Rail transit maintenance process structuring method and system

Abstract

The invention discloses a rail transit overhaul process structuring method and system, and the method comprises the following steps: dividing the assembly operation of a framework after the overhaul of a rail transit bogie according to the station system rhythm, and building a station system rhythm bogie assembly line; an intelligent card control management system is constructed, a bogie maintenance process file is subjected to decomposition and structural processing, the rail transit maintenance process flow and sequence are displayed in a graphical mode, bogie assembly line maintenance information data are collected in real time, and closed-loop management and control are conducted on the whole bogie maintenance process; the intelligent equipment for auxiliary production is additionally arranged in the bogie assembly line, the bogie of the previous station is transferred to the next station after the work content of each station is completed, the operation state and parameter information of key equipment are synchronously displayed, and the bogie assembly quality and efficiency are improved. According to the method, on-site paperless office work is achieved, and effective support can be provided for follow-up bogie assembly workshop planning, the assembly production process and model selection improvement of tool equipment.

Description

Technical Field

[0001] The present invention relates to the technical field of rail transit maintenance, and in particular to a rail transit maintenance process structuring method and system. Background Art

[0002] With the rapid development of the domestic economy, the domestic demand for railway passenger cars is also gradually increasing, but the intelligent level of production and maintenance equipment in maintenance workshops is not high, which makes the maintenance task of railway passenger cars very heavy and the maintenance efficiency low. Under the background of the large-scale promotion and application of Industrial Internet 4.0 and big data, it has become a general trend to build intelligent, information-based and efficient maintenance workshops based on Industrial Internet 4.0.

[0003] Chinese invention patent CN117764550B discloses a maintenance management system and method for rail transit vehicles. Through data sharing and application among the operation management module, maintenance management module and knowledge center module, accurate fault diagnosis, accurate maintenance implementation and accurate maintenance operation scheduling of rail transit vehicles are realized from an overall linkage, thereby improving the intelligent maintenance capability and maintenance quality of vehicles. However, the traditional maintenance process of railway passenger cars involves many operators and maintenance equipment, and the maintenance process documents are mostly in paper form, which are easy to lose, damage and difficult to find. Document updating and version control are also difficult, and different versions of process documents are prone to coexist, leading to production chaos. It is difficult to integrate with other systems, and the phenomenon of information islands is serious, which affects the efficiency and accuracy of production management.

[0004] In view of the needs for systematic, standardized and standardized management of traditional railway passenger car maintenance process management, it is necessary to develop a structured method and system for rail transit maintenance process, which has the functions of real-time monitoring of the behavior of maintenance operators, the status of maintenance equipment, the distribution of maintenance materials, and the safety inspection of the working environment, and can issue online alarms for illegal operations discovered during monitoring. Summary of the invention

[0005] The problem to be solved by the present invention is to provide a method and system for structuring rail transit maintenance process, which combines intelligent maintenance hardware, professional platform software and the Internet on the basis of the concept of workstation rhythm, and monitors the rail transit maintenance process in real time.

[0006] The present invention adopts the following technical solution: a rail transit maintenance process structured method, comprising the following steps:

[0007] S1. The frame assembly work of rail transit bogies after overhaul is divided into workstation-based rhythmic divisions, and a workstation-based rhythmic bogie assembly line is established, with each workstation performing operations simultaneously;

[0008] S2. Build an intelligent card control management system to decompose and structure the bogie maintenance process files, and graphically display the rail transit maintenance process flow and sequence;

[0009] S3. Adding intelligent equipment for auxiliary production to the bogie assembly line, after the work content of each station is completed, the bogie at the previous station is transferred to the next station, and the operating status and parameter information of key equipment are displayed synchronously, so as to improve the quality and efficiency of the frame assembly after the bogie is overhauled;

[0010] S4. Collect the maintenance information data of the bogie assembly line in real time, and through the intelligent card control management system, conduct closed-loop control of the entire process of frame assembly after the bogie maintenance, and realize the bogie maintenance process procedures based on condition maintenance.

