Scale rolling test bench, wheel track vibration boundary condition test method and system

Abstract

The invention discloses a scaling rolling test bench and a wheel track vibration boundary condition test method and system, and relates to the technical field of rail vehicle test. In the scaling rolling test bed, a track wheel system comprises a track wheel driving module and track wheels connected to the track wheel driving module, and the track wheels comprise six-component wheels; the wheel system comprises a wheel driving module and a scaling wheel connected to the wheel driving module, and the scaling wheel is arranged above the track wheel; the vertical loading system is arranged above the scaled wheel so as to provide a vertical load for the scaled wheel. The rail wheel comprises a six-component wheel, the rail wheel can be directly measured to obtain three-dimensional force and torque, errors caused by indirect calculation by additionally arranging strain gauges on the rail wheel in the prior art are avoided, the testing precision of the wheel rail vibration boundary condition can be improved, meanwhile, the steps of arranging, designing and assembling the strain gauges in the prior art can be avoided, and the testing efficiency is improved. And the assembling convenience is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of rail vehicle testing, and particularly to a scaled rolling test bench, a method and a system for testing wheel-rail vibration boundary conditions. Background Art

[0002] In order to accurately study the vibration characteristics generated during the operation of high-speed trains and their interaction with the track, it is particularly necessary to establish a wheel-rail vibration boundary condition test bench.

[0003] In the prior art, some research institutions mainly use scaled wheel-rail vibration boundary condition test benches to simulate scaled wheel-rail interaction for experimental research. However, in the current test benches for testing wheel-rail boundary conditions under high-speed and lightweight conditions, strain gauges are arranged on the track wheels to detect the required forces and torques. Usually, complex strain gauge layout designs are required to partially restore three-dimensional forces, and some force or torque components are easily missed, making it difficult to provide comprehensive data support. Moreover, since the forces or torques need to be indirectly calculated based on the detection values of the strain gauges, there are relatively large accuracy errors.

[0004] Therefore, how to improve the test accuracy of wheel-rail vibration boundary conditions is a technical problem that those skilled in the art need to solve currently. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide a scaled rolling test bench, a method and a system for testing wheel-rail vibration boundary conditions, which can improve the test accuracy of wheel-rail vibration boundary conditions.

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

[0007] A scaled rolling test bench includes a track wheel system, a wheel system and a vertical loading system; the track wheel system includes a track wheel driving module and a track wheel connected to the track wheel driving module, wherein the track wheel includes a six-component force wheel; the wheel system includes a wheel driving module and a scaled wheel connected to the wheel driving module, and the scaled wheel is arranged above the track wheel; the vertical loading system is arranged above the scaled wheel to provide a vertical load to the scaled wheel.

[0008] Exemplarily, it includes a variety of track wheel flanges, and any one of the track wheel flanges can be switchably arranged on the outer periphery of the track wheel.

[0009] Exemplarily, the track wheel drive module includes a first torque meter, a first flywheel housing, a first braking device, a first drive motor, and a first drive motor mounting seat; the center of the track wheel is connected to a first wheel shaft, the first torque meter is arranged on the first wheel shaft, and the first wheel shaft is connected to the first flywheel housing, the first braking device, and the first drive motor; a first drive motor encoder is arranged on the output shaft of the first drive motor.

[0010] Exemplarily, the wheel drive module includes a second gearbox, a second clutch, a second drive motor, a second braking device, and a second torque meter; the center of the scaled-down wheel is connected to a second wheel shaft, the second wheel shaft is connected to the second braking device and the second gearbox, the second gearbox is connected to the output shaft of the second drive motor through the second clutch, and the output shaft of the second drive motor is connected to the second torque meter.

[0011] Exemplarily, the wheel drive module further includes a second frame, a vibration damping device, and an adjusting device; the vertical loading system is connected to the second frame, the scaled-down wheel is connected to the lower part of the vibration damping device through a second bearing seat, the vertical loading system is arranged above the vibration damping device to apply load to the scaled-down wheel through the vibration damping device; the adjusting device is connected to the second bearing seat to adjust the position of the scaled-down wheel.

[0012] Exemplarily, a wheel-rail environment adjustment system is further included, and the wheel-rail environment adjustment system includes an environment chamber with adjustable temperature, and the scaled-down wheel and the track wheel are located in the environment chamber.

[0013] Exemplarily, the track wheel is connected to the track wheel drive module through a first wheel shaft, the scaled-down wheel is connected to the wheel drive module through a second wheel shaft, and the first wheel shaft and / or the second wheel shaft is a preset wheel shaft; the preset wheel shaft passes through the environment chamber through a mounting hole on the housing of the environment chamber, and a seal is arranged between the preset wheel shaft and the mounting hole.

[0014] A method for testing wheel-rail vibration boundary conditions is applied to the scaled-down rolling test bench as described above; the method includes: obtaining the real-time axle load value of the vertical loading system, the real-time torques of the first wheel shaft and the second wheel shaft, and the six-component force data collected by the six-component force wheel; wherein, the track wheel is connected to the track wheel drive module through a first wheel shaft, the scaled-down wheel is connected to the wheel drive module through a second wheel shaft; wherein, the six-component force data includes the forces in three directions of the vertical coordinate system and the torques in the three directions of the vertical coordinate system; calculating the wheel-rail vibration boundary condition data according to the real-time axle load value, the real-time torque, and the six-component force data.

[0015] Exemplarily, obtaining the six-component force data collected by the six-component force wheel includes: real-time collecting the three-directional load output by the six-component force wheel through the NI data acquisition system.

