Equipment for rapidly cleaning contact rail insulation protection system and control method

Abstract

The invention discloses equipment for rapidly cleaning a contact rail insulation protection system and a control method, and belongs to the technical field of contact rail insulation protection. The equipment for rapidly cleaning the contact rail insulation protection system comprises a rail transportation platform, a power generator, a water storage tank, an air pump, a control cabinet and a flushing pump are arranged at the top of the upper portion of the rail transportation platform, the water storage tank and the air pump communicate with the flushing pump, and a PLC control system is arranged in the control cabinet; comprising a main power switch QF, a first branch QF1, a second branch QF2, a third branch QF3, an input module and an output module. The problems that the manual cleaning efficiency of an existing metro contact rail insulation support and a protective cover is low, the flexibility of a flushing machine is poor, and the cost is increased are solved. The functions of automatic walking, automatic cleaning and the like are achieved through program instructions, the cost of manpower and material resources can be reduced, and the overall automation level of enterprises can be improved.

Description

Technical Field

[0001] The present invention relates to the technical field of contact rail insulation protection, in particular to equipment and a control method for quickly cleaning a contact rail insulation protection system. Background Art

[0002] The insulation brackets and protective covers of the subway contact rails are directly exposed in the tunnel, causing the insulation brackets and protective covers to be seriously dirty. The existing cleaning methods have the following problems: First, manual cleaning efficiency is low: At present, the protective covers are cleaned by manual water extraction and wiped with mops, rags, etc. According to the existing manual cleaning method, the cleaning effect is poor, and each work point can only advance about 200 meters. If all energy is devoted to the cleaning of the insulation brackets and protective covers, it is bound to cause the maintenance of other contact rail equipment to be inadequate. Relying solely on manual cleaning seriously restricts work efficiency, and due to the large amount of water used, there are problems such as difficulty in obtaining water in the section; Second, the flexibility of the flushing machine is poor: The flushing machine is used for cleaning, but the flushing machine is heavy and difficult to carry, and the cleaning effect on stains such as oil, carbon powder, and seabed salt spray crystals is poor; Third, cost increase: Due to many factors such as the long and long sections of the subway line submarine tunnel, relying solely on manual cleaning seriously restricts work efficiency, increases manpower and material costs, and cannot meet the safe operation of the contact rail system.

[0003] A Chinese patent, published under announcement number CN218424366U, specifically discloses an automatic cleaning device for a protective system of a lower-contact contact rail. The protective system includes a protective cover and an insulating bracket, with a running rail laid on one side of the protective system; a track trolley is provided on the running rail, and a trolley crossbeam is fixed to the track trolley and extends toward the protective system; the trolley crossbeam is mounted with a first cleaning mechanism for cleaning the protective cover, and / or a second cleaning mechanism for cleaning the insulating bracket. This patent utilizes only a nozzle assembly for water flushing, failing to select the appropriate cleaning method based on the type of stain. This device is ineffective in removing stubborn contaminants, particularly on inner surfaces, corners, and crevices, where stains are likely to remain, creating blind spots for cleaning. Furthermore, the patent lacks an integrated automated movement system, requiring manual adjustment or low-speed movement during the cleaning process. Summary of the Invention

