CR200J motor train unit safety loop test device
By designing the CR200J EMU safety loop test device, using wireless communication and relay control, the problem of the failure to detect the single-car safety loop after the EMU is unpacked, and efficient and accurate safety loop detection and maintenance are achieved.
Patent Information
- Application Number
- CN202421437761.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-06-21
- Publication Date
- 2025-03-25
- Estimated Expiration
- 2034-06-21
AI Technical Summary
After the CR200J EMU was unorganized, the safety loop of a single car was not tested and inspected, resulting in the impact of the maintenance and production order.
A CR200J EMU safety loop test device is designed, including a safety loop detection plug end and a handheld detection control end. Through wireless communication and relay control, independent detection and testing of a single-car safety loop is realized.
It realizes independent inspection of single-car safety loops, improves maintenance efficiency, ensures that the safety loops of the car safety loops are in good condition after maintenance, and provides favorable support for system testing after marshalling.
Smart Images
Figure CN222671439U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the field of motor vehicle safety detection operations, in particular to a CR200J motor vehicle group safety loop test device. Background Art
[0002] When the CR200J EMU passenger car is disassembled and repaired in the depot, the EMU safety loop is separated after each car is disassembled, and only the local safety loop (input power supply and resistance) of the dining car can be statically checked. After reassembly, the safety loop is tested and checked intensively. If the safety loop fails, further maintenance is required, or even the EMU is disassembled again. Therefore, the EMU safety loop cannot be tested and repaired during disassembly, which will have a serious impact on the EMU maintenance production order.
[0003] Safety loop, also known as safety circuit, is a crucial concept in automated control systems, especially in the field of safety-critical systems. It is a circuit or software logic structure designed to monitor and ensure the safety state of the system. The safety loop usually includes sensors, logic controllers (such as programmable logic controllers PLC), actuators, and necessary hardware and software components, which work together to detect potential dangerous situations and take corresponding preventive measures, such as initiating emergency shutdown mechanisms, to protect personnel, equipment and the environment from injury or damage.
[0004] The CR200J EMU safety loop includes the door safety loop, brake safety loop, axle temperature alarm safety loop and fire alarm safety loop. When the vehicle safety loop is in alarm state, the corresponding safety loop outputs a low-level signal, the loop signal relay installed on the power car loses power, triggers the corresponding protection action, and the display screen shows the alarm state of a certain loop.
[0005] The disassembly and marshaling of EMUs are two basic operations involving train structure adjustment in railway transportation. Disassembly refers to splitting the EMU vehicles that were originally connected together into two or more independent parts. Marshalling is to reconnect multiple EMU vehicles according to a predetermined configuration to form a complete train. Therefore, when the vehicle is in the disassembly state, due to the disconnection of the safety loop of each carriage, the safety loop cannot form a systematic closed loop, and the working power supply and response circuit cannot be provided for the safety loop of each carriage, and the safety loop test inspection of a single carriage cannot be completed.
[0006] The CR200J EMU consists of 1 power car + 7 trailer cars + 1 control car (9 cars in total). The power car and the control car are located at both ends of the EMU, and both are equipped with driver's cabs.
[0007] When the EMU is put into storage for D3\D4 maintenance, it is necessary to disassemble the EMU (split into 9 carriages) and inspect each carriage one by one. After disassembly, the safety loop is disconnected and related tests cannot be carried out.
[0008] According to relevant technical standards, the depot needs to inspect the safety loop of the EMU carriages during maintenance of D3 / D4.
[0009] During the marshaling test, if there is no relevant test equipment, two people are required to use intercoms to cooperate with each other to test the safety loop. One person sets the safety loop alarm faults of doors, axle alarms, fireworks, brakes, and parking brakes in each car, and the other person checks the safety loop action status in the driver's cab. The test efficiency is low and errors caused by poor communication are prone to occur. In addition, the safety loop branches and trunks of each car cannot be checked. If problems can only be found during joint debugging and testing, it will inevitably affect the acceptance of the entire vehicle. At the same time, inadequate maintenance will inevitably affect the safety loop status of the EMU. Utility Model Content
[0010] In order to solve the deficiencies and defects of the above-mentioned prior art, the inventors have developed and designed a CR200J EMU safety loop test device, which solves the problem that the safety loop of a single carriage cannot be tested and inspected after the CR200J EMU is de-marshalled and separated, and also solves the problem that such through loops cannot be tested due to maintenance conditions when they are separated for maintenance; thereby, maintenance personnel can directly test the safety loop of a single carriage, ensuring that the safety loop of each carriage is in good condition after maintenance, and providing favorable support for the normal passing of the system test after marshalling.
