Device for testing fatigue performance of integral dropper and electric connection of overhead line system

Abstract

The invention discloses a fatigue performance testing device for an integral dropper and electric connection of an overhead line system. The testing device comprises a double-station four-column frame main frame, an electromagnetic linear actuator, a liftable cross beam system, a double-station testing tool, a sensor system, a power system and a control system. The electromagnetic actuator is composed of an actuator body, a piston rod and an electromagnetic control module. The liftable cross beam system comprises a cross beam, a hydraulic driving mechanism and a cross beam driving module; the testing tool comprises an upper supporting assembly, a lower supporting assembly, a force applying part and a force buffering part. The power system is used for hydraulic driving and electromagnetic actuator cooling. The control system is composed of a servo controller, an electric cabinet, a computer and test software. The device provided by the invention can realize composite simulation of mechanical load, current load and environmental working condition, is suitable for multi-load fatigue test of an integral dropper and an electric connector of the contact network, and obtains experimental data required by reliability evaluation and life prediction of parts of the contact network.

Description

Technical Field

[0001] The present invention relates to the technical field of electrified railways, and particularly relates to a fatigue performance test device for an integral catenary suspension and electrical connection. Background Art

[0002] With the rapid development of high-speed railways, the catenary, as a key component in the railway electrification system, the reliability of its components is directly related to the safety and stability of railway operation. The catenary suspension and electrical connection, as key components for carrying current and ensuring electrical transmission, their fatigue performance during long-term operation is particularly important. Since in actual operation, the suspension and electrical connection often bear multiple loads such as different compression amplitudes, tensile forces, and current impacts, it is easy to cause fatigue damage, which in turn affects the normal operation of the catenary and power supply stability. To ensure the long-term reliability of catenary components, it is urgently necessary to conduct in-depth tests and research on the reliable life of the suspension and electrical connection, especially the fatigue life and performance degradation under complex working conditions. Through the comprehensive fatigue performance test machine for catenary suspension and electrical connection, relevant tests are carried out to provide a scientific basis for the design optimization, life assessment, and maintenance decision-making of the suspension and electrical connection, and to improve the overall operation reliability and safety of the high-speed railway catenary.

[0003] Although the existing fatigue test devices for catenary suspension and electrical connection can well evaluate the performance and life of the integral suspension and electrical connection, they have the following defects:

[0004] (1) Most of the existing test devices can only simulate vibrations or static loads in a single direction, while in actual operation, the suspension and electrical connection need to bear multi-directional dynamic loads such as vertical vibrations, lateral swings, and longitudinal tensile forces, resulting in a large deviation between the test results and the actual fatigue life.

[0005] (2) The dynamic load control accuracy of the device is insufficient. The dynamic response speed of the load loading system of most existing test devices is insufficient, making it difficult to accurately simulate the transient impact load when a high-speed train passes. At the same time, the adjustment range of the load amplitude and frequency is limited and cannot cover the complex and changeable actual working conditions.

[0006] (3) The data acquisition and analysis capabilities of most existing test devices are weak, and the types of sensors are single. For example, only displacement or strain is monitored, lacking real-time monitoring of the vibration spectrum of the test sample and microscopic damage of the material.

[0007] (4) The simulation of multi-load coupling is insufficient. Most existing devices test the current load and mechanical vibration separately, while in actual operation, the suspension and electrical connection need to bear the current thermal effect and mechanical vibration simultaneously, and the coupling effect of the two accelerates fatigue damage, but it is difficult for the existing test devices to truly reproduce.

[0008] (5) The standardization and versatility of the device are insufficient. There are significant differences in the design of test devices among different manufacturers or research institutions, lacking a unified test standard, making it difficult to adapt to test samples of different specifications, and taking a long time to adjust parameters, etc. Summary of the Invention

[0009] To overcome the problems existing in the above prior art, the present invention proposes a fatigue performance test device for the integral catenary suspension and electrical connection, which realizes the fatigue performance test of the catenary suspension and electrical connection under complex working conditions through a high-precision control system and a multi-functional test platform. This device can simultaneously simulate mechanical vibration, current load and other environmental factors to meet the life reliability performance test requirements of high-speed railway catenary components in actual operation.