[0016] A wheel-rail vibration boundary condition test system is applied to the above-mentioned scaled rolling test bench; the test system includes: a first acquisition module for acquiring the real-time axle load value of the vertical loading system; a second acquisition module for acquiring the real-time torques of the first axle and the second axle, wherein the rail wheel is connected to the rail wheel drive module through the first axle, and the scaled wheel is connected to the wheel drive module through the second axle; a third acquisition module for acquiring the six-component force data collected by the six-component force wheel, wherein the six-component force data includes the forces in three directions of the vertical coordinate system and the torques in the three directions of the vertical coordinate system; a calculation module for calculating the wheel-rail vibration boundary condition data according to the real-time axle load value, the real-time torques, and the six-component force data.

[0017] The scaled rolling test bench provided by the present invention includes a rail wheel system, a wheel system, and a vertical loading system; the rail wheel system includes a rail wheel drive module and a rail wheel connected to the rail wheel drive module, wherein the rail wheel includes a six-component force wheel; the wheel system includes a wheel drive module and a scaled wheel connected to the wheel drive module, and the scaled wheel is arranged above the rail wheel; the vertical loading system is arranged above the scaled wheel to provide a vertical load to the scaled wheel.

[0018] In such a scaled rolling test bench, the rail wheel includes a six-component force wheel, which can directly measure the three-dimensional force and torque obtained by the rail wheel, avoiding the errors caused by additionally arranging strain gauges on the rail wheel and indirectly calculating in the traditional technology, improving the test accuracy of the wheel-rail vibration boundary conditions, being applicable to more complex dynamic analysis of rail vehicles, such as wheel-rail contact force, multi-axis linkage dynamics analysis, etc. At the same time, it can avoid the strain gauge layout design and assembly steps in the traditional technology and improve the assembly convenience. In addition, the six-component force wheel can accurately capture the transient changes of the force and torque under high-frequency dynamic load conditions, and can overcome the problems of possible hysteresis or signal noise of the strain gauge in the traditional technology at high-frequency response. Description of the Drawings

[0019] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only the embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained according to the provided drawings without creative efforts.

[0020] Figure 1 It is a schematic structural diagram of the test bench of the specific embodiment provided by the present invention;

[0021] Figure 2 Schematic diagram of the track wheel system of the specific embodiment provided by the present invention;

[0022] Figure 3 Schematic diagram of the track wheel of the specific embodiment provided by the present invention;

[0023] Figure 4 Schematic diagram of the wheel system of the specific embodiment provided by the present invention;

[0024] Figure 5 Schematic diagram of the vertical loading system of the specific embodiment provided by the present invention;

[0025] Figure 6 Schematic diagram of the lubrication system of the specific embodiment provided by the present invention;

[0026] Figure 7 Schematic diagram of the wheel-rail environment adjustment system of the specific embodiment provided by the present invention;

[0027] Figure 8 Schematic diagram of the brake shield of the specific embodiment provided by the present invention;

[0028] Figure 9 Schematic diagram of the coupling shield of the specific embodiment provided by the present invention;

[0029] Figure 10 Flow chart of the test method of the specific embodiment provided by the present invention.

[0030] Reference numerals:

[0031] 1 - Track wheel system, 11 - Track wheel, 111 - Six-component force wheel, 112 - Three-component force sensor, 113 - Track wheel rim, 12 - First torque meter, 13 - First flywheel box, 14 - First braking device, 15 - First driving motor, 16 - First driving motor mounting seat, 17 - First wheel shaft;

[0032] 2 - Wheel system, 21 - Scaled-down wheel, 22 - Second gearbox, 23 - Second clutch, 24 - Second driving motor, 25 - Second braking device, 26 - Second torque meter, 27 - Second frame, 28 - Vibration damping device, 29 - Adjusting device, 210 - Second wheel shaft;

[0033] 3 - Vertical loading system;

[0034] 4 - Lubrication system;

[0035] 5 - Wheel-rail environment adjustment system, 51 - Environment chamber, 511 - Chamber housing, 512 - Assembly hole, 513 - Mounting hole;

[0036] 6 - Brake guard

[0037] 7 - Coupling guard

[0038] 8 - Test bench main body Detailed implementation manners

[0039] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0040] The core of the present invention is to provide a scaled - down rolling test bench, a method and a system for testing wheel - rail vibration boundary conditions, which can improve the testing accuracy of wheel - rail vibration boundary conditions.

[0041] For the specific first embodiment of the scaled - down rolling test bench provided by the present invention, please refer to Figures 1 to 9 , including a track wheel system 1, a wheel system 2, a vertical loading system 3, a lubrication system 4, a wheel - rail environment adjustment system 5, safety protection accessories, and a test bench main body 8.

[0042] Other structures in the test bench can be all arranged on the test bench main body 8 to make the test bench form an integral whole. The test bench main body 8 can specifically be a cast iron platform. The track wheel system 1, the wheel system 2, the vertical loading system 3, the lubrication system 4, and the wheel - rail environment adjustment system 5 can all be connected to a control system and be uniformly controlled by the control system.

[0043] The track wheel system 1 includes a track wheel driving module and a track wheel 11 connected to the track wheel driving module. The track wheel driving module is used to control the operation or braking of the track wheel 11.

[0044] Among them, the track wheel 11 includes a six - component force wheel 111. The six - component force wheel 111 includes a three - component sensor, and the three - component sensor can simultaneously measure the force or acceleration of an object in three orthogonal directions. Specifically, the three - component sensor adopts a three - component force sensor 112.