[0004] The purpose of the present invention is to provide a device and control method for quickly cleaning the contact rail insulation protection system, which can realize functions such as automatic walking and automatic cleaning through program instructions, thereby reducing the cost of manpower and material resources and improving the overall level of enterprise automation, thereby solving the problems raised in the above-mentioned background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions: A device for quickly cleaning a contact rail insulation protection system comprises a rail transport platform, wherein a generator, a water storage tank, an air pump, a control cabinet and a flushing pump are arranged on the top of the rail transport platform, the water storage tank and the air pump are connected to the flushing pump, a mounting folding rod is arranged on one side of the flushing pump of the rail transport platform, a first mounting block is arranged on the end of the mounting folding rod, a lifting motor is arranged on the top of the first mounting block, an output shaft of the lifting motor passes downward through the first mounting block and is fixed to the second mounting block, horizontal brushes are symmetrically arranged on both sides of the second mounting block, one side of the horizontal brush is connected to the first brush motor, a side brush is symmetrically arranged on the bottom of the second mounting block, and the side brush is connected to the second brush motor, four track wheels are symmetrically arranged on the bottom of the rail transport platform, and the track wheels on one side are connected to the track motor; The control cabinet is internally provided with a PLC control system, including: Main power switch QF, used to connect emergency stop contactor KM; The first branch QF1 is used to supply power to the air pump, flushing pump and steam generator; The second branch QF2 is used to connect the servo controllers of the track motor, the lifting motor, the first brush motor and the second brush motor; The third branch QF3 is used to connect to the PLC main control unit and DC power supply module, and output 24V DC power; Input module, used to receive touch screen commands and physical button signals; The output module is used to output pulse signals to the servo controller through the Y0-Y4 ports to adjust the speed of the track motor, lifting motor, first brush motor or second brush motor, and output direction signals through the Y10-Y14 ports to control the direction of the motor.

[0006] Preferably, the first brush motor is fixed to the second mounting block via a supporting block.

[0007] Preferably, the side brushes are located on both sides of the track, and the transverse brush is arranged laterally above the track.

[0008] Preferably, the generator is electrically connected to the air pump, the control cabinet, the flushing pump, the track motor, the lifting motor, the first brush motor and the second brush motor respectively.

[0009] Preferably, the control cabinet is communicatively connected with the air pump, the flushing pump, the track motor, the lifting motor, the first brush motor and the second brush motor.

[0010] Preferably, an identification system is provided inside the second mounting block, and a sensor for real-time detection of the type of stain is provided at the bottom of the second mounting block, and the sensor is communicatively connected with the identification system.

[0011] A control method for a device for quickly cleaning a contact rail insulation protection system is implemented based on the device for quickly cleaning the contact rail insulation protection system, comprising the following steps: Step 1: Close the QF main switch, and the DC power module outputs 24V DC power to the PLC; Step 2: The PLC receives instructions from the touch screen or physical buttons and generates pulse signals Y0-Y4 and direction signals Y10-Y14; Step 3: The servo controller adjusts the rotation speed of the side brushes and the transverse brushes according to the pulse frequency, and switches the rotation direction of the side brushes and the transverse brushes according to the direction signal; Step 4: The identification system feeds back the stain type to the PLC, which automatically selects the cleaning mode. For dust stains, the high-pressure air blowing mode is activated, and for oil stains, the high-temperature steam + high-pressure water gun combination mode is activated. Step 5: The emergency stop contactor KM monitors the operating status in real time and cuts off the power supply of the QF1-QF3 branch when an abnormality is triggered.

[0012] Preferably, as described in step four, the parameters of the cleaning mode are dynamically adjusted through the touch screen, including but not limited to the steam injection duration, water pressure intensity and the rotation speed of the side brushes and the horizontal brushes.

[0013] Preferably, the frequency of the pulse signals Y0-Y4 is linearly positively correlated with the rotational speed of the servo motor, and the frequency adjustment range is 1-10 kHz.

[0014] Preferably, the PLC communicates with the touch screen via the Modbus protocol, and the physical buttons include independent up / down control keys, which have a higher priority than touch screen commands.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. The present invention integrates a generator, a water tank, an air pump and a control cabinet through a rail transport platform, and drives a liftable second mounting block through a lifting motor. Side brushes are symmetrically arranged on both sides of the track to clean the track facade, and horizontal brushes are arranged horizontally above the track to clean the top surface, forming a three-dimensional cleaning structure to achieve all-round cleaning of the contact rail without dead angles. The side brushes and horizontal brushes work together to efficiently remove stubborn stains on the surface and gaps of the protective cover; the rail platform has its own track wheels and drive motor, and can move autonomously on the track, significantly improving cleaning efficiency and solving the problems of low manual cleaning efficiency and difficulty in obtaining water in intervals.

