High-speed rail axle box bearing full-life-cycle test bench and test method

Abstract

The invention relates to the technical field of fault diagnosis and bearing life detection, in particular to a high-speed rail axle box bearing life cycle test bench and a test method.The test bench comprises a test bench body, a test head, a driving system, a loading system, a temperature control system, an electrical control system, a computer monitoring system and a data acquisition system; the speed spectrum and the load spectrum can be preset through program control, complex and strong load conditions and variable environment temperatures of a high-speed train can be comprehensively simulated, full-life-cycle tests can be carried out on high-speed rail axle box bearings of various models under high-speed, heavy-load and high-frequency vibration conditions, and the device has the advantages of being easy to operate, safe, reliable and efficient in testing and has a wide application prospect. The problems that in the prior art, the high-speed rail axle box bearing operation environment simulation is incomplete, and the service life evaluation credibility is low can be effectively solved.

Description

Technical Field

[0001] The invention relates to the technical field of fault diagnosis and bearing life detection, and in particular to a full life cycle test bench and test method for a high-speed railway axle box bearing. Background Art

[0002] High-speed rail axle box bearings are key components in the high-speed rail train operation system. They bear huge dynamic loads and complex environmental conditions during the operation of the train. Their operation quality directly determines the safety and economy of the high-speed rail train. Therefore, the performance test and life evaluation of high-speed rail axle box bearings have always been one of the research focuses in the field of rail transportation. At present, the test methods of high-speed rail axle box bearings are mainly divided into actual vehicle operation test and test bench simulation test. The actual vehicle operation test is to install the bearings on the high-speed rail train and observe their performance and life through long-term operation. However, the actual vehicle operation test has a long cycle, high cost, and it is difficult to accurately control the test conditions, which is subject to many restrictions in practical applications. In contrast, the test bench simulation test can be carried out in a controllable environment, with the advantages of short cycle, low cost, and strong repeatability, and has become an important means of performance testing and life evaluation of high-speed rail axle box bearings.

[0003] However, the operating environment of high-speed trains is complex and changeable, and the axle box bearings need to withstand high load intensity and drastic temperature changes. The existing bearing life test benches are difficult to fully simulate the complex and strong load conditions and changeable ambient temperature of high-speed trains, and lack a test environment close to the actual operating conditions. In addition, the existing bearing life test benches mostly adopt an integrated design, which is time-consuming and labor-intensive to disassemble and assemble the test bearings, and the replacement and maintenance costs are high. The performance test and life evaluation of high-speed rail axle box bearings are crucial to the design, development and safe operation of high-speed trains. Therefore, it is urgent to develop a test device that can effectively simulate the working environment of high-speed rail train axle box bearings in high speed, heavy load, high-frequency vibration, etc., and can efficiently and reliably evaluate its performance and life. Summary of the invention

[0004] In view of the problem that the existing bearing life test benches in the prior art are difficult to fully simulate the complex and strong load conditions and changeable ambient temperature of high-speed trains, and lack a test environment close to actual operating conditions, the present invention provides a high-speed railway axle box bearing full life cycle test bench and test method.

