Empty vehicle low-speed coupling and abnormal coupling prevention detection system and method
By designing a low-speed connecting hook detection system for empty vehicles and anti-abnormal hooks, the sensor and PLC control system are used to realize low-speed connecting hooks and hook status monitoring of empty vehicles, the safety problems caused by excessive impact of connecting hooks and abnormal hooks in traditional systems are solved, and the equipment life and the safety of the railway system are improved.
Patent Information
- Application Number
- CN202510170740.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-17
- Publication Date
- 2025-05-09
AI Technical Summary
When the traditional overturning machine system is connected at low speed, the impact will be too large and the equipment life will be affected, and safety accidents will be caused by abnormal hook connections.
A system for detecting low-speed connecting and anti-abnormal hooks for detection of empty vehicles is designed, including shunting devices, car cabin detection devices, empty vehicle connecting and detection devices and PLC control systems. Through the coordination of the radial sensor and the adjustable background suppression straight-reverse sensor, the empty vehicle is connected at a low speed, and the hook state is detected in real time when the shunting device returns to its original position to issue an alarm signal.
It effectively reduces the impact of empty vehicles when they are connected, extends the service life of the equipment, and improves the safety and reliability of the railway system through real-time monitoring and alarm, and avoids derailment accidents caused by hook failure.
Smart Images
Figure CN119953414A_ABST
Abstract
Description
Technical Field
[0001] The present invention belongs to the field of car dumper shunting systems, and in particular relates to an empty car low-speed coupling and abnormal coupling prevention detection system and method applied to a railway car dumper system. Background Art
[0002] The railway car tipper unloading system is a key equipment in the field of bulk material handling and loading and unloading. After the unloading is completed, the empty car is usually moved to the empty car line through the car transfer platform, and then the empty car shunting machine pushes it out of the car transfer platform to the designated position of the empty car line for assembly. Moreover, in the traditional car tipper system, when pushing to the empty car line for assembly, the two empty cars are usually connected at the normal speed of the shunting machine, which is generally 0.7m / s~0.8m / s, which often causes a violent impact and affects the service life of the railway carriage and the shunting machine arm, thereby affecting the safety of railway operation.
[0003] After positioning the empty car, the empty car shunting machine automatically unhooks and returns to its original position. However, the vehicle coupler fails to unhook due to long-term use or the inertia of parking, causing a "dead hook" problem. At this time, the car transfer platform has returned to the heavy car line, and the empty car shunting machine returns with the empty car, causing serious accidents such as vehicle derailment.
[0004] In the existing car tipper production process, the coupling status is reflected by detecting the open signal of the empty car shunting machine's hook tongue. However, even if the hook tongue is opened in time after long-term use, abnormal coupling may occur due to ectopic deformation of the hook tongue. Some sites also monitor and observe abnormal coupling problems through monitoring by on-site workers and central control room operators. As the car tipper system usually runs continuously, operators are prone to negligence at night, posing a greater safety hazard. Summary of the invention
[0005] The present invention aims at solving the above problems and provides an empty car low-speed coupling and anti-abnormal coupling detection system and method applied to a railway car tipping machine system to solve the problems in the prior art of excessive coupling impact affecting equipment life and abnormal coupling causing safety accidents.
[0006] In order to achieve the above-mentioned purpose of the present invention, the present invention adopts the following technical scheme, an empty car low-speed coupling and anti-abnormal coupling detection system of the present invention is characterized in that it includes a shunting device, a carriage detection device, an empty car coupling detection device and a PLC control system; the shunting device includes a shunting locomotive body with a traveling transmission mechanism, a detection mechanism for detecting its own position is arranged on the shunting locomotive body, a big arm mechanism is arranged on one side of the shunting locomotive body, and a hook device and a lifting and pinning device are arranged at the end of the big arm mechanism; the carriage detection device includes a switch fixing frame fixedly arranged on the empty car entry side of the railway empty car line, the switch fixing frame is provided with a beam sensor, and the railway empty car line is located between the beam ranges of the beam sensor; the empty car coupling detection device is arranged on the shunting locomotive body, the empty car coupling detection device includes a switch fixing frame arranged on the shunting locomotive body, and an adjustable background suppression type direct-reverse sensor is arranged on the switch fixing frame; the sensing direction of the adjustable background suppression type direct-reverse sensor corresponds to the empty car entry side of the railway empty car line.