[0011] Specifically, the utility model is implemented as follows: a CR200J EMU safety loop test device includes: a safety loop detection plug end and a handheld detection control end; wherein the safety loop detection plug end includes: a plug housing, an internal portion for installing a plug end communication module, an intermediate relay terminal block, and a plug end power module, a plug end display panel is embeddedly installed on the front of the plug housing, and a communication socket plug is installed on the back of the plug housing; a communication socket plug is a pin-type plug that matches the vehicle-end communication socket of the vehicle to be tested, and is used to connect to the vehicle-end communication socket of the vehicle to be tested and access various safety loops on the vehicle end; a plug end communication module is used to receive a control signal from a handheld detection control end, and can control multiple relay circuits based on the control signal. When the normally open contacts of the relay are closed, each safety loop can be short-circuited with the negative line to test the safety loop action status of the circuit, and the safety loop action status signal of each circuit can be sent back to the handheld detection control terminal; the intermediate relay wiring board is connected to the plug-end communication module through the socket wire, and can monitor the status of each safety loop through a detection circuit composed of several optocouplers and resistors; the plug-end display board is connected to each safety loop by two rows of light groups, which are used to indicate whether different safety loop states are energized, and has a step-down current-limiting resistor and a diode, and is connected to the communication socket plug and the intermediate relay wiring board through the socket pins; the plug-end power supply module is a built-in lithium battery, which can provide power for the safety loop detection plug end, and can provide power for the overall device safety loop test;
[0012] The handheld detection control terminal includes: a handheld terminal shell, which is equipped with a handheld terminal communication module and a handheld terminal power supply module; a handheld terminal display panel and a button control panel are installed in an embedded manner and exposed on the front of the handheld terminal shell; the handheld terminal display panel is composed of two rows of lights, each row corresponds to a different safety loop state; when a signal indicating a change in the state of any safety loop is received, the corresponding light group state will change for display; a button control panel is connected to the handheld terminal communication module, and there are several button switches, including a spare switch and a control switch corresponding to each safety loop of the safety loop detection plug end; the handheld terminal communication module can receive safety loop action status signals of each circuit from the safety loop detection plug end; it can send control signals that the button control panel actively sends to the safety loop plug, and the handheld terminal power supply module has a built-in battery pack, which can power the handheld terminal display panel, the button control panel, and the handheld terminal communication module.
[0013] Furthermore, the various safety loops include: a Sierra door control system safety loop, an axle temperature alarm system safety loop, a fire alarm system safety loop, a brake system safety loop, and a parking brake system safety loop.
[0014] Furthermore, the plug-end communication module includes a receiving control module circuit A and a sending control module circuit A; wherein: the receiving control module circuit A includes a normally open relay interfaced with each safety loop, in which one end of the normally open relay is connected to the corresponding safety loop, and the other end of the relay is connected to a common feedback negative line; when the relay receives a trigger signal and closes, the safety loop can be short-circuited with the negative line; the sending control module circuit A is connected to each safety loop through a number of photoelectric couplers, and can send the safety loop action status signal of each circuit back to the handheld detection control end.
[0015] Furthermore, the intermediate relay wiring board also includes: three double-contact relays, five D631 optocouplers, five 47K1 / 4W resistors and connecting plug wires; the intermediate relay board is connected to the receiving control module circuit and the sending control module circuit integrated board through the strip wire. When the 12V relay is used for non-restaurant car (ordinary car) testing, the device power supply system A is used to send power to the five-way safety loop through the step-down resistor and the anti-reverse diode, and the LED light is turned on through the normally open contact of the relay. The power supply of the restaurant bar car is provided by the control cabinet to the safety loop. When the safety loop has a DC110V power supply, the optocoupler of the branch is lit through the 47KΩ resistor. When the power supply of the safety loop is DC12V input (non-restaurant car, the test switch is turned on), due to the large impedance of 47KΩ, the DC12V power supply is passed through the light-emitting diode of the LED light display board A and the normally open contact of the relay to light the optocoupler of the safety loop.
[0016] Furthermore, the step-down and current-limiting resistors and diodes in the plug-end display panel include: two rows of LED light groups, each row is used to indicate the safety loop status of different vehicle models, and the LED light groups are connected to the communication socket plug and the intermediate relay board through the row of pins; the series resistors can step down the voltage and limit the current, which is used to protect the LED lamps from damage by excessive voltage, extend the service life, and also ensure the stable operation of the circuit.
[0017] Furthermore, the plug-end power module includes: a DC12V lithium battery pack, a fuse, a power switch, a voltmeter and a charging interface; the DC12V lithium battery pack is connected to one end of a 3A glass tube fuse through its positive pole, the other end of the 3A glass tube fuse is connected to the power switch K1, and the negative pole is directly connected to the common negative line of the circuit; the fuse is installed on the fuse holder, which can protect the current in the circuit from exceeding 3A, and the fuse will melt and interrupt the current; the power switch includes a main power switch and a test switch; one side of the main power switch is connected to a parallel circuit of a fuse and a power indicator LED current limiting resistor, and the other side is connected to the input end of the test switch; when the test switch is activated, power can be transferred to the intermediate relay board and the LED light group; the voltmeter is connected in parallel to the input end of the test switch, on the same path that powers the safety loop; the charging interface: at the bottom of the plug housing. The negative pole of the battery pack is directly connected to the ground wire (GND) of the circuit. The fuse is installed on the fuse holder to play an overload protection role. Once the current in the circuit exceeds 3A, the fuse will blow, interrupting the current and protecting the subsequent circuit components from damage. The system is equipped with two main rocker switches, one is the main power switch and the other is the test switch. One side of the main power switch is connected to the parallel circuit of the fuse and the power indicator LED current limiting resistor, and the other side is connected to the input of the test switch. This design allows the main power to be turned on first, and then decide whether to activate the test mode as needed. When the test switch is activated, it receives power from the main power switch and passes it to two places: one is the intermediate relay board, and the other is the LED light display board A. In this way, when testing non-dining bar vehicles, since the safety loop of the dining bar vehicle does not have a DC110V power supply, the safety loop can obtain the required DC12V power supply, and the LED light can be used to indicate the status of the non-dining bar vehicle safety loop system. In order to monitor the battery status in real time, the voltmeter is connected in parallel to the output of the test switch, that is, on the same path that powers the safety loop. The voltmeter displays the battery voltage. When the reading is low, it reminds the user to charge the lithium battery pack through the external charging port in time. At the bottom of the device housing, there is a charging port designed specifically for lithium battery packs, which is convenient for connecting an adapter for charging when the battery is low on power.