[0010] The object of the present invention can be achieved through the following technical solutions:

[0011] A fatigue performance test device for the integral catenary suspension and electrical connection includes a main frame, an electromagnetic linear actuator, a crossbeam system, a two-station test tooling, a sensor system, a power system and a control system, which can accurately apply loads under various complex working conditions to ensure the accuracy and repeatability of test data. Its structural and functional characteristics are as follows:

[0012] The main frame is a two-station four-column frame structure. Four columns are vertically installed at the four corners of the base, and the tops of the columns are rigidly connected to the top plate to form a closed load-bearing frame, providing stable support for the test system.

[0013] The electromagnetic linear actuator includes an actuator body, a piston rod and an electromagnetic control module. The actuator body is fixedly installed at the center of the base, and the piston rod is rigidly connected to the liftable crossbeam system and arranged along the axial direction of the main frame, responsible for applying axial dynamic loads.

[0014] The crossbeam system includes a main crossbeam system and a crossbeam system for the two-station test system;

[0015] Among them, the main crossbeam system includes a crossbeam, a hydraulic drive mechanism and a crossbeam drive module. The two ends of the crossbeam are slidably connected to the columns through linear guides. The hydraulic drive mechanism includes symmetrically arranged double hydraulic cylinders for lifting, a hydraulic locking device and an elastic release mechanism; the lifting and positioning adjustment of the main crossbeam are realized through the lifting of double hydraulic cylinders, the locking of double-position synchronous hydraulic cylinders and elastic release, ensuring the stability and reliability of the crossbeam during the test process, and at the same time keeping the crossbeam locked and immovable in the non-test state.

[0016] The crossbeam system of the two-station test system serves the double-station test tooling. It adopts a hydraulic lifting and hydraulic locking structure and is equipped with a fatigue test standard space adjustment mechanism. Before the test, the crossbeam can be lowered to a low position for easy specimen installation. After the specimen is fixed, the crossbeam can be raised to the working position and automatically locked with one-key operation to ensure rigidity and stability during the whole test process.

[0017] The double-station test tooling includes an upper support assembly, a lower support assembly, a force application component, and a force buffer component. Among them, the upper support assembly is installed on the bottom surface of the crossbeam, and the lower support assembly is installed on the base platform surface. The upper support assembly and the lower support assembly are coaxially arranged and form a specimen clamping space with adjustable spacing and multi-size compatibility. The force application component is fixed on the lower support assembly, and the force buffer component is fixed on the upper support assembly. The force application component and the force buffer component are coaxially arranged, and precise clamping is achieved by adjusting the specimen position, providing a reliable test space for the fatigue loading of suspension insulators or electrical connections.

[0018] The sensor system includes:

[0019] (1) A multi-dimensional force sensor arranged on the force buffer component to real-time monitor the force information during the loading process;

[0020] (2) A displacement sensor integrated in the electromagnetic linear actuator to monitor the piston rod stroke and the loading displacement;

[0021] (3) A temperature sensor installed around the specimen to real-time monitor the environmental and specimen temperature status.

[0022] The power system includes a hydraulic station for supplying energy to the hydraulic drive mechanism and a cooling system for cooling the electromagnetic linear actuator;

[0023] The control system includes a full-digital single-channel servo controller, a full-power electrical cabinet, a computer, and its integrated test operation software, which are electrically connected to the electromagnetic linear actuator; it can realize the alternate loading of compression-tension of suspension insulators, the fatigue test loading of current-carrying suspension insulators, and the random vibration test of electrical connections according to parameters such as the current amplitude, vibration frequency, compression amplitude, and dynamic tensile force set by the user;

[0024] The test device adopts a modular fixture system, and realizes the integration of suspension insulator-related tests and electrical connection-related tests by switching the specimen clamping mechanism, thereby improving the adaptability and utilization rate of the test device.

[0025] Furthermore, the test device also includes test accessories, a current source, acquisition sensors, an insulation protection system, and other auxiliary accessories.

[0026] Furthermore, the electromagnetic linear actuator adopts a floating guiding structure, is provided with a self-centering locking mechanism and an anti-side deviation guiding ring, and a water cooling channel is built in the electromagnetic linear actuator body to form a closed-loop circuit with an external cooling system, effectively controlling the working temperature rise of the actuator.

[0027] Furthermore, the hydraulic locking device adopts a two-position synchronous hydraulic cylinder structure, including an elastic loosening mechanism and a pressure maintaining valve group, and can realize the automatic switching between the lifting state of the crossbeam during the test and the locking state during non-test.

[0028] Furthermore, the outer surface of the column of the main frame is treated with electroplated hard chromium to improve its anti-wear and corrosion resistance, and is suitable for the test requirements under long-term high-intensity and multi-environment conditions.

