On-line detection system for brake lining and brake disc of motor train unit brake system

Abstract

The utility model discloses an on-line detection system for a brake pad and a brake disc of a motor train unit braking system. The on-line detection system comprises a control box, and a brake pad image acquisition device, a wheel position sensor, an incoming line wheel sensor and an off-line wheel sensor which are respectively connected with the control box, the brake pad image acquisition device is linearly arranged in the direction perpendicular to the track; the brake pad image collecting device comprises a plurality of collecting boxes, the collecting boxes, the brake pads and the brake disc form a 3D triangular relation, and images of the brake pads and the brake disc are comprehensively collected in real time. According to the utility model, the problem of full-coverage detection universality of brake pads and brake discs of brake systems on different motor train units with different positions, different numbers, different types and different specifications can be solved; and meanwhile, the problems that the acquired images are missing, unclear, incomplete and the like, which are not beneficial to complete coverage, complete contour and high-definition image detection of the brake disc and the brake pad of the brake system are solved.

Description

Technical Field

[0001] The utility model belongs to the field of safety early warning detection of defects such as wear, damage, excessive brake clearance, and brake system failure of brake pads and brake discs of a brake system of an EMU, and relates to a 3D laser scanning image detection system, and specifically to an online detection system for brake pads and brake discs of a brake system of an EMU. Background Art

[0002] With the increase in the speed of EMUs, the braking system, as an important component of EMUs, is a reliable guarantee for the high-speed operation of EMUs and plays an important role in the safety of train driving. The combination of regenerative braking and air braking is the main braking method of the braking system of today's high-speed EMUs. Among them, air braking is to achieve the deceleration and parking of the EMU by generating a resistance torque on the wheelset through the friction between the brake disc and the brake pad. The long-term use of air braking during the operation of the EMU will cause the brake pad and brake disc to overheat and increase the wear. The brake disc may produce thermal cracks due to the influence of heat, and excessive wear will inevitably affect driving safety. Therefore, it is necessary to conduct comprehensive monitoring and wear detection of the brake pads and brake discs of the EMU braking system.

[0003] At present, the existing brake pad and brake disc detection systems have the following defects: the current layout of the detection device in a small area cannot effectively meet the full coverage detection requirements of brake pads and brake discs of different positions, quantities, types and specifications on different EMU models such as CRH1, CRH2, CRH3 and CRH5. It is not very universal and economical, and it cannot achieve full coverage, complete contour and high-definition image detection of brake discs and brake pads of the brake system collected for different EMU models.

[0004] In summary, there is an urgent need for an online detection system for brake pads and brake discs of a motor vehicle brake system to overcome the above-mentioned defects. Summary of the invention

[0005] The purpose of the utility model is to provide an online detection system for brake pads and brake discs of a brake system of an EMU, so as to solve the problem of universal full coverage detection of brake pads and brake discs of different positions, quantities, types and specifications on different EMU models, and at the same time solve the problems that the collected images are missing, unclear, incomplete, etc., which are not conducive to full coverage, complete contour and high-definition image detection of brake discs and brake pads of the brake system.

[0006] The technical solution of the utility model is:

[0007] An online detection system for brake pads and brake discs of a motor vehicle brake system comprises a control box and a brake pad image acquisition device, a wheel position sensor, an incoming wheel sensor, and an offline wheel sensor respectively connected to the control box; the brake pad image acquisition device is arranged in a straight line in a direction perpendicular to the track; the brake pad image acquisition device comprises a plurality of acquisition boxes, and the acquisition boxes and the brake pads and brake discs form a 3D stereoscopic triangle relationship, so as to comprehensively acquire images of the brake pads and brake discs in real time.

[0008] Furthermore, the multiple collection boxes are arranged on a crossbeam, and the crossbeam is fixed on the concrete roadbed perpendicular to the track, and the position of the collection box in the length direction of the crossbeam is adjustable.

[0009] Furthermore, the gate image acquisition device includes six acquisition boxes, which are arranged symmetrically based on the center of the track: four acquisition boxes are located on both sides of the rail and each acquisition box is 30 to 80 mm away from the rail, and the two middle acquisition boxes are centered and spaced 90 to 160 mm apart; the distance between the top surface of the acquisition box and the top surface of the track is 100-350 mm.

[0010] Furthermore, the top of the collection box is hollowed out and sealed with an optical lens to form a sealed box body. Multiple cameras and multiple groups of lasers are arranged in the collection box. The multiple groups of lasers emit lasers to form multiple linear laser planes on the gate pad and the brake disc, which is convenient for the camera to collect the multiple linear laser planes.