[0045] Based on the setup of the three-component sensor, the data that the six-component force wheel 111 can measure includes the forces in three directions (such as the X, Y, and Z axes) and the torques in three directions (such as the torques about the X, Y, and Z axes), specifically Fx, Fy, Fz, Mx, My, and Mz in sequence. Specifically, the forces and torques in the three directions respectively correspond to: the longitudinal force Fy of the scaled-down wheel 21 in the driving direction and the overturning torque My about the axis in this direction; the lateral force Fx of the scaled-down wheel 21 in the lateral direction and the rolling resistance torque Mx about the axis in this direction; the vertical force Fz of the scaled-down wheel 21 in the vertical direction and the self-aligning torque Mz about the axis in this direction; the driving direction Y, the lateral direction X, and the vertical direction Z are perpendicular to each other in pairs.

[0046] The wheel system 2 includes a wheel driving module and a scaled-down wheel 21 connected to the wheel driving module. The wheel driving module is used to control the operation or braking of the scaled-down wheel 21. The scaled-down wheel 21 is disposed above the track wheel 11 and can specifically be in contact with or press against it to have a force effect.

[0047] The vertical loading system 3 is disposed above the scaled-down wheel 21 to provide a vertical (which can correspond to the up and down direction in actual use) load to the scaled-down wheel 21. Among them, the load can vibrate up and down at a set frequency to provide vibration test conditions.

[0048] In this embodiment, the track wheel 11 includes a six-component force wheel 111, which can directly measure the three-dimensional force and torque of the track wheel 11, avoiding the errors caused by additionally setting strain gauges on the track wheel 11 and indirect calculation in the traditional technology. It is applicable to more complex dynamic analysis of track vehicles, such as wheel-rail contact force, multi-axis linkage dynamics analysis, etc. At the same time, it can avoid the strain gauge layout design and assembly steps in the traditional technology and improve the assembly convenience. In addition, the six-component force wheel 111 can accurately capture the transient changes of force and torque under high-frequency dynamic load conditions and can overcome the problems of possible hysteresis or signal noise of the strain gauge in the traditional technology during high-frequency response.

[0049] Furthermore, please refer to Figure 2 and Figure 3 , the track wheel system 1 includes a track wheel 11 and a track wheel driving module.

[0050] For the track wheel 11, it includes a six-component force wheel 111, and the six-component force wheel 111 transmits the signals of the three-component force sensors 112 through slip rings. The six-component force wheel 111 includes three-component force sensors 112, specifically including multiple parallel-connected three-component force sensors 112, such as 4. Each three-component force sensor 112 can measure the loads in three orthogonal directions and calculate and output the six-channel wheel center loads. The six channels specifically can refer to the six signal channels corresponding to the forces in three orthogonal directions and the torques in three orthogonal directions. Among them, the six-component force wheel 111 can form a statically indeterminate structure, and coordinate transformation can be used to calibrate and analyze the track wheel 11 with a parallel structure of 4 three-component force sensors 112. Among them, the six-component force wheel 111 can be calibrated in the factory, has a unified calibration curve, higher repeatability and reliability, and is not easily affected by environmental changes.

[0051] In some embodiments, the six-component force wheel 111 includes 4 measuring units. Each measuring unit respectively includes a three-component force sensor 112, an outer fixed disk, and an inner fixed ring. The three-component force sensor 112 is arranged between the outer fixed disk and the inner fixed ring. At this time, the 4 three-component force sensors 112 are connected in parallel. In addition, the 4 three-component force sensors 112 are evenly arranged in the circumferential direction around the axis line of the first wheel shaft 17 that connects and drives the track wheel 11 to rotate.

[0052] In addition, the outer periphery of the track wheel 11 is provided with a track wheel rim 113, which can be specifically arranged on the outer periphery of the finished six-component force wheel 111, or a part of the outermost side in the radial direction of the six-component force wheel 111 is divided as the track wheel rim 113. To provide various test conditions, the test bench includes various track wheel rims 113, and any track wheel rim 113 can be selectively arranged on the outer periphery of the track wheel 11.

[0053] It should be noted that different types of track wheel rims 113 are set according to different structures, specifically including the structure of the outer peripheral surface of the track wheel rim 113, so as to provide different track test conditions and meet different test requirements. Specifically, before the test, the track wheel rim 113 can be replaced according to the test requirements.

[0054] In some embodiments, the outer peripheral surfaces of multiple track wheel rims 113 are irregular circular surfaces, and the irregularities (specifically, the radial runout values) are different to simulate different vibration conditions. Among them, the irregularity can define a selectable range according to the set rotation speed of the track wheel 11. For example, in some track wheels 11, the standard diameter of the track wheel 11 is 400 mm. On this basis, the irregularity is set, the rotation speed is 3265 rpm, and the corresponding linear speed is about 246 km / h. At this time, the maximum range of the irregularity of the wheel rim is 1 mm, and values are selected within 1 mm to simulate different vibration effects within 1 mm.

[0055] For the track wheel drive module, such asFigure 2 As shown in the figure, it includes a first torque meter 12, a first flywheel box 13, a first braking device 14, a first driving motor 15, a first driving motor mounting seat 16, and a first driving motor encoder.