[0016] 2. The present invention embeds a sensor at the bottom of the second mounting block and combines it with an identification system to analyze the stains in real time. The PLC automatically switches the cleaning mode according to the feedback. The high-pressure air pump is activated for dust purge, and the steam generator and high-pressure water gun are linked to perform high-temperature steam and chemical cleaning for oil stains. The cleaning strategy is dynamically adjusted for different stains such as salt spray crystallization, carbon powder, and oil stains, improving the cleaning effect by more than 40%, avoiding the problem of poor adaptability of traditional equipment to complex stains, and reducing repeated operations and resource waste.

[0017] 3. The present invention adopts a three-level power supply architecture of QF1-QF3 branches through the control cabinet, outputs 1~10kHz pulse signals through the Y0-Y4 ports of the PLC output module, and outputs direction signals through the Y10-Y14 ports, so as to accurately control the servo systems of the track motor, lifting motor and brush motor; the physical buttons have higher priority than the touch screen commands, supporting emergency intervention, and the servo system realizes stepless adjustment of the brush speed and switching of the rotation direction to adapt to different cleaning intensity requirements; the emergency stop contactor KM cuts off the power supply within 0.1 seconds to ensure equipment safety; the modular design reduces the failure rate and reduces maintenance costs by 30%. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a rear view of the overall structure of the present invention; Figure 2 It is a front view of the overall structure of the present invention; Figure 3 This is the first wiring diagram of the PLC of the present invention; Figure 4 This is the cleaning mode wiring diagram of the present invention.

[0019] In the figure: 1. Track transport platform; 2. Generator; 3. Water tank; 4. Air pump; 5. Control cabinet; 6. Flushing pump; 7. Track motor; 8. Track wheel; 9. Mounting folding rod; 10. First mounting block; 11. Lifting motor; 12. Output shaft; 13. Second mounting block; 14. Horizontal brush; 15. First brush motor; 16. Support block; 17. Side brush; 18. Second brush motor. DETAILED DESCRIPTION

[0020] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0021] In order to solve the problems of low manual cleaning efficiency, poor flexibility of washing machines and increased costs of existing subway contact rail insulation brackets and protective covers, please refer to Figure 1-4, this embodiment provides the following technical solutions: A device for quickly cleaning the insulation protection system of a contact rail includes a rail transport platform 1. A generator 2, a water tank 3, an air pump 4, a control cabinet 5 and a flushing pump 6 are provided on the top of the rail transport platform 1. The water tank 3 and the air pump 4 are connected to the flushing pump 6. The rail transport platform 1 can also be used as a transport trolley.

[0022] The rail transport platform 1 is provided with a mounting folding rod 9 on one side of the flushing pump 6, and a first mounting block 10 is provided at the end of the mounting folding rod 9. A lifting motor 11 is provided on the top of the first mounting block 10, and the output shaft 12 of the lifting motor 11 passes downward through the first mounting block 10 and is fixed to the second mounting block 13. Horizontal brushes 14 are symmetrically provided on both sides of the second mounting block 13 to clean the top surface of the rail. One side of the horizontal brush 14 is connected to the first brush motor 15. Side brushes 17 are symmetrically provided on the bottom of the second mounting block 13 to clean the vertical surface of the rail. The side brushes 17 are connected to the second brush motor 18.

[0023] Four track wheels 8 are symmetrically provided at the bottom of the track transport platform 1 , wherein the track wheels 8 on one side are connected to the track motor 7 .

[0024] The first brush motor 15 is fixed to the second mounting block 13 via a supporting block 16 .

[0025] The side brushes 17 are respectively located on both sides of the track, and the horizontal brush 14 is laterally arranged above the track.

[0026] The generator 2 is electrically connected to the air pump 4 , the control cabinet 5 , the flushing pump 6 , the track motor 7 , the lifting motor 11 , the first brush motor 15 and the second brush motor 18 , respectively.

[0027] The control cabinet 5 is in communication connection with the air pump 4 , the flushing pump 6 , the track motor 7 , the lifting motor 11 , the first brush motor 15 and the second brush motor 18 .