[0011] Furthermore, there are 6 to 12 groups of lasers in the collection box, and at least 2 cameras, one camera is located at the center of the hollow top of the collection box, and the other camera is located on the left side of the hollow top of the collection box; there are at least 3 groups of lasers on the left and right sides of the hollow top of the collection box and they are arranged at intervals of 40 to 50 mm.

[0012] Furthermore, the collection box has a length of 380-420 mm, a width of 180-220 mm, and a height of 180-250 mm. When arranged, the length direction of the collection box is along the track direction.

[0013] Furthermore, the gate image acquisition device also includes a window protection mechanism, which includes a warehouse door, an electric push rod, and a sliding guide rail. The fixed end of the electric push rod is fixed on the concrete road bed, and the telescopic end of the electric push rod is connected to the warehouse door. The warehouse door is opposite to the detection window of the collection box, and the sliding guide rail assists in guiding the movement of the warehouse door.

[0014] Furthermore, the gate image acquisition device also includes a cover structure, which is fixed above the acquisition box, and the hollow part of the cover structure corresponds to the detection window of the acquisition box.

[0015] Furthermore, the wheel position sensors are arranged in the track symmetrically based on the longitudinal center line of the brake pad image acquisition device, and the arrangement interval between the two wheel position sensors is 100 to 400 mm.

[0016] Compared with the prior art, the advantages of the utility model are as follows:

[0017] (1) The online detection system for brake pads and brake discs of the EMU brake system of the utility model can effectively meet the detection requirements of full coverage, complete contour and clear image of brake pads and brake discs of different positions, quantities, types and specifications on different EMU models such as CRH1, CRH2, CRH3 and CRH5 through a linearly arranged brake pad image acquisition device, and has strong versatility.

[0018] Moreover, the collection box is adjustable in the length direction on the brake pad installation beam, which can effectively adjust the relative position (not the vertical distance) between the collection box, the brake disc and the brake pad. The collection box further effectively meets the detection requirements for clear images of brake pads and brake discs of the brake systems of different EMU models.

[0019] (2) The brake pad and brake disc online detection system of the EMU brake system of the utility model has a linearly arranged brake pad image acquisition device, which occupies less space on the track than existing acquisition devices of the same type.

[0020] (3) The online detection system for brake pads and brake discs of the EMU brake system of the utility model optimizes the 3D triangular position relationship formed by the acquisition box, the brake pads and brake discs of the EMU brake system; the wheel position sensor can accurately locate the positions of the brake pads and brake discs on the wheelset, and realizes the acquisition of the 3D image of the laser contour line on the axial section of the brake disc and brake pad and the 2D image of the current position of the brake disc and brake pad by simulating the 3D triangular relationship verified by the on-site dynamic detection test.

[0021] (4) The utility model of the brake pad and brake disc online detection system of the EMU brake system increases the number of cameras and lasers, that is, multiple groups of lasers are added in a single acquisition box to form multiple line laser planes. The camera can therefore collect more light-section images, thereby improving data redundancy and effectiveness. In addition, the acquisition box has a reasonable structural design, a compact structure, and a small three-dimensional space.

[0022] (5) The brake pad and brake disc online detection system of the EMU brake system of the utility model adds a window protection mechanism to realize the opening and closing of the detection window of the collection box, thereby protecting the lens of the collection box when it is not working and extending its service life. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1This is a plan view of the brake pad and brake disc online detection system of the EMU brake system of the utility model;

[0024] Figure 2 It is an exploded diagram of the brake pad image acquisition device in the online detection system of brake pads and brake discs of the brake system of the EMU of the utility model;

[0025] Figure 3 It is a structural diagram of the collection box;

[0026] Figure 4 It is a schematic diagram of the laser plane generated by the acquisition box between the brake pad and the brake disc;

[0027] Figure 5 It is a schematic diagram of a brake pad image acquisition device (multiple acquisition boxes) in the laser plane between the brake pad and the brake disc;

[0028] Among them, 1-brake pad image acquisition device, 2-wheel position sensor, 3-in-line wheel sensor, 4-offline wheel sensor, 5-control box, 6-prestressed concrete sleeper, 7-track, 8-brake disc, 9-brake pad, 10-wheel set;

[0029] 101-gate piece mounting crossbeam, 102-ball head bolt, 103-crossbeam adjustment base, 104-crossbeam adjustment lock block, 105-collection box left bracket, 106-collection box right bracket, 107-collection box flat bracket, 108-outer support leg, 109-middle support leg, 110-middle cover bracket, 111-outer cover bracket, 112-outer warehouse door bracket, 113-middle warehouse door bracket, 114-push rod connecting rod, 115-outer warehouse door, 116-middle warehouse door, 117-outer cover, 118-middle cover, 119-sensor, 120-bottom connecting plate, 121-collection box, 122-electric push rod, 123-sensor bracket, 124-slider guide rail.