[0029] Furthermore, the exposed metal parts of the testing device, all connectors and the bare metal of the lower platform are covered with insulating films, and circular shields are used for protection on both sides of the column, which not only ensures the safety of personnel, but also does not affect the lifting of the crossbeam. All connecting wire harnesses are fixed and isolated with insulating materials, and insulating materials are used to ensure the insulation protection from other equipment parts, ensuring that the whole machine meets the high-standard electrical safety requirements of the catenary industry.

[0030] Furthermore, the crossbeam drive module adopts a manual rotary valve control method to control the coordinated movement of the double hydraulic cylinders and the clamping device, and realizes the lifting and positioning adjustment of the crossbeam.

[0031] Furthermore, the testing device also includes an external current generator, which can simulate the current-carrying conditions of the dropper with different amplitudes and intermittent periods by connecting with the control system, and provides a real electrical environment for the current-carrying fatigue test of the electrical connection.

[0032] Furthermore, the control system can set and control test parameters including vibration frequency, current amplitude, displacement, force, acceleration, etc. through a software interface, realize the control of arbitrarily given force and displacement waveforms, meet complex and diverse fatigue loading conditions, and ensure the precise execution of the test process.

[0033] Furthermore, the random vibration test of the electrical connection outputs a time-displacement signal through computer processing according to the position power spectral density input by the user, and uses this signal for real-time driving and loading of the actuator to simulate the force condition at the moment of the relative movement between the pantograph and the catenary, and realizes the accurate simulation of the actual vibration environment of the electrical connection.

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

[0035] (1) Multi-load composite loading technology: The device of the present invention can achieve synchronous coupling loading of mechanical vibration and current load, breaking through the limitation of traditional testing equipment that can only apply a single mechanical or electrical load; through the cooperative control of the electro-dynamic servo system and the current generator, it accurately simulates the composite working conditions of current impact and mechanical vibration of key components of the catenary when the train pantograph slides.

[0036] (2) Integrated design of dual test objects: The device of the present invention designs a modular fixture system, and realizes the functional integration of integral dropper testing and electrical connection testing by switching the clamping mechanism. Using one device for two purposes significantly improves the equipment utilization rate.

[0037] (3) Comprehensive coverage of working conditions and strong compatibility and expandability: The device of the present invention can accurately control the vibration frequency and simulate the vibration conditions of the high-speed railway catenary at different operating speeds; compared with traditional testing equipment, it can cover a wider frequency range and allows users to customize the input waveforms, including various waveforms such as sine waves, square waves, and pulse waves. Brief Description of the Drawings

[0038] Figure 1 is the front view of the testing device of the present invention;

[0039] Figure 2 is the side view of the testing device of the present invention;

[0040] Figure 3 is the effect diagram of the testing device of the present invention;

[0041] Figure 4 is the system working principle diagram.

[0042] 1. Crossbeam system of the two-station testing system, 2. Upper support component, 3. Lower support component, 4. Force applying component, 5. Force buffer component. Detailed Embodiments

[0043] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the 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, any modifications, equivalent replacements, improvements, etc., shall be included in the protection scope of the present invention.

[0044] Such as Figure 1 、 Figure 2 and Figure 3As shown in the figure, this embodiment provides a fatigue performance test device for the integral catenary suspension and electrical connection. The test device includes a main frame, an electromagnetic linear actuator 1, a crossbeam system, a two-station test tooling 2, a sensor system, a power system, a control system, an external current generator connected to the control system, test fixtures, a current source, acquisition sensors, an insulation protection system, and other auxiliary accessories. The test device can accurately apply loads under various complex working conditions, simulate the current-carrying working conditions of the suspension with different amplitudes and intermittent periods, provide a real electrical environment for the current-carrying fatigue test of the electrical connection, and ensure the accuracy and repeatability of the test data.

[0045] This test device is a special equipment for testing the fatigue performance of the integral catenary suspension and electrical connection, integrating various working condition simulation tests such as multi-load fatigue tests, current-carrying fatigue tests, and random vibration tests. By obtaining the experimental data required for the reliability assessment and life prediction of catenary components, it evaluates the reliability and life prediction of catenary components, providing experimental data support for the electrical safety and equipment optimization of the rail transit industry. Its structural and functional characteristics are as follows:

[0046] The main frame is a two-station four-column frame structure. Four columns are vertically installed at the four corners of the base, and the tops of the columns are rigidly connected to the top plate, forming a closed load-bearing frame to provide stable support for the test system.