[0011] Preferably, in step S1, a station-based rhythmic bogie assembly line is established, and the method is as follows:

[0012] S1.1. According to the process flow of the frame assembly after the bogie overhaul, the assembly process is modularized and divided into several workstations, each of which completes a specific operation task;

[0013] The frame assembly operation after the bogie is overhauled includes: traction center body, traction rod, anti-roll torsion bar, axle box spring, positioning swing arm, swing arm node, a series of vertical hydraulic shock absorbers, brake pipeline, basic brake device, drop wheel, axle box clamping hoop; the positioning swing arm includes axle box spring;

[0014] The bogie assembly line workstations obtained by division include: the first reverse position assembly station, the second reverse position assembly station, the flipping station, the normal position assembly station, the buffer station, and the wheel drop station; hardware equipment is configured for each station, and corresponding operators are arranged.

[0015] Furthermore, the first reverse position assembly station is used to assemble the bogie axle box spring, positioning swing arm and swing arm node, etc.; the second reverse position assembly station is used to assemble the bogie traction center body, traction rod, anti-roll torsion bar; the flipping station flips the frame ±180 degrees through the flipping positioner; the positive position assembly station is used to assemble the brake line and basic braking device; the cache station is used for wheel drop frame cache; the wheel drop station is used for bogie wheel drop operation and installation of the axle box central clamp.

[0016] S1.2. Based on the operation time, material delivery time and equipment adjustment time of each process of the frame assembly operation after the bogie overhaul, each assembly process is divided into different workstations according to the length of the operation time, and the operators are arranged at the corresponding workstations, and each workstation performs operations simultaneously.

[0017] Preferably, in step S2, the rail transit maintenance process flow and sequence are displayed in a graphical manner, including each process, operation steps, inspection links, and descriptions of the operators, operation methods, process parameters, required materials, equipment tools and quality requirements of each process.

[0018] Preferably, in step S3, the intelligent equipment for auxiliary production includes: a C-type rotary press, a process transfer vehicle, a platform lifting device, a flip positioner, a power manipulator, and an auxiliary wheel positioning device;

[0019] C-type rotary press, configured at the first reverse assembly station, is used for press-fitting the steel spring arm node;

[0020] The process transfer vehicle is arranged at the first reverse assembly station, the second reverse assembly station, the flipping station, and the normal assembly station, and is used to carry and transport the carrier of the frame;

[0021] The platform lifting device is configured at the first reverse assembly station, the second reverse assembly station, and the positive assembly station, and is used to assemble the work platform and coordinate with the trolley to transport the frame;

[0022] The flipping positioner is configured at the flipping station and is used to flip and position the frame.

[0023] The power manipulator is configured at the first reverse assembly station, the second reverse assembly station, and the positive assembly station to assist in lifting parts for frame assembly operations;

[0024] The auxiliary wheel drop positioning device is configured with the wheel drop station and is used for wheel drop wheelbase positioning and lifting auxiliary operations.

[0025] Preferably, in step S4, the smart card control management system adopts a B / S architecture, including: a background management unit and several handheld terminals. The background management unit and the handheld terminals are connected via a network to collect equipment data of the frame assembly line after bogie maintenance in real time, monitor and analyze equipment status and operation information in real time, and perform full life cycle management of assembly line equipment.

[0026] Furthermore, the background management unit includes a main server, an industrial computer, and a smart card control terminal, which are connected and transmit data through a network;

[0027] The smart card control terminal collects and displays the real-time data of the trolley and battery status, elevator, and flip positioner of each process through the industrial computer, stores it in the main server, and provides instructions to the handheld terminal;

[0028] The industrial computer is installed in the station-based rhythmic bogie assembly line to transmit equipment data between the lines in real time and control the operations of each station.

[0029] Furthermore, the whole process of frame assembly after bogie maintenance is subject to closed-loop control, as follows: the smart card control management system generates assembly tasks on the smart card control terminal according to the assembly plan, and distributes them to the handheld terminals of each team leader. After each leader divides the work, the specific work tasks are distributed to the handheld terminals of the corresponding operators. The operators perform the work according to the task reminders on the handheld terminals, and fill in the work process data on the handheld terminals, which are finally transmitted back to the bogie smart card control terminal to form a closed-loop management.