[0018] Furthermore, the light group of the handheld display panel is two groups of LED light groups, and its multiple positive power supplies are connected in parallel to the handheld power module, and are connected to the 47K chip current limiting resistor and the red LED light through the normally closed contacts of the handheld communication module; after a certain circuit of the handheld communication module is actuated, the power supply's normally open contacts are connected to the 39K current limiting resistor and the green LED light; the cathodes of the two rows of red and green LED light groups are connected to the negative end of the handheld communication module; the handheld display panel is connected to the handheld communication module through a plug line.
[0019] Furthermore, a button control panel is connected to the handheld communication module through a plug line or a flat cable; the control switch presses any button switch to control the corresponding remote control switch relay in the safety loop detection plug end to turn on, so that the corresponding safety loop is activated and connected to the negative line.
[0020] Furthermore, the button control panel has a total of 6 button switches with silicone number stickers on the surface. 1-5 correspond to the door control, axle alarm, fire, braking, and parking brake safety loops of the safety loop plug respectively.
[0021] Furthermore, the handheld communication module includes a receiving control module circuit B and a sending control module circuit B; the receiving control module circuit B is used to receive the safety loop action status signal of the safety loop detection plug end, and display the status of each safety loop through the handheld display panel; the sending control module circuit B is used to send a safety loop action control signal to the safety loop detection plug end to control a certain line.
[0022] Working principle of the utility model: The technical solution of the utility model is a safety loop detection device for CR200J EMU, which mainly solves the problem of detecting the safety loop of a single carriage after the EMU is disassembled, and the problem that effective and efficient testing cannot be performed due to limited conditions during maintenance. As for the components of the utility model, it is mainly realized by the safety loop detection plug end and the handheld detection control end establishing a remote control wireless communication transmission connection and cooperating with each other. Safety loop detection plug end: includes a communication socket plug, a communication module, an intermediate relay wiring board, a display board and a power module; wherein, the communication socket plug is connected to the vehicle end and connected to each safety loop of the vehicle end, and the communication module is responsible for receiving the control signal and controlling the relay closure to control the short-circuit action of the safety loop; the intermediate relay wiring board monitors the loop status and performs electrical isolation through an optical coupler, and can feed back the loop status change information to the handheld detection control end, so as to intuitively display the status of each loop through the display board of the handheld detection control end; the power module can provide low-voltage power supply for non-bar carriages or non-control carriages without a power system when detecting, so that the safety loop can use electricity smoothly; the handheld detection control end includes a display board, a button control board, a communication module and a power module. The display board reflects the status of the safety loop, the button control board is used to select and trigger the short-circuit detection control of a specific safety loop, the communication module is responsible for sending and receiving signals, and the power module supplies power to the handheld end. Operate the button control panel on the handheld end to send a specific control signal to the communication module on the detection plug end. The communication module controls the relay to close, so that the specific safety loop is short-circuited with the negative line to simulate a fault state. After the handheld communication module receives the change action status signal of the safety loop, the status indicator of the display panel becomes normal, so that it can be intuitively displayed whether the tested safety loop responds normally, that is, whether it is successfully short-circuited and triggers the expected safety mechanism. The handheld detection control end communicates wirelessly with the safety loop detection plug end, so that maintenance personnel can receive the safety loop status of the safety loop detection plug end when performing door, fire, axle alarm, braking, and parking brake safety loops on the vehicle control cabinet or test vehicle. At the same time, maintenance personnel can control the action of the safety loop on the socket end, which is convenient for maintenance personnel to compare and check the status of the safety loop action of the vehicle control monitoring screen.
[0023] Beneficial technical effects of the utility model:
[0024] 1. Independent detection capability of a single carriage: The system of the utility model provides a working power supply and a response circuit, which can meet the safety loop test of the dining car (with a safety loop power supply) and the ordinary car (without a safety loop power supply) after the carriages are separated. At the same time, by adopting wireless communication, maintenance personnel can test the safety loops of the doors, axle alarms, fireworks, brakes, and parking brakes one by one, and receive the response of the safety loop, thus breaking through the traditional limitation of having to detect the entire train, and allowing detailed safety inspections of single carriages.