[0028] An identification system is provided inside the second installation block 13 , and a sensor for real-time detection of the type of stain is provided at the bottom of the second installation block 13 , and the sensor is in communication connection with the identification system.

[0029] A PLC control system is set inside the control cabinet 5, including: Main power switch QF, used to connect emergency stop contactor KM; The first branch QF1 is used to supply power to the air pump 4, the flushing pump 6 and the steam generator; The second branch QF2 is used to connect the servo controllers of the track motor 7, the lifting motor 11, the first brush motor 15 and the second brush motor 18; The third branch QF3 is used to connect to the PLC main control unit and DC power supply module, and output 24V DC power; Input module, used to receive touch screen commands and physical button signals; The output module is used to output pulse signals to the servo controller through the Y0-Y4 ports to adjust the speed of the track motor 7, the lifting motor 11, the first brush motor 15 or the second brush motor 18, and output direction signals through the Y10-Y14 ports to control the direction of the motor.

[0030] A control method for a device for quickly cleaning a contact rail insulation protection system is implemented based on the device for quickly cleaning the contact rail insulation protection system, comprising the following steps: Step 1: Close the QF main switch, and the DC power module outputs 24V DC power to the PLC; Step 2: The PLC receives instructions from the touch screen or physical buttons and generates pulse signals Y0-Y4 and direction signals Y10-Y14; Step 3: The servo controller adjusts the rotation speed of the side brushes 17 and the transverse brush 14 according to the pulse frequency, and switches the rotation direction of the side brushes 17 and the transverse brush 14 according to the direction signal; Step 4: The identification system feeds back the stain type to the PLC, which automatically selects the cleaning mode. For dust stains, the high-pressure air blowing mode is activated, and for oil stains, the high-temperature steam + high-pressure water gun combination mode is activated. Step 5: The emergency stop contactor KM monitors the operating status in real time and cuts off the power supply of the QF1-QF3 branch when an abnormality is triggered.

[0031] As described in step 4, the parameters of the cleaning mode are dynamically adjusted through the touch screen, including but not limited to the steam injection duration, water pressure intensity and the rotation speed of the side brush 17 and the horizontal brush 14.

[0032] The high-pressure steam cleaning module consists of a steam generator and a steam nozzle. The principle is to use high-temperature steam to spray the surface to be cleaned, so as to achieve the purpose of cleaning; the high-pressure air blowing cleaning module consists of an air pump 4, an air compressor and a vortex air nozzle, and uses the powerful impact force of high-pressure air to clean the surface dust; the high-pressure water gun cleaning module consists of a flushing pump 6, a water tank 3 and a spray pipeline to which detergent can be added. It has stable water pressure and precise spray angle to ensure the cleaning effect.

[0033] The recognition system and sensors detect stains on the surface of the protective cover. If the reflectivity is greater than 80%, it is judged as dust and the high-pressure blowing mode is activated; if the oil adhesion area is greater than 15%, the high-temperature steam + high-pressure water gun combination mode is activated.

[0034] The frequency of the pulse signal Y0-Y4 is linearly positively correlated with the servo motor speed, and the frequency adjustment range is 1~10kHz.

[0035] The PLC communicates with the touch screen via the Modbus protocol. The physical buttons include independent up / down control keys, which have a higher priority than the touch screen commands.

[0036] This device is powered by AC / DC dual-purpose power supply, and the power supply mode is selected according to different conditions.

[0037] After the power supply is connected, open QF, the power supply is connected to each device through the KM emergency stop contactor and is controlled by the emergency stop switch.

[0038] QF1 is the power supply for air pump 4, water pump, and steam generator. QF2 is the driving power supply for each servo motor, which is connected to each servo motor controller and controlled by PLC. QF3 is the main power supply for controlling PLC. The power enters the DC power supply module through QF3 to generate 24V DC power for PLC and various inputs and outputs.

[0039] When the PLC receives instructions from the touch screen or external button commands, it will generate a pulse instruction and direction instruction set on the touch screen, transmit it to each servo controller, and the servo controller will execute and control the operation of the servo motor.

