A hydraulic rail replacer test system and test method

Abstract

The present invention discloses a hydraulic rail replacer test system and a test method, which include a test device, a host computer, a controller, an oil distributor, a hydraulic oil source, a hydraulic sub-station control console, a control system, a hydraulic pipeline, a hydraulic rail replacer to be tested and a foundation. The test method includes steps of carrying out a rated load test, a static load test, a pressure holding test, an emergency test and a safety test. A vertical load applied by a vertical servo actuator is used to simulate the dead weight of a field rescue vehicle, and a lateral load applied by a lateral servo actuator is used to simulate the lateral movement resistance suffered by a locomotive and rolling stock during the rescue process of a train accident. The load magnitude can also be adjusted in a timely manner according to the lateral resistance of different types of hydraulic rail replacers. The present invention solves the disadvantages of single test model and inability to simulate the whole rescue process, improves the test efficiency, detection flexibility and accuracy; a hydraulic sub-station control console is set to enable an operator to remotely operate and control the oil quantity and the start and stop of the oil source, thereby improving the test safety.

Description

Technical Field

[0001] The present invention relates to the technical field of testing and experimental technologies for train operation accident rescue equipment in rail transit, and in particular, to a hydraulic rail replacer test system and a test method. Background Art

[0002] The hydraulic rail replacer is one of the essential equipment for railway train operation accident rescue and plays a very important role in accident rescue; especially for large track maintenance machinery, it is stipulated that each vehicle must be equipped with a hydraulic rail replacer. The hydraulic rail replacer has become the main rescue tool for train operation accident rescue in rail transit, and its reliability and quality stability affect whether the train operation accident rescue work can be carried out smoothly. Quality inspection is crucial for ensuring railway transportation safety. At present, the quality of hydraulic rail replacers varies, and during road rescue, there have been many secondary accidents where rescue equipment malfunctioned and led to rescue failures. Therefore, it is particularly important to inspect the quality of hydraulic rail replacers.

[0003] Currently, there are mainly two ways to inspect existing hydraulic rail replacers: The first way is to conduct on-site simulation exercises using real locomotives or vehicles. This way can effectively simulate the real rescue process of the hydraulic rail replacer, but this way is limited by the test vehicle body and test site conditions, and often can only verify the functionality of the hydraulic rail replacer, and cannot verify the rated design capabilities of the hydraulic rail replacer (such as the maximum jacking load and jacking distance, the maximum transverse movement thrust and maximum transverse movement distance, etc.). The rail replacers verified by this way may have the risk of rescue failure when rescuing large-tonnage locomotives and vehicles during the real rescue process. The second way is to verify the vertical jacking load and lateral movement load of the cylinder by verifying the output load of the hydraulic cylinder of the rail replacer in the laboratory. Currently, the existing laboratory means cannot simulate the complete process of train operation accident rescue by the hydraulic rail replacer, thus there is a risk that the expected function cannot be achieved during the actual rescue process. In order to more efficiently, reliably, and fully verify the quality of the hydraulic rail replacer, it is necessary to develop a general-purpose hydraulic rail replacer test system to ensure the reliability and safety of the operation of its various mechanical components.

[0004] Hydraulic repatriators are mainly divided into two types according to their structural forms. One is the "herringbone" hydraulic repatriator, and the other is the "direct top and lateral movement type" hydraulic repatriator. Both types of hydraulic repatriators are very commonly used in the field of railway rescue. Both repatriators can achieve the function of jacking up and realigning an overturned locomotive (or vehicle). However, when the two repatriators are working, the movement trajectories of the locomotive (or vehicle) being rescued are different: for the "herringbone" repatriator, during the process of jacking up the locomotive (or vehicle) being rescued, it is necessary to operate the left and right cylinders simultaneously to make the locomotive (or vehicle) move along an approximate circular arc trajectory and reset it onto the rail to complete the rescue operation; while for the direct top and lateral movement type repatriator, the principle of realignment is to jack up the overturned locomotive (or vehicle) through a vertical cylinder, then translate it above the rail through a lateral movement cylinder, and then place the locomotive (or vehicle) flat on the rail to achieve the realignment operation. The interfaces and dimensions of the two types of hydraulic repatriators are not unified, and the designed test system should be able to meet the test requirements of both types of hydraulic repatriators simultaneously. Summary of the Invention

[0005] The purpose of the present invention is to provide a test system and test method for hydraulic repatriators to solve the problems raised in the above background technology. Moreover, in order to make the test of hydraulic repatriators more in line with the actual working conditions, the present invention designs a test system for hydraulic repatriators and formulates a test method according to the test standards.

[0006] To achieve the above purpose, the present invention provides the following technical solutions:

[0007] A test system for hydraulic repatriators includes a test device, a host computer, a controller, an oil distributor, a hydraulic oil source, a hydraulic sub-station control console, a control system, hydraulic pipelines, a tested hydraulic repatriator, and a foundation.

[0008] The test device is installed on the foundation; the control system is installed in the host computer; the host computer is electrically connected to the controller through a control line; the controller is connected to the servo actuator in the test device through a control line; the hydraulic oil source is connected to the oil distributor through a hydraulic pipeline; the hydraulic sub-station control console is connected to the oil distributor through a control line; the hydraulic sub-station control console controls the start and stop of the high-pressure end and the low-pressure end of the oil distributor.

