A real-time online verification device and method for a rail vehicle weighing test bench

Abstract

The present invention belongs to the technical field of rail transit equipment. In order to solve the problem that the current verification method of vehicle weighing test bench cannot simulate the actual use state and cannot realize the non-stop production verification, a real-time online verification device and method for rail vehicle weighing test bench is provided. Among them, the device includes a force sensor, a weighing rail base and a wheel limit device; the upper surface of the weighing rail base is provided with a groove, and the shape of the groove matches the shape of the force sensor; the force sensor is assembled in the groove during real-time online verification; the wheel limit device is symmetrically fixed on the upper surface of the weighing rail base and is located on both sides of the force sensor; when the rail vehicle load is applied, the force sensor and the rail vehicle weighing test bench both generate feedback force values ​​at the same time, and then the real-time online verification of the rail vehicle weighing test bench is realized by comparing the two feedback force values. It can realize the non-stop production online verification and improve the verification efficiency of the weighing platform.

Description

Technical Field

[0001] The present invention belongs to the technical field of rail transit equipment, and in particular relates to a real-time online verification device and method for a rail vehicle weighing test bench. Background Art

[0002] The statements in this section merely provide background information related to the present invention and do not necessarily constitute prior art.

[0003] The rail vehicle weighing test bench is a railway-specific measuring device used to measure the wheel weight, axle weight and total weight of various rail vehicles. Among them, the total weight and weight balance of the vehicle directly affect the adhesion and traction of the vehicle and the braking performance of the vehicle, which in turn affects the safety, stability and comfort of the vehicle operation. Therefore, the accuracy and reliability of the rail vehicle weighing test bench is an important guarantee for the reliable adjustment of vehicle weight balance and the controllable total weight value.

[0004] Usually, the rail vehicle weighing test bench needs to be inspected on site in the following cases, for example, when the on-site personnel have doubts about the measurement data of the rail vehicle weighing test bench, when the rail vehicle weighing test bench changes its range, or when it undergoes fault repair. At present, the verification of the rail vehicle weighing test bench is based on the existing verification procedures, which measures the weighing units one by one by loading weights or force sensors with force application tools. This has the following problems:

[0005] (1) During the calibration process, the rail vehicle weighing test bench must be shut down, and a workstation must be vacated to install the calibration tooling for on-site calibration, which affects the normal production rhythm of rail vehicles;

[0006] (2) Each time calibration is performed, at least a set number of work units must be calibrated one by one to confirm the cause of the problem, and the calibration tooling must be manually disassembled several times. This puts a greater workload on the measurement personnel, affects the work efficiency of the rail vehicle production line, and increases the cost of using the rail vehicle weighing test bench. Summary of the invention

[0007] In order to solve the technical problem that the current calibration method of a vehicle weighing test bench cannot simulate the actual use status and cannot realize verification without stopping production, the present invention provides a real-time online verification device and method for a rail vehicle weighing test bench, which can realize online verification without stopping production, improve the verification efficiency of the weighing bench, reduce labor and time costs, and reduce the impact of verification on production rhythm.

[0008] In order to achieve the above object, the present invention adopts the following technical solution:

[0009] A first aspect of the present invention provides a real-time online verification device for a rail vehicle weighing test bench.

[0010] A real-time online verification device for a rail vehicle weighing test bench, comprising a force sensor, a weighing rail base and a wheel limit device;

[0011] The upper surface of the weighing rail base is provided with a groove, the shape of which matches the shape of the force sensor; during online verification, the force sensor is assembled in the groove;

[0012] The wheel limiting device is symmetrically fixed on the upper surface of the weighing rail base and is located on both sides of the force sensor; the upper surface of the wheel limiting device is in contact with the wheel tread, and the shape matches the wheel tread;

[0013] When the rail vehicle load is applied, the force sensor and the rail vehicle weighing test bench both generate feedback force values ​​simultaneously, and then the real-time online non-stop verification of the rail vehicle weighing test bench is achieved by comparing the two feedback force values.

[0014] As an implementation mode, the force sensor is a convex structure with a high middle and low ends, and the convex portion is a working surface.

[0015] As an implementation manner, the working surface of the force sensor is composed of an upper arc surface and rounded arc surfaces connected to two side edges thereof.

[0016] As an implementation manner, the contact mode between the working surface of the force sensor and the wheel tread is point contact.

[0017] As an implementation manner, the groove is provided with an oblique slope, and the oblique slope matches the shape of the outer surface of the force sensor.