[0030] 1211--Box body, 1212-Box side panel, 1213-Window blowing assembly, 1214-Optical visualization window, 1215-Camera, 1216-Laser, 1217-Sealing gasket, 1218-Electrical connector;

[0031] G-line laser plane. DETAILED DESCRIPTION

[0032] The utility model is further described below in conjunction with the accompanying drawings and embodiments.

[0033] Reference Figure 1 and Figure 2As shown, the online detection system for brake pads and brake discs of the EMU brake system of this embodiment includes a brake pad image acquisition device 1, a wheel position sensor 2, an incoming wheel sensor 3, an offline wheel sensor 4, and a control box 5. The control box 5 is communicatively connected with the incoming wheel sensor 3, the offline wheel sensor 4, the wheel position sensor 2 and the brake pad image acquisition device 1 respectively.

[0034] The wheel position sensors 2 are arranged in the track 7 symmetrically based on the longitudinal center line of the brake pad image acquisition device 1 , and the arrangement spacing between the two wheel position sensors 2 is 100-400 mm, preferably 300 mm.

[0035] Among them, the layout position of the incoming wheel sensor 3 needs to be determined with reference to the maximum passing speed of the train and the opening time of the window protection mechanism. Generally, it is necessary to increase it by several meters or longer to prepare for emergencies.

[0036] Among them, the gate image acquisition device 1 is arranged in a straight line on both sides of the inner and outer sides in the direction perpendicular to the track 7; and the acquisition box 121 in the gate image acquisition device 1 is arranged symmetrically based on the center of the track 7; the distance between the top surface of the acquisition box 121 and the top surface of the track 7 is 100-350mm, preferably 200mm.

[0037] The acquisition box 121 in the brake pad image acquisition device 1 forms a 3D stereoscopic triangular relationship with the brake disc 8 and brake pad 9 of the brake system located above it. The wheel position sensor 4 can accurately locate the shooting position of the brake disc 8 and brake pad 9 of the brake system, and the 3D stereoscopic triangular relationship verified by the simulated on-site dynamic detection test realizes the acquisition of the brake disc 8 and brake pad 9 of the brake system with full coverage, complete contour and high-definition images.

[0038] Reference Figure 2 As shown, the gate image acquisition device 1 includes a gate installation beam 101, a ball stud 102, a beam adjustment base 103, a beam adjustment lock block 104, a left bracket 105 of the acquisition box, a right bracket 106 of the acquisition box, a flat bracket 107 of the acquisition box, an outer leg 108, a middle leg 109, an intermediate cover bracket 110, an outer cover bracket 111, an outer door bracket 112, an intermediate door bracket 113, a push rod connecting rod 114, an outer door 115, an intermediate door 116, an outer cover 117, an intermediate cover 118, a sensor 119, a bottom connecting plate 120, a collection box 121, an electric push rod 122, a sensor bracket 123, and a slider guide rail 124.

[0039] The sensor 119 can be equivalent to replacing the wheel position sensor 2, installed on the inner side of the track 7, and is used to determine the specific position of the wheel when the train is in motion, and send a trigger signal to enable the brake pad image acquisition device 1 to work.

[0040] The collection box 121 and the electric push rod 122 are fixed on the concrete integral roadbed made of insulating material through the segmented brake pad installation beam 101, ball stud 102, beam adjustment base 103, beam adjustment lock block 104, collection box left bracket 105, collection box right bracket 106, collection box flat bracket 107, outer support leg 108, middle support leg 109, and bottom connecting plate 120 to avoid contact with the track 7, which can effectively avoid the influence of track signals on electrical components.

[0041] Specifically, the collection box 121 is fixed on the gate piece installation beam 101 through the collection box left bracket 105, the collection box right bracket 106, and the collection box flat bracket 107.

[0042] Moreover, an array of symmetrical mounting holes is preset on the brake pad mounting beam 101, so that the position of the collection box 121 in the length direction of the brake pad mounting beam 101 can be effectively adjusted, thereby effectively adjusting the relative position of the collection box 121 and the brake disc 8 and brake pad 9 (the vertical distance remains unchanged, but the length distance changes). Furthermore, the collection box 121 can more effectively meet the detection requirements of full coverage, complete contour and clear image for collecting brake pads and brake discs of different positions, quantities, types and specifications on different EMU models such as CRH1, CRH2, CRH3 and CRH5.