[0025] 2. Efficient remote communication and control: The wireless or wired communication mechanism between the handheld terminal and the detection plug makes the operation flexible and efficient. According to the maintenance personnel and on-site test requirements, the wireless transceiver module can be used for communication, control and view the action status of a certain safety loop. The detection efficiency is high and only one person is required to complete it, realizing efficient and accurate detection of the EMU safety loop.
[0026] 3. Adjustable power supply strategy: It can meet the safety loop test of restaurant bar cars (with safety loop power supply) and ordinary cars (without safety loop power supply). The electrical isolation achieved by components such as optocouplers enhances the stability and safety of the system in high voltage or current fluctuation environments, ensuring the versatility and accuracy of detection. BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Figure 1 This is a schematic diagram of the structural composition principle of the CR200J EMU safety loop test device of the utility model;
[0028] Figure 2 This is a schematic diagram of the circuit connection structure of the safety loop detection plug end of the utility model;
[0029] Figure 3 It is a schematic diagram of the circuit connection structure of the handheld detection control terminal of the utility model;
[0030] Figure 4 A three-dimensional diagram of the safety loop detection plug end of the utility model;
[0031] Figure 5 This is a schematic diagram of the safety loop detection plug end of the utility model being connected to the vehicle end communication socket;
[0032] Figure 6 It is a three-dimensional diagram of the handheld detection control terminal of the utility model;
[0033] in:
[0034] 1—safety loop detection plug end, 10—plug housing, 11—communication socket plug, 12—plug end communication module, 121—receiving control module circuit A, 122—transmitting control module circuit A, 123—interactive panel A, 13—intermediate relay wiring board, 14—plug end display panel, 15—plug end power module;
[0035] 2—handheld detection control terminal, 20—handheld terminal housing, 21—handheld terminal display panel, 22—button control panel, 221—button switch, 23—handheld terminal communication module, 231—receiving control module circuit B, 232—transmitting control module circuit B, 233—interactive panel B, 24—handheld terminal power module;
[0036] 3—Vehicle-end communication socket. DETAILED DESCRIPTION
[0037] In order to make the purpose, technical solution and advantages of the utility model clearer, the utility model is further described in detail below in combination with specific implementation methods and with reference to the accompanying drawings. It should be understood that these descriptions are only exemplary and are not intended to limit the scope of the utility model. In addition, in the following description, the description of well-known structures and technologies is omitted to avoid unnecessary confusion of the concept of the utility model.
[0038] Example 1: CR200J EMU safety loop test device
[0039] 1. Introduction to functional principles
[0040] (1) The safety loop detection plug terminal 1 is connected to the 60-pin communication socket at the vehicle end to achieve docking between the plug and the socket. A detection circuit is made to transmit the signal status of the door, fire, brake, axle alarm, and parking brake safety loops to the handheld detection control terminal 2 through the remote control switch communication module.
[0041] (2) Since the safety loop power supply of the ordinary car needs to be provided by the control cabinet of the dining car, it is not convenient to provide power after the EMU is disassembled. Therefore, in this embodiment, the ordinary car test uses the plug-end power module 15 to directly provide DC12V power for the safety loop (the dining car directly uses the DC110V power supply of the car), and only the voltage-dropping resistor in the circuit needs to be improved and changed.
[0042] (3) Use a remote control switch to manually short-circuit the safety loop, so that the person can check the safety loop status information during maintenance and testing.
[0043] 2. Production of safety loop detection plug terminal 1
[0044] The "safety loop detection plug end 1" is composed of a communication socket plug 11, a remote control switch communication module A, an intermediate relay wiring board 13, an LED light display board A, and a power supply system A.
[0045] (1) Communication socket plug 11
[0046] The communication socket plug 11 uses the original 60-pin communication connector plug of the CR200J EMU, and the tail of the metal shell is modified. The shell is printed with PLA material and connected to the modified metal shell, and fixed with screws. The metal shell has a positioning hole. When it is plugged into the communication socket, the positioning hole is connected to the positioning pin, so that the safety loop detection plug end 1 and the vehicle-end communication socket 3 are connected stably and firmly.
[0047] (2) Plug-end communication module 12
[0048] The plug-end communication module 12 is composed of a receiving control module circuit A121, a sending control module circuit A122, and an interactive panel A123; the receiving control module circuit A121 and the sending control module circuit A122 are integrated on a whole board.
[0049] The receiving control module circuit A121 is used to receive the signal from the handheld detection control terminal 2, and control the closure of the five relay circuits respectively. After the normally open contacts of the relays are closed, the door, axle alarm, fire, brake, and parking brake safety loops are short-circuited with the negative line respectively, so as to artificially test the action status of a certain safety loop.
[0050] The sending control module circuit A122 is used to receive signals from the door, axle alarm, fire, brake, and parking brake safety loops, and send the signals to the handheld detection control terminal 2 respectively, and the status information of the five safety loops is displayed on the handheld detection control terminal 2.