[0030] The technical solution of the present invention also provides: a rail transit maintenance process structuring system for implementing any of the above rail transit maintenance process structuring methods, including: a bogie assembly line, intelligent equipment for auxiliary production, and an intelligent card control management system;

[0031] The bogie assembly line divides the frame assembly work of the rail transit bogie after overhaul into a rhythmic workstation system, forming the first reverse assembly station, the second reverse assembly station, the flipping station, the normal assembly station, the buffer station, and the wheel drop station;

[0032] The intelligent card control management system decomposes and structures the bogie maintenance process documents, graphically displays the rail transit maintenance process flow and sequence, collects real-time equipment data of the bogie frame assembly line after maintenance, monitors and analyzes equipment status and operation information in real time, and manages the entire process of assembly line equipment and maintenance information;

[0033] Intelligent equipment to assist production allows users to transfer the bogie from the previous station to the next station, and simultaneously display the operating status and parameter information of key equipment to improve the quality and efficiency of bogie assembly.

[0034] Compared with the prior art, the present invention adopts the above technical solution and has the following technical effects:

[0035] 1. The rail transit maintenance process structured system of the present invention realizes the whole process control of maintenance information through the setting of the workstation system rhythmic assembly line, the configuration of intelligent hardware and the matching of the bogie assembly intelligent card control system. Each workstation works in coordination to achieve the full process control of maintenance information, thereby improving the assembly production efficiency and quality.

[0036] 2. The structured method of rail transit maintenance process of the present invention enhances the information management and control of bogie assembly from planning, process, materials, operations, quality, and billboard display, and realizes on-site paperless office operations. It can provide effective support for the subsequent bogie assembly workshop planning, assembly production process and tool equipment selection and improvement, and also optimizes the bogie maintenance process regulations and lays the foundation for the transformation from planned maintenance to condition-based maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1The structural diagram of the bogie assembly station division of the present invention;

[0038] Figure 2 The station layout diagram of the bogie assembly line according to the embodiment of the present invention;

[0039] Figure 3 This is a block diagram of the smart card control management system according to an embodiment of the present invention;

[0040] Figure 4 The figure is a flowchart of the smart card control management process according to an embodiment of the present invention. DETAILED DESCRIPTION

[0041] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the application is further elaborated in detail below in conjunction with the accompanying drawings. The described embodiments are only a part of the embodiments involved in the present invention. All non-innovative embodiments of other researchers in the field on this embodiment belong to the protection scope of the present invention. At the same time, for the step numbering in the embodiment of the present invention, it is only set for the convenience of explanation, and the order between the steps is not limited in any way. The execution order of each step in the embodiment can be adaptively adjusted according to the understanding of those skilled in the art.

[0042] In one embodiment of the present invention, taking the PW-220K bogie of a railway bureau as an example, the assembly of the frame after the bogie is overhauled includes: traction center tie rod, anti-roll torsion bar, positioning swing arm (including axle box spring), a series of vertical shock absorbers, brake lines, basic braking devices, wheel drop, axle box clamping hoop and other installation processes. The assembly process is relatively complicated, but it has the characteristics of modularization. Each assembly process can be modularly divided into multiple workstations to enable multiple workstations to operate simultaneously.

[0043] Specifically, the frame assembly work after the bogie overhaul is divided into six workstations according to the workstation system rhythm. Figure 1 As shown, each workstation is responsible for completing a specific operation task.

[0044] The first and second stations are two reverse assembly stations, the third station is a flip station, the fourth station is a positive assembly station, the fifth station is a buffer station, and the sixth station is a wheel drop station. The station layout of the bogie assembly line is shown in the figure below: Figure 2 As shown; equipment is configured for each workstation, as shown in Table 1 below.