[0018] As an implementation mode, during online verification, the force sensor is assembled in the groove by means of a combination of a positioning hole and an inclined slope.

[0019] As an implementation mode, the wheel limiting device includes a wedge-shaped block and a fixed block at the bottom thereof, wherein the fixed block is clamped in a limiting hole, and the limiting hole is provided on the weighing rail base and has a shape matching that of the fixed block.

[0020] As an implementation mode, the real-time online verification device of the rail vehicle weighing test bench further includes a sensor replacement tool; during non-online verification, the sensor replacement tool is used to replace the force sensor.

[0021] As an implementation mode, the real-time online verification device of the rail vehicle weighing test bench further includes a mounting ring, and the mounting ring is arranged on the weighing rail base.

[0022] As an implementation mode, the real-time online verification device of the rail vehicle weighing test bench also includes a data transmission module, one end of which communicates with the force sensor and the rail vehicle weighing test bench respectively, and the other end communicates with the remote monitoring terminal.

[0023] The second aspect of the present invention provides an online verification method based on the real-time online verification device of the rail vehicle weighing test bench.

[0024] An online verification method based on the real-time online verification device of the rail vehicle weighing test bench comprises:

[0025] When the rail vehicle weighing test bench needs real-time online verification, the sensor replacement tooling is replaced with a force sensor;

[0026] When the force sensor is fixed, both the force sensor and the rail vehicle weighing test bench generate feedback force values ​​for the applied rail vehicle load at the same time;

[0027] The difference between the feedback force values ​​of the force sensor and the rail vehicle weighing test bench is compared. If the difference is within the set range, the rail vehicle weighing test bench is judged to be qualified; otherwise, a warning message of unqualified verification is output.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] (1) The real-time online verification device for the rail vehicle weighing test bench of the present invention is based on the premise of not destroying the main structure of the weighing platform, not affecting the normal production rhythm, and not making large-scale changes. It is based on the force sensor and its supporting tooling, so that it is consistent with the original weighing rail component in terms of appearance and size matching. On the basis of replacing the original function, the entire verification process will not cause any impact on the on-site production except for replacing the sensor before the weighing test begins. The whole vehicle can be directly used to realize the online verification function without stopping production, overcoming the problem of shutdown calibration, realizing the reliability and value traceability accuracy during the use of the weighing platform, solving the pain points and difficulties of the weighing platform verification, and thus achieving the effect of online verification of the weighing platform without stopping production and real-time monitoring of measurement data, improving the efficiency of weighing platform verification, reducing labor and time costs, and reducing the impact of verification on the production rhythm.

[0030] (2) The present invention also designs a sensor replacement tool. When the load cell is not checked online, the load cell is replaced with the sensor replacement tool to prevent fatigue of the load cell. This can realize the normal daily use of the rail vehicle weighing test bench and can also realize online verification without stopping production, thereby improving the verification efficiency of the weighing bench.

[0031] (3) The present invention generates feedback force values ​​for the applied rail vehicle load based on both the force sensor and the rail vehicle weighing test bench, and subtracts the two to obtain the corresponding difference. Based on the comparison between the difference and the set range, it is determined whether the rail vehicle weighing test bench has passed the inspection, thereby reducing labor and time costs and reducing the impact of the inspection on the production cycle.

[0032] Advantages of additional aspects of the present invention will be given in part in the following description, and in part will become obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The accompanying drawings in the specification, which constitute a part of the present invention, are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations on the present invention.

[0034] Figure 1 2 is a schematic structural diagram of a real-time online verification device for a rail vehicle weighing test bench according to an embodiment of the present invention;

[0035] Figure 2 is a schematic diagram of the structure of a weighing rail base according to an embodiment of the present invention;

[0036] Figure 3 is a schematic structural diagram of a force sensor according to an embodiment of the present invention;

[0037] Figure 4 is a schematic diagram of the assembly of a force sensor according to an embodiment of the present invention;

[0038] Figure 5 Schematic diagram of the contact point between the working surface of the force sensor and the wheel tread according to an embodiment of the present invention;

[0039] Figure 6 Schematic diagram of the stress state of a single-side wheel after it is raised in an embodiment of the present invention;

[0040] Figure 7 Schematic diagram of the force state of the load-bearing surface of the force sensor and the wheel tread in an embodiment of the present invention;

[0041] Figure 8 is a schematic structural diagram of a sensor replacement tooling according to an embodiment of the present invention;

[0042] Fig. 9 is a schematic structural diagram of a wheel limiting device according to an embodiment of the present invention;

[0043] Fig.10 It is a working state diagram of the real-time online verification device of the rail vehicle weighing test bench according to an embodiment of the present invention. DETAILED DESCRIPTION

[0044] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0045] It should be noted that the following detailed descriptions are all illustrative and intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which the present invention belongs.