[0040] When the QF switch is closed, the DC rectifier module begins operating, outputting 24V DC power to the PLC. Input commands are provided by the touch screen and panel buttons, providing a 24V+ high level. The direction and pulse signals output to each servo motor controller are provided by a 24V- low level, controlling the operation of the corresponding servo motor. The touch screen issues the operating commands for each servo motor. Additionally, a set of external buttons for raising and lowering the servo motor are connected to the panel, providing the same functions as the touch screen for ease of operation. The raising and lowering limits are unused protection features for the device in automatic mode. The servo motor alarms remain unused, with the alarm signals coming from the servo motor controllers.

[0041] Y0-Y4 are the pulse signals for each servo motor and are connected between the PLC and each servo controller. Changing the touchscreen pulse parameters causes the PLC to issue different pulse commands, which in turn changes the servo motor's operating speed. Y10-Y14 are the direction signals for each servo motor and are connected between the PLC and each servo motor controller. The touchscreen issues a direction command for the motor. Upon receiving the command, the PLC issues a direction command signal to each servo motor, causing the servo motor to operate in the commanded direction.

[0042] The control cabinet adopts a three-level power supply architecture with QF1-QF3 branches, and outputs 1-10kHz pulse signals through the Y0-Y4 ports of the PLC output module and direction signals through the Y10-Y14 ports, accurately controlling the servo systems of the track motor, lifting motor, and brush motor. Physical buttons have higher priority than touch screen commands and support emergency intervention. The servo system achieves stepless adjustment of brush speed and switching of rotation direction to adapt to different cleaning intensity requirements. The emergency stop contactor KM cuts off the power supply within 0.1 seconds to ensure equipment safety. The modular design reduces the failure rate. When the current sensor detects a motor overload, the PLC immediately cuts off the Y0-Y4 pulse output, the emergency stop contactor KM is activated, and the QF1-QF3 branch power supply is disconnected within 0.1 seconds, reducing maintenance costs by 30%.

[0043] Working principle: Close the main power switch QF, the DC power module outputs 24V DC power to the PLC control system, the emergency stop contactor KM enters the standby state, the operator sends instructions to the PLC through the touch screen or physical button, the PLC outputs a pulse signal of 1~10kHz to the servo controller through the Y0-Y4 port, adjusts the speed of the track motor 7, the lifting motor 11 and the first brush motor 15 and the second brush motor 18; the direction signal is output through the Y10-Y14 port to control the direction of the motor, the track motor 7 drives the track wheel 8 to drive the platform to move along the track, the side brush 17 rotates to clean the vertical surfaces on both sides of the track, and the horizontal brush 14 rotates to clean the top surface of the track. The sensor at the bottom of the second mounting block 13 detects the type of stain in real time. When it is dust stain, the PLC starts the high-pressure blowing mode, and the air pump 4 outputs high-speed airflow to remove the dust. When it is oil stain, the PLC links the steam generator and the flushing pump 6. After using high-temperature steam to soften the oil, the high-pressure water gun sprays water to flush. The emergency stop contactor KM continuously monitors the current and cuts off the power supply of the QF1-QF3 branch within 0.1 seconds in case of an abnormality to ensure equipment safety.

[0044] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0045] While the embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that various changes, modifications, substitutions, and alterations can be made to the embodiments without departing from the principles and spirit of the invention.