[0051] Interactive panel A123: used for channel calibration between the remote control switch communication module A inside the safety loop detection plug terminal 1 and the remote control switch communication module B inside the handheld detection control terminal 2.
[0052] (3) Intermediate relay terminal board 13
[0053] The intermediate relay terminal board 13 is composed of three double-contact relays, five D631 optocouplers, five 47K1 / 4W resistors and connecting plug wires. When the 12V relay is used for non-dining bar vehicles (ordinary vehicles) testing, the device power supply system A is used to supply power to the five-way safety loop through the step-down resistor and the anti-reverse diode, and the LED lights are turned on through the normally open contacts of the relay. The dining bar vehicle power supply provides a DC110V power supply to the safety loop from the control cabinet. When the safety loop has a DC110V power supply, the optocoupler of this branch is lit through a 47KΩ resistor. When the power supply of the safety loop is a DC12V input (non-dining bar vehicle, the test switch is turned on), due to the large impedance of 47KΩ, the DC12V power supply passes through the light-emitting diode of the LED light display board A and the normally open contacts of the relay to light the optocoupler of the safety loop.
[0054] The intermediate relay wiring board 13 is connected to the receiving control module circuit and the sending control module circuit A122 integrated board through a socket wire.
[0055] (4) Plug-end display panel 14, i.e., LED light display panel A
[0056] LED light display board A consists of two rows of LED lights that display the power supply of the gate control, axle alarm, fire, brake, and parking brake safety loops. At the same time, a 1.2KΩ+10KΩ step-down current limiting resistor is added to the DC12V powered safety loop power supply circuit, and a diode is used to prevent the DC110V power supply from supplying power to the 12V loop during the restaurant car test. LED light display board A is connected to the communication socket pin and the intermediate relay board through a row of pins.
[0057] (5) Plug-end power module 15
[0058] The plug-end power supply module 15 not only provides the necessary power for the "plug-end communication module 12", but is also used to provide DC12V power for the safety loop during the test of ordinary vehicles (non-restaurant vehicles).
[0059] The plug-end power module 15 includes a DC12V lithium battery pack, a fuse, a power switch, and a voltmeter.
[0060] The DC12V lithium battery pack uses a 18650 battery pack with a battery capacity of 3000mah and is equipped with a battery adapter for charging when the battery is low. The bottom of the communication socket head PLA shell has a charging port for the lithium battery pack and a digital voltmeter opening.
[0061] The fuse uses a 3A glass tube fuse and a fuse holder, and the two ends of the fuse are connected to the positive end of the battery and the power switch K1 respectively.
[0062] The power switch is divided into the main power switch of the power system A and the test switch. The ship-type switch is used to control the positive power line; the input end of the main power switch is connected in parallel with the fuse holder and the current-limiting resistor of the power indicator LED light. The input end of the test switch is connected to the output end of the main power switch and the power terminal of the plug-end communication module 12. The output end of the test switch is connected to the intermediate relay terminal board 13 and the LED light display board A. When testing ordinary vehicles, the test switch needs to be turned on to provide power for the safety loop.
[0063] The voltmeter is connected in parallel to the output end of the power switch to visually display the battery status and to charge immediately when the voltage is low.
[0064] 3. Production of handheld detection control terminal 2
[0065] Principle function
[0066] (1) The wireless remote control switch receives and displays the status of the door, axle alarm, fire, brake, and parking brake safety loops (powered or not) through LED lights.
[0067] (2) Send a control command to the "safety loop detection plug terminal 1" through the wireless remote control switch to short-circuit the vehicle-side safety loop, so as to facilitate the purpose of checking the safety loop status information.
[0068] Circuit Configuration
[0069] The handheld detection control terminal 2 is composed of an LED light display panel B, a button control panel 22, a remote control switch communication module B, a power supply system B, and a housing.
[0070] (1) Handheld display panel 21, i.e. LED light display panel B
[0071] LED light display panel B consists of two rows of LED lights that display the status of the door control, axle alarm, fire, brake, and parking brake safety loops. The green light indicates that the safety loop is normal (powered), and the red light indicates that the safety loop is in action (power-off state).
[0072] When the power switch of "Handheld Detection Control Terminal 2" is turned on, the red lights of the door control, axle alarm, fire, brake, and parking brake safety loop status are all on. When the safety loop detection plug terminal 1 detects a change in the status of a certain safety loop and sends a signal to "Handheld Detection Control Terminal 2", the red light turns green.
[0073] The five positive power supplies of the LED light display board are connected in parallel to the positive terminal of the power supply system B, and are connected to the 47K chip current limiting resistor and the red LED light through the normally closed contact of the remote control switch B. After one of the remote control switch B is activated, the normally open contact of the power supply is connected to the 39K current limiting resistor and the green LED light.
[0074] The cathodes of the red and green LED lamps are connected to the negative terminal of the power supply system B. The LED lamp display panel is connected to the remote control switch B through a plug wire.
[0075] (2) Button control panel 22
[0076] The button control panel 22 consists of 6 button switches 221, one of which is a standby switch with a silicone number sticker on the surface. Numbers 1-5 correspond to the door control, shaft alarm, fire, brake, and parking brake safety loops of the safety loop plug. Pressing any button for 3 seconds will control the corresponding remote control switch relay in the safety loop plug to turn on, so that the safety loop is activated (connected to the negative line).