[0009] The test device includes a vertical load application mechanism, a lateral load application mechanism, and a reaction frame. The vertical load application mechanism and the lateral load application mechanism are both installed on the reaction frame. The lateral load application mechanism is used to apply a lateral load to the vertical load application mechanism; the reaction frame includes an upper clamping plate, a guide rail plate, a screw, a cross beam, a support beam, and a base; there are two support beams. The upper clamping plate and the guide rail plate are connected to the cross beam through screws and nut fasteners. The upper clamping plate is located above the cross beam; the guide rail plate is located below the cross beam. The two ends of the cross beam are respectively connected to the upper ends of the two support beams through bolts. The bottoms of the two support beams are both connected to the base through bolts, and the base is pre-buried in the foundation.

[0010] The vertical load applying mechanism is mainly composed of a vertical servo actuator, a lateral movement component, a side guide plate, a lateral movement slide, a lateral movement limit plate, a vertical displacement sensor and a vertical load sensor; there are two side guide plates, two lateral movement slides and two lateral movement limit plates, and the lateral movement component includes a lateral roller bearing, a lateral roller bearing fixing plate, a support shaft, a cylindrical roller bearing, a lateral movement seat and a bearing screw; the top of the vertical servo actuator is connected to the lateral movement seat of the lateral movement component by bolts, and both sides of the lateral movement seat are fixed and embedded in the guide plate, the side guide plate, the lateral movement slide, the lateral movement limit plate by cylindrical roller bearings, bearing screws and washers. The inverted frame; the transverse roller bearing fixing plate is fixedly connected to the transverse moving seat by bolts, and five rows of transverse roller bearings are evenly distributed in the transverse direction in the transverse roller bearing fixing plate, and each row is provided with ten transverse roller bearings; the transverse roller bearings are connected to the transverse roller bearing fixing plate through the support shaft, and are symmetrically distributed on both sides of the transverse center line; the upper part of the transverse moving component is connected to the guide plate surface through the transverse roller bearing; the upper parts of the two side guide plates are installed on the bottom of the guide plate by bolts, and are symmetrically distributed, and the bottom of each side guide plate is connected to the transverse moving slideway by bolts, and the transverse sides of the inverted frame composed of the guide plate, the side guide plate, and the transverse moving slideway are respectively connected to the transverse moving limit plate by bolts.

[0011] The lateral load applying mechanism includes a lateral servo actuator, a cylinder support, a support suspension rod, a lateral load sensor, a lateral displacement sensor and a ball joint support; the fixed end of the lateral servo actuator is installed on the cylinder support by bolts, and multiple bolt holes are provided on both sides of the cylinder support, which is installed on a support beam on one side by bolts; the output end of the lateral servo actuator is connected to the ball joint support by bolts, and the ball joint support is connected to the vertical servo actuator by bolts. The upper end of the support suspension rod is connected to the guide plate by bolts, and the lower end of the support suspension rod is connected to the cylinder support by bolts.

[0012] The tested hydraulic rerailer mainly has two structural forms: a straight top transverse displacement type hydraulic rerailer and a "herringbone" hydraulic rerailer. The straight top transverse displacement type hydraulic rerailer includes a bearing mechanism (rerailing beam), a cylinder mechanism (composed of a transverse displacement mechanism with a transverse displacement cylinder and a straight top cylinder), a jacking seat, a power source (electric pump or manual pump) and high and low pressure oil pipes, etc.; the herringbone hydraulic rerailer includes a bearing mechanism (rerailing beam or rerailing base), a cylinder mechanism (composed of a left and right cylinder connecting mechanism and left and right cylinders), a jacking seat, a power source (electric pump or manual pump) and high and low pressure oil pipes, etc.

[0013] As a further solution of the present invention: the cross beam, the support beam and the base are all welded from steel plates, and reinforcing ribs are arranged inside the cross beam, the support beam and the base to enhance the strength of the overall structure.

[0014] As a further solution of the present invention: multiple rows of bolt holes are provided on the upper part of the support beam, and the cross beam and the oil cylinder support can be freely adjusted in height on the support beam according to the requirements of the installation height.

[0015] As a further solution of the present invention: a vertical displacement sensor and a vertical load sensor are provided on the vertical servo actuator, a lateral load sensor and a lateral displacement sensor are provided on the lateral servo actuator, the accuracy of the load sensor is not less than 0.5%, and the static system error is not greater than 1.0%.

[0016] As a further solution of the present invention: the lateral moving components are symmetrically and uniformly distributed in the lateral and longitudinal directions.

[0017] On the other hand, the present invention also provides a test method for a hydraulic rail replacer. The test is carried out by using a hydraulic rail replacer test system. The hydraulic rail replacer is composed of a bearing mechanism (a rail replacement beam or a rail replacement base), an oil cylinder mechanism (a lateral moving mechanism with a lateral moving oil cylinder of the hydraulic rail replacer and a direct lifting oil cylinder or left and right oil cylinders and a left and right oil cylinder connection mechanism), a power source (an electric pump or a manual pump), a lifting seat and high and low pressure oil pipes to form a tested system. The bearing mechanism is placed on the upper plane of the reaction frame base, the oil cylinder mechanism of the hydraulic rail replacer is placed on the bearing mechanism, and the coincidence of the center line of the oil cylinder mechanism of the hydraulic rail replacer and the center line of the vertical servo actuator is detected by a plumb bob. The oil cylinder mechanism of the hydraulic rail replacer is connected to the power source through high and low pressure oil pipes; the hydraulic oil source controls the hydraulic pressure of the test device through an oil distributor, and the upper computer controls the test loading through a control system and a controller; the test method includes steps of carrying out a rated load test, a static load test, a pressure holding test, an emergency test and a safety test.