[0047] The electromagnetic linear actuator includes an actuator body, a piston rod, and an electromagnetic control module. The actuator body is fixedly installed at the center of the base, and the piston rod is rigidly connected to the liftable crossbeam system, arranged along the axial direction of the main frame, responsible for applying axial dynamic loads.

[0048] The crossbeam system includes a main crossbeam system of the host and a crossbeam system of the two-station test system;

[0049] Among them, the main crossbeam system of the host includes a crossbeam, a hydraulic drive mechanism, and a crossbeam drive module. Both ends of the crossbeam are slidably connected to the columns through linear guides. The hydraulic drive mechanism includes symmetrically arranged double hydraulic cylinders for lifting, a hydraulic locking device, and an elastic release mechanism; the lifting and positioning adjustment of the main crossbeam of the host are realized through the lifting of double hydraulic cylinders, the locking of double-position synchronous hydraulic cylinders, and elastic release, ensuring the stability and reliability of the crossbeam during the test process, and at the same time keeping the crossbeam locked and immovable in the non-test state.

[0050] The crossbeam system of the two-station test system 1 serves the two-station test tooling, adopts a hydraulic lifting and hydraulic locking structure, and is equipped with a standard space adjustment mechanism for fatigue tests. Before the test, the crossbeam can be lowered to a low position for easy installation of the specimen. After the specimen is fixed, the crossbeam can be raised to the working position with one key operation and automatically locked to ensure the rigidity and stability during the entire test process.

[0051] The double-station test tooling includes an upper support assembly 2, a lower support assembly 3, a force application component 4, and a force buffer component 5. Among them, the upper support assembly 2 is installed on the bottom surface of the crossbeam, and the lower support assembly 3 is installed on the base platform surface. The upper support assembly 2 and the lower support assembly 3 are coaxially arranged and form a sample clamping space with adjustable spacing and multi-size compatibility. The force application component 4 is fixed on the lower support assembly, and the force buffer component 5 is fixed on the upper support assembly 2. The force application component 4 and the force buffer component 5 are coaxially arranged. Precise clamping is achieved by adjusting the sample position, providing a reliable test space for the fatigue loading of suspension insulators or electrical connections.

[0052] The sensor system includes:

[0053] (1) A multi-dimensional force sensor disposed on the force buffer component, which real-time monitors the force information during the loading process;

[0054] (2) A displacement sensor integrated in the electromagnetic linear actuator, which monitors the piston rod stroke and the loading displacement;

[0055] (3) A temperature sensor installed around the sample, which real-time monitors the environmental and sample temperature states.

[0056] The power system includes a hydraulic station that supplies energy to the hydraulic drive mechanism and a cooling system that cools the electromagnetic linear actuator;

[0057] The control system includes a full-digital single-channel servo controller, a full-power electrical cabinet, a computer, and its integrated test operation software that are electrically connected to the electromagnetic linear actuator; it can achieve the alternate compression-tension loading of suspension insulators, the current-carrying fatigue test loading of suspension insulators, and the random vibration test of electrical connections according to parameters such as the current amplitude, vibration frequency, compression amplitude, and dynamic tensile force set by the user;

[0058] The test device adopts a modular fixture system, and the integration of suspension insulator-related tests and electrical connection-related tests is achieved by switching the sample clamping mechanism, thereby improving the adaptability and utilization rate of the test device.

[0059] The electromagnetic linear actuator adopts a floating guide structure, is provided with a self-centering locking mechanism and an anti-side deviation guide ring. The main body of the electromagnetic linear actuator is internally provided with a water cooling channel to form a closed-loop circuit with the external cooling system, effectively controlling the working temperature rise of the actuator. In the low-temperature state, it can ensure that the actuator has the maximum power output. The specific model selection is as follows:

[0060] (1) When the frequency is 5 Hz and the corresponding amplitude is ±20 mm (peak to valley 40 mm), the average acceleration is 2.5 m / s 2 ;

[0061] (2) The limit value is 2.5 m / s 2 π = 7.85 m / s2 ≈8 m / s 2 ;

[0062] (3) The actuator reserves a safety factor of one time, ≈15 m / s 2 , 15 m / s 2 It can meet the test conditions at a frequency of 5 Hz and an amplitude of 40 mm;