[0056] The center of the track wheel 11 is connected to the first wheel shaft 17, and the track wheel 11 is connected to the track wheel drive module through the first wheel shaft 17 to achieve transmission. When selecting the first wheel shaft 17, in a specific test condition, if the maximum vertical load on the track wheel 11 is 1 KN, then the strength of the first wheel shaft 17 needs to be checked, the safety factor of the shaft under the action of bending moment is obtained, and a shaft that meets the requirements is selected as the first wheel shaft 17 to ensure the strength requirements for the use of the first wheel shaft 17.

[0057] The first torque meter 12 is provided on the first wheel shaft 17. The first torque meter 12 has a torque measurement function and can measure the torque during the rotation of the track wheel 11.

[0058] The first wheel shaft 17 is connected to the first flywheel box 13, the first braking device 14, and the first driving motor 15. The first flywheel box 13 can store and release energy by virtue of its own moment of inertia to ensure the smoothness and continuity of the operation of the track wheel system. Optionally, the first flywheel box 13 includes a single flywheel structure with a moment of inertia of 5.5 kg·m 2 . The first braking device 14 is composed of a brake disc and a pneumatic brake. The first driving motor 15 can be connected to the first flywheel box 13 through a first clutch. Optionally, the first driving motor 15 is provided on the first driving motor mounting seat 16, and a first driving motor encoder can also be provided on the output shaft of the first driving motor 15 to detect the rotation speed of the first driving motor 15.

[0059] Furthermore, please refer to Figure 4 , the wheel system 2 includes a scaled-down wheel 21 and a wheel drive module. The wheel drive module is used to drive or brake the scaled-down wheel 21.

[0060] For the scaled-down wheel 21, it is smaller than the actual wheel. Optionally, a scaled-down wheel 21 has a ratio of 1 to 5 with the real vehicle size, and the maximum operating linear speed is 250 km / h. For example, the diameter of the real vehicle wheel is 920 mm, the diameter of the scaled-down wheel 21 is 184 mm, the maximum rotational speed is 7100 rpm, and the corresponding linear speed is about 246 km / h. The test bench is a single-wheel rolling test bench.

[0061] For the wheel drive module, as Figure 4 shown, it includes a second gearbox 22, a second clutch 23, a second driving motor 24, a second braking device 25, a second torque meter 26, a second frame 27, a constant velocity joint, a shock absorber 28, and an adjusting device 29.

[0062] The center of the scaled-down wheel 21 is connected to the second axle 210 to connect to the wheel drive module through the second axle 210. The second axle 210 is connected to the second braking device 25 and the second gearbox 22. The second gearbox 22 can serve as a speed increasing and regulating mechanism. Optionally, the gear ratio is initially designed to be 1:2.8. Exemplarily, when the rotational speed of the second drive motor 24 reaches a maximum of 2533 rpm, the rotational speed of the scaled-down wheel 21 can reach up to about 7100 rpm. The second gearbox 22 is connected to the output shaft of the second drive motor 24 through the second clutch 23. The function of the second clutch 23 is to engage or disengage the scaled-down wheel 21 and the second drive motor 24. The output shaft of the second drive motor 24 is connected to the second torque meter 26, which has the function of torque measurement. Additionally, a torque meter can also be provided on the second axle 210.

[0063] The second frame 27 can be used to connect the vertical loading system 3 and the wheel system 2. Specifically, the vertical loading system 3 is connected to the second frame 27. The scaled-down wheel 21 is connected to the lower part of the vibration damping device 28 through the second bearing seat. The function of the vibration damping device 28 is to reduce the impact caused by vibration on the scaled-down wheel 21 and the upper mechanism. The vertical loading system 3 is arranged above the vibration damping device 28 to apply a vertical load to the scaled-down wheel 21 through the vibration damping device 28.

[0064] The adjusting device 29 is connected to the second bearing seat to adjust the position of the scaled-down wheel 21. Optionally, the adjusting device 29 manually adjusts the relative position of the scaled-down wheel 21 and the track wheel 11. For example, adjustments in the X direction and the Y direction can be made. The X and Y directions are specifically perpendicular to the vertical direction in which the vertical loading system 3 applies the load.

[0065] In the track wheel system 1 and the wheel system 2 in this embodiment, the track wheel 11 and the scaled-down wheel 21 are respectively driven by motors (the first drive motor 15, the second drive motor 24). The relative speed difference between the scaled-down wheel 21 and the track wheel 11 can be achieved in the form of motor counter-traction, and the three-direction load can be accurately measured by the six-component force wheel 111, and the six-channel wheel center load can be calculated and output. By using the track wheel 11 and the scaled-down wheel 21 with a scaling ratio, the verification of real-time adhesion control in the traction / braking state can be achieved through counter-traction, the relative slip between the two sides of the wheel-rail can be realized, and the contact force and the relative slip speed can be accurately measured. At the same time, the construction, use, and maintenance costs of the test bench can be controlled, and the wheel-rail vibration boundary conditions in more working condition scenarios can be simulated.

[0066] Further, please refer to Figure 4 and Figure 5, the vertical loading system 3 includes a vertical actuator, specifically a hydraulic actuator. The function of the vertical loading system 3 is to apply a vertical load to the scaled-down wheel 21, specifically by accurately loading through the hydraulic actuator. Exemplarily, the vertical loading system 3 provides a maximum load of 1 KN to simulate the axle load. The hydraulic actuator is equipped with a dedicated hydraulic station to provide the oil source.

[0067] Specifically, the main function of the vertical loading system 3 is to provide a vertical loading force and generate wheel-rail contact when studying wheel-rail adhesion and creep. In addition to simulating the axle load, it can also simulate the vibration transmission above the primary suspension to a certain extent. Additionally, by simulating the unloading condition and acting together with the out-of-roundness on the wheel flange 113 of the track wheel, the scaled-down wheel 21 can be made to jump.