[0045] Table 1: Bogie assembly line station equipment configuration table

[0046] Workstation Device Configuration First counter-position assembly station (first station) 1 process operation vehicle, 1 set of power manipulator (including sling), 1 set of reverse lifting device (4 lifting columns, switchable to normal position), 4 sets of C-type rotary presses (distributed in the 4 rotating arm positions of the frame), 1 19-inch industrial touch screen Second reverse assembly station (second station) 1 process operation vehicle, 1 set of power manipulator (including sling), 1 set of reverse lifting device (4 lifting columns, switchable to normal position), 1 19-inch industrial touch screen Turning position (third position) 1 process transfer vehicle, 1 set of turning positioner (2 units, left and right clamping) Normal assembly station (the fourth station) 1 process operation vehicle, 1 set of upright lifting device (4 lifting columns), 1 set of power manipulator (including sling), 1 19-inch industrial touch screen Cache station (fifth station) none Wheel drop station (the sixth station) Wheel set positioning device, 1 19-inch industrial touch screen

[0047] According to the configuration of each workstation, the operation time, material delivery time, and equipment adjustment time of each process of the frame assembly operation are comprehensively considered, and each assembly process is evenly divided into each workstation according to the length of the operation time. By arranging specific process assembly operators at the corresponding workstations, the efficiency and quality of the bogie assembly operation can be greatly improved.

[0048] Furthermore, in order to realize rhythmic assembly line production, on the basis of establishing a rhythmic bogie assembly line with a workstation system, corresponding systematic and intelligent auxiliary production equipment (such as transfer trolleys, lifting platforms, flip positioners, etc.) are added. After the work content of each workstation is completed at the same time, the bogie at the previous workstation is transferred to the next workstation for the next assembly operation by controlling the equipment control system, and the operating status and parameter information of key equipment are displayed synchronously, which can further improve the efficiency of the operation and reduce the labor intensity of workers.

[0049] The intelligent hardware configuration of each workstation in this embodiment is shown in Table 2 below.

[0050] Table 2: Intelligent hardware configuration table for each workstation

[0051] Serial number Device Name Configure workstations Key Features 1 C-type rotary press Reverse installation station 1 Press-fitting of steel spring swing arm nodes 2 Process transfer vehicle Reverse installation 1, 2 stations, flip station, normal station Carrier for carrying and transporting the frame 3 Table lifting device Reverse installation 1, 2 stations, normal installation station Assemble the work platform and coordinate with the trolley to transfer the frame 4 Flip positioner Flip-over station Flip the frame. 5 Power manipulator Reverse installation 1, 2 stations, normal installation station Auxiliary frame assembly work parts lifting 6 Auxiliary drop wheel positioning device Wheel drop station Wheelbase positioning and lifting auxiliary operations

[0052] Furthermore, an intelligent card control management system is constructed to decompose and structure the bogie maintenance process documents, and to display the rail transit maintenance process flow and sequence in a graphical manner.

[0053] Traditional bogie maintenance process documents are mainly paper documents, and the text descriptions may be lengthy and complex, lacking in intuitiveness. For complex process steps, a large amount of text explanation may be required, which is easy to cause misunderstandings, and takes up a large amount of space, with high storage and management costs. The required information cannot be obtained anytime and anywhere, and can only be transmitted and shared within a limited range, making it difficult for multiple people to view it at the same time. The modification and maintenance of the files need to be done manually, which is prone to errors and omissions.

[0054] Constructing an intelligent card control management system, starting from the people (operating personnel), machines (equipment and tools), materials (materials required for assembly), methods (process procedures and operating standards), and environment (on-site operating environment requirements) involved in bogie maintenance, the traditional bogie maintenance process documents are decomposed and structured through the bogie intelligent card control management system, stored in a digital way, and presented in a variety of forms such as text, pictures, animations, and videos. The process and sequence of the entire process are displayed more intuitively and vividly, including each process, operating steps, and inspection links. The operators, operating methods, process parameters, required materials, equipment tools, and quality requirements of each process are described in detail, realizing the full process control of maintenance information, laying the foundation for the subsequent optimization of bogie maintenance process procedures and the transformation from planned maintenance to condition-based maintenance.

[0055] At the same time, the smart card control management system supports the modification and optimization of process content. The system can record the modification history for easy traceability and review, and can achieve real-time sharing among users in different locations to promote team collaboration; it supports simultaneous access and editing by multiple people to improve work efficiency.

[0056] The intelligent card control management system collects equipment data from the frame assembly line after bogie maintenance in real time, realizes real-time monitoring and analysis of equipment status and operation information, and ultimately achieves full life cycle management of the equipment. The system can also be integrated with other management systems to achieve information interoperability and improve the overall management level of the enterprise.