[0063] (4) Actuator loading frequency: 0 - 100 Hz;

[0064] (5) Static force: ±790 N (natural cooling). If considering the equipment performance and design margin requirements, after adding a water-cooling device, the testing machine can provide a maximum dynamic force of ±2000 N;

[0065] (6) Effective stroke of the actuator: 200 mm;

[0066] (7) Maximum linear velocity: 4 m / s; Maximum acceleration: 35 m / s 2 ;

[0067] (8) The actuator is equipped with a Renishaw high-precision laser displacement sensor. A buffer zone is designed at the limit position of the actuator amplitude to avoid damage caused by out-of-control operation;

[0068] The test fixture includes a special ceramic / phenolic resin fixture for the fatigue test of suspension strings. The fixture is composed of a combination of steel metal parts and high-density non-metal parts, and has the characteristics of anti-impact load, insulation, corrosion resistance (insulation under energized state), high temperature resistance when the connecting parts are energized and heated, etc. The composite test fixture can meet the dynamic and static tests under loaded (energized) conditions. The jaws of the fixture adopt a V-shaped structure, which can meet the tensile clamping of specimens with different diameters. The V-shaped jaws are well-centered, and the inclined surfaces are provided with corresponding horizontal or inclined stripes to ensure no slipping and no side slip during the tensile process.

[0069] The hydraulic locking device adopts a two-position synchronous hydraulic cylinder structure, including an elastic release mechanism and a pressure-holding valve group, and can realize the automatic switching between the lifting state of the crossbeam during the test and the locking state during non-test.

[0070] The outer surface of the columns of the main frame is treated with electroplated hard chromium to improve its anti-wear and corrosion resistance performance, and is suitable for the test requirements under long-term high-intensity and multi-environment conditions.

[0071] The exposed metal parts of the test device, all connecting parts, and the exposed metal of the lower platform are covered with insulating films, and circular shields are used to protect both sides of the columns. This not only ensures the safety of personnel, but also does not affect the lifting of the crossbeam. All connecting wire harnesses are fixed and isolated with insulating materials, and insulating materials are used to ensure the insulation protection from other equipment parts, ensuring that the whole machine meets the high-standard electrical safety requirements of the catenary industry.

[0072] The crossbeam drive module adopts a manual rotary valve control method to control the coordinated movement of the double hydraulic cylinders and the clamping device, so as to realize the lifting and positioning adjustment of the crossbeam.

[0073] The control system adopts a full-digital single-channel servo control system, which can set and control test parameters including vibration frequency, current amplitude, displacement, force, acceleration, etc. through a software interface, realize the control of arbitrarily given force and displacement waveforms, meet complex and diverse fatigue loading conditions, and ensure the precise execution of the test process.

[0074] The servo control system includes 2 control channels, including three closed-loop control loops for test force, test displacement, and test deformation, and has the function of seamless switching of control modes. The highest closed-loop control data refresh frequency is 1 kHz; the A / D and D / A resolutions of the controller are 16 bits; the signal generation frequency range is 0.001 Hz to 100 Hz; the signal generator waveforms include sine wave, triangular wave, square wave, and sawtooth wave; the servo drive unit is used to drive the linear motor; the remote servo enable control function is used to remotely control the drive power supply of the linear motor; the controller has the function of setting limit parameters and has complete protection functions. In addition to overload (110%) protection and secondary overcurrent protection, it also has dynamically set upper and lower load limits, static load upper and lower limits, frequency protection, etc. During the test process, when the test peak force fluctuation exceeds ±10% of the set parameter of the test tensile force (peak force), the equipment can realize the determination of specimen failure and shutdown, and automatically stop.

[0075] The described electrical connection random vibration test outputs a time-displacement signal through computer processing according to the position power spectral density input by the user, and uses this signal for real-time drive loading of the actuator to simulate the force condition at the moment of the relative movement between the pantograph and the catenary, so as to accurately simulate the actual vibration environment of the electrical connection.

[0076] This embodiment adopts a catenary integral suspension string and electrical connection fatigue performance test device. The design purpose is to comprehensively test the performance of catenary components by simulating different working conditions, and evaluate their fatigue life and reliability under multi-load conditions. The test device of the present invention supports suspension string fatigue tests, electrical connection random vibration tests, current-carrying fatigue tests, etc., and can accurately simulate the vibration, pressure and current loads in the actual operation of the catenary, help evaluate the reliability of components, predict their service life, and provide data support for component material selection, maintenance and optimization in rail transit and power systems.