[0018] The rated load test step: the bottom surface of the vertical servo actuator contacts with the upper surface of the lifting seat of the hydraulic rail replacer. The upper computer controls the vertical load applying mechanism to output a load equivalent to the rated lifting force of the hydraulic rail replacer, and controls the lateral load applying mechanism to output a load equivalent to the rated lateral moving force of the hydraulic rail replacer. The vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data, and the lateral load sensor and the lateral displacement sensor collect the actual lateral moving force value and the lateral moving displacement data. The oil cylinder mechanism of the hydraulic rail replacer is lifted to the highest position through the control of the power source, and is laterally moved to the maximum lateral moving position through the oil cylinder mechanism of the hydraulic rail replacer. The lateral load sensor and the lateral displacement sensor in the lateral load applying mechanism can collect the actual force and displacement data and feed the test data back to the upper computer; after reaching the maximum lateral moving position, the upper computer controls the load in the lateral load applying mechanism to be cleared to zero, so that the hydraulic rail replacer slowly falls only overcoming the vertical load. During the test process, visually observe whether the hydraulic rail replacer can achieve the above functions and whether there is any damage to each mechanism.

[0019] The steps of the static load test are as follows: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic rail replacer. The upper computer controls the vertical load applying mechanism to output a load equivalent to 1.25 times the rated lifting force of the hydraulic rail replacer, and controls the lateral load applying mechanism to output a load equivalent to the rated lateral displacement force of the hydraulic rail replacer. The vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data, and the lateral load sensor and the lateral displacement sensor collect the actual lateral displacement force value and the lateral displacement data. The power source controls the hydraulic cylinder mechanism of the hydraulic rail replacer to lift to the highest position and traverse to the maximum traverse position through the hydraulic cylinder mechanism of the hydraulic rail replacer. The lateral load sensor and the lateral displacement sensor in the lateral load applying mechanism can collect the actual force and displacement data and feed the test data back to the upper computer. After reaching the maximum traverse position, the upper computer controls the lateral load applying mechanism to clear the load, so that the hydraulic rail replacer slowly falls only overcoming the vertical load. During the test, visually check whether the hydraulic rail replacer can achieve the above functions and whether cracks, permanent deformations and other damage phenomena occur in each mechanism and structure.

[0020] The steps of the pressure holding test are as follows: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic rail replacer. The upper computer controls the vertical load applying mechanism to output a load equivalent to the rated lifting force of the hydraulic rail replacer. The vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data and feed them back to the upper computer. The power source controls the hydraulic cylinder mechanism of the hydraulic rail replacer to lift to 2 / 3 of the full stroke of the cylinder extension and hold the pressure for 5 minutes. During the test, detect the position of the hydraulic cylinder mechanism of the hydraulic rail replacer. The vertical load sensor and the vertical displacement sensor collect the actual load value and the displacement data and feed them back to the upper computer. The upper computer records and detects whether the hydraulic cylinder mechanism of the hydraulic rail replacer has a descent distance greater than 10 mm.

[0021] The steps of the emergency test are as follows: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic rail replacer. The upper computer controls the vertical load applying mechanism to output a load equivalent to the rated lifting force of the hydraulic rail replacer. The actual lifting force value and the lifting displacement data are collected through the vertical load sensor and the vertical displacement sensor and fed back to the upper computer. The power source controls the hydraulic cylinder mechanism of the hydraulic rail replacer to lift to the highest position, turn off the power source of the hydraulic rail replacer. The vertical load sensor and the vertical displacement sensor collect the actual load value and the displacement data and feed them back to the upper computer for real-time observation to detect whether the hydraulic cylinder mechanism of the hydraulic rail replacer can slowly fall within 2 minutes.

[0022] The described safety test steps are as follows: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic rail replacer. The host computer controls the vertical load application mechanism to output a load equivalent to the rated lifting force of the hydraulic rail replacer. The vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data and feedback them to the host computer. The power source controls the hydraulic cylinder mechanism of the hydraulic rail replacer to lift to the highest position, shuts off the power source of the hydraulic rail replacer, and disconnects the oil inlet pipe of the cylinder mechanism. The actual load value and displacement data are collected through the vertical load sensor and the vertical displacement sensor and feedback them to the host computer for real-time observation to detect the position of the hydraulic cylinder mechanism of the hydraulic rail replacer. The host computer records and detects whether the hydraulic cylinder mechanism of the hydraulic rail replacer has a descent distance greater than 10 mm within 5 minutes.

[0023] The load applied by the vertical servo actuator is used to simulate the self-weight of the on-site rescue vehicle, and the load applied by the horizontal servo actuator is used to simulate the lateral movement resistance of the on-site rescue vehicle.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows: The existing test device can only perform one-way loading on the hydraulic cylinder of the hydraulic rail replacer and cannot simulate the complete process of the hydraulic rail replacer in rescuing a train accident, resulting in problems such as incomplete function testing and inaccurate control. The present invention mainly adopts a hydraulic servo system, which can accurately detect the output force value of the hydraulic rail replacer and the actual stroke of the hydraulic cylinder by using load sensors and displacement sensors, and can achieve precise control of the loading load and displacement; a lateral movement component is designed, which can effectively reduce the friction of lateral movement and improve the loading accuracy of the lateral load; a structure in which the horizontal servo actuator and the vertical servo actuator are connected near the jacking position of the hydraulic rail replacer is designed, effectively simulating the center of gravity height of the rescue locomotive (or vehicle), improving the structural stability of the test system and more realistically simulating the rescue site; a general test system structure is designed, and the relevant parameters of the test system equipment can be flexibly adjusted according to the specifications and models of the hydraulic rail replacer to meet the test requirements of different models of hydraulic rail replacers, facilitating disassembly and installation; the redundant degrees of freedom of the moving mechanism can be flexibly restricted, and safety protection measures such as lateral movement limit plates are provided to ensure the safety of the detection process and can completely simulate and restore the whole process of on-site rescue; the disadvantages of the existing test device with a single test model and inability to simulate the whole rescue process are solved, improving the test efficiency, detection flexibility and accuracy; setting up a hydraulic sub-station control console enables operators to operate and control the oil volume and the start and stop of the oil source remotely (in the control room), improving the test safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The features and advantages of the present invention will be more clearly understood by referring to the accompanying drawings. The drawings are schematic and should not be construed as limiting the present invention in any way. In the drawings:

[0026] Figure 1 This is a schematic diagram of the hydraulic rail replacer test system in the present invention.

