spring washer 6 is made of elastic material (such as elastic rubber). The spring washer 6 is between the base 3 and the light box 1. When the light box 1 is vibrated, it will be transmitted to the base 3 through the spring washer 6. Since the spring washer 6 can absorb and buffer the vibration force, the vibration force on the base 3 is greatly reduced, thereby preventing the bolt fasteners on the mounting holes 301 from loosening and falling off. The upper end face of the base 3 is bolted to the bottommost light box 1. It should be noted that all light boxes 1 adopt a stacked connection structure with upper and lower light positions. The connection part of each light box 1 is square, with the upper part larger than the lower part, and they are connected in a nested manner. Because of the "square, nested" connection method, the center of all light boxes 1 is on a central line, and the signal device will not have any light deviation. Specifically, in the connection structure of each pair of adjacent light boxes 1, the connection structure of the upper light box 1 is a square sleeve shape. For example, the length and width of the connection structure of the upper light box 1 are both set between 70mm and 80mm. The connection structure of the lower light box 1 is a square core shape, with the length and width both smaller than the upper one. The length and width of the connecting structure of the square light box 1 are such that the gap between the two is between 0.1-0.5mm. Each gap is fitted with a rubber ring. In this embodiment, the rubber ring is fixedly set on the square connecting structure of the upper light box 1. In other embodiments, the rubber ring is fixedly set on the square connecting structure of the lower light box 1. When the two are fitted together, they achieve a precise pressing fit, tightly connecting the upper light box 1 and the lower light box 1 together, which plays a role in waterproofing, dustproofing, and vibration damping. At the same time, during the use of the mechanism, even if it is affected by vibration, the connecting screws between the light boxes 1 will not loosen or fall off, and the light boxes 1 will not have problems such as rotation.

[0022] Each light box 1 is detachably mounted with a canopy 2 made of aluminum alloy in an arc shape. The canopy 2 has four screw holes at its mounting end, and is fixed to the light box 1 with four screws in a crisscross pattern to protect the LED lights. The canopy 2 can be disassembled and replaced according to the usage environment. If the canopy 2 is threatened with collapse due to strong winds or heavy impacts, which may cause obstruction of the signal lights, the canopy 2 can be replaced with a wider one to enhance its load-bearing capacity and solve this problem.

[0023] The light box 1 is equipped with a lens group 7. The light-transmitting part is made of tempered glass with a light transmittance of ≥92%. The screw rotation distance is 25mm, and the adjustment range is 0-25mm. It is used in conjunction with the internal fixed-focus plate lamp holder to adjust the light intensity. The lens assembly 7 has a mounting bracket 76, on which a light-emitting disk housing 73 is fixedly connected. A substrate 74 is mounted on the light-emitting disk housing 73 to form a frame. Multiple LED beads 72 are evenly distributed on the plane of the substrate 74, and each LED bead 72 is surrounded by an LED lens 71. The light-emitting disk housing 73 also has a control circuit, an LED color identification pin 75, a program programming socket 78, a lamp-off test button 79, and a universal terminal 710. The control circuit is integrated on the PCB circuit board, and the various electronic components and circuits inside the solid-state relay are installed on the PCB circuit in a distributed manner. On the board, the LED power supply circuit and load circuit are isolated and controlled. When 30% of the LED beads 72 in use are damaged for some reason, the control circuit will output a broken filament alarm signal. When 50% of the damaged LED beads are damaged, the control circuit will control the entire LED light-emitting panel to automatically turn off the lights. At the same time, the filament relay in the control room will drop. The universal terminal 710 is used as the power input terminal. The power cord of the output voltage in the room is plugged into the universal terminal 710 to work. The back of the light-emitting panel shell 73 is also provided with heat dissipation holes 711 and LED color markings 77. The substrate 74 is electrically connected to the control circuit and is encapsulated within the light-emitting disk housing 73. The surface of the light-emitting disk housing 73 is marked with LED color labels 77 corresponding to different colored LED areas, which can clearly indicate the LED color and prevent incorrect installation of different colored lamps on site. A program programming port 78 is provided for later program upgrades of the product. A lamp-off test button 79 is provided to realize alarm tests for 30% and 50% LED off. The heat dissipation holes 711 opened on the side wall of the light-emitting disk housing 73 can radiate the heat generated by the circuit operation to the outside for heat dissipation.

[0024] A door cover 4 is hinged to one side of the light box 1. The free end of the door cover 4 is equipped with a self-locking lock nose 5. Tightening the self-locking lock nose 5 can press the door cover 4 firmly onto the light box 1 to prevent it from loosening due to vibration.