[0077] The specific functions achieved include:

[0078] (1) Multi-load fatigue loading: Support the alternating loading of compression-tension conditions of suspension strings, current-carrying fatigue loading of suspension strings, and can simulate the random vibration of electrical connections.

[0079] (2) Precise testing can simulate the working environment of catenary components under actual working conditions by precisely controlling various test parameters (such as force, displacement, frequency, current, etc.).

[0080] (3) Simulation of multiple environmental conditions: It supports the monitoring and adjustment of multiple test parameters such as environmental temperature, force, and acceleration to ensure the comprehensiveness and accuracy of test data.

[0081] The test device of the present invention controls parameters such as displacement, force, acceleration, and compression amplitude loading through a supporting host computer to ensure the controllability of various indicators during the specimen test. In the dropper fatigue test, the test device can achieve semi-cycle displacement and semi-cycle force control, and perform compression-tension cyclic loading on the dropper. In addition, the device can carry out random vibration tests according to the power spectrum or energy spectrum provided by the user, and reproduce the external input loading curve.

[0082] Specifically, in the dropper fatigue test, the device of the present invention supports the following loading methods for multiple working conditions:

[0083] (1) Alternate compression-tension loading of the dropper: According to the maximum compression amplitude (the maximum compression amplitude is 100 mm when the loading frequency is 2 Hz) and the maximum dynamic tensile force (maximum 2000 N) input by the user, the maximum test frequency can reach 100 Hz (the amplitude-frequency characteristic satisfies that the product of frequency and amplitude is a constant value of 200, such as the maximum compression amplitude is 40 mm when the frequency is 5 Hz).

[0084] (2) Current-carrying fatigue loading of the dropper: After adding an external current generator, the device supports simulating the fatigue loading of the dropper under current load, and setting the current amplitude and the electrical continuity interruption time. The dropper fatigue test is a compression-tension cycle composed of semi-cycle compression and semi-cycle tension (subject to the test cycle in the standard "Q / CR 979.7-2023 Test Methods for Catenary Components of Railways"), and the corresponding dropper fatigue test frequency is the number of times the device completes this test cycle within 1 s.

[0085] During the experiment, the device of the present invention can monitor and record the following data in real time:

[0086] (1) Force and displacement data: Record the force and deformation of the dropper during the loading process through a force sensor and a displacement sensor.

[0087] (2) Electrical data: Monitor the influence of electrical load through a current sensor and evaluate the influence of electrical continuity interruption on the dropper.

[0088] (3) Life prediction: Calculate the fatigue life of the dropper based on the fatigue data generated during the test and predict its reliability performance under actual working conditions.

[0089] Specific experimental steps include:

[0090] (1) Load application: Through an electromagnetic linear actuator, an axial dynamic load perpendicular to the suspension string is accurately applied to simulate the pressure fluctuations that the suspension string may encounter during the operation of high-speed railways.

[0091] (2) Current simulation: Using an external current generator, the device can simulate the influence of current on the suspension string according to the set current amplitude, frequency, and duration, and conduct alternating experiments with mechanical fatigue loading.

[0092] (3) Test control: The test process is completed through a supporting host computer control system. Users can adjust the test parameters in real time, including force, displacement, acceleration, and compression amplitude, to ensure the accuracy and reliability of each loading.

[0093] The specific parameters of the current generator include:

[0094] (1) Input power supply: AC 220V, input current: 22A, frequency: 50Hz.

[0095] (2) Current output range: 0 - 1000A, voltage 0 - 5V.

[0096] (3) Current accuracy is better than: 0.2%, distortion: less than 0.1%.

[0097] (4) Display control method: 10-inch TFT liquid crystal touch screen control or host computer control.

[0098] (5) Output type: Transient long-term output.

[0099] Among them, the electrical connection random vibration test aims to simulate the vibration characteristics of the catenary electrical connection during actual operation. The test equipment calculates the corresponding time-displacement signal according to the power spectral density input by the user, and precisely drives the sample for vibration loading through the actuator.

[0100] During the electrical connection random vibration test, according to the position power spectral density input by the user, the time-displacement signal is processed by the computer. The random vibration test should specify the time-displacement waveform after computer processing and the time-displacement waveform after loading, and compare the two. The test machine can import the power spectral density curve during the test, simulate the force condition at the moment of the relative movement between the pantograph and the catenary, and convert it into the real-time driving spectrum of the actuator to be loaded onto the specimen; by adding an external current generator, the electrical connection current-carrying random vibration test can be realized, and the time and current amplitude of electrical continuity interruption can be set.