[0027] Figure 2 This is a schematic diagram of the structure of the test device in the present invention.

[0028] Figure 3 This is a partial structure sectional view of the hydraulic rail replacer test system in the present invention.

[0029] Figure 4 This is a schematic diagram of the structure of the reaction frame in the present invention.

[0030] Figure 5 This is a schematic diagram of the structure of the vertical load applying mechanism in the present invention.

[0031] Figure 6 This is a top view of the lateral movement assembly in the present invention.

[0032] Figure 7 This is a schematic diagram of the connection relationship between the guide rail plate and the vertical load applying mechanism in the present invention.

[0033] Figure 8 This is a schematic diagram of the control flow of the hydraulic rail replacer test system in the present invention.

[0034] Wherein: 1 - test device, 2 - host computer, 3 - controller, 4 - oil distributor, 5 - hydraulic oil source, 6 - hydraulic sub-station control console, 7 - hydraulic rail replacer to be tested, 8 - foundation, 11 - vertical load applying mechanism, 12 - lateral load applying mechanism, 13 - reaction frame, 71 - bearing mechanism, 72 - oil cylinder mechanism, 73 - jacking seat, 74 - power source, 111 - vertical servo actuator, 112 - lateral movement assembly, 113 - side guide rail plate, 114 - lateral movement slideway, 115 - lateral movement limit plate, 116 - vertical displacement sensor, 117 - vertical load sensor, 121 - lateral servo actuator, 122 - oil cylinder support, 123 - support rod of the support, 124 - lateral load sensor, 125 - lateral displacement sensor, 126 - spherical hinge support, 131 - upper clamping plate, 132 - guide rail plate, 133 - screw, 134 - cross beam, 135 - support beam, 136 - base, 1121 - lateral roller bearing, 1122 - fixing plate of the lateral roller bearing, 1123 - support shaft, 1124 - cylindrical roller bearing, 1125 - lateral movement seat, 1126 - bearing screw. Specific embodiments

[0035] In order to more clearly understand the above-mentioned objects, features and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, without conflict, the embodiments of the present application and the features in the embodiments may be combined with each other.

[0036] In the following description, numerous specific details are set forth to provide a thorough understanding of the present invention. However, the present invention may be practiced in other ways different from those described herein. Therefore, the scope of protection of the present invention is not limited by the specific embodiments disclosed below.

[0037] According to the test requirements of the hydraulic rail replacer, the present invention designs a test system for hydraulic rail replacers applicable to different models, which is closer to the actual working conditions and obtains test results closer to the actual data. The present invention also relates to a test method for hydraulic rail replacers. According to the actual working condition characteristics of the hydraulic rail replacer, it can completely simulate and restore the whole process of on-site rescue and evaluate the performance of the hydraulic rail replacer to the greatest extent.

[0038] Specifically, as Figure 1 shown, the present invention provides a test system for a hydraulic rail replacer, including a test device 1, a host computer 2, a controller 3, an oil distributor 4, a hydraulic oil source 5, a hydraulic sub-station control console 6, a control system, a hydraulic pipeline, a tested hydraulic rail replacer 7 and a foundation 8.

[0039] The test device 1 is installed on the foundation 8; a control system for controlling the test device 1 is installed in the host computer 2; the host computer 2 is electrically connected to the controller 3 through a control line; the controller 3 is connected to a servo actuator in the test device 1 through a control line; the hydraulic oil source 5 is connected to the oil distributor 4 through a hydraulic pipeline; the hydraulic sub-station control console 6 is connected to the oil distributor 4 through a control line; the hydraulic sub-station control console 6 controls the start and stop of the high-pressure end and the low-pressure end of the oil distributor 4.

[0040] As Figure 2 shown, the test device 1 includes a vertical load applying mechanism 11, a lateral load applying mechanism 12 and a reaction frame 13; the vertical load applying mechanism 11 and the lateral load applying mechanism 12 are both installed on the reaction frame 13, and the lateral load applying mechanism 11 is used to apply a lateral load to the vertical load applying mechanism 12; as Figure 4 shown, the reaction frame 13 includes an upper clamping plate 131, a guide rail plate 132, a screw 133, a cross beam 134, two support beams 135 and a base 136; the upper clamping plate 131 and the guide rail plate 132 are connected to the cross beam 134 through the screw 133 and nut fasteners, the upper clamping plate 131 is arranged at the top of the cross beam 134, and the guide rail plate 132 is arranged at the lower part of the cross beam 134; both ends of the cross beam 134 are connected by two parallel support beams 135 through bolts, and the bottoms of the two support beams 135 are respectively connected to the base 136 through bolts, and the base 136 is embedded in the foundation 8;

[0041] Furthermore, the cross beam 134, the support beams 135 and the base 136 are all welded by steel plates, and reinforcing rib plates are arranged inside the cross beam 134, the support beams 135 and the base 136 to enhance the overall strength.