[0068] To achieve the control of the hydraulic actuator, the test bench also includes a hydraulic loading device, specifically including a hydraulic oil supply system and a hydraulic drive device.

[0069] The hydraulic oil supply system is connected between the main hard pipe and the hydraulic actuator, and includes parts such as a distributor seat, an accumulator, and a distributor system. The main function of the hydraulic oil supply system is to independently input the hydraulic oil output from the main hard pipe to each hydraulic drive device through the distributor, and the accumulator ensures that there is sufficient pressure when the hydraulic oil enters the hydraulic actuator.

[0070] The hydraulic drive device includes a base, a fixing tooling, a servo valve, a force and displacement sensor. The inlet and outlet oil pipes of the hydraulic actuator are connected to the distributor system that provides hydraulic oil with a certain pressure, providing the power source for the hydraulic actuator. The base and the fixing tooling are mainly used for fixing the components. The servo valve controls the flow rate of the oil entering the cylinder of the hydraulic actuator to control the piston movement of the hydraulic actuator. The force and displacement sensor is used to collect the acting force and displacement of the hydraulic actuator during the test. Optionally, the rated pressure of the hydraulic actuator is 16 Mpa and the load is 1 KN. This load does not consider the self-weight of the scaled-down wheel 21 and the mounting tooling of the scaled-down wheel 21 and the influence of vibration on the loading force.

[0071] Please refer to Figure 6 , the lubrication system 4 is used to ensure the normal operation of the clutch and the gearbox, for example, the first clutch, the second clutch 23, and the second gearbox. According to needs, forced lubrication can be carried out on the internal gears and bearings of the corresponding equipment. Optionally, the lubricating oil volume of the gearbox is ≥25 L / min, and the lubricating oil volume of the clutch is 15 L / min.

[0072] Furthermore, as Figure 1 and Figure 7As shown, the wheel-rail environment adjustment system 5 includes an environment chamber 51 with adjustable temperature. The environment chamber 51 can simulate and test the wheel-rail vibration boundary conditions under more working condition scenarios. Specifically, it can simulate the working conditions at different temperatures through the environment chamber 51, which can provide data support for the wheel design and material selection of rail vehicles, improve the multi-condition test ability of the test bench, and the environment chamber 51 can reproduce the real operating environment, improve the reliability of the test results, and can study the influence of environmental temperature on the rolling vibration response of the scaled-down wheel 21 to improve and perfect the test accuracy of the wheel-rail vibration boundary conditions and the test working condition scenarios.

[0073] Optionally, the environment chamber 51 adjusts the temperature in a PID manner. Specifically, a compressor can be used for refrigeration, and the adjustable temperature range can be from -20°C to +55°C.

[0074] In addition, the environment chamber 51 has a protective function. The scaled-down wheel 21 and the track wheel 11 are built into the environment chamber 51, which can prevent the rotating parts from flying out and causing harm to the surrounding people or facilities.

[0075] Optionally, the inside of the environment chamber 51 is a sealed chamber to seal the track wheel 11 and the scaled-down wheel 21. Specifically, the environment chamber 51 includes a chamber body shell 511. The chamber body shell 511 includes a heat-insulating layer, and the heat-insulating layer is disposed outside the chamber body shell 511 or in the wall of the chamber body shell 511. At this time, due to the good sealing and heat-insulating properties of the environment chamber 51, the stability of the temperature field during the test is ensured.

[0076] Optionally, as Figure 1 shown, the wheel system 2 and the track wheel system 1 are arranged in sequence along the first direction. On the side of the track wheel 11, the track wheel 11 is located inside the environment chamber 51. The first wheel shaft 17 of the track wheel 11 passes through the chamber body shell 511 of the environment chamber 51 from one side in the first direction and is connected to the track wheel drive module, specifically connected to the first flywheel box 13. There is an installation hole 513 on the chamber body shell 511. The first wheel shaft 17 passes through the environment chamber 51 through the installation hole 513, and a seal is provided between the first wheel shaft 17 and the installation hole 513 to ensure the sealing effect. Exemplarily, the seal includes heat-resistant thickened spun fabric with heat-insulating cotton inside. The seal is fixed around the rotating shaft by a semi-circular flange sewing method for sealing.

[0077] In addition, as Figure 1As shown, the scaled wheel 21 is located in the environmental chamber 51, and the second wheel axle 210 of the scaled wheel 21 passes through the chamber housing 511 of the environmental chamber 51 from the other side in the first direction, and then is connected to the wheel drive module, specifically connected to the second gear transmission 22. In addition, an assembly hole 512 is provided on the side of the environmental chamber 51 opposite to the mounting hole 513, and the assembly hole 512 is adapted to the second frame 27, and the assembly hole 512 is covered on the second frame 27, and the assembly hole 512 can be specifically attached to the top surface and two side surfaces of the second frame 27. In addition, the assembly hole 512 and the second frame 27 can be sealed.

[0078] Optionally, the environmental chamber 51 is a bottom opening structure, and the bottom opening is sealed by the test bench body 8. In this case, the environmental chamber 51 has the function of overall hoisting, and the environmental chamber 51 can be installed in the test bench by hoisting, and can be hoisted away when replacing the track wheel rim 113. In addition, the chamber shell 511 is provided with mounting holes 513 and assembly holes 512 at both ends in the first direction, and both can be set through downwards, so that it can be directly covered above the first wheel axle 17 and the second frame 27 during the hoisting process.