[0005] The present invention is achieved through the following technical solutions: A full life cycle test bench for axle box bearings of a high-speed railway includes a test bench body, a test head, a drive system, a loading system, a temperature control system, an electrical control system, a computer monitoring system and a data acquisition system. The test head is detachably connected to the test bench body, a rotating shaft is arranged on the test head, a plurality of bearings to be tested are arranged on the rotating shaft through sleeves and locking nuts, a driving end of the drive system is fixedly connected to the rotating shaft, and the drive system drives the test head to rotate; The loading system includes a radial loading system and an axial loading system. The radial loading system applies a force perpendicular to the shaft on the sleeve surface of the test bearing outer ring to simulate the vertical load of the train when it is running. The axial loading system applies a load on the end face of the shaft to simulate the thrust generated by the train when turning or accelerating or decelerating. The temperature control system includes a heating system and a heat dissipation system. The heating system includes a heating box and a heating rod. The heating box is arranged on the outer surface of the test head, and the heating rod is installed at the test bearing. The heat dissipation system includes a water cooling system and air cooling auxiliary equipment. The water cooling system includes a water cooling unit, a water pump, a heat exchange box, and a water pipeline. The test bearing is quickly cooled by circulating cooling water. The air cooling auxiliary equipment includes a fan and an air guide cover. The fan is arranged at the air inlet of the air guide cover, and the air outlet is respectively located at the end of the test head and the actuator of the loading system. The electrical control system controls the working state of the test bench according to the set parameters and the data fed back by the sensor. The electrical control system includes a controller and a sensor. The output end of the sensor is connected to the input end of the controller, and the output end of the controller is connected to the drive end of each system. The computer monitoring system includes a data acquisition module and a display control module. The input end of the data acquisition module is connected to the output end of the sensor, and the output end is connected to the input end of the display control module. The display control module is used to display the rotor speed, test bearing temperature, cumulative test time, radial and axial loading data, vibration time domain and frequency domain graphics in real time, and at the same time, it commands the controller of the electrical control system according to the set parameters and issues corresponding instructions to the drive system, loading system and temperature control system. The data acquisition system includes an additional sensor, a data acquisition device, data acquisition software and a reserved interface. The additional sensor is arranged on the test head, the output end of the additional sensor is connected to the input end of the data acquisition device, the output end of the data acquisition device is connected to the data acquisition software, and the reserved interface is used to graft other acquisition systems.

[0006] Preferably, the test head is detachably connected to the test bench by means of a positioning pin and a locking bolt, the positioning pin passes through the positioning hole on the test bench body to connect the test head, and the locking bolt passes through the mounting threaded hole of the test bench body to threadably connect the test head.

[0007] Preferably, the drive system includes a drive motor, a belt drive system and a drive shaft, the output shaft of the drive motor is connected to the input end of the belt drive structure, the output end of the belt drive structure is connected to the drive shaft, and the drive shaft is connected to the rotating shaft as a drive end.

[0008] Preferably, both the radial loading system and the axial loading system adopt hydraulic loading, and the loading force is adjusted by a program-controlled load spectrum. The maximum radial load is 500kN, the maximum axial load is 100kN, and the steady-state error is ±2%FS.

[0009] Preferably, a plurality of mounting holes are provided on the test head, and the additional sensors are detachably connected to the mounting holes.

[0010] Preferably, the sensors include a force sensor, a speed sensor, an acceleration sensor, a displacement sensor and a temperature sensor. The force sensor is arranged at the loading end of the hydraulic system, the speed sensor is arranged at the transmission shaft of the drive system, the acceleration sensor is arranged on the surface of the test head, the outer ring of the test bearing and the test bench body, the displacement sensor is arranged at the outer ring of the test bearing, and the temperature sensor is arranged at the outer ring of the test bearing and the loading system actuator.

[0011] Preferably, the data acquisition system is provided with sixteen channels for simultaneously acquiring load, rotation speed, temperature, vibration and current signals.

[0012] Preferably, the data acquisition system is integrated with a signal analysis module, including an FFT analysis module, a transfer function analysis module, a response spectrum analysis module and an octave analysis module, for performing multi-point multi-data measurement. A test method for a high-speed railway axle box bearing full life cycle test bench comprises the following steps: Step 1: Install the test bench body firmly on the test site foundation with anchor bolts, check the dimensions of the rotating shaft and sleeve seat that match the inner and outer rings of the test bearing, position the test bearing with the sleeve and locking nut and install it on the test head, and fix the test head to the test bench body with the quick disassembly and assembly structure; Step 2: Check whether the shaft is blocked, check whether the drive system, loading system, temperature control system, electrical control system, computer monitoring system and data acquisition system are operating normally, and calibrate the accuracy of the sensor; Step 3: According to the test requirements, set the test speed change curve, axial load change curve, radial load change curve, ambient temperature parameter value and temperature control range, and set the vibration, temperature and time thresholds for terminating the test; Step 4: Install additional sensors, connect data acquisition equipment and data acquisition software, select data acquisition mode, and set data storage time; Step 5: Inject grease into the test bearing, apply a small amount of axial load first, then gradually increase the radial load, conduct a running-in test, and slowly increase the load and speed to the set value within 5 hours; Step 6: Officially start the full life cycle test bench, check whether the monitoring data of the computer monitoring system is within the required range, and check whether the data acquisition system is operating normally; Step 7: After the test, disassemble the test head and test bearing, check whether the test bearing is failed, take photos of the failed sample and its failure morphology, and properly preserve the test bearing sample; Step 8: Export all data recorded during the test, perform data processing and offline analysis, and evaluate the performance and life characteristics of the bearing during the test; Step 9: Check and maintain the test bench's drive system, loading system, temperature control system, electrical control system, computer monitoring system and data acquisition system, and clean the test bench and its surrounding areas.