[0042] As Figure 3 and Figure 5 shown, the vertical load applying mechanism 11 mainly consists of a vertical servo actuator 111, a lateral movement assembly 112, side guide plates 113, lateral movement slideways 114, lateral movement limit plates 115, a vertical displacement sensor 116 and a vertical load sensor 117; there are two side guide plates 113, lateral movement slideways 114 and lateral movement limit plates 115, and the lateral movement assembly 112 includes lateral roller bearings 1121, a lateral roller bearing fixing plate 1122, a support shaft 1123, cylindrical roller bearings 1124, a lateral movement seat 1125 and bearing screws 1126; the top end of the vertical servo actuator 111 is connected to the lateral movement seat 1125 of the lateral movement assembly 112 by bolts, and both sides of the lateral movement seat 1125 are fixedly embedded in an inverted frame formed by a guide plate 132, side guide plates 113, lateral movement slideways 114 and lateral movement limit plates 115 through cylindrical roller bearings 1124, bearing screws 1126 and washers; the lateral roller bearing fixing plate 1122 is fixedly connected to the lateral movement seat 1125 by bolts. As Figure 6 shown, five rows of lateral roller bearings 1121 are evenly distributed in the lateral direction inside the lateral roller bearing fixing plate 1122, with ten lateral roller bearings 1121 in each row, and the lateral movement assembly 112 is symmetrically and evenly distributed both laterally and longitudinally; the lateral roller bearings 1121 are connected to the lateral roller bearing fixing plate 1122 through support shafts 1123 and are symmetrically distributed on both sides of the lateral center line; the upper part of the lateral movement assembly 112 is in surface contact connection with the guide plate 132 through lateral roller bearings 1121. As Figure 7 shown, the two side guide plates 113 are installed at the bottom of the guide plate 132 by bolts, and the two side guide plates 113 are symmetrically distributed on both sides. The bottom of each side guide plate 113 is connected to the lateral movement slideway 114 by bolts. The inverted frame formed by the guide plate 132, side guide plates 113 and lateral movement slideways 114 is respectively connected to the lateral movement limit plates 1134 by bolts on both lateral sides; the vertical servo actuator 111 can move laterally along the lateral movement slideway 114 through the lateral movement assembly 112.

[0043] The lateral load applying mechanism 12 includes a lateral servo actuator 121, an oil cylinder support 122, a support hanger 123, a lateral load sensor 124, a lateral displacement sensor 125, and a spherical hinge support 126; the fixed end of the lateral servo actuator 121 is installed on the oil cylinder support 122 by bolts, and a plurality of bolt holes are provided on both sides of the oil cylinder support 122. The oil cylinder support 122 is installed on a support beam 135 on one side by bolts, and the height position of the oil cylinder support 122 can be flexibly adjusted through the plurality of bolt holes; the output end of the lateral servo actuator 121 is connected to the spherical hinge support 126 by bolts, and the spherical hinge support 126 is connected to the vertical servo actuator 111 by bolts. The upper end of the support hanger 123 is connected to the guide rail plate 132 by bolts, and the lower end of the support hanger 123 is connected to the oil cylinder support 122 by bolts, which plays a role in enhancing the vertical stability.

[0044] The tested hydraulic rail replacer 7 includes a bearing mechanism 71, an oil cylinder mechanism 72, a jacking seat 73, and a power source 74; the bearing mechanism 71 is installed on the oil cylinder mechanism 72, the oil cylinder mechanism 72 is installed on the jacking seat 73, and the power source 74 is used to drive the oil cylinder mechanism 72; the power source 74 is an electric pump or a manual pump; the tested hydraulic rail replacer 7 has two structural forms: a direct jacking and lateral moving type hydraulic rail replacer and a chevron type hydraulic rail replacer. The bearing mechanism 71 of the direct jacking and lateral moving type hydraulic rail replacer is a rail replacement beam, and the oil cylinder mechanism 72 of the tested hydraulic rail replacer 7 is composed of a lateral moving mechanism with a lateral moving oil cylinder and a direct jacking oil cylinder; the bearing mechanism 71 of the chevron type hydraulic rail replacer is a rail replacement beam or a rail replacement base, and the oil cylinder mechanism 72 of the chevron type hydraulic rail replacer is composed of a left and right oil cylinder connecting mechanism and left and right oil cylinders.

[0045] A plurality of rows of bolt holes are provided in the upper part of the support beam 135, and the cross beam 134 and the oil cylinder support 122 can be adjusted in height according to the installation height requirements on the support beam 135.

[0046] A vertical displacement sensor 116 and a vertical load sensor 117 are provided on the vertical servo actuator 111, a lateral load sensor 124 and a lateral displacement sensor 125 are provided on the lateral servo actuator 121, the accuracy of the load sensor is not less than 0.5%, and the static system error is not greater than 1.0%.

[0047] The test system involved in the present invention leaves a unified mechanical interface, and different models of hydraulic rail replacers can use the same set of test systems for testing, which increases convenience and can also unify the test conditions.

[0048] On the other hand, the present invention also provides a test method for a hydraulic rail replacer, which is tested by a hydraulic rail replacer test system. The hydraulic rail replacer is composed of a bearing mechanism (rail replacement beam or rail replacement base), an oil cylinder mechanism (a transverse movement mechanism with a transverse oil cylinder on the hydraulic rail replacer and a direct top oil cylinder or left and right oil cylinders and a left and right oil cylinder connection mechanism), a power source (an electric pump or a manual pump), a jacking seat and high and low pressure oil pipes to form a test system to be tested. The bearing mechanism is placed on the upper plane of the reaction frame base, and the oil cylinder mechanism of the hydraulic rail replacer is placed on the bearing mechanism. The coincidence of the center line of the oil cylinder mechanism of the hydraulic rail replacer and the center line of the vertical servo actuator is detected by a plumb bob. The oil cylinder mechanism of the hydraulic rail replacer is connected to the power source through high and low pressure oil pipes; the hydraulic oil source controls the test device through an oil distributor, and the upper computer controls the test loading through a control system and a controller; the test method includes a rated load test step S1, a static load test step S2, a pressure holding test step S3, an emergency test step S4 and a safety test step S5:

[0049] The specific test load of the hydraulic rail replacer shall comply with the provisions of Table 1:

[0050] Table 1 Performance parameters of various models of hydraulic rail replacers

[0051]

[0052]

[0053] After the hydraulic rail replacer to be tested is installed, check and confirm the correctness of the working positions of the test device, the loading equipment and the test piece, and calibrate the zero positions of the horizontal and vertical servo actuators.