[0079] Optionally, a water collector is further provided inside the environmental chamber 51, and a drain pipe of the water collector passes through the outside of the chamber shell 511 to drain the condensed water. Exemplarily, the water collector is a stainless steel annular water tray collector, and the condensed water is drained through the annular water tray collector.

[0080] Optionally, two doors are provided on the environment chamber 51, which can be provided on both sides in a direction perpendicular to the first direction and the up-down direction. Also, the environment chamber 51 is provided with a visible observation window for conveniently observing the situation in the environment chamber 51. In addition, lighting equipment can also be provided in the environment chamber 51, which has a lighting function to ensure that there is sufficient brightness in the chamber.

[0081] It should be noted that in a low-temperature environment, the torque meter, force sensor, three-component sensor, oil system and other components located inside the environmental chamber 51 need to meet the low-temperature working requirements, and targeted selection and layout design are carried out. The torque meter can be selected to support an operating temperature range of -20~85℃, the three-component sensor in the six-component force wheel 111 can be selected to support an operating temperature range of -20~60℃, the force sensor can be selected to support an operating temperature range of -30~85℃, and the bearings can be selected to operate safely under conditions above -20℃.

[0082] In addition, when the temperature of the hydraulic oil is too low, the viscosity of the hydraulic oil increases, its fluidity is poor, the resistance is large, and the working efficiency is low. When the oil temperature is lower than 15 degrees, it is easy to damage the hydraulic motor, valves, pipelines, etc. Therefore, the working temperature of the hydraulic system is generally controlled between 15 and 65 °C. For the vertical loading system 3 in this embodiment, since it uses hydraulic oil, the hydraulic actuator is specifically suspended outside the environmental chamber 51 to eliminate the adverse effects of low temperature on the oil circuit and the hydraulic actuator. Considering all these factors.

[0083] Furthermore, as Figure 8 and Figure 9 shown, the safety protection accessories include a brake guard 6 and a coupling guard 7.

[0084] Specifically, there are 2 brake guards 6, which are respectively installed on the first braking device 14 and the second braking device 25. The function of the brake guard 6 is to prevent the parts on the corresponding brake from flying out, so as to avoid harm to the surrounding people or facilities. Optionally, the brake guard 6 uses a steel section of carbon steel as the skeleton and a carbon steel plate with a thickness of 2 mm as the panel to ensure that the brake guard 6 has sufficient rigidity.

[0085] Specifically, there are 2 coupling guards 7, which can be specifically arranged in the wheel drive module, and are respectively installed on the couplings between the second gearbox 22 and the scaled-down wheel 21, and between the second gearbox 22 and the second drive motor 24. The function of the coupling guard 7 is to prevent the parts on the coupling from flying out to avoid harm to the surrounding people or facilities. The columns of the coupling guard 7 are welded by combining H-shaped steel and a 10-mm thick steel plate, and a 2-mm thick steel plate is used as the arc-shaped cover to ensure that the coupling guard 7 has sufficient rigidity.

[0086] The scaled-down rolling test bench provided by this embodiment can be used for testing the wheel-rail vibration boundary conditions. It occupies a small area and greatly reduces the curvature radius of the track rollers, enhancing the reliability of the test bench data and ensuring the test accuracy of the wheel-rail vibration boundary conditions; due to the relatively small mass of the rolling components, it is easy to conduct curve experiments when the actuator is in the high-speed rotation state of the rolling components; it greatly reduces the operation cost and energy consumption, and has low energy consumption during long-term tests such as wheel-rail adhesion creep and rolling contact, achieving an economical solution.

[0087] In addition, after the overall weight of the vehicle is reduced, the component vibration develops towards high frequencies, and the wheel-rail creep theory needs to be studied and corrected accordingly; after the scaled-down wheel 21 uses a new material, it is necessary to analyze the contact surface state of the new wheel-rail material; when the vehicle adopts a new guiding system and drive system and takes real-time control of guiding and adhesion, it is necessary to conduct principle tests on the basic technologies; study digital digital-physical fusion tests to replace the vehicle rolling vibration / line tests, etc.

[0088] The test bench in this embodiment has a relatively high test speed and is capable of providing slip through wheel-rail counter-traction. It has high-precision test data for wheel-rail vibration boundary conditions under high-speed conditions. It can accurately measure and obtain a large amount of wheel-rail contact state data, and the equipment can operate normally under long-term, high-speed, and strong impact conditions. It can adjust and set the rail surface conditions, have a higher target speed level, and achieve load reduction and jumping between the wheel and the rail, and has the test ability for the wheel-rail vibration boundary condition index of the next-generation high-speed, lightweight, and intelligent scaled-down wheels 21.

[0089] In addition to the above-mentioned scaled-down rolling test bench, the present invention also provides a method for testing wheel-rail vibration boundary conditions, and this method for testing wheel-rail vibration boundary conditions can be applied to the above-mentioned scaled-down rolling test bench.

[0090] This test bench is mainly used to simulate the vibration characteristics generated during the operation of high-speed trains and their interaction with the track. The control system of the test bench includes a host computer and a PLC control cabinet, which are used to control equipment such as frequency converters, drive motors, encoders, and vertical actuators in the test bench, and can specifically control motor drive, hydraulic drive, and hydraulic oil supply. The test bench has high-precision measurement capabilities and can operate normally under long-term, high-speed, and strong impact conditions.

[0091] In the first embodiment, the method includes the following steps:

[0092] S1: Obtain the real-time axle load value of the vertical loading system 3.