[0013] Preferably, the driving motor controls the speed through a program to perform stepless speed change. During the test, the speed range is 600~3100 r / min, the temperature control range is 10℃~150℃, and the accuracy is ±3℃; the electrical control system controls the working state of the test bench according to the set parameters and the data fed back by the sensor, and can automatically alarm and judge to shut down when the test bearing fails or the machine fails.

[0014] Compared with the prior art, the present invention has the following beneficial effects: The invention discloses a full life cycle test bench for axle box bearing of a high-speed railway, which adopts a modular design method. The test bench has a relatively large structural rigidity, the test head is convenient to be disassembled and replaced, and the test machine is easy to maintain. The full life cycle test can be carried out under the conditions of high speed, heavy load and high frequency vibration. The speed spectrum and the load spectrum are controlled by a program, and the temperature control system can accurately adjust the working environment temperature of the test bearing, and has a high degree of restoration for the typical service working conditions of the axle box bearing of a high-speed railway train. The electrical control system and the computer monitoring system have the functions of automatic control and automatic monitoring of the test process, the test parameters are displayed in real time, and automatic alarm and judgment shutdown can be performed, so the safety is relatively high. The structure is reliable, the operation is simple, and the test efficiency is relatively high. According to the material strength, structural reliability and maximum loading conditions of the test bench, the test bench can achieve a continuous operation time of more than 3 months under full load, and the automatic monitoring and automatic control functions are realized by the electrical control system and the computer monitoring system. The alarm temperature value and the alarm vibration value can be set, and real-time monitoring is performed by the program to realize over-threshold alarm and over-limit automatic shutdown.

[0015] Furthermore, the multiple channels of the data acquisition system can collect multiple types of data simultaneously, and the storage time is adjustable. The reserved installation holes can expand the test data type and graft additional acquisition systems, which has strong adaptability.

[0016] Furthermore, the test head can be detachably connected to the test bench body, and positioning pins and locking bolts are used to achieve rapid disassembly and assembly, which helps to improve the replacement efficiency of the test head.

[0017] Furthermore, a force sensor is arranged at the loading end of the hydraulic system to measure the loading force; a speed sensor is arranged at the transmission shaft of the drive system to measure the shaft speed; an acceleration sensor is arranged on the surface of the test head, the outer ring of the test bearing and the test bench body to measure the vibration acceleration; a displacement sensor is arranged at the outer ring of the test bearing to measure the displacement change of the bearing; a temperature sensor is arranged at the outer ring of the test bearing and the actuator of the loading system to measure the temperature change. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is the equipment principle diagram of the high-speed railway axle box bearing full life cycle test bench of the present invention; Figure 2 This is a schematic diagram of the main structure of the high-speed railway axle box bearing full life cycle test bench of the present invention; Figure 3 It is a schematic diagram of the test head structure of the high-speed railway axle box bearing full life cycle test bench of the present invention. In the figure, 1. test bench body; 2. test head; 2a. sleeve; 2b. locking nut; 2c. test bearing; 2d. rotating shaft; 3. driving system; 4. loading system; 5. temperature control system; 6. electrical control system; 7. computer monitoring system; 8. data acquisition system. DETAILED DESCRIPTION

[0019] The present invention is further described in detail below in conjunction with specific embodiments, which are intended to explain the present invention rather than to limit it.