[0054] In the rated load test step S1: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic rail replacer. The upper computer controls the vertical load applying mechanism to output a load equivalent to the rated lifting force of the hydraulic rail replacer, and controls the horizontal load applying mechanism to output a load equivalent to the rated transverse movement force of the hydraulic rail replacer; the vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data; the horizontal load sensor and the horizontal displacement sensor collect the actual transverse movement force value and the transverse movement displacement data; the oil cylinder mechanism of the hydraulic rail replacer is controlled by the power source to be lifted to the highest position, and is transversely moved to the maximum transverse movement position through the oil cylinder mechanism of the hydraulic rail replacer. The horizontal load sensor and the horizontal displacement sensor in the horizontal load applying mechanism collect the actual force and displacement data and feed the test data back to the upper computer; after reaching the maximum transverse movement position, the upper computer controls the horizontal load applying mechanism to clear the load; the hydraulic rail replacer is slowly lowered only by overcoming the vertical load. During the test process, visually check whether the hydraulic rail replacer can achieve the above functions and whether there is any damage to each mechanism.

[0055] Steps of the static load test S2: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic rail replacer. The upper computer controls the vertical load application mechanism to output a load equivalent to 1.25 times the rated lifting force of the hydraulic rail replacer, and controls the lateral load application mechanism to output a load equivalent to the rated lateral movement force of the hydraulic rail replacer. The vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data, and the lateral load sensor and the lateral displacement sensor collect the actual lateral movement force value and the lateral movement displacement data. The power source control raises the hydraulic cylinder mechanism of the hydraulic rail replacer to the highest, and laterally moves it to the maximum lateral movement position. The lateral load sensor and the lateral displacement sensor in the lateral load application mechanism collect the actual force and displacement data and feed the test data back to the upper computer. After reaching the maximum lateral movement position, the upper computer controls the lateral load application mechanism to clear the load, so that the hydraulic rail replacer slowly falls only overcoming the vertical load. During the test, visually check whether the hydraulic rail replacer can achieve the above functions and whether there are cracks, permanent deformations and other damage phenomena in each mechanism and structure.

[0056] Steps of the pressure holding test S3: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic rail replacer. The upper computer controls the vertical load application mechanism to output a load equivalent to the rated lifting force of the hydraulic rail replacer. The vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data and feed them back to the upper computer. The power source controls the hydraulic cylinder mechanism of the hydraulic rail replacer to be raised to 2 / 3 of the full stroke of the cylinder extension and holds the pressure for 5 minutes. During the test, detect the position of the hydraulic cylinder mechanism of the hydraulic rail replacer. The vertical load sensor and the vertical displacement sensor collect the actual load value and the displacement data and feed them back to the upper computer. The upper computer records and detects whether the hydraulic cylinder mechanism of the hydraulic rail replacer has a descent distance greater than 10 mm.

[0057] Steps of the emergency test S4: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic rail replacer. The upper computer controls the vertical load application mechanism to output a load equivalent to the rated lifting force of the hydraulic rail replacer. The vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data and feed them back to the upper computer. The power source controls the hydraulic cylinder mechanism of the hydraulic rail replacer to be raised to the highest, turns off the power source of the hydraulic rail replacer. The vertical load sensor and the vertical displacement sensor collect the actual load value and the displacement data and feed them back to the upper computer, and conduct real-time observation to detect whether the hydraulic cylinder mechanism of the hydraulic rail replacer can slowly fall within 2 minutes.

[0058] Steps of the safety test S5: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic rail replacer. The upper computer controls the vertical load applying mechanism to output a load equivalent to the rated lifting force of the hydraulic rail replacer. The vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data and feedback them to the upper computer. The power source controls the oil cylinder mechanism of the hydraulic rail replacer to lift to the highest position, shuts off the power source of the hydraulic rail replacer, and disconnects the oil inlet pipe of the oil cylinder mechanism. The vertical load sensor and the vertical displacement sensor collect the actual load value and the displacement data and feedback them to the upper computer for real-time observation to detect the position of the oil cylinder mechanism of the hydraulic rail replacer, and record and detect through the upper computer whether the oil cylinder mechanism of the hydraulic rail replacer has a descent distance greater than 10 mm within 5 minutes.

[0059] During the test, a vertical servo actuator is used to apply a vertical load to simulate the weight of the locomotive and rolling stock in the rescue of train accidents. According to the requirements of the tonnage of different models of hydraulic rail replacers, the load size is adjusted in a timely manner. A horizontal servo actuator is used to apply a horizontal load to simulate the lateral movement resistance suffered by the locomotive and rolling stock during the rescue of train accidents, and the load size can also be adjusted according to the lateral resistance of different models of hydraulic rail replacers in a timely manner to evaluate whether the lateral movement thrust of the hydraulic rail replacer can reach the designed tonnage.

[0060] The control system sets the limit values for the test load, displacement, and the maximum test pressure output by the hydraulic oil source respectively. During the test, protection measures are taken according to different test environments. The limitation of the above parameters is also a protection of the equipment and the test piece to a certain extent, preventing situations such as excessive load on the test piece causing deformation and damage, or failures occurring in the test system equipment.