[0007] Preferably, the empty car coupling detection device is arranged on the boom mechanism of the shunting device.
[0008] Preferably, the carriage detection device is arranged at a predetermined position for coupling two empty cars on the empty car entry side of the empty car line.
[0009] Preferably, after receiving the feedback signal from the carriage detection device, the PLC control system controls the shunting device to slow down from a normal speed to a speed required for coupling, and performs low-speed coupling.
[0010] Preferably, the PLC control system delays a set time while the shunting device is returning to its original position, and after receiving a signal from the empty car coupling detection device and the car detection device that a car coupling exists, sends an alarm signal to a host computer.
[0011] The present invention uses the empty car coupling and anti-hookup detection method of the vehicle low-speed coupling and anti-abnormal coupling detection system, which is characterized by comprising the following steps: Step 1: Set the detection distance of the adjustable background suppression type direct-reverse sensor to be 1 meter in front of the coupling device to feedback a normally open switch signal.
[0012] Step 2: Set the transmitting end and receiving end of the beam sensor to be arranged at the predetermined empty car line empty car assembly position, 1 meter away from the rear of the car along the railway line close to the car transfer platform, and provide a normally closed switch signal after alignment.
[0013] Step 3: The shunting device pushes the empty car out of the transfer platform at normal speed. After the empty car moves to the position described in step 2, the through-beam sensor is blocked by the vehicle, the normally closed signal is disconnected, and the PLC sends a deceleration command to the shunting device to achieve low-speed coupling of the empty car.
[0014] Step 4: After the empty car arrives at the empty car line assembly position, the shunting device lifts the pin and removes the hook to return to the original position. On the way back to the original position, when it is unhooked and returns normally, the empty car coupling detection device is away from the empty car and no signal is sent. If the shunting device fails to unhook from the empty car and an abnormal coupling failure occurs, the empty car is always within the range of the empty car coupling detection device and continues to send signals to the PLC. The PLC sends an alarm signal to the central control after continuously receiving the signal from the empty car coupling detection device for more than 10 seconds.
[0015] The beneficial effects of the present invention are as follows: 1. By setting up a car detection device at a predetermined assembly position on the empty car line, the position where the car is about to be coupled can be more accurately reflected, which can ensure low-speed coupling and avoid causing premature deceleration and long low-speed running time to affect the efficiency of shunting operations.
[0016] 2. By setting up the empty car coupling detection device on the boom device, it is more reliable to obtain whether the coupler is abnormally coupled with the open car when returning, avoiding the false signal of uncoupling caused by the "dead hook" problem. It has higher reliability, simple method and low cost. BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Figure 1 The figure is a schematic diagram of the plan layout of an empty vehicle coupling and anti-hook detection system of the present invention.
[0018] Figure 2 The present invention is a side view of the arrangement of a carriage detection device of an empty car coupling and anti-hook detection system.
[0019] Figure 3 The present invention provides an axonometric view of the carriage detection device layout of an empty car coupling and anti-hook detection system.
[0020] Figure 4 The present invention is a schematic diagram of the arrangement of an empty car coupling detection device of an empty car coupling and anti-hook detection system.
[0021] Figure 5 It is a partial view of a coupler device of an empty car coupling and anti-coupling detection system of the present invention.
[0022] Figure 6 It is an axonometric view of a coupler device of an empty car coupling and anti-coupling detection system of the present invention.