[0077] The button control panel 22 is connected to the handheld terminal communication module 23 via a plug line.
[0078] (3) Handheld communication module 23
[0079] The handheld communication module 23 is composed of a receiving control module circuit B231, a sending control module circuit B232, and an interactive panel B233; the receiving control module circuit B231 and the sending control module circuit B232 are integrated on a whole board.
[0080] The receiving control module circuit B231 is used to receive the signal from the "safety loop plug" and display the status of the door, axle alarm, fire, brake, and parking brake safety loops respectively.
[0081] The sending control module circuit B232 is used by maintenance personnel to send a signal to the "safety loop plug" to control the safety loop action of a certain circuit.
[0082] Interactive panel B233: used for channel calibration between remote control switch communication module B inside the "handheld detection control terminal 2" and remote control switch communication module A inside the "safety loop detection plug terminal 1".
[0083] (4) Handheld terminal power module 24
[0084] The handheld terminal power supply module 24 provides DC12V power to the “handheld terminal communication module 23 ” and the handheld terminal display panel 21 .
[0085] The handheld power module 24 includes a DC12V lithium battery pack, a fuse, a power switch, and a voltmeter.
[0086] The DC12V lithium battery pack uses a 18650 battery pack with a battery capacity of 3000mah and is equipped with a battery adapter for charging when the battery is low. The bottom of the communication socket head PLA shell has a charging port for the lithium battery pack and a digital voltmeter opening.
[0087] The fuse uses a 3A glass tube fuse and a fuse holder, and the two ends of the fuse are connected to the positive end of the battery and the power switch K respectively.
[0088] The power switch K uses a rocker switch to control the positive power line;
[0089] The voltmeter is connected in parallel to the output end of the power switch to visually display the battery status and to charge immediately when the voltage is low.
[0090] (5) PLA shell
[0091] The "handheld detection control terminal 2" is printed and made of PLA material. The power system B is installed at the bottom of the shell, and the remote control communication module B is installed above the power system B. The interactive panel B233 of the remote control communication module B and the LED display panel B and the button control panel 22 are installed at the top. The PLA shell is opened and fixed according to the position and size of the interactive panel B233, the LED display panel B, and the button control panel 22.
[0092] 4. Practical operation
[0093] 1. Safety loop test of restaurant bar car
[0094] (1) Vehicle-side safety loop status indication
[0095] Plug the safety loop detection plug terminal 1 into the 60-pin communication socket terminal of the CR200J EMU and turn on the power switch K1, turn on the power switch of the handheld detection control terminal 2, at this time, the red light of the handheld detection control terminal 2 is all on, when the safety loop power key of the control cabinet on the dining bar car is turned on, the safety loop is energized, and the corresponding safety loop of the handheld detection control terminal 2 lights up green normally.
[0096] (2) Check the security loop status information
[0097] Use the buttons on the handheld detection control terminal 2 to control the door control, shaft alarm, fire, braking, and parking brake safety loop actions of the safety loop detection plug terminal 1 respectively, check the safety loop action status of the corresponding channel of the handheld detection control terminal 2, and check the safety loop action status information on the information display screen.
[0098] 2. Ordinary vehicle safety loop test
[0099] (1) Vehicle-side safety loop status indication
[0100] Plug the safety loop detection plug terminal 1 into the 60-pin communication socket terminal of the CR200J EMU and turn on the power switch K1, turn on the power switch of the handheld detection control terminal 2, at this time, the red lights of the handheld detection control terminal 2 are all on, turn on the safety loop detection plug terminal 1K2, and the corresponding safety loop normal light of the handheld detection control terminal 2 will turn on green.
[0101] (2) Check the security loop status information
[0102] Use the buttons on the handheld detection control terminal 2 to control the door control, shaft alarm, fire, braking, and parking brake safety loop actions of the safety loop detection plug terminal 1 respectively, check the safety loop action status of the corresponding channel of the handheld detection control terminal 2, and check the safety loop action status information on the information display screen.
[0103] Differentiated power supply solution: Different power supply strategies are used for the safety circuits of the dining car and ordinary carriages. The dining car uses the vehicle's existing DC110V power supply to power the safety circuit, while the ordinary carriage lacks a dedicated safety circuit power supply. The project team cleverly uses the built-in DC12V power supply of the device and designs an intermediate relay control board to achieve the circuit interlocking function. This innovative design not only provides the necessary power support for the safety circuit of the ordinary carriage, but also enhances the safety of the system through the circuit interlocking mechanism.
[0104] Application of eight-way mutual transmission and reception remote control switch: The core of this solution is the introduction of advanced eight-way two-way communication remote control technology. Each channel can send and receive signals independently, which significantly reduces the confusion and risk of misoperation caused by previous multi-point operations. It allows a single operator to independently and efficiently complete all necessary control operations, greatly improving work efficiency.