[0020] The present invention discloses a high-speed rail axle box bearing full life cycle test bench, referring to Figure 1 , 2 , including a full life cycle test bench for a high-speed railway axle box bearing, including a test bench body 1, a test head 2, a drive system 3, a loading system 4, a temperature control system 5, an electrical control system 6, a computer monitoring system 7 and a data acquisition system 8, wherein the test bench body 1 is reasonably designed according to the requirements of the test, is made of high-rigidity alloy steel material, and is subjected to relevant strength, stiffness and stability verification to meet the statics and dynamics criteria, and the test bench body 1 is provided with a plurality of positioning surfaces and mounting holes for positioning and mounting each test module, and is connected to the foundation through anchor bolts to ensure the stability of the test bench body 1.

[0021] Reference Figure 3, the test head 2 is detachably connected to the test bench body 1. Specifically, the test head 2 is detachably connected to the test bench by a positioning pin and a locking bolt. The positioning pin passes through the positioning hole on the test bench body 1 to connect the test head 2 and the locking bolt passes through the mounting threaded hole of the test bench body 1 to be threadedly connected. The test head 2 adopts a separately designed scheme to facilitate the disassembly, replacement and testing of different types of high-speed rail axle box bearings, and then is installed on the test bench body 1 through a quick disassembly structure. A rotating shaft 2d and multiple groups of test bearings 2c are assembled in the test head 2, and the positioning and installation of the test bearing 2c are achieved through a sleeve 2a and a locking nut 2b. The quick disassembly structure connecting the test head 2 and the test bench body 1 includes a positioning pin and a locking bolt. The positioning pin realizes the positioning of the test head 2 on the test bench, and the locking bolt is used to fix the test head 2; a sensor installation hole is set inside the test head 2 to facilitate the collection of the working parameters of the test bearing 2c; the lubrication method of the test bearing 2c is grease lubrication, specifically, the test bearing 2c is lubricated by injecting grease.

[0022] The test head 2 is provided with a rotating shaft 2d, and a plurality of bearings to be tested are provided on the rotating shaft 2d through a sleeve 2a and a locking nut 2b. The driving end of the driving system 3 is fixedly connected to the rotating shaft 2d, and the driving system 3 drives the test head 2 to rotate. Specifically, the driving system 3 includes a driving motor, a belt transmission system and a transmission shaft. The output shaft of the driving motor is connected to the input end of the belt transmission structure, the output end of the belt transmission structure is connected to the transmission shaft, and the transmission shaft is connected to the rotating shaft 2d as the driving end. The driving system 3 drives the rotating shaft 2d in the test head 2 to rotate through the driving motor, the belt transmission and the transmission shaft. The driving system 3 adopts a belt transmission method to ensure smooth transmission and low noise; the driving motor controls the speed through a program, which can simulate the running speed of a real high-speed train and realize a stepless speed change test; the test speed range is 600-3100 r / min, covering the current speed range of high-speed trains.

[0023] The loading system 4 includes a radial loading system 4 and an axial loading system 4. The radial loading system 4 simulates the vertical load of the train when it is running by applying a force perpendicular to the rotating shaft 2d on the surface of the sleeve 2a of the outer ring of the test bearing 2c. The axial loading system 4 applies the load on the end face of the rotating shaft 2d to simulate the thrust generated by the train when turning or accelerating or decelerating. Specifically, the radial loading system 4 and the axial loading system 4 both adopt hydraulic loading, and the actuator is a hydraulic cylinder, which is fixedly connected to the test bench body 1 by bolts and is equipped with a hydraulic oil station. The loading system 4 is equipped with a cooling device, and the surface of the hydraulic cylinder rod is anti-wear treated, so that it can run stably for a long time; the loading force output by the hydraulic cylinder is controlled by a program, and can provide square wave, sine wave, sawtooth wave and trapezoidal wave preset load spectra, which can simulate the actual complex load-bearing conditions of the high-speed rail axle box bearing; the loading force is controlled by the program-controlled load spectrum, the maximum radial load is 500kN, the maximum axial load is 100kN, and the steady-state error is ±2%FS.