[0023] In the figure, 1 is a shunting device, 2 is a carriage detection device, 3 is an empty car coupling detection device, 4 is a PLC control system, 11 is a shunting locomotive body, 12 is a travel transmission mechanism, 13 is a detection mechanism, 14 is a boom mechanism, 15 is a coupler device, 16 is a lifting and pinning device, 21 is a switch fixing frame, 22 is a through-beam sensor, 31 is a switch fixing frame, and 32 is an adjustable background suppression type direct-reflective sensor. DETAILED DESCRIPTION
[0024] The present invention comprises a shunting device 1, a carriage detection device 2, an empty car coupling detection device 3 and a PLC control system 4; the shunting device 1 comprises a shunting locomotive body 11 with a travel transmission mechanism 12, a detection mechanism 13 for detecting its own position is arranged on the shunting locomotive body 11, a large arm mechanism 14 is arranged on one side of the shunting locomotive body 11, and a coupling device 15 and a lifting and pinning device 16 are arranged at the end of the large arm mechanism 14; the carriage detection device 2 comprises a first switch fixing frame 21 fixedly arranged on the empty car entry side of the railway empty car line A first switch fixed frame 21 is provided with a through-beam sensor 22, and the railway empty car line is located within the through-beam range of the through-beam sensor 22; the empty car coupling detection device 3 is provided on the shunting locomotive body 11, and the empty car coupling detection device 3 includes a second switch fixed frame 31 provided on the shunting locomotive body 11, and an adjustable background suppression type direct-reverse sensor 32 is provided on the second switch fixed frame 31; the sensing direction of the adjustable background suppression type direct-reverse sensor 32 corresponds to the empty car entry side of the railway empty car line.
[0025] Through the overall design of the shunting device 1, the carriage detection device 2, the empty car coupling detection device 3 and the PLC control system 4, the empty car coupling at low speed can be accurately achieved, the severe impact between the vehicle and the shunting locomotive can be avoided, the service life of the vehicle and equipment can be increased, and the coupling status can be monitored in real time to improve the safety and reliability of the railway system.
[0026] The empty car coupling detection device 3 is arranged on the boom mechanism 14 of the shunting device 1 .
[0027] The empty car coupling detection device 3 is arranged on the boom mechanism 14 of the shunting device 1, so that the coupling detection can be performed closer to the coupling position, thereby improving the accuracy and response speed of the coupling status detection, and effectively avoiding coupling abnormalities caused by the "dead hook" problem.
[0028] The carriage detection device 2 is arranged at a predetermined position for coupling two empty carriages on the empty carriage line side where an empty carriage enters.
[0029] By setting the carriage detection device 2 at the predetermined position for coupling two carriages on the empty line, the deceleration control command of the shunting device 1 can be accurately triggered to avoid efficiency reduction or coupling impact problems caused by deceleration too early or too late, and achieve precise low-speed coupling.
[0030] After receiving the feedback signal from the carriage detection device 2, the PLC control system 4 controls the shunting device 1 to decelerate from the normal speed to the speed required for coupling, and performs low-speed coupling.
[0031] The PLC control system 4 accurately controls the shunting device 1 to decelerate to a speed suitable for coupling according to the signal fed back by the carriage detection device 2, ensuring a smooth coupling process, reducing the mechanical impact between the vehicle and the shunting locomotive, and improving the stability of equipment operation and coupling efficiency.
[0032] The PLC control system 4 delays a set time when the shunting device 1 is returning to its original position, and after receiving a signal from the empty car coupling detection device 3 and the car detection device 2 that a car coupling exists, sends an alarm signal to the upper computer.
[0033] When the shunting device 1 is returning to its original position, the PLC control system 4 can detect coupling anomalies in time and send an alarm signal to the upper computer through delayed detection and combining the signals of the carriage detection device 2 and the empty car coupling detection device 3, so as to prevent derailment accidents caused by coupling failures and further improve system safety.
[0034] The present invention uses the empty car coupling and anti-hookup detection method of the vehicle low-speed coupling and anti-abnormal coupling detection system, which is characterized by comprising the following steps: Step 1: Set the detection distance of the adjustable background suppression direct-reverse sensor 32 to 1 meter in front of the coupling device 15 to feedback a normally open switch signal.
[0035] Step 2: Set the transmitting end and receiving end of the beam sensor 22 to be arranged at the predetermined empty car line empty car assembly position, 1 meter away from the rear of the car along the railway line close to the car transfer platform, and provide a normally closed switch signal after alignment.