[0057] Smart card control management system, such as Figure 3 As shown, it includes a background management system and a handheld terminal system, adopts a B / S architecture, including: a background management unit and several handheld terminals. The background management unit includes a main server, an industrial computer, and a smart card control terminal, which are connected and data transmitted through the network.

[0058] Specifically, this embodiment places a set of servers in the central computer room and deploys a complete service system. The network topology diagram is as follows: Figure 4 The smart card control terminal in the background management unit provides support for the hardware system and the handheld terminal, and is the core of the smart card control management system. All real-time data of each assembly process, trolley (including battery), and reverse positioner will be displayed on the smart card control terminal.

[0059] The background management unit and the handheld terminal are connected via a network to collect real-time equipment data of the frame assembly line after bogie maintenance, monitor and analyze the equipment status and operation information in real time, and manage the entire life cycle of the assembly line equipment.

[0060] During operation, the smart card control management system generates corresponding assembly tasks on the PC side according to the assembly plan and distributes them to the handheld terminal of the corresponding foreman. After receiving the tasks, the foreman distributes the tasks to the handheld terminals of specific operators in the team through the handheld terminal. The operators perform the operations according to the task reminders on the handheld terminal and fill in the operation process data (such as torque data, operation quality data, etc.) on the handheld terminal, which are finally transmitted back to the PC side of the bogie smart card control system to form a closed-loop management.

[0061] By implementing the workstation-based rhythmic assembly line setting, through the configuration of the above-mentioned intelligent hardware and the supporting intelligent card control system for bogie assembly, the output has been increased from 4 frames per shift to 8 frames, and the information management and control of bogie assembly from planning, process, materials, operations, quality, and billboard display has been enhanced, the assembly production efficiency and quality have been improved, and on-site paperless office operations have been realized, which can provide effective support for the subsequent bogie assembly workshop planning, assembly production process and selection and improvement of tools and equipment.

[0062] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A rail transit maintenance process structured method, characterized in that: The steps include: S1. The frame assembly work of rail transit bogies after overhaul is divided into workstation-based rhythmic divisions, and a workstation-based rhythmic bogie assembly line is established, with each workstation performing operations simultaneously; S2. Build an intelligent card control management system to decompose and structure the bogie maintenance process files, and graphically display the rail transit maintenance process flow and sequence; S3. Adding intelligent equipment for auxiliary production to the bogie assembly line, after the work content of each station is completed, the bogie at the previous station is transferred to the next station, and the operating status and parameter information of key equipment are displayed synchronously, so as to improve the quality and efficiency of the frame assembly after the bogie is overhauled; S4. Collect the maintenance information data of the bogie assembly line in real time, and through the intelligent card control management system, conduct closed-loop control of the entire process of frame assembly after the bogie maintenance, and realize the bogie maintenance process procedures based on condition maintenance.

2. The rail transit maintenance process structured method according to claim 1 is characterized in that: In step S1, a station-based, rhythmic bogie assembly line is established in the following manner: S1.

1. According to the process flow of the frame assembly after the bogie overhaul, the assembly process is modularized and divided into several workstations, each of which completes a specific operation task; S1.

2. Based on the operation time, material delivery time and equipment adjustment time of each process of the frame assembly operation after the bogie overhaul, each assembly process is divided into different workstations according to the length of the operation time, and the operators are arranged at the corresponding workstations, and each workstation performs operations simultaneously.

3. The rail transit maintenance process structured method according to claim 2 is characterized in that: In step S1.1, the frame assembly operation after the bogie is overhauled includes: a traction center body, a traction rod, an anti-roll torsion bar, an axle box spring, a positioning swing arm, a swing arm node, a series of vertical hydraulic shock absorbers, a brake line, a basic brake device, a drop wheel, and an axle box clamp; the positioning swing arm includes an axle box spring; The bogie assembly line workstations obtained by division include: the first reverse position assembly station, the second reverse position assembly station, the flipping station, the normal position assembly station, the buffer station, and the wheel drop station; hardware equipment is configured for each station, and corresponding operators are arranged.