[0024] The temperature control system 5 includes a heating system and a cooling system. The temperature control system 5 monitors the temperature of the test bearing 2c in real time through a temperature sensor, and automatically adjusts the working state of the heating system and the cooling system according to the feedback data. The temperature control range is 10°C~150°C, and the accuracy is ±3°C. The heating system controls the temperature rise of the test bearing 2c by adjusting the heating box and the heating rod. If the temperature exceeds the set value, the cooling system realizes the cooling of the test bearing 2c through the circulating cooling water of the water cooling system and the air cooling auxiliary equipment.

[0025] Specifically, the heating system includes a heating box and a heating rod, the heating box is arranged on the outer surface of the test head 2, and the heating rod is installed at the test bearing 2c; multiple circulating water channels are opened inside the test system, and the closed-loop control of the working environment temperature of the test bearing 2c can be achieved through the feedback value of the temperature sensor. The heat dissipation system includes a water cooling system and air cooling auxiliary equipment. The water cooling system includes a water cooling unit, a water pump, a heat exchange box, and a water pipeline. The test bearing 2c is quickly cooled by circulating cooling water. The water cooling unit is connected to the heat exchange box through a water pipeline to transport the low-temperature coolant to the heat exchange box. The water inlet of the water pump is connected to the water outlet of the water cooling unit, and the low-temperature coolant is pumped out through the water pipeline; the water outlet of the water pump is connected to the water inlet of the heat exchange box to transport the coolant to the heat exchange box. The water inlet of the heat exchange box is connected to the water outlet of the water pump to receive the low-temperature coolant; the water outlet of the heat exchange box is connected to the water inlet of the water cooling unit to send the heated coolant back to the water cooling unit for cooling. The water cooling unit generates low-temperature coolant through refrigeration cycle, providing a cooling source for the bearing, ensuring the stability of the temperature and flow of the coolant, and ensuring the cooling effect; the water pump provides sufficient pressure for the coolant to circulate in the cooling system. By adjusting the speed of the water pump or the valve opening, the flow of the coolant can be accurately controlled to meet different cooling needs. The coolant in the heat exchange box exchanges heat with the test bearing 2c, absorbs the heat generated by the bearing, and reduces the temperature of the bearing, thereby achieving rapid cooling of the test bearing 2c. Each component plays a vital role in the system, jointly ensuring the stable operation and cooling effect of the system.

[0026] The air cooling auxiliary equipment includes a fan and an air guide cover. The fan is arranged at the air inlet of the air guide cover, and the air outlet is respectively located at the end of the test head 2 and the actuator of the loading system 4. The airflow introduced by the fan can smoothly enter the air guide cover and be guided to the target area. The air guide cover evenly and efficiently covers the airflow to the heat dissipation area, thereby assisting the heat dissipation system to cool down the bearing to be tested.

[0027] The electrical control system 6 controls the working state of the test bench according to the set parameters and the data fed back by the sensor. The electrical control system 6 includes a controller and a sensor. The output end of the sensor is connected to the input end of the controller, and the output end of the controller is connected to the driving end of each system. The controller issues instructions to drive the corresponding system to achieve corresponding working conditions. For example, when the temperature value or load force value returned by the sensor exceeds the set value, the controller issues instructions to the heat dissipation device of the temperature control system 5 and the hydraulic device of the loading system 4 for adjustment.

[0028] The sensors include force sensors, speed sensors, acceleration sensors, displacement sensors and temperature sensors. The force sensors are arranged at the loading end of the hydraulic system, the speed sensors are arranged at the transmission shaft of the drive system 3, the acceleration sensors are arranged on the surface of the test head 2, the outer ring of the test bearing 2c and the test bench body 1, the displacement sensors are arranged at the outer ring of the test bearing 2c, and the temperature sensors are arranged at the outer ring of the test bearing 2c and the actuator of the loading system 4. The electrical control system drives the controller and other systems (temperature control system 5, loading system 4, etc.) to make corresponding working states according to the set parameters and the data fed back by the sensors, which is used to monitor and control various parameters in the test. When the temperature or vibration exceeds the alarm value, the test bearing 2c fails, or the machine fails, it can automatically alarm and judge the shutdown.