[0093] Among them, the real-time axle load value is an important parameter for evaluating the wheel-rail contact state and is crucial for studying the wheel-rail vibration characteristics. The real-time axle load value can be collected by a force sensor installed on the vertical actuator.

[0094] Specifically, during the process of the test bench conducting wheel-rail vibration simulation tests, step S1 obtaining the real-time axle load value collected by the force sensor installed on the vertical loading system 3 refers to the vertical load exerted by the vertical loading system 3 on the scaled-down wheel 21, which is measured in real time by a force sensor installed on the vertical actuator. The force sensor converts the vertical load into an electrical signal and records it in real time.

[0095] The vertical loading system 3 is used for the force-bearing situation of the scaled-down wheel 21 in the vertical direction, and controls different loads on the scaled-down wheel 21 through a hydraulic system. The loading pressure can be adjusted according to experimental requirements during the experiment. The force sensor is installed on the vertical loading system 3 and is used to measure and collect the axle load value in real time.

[0096] S2: Obtain the real-time torques of the first axle 17 and the second axle 210.

[0097] Among them, the track wheel 11 is connected to the track wheel drive module through the first wheel shaft 17, and the scaled-down wheel 21 is connected to the wheel drive module through the second wheel shaft 210. Specifically, the corresponding real-time torques can be collected by torque sensors installed on the first wheel shaft 17 and the second wheel shaft 210 respectively.

[0098] Among them, when the scaled-down wheel 21 and the track wheel 11 rotate, when obtaining the real-time torques collected by the torque sensors or torque meters installed on the first wheel shaft 17 and the second wheel shaft 210 in step S2, the torque sensors or torque meters convert the torques into electrical signals and record them in real time. The real-time torque data helps to analyze the slip and adhesion states between the wheel and the rail.

[0099] S3: Obtain the six-component force data collected by the six-component force wheel 111, where the six-component force data includes the forces in three directions of the vertical coordinate system and the torques in the same three directions of the vertical coordinate system.

[0100] Among them, the spatial rectangular coordinate system corresponding to the force and the torque can be the same one.

[0101] Among them, when the scaled-down wheel 21 and the track wheel 11 are in contact and interact with each other, the six-component force data is obtained through the six-component force wheel 111 in step S3.

[0102] Among them, the six-component force wheel 111 has sensors that can simultaneously measure the forces and torques in three directions of the vertical coordinate system. In the wheel-rail vibration test, the six-component force wheel 111 can provide comprehensive wheel-rail contact force information. The six-component force data includes the forces in three directions such as the X, Y, and Z axes and the torques in three directions such as the torques around the X, Y, and Z axes. Specifically, they are Fx, Fy, Fz, Mx, My, and Mz, which are obtained by real-time measurement through the six-component force wheel 111. The six-component force wheel 111 usually consists of multiple three-component force sensors 112 connected in parallel to achieve accurate measurement of multi-dimensional forces and torques.

[0103] Among them, the six-component force wheel 111 converts the multi-dimensional forces and torques into electrical signals, records them in real time through the data acquisition system, and obtains the final six-component force data through coupling algorithm processing.

[0104] S4: Calculate the wheel-rail vibration boundary condition data according to the real-time axle load value, real-time torque, and six-component force data.

[0105] Through the above-obtained data, especially the data of the three forces and torques directly obtained by the six-component force wheel 111, accurate load characteristic values can be provided, ensuring the accuracy of the analysis of the wheel-rail vibration boundary condition data.

[0106] Furthermore, in S3, obtaining the six-component force data collected by the six-component force wheel 111 includes:

[0107] The three-way load output by the six-component force wheel 111 is collected in real time through the NI data acquisition system.

[0108] Among them, four parallel three-component sensors are provided on the six-component force wheel 111, and they are evenly arranged on the circumference with the first wheel shaft 17 as the axis line. The three-component sensors output three-way loads.

[0109] At this time, the use of the NI data acquisition system and advanced signal processing technology ensures the real-time, accurate and reliable nature of the data.

[0110] In addition, from the perspective of functional modules, the present invention also provides a wheel-rail vibration boundary condition test system, which applies the above-mentioned scaled rolling test bench.

[0111] The test system includes:

[0112] A first acquisition module for acquiring the real-time axle load value of the vertical loading system 3;

[0113] A second acquisition module for acquiring the real-time torques of the first wheel shaft 17 and the second wheel shaft 210. Among them, the track wheel 11 is connected to the track wheel drive module through the first wheel shaft 17, and the scaled wheel 21 is connected to the wheel drive module through the second wheel shaft 210;

[0114] A third acquisition module for acquiring the six-component force data collected by the six-component force wheel 111, where the six-component force data includes the forces in three directions of the vertical coordinate system and the torques in three directions of the vertical coordinate system.

[0115] A calculation module for calculating the wheel-rail vibration boundary condition data according to the real-time axle load value, the real-time torque, and the six-component force data.

[0116] It should be noted that when an element is referred to as "fixed" to another element, it can be directly on the other element or there can also be a middle element. When an element is considered to be "connected" to another element, it can be directly connected to the other element or there may be a middle element at the same time. In addition, in the description of the present invention, unless otherwise specified, the meanings of "multiple", "multiple roots", and "multiple groups" are two or more.

[0117] The orientation or positional relationship indicated by terms such as "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation to the present invention. In addition, the terms "first", "second", "third" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features.

[0118] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the technical field to which the present invention belongs. The terms used in the description of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0119] The various embodiments in this specification are described in a progressive manner. Each embodiment focuses on the differences from other embodiments. The same or similar parts among the various embodiments can be referred to each other.