[0025] A method for using an LED signal controller, the specific steps of which are as follows: S1: Fix base 3 to the signal pole at the railway site with expansion bolts, and use a level to calibrate to ensure that the tilt of base 3 is ≤0.5°; S2: Attach the lower end of the bottom light box 1 to the upper end of the base 3, and tighten it with bolts to a torque of 30N. m, ensuring no connection gaps; S3: Install and press each light box 1 from bottom to top to ensure precise fit of the quadrilateral joints with no circumferential gaps; S4: Install the lens group 7 into the light-transmitting end of the lamp chamber of the light box 1. According to the on-site pre-aiming requirements, rotate the lens group 7 to adjust the distance between the inner and outer lenses and fix it initially. S5: Attach the mounting end of the eaves 2 to the light box 1, and tighten the four screws in a crisscross pattern, with a tightening torque of 15N. m, ensuring that the eaves fit snugly against the light box 1 without any looseness; S6: Hinge the hinge end of the door cover 4 to the hinge seat of the light box 1, and fix the self-locking lock nose 5 to the free side of the door cover 4, aligning it with the lock of the light box 1. S7: Snap the door cover 4 onto the outside of the light box 1, rotate the self-locking lock nose 5 to the 90° locking state, and lock the free side of the door cover 4. S8: Detect the light intensity of the signal lights using a light intensity tester. Based on the on-site observation conditions, rotate the lens group again to adjust the spacing until the light intensity reaches the required value on site, thus completing the overall assembly.

[0026] 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," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used 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.

[0027] 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, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0028] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. An LED signal controller, characterized in that, include: Base (3); At least two light boxes (1), all of the light boxes (1) are stacked and connected from top to bottom, the center of all the light boxes (2) is on a center line, the connection part of each two adjacent light boxes (1) is a square sleeve structure, the connection part of the upper light box (1) is a square sleeve shape, the connection part of the lower light box (1) is a square core shape, and the length and width gap between the connection part of the upper light box (1) and the connection part of the lower light box (1) is 0.1-0.5mm; A rubber ring is interference-fitted in the gap between the upper light box (1) connecting part and the lower light box (1) connecting part; Spring pad (6), the spring pad (6) is made of elastic rubber, is set on the top of the base (3), and is fixedly connected to the light box (1) at the bottom; The lens group (7) is fixedly installed at the light-transmitting end of the lamp chamber of the lamp box (1).

2. The LED signal controller according to claim 1, characterized in that, The base (3) has at least two mounting holes (301) on its bottom.

3. The LED signal controller according to claim 1, characterized in that, The square sleeve-shaped connecting part of the light box (1) located above has a length and width of 70mm-80mm.

4. An LED signal controller according to claim 1, characterized in that, The light box (1) is equipped with a canopy (2), which is made of aluminum alloy and has an arc-shaped structure.

5. An LED signal controller according to claim 4, characterized in that, The mounting end of the awning (2) has four screw holes, and the awning (2) is fixed to the light box (1) by four screws.

6. An LED signal controller according to claim 1, characterized in that, A door cover (4) is hinged to one side of the light box (1). The free end of the door cover (4) is equipped with a self-locking latch (5). Tightening the self-locking latch (5) can press the door cover (4) onto the light box (1).

7. An LED signal controller according to claim 1, characterized in that, The lens assembly (7) includes an LED lens (71), multiple LED beads (72), a light-emitting disk housing (73), a substrate (74), LED color identification pins (75), a mounting bracket (76), LED color markings (77), a programmable socket (78), a light-off test button (79), a universal terminal (710), heat dissipation holes (711), and a control circuit. The mounting bracket (76) is fixed on the lens assembly (7), the light-emitting disk housing (73) is mounted on the mounting bracket (76), and the substrate (74) is located inside the light-emitting disk housing (73). LED beads (72) are evenly distributed on the plane of substrate (74), and each LED bead (72) is covered with an LED lens (71). The outer shell (73) of the light-emitting disk is provided with LED color identification pin (75), LED color mark (77), program writing socket (78), lamp off test button (79), universal terminal (710) and heat dissipation hole (711). The LED color mark (77) is set for different color LED areas. The universal terminal (710) is the power input terminal. The heat dissipation hole (711) is opened on the side wall of the outer shell (73).

8. An LED signal controller according to claim 7, characterized in that, The control circuit is integrated on the PCB circuit board, and the various electronic components and circuits inside the solid-state relay are installed on the PCB circuit board in a distributed manner. The substrate (74) is electrically connected to the control circuit.

9. A method of using an LED signal controller as described in any one of claims 1-8, characterized in that, The specific steps are as follows: S1: Fix the base (3) to the signal pole at the railway site with expansion bolts, and use a level to calibrate it to ensure that the tilt of the base (3) is ≤0.5°; S2: Fit the lower end of the bottom light box (1) with the upper end of the base (3) and tighten it with bolts to a torque of 30N. m, ensuring no connection gaps; S3: Install and press each light box (1) from bottom to top to ensure that the square socket parts fit precisely without circumferential gaps; S4: Install the lens group (7) into the light-transmitting end of the lamp chamber of the lamp box (1). According to the on-site pre-aiming requirements, rotate the lens group (7) to adjust the distance between the inner and outer lenses and fix it initially. S5: Fit the mounting end of the awning (2) with the light box (1), and tighten it with four screws in a crisscross pattern, with a tightening torque of 15N. m, to ensure that the eaves and the light box (1) fit together without any looseness; S6: Hinge the hinge end of the door cover (4) to the hinge seat of the light box (1), and fix the self-locking lock nose (5) to the free side of the door cover (4) and align it with the lock of the light box (1); S7: Snap the door cover (4) onto the outside of the light box (1), rotate the self-locking lock nose (5) to the 90° snapping state, and lock the free side of the door cover (4); S8: Detect the light intensity of the signal lights using a light intensity tester. Based on the on-site observation conditions, rotate the lens group again to adjust the spacing until the light intensity reaches the required value on site, thus completing the overall assembly.

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