[0029] The computer monitoring system 7 includes a data acquisition module and a display control module. The input end of the data acquisition module is connected to the output end of the sensor, and the output end is connected to the input end of the display control module. The data acquisition module collects the working parameters of the current test bearing 2c in real time through multiple sensors. The display control module displays the rotor speed, test bearing 2c temperature, cumulative test time, radial and axial loading data, vibration time domain and frequency domain graphics in the current test process in real time through a computer embedded integrated cabinet. The test personnel can easily monitor the test process and analyze the test data. At the same time, according to the set parameters (touch screen, keyboard, etc.), the controller of the electrical control system 6 is commanded to issue corresponding instructions to the drive system 3, loading system 4 and temperature control system 5.

[0030] The data acquisition system 8 includes an additional sensor, a data acquisition device, data acquisition software and a reserved interface. The additional sensor is arranged on the test head 2. Specifically, the test head 2 is provided with a plurality of mounting holes, and the additional sensor is detachably connected to the mounting holes. The output end of the additional sensor is connected to the input end of the data acquisition device, and the output end of the data acquisition device is connected to the data acquisition software. The reserved interface is used to connect other acquisition systems. The data acquisition system 8 is provided with sixteen channels for simultaneously collecting load, rotation speed, temperature, vibration and current signals, and the storage time of the collected data is adjustable. The data acquisition system 8 is integrated with a signal analysis module, including an FFT analysis module, a transfer function analysis module, a response spectrum analysis module and an octave analysis module, for multi-point multi-data measurement.

[0031] The electrical control system 6 and the computer monitoring system 7 are used to comprehensively monitor, control and protect the test bench. Through the cooperation of the two systems, the test bench is highly automated and intelligent, with a simple operating process, strong safety and high work efficiency; the data acquisition system 8 can simultaneously collect the load, speed, temperature, vibration and current signals of the test bearing 2c. Its data recording methods are divided into continuous recording and periodic recording, and the storage time of the collected data is adjustable, and offline data analysis can be performed; the data acquisition system 8 is designed with a reserved interface, which can be grafted with other acquisition systems to expand the test data type.

[0032] The auxiliary equipment of the test bench includes a lifting hydraulic crane, a loading and unloading hook, a test head 2 disassembly and assembly frame, a tool cabinet and supporting tools, which are used for the installation and disassembly of the test bearing 2c.

[0033] The high-speed railway axle box bearing full life cycle test bench of the present invention can effectively simulate the complex working environment of the axle box bearing of the high-speed railway train in actual operation, can realize the preset of speed spectrum and load spectrum through program control, can comprehensively simulate the complex and strong load conditions and changeable ambient temperature of the high-speed railway train, can carry out full life cycle test on various types of high-speed railway axle box bearings under high speed, heavy load and high-frequency vibration conditions, has the characteristics of simple operation, safety and reliability, and efficient testing, and can effectively solve the problems of incomplete simulation of the operating environment of the high-speed railway axle box bearing and low credibility of life assessment in the prior art.

[0034] The present invention also discloses a full life cycle test method for a high-speed railway axle box bearing, comprising the following steps: Step 1: Install the test bench body firmly on the test site foundation through anchor bolts, check the dimensions of the rotating shaft 2d and the sleeve 2a hole seat that match the inner and outer rings of the test bearing 2c, position the test bearing 2c through the sleeve 2a and the locking nut 2b and install it on the test head 2, and fix the test head 2 to the test bench body 1 through the quick disassembly and assembly structure; Step 2, check whether the rotating shaft 2d is blocked, check whether the driving system 3, loading system 4, temperature control system 5, electrical control system 6, computer monitoring system 7 and data acquisition system 8 are operating normally, and calibrate the accuracy of the sensor; Step 3: According to the test requirements, set the test speed change curve, axial load change curve, radial load change curve, ambient temperature parameter value and temperature control range, and set the vibration, temperature and time thresholds for terminating the test; Step 4: Install additional sensors, connect data acquisition equipment and data acquisition software, select data acquisition mode, and set data storage time; Step 5: Inject grease into the test bearing 2c, apply a small amount of axial load first, then gradually increase the radial load, carry out a running-in test, and slowly increase the load and speed to the set value within 5 hours; Step 6: formally start the full life cycle test bench, check whether the monitoring data of the computer monitoring system 7 is controlled within the required range, and check whether the data acquisition system 8 is operating normally; Step 7: After the test, disassemble the test head 2 and the test bearing 2c, check whether the test bearing 2c is failed, take photos of the failed sample and its failure morphology, and properly preserve the test bearing 2c sample; Step 8: Export all data recorded during the test, perform data processing and offline analysis, and evaluate the performance and life characteristics of the bearing during the test; Step 9: Check and maintain the test bench's drive system 3, loading system 4, temperature control system 5, electrical control system 6, computer monitoring system 7 and data acquisition system 8, and clean the test bench and its surrounding areas.