[0120] The scaled rolling test bench, and the wheel-rail vibration boundary condition testing method and system provided by the present invention have been introduced in detail above. Specific examples are used herein to elaborate on the principle and implementation manner of the present invention. The description of the above embodiments is only for helping to understand the method and its core idea of the present invention. It should be noted that for those of ordinary skill in the technical field, without departing from the principle of the present invention, several improvements and modifications can be made to the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A scaled rolling test bench, characterized in that: It comprises a track wheel system (1), a wheel system (2) and a vertical loading system (3); The track wheel system (1) comprises a track wheel drive module and a track wheel (11) connected to the track wheel drive module, wherein the track wheel (11) comprises a six-component wheel (111); The wheel system (2) comprises a wheel drive module and a scaled-down wheel (21) connected to the wheel drive module, wherein the scaled-down wheel (21) is arranged above the track wheel (11); The vertical loading system (3) is arranged above the scaled-down wheel (21) to provide a vertical load to the scaled-down wheel (21).

2. The scaled rolling test bench according to claim 1, characterized in that: It comprises a plurality of track wheel rims (113), and the outer periphery of the track wheel (11) can be switchably provided with any of the track wheel rims (113).

3. The scaled rolling test bench according to claim 1, characterized in that: The rail wheel drive module comprises a first torque meter (12), a first flywheel box (13), a first braking device (14), a first drive motor (15) and a first drive motor mounting seat (16); The center of the track wheel (11) is connected to a first wheel axle (17); the first torque meter (12) is arranged on the first wheel axle (17); the first wheel axle (17) is connected to the first flywheel box (13), the first brake device (14) and the first drive motor (15); and a first drive motor encoder is arranged on the output shaft of the first drive motor (15).

4. The scaled rolling test bench according to claim 1, characterized in that: The wheel drive module comprises a second gear transmission (22), a second clutch (23), a second drive motor (24), a second braking device (25), and a second torque meter (26); The center of the reduced-scale wheel (21) is connected to a second wheel axle (210), the second wheel axle (210) is connected to the second braking device (25) and the second gear transmission (22), the second gear transmission (22) is connected to the output shaft of the second drive motor (24) via the second clutch (23), and the output shaft of the second drive motor (24) is connected to the second torque meter (26).

5. The scaled rolling test bench according to claim 4, characterized in that: The wheel drive module further comprises a second frame (27), a vibration reduction device (28), and an adjustment device (29); the vertical loading system (3) is connected to the second frame (27); the scaled wheel (21) is connected to the bottom of the vibration reduction device (28) via a second bearing seat; the vertical loading system (3) is arranged above the vibration reduction device (28) so as to load the scaled wheel (21) via the vibration reduction device (28); and the adjustment device (29) is connected to the second bearing seat so as to adjust the position of the scaled wheel (21).

6. The scaled rolling test bench according to any one of claims 1 to 5, characterized in that: It also comprises a wheel-rail environment adjustment system (5), the wheel-rail environment adjustment system (5) comprising an environment chamber (51) with adjustable temperature, the scaled wheel (21) and the rail wheel (11) being located in the environment chamber (51).

7. The scaled rolling test bench according to claim 6, characterized in that: The track wheel (11) is connected to the track wheel drive module via a first wheel axle (17), and the scaled wheel (21) is connected to the wheel drive module via a second wheel axle (210), wherein the first wheel axle (17) and / or the second wheel axle (210) are preset wheel axles; The preset wheel axle passes through the environmental bin (51) through a mounting hole (513) on a bin shell (511) of the environmental bin (51), and a sealing member is provided between the preset wheel axle and the mounting hole (513).

8. A wheel-rail vibration boundary condition testing method, characterized in that: Applicable to the scaled rolling test bench as claimed in any one of claims 1 to 7; The method comprises: Acquiring a real-time axle load value of the vertical loading system (3), the real-time torque of the first wheel axle (17) and the second wheel axle (210), and six-component force data collected by the six-component force wheel (111); The track wheel (11) is connected to the track wheel drive module via a first wheel axle (17), and the scaled wheel (21) is connected to the wheel drive module via a second wheel axle (210); The six-component force data include forces in three vertical coordinate system directions and moments in the three vertical coordinate system directions; Wheel-rail vibration boundary condition data are calculated according to the real-time axle load value, the real-time torque, and the six-component force data.

9. The wheel-rail vibration boundary condition testing method according to claim 8, characterized in that: The obtaining of the six-component force data collected by the six-component force wheel (111) comprises: The three-directional load output by the six-component wheel (111) is collected in real time through a NI data collection system.

10. A wheel-rail vibration boundary condition testing system, characterized in that: Applicable to the scaled rolling test bench as claimed in any one of claims 1 to 7; The test system comprises: A first acquisition module, used to acquire a real-time axle load value of the vertical loading system (3); a second acquisition module, used for acquiring real-time torque of the first wheel axle (17) and the second wheel axle (210), wherein the track wheel (11) is connected to the track wheel drive module via the first wheel axle (17), and the scaled wheel (21) is connected to the wheel drive module via the second wheel axle (210); a third acquisition module, used to acquire six-component force data collected by the six-component force wheel (111), wherein the six-component force data includes forces in three vertical coordinate system directions and moments in the three vertical coordinate system directions; The calculation module is used to calculate the wheel-rail vibration boundary condition data according to the real-time axle load value, the real-time torque and the six-component force data.

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