[0046] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprising" and / or "including" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0047] In one or more embodiments, Figure 1 As shown, a real-time online verification device for a rail vehicle weighing test bench is provided, which includes a force sensor 1, a weighing rail base 2 and a wheel limiting device 3; the upper surface of the weighing rail base 2 is provided with a groove, and the shape of the groove matches the shape of the force sensor 1;

[0048] During online verification, the force sensor 1 is assembled in the groove; the wheel stopper is symmetrically fixed on the upper surface of the weighing rail base 2 and is located on both sides of the force sensor 1; the upper surface of the wheel stopper 3 contacts the wheel tread, and the shape matches the wheel tread;

[0049] When the rail vehicle load is applied, the force sensor and the rail vehicle weighing test bench both generate feedback force values ​​simultaneously, and then the real-time online non-stop verification of the rail vehicle weighing test bench is achieved by comparing the two feedback force values.

[0050] In the specific implementation process, Figure 2 As shown, the outer dimensions and structural strength of the weighing rail base 2 are completely consistent with those of the existing weighing unit, and can directly replace the existing weighing unit without affecting the daily use of the weighing platform after replacement.

[0051] In some specific embodiments, the groove is provided with an inclined slope, and the inclined slope matches the shape of the outer surface of the force sensor. During online verification, the force sensor 1 is assembled in the groove by a combination of a positioning hole and an inclined slope, such as Figure 4 This embodiment uses a positioning hole and an inclined slope combination assembly method to make the force sensor 1 automatically slide down and cling to the inner wall of the weighing rail under the action of the inclined surface and its own gravity, and then accurately position it through the positioning hole.

[0052] In this embodiment, the force sensor is a special force sensor, and its technical indicators are: range: 15t; accuracy: ±0.1% FS; working voltage: 10V; output resistance: 700Ω; output interface: 9-core rectangular socket.

[0053] This special force sensor adopts a mature bridge structure. The sensor power supply voltage is 10V. The output millivolt voltage signal is transmitted to the back-end signal conditioning module through the test cable for conditioning and display. The sensor is sealed by laser welding as a whole, with high precision, good consistency, and easy installation and maintenance. The output interface is a nine-core rectangular socket with a test cable for easy on-site installation and use. It has a simple structure, no moving parts, simple maintenance, and a long service life. It can be easily fully sealed, can work reliably and stably in complex environments, can realize automatic compensation according to different environments, and has good environmental adaptability. Under laboratory conditions, it is expected to meet the 10-year life requirement.

[0054] The main body of the special force sensor of this embodiment is made of high-strength stainless steel forgings, which are inspected after forging and subjected to a reasonable heat treatment process to ensure the strength of the overall structure and the deformation consistency of the elastic sensitive area.

[0055] Taking the hardness of domestic wheel tread as HBW 250-280 as an example, the converted Rockwell hardness is about HRC 25-29.5. The hardness of imported wheel tread is HBW 360, which is HRC 39 when converted to Rockwell hardness. After the special force sensor is heat treated according to the prescribed material heat treatment specifications, the specified Rockwell hardness value is HRC ≥ 39. The actual measured value is greater than HRC 45, which is much greater than the wheel hardness. Therefore, multiple weighing will not cause indentation damage to the sensor surface.

[0056] According to the mechanical properties table of rail materials specified in GB / T 2585-2007 "Hot-rolled rails for railways" (see Table 1), the mechanical properties of the sensor materials after heat treatment in this solution are much better than those of hot-rolled rail materials. At the same time, the operating condition of the sensor is a static condition, which is much better than the railway rail condition. Therefore, the safe use of the sensor can be guaranteed under the premise of reasonable design.

[0057] Table 1 Mechanical properties of rail materials

[0058]

[0059]

[0060] In this embodiment, if Figure 3 As shown, the force sensor is a convex structure with a high middle and low ends, and the convex part is the working surface. The contact mode between the working surface of the force sensor 1 and the wheel tread 5 is point contact 6. Figure 5 shown.