[0035] The electrical control system 6 controls the working state of the actuator according to the set parameters and the data fed back by the sensor, and can automatically alarm and judge to shut down when the test bearing 2c fails or the machine fails.

[0036] The above description is only a preferred embodiment of the present invention and is not intended to impose any limitation on the technical solution of the present invention. Those skilled in the art should understand that, without departing from the spirit and principles of the present invention, the technical solution can also be subjected to several simple modifications and substitutions, and these modifications and substitutions are also within the scope of protection covered by the claims.

Claims

1. A high-speed railway axle box bearing full life cycle test bench, characterized in that: It includes a test bench body, a test head, a drive system, a loading system, a temperature control system, an electrical control system, a computer monitoring system and a data acquisition system. The test head is detachably connected to the test bench body. A rotating shaft is arranged on the test head. A plurality of bearings to be tested are arranged on the rotating shaft through sleeves and locking nuts. The driving end of the drive system is fixedly connected to the rotating shaft. The drive system drives the test head to rotate. The loading system includes a radial loading system and an axial loading system. The radial loading system applies a force perpendicular to the shaft on the sleeve surface of the test bearing outer ring to simulate the vertical load of the train when it is running. The axial loading system applies a load on the end face of the shaft to simulate the thrust generated by the train when turning or accelerating or decelerating. The temperature control system includes a heating system and a heat dissipation system. The heating system includes a heating box and a heating rod. The heating box is arranged on the outer surface of the test head, and the heating rod is installed at the test bearing. The heat dissipation system includes a water cooling system and air cooling auxiliary equipment. The water cooling system includes a water cooling unit, a water pump, a heat exchange box, and a water pipeline. The test bearing is quickly cooled by circulating cooling water. The air cooling auxiliary equipment includes a fan and an air guide cover. The fan is arranged at the air inlet of the air guide cover, and the air outlet is respectively located at the end of the test head and the actuator of the loading system. The electrical control system controls the working state of the test bench according to the set parameters and the data fed back by the sensor. The electrical control system includes a controller and a sensor. The output end of the sensor is connected to the input end of the controller, and the output end of the controller is connected to the drive end of each system. The computer monitoring system includes a data acquisition module and a display control module. The input end of the data acquisition module is connected to the output end of the sensor, and the output end is connected to the input end of the display control module. The display control module is used to display the rotor speed, test bearing temperature, cumulative test time, radial and axial loading data, vibration time domain and frequency domain graphics in real time, and at the same time, it commands the controller of the electrical control system according to the set parameters and issues corresponding instructions to the drive system, loading system and temperature control system. The data acquisition system includes an additional sensor, a data acquisition device, data acquisition software and a reserved interface. The additional sensor is arranged on the test head, the output end of the additional sensor is connected to the input end of the data acquisition device, the output end of the data acquisition device is connected to the data acquisition software, and the reserved interface is used to graft other acquisition systems.

2. The high-speed railway axle box bearing full life cycle test bench according to claim 1 is characterized in that: The test head is detachably connected to the test bench by means of a positioning pin and a locking bolt. The positioning pin passes through the positioning hole on the test bench body to connect the test head, and the locking bolt passes through the mounting threaded hole of the test bench body to thread the test head.