[0043] The brake pad mounting beam 101 is fixed on the concrete integral roadbed through a ball stud 102 , a beam adjustment base 103 , a beam adjustment locking block 104 and a bottom connecting plate 120 .

[0044] The fixed end of the electric push rod 122 is mounted on the brake shoe mounting crossbeam 101 through the outer supporting legs 108 and the middle supporting legs 109 and is integrally fixed on the concrete integral roadbed.

[0045] The window protection mechanism includes an outer door 115, an intermediate door 116, an electric push rod 122, a push rod connecting rod 114, and a sliding guide rail 124. The telescopic end of the electric push rod 122 is connected to the outer door 115 or the intermediate door 116. The sliding guide rail 124 for the intermediate door 116 is located in a smaller space above the middle of the visualization windows of the two sets of collection boxes 121 to ensure that the camera field of view is not blocked. The sliding guide rails 124 for the outer door 115 are located on both sides above the middle of the visualization window of the collection box 121, and also need to ensure that the camera field of view is not blocked.

[0046] In the online detection system for brake pads and brake discs of the EMU brake system of the present embodiment, before the train passes through the detection area, the outer door 115 and the middle door 116 are located on the detection window of the collection box 121, and the outer door 115 and the middle door 116 are connected to the electric push rod 122 through the push rod connecting rod 114 or directly, and the push rod connecting rod 114, the outer door 115 and the middle door 116 realize the opening and closing of the detection window of the collection box 121 with the forward and reverse movements of the electric push rod 122; assisted by the outer cover 117 and the middle cover 118 fixed on the middle cover bracket 110 and the outer cover bracket 111, so as to protect the lens of the brake disc 8 and the brake pad 9 of the brake system when the image collection box 121 is not working, thereby extending the service life.

[0047] Reference Figure 3 As shown, the collection box 121 includes a box body 1211, a box side panel 1212, a window blowing assembly 1213, an optical lens 1214, a camera 1215, a laser 1216, a sealing gasket 1217 and an electrical connector 1218.

[0048] The box body 1211, the box side panel 1212, the optical lens 1214, the sealing gasket 1217 and the electrical connector 1218 are connected or bonded by fasteners and sealants to form a dustproof and moisture-proof sealed box. Among them, the optical lens 1214 is located above the sealed box. The box side panel 1212 is connected to both sides of the box body 1211 through the sealing gasket 1217. The camera 1215 and the laser 1216 are placed in the sealed box according to the preset position. The dustproof and moisture-proof function of the sealed box can effectively improve the service life of the camera 1215 and the laser 1216.

[0049] Multiple groups of lasers 1216 are arranged in the sealed box to form multiple line laser planes, so that the camera 1215 can collect more light-section images, and the data redundancy and effectiveness are improved. There are 6 to 12 groups of lasers 1216 in the sealed box, and at least 2 cameras 1215 are arranged. One camera 1215 is located in the center of the hollow top of the collection box, and the other camera 1215 is located on the left side of the hollow top of the collection box; there are at least 3 groups of lasers 1216 on the left and right sides of the hollow top of the collection box, and they are arranged at intervals of 40 to 50 mm.

[0050] When the laser 1216 is working, it emits a line laser to illuminate the plane G. When the axial section of the moving brake disc 8 and brake pad 9 coincides with the laser irradiation plane G, the laser contour line on the axial section of the brake disc 8 and brake pad 9 will appear on the brake disc 8 and brake pad 9. At this time, the camera 1215 collects the 3D image of the laser contour line on the axial section of the brake disc 8 and brake pad 9 and the 2D image of the current position of the brake disc 8 and brake pad 9 for analysis and calculation of the wear value and defect condition of the brake disc 8 and brake pad 9 (such as Figure 4 shown).

[0051] The working process of the online detection system for brake pads and brake discs of the EMU brake system of this embodiment is as follows:

[0052] When a railway vehicle passes through the detection line, the railway vehicle wheelset 10 first triggers the incoming wheel sensor 3. After receiving the railway vehicle incoming signal, the control box 5 sends a ready acquisition signal to the gate image acquisition device 1 to prepare for data acquisition. That is, the electric push rod 122 in the gate image acquisition device 1, assisted by the sliding guide rail 124 with a guiding function, drives the outer compartment door 115 and the middle compartment door 116 to move linearly to realize the opening of the window protection mechanism.