[0061] The function of the hydraulic rail replacer test system meets the requirements of the test standard. It adopts a hydraulic servo system, which can accurately detect the output force value of the hydraulic rail replacer and the actual stroke of the oil cylinder by using load sensors and displacement sensors, and can achieve precise control of the loading load and displacement; a lateral movement component is designed, which can effectively reduce the friction of lateral movement and improve the loading accuracy of lateral loads; a structure is designed in which the lateral servo actuator and the vertical servo actuator are connected near the jacking position of the hydraulic rail replacer, effectively simulating the center of gravity height of the rescue locomotive (or vehicle), which not only improves the structural stability of the test system, but also more realistically simulates the rescue site; a general test system structure is designed, and the relevant parameters of the test system equipment can be flexibly adjusted according to the specifications and models of the hydraulic rail replacer to meet the test needs of different models of hydraulic rail replacers, which is convenient for disassembly and installation; the redundant degrees of freedom of the moving mechanism can be flexibly constrained, and safety protection measures such as lateral movement limit plates are provided to ensure the safety of the detection process and can completely simulate the whole process of on-site rescue restoration; it solves the disadvantages of the existing test devices, such as single test model and inability to simulate the whole rescue process, and improves the test efficiency, detection flexibility and accuracy; a hydraulic sub-station control console is set up, which enables the operator to operate and control the oil volume and the start and stop of the oil source remotely (in the control room), improving the test safety.

[0062] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A hydraulic rail replacer test system, characterized in that: The test device is installed on the foundation; a control system for controlling the test device is installed in the upper computer; the upper computer and the controller are electrically connected through a control line; the controller is connected to the servo actuator in the test device through the control line; the hydraulic oil source and the oil distributor are connected through a hydraulic pipeline; the hydraulic substation console is connected to the oil distributor through a control line; the hydraulic substation console controls the start and stop of the high-pressure end and the low-pressure end of the oil distributor; The test device includes a vertical load applying mechanism, a lateral load applying mechanism and a reaction frame; the vertical load applying mechanism and the lateral load applying mechanism are both installed on the reaction frame, and the lateral load applying mechanism is used to apply a lateral load to the vertical load applying mechanism; the reaction frame includes an upper clamping plate, a guide plate, a screw, a beam, a support beam and a base; the upper clamping plate and the guide plate are connected to the beam through screw and nut fasteners, the upper clamping plate is arranged on the top of the beam, and the guide plate is arranged on the lower part of the beam; the two ends of the beam are connected by two parallel support beams, and the bottoms of the two support beams are respectively connected to the base, and the base is pre-buried in the foundation; the vertical load applying mechanism is composed of a vertical servo actuator, a lateral moving assembly, a side guide plate, a lateral moving slide, a lateral moving limit plate, a vertical displacement sensor and a vertical load sensor; the lateral moving assembly includes a lateral roller bearing, a lateral roller bearing fixing plate, a support shaft, a cylindrical roller bearing, a lateral moving seat, a bearing screw nail; the top of the vertical servo actuator is connected to the lateral moving seat of the lateral moving assembly, and both sides of the lateral moving seat are fixed and embedded in the inverted frame composed of the guide plate, side guide plate, lateral moving slideway, and lateral moving limit plate through cylindrical roller bearings, bearing screws and washers; the lateral roller bearing fixing plate is fixedly connected to the lateral moving seat, and the lateral moving assembly is symmetrically distributed in the horizontal and vertical directions; the lateral roller bearing is connected to the lateral roller bearing fixing plate through a support shaft, and is symmetrically distributed on both sides of the lateral center line; the upper part of the lateral moving assembly is connected to the guide plate surface through a lateral roller bearing; two side guide plates are installed at the bottom of the guide plate, and the two side guide plates are symmetrically distributed on both sides, and the bottom of each side guide plate is connected to the lateral moving slideway, and the lateral sides of the inverted frame composed of the guide plate, the side guide plate, and the lateral moving slideway are respectively connected to the lateral moving limit plate; the vertical servo actuator moves laterally along the lateral moving slideway through the lateral moving assembly.

2. The hydraulic rail replacer test system according to claim 1, characterized in that: The cross beam, support beam and base are all welded from steel plates, and reinforcing rib plates are arranged inside the cross beam, support beam and base.

3. The hydraulic rail replacement tester system according to claim 1, characterized in that: The lateral load applying mechanism includes a lateral servo actuator, a cylinder support, a support hanger, a lateral load sensor, a lateral displacement sensor and a ball joint support; the fixed end of the lateral servo actuator is installed on the cylinder support, and a plurality of bolt holes are provided on both sides of the cylinder support. The cylinder support is installed on a support beam on one side, and the height position of the cylinder support can be flexibly adjusted through the plurality of bolt holes; the output end of the lateral servo actuator is connected to the ball joint support, and the ball joint support is connected to the vertical servo actuator; the upper end of the support hanger is connected to the guide plate, and the lower end of the support hanger is connected to the cylinder support, which plays a role in enhancing the vertical stability.

4. The hydraulic rail replacer test system according to claim 1, characterized in that: There are multiple rows of bolt holes on the upper part of the support beam, and the cross beam and the oil cylinder support can adjust the height according to the installation height requirements on the support beam.

5. The hydraulic rail replacement tester system according to claim 1, characterized in that: The vertical servo actuator is equipped with a vertical displacement sensor and a vertical load sensor, and the horizontal servo actuator is equipped with a horizontal load sensor and a horizontal displacement sensor.