[0036] Step 3: The shunting device 1 pushes the empty car out of the transfer platform at normal speed. After the empty car moves to the position described in step 2, the through-beam sensor 22 is blocked by the vehicle, the normally closed signal is disconnected, and the PLC sends a deceleration command to the shunting device 1 to achieve low-speed coupling of the empty car.
[0037] Step 4: After the empty car arrives at the empty car line assembly position, the shunting device 1 lifts the pin and removes the hook to return to the original position. On the way back to the original position, when it is unhooked and returns normally, the empty car coupling detection device 3 is away from the empty car and no signal is sent. If the shunting device 1 fails to unhook from the empty car and an abnormal coupling failure occurs, the empty car is always within the range of the empty car coupling detection device 3 and continues to send signals to the PLC. The PLC sends an alarm signal to the central control after continuously receiving the signal sent by the empty car coupling detection device 3 for more than 10 seconds.
[0038] Through specific steps, precise control of empty car low-speed coupling and hook detection can be achieved, which can not only reduce the impact of coupling impact on equipment, but also monitor the coupling status in real time and issue an alarm to ensure the safety and efficiency of the operation process. At the same time, the system design method is simple, low-cost, and has wide practical application value.
[0039] Example: Figures 1 to 6The system includes a shunting device 1, a carriage detection device 2, an empty car coupling detection device 3, and a PLC control system 4. The shunting device 1 is mainly composed of a shunting locomotive body 11, a travel transmission mechanism 12, a position detection mechanism 13, a boom mechanism 14, a coupler device 15, and a lifting and pinning device 16. The travel transmission mechanism 12 and the position detection mechanism 13 are arranged on the shunting locomotive body 11, the boom mechanism 14 is bolted to the side of the shunting locomotive body 11, the coupler device 15 and the lifting and pinning device 16 are arranged at the end of the boom mechanism 14 for pushing an empty car, and the carriage detection device 2 is mainly composed of a switch fixing frame 21 and a beam sensor 22. The through-beam sensor 22 is arranged near the empty car line assembly position through the switch fixing frame 21. The empty car coupling detection device 3 is mainly composed of a switch fixing frame 31 and an adjustable background suppression type direct-reverse sensor 32. The adjustable background suppression type direct-reverse sensor 32 is arranged on the arm mechanism 14 through the switch fixing frame 31, next to the coupler device 15. The position detection mechanism 13 has an encoder inside, which is used to detect the position of the shunting device 1 itself.
[0040] See also Figure 1 The method of the system includes the following steps: Step 1: Set the detection distance of the adjustable background suppression type direct-reverse sensor 32 to 1 meter in front of the coupler device 15 to feedback a normally open switch signal.
[0041] Step 2: Set the transmitting end and receiving end of the beam sensor 22 to be arranged at the predetermined empty car line empty car assembly position, 1 meter away from the rear of the car along the railway line close to the car transfer platform, and provide a normally closed switch signal after alignment.
[0042] Step 3: The shunting device 1 pushes the empty car out of the transfer platform at normal speed. After the empty car moves to the position described in step 2, the through-beam sensor 22 is blocked by the vehicle, the normally closed signal is disconnected, and the PLC sends a deceleration command to the shunting device 1 to achieve low-speed coupling of the empty car.
[0043] Step 4: After the empty car arrives at the empty car line assembly position, the shunting device 1 lifts the pin and removes the hook to return to the original position. On the way back to the original position, when it is unhooked and returns normally, the empty car coupling detection device 3 is away from the empty car and no signal is sent. If the shunting device 1 fails to unhook from the empty car and an abnormal coupling failure occurs, the empty car is always within the range of the empty car coupling detection device 3 and continues to send signals to the PLC. The PLC sends an alarm signal to the central control after continuously receiving the signal sent by the empty car coupling detection device 3 for more than 10 seconds.
[0044] In summary, the present invention realizes automatic deceleration and coupling of empty vehicles when coupling empty vehicles, thereby increasing the service life of vehicles and shunting device 1, and having high safety and reliability. When shunting device 1 returns to its original position, the coupling state of the vehicle coupler is constantly detected, and an alarm is issued when a coupling abnormality occurs, thereby avoiding derailment accidents and improving system safety.