[0101] During the experiment, the device of the present invention can monitor the following data in real time:

[0102] (1) Displacement and acceleration: The deformation and vibration response of the electrical connection under random vibration loading are recorded in real time through a displacement sensor and an acceleration sensor.

[0103] (2) Electrical continuity: Monitor the degradation of the electrical performance of the electrical connection under random vibration conditions and analyze the combined effects of vibration and electrical loads.

[0104] (3) Performance degradation: Evaluate the performance degradation and fatigue life of the electrical connection by comparing the performance changes before and after the test.

[0105] In the device of the present invention, the host computer software can set the test scheme according to the experimental requirements, including the tensile force, compression amplitude and frequency, or the corresponding spectrum file. As Figure 4 shown, the signal is transmitted from the host computer instruction system to the signal generator, and the signal generator converts the instruction into a digital signal. This digital signal is transmitted to the servo driver through the servo controller, and then accurately drives the linear actuator for loading control. The output rod of the actuator is connected to the pressure plate fixture to drive the test piece to move. The mutual acting force is fed back to the measurement amplifier, processed by the AD amplification chip and the digital tuning circuit, converted into a digital signal, and transmitted to the servo control system through the feedback loop. The servo control system adjusts the amplitude in real time to ensure the accuracy and precise control during the test. The built-in DSP chip in the system compares the input signal and the feedback signal, automatically adjusts the amplitude and the signal waveform, and maintains the consistency of the input and feedback waveforms, so as to realize PID automatic self-tuning without manual intervention.

[0106] The device of the present invention can realize comprehensive simulation of multiple working conditions, precise control and adjustment, and high-performance data acquisition and analysis:

[0107] (1) Comprehensive simulation of multiple working conditions: Support the fatigue performance test of catenary droppers and electrical connection components under multiple working conditions, including the simulation of complex loads such as force, vibration, and current, and can comprehensively evaluate the reliability of catenary components.

[0108] (2) Precise control and adjustment: Through the host computer control system, the user can flexibly set the test parameters according to the experimental requirements, accurately control the loading process, and ensure the repeatability and reliability of the data.

[0109] (3) High-performance data acquisition and analysis: Integrate multiple sensors to collect various physical data during the test in real time, providing a scientific basis for subsequent data analysis and performance evaluation.

[0110] The catenary dropper and electrical connection fatigue performance test device of the present invention has a wide range of technical and product application fields and can be widely applied in the rail transit industry, power transmission systems, aviation, and other high-reliability system fields:

[0111] (1) Rail transit industry: Used for fatigue performance testing of catenary droppers and electrical connections in high-speed railways, simulating vibration, pressure, and current loads under actual operating conditions to evaluate the reliability and lifespan of components, and assisting the railway system in optimizing component material selection and maintenance.

[0112] (2) Power transmission system: Used for mechanical vibration and current load testing of power conductors, electrical connectors, and suspension devices to evaluate performance degradation and failure mechanisms during long-term use, and provide fatigue performance data based on actual operating conditions.

[0113] (3) Aviation and other high-reliability systems: Conduct fatigue performance evaluation on aviation and other high-demand system components to ensure their stability in complex environments.