[0061] Since the wheel set shape of the vehicle is in accordance with the LM and JM series locomotive wheel rim tread dimension drawing in TB / T 449-2016 "Rolling stock wheel rim tread shape", in order to ensure the effective and safe load-bearing of the weighing sensor during measurement, the top load-bearing surface of the force sensor is designed with reference to the 50kg / m rail head size in GB / T 2585-2007 "Hot-rolled rails for railways".

[0062] Specifically, the working surface of the force sensor is composed of an upper arc surface and fillet arc surfaces connected to two side edges thereof, wherein the radius of the upper arc surface is greater than the radius of the fillet arc surface.

[0063] When designing the sensor bearing surface, the contact point, safety and other factors are taken into consideration. For example, the top arc corner still uses the design size of R13, and the upper arc uses the size of R400.

[0064] In some specific embodiments, the weighing rail and the rail vehicle weighing test bench are designed to be connected by a plurality of 8.8-grade M12 bolts. To verify the strength of the bolt connection, an extreme working condition is taken as an example, that is, the wheel on one side is raised by 5 mm for strength verification. The stress state after the wheel on one side is raised is shown as follows: Figure 6 shown.

[0065] The lateral installation distance of the force sensor is 1480mm, the wheel on one side is raised by 5mm, the angle between the axle and the horizontal plane is θ1=Arctan(5 / 1480)≈0.2°, and the angle between the tangent line of the contact point between the top bearing surface of the force sensor and the wheelset tread and the horizontal plane is θ2=2.16°. Figure 7 As shown. The horizontal force F on the force sensor is: F1+F2. Combined with the bolt cross-sectional area, yield strength and preload calculation, it is obtained that the equivalent of the dangerous section of the bolt in the limit case is σe=457.5MPa, which is less than the yield strength σs=640MPa, and the safety factor is greater than 1.4. Therefore, the safety of the verification device of the present invention can meet the requirements.

[0066] In addition, when the vehicle enters the weighing platform, the vehicle moves in the longitudinal direction, which is a fully open state. The raised part of the force sensor is the working surface, and the longitudinal length can be set to 84mm. Since the weighing platform lifts the entire vehicle when it is working, the vehicle will completely leave the track. When starting, the vehicle will have a certain shaking, and the size of this shaking is irregular. Therefore, from the perspective of safety, in order to prevent the vehicle from slipping longitudinally, the present invention adds a wheel limit device to the working surface of the weighing rail, such as Fig. 9Considering the working surface size of the force sensor and the maximum distance that the wheel may slip longitudinally, for example, the wheel limit device is set at the maximum distance of 38mm offset from the center of the sensor, and the stress state of the wheel limit device is simulated and analyzed to ensure that it meets the use requirements.

[0067] In some optional embodiments, such as Figure 8 As shown, the wheel limiting device includes a wedge-shaped block and a fixed block at the bottom thereof, wherein the fixed block is clamped in a limiting hole, and the limiting hole is formed on the weighing rail base and has a shape matching that of the fixed block.

[0068] The shape of the fixed block can be set according to actual conditions, for example, it can be set to a cylindrical or cubic shape, etc., which will not be described in detail here.

[0069] In other embodiments, the real-time online verification device of the rail vehicle weighing test bench further includes a sensor replacement tool; during non-online verification, the sensor replacement tool is used to replace the force sensor. In order to prevent sensor fatigue, the sensor replacement tool is processed simultaneously. In daily on-site work, the replacement tool is installed in the weighing rail base, and the weighing work can be carried out normally.

[0070] In one or more embodiments, the real-time online verification device for the rail vehicle weighing test bench further comprises a mounting ring 4, and the mounting ring 4 is arranged on the weighing rail base 2. In this way, the mounting ring can facilitate the rapid installation of the rail vehicle weighing test bench.

[0071] In other embodiments, the real-time online verification device of the rail vehicle weighing test bench further includes a data transmission module, one end of which communicates with the force sensor and the rail vehicle weighing test bench respectively, and the other end communicates with the remote monitoring terminal.

[0072] The data transmission module here can be a wireless transmission module, so that the force measurement data of the force sensor and the rail vehicle weighing test bench can be transmitted to a remote end by wireless transmission.

[0073] In other embodiments, the data transmission module may also be a wired transmission module, and those skilled in the art may make a specific selection based on actual conditions, which will not be described in detail here.