4. The rail transit maintenance process structured method according to claim 3 is characterized by: The first reverse assembly station is used to assemble the bogie axle box spring, positioning arm and arm node, etc.; the second reverse assembly station is used to assemble the bogie traction center body, traction rod, and anti-roll torsion bar; the flipping station flips the frame ±180 degrees through the flipping positioner; the positive assembly station is used to assemble the brake pipeline and the basic brake device; the buffer station is used for the wheel drop frame buffer; The wheel-dropping station is used for bogie wheel-dropping operations and installation of axle box central clamps.

5. The rail transit maintenance process structured method according to claim 3 is characterized in that: In step S2, the rail transit maintenance process flow and sequence are displayed in a graphical manner, including each process, operation steps, inspection links, and descriptions of the operators, operation methods, process parameters, required materials, equipment tools and quality requirements of each process.

6. The rail transit maintenance process structured method according to claim 3 is characterized in that: In step S3, the intelligent equipment for auxiliary production includes: a C-type rotary press, a process transfer vehicle, a platform lifting device, a flip positioner, a power manipulator, and an auxiliary wheel positioning device; The C-type rotary press is arranged at the first reverse assembly station and is used for press-fitting the steel spring pivot node; The process transfer vehicle is configured at the first reverse assembly station, the second reverse assembly station, the flipping station, and the normal assembly station, and is used to carry and transport the carrier of the frame; The platform lifting device is arranged at the first reverse assembly station, the second reverse assembly station, and the normal assembly station, and is used to assemble the working platform and coordinate with the trolley to transport the frame; The flipping and positioning machine is arranged at the flipping station and is used to flip and position the frame. The assisting manipulator is arranged at the first reverse assembly station, the second reverse assembly station, and the normal assembly station, and is used to assist in lifting parts for frame assembly operations; The auxiliary wheel drop positioning device is arranged at the wheel drop station and is used for wheel drop wheelbase positioning and lifting auxiliary operations.

7. The rail transit maintenance process structured method according to claim 6, characterized in that: In step S4, the smart card control management system adopts a B / S architecture, including: a background management unit and several handheld terminals. The background management unit and the handheld terminals are connected via a network to collect equipment data of the frame assembly line after bogie maintenance in real time, monitor and analyze equipment status and operation information in real time, and manage the entire life cycle of the assembly line equipment.

8. The rail transit maintenance process structured method according to claim 7, characterized in that: The background management unit includes a main server, an industrial computer, and a smart card control terminal, which are connected and transmit data through the network; The smart card control terminal collects and displays the real-time data of the trolley and battery status, lift, and flip positioner of each process through the industrial computer, stores it in the main server, and provides instructions to the handheld terminal; The industrial control computer is arranged in a station-based rhythmic bogie assembly line, transmits equipment data between the lines in real time, and controls the operation of each station.

9. The rail transit maintenance process structuring method according to claim 8, characterized in that: In step S4, the whole process of frame assembly after the bogie maintenance is closed-loop controlled, specifically as follows: the smart card control management system generates assembly tasks on the smart card control terminal according to the assembly plan, and distributes them to the handheld terminals of the leaders of each team. After each leader divides the work, the specific work tasks are distributed to the handheld terminals of the corresponding operators. The operators perform the work according to the task reminders of the handheld terminals, and fill in the work process data on the handheld terminals, which are finally transmitted back to the bogie smart card control terminal to form a closed-loop management.

10. A rail transit maintenance process structuring system, used to implement the rail transit maintenance process structuring method according to any one of claims 1 to 9, characterized in that: include: Bogie assembly lines, intelligent equipment for auxiliary production, and intelligent card control management systems; The bogie assembly line divides the frame assembly work after the rail transit bogie is overhauled into a station-based rhythmic division, forming a first reverse assembly station, a second reverse assembly station, a flip station, a normal assembly station, a buffer station, and a wheel drop station; The intelligent card control management system decomposes and structures the bogie maintenance process documents, graphically displays the rail transit maintenance process flow and sequence, collects equipment data of the bogie frame assembly line after maintenance in real time, monitors and analyzes equipment status and operation information in real time, and manages the entire process of assembly line equipment and maintenance information; The intelligent equipment for auxiliary production allows the user to transfer the bogie from the previous workstation to the next workstation, and simultaneously display the operating status and parameter information of key equipment, thereby improving the quality and efficiency of bogie assembly.

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