[0105] Module integration innovation: In order to further improve the convenience and compatibility of operation, the project team integrated the plug and detection module circuit required for safety circuit detection into a unified component. By modifying the original metal shell, the detection module was successfully combined with it to form an integrated detection plug. This integrated design not only simplifies the on-site operation process and reduces the burden on operators, but also realizes universal adaptation to both restaurant and bar vehicles and ordinary vehicles, improving the flexibility and practicality of the system.
[0106] Specific operation process:
[0107] 1. Connect the testing equipment: First, insert the dedicated communication socket plug 11 into the vehicle-end communication socket 3 of the vehicle to be tested to ensure a firm physical connection so as to access the various safety loops of the vehicle.
[0108] 2. Start communication and power supply: Turn on the power switches of the safety loop detection plug terminal 1 and the handheld detection control terminal 2, and establish a stable two-way communication connection through the eight-way two-way feedback switch. At this time, the initial status indicators of the handheld terminal and the plug terminal should light up, indicating that the communication link has been successfully established.
[0109] 3. Power supply safety loop: Activate the battery pack of the power module 15 at the plug end to provide necessary power for the connected vehicle end safety loop. At this time, the indicator light on the display panel at the plug end will also light up to confirm that the power supply is normal.
[0110] 4. Perform the test operation: Use the button control panel 22 of the handheld test control terminal 2 to select and press the test button of the corresponding safety loop as needed. After pressing the button, the control signal is sent through the communication module of the plug end, indicating that a short circuit test is performed on the specific safety loop.
[0111] 5. Control relay closure: After receiving the control signal, the communication module at the safety loop detection plug terminal 1 controls the corresponding relay circuit to close the normally open contact of the corresponding relay, thereby short-circuiting the selected safety loop with the negative line, simulating a circuit fault and performing functional verification.
[0112] 6. Monitoring and feedback loop status: The intermediate relay terminal board 13 continuously monitors the status changes of the safety loop and performs electrical isolation through optical coupling to protect the handheld device. These status change information is then transmitted back to the handheld detection control terminal 2 in real time through the communication module.
[0113] 7. Display the test results: After the handheld communication module 23 receives the signal of the safety loop state change, the initial state indicator light of the handheld display panel 21 goes out. If the detected safety loop responds correctly (i.e., the short circuit is successful and the safety mechanism is triggered), the normal state indicator light will light up. On the contrary, if there is no change, the normal state indicator light remains off, indicating that the loop may be faulty or not responding correctly.
[0114] This detection process establishes an efficient information exchange channel between the handheld detection control terminal 2 and the safety loop detection plug terminal 1 through wireless remote control, which not only improves the detection efficiency, but also greatly facilitates maintenance personnel to quickly and accurately diagnose and maintain the CR200J EMU safety loop, especially when the vehicle is disassembled or restricted by on-site conditions, ensuring the convenience and accuracy of the detection.
[0115] It should be understood that the above specific embodiments of the present invention are only used to illustrate or explain the principles of the present invention, and do not constitute a limitation on the present invention. Therefore, any modifications, equivalent substitutions, improvements, etc. made without departing from the spirit and scope of the present invention should be included in the protection scope of the present invention. In addition, the claims attached to the present invention are intended to cover all changes and modifications that fall within the scope and boundaries of the attached claims, or the equivalent forms of such scope and boundaries.
Claims
1. CR200J EMU safety loop test device, characterized by include: A safety loop detection plug end (1) and a handheld detection control end (2); wherein, The safety loop detection plug end (1) comprises: A plug housing (10) is used to install a plug-end communication module (12), an intermediate relay wiring board (13), and a plug-end power module (15) inside, a plug-end display panel (14) is embedded in the front of the plug housing (10), and a communication socket plug (11) is installed on the back of the plug housing (10); The communication socket plug (11) is a pin-type plug that matches the vehicle-side communication socket (3) of the vehicle to be tested, and is used to connect to the vehicle-side communication socket (3) of the vehicle to be tested and access various safety loops at the vehicle end; The plug-end communication module (12) is used to receive control signals from the handheld detection control terminal (2), and can control the closing of the normally open contacts of the relays of the multiple relay circuits based on the control signals, can short-circuit each safety loop with the negative line, thereby testing the safety loop action state of the circuit, and can send the safety loop action state signal of each circuit back to the handheld detection control terminal (2); The intermediate relay wiring board (13) is connected to the plug-end communication module (12) through a plug-in lead and can monitor the status of each safety loop through a detection circuit composed of a plurality of optical couplers and resistors; The plug-end display panel (14) is connected to each safety loop by two rows of light groups, and is used to indicate whether different safety loop states are powered. It has a voltage-reducing current-limiting resistor and a diode, and is connected to the communication socket plug (11) and the intermediate relay wiring board (13) through a row of pins; The plug-end power supply module (15) is a built-in lithium battery, which can provide power for the safety loop detection plug end (1) and can also provide power for the safety loop test of the entire device; The handheld detection control terminal (2) comprises: The handheld terminal housing (20) has a handheld terminal communication module (23) and a handheld terminal power module (24) built in; the handheld terminal display panel (21) and the button control panel (22) are embedded and exposed on the front side of the handheld terminal housing (20); The handheld display panel (21) comprises two rows of lights, each row corresponding to a different safety loop state; when a signal indicating a change in the state of any safety loop is received, the state of the corresponding light group will change for display; A button control panel (22) is connected to the handheld communication module (23), and a plurality of button switches (221) are provided, including a standby switch and a control switch for each safety loop of the corresponding control safety loop detection plug end (1); The handheld communication module (23) can receive safety loop action status signals of various circuits from the safety loop detection plug end (1); can send control signals actively sent by the button control panel (22) to the safety loop plug, The handheld terminal power supply module (24) and the built-in battery pack can supply power to the handheld terminal display panel (21), the button control panel (22), and the handheld terminal communication module (23).