[0074] In one or more embodiments, an online verification method based on the real-time online verification device of the rail vehicle weighing test bench includes:

[0075] Step 1: When the rail vehicle weighing test bench needs real-time online verification, the sensor replacement tooling is replaced with a force sensor;

[0076] Step 2: After the force sensor is fixed, both the force sensor and the rail vehicle weighing test bench generate feedback force values ​​for the applied rail vehicle load, such as Fig.10 As shown;

[0077] Step 3: Compare the difference between the feedback force values ​​of the force sensor and the rail vehicle weighing test bench. If the difference is within the set range, it is determined that the rail vehicle weighing test bench has passed the inspection; otherwise, an early warning message indicating that the inspection has failed is output.

[0078] The verification device of the present invention can display the force value through the on-site meter, and can also monitor the verification results remotely online through the local area network. Usually the weighing platform has several (for example, 8) weighing units, so the present invention can copy several sets of verification devices and install them in each weighing unit. Except for replacing the sensor before the weighing test, the entire verification process will not cause any impact on the on-site production, and the whole vehicle weighing verification can be carried out directly, realizing online verification without stopping production, improving the verification efficiency of the weighing platform, reducing labor and time costs, and reducing the impact of verification on the production rhythm.

[0079] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A real-time online verification device for a rail vehicle weighing test bench, characterized in that: It includes a force sensor, a weighing rail base and a wheel limit device; The upper surface of the weighing rail base is provided with a groove, the shape of which matches the shape of the force sensor; during online verification, the force sensor is assembled in the groove; The wheel limiting device is symmetrically fixed on the upper surface of the weighing rail base and is located on both sides of the force sensor; the upper surface of the wheel limiting device is in contact with the wheel tread, and the shape matches the wheel tread; When the rail vehicle load is applied, the force sensor and the rail vehicle weighing test bench both generate feedback force values ​​simultaneously, and then the real-time online non-stop verification of the rail vehicle weighing test bench is achieved by comparing the two feedback force values.

2. The real-time online verification device for the rail vehicle weighing test bench according to claim 1, characterized in that: The force sensor is a convex structure with a high middle and low ends, and the convex part is the working surface.

3. The real-time online verification device for the rail vehicle weighing test bench according to claim 2, characterized in that: The working surface of the force sensor is composed of an upper arc surface and rounded arc surfaces connected to two side edges thereof.

4. The real-time online verification device for the rail vehicle weighing test bench according to claim 2 or 3, characterized in that: The contact mode between the working surface of the force sensor and the wheel tread is point contact.

5. The real-time online verification device for a rail vehicle weighing test bench according to claim 1, characterized in that: The groove is provided with an oblique slope, and the oblique slope matches the shape of the outer surface of the force sensor.

6. The real-time online verification device for the rail vehicle weighing test bench according to claim 5, characterized in that: During online verification, the force sensor is assembled in the groove by means of a combination of a positioning hole and an inclined slope.

7. The real-time online verification device for a rail vehicle weighing test bench according to claim 1, characterized in that: The wheel limiting device comprises a wedge-shaped block and a fixing block at the bottom thereof, wherein the fixing block is clamped in a limiting hole, and the limiting hole is formed on the weighing rail base and has a shape matching that of the fixing block.

8. The real-time online verification device for a rail vehicle weighing test bench according to claim 1, characterized in that: The real-time online verification device of the rail vehicle weighing test bench also includes a sensor replacement tool; during non-online verification, the sensor replacement tool is used to replace the force sensor.

9. The real-time online verification device for a rail vehicle weighing test bench according to claim 1, characterized in that: The real-time online verification device of the rail vehicle weighing test bench also includes a mounting ring, which is arranged on the weighing rail base; Or a real-time online verification device for a rail vehicle weighing test bench, further comprising a data transmission module, one end of which communicates with the force sensor and the rail vehicle weighing test bench respectively, and the other end of which communicates with a remote monitoring terminal.

10. An online verification method based on the real-time online verification device of a rail vehicle weighing test bench according to any one of claims 1 to 9, characterized in that: include: When the rail vehicle weighing test bench needs real-time online verification, the sensor replacement tooling is replaced with a force sensor; When the force sensor is fixed, both the force sensor and the rail vehicle weighing test bench generate feedback force values ​​for the applied rail vehicle load at the same time; Compare the difference between the feedback force values ​​of the force sensor and the rail vehicle weighing test bench. If the difference is within the set range, it is determined that the rail vehicle weighing test bench has passed the inspection; Otherwise, a warning message indicating that the verification failed is output.

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