Claims

1. An overall catenary dropper and electrical connection fatigue performance test device, characterized in that It includes a main frame, an electromagnetic linear actuator, a crossbeam system, a two-station test tooling, a sensor system, a power system, and a control system; The main frame is a two-station four-column frame structure. Four columns are vertically installed at the four corners of the base, and the tops of the columns are rigidly connected to the top plate to form a closed load-bearing frame; The electromagnetic linear actuator includes an actuator body, a piston rod, and an electromagnetic control module. The actuator body is fixedly installed at the center of the base, and the piston rod is rigidly connected to the liftable crossbeam system and arranged along the axial direction of the main frame. The electromagnetic linear actuator uses a closed-loop servo system to precisely control the speed, thrust, and position required for the test; The crossbeam system includes a main crossbeam system and a crossbeam system for the two-station test system; The main crossbeam system includes a crossbeam, a hydraulic driving mechanism, and a crossbeam driving module. The two ends of the crossbeam are slidably connected to the columns through linear guides. The hydraulic driving mechanism includes symmetrically arranged double hydraulic cylinders for lifting, a hydraulic locking device, and an elastic release mechanism; The crossbeam system of the two-station test system is used for the two-station test tooling and adopts a hydraulic lifting and locking mechanism, which is convenient for the installation, adjustment, and locking of the specimen; The two-station test tooling includes an upper support assembly, a lower support assembly, a force application component, and a force buffer component. The upper support assembly is installed on the bottom surface of the crossbeam, and the lower support assembly is installed on the base platform surface. The upper support assembly and the lower support assembly are coaxially arranged and form a specimen clamping space with adjustable spacing. The force application component is fixed on the lower support assembly, and the force buffer component is fixed on the upper support assembly. The force application component and the force buffer component are coaxially arranged; The sensor system includes a multi-dimensional force sensor arranged on the force buffer component, a displacement sensor integrated in the electromagnetic linear actuator, and a temperature sensor for monitoring the environment and the state of the specimen; The power system includes a hydraulic station for supplying energy to the hydraulic driving mechanism and a cooling system for cooling the electromagnetic linear actuator; The control system includes a full-digital single-channel servo controller electrically connected to the electromagnetic linear actuator, a full-power electrical cabinet, a computer, and its integrated test operation software; The test device is used to carry out multi-load fatigue tests on the integral suspension strings and electrical connections of the catenary to test and analyze the reliable life of catenary components and obtain experimental data required for the reliability assessment and life prediction of catenary components; The test device can, according to parameters such as current amplitude, vibration frequency, compression amplitude, and dynamic tensile force set by the user, through computer control, realize the alternate loading of compression-tension of the suspension string, the fatigue test loading of the current-carrying suspension string, and the random vibration test of the electrical connection; The test device adopts a modular fixture system, and realizes the integration of suspension string-related tests and electrical connection-related tests by switching the specimen clamping mechanism, thereby improving the adaptability and utilization rate of the test device.

2. The catenary integral dropper and electrical connection fatigue performance testing device according to claim 1, wherein, The test device also includes test fixtures, a current source, acquisition sensors, an insulation protection system, and other auxiliary accessories.

3. The catenary integral dropper and electrical connection fatigue performance test device according to claim 2, characterized in that The electromagnetic linear actuator adopts a floating guiding structure, is provided with a self-centering locking mechanism and an anti-side deviation guiding ring. The actuator body of the electromagnetic linear actuator is internally provided with a water cooling channel to form a closed-loop circuit with the external cooling system.

4. The catenary integral suspension string and electrical connection fatigue performance test device according to claim 3, wherein, The hydraulic locking device adopts a double-position synchronous hydraulic cylinder structure, including an elastic release mechanism and a pressure maintaining valve group, and can realize the automatic switching between the lifting state of the crossbeam during the test and the locking state during non-test.

5. The catenary integral dropper and electrical connection fatigue performance testing device according to claim 4, characterized in that The outer surface of the column of the main frame is treated with electroplated hard chromium to improve its anti-wear and corrosion resistance.

6. The catenary integral suspension string and electrical connection fatigue performance test device according to claim 5, characterized in that All the metal exposed parts of the test device are covered with insulating films, the column is provided with a circular shield, and the connecting wire harness is fixed and isolated with insulating materials to ensure the overall electrical safety.

7. The catenary integral suspension string and electrical connection fatigue performance testing device according to claim 6, characterized in that, The crossbeam drive module adopts a manual rotary valve control method to control the coordinated movement of the double hydraulic cylinders and the clamping device, and realizes the lifting and positioning adjustment of the crossbeam.

8. The catenary integral suspension string and electrical connection fatigue performance test device according to claim 7, characterized in that The test device also includes an external current generator, which is connected to the control system and is used to simulate the catenary current load. By setting the current amplitude and interruption time, the electrical connection current-carrying fatigue test is carried out.

9. The catenary integral dropper and electrical connection fatigue performance testing device according to claim 8, characterized in that, The control system can set and control the test parameters including vibration frequency, current amplitude, displacement, force, and acceleration through a software interface, realize the control of any given force and displacement waveforms, and ensure the accurate execution of the test process.

10. The catenary integral suspension string and electrical connection fatigue performance test device according to claim 9, wherein, The electrical connection random vibration test outputs a time-displacement signal through computer processing according to the position power spectral density input by the user, and uses this signal for real-time drive loading of the actuator to simulate the force condition at the moment of the relative movement between the pantograph and the catenary.

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