[0053] Secondly, the train wheels 10 trigger the wheel position sensors 2 in turn. After receiving the signal that the wheels 10 are in position, the control box 5 gives the brake image acquisition device 1 a start acquisition signal to start collecting data. After collecting valid data, the control box 5 gives the brake image acquisition device 1 a stop acquisition signal to stop collecting data. Subsequently, the train wheels 10 trigger the wheel position sensors 2 in turn, and the above process is repeated, and finally all the valid data that needs to be collected are collected.

[0054] Finally, after the train wheelset 10 triggers the offline wheel sensor 4 and the control box 5 receives the train offline signal, the system returns to the state of waiting for the train to enter the line.

[0055] The above description is only a preferred embodiment of the present invention and does not constitute a limitation on the protection scope of the present invention. Any modification, equivalent replacement and improvement made within the spirit and principle of the present invention shall be included in the protection scope of the claims of the present invention.

Claims

1. An online detection system for brake pads and brake discs of a motor vehicle brake system, characterized in that: The system includes a control box and a brake pad image acquisition device, a wheel position sensor, an incoming wheel sensor, and an offline wheel sensor respectively connected to the control box; The gate pad image acquisition device is arranged linearly in a direction perpendicular to the track; the gate pad image acquisition device includes a plurality of acquisition boxes, and the acquisition boxes and the gate pad and the brake disc form a 3D stereoscopic triangle relationship to fully and real-timely acquire images of the gate pad and the brake disc.

2. The online detection system for brake pads and brake discs of a motor vehicle brake system according to claim 1, characterized in that: The multiple collection boxes are arranged on a crossbeam, which is fixed on the concrete roadbed perpendicular to the track, and the positions of the collection boxes in the length direction of the crossbeam are adjustable.

3. An online detection system for brake pads and brake discs of a motor vehicle brake system as claimed in claim 1 or 2, characterized in that: The gate image acquisition device includes six acquisition boxes, which are arranged symmetrically based on the center of the track: four acquisition boxes are located on both sides of the rail and each acquisition box is 30 to 80 mm away from the rail, and the two middle acquisition boxes are in the middle and the interval is 90 to 160 mm; The distance between the top surface of the collection box and the top surface of the track is 100-350mm.

4. An online detection system for brake pads and brake discs of a motor vehicle brake system as claimed in claim 1 or 2, characterized in that: The top of the collection box is hollowed out and sealed with optical lenses to form a sealed box body. Multiple cameras and multiple groups of lasers are arranged in the collection box. The multiple groups of lasers emit lasers to form multiple linear laser planes on the gate pad and the brake disc, which is convenient for the camera to collect the multiple linear laser planes.

5. The online detection system for brake pads and brake discs of a motor vehicle brake system as claimed in claim 4, characterized in that: There are 6 to 12 groups of lasers in the collection box, and at least 2 cameras. One camera is located in the center of the hollow top of the collection box, and the other camera is located on the left side of the hollow top of the collection box; there are at least 3 groups of lasers on the left and right sides of the hollow top of the collection box and they are arranged at intervals of 40 to 50 mm.

6. The online detection system for brake pads and brake discs of a motor vehicle brake system as claimed in claim 4, characterized in that: The collection box has a length of 380-420 mm, a width of 180-220 mm, and a height of 180-250 mm. When arranged, the length direction of the collection box is along the track direction.

7. An online detection system for brake pads and brake discs of a motor vehicle brake system as claimed in claim 1 or 2, characterized in that: The gate image acquisition device also includes a window protection mechanism, which includes a warehouse door, an electric push rod, and a sliding guide rail. The fixed end of the electric push rod is fixed on the concrete road bed, and the telescopic end of the electric push rod is connected to the warehouse door. The warehouse door faces the detection window of the acquisition box, and the sliding guide rail assists in guiding the movement of the warehouse door.

8. An online detection system for brake pads and brake discs of a motor vehicle brake system as claimed in claim 1 or 2, characterized in that: The gate blade image acquisition device also includes a cover structure, which is fixed above the acquisition box, and the hollow part of the cover structure corresponds to the detection window of the acquisition box.

9. An online detection system for brake pads and brake discs of a motor vehicle brake system as claimed in claim 1 or 2, characterized in that: The wheel position sensors are arranged in the track symmetrically based on the longitudinal center line of the brake pad image acquisition device, and the arrangement spacing between the two wheel position sensors is 100 to 400 mm.

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