Claims

1. A device for quickly cleaning a contact rail insulation protection system, comprising a rail transport platform (1), characterized in that: A generator (2), a water tank (3), an air pump (4), a control cabinet (5) and a flushing pump (6) are provided on the top of the rail transport platform (1). The water tank (3) and the air pump (4) are connected to the flushing pump (6). A mounting folding rod (9) is provided on one side of the flushing pump (6) of the rail transport platform (1). A first mounting block (10) is provided at the end of the mounting folding rod (9). A lifting motor (11) is provided on the top of the first mounting block (10). The output shaft (12) of the lifting motor (11) is downwardly The first mounting block (10) is passed through and fixed to the second mounting block (13). Horizontal brushes (14) are symmetrically provided on both sides of the second mounting block (13). One side of the horizontal brush (14) is connected to the first brush motor (15). The bottom of the second mounting block (13) is symmetrically provided with side brushes (17). The side brushes (17) are connected to the second brush motor (18). The bottom of the track transport platform (1) is symmetrically provided with four track wheels (8), and the track wheels (8) on one side are connected to the track motor (7). The control cabinet (5) is internally provided with a PLC control system, including: Main power switch QF, used to connect emergency stop contactor KM; The first branch QF1 is used to supply power to the air pump (4), the flushing pump (6) and the steam generator; The second branch QF2 is used to connect the servo controllers of the track motor (7), the lifting motor (11), the first brush motor (15) and the second brush motor (18); The third branch QF3 is used to connect to the PLC main control unit and DC power supply module, and output 24V DC power; Input module, used to receive touch screen commands and physical button signals; The output module is used to output pulse signals to the servo controller through the Y0-Y4 ports to adjust the speed of the track motor (7), the lifting motor (11), the first brush motor (15) or the second brush motor (18), and output direction signals through the Y10-Y14 ports to control the direction of the motor.

2. The device for quickly cleaning the contact rail insulation protection system according to claim 1, characterized in that: The first brush motor (15) is fixed to the second mounting block (13) via a supporting block (16).

3. The device for quickly cleaning the contact rail insulation protection system according to claim 2, characterized in that: The side brushes (17) are respectively located on both sides of the track, and the transverse brush (14) is laterally arranged above the track.

4. The device for quickly cleaning the contact rail insulation protection system according to claim 3, characterized in that: The generator (2) is electrically connected to the air pump (4), the control cabinet (5), the flushing pump (6), the track motor (7), the lifting motor (11), the first brush motor (15) and the second brush motor (18).

5. The device for quickly cleaning the contact rail insulation protection system according to claim 4, characterized in that: The control cabinet (5) is communicatively connected to the air pump (4), the flushing pump (6), the track motor (7), the lifting motor (11), the first brush motor (15), and the second brush motor (18).

6. The device for quickly cleaning the contact rail insulation protection system according to claim 5, characterized in that: An identification system is provided inside the second installation block (13), and a sensor for real-time detection of the type of stain is provided at the bottom of the second installation block (13), the sensor being in communication connection with the identification system.

7. A control method for a device for quickly cleaning a contact rail insulation protection system, implemented based on the device for quickly cleaning a contact rail insulation protection system according to any one of claims 1 to 6, characterized in that: The following steps are involved: Step 1: Close the QF main switch, and the DC power module outputs 24V DC power to the PLC; Step 2: The PLC receives instructions from the touch screen or physical buttons and generates pulse signals Y0-Y4 and direction signals Y10-Y14; Step 3: The servo controller adjusts the rotation speed of the side brush (17) and the transverse brush (14) according to the pulse frequency, and switches the rotation direction of the side brush (17) and the transverse brush (14) according to the direction signal; Step 4: The identification system feeds back the stain type to the PLC, which automatically selects the cleaning mode. For dust stains, the high-pressure air blowing mode is activated, and for oil stains, the high-temperature steam + high-pressure water gun combination mode is activated. Step 5: The emergency stop contactor KM monitors the operating status in real time and cuts off the power supply of the QF1-QF3 branch when an abnormality is triggered.

8. The control method for a device for quickly cleaning a contact rail insulation protection system according to claim 7, characterized in that: Regarding step 4, the parameters of the cleaning mode are dynamically adjusted through the touch screen, including but not limited to the steam jet duration, water pressure intensity, and the rotation speed of the side brush (17) and the horizontal brush (14).

9. The control method for a device for quickly cleaning a contact rail insulation protection system according to claim 8, characterized in that: The frequency of the pulse signals Y0-Y4 is linearly positively correlated with the rotational speed of the servo motor, and the frequency adjustment range is 1-10kHz.

10. The control method for a device for quickly cleaning a contact rail insulation protection system according to claim 9, characterized in that: The PLC communicates with the touch screen via the Modbus protocol, and the physical buttons include independent up / down control keys that have a higher priority than touch screen commands.

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