6. A test method using the test system described in claim 1, which conducts tests using a hydraulic rail replacer test system. The hydraulic rail replacers to be tested have two structural forms: a direct-lift and lateral-movement type hydraulic rail replacer and a V-shaped hydraulic rail replacer. The hydraulic rail replacer is composed of a bearing mechanism, an oil cylinder mechanism, a power source, a jacking seat, and high- and low-pressure oil pipes to form the test system to be tested. The bearing mechanism is placed on the upper plane of the reaction frame base, and the oil cylinder mechanism of the hydraulic rail replacer is placed on the bearing mechanism. The coincidence of the center line of the oil cylinder mechanism of the hydraulic rail replacer with the center line of the vertical servo actuator is detected by a plumb bob. The oil cylinder mechanism of the hydraulic rail replacer is connected to the power source through high- and low-pressure oil pipes. The hydraulic oil source controls the test device through an oil distributor, and the upper computer controls the test loading through a control system and a controller. It is characterized in that: The test method includes a rated load test step S1, a static load test step S2, a pressure holding test step S3, an emergency test step S4, and a safety test step S5.

7. The test method according to claim 6, wherein: After the hydraulic rail replacer under test is installed, check and confirm the correctness of the test device, the loading equipment, and the working position of the test piece, and calibrate the zero positions of the horizontal and vertical servo actuators.

8. The test method according to claim 6, characterized in that: Rated load test step S1: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic rail replacer. The upper computer controls the vertical load applying mechanism to output a load equivalent to the rated lifting force of the hydraulic rail replacer, and controls the horizontal load applying mechanism to output a load equivalent to the rated lateral movement force of the hydraulic rail replacer; the vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data; the horizontal load sensor and the horizontal displacement sensor collect the actual lateral movement force value and the lateral movement displacement data; the power source controls the hydraulic cylinder mechanism of the hydraulic rail replacer to lift to the highest position, and the hydraulic cylinder mechanism of the hydraulic rail replacer is laterally moved to the maximum lateral movement position. The horizontal load sensor and the horizontal displacement sensor in the horizontal load applying mechanism collect the actual force and displacement data and feed the test data back to the upper computer; after reaching the maximum lateral movement position, the upper computer controls the load of the horizontal load applying mechanism to be cleared; the hydraulic rail replacer is slowly lowered only by overcoming the vertical load. During the test, visually check whether the hydraulic rail replacer can achieve the above functions and whether there is any damage to each mechanism. Static load test step S2: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic rail replacer. The upper computer controls the vertical load applying mechanism to output a load equivalent to 1.25 times the rated lifting force of the hydraulic rail replacer, and controls the horizontal load applying mechanism to output a load equivalent to the rated lateral movement force of the hydraulic rail replacer; the vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data, and the horizontal load sensor and the horizontal displacement sensor collect the actual lateral movement force value and the lateral movement displacement data; the power source controls the hydraulic cylinder mechanism of the hydraulic rail replacer to lift to the highest position, and the hydraulic cylinder mechanism of the hydraulic rail replacer is laterally moved to the maximum lateral movement position. The horizontal load sensor and the horizontal displacement sensor in the horizontal load applying mechanism collect the actual force and displacement data and feed the test data back to the upper computer; after reaching the maximum lateral movement position, the upper computer controls the load of the horizontal load applying mechanism to be cleared, and the hydraulic rail replacer is slowly lowered only by overcoming the vertical load. During the test period, visually check whether the hydraulic rail replacer can achieve the above functions and whether there are any cracks, permanent deformations, or other damages to each mechanism and structure. Steps of the holding pressure test S3: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic replacer. The upper computer controls the vertical load applying mechanism to output a load equivalent to the rated lifting force of the hydraulic replacer. The vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data and feedback them to the upper computer. The power source controls the hydraulic cylinder mechanism of the hydraulic replacer to lift to 2 / 3 of the full stroke of the cylinder extension and hold the pressure for 5 minutes. During the test, the position of the hydraulic cylinder mechanism of the hydraulic replacer is detected. The vertical load sensor and the vertical displacement sensor collect the actual load value and the displacement data and feedback them to the upper computer. The upper computer records and detects whether the hydraulic cylinder mechanism of the hydraulic replacer has a descent distance greater than 10 mm. Steps of the emergency test S4: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic replacer. The upper computer controls the vertical load applying mechanism to output a load equivalent to the rated lifting force of the hydraulic replacer. The vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data and feedback them to the upper computer. The power source controls the hydraulic cylinder mechanism of the hydraulic replacer to lift to the highest position, turn off the power source of the hydraulic replacer, and the vertical load sensor and the vertical displacement sensor collect the actual load value and the displacement data and feedback them to the upper computer for real-time observation to detect whether the hydraulic cylinder mechanism of the hydraulic replacer can slowly fall within 2 minutes. Steps of the safety test S5: The bottom surface of the vertical servo actuator contacts the upper surface of the jacking seat of the hydraulic replacer. The upper computer controls the vertical load applying mechanism to output a load equivalent to the rated lifting force of the hydraulic replacer. The vertical load sensor and the vertical displacement sensor collect the actual lifting force value and the lifting displacement data and feedback them to the upper computer. The power source controls the hydraulic cylinder mechanism of the hydraulic replacer to lift to the highest position, turn off the power source of the hydraulic replacer, and disconnect the inlet pipe of the cylinder mechanism. The vertical load sensor and the vertical displacement sensor collect the actual load value and the displacement data and feedback them to the upper computer for real-time observation to detect the position of the hydraulic cylinder mechanism of the hydraulic replacer. The upper computer records and detects whether the hydraulic cylinder mechanism of the hydraulic replacer has a descent distance greater than 10 mm within 5 minutes.

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