2. The safety loop test device for CR200J EMU according to claim 1 is characterized in that: The various safety loops include: a plug sliding door control system safety loop, an axle temperature alarm system safety loop, a fire alarm system safety loop, a brake system safety loop, and a parking brake system safety loop.
3. The safety loop test device for CR200J EMU according to claim 1 is characterized in that: The plug-end communication module (12) comprises a receiving control module circuit A (121) and a sending control module circuit A (122); in: A receiving control module circuit A (121) includes a normally open relay connected to each safety loop interface, wherein one end of the normally open relay is connected to the corresponding safety loop, and the other end of the relay is connected to a common feedback negative line; when the relay receives a trigger signal and closes, the safety loop can be short-circuited with the negative line; The sending control module circuit A (122) is connected to each safety loop through a plurality of photoelectric couplers, and can send the safety loop action state signal of each circuit back to the handheld detection control terminal (2).
4. The safety loop test device for CR200J EMU according to claim 1 is characterized in that: The intermediate relay wiring board (13) also includes: three double-contact relays, five D631 optical couplers, five 47K1 / 4W resistors and connecting plug wires; the intermediate relay board is connected to the receiving control module circuit and the sending control module circuit integrated board through the plug-in wires.
5. The safety loop test device for CR200J EMU according to claim 2 is characterized in that: The voltage-reducing and current-limiting resistors and diodes in the plug-end display panel (14) include: two rows of LED light groups, each row is used to indicate the safety loop status of different vehicle models, and the LED light groups are connected to the communication socket plug (11) and the intermediate relay board through the row of pins; the series resistor can reduce voltage and limit current, which is used to protect the LED lamp from damage by excessive voltage, prolong the service life, and also ensure the stable operation of the circuit.
6. The safety loop test device for CR200J EMU according to claim 5 is characterized in that: The plug-end power module (15) comprises: a DC12V lithium battery pack, a fuse, a power switch, a voltmeter and a charging interface; The DC12V lithium battery pack is connected to one end of a 3A glass tube fuse through its positive pole, the other end of the 3A glass tube fuse is connected to the power switch K1, and the negative pole is directly connected to the common negative line of the circuit; The fuse is installed on the fuse holder, which can protect the circuit current from exceeding 3A. The fuse will blow and interrupt the current. The power switch includes a main power switch and a test switch; one side of the main power switch is connected to a parallel circuit of a fuse and a power indicator LED current limiting resistor, and the other side is connected to the input end of the test switch; when the test switch is activated, power can be transmitted to the intermediate relay board and the LED light group; The voltmeter is connected in parallel to the input of the test switch, on the same path that supplies power to the safety loop; Charging port: at the bottom of the plug housing (10).
7. The safety loop test device for CR200J EMU according to claim 2 is characterized in that: The light groups of the handheld display panel (21) are two groups of LED light groups, and multiple positive power sources thereof are connected in parallel to the handheld power module (24), and are connected to the 47K chip current limiting resistor and the red LED light via the normally closed contact of the handheld communication module (23); after a certain path of the handheld communication module (23) is actuated, the normally open contact of the power source is connected to the 39K current limiting resistor and the green LED light; the cathodes of the two rows of red and green LED light groups are connected to the negative end of the handheld communication module (23); and the handheld display panel (21) and the handheld communication module (23) are connected via a plug line.
8. The safety loop test device for CR200J EMU according to claim 2 is characterized in that: A button control panel (22) is connected to a handheld communication module (23) via a plug line or a flat line; the control switch presses any button switch (221) to control the corresponding remote control switch relay in the safety loop detection plug end (1) to be turned on, so that the corresponding safety loop is activated and connected to the negative line.
9. The safety loop test device for CR200J EMU according to claim 8, characterized in that: The button control panel (22) has a total of 6 button switches (221), the surface of which is provided with silicone number stickers, 1-5 corresponding to the door control, shaft alarm, fire, brake, and parking brake safety loops of the control safety loop plug respectively.
10. The safety loop test device for CR200J EMU according to claim 2, characterized in that: The handheld communication module (23) comprises a receiving control module circuit B (231) and a sending control module circuit B (232); The receiving control module circuit B (231) is used to receive the safety loop action state signal from the safety loop detection plug end (1), and display the state of each safety loop through the handheld end display panel (21); The sending control module circuit B (232) is used to send a safety loop action control signal for controlling a certain path to the safety loop detection plug terminal (1).