3. The high-speed railway axle box bearing full life cycle test bench according to claim 1 is characterized in that: The drive system includes a drive motor, a belt transmission system and a transmission shaft. The output shaft of the drive motor is connected to the input end of the belt transmission structure, the output end of the belt transmission structure is connected to the transmission shaft, and the transmission shaft is connected to the rotating shaft as a drive end.

4. The high-speed railway axle box bearing full life cycle test bench according to claim 1 is characterized in that: Both the radial loading system and the axial loading system adopt hydraulic loading. The loading force is adjusted by the program-controlled load spectrum. The maximum radial load is 500kN, the maximum axial load is 100kN, and the steady-state error is ±2%FS.

5. The high-speed railway axle box bearing full life cycle test bench according to claim 1 is characterized in that: The test head is provided with a plurality of mounting holes, and the additional sensors are detachably connected to the mounting holes.

6. The high-speed railway axle box bearing full life cycle test bench according to claim 1 is characterized in that: The sensors include force sensors, speed sensors, acceleration sensors, displacement sensors and temperature sensors. The force sensor is arranged at the loading end of the hydraulic system, the speed sensor is arranged at the transmission shaft of the drive system, the acceleration sensor is arranged on the surface of the test head, the outer ring of the test bearing and the test bench body, the displacement sensor is arranged at the outer ring of the test bearing, and the temperature sensor is arranged at the outer ring of the test bearing and the loading system actuator.

7. The high-speed railway axle box bearing full life cycle test bench according to claim 1 is characterized in that: The data acquisition system is equipped with sixteen channels for simultaneously collecting load, speed, temperature, vibration and current signals.

8. The high-speed railway axle box bearing full life cycle test bench according to claim 1 is characterized in that: The data acquisition system is integrated with signal analysis modules, including FFT analysis module, transfer function analysis module, response spectrum analysis module and octave analysis module, for multi-point and multi-data measurement.

9. A test method using the high-speed railway axle box bearing full life cycle test bench as claimed in any one of claims 1 to 8, characterized in that: The following steps are involved: Step 1: Install the test bench body firmly on the test site foundation with anchor bolts, check the dimensions of the rotating shaft and sleeve seat that match the inner and outer rings of the test bearing, position the test bearing with the sleeve and locking nut and install it on the test head, and fix the test head to the test bench body with the quick disassembly and assembly structure; Step 2: Check whether the shaft is blocked, check whether the drive system, loading system, temperature control system, electrical control system, computer monitoring system and data acquisition system are operating normally, and calibrate the accuracy of the sensor; Step 3: According to the test requirements, set the test speed change curve, axial load change curve, radial load change curve, ambient temperature parameter value and temperature control range, and set the vibration, temperature and time thresholds for terminating the test; Step 4: Install additional sensors, connect data acquisition equipment and data acquisition software, select data acquisition mode, and set data storage time; Step 5: Inject grease into the test bearing, apply a small amount of axial load first, then gradually increase the radial load, conduct a running-in test, and slowly increase the load and speed to the set value within 5 hours; Step 6: Officially start the full life cycle test bench, check whether the monitoring data of the computer monitoring system is within the required range, and check whether the data acquisition system is operating normally; Step 7: After the test, disassemble the test head and test bearing, check whether the test bearing is failed, take photos of the failed sample and its failure morphology, and properly preserve the test bearing sample; Step 8: Export all data recorded during the test, perform data processing and offline analysis, and evaluate the performance and life characteristics of the bearing during the test; Step 9: Check and maintain the test bench's drive system, loading system, temperature control system, electrical control system, computer monitoring system and data acquisition system, and clean the test bench and its surrounding areas.

10. The test method of the high-speed railway axle box bearing full life cycle test bench according to claim 9 is characterized in that: The driving motor is program-controlled for stepless speed change. During the test, the speed range is 600~3100 r / min, the temperature control range is 10℃~150℃, and the accuracy is ±3℃. The electrical control system controls the working state of the actuator according to the set parameters and sensor feedback data. When the test bearing fails or the machine fails, it can automatically alarm and judge to shut down.

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