[0045] It can be understood that the above specific description of the present invention is only used to illustrate the present invention and is not limited to the technical solutions described in the embodiments of the present invention. Those skilled in the art should understand that the present invention can still be modified or replaced by equivalents to achieve the same technical effects; as long as the use requirements are met, they are within the protection scope of the present invention.
Claims
1. An empty vehicle low-speed coupling and abnormal coupling prevention detection system, characterized by: It comprises a shunting device (1), a carriage detection device (2), an empty car coupling detection device (3) and a PLC control system (4); The shunting device (1) comprises a shunting locomotive body (11) having a travel transmission mechanism (12); a detection mechanism (13) for detecting its own position is arranged on the shunting locomotive body (11); a boom mechanism (14) is arranged on one side of the shunting locomotive body (11); and a coupling device (15) and a lifting and pinning device (16) are arranged at the end of the boom mechanism (14); The carriage detection device (2) comprises a first switch fixing frame (21) fixedly arranged on the empty carriage line of the railway on the side where the empty carriage enters, a beam sensor (22) being arranged on the first switch fixing frame (21), and the empty carriage line of the railway is located within the beam range of the beam sensor (22); The empty car coupling detection device (3) is arranged on the shunting locomotive body (11), and comprises a second switch fixing frame (31) arranged on the shunting locomotive body (11), and an adjustable background suppression type direct-reflective sensor (32) is arranged on the second switch fixing frame (31); the sensing direction of the adjustable background suppression type direct-reflective sensor (32) corresponds to the empty car entry side of the railway empty car line.
2. The empty vehicle low-speed coupling and abnormal coupling prevention detection system according to claim 1 is characterized by: The empty car coupling detection device (3) is arranged on the boom mechanism (14) of the shunting device (1).
3. The empty vehicle low-speed coupling and abnormal coupling prevention detection system according to claim 1 is characterized by: The carriage detection device (2) is arranged at a predetermined position for coupling two empty carriages on the empty carriage entry side of the empty carriage line.
4. The system for detecting low-speed empty vehicle coupling and abnormal coupling prevention according to claim 1 is characterized in that: After receiving the feedback signal from the carriage detection device (2), the PLC control system (4) controls the shunting device (1) to decelerate from a normal speed to a speed required for coupling, thereby performing low-speed coupling.
5. The vehicle low-speed coupling and abnormal coupling prevention detection system according to claim 1 is characterized in that: The PLC control system (4) delays a set time when the shunting device (1) is returning to its original position, and after receiving a signal from the empty car coupling detection device (3) and the car detection device (2) that a car coupling exists, sends an alarm signal to the upper computer.
6. A method for detecting an empty vehicle coupling and preventing coupling using the vehicle low-speed coupling and preventing abnormal coupling detection system according to any one of claims 1 to 5, characterized in that: The following steps are involved: The method comprises the following steps: Step 1: setting the detection distance of the adjustable background suppression type direct-reverse sensor (32) to 1 meter in front of the coupler device (15) to feed back a normally open switch signal; Step 2: Setting the transmitting end and receiving end of the beam sensor (22) to be arranged at the predetermined empty car line empty car assembly position, 1 meter from the rear of the car along the railway line close to the car transfer platform, and providing a normally closed switch signal after alignment; Step 3: The shunting device (1) pushes the empty car out of the transfer platform at a normal speed. After the empty car moves to the position described in step 2, the through-beam sensor (22) is blocked by the vehicle, the normally closed signal is disconnected, and the PLC sends a deceleration command to the shunting device (1), thereby realizing the low-speed coupling of the empty car; Step 4: After the empty car arrives at the empty car line assembly position, the shunting device (1) lifts and removes the hook and returns to the original position. On the way back to the original position, when the hook is normally unhooked and returns, the empty car coupling detection device (3) is away from the empty car and no signal is sent. If the shunting device (1) fails to unhook from the empty car and an abnormal coupling failure occurs, the empty car is always within the range of the empty car coupling detection device (3) and continues to send signals to the PLC. After the PLC continues to receive the signal sent by the empty car coupling detection device (3) for more than 10 seconds, it sends an alarm signal to the central control.