Urban rail vehicle passenger room door comprehensive maintenance test platform

Abstract

The invention belongs to the technical field of rail transit, and discloses an urban rail vehicle passenger room door comprehensive maintenance test platform comprising a passenger room door mounting rack; the training platform is arranged in front of the mounting frame; the comprehensive control cabinet and the layered maintenance operation platform are arranged on the training platform. The core of the platform is a control module, the module adopts a redundancy control system combining a programmable logic controller (PLC), a touch screen and entity keys, various modes such as hardware manual control, software automatic control and part fatigue test can be realized, and the control module has a clear control priority. The platform can monitor, record and analyze vehicle door operation data in real time, and fast switching comparison of the door controller to be tested can be realized through special circuit design. Through the integrated and modular design, the functions of personnel training, fault simulation analysis, part testing and acceptance inspection and the like are safely and efficiently realized.

Description

Technical Field

[0001] The invention belongs to the technical field of rail transportation, and in particular relates to a comprehensive maintenance test platform for passenger compartment doors of urban rail vehicles. Background Art

[0002] The passenger doors of urban rail vehicles (or subway trains) are critical equipment for ensuring operational safety and facilitating passenger boarding and alighting. To ensure reliability, vehicle maintenance departments must regularly inspect and maintain the door systems. However, with the rapid expansion of urban rail transit networks and the increasing service life of trains, door system maintenance faces numerous challenges:

[0003] 1. Limited and risky training methods: Currently, practical training for new employees and maintenance personnel often relies on halting trains operating on the line. This approach not only impacts normal train operation and availability, resulting in lengthy training cycles and project limitations, but also poses the risk of equipment damage or safety hazards during disassembly, installation, and adjustment operations, potentially impacting subsequent train operations. Furthermore, the high installation position of the door mechanism often requires trainees to operate with the aid of a heightened stool, posing a safety risk of falls.

[0004] 2. Difficulty in fault analysis and location: Passenger doors are a hybrid electromechanical system. As equipment ages, sporadic and intermittent faults increase, and the fault symptoms become more diverse. In actual operating environments, such faults are difficult to reproduce, making it extremely difficult to troubleshoot and locate the root cause of the problem. Existing technical methods cannot simulate and conduct in-depth fault analysis without the vehicle, making it impossible to completely eliminate safety hazards.

[0005] 3. Lack of effective component testing methods: There is currently a lack of systematic testing platforms and verification methods for newly purchased spare parts (such as door controllers and motors) or repaired parts. This makes it difficult for maintenance personnel to fully confirm the quality, function, and reliability of components before installation on trains, nor can they determine whether repaired parts have been fully restored to a reliable operating state, creating uncertainty in train operation quality.

[0006] At present, there is no systematic and standardized equipment platform in the industry specifically for urban rail vehicle passenger compartment door systems that integrates maintenance personnel training, fault analysis and repair, and component testing functions. Summary of the Invention

[0007] The present invention aims to solve the above technical problems at least to a certain extent. To this end, the present invention aims to provide a comprehensive inspection and testing platform for passenger compartment doors of urban rail vehicles.

[0008] The technical solution adopted in the present invention is:

[0009] A comprehensive inspection and testing platform for passenger compartment doors of urban rail vehicles, comprising:

[0010] The passenger compartment door mounting frame is used to simulate the urban rail vehicle body environment at a 1:1 scale and to install the passenger compartment door system to be inspected and tested;

[0011] A training platform is provided in front of the passenger door mounting frame, the platform of the training platform being elevated to provide an operator with a standing platform for operating and repairing the passenger door system without the need for auxiliary height raising;

[0012] An integrated control cabinet, which is arranged on the table of the training podium and has electrical components installed therein for driving and monitoring the passenger compartment door system;

[0013] A maintenance operation platform is provided on the top of the integrated control cabinet and is used to place a control panel and components to be tested;

[0014] The control module is arranged in the integrated control cabinet and is electrically connected to the control panel on the maintenance operation platform, and is used to control the operation of the passenger compartment door system, simulate faults, perform tests and monitor and record operation data.

[0015] Preferably, the passenger compartment door mounting frame includes: a main frame, the door opening of which is designed according to the actual door size and fits the curvature of the vehicle body; a mechanism mounting portion for installing the passenger compartment door mechanism; an upper fixed foot extending from the upper part of the main frame and connected to the wall or other infrastructure fixed body through a fixing plate; and a lower supporting leg arranged at the lower part of the main frame for supporting the overall weight and adjusting the flatness.

[0016] Preferably, the passenger compartment door mounting frame further includes an external equipment mounting frame for integrating external equipment such as internal and external emergency unlocking switches to facilitate emergency unlocking testing.

[0017] Preferably, the bottom of the training platform is provided with a keel frame made of angle steel to ensure strength, and is transitioned to the ground through at least one step to facilitate people getting on and off; the integrated control cabinet is arranged in a mirrored manner along both sides of the training platform surface, leaving a spacious observation and operation area in the middle.

[0018] Preferably, the maintenance operation platform is designed in layers, including: a first-layer platform located on the top of the integrated control cabinet, used to install a hardware control panel with integrated mechanical buttons and indicator lights; and a second-layer platform located on the upper and rearward sides of the first-layer platform, which has a moderate width and is used to place the door controller to be tested and other detection instruments, such as oscilloscopes, protocol analyzers, etc.

[0019] Preferably, the control module utilizes a redundant control design, comprising a software control unit and a physical hardware control unit. The software control unit, with a programmable logic controller (PLC) at its core, utilizes a human-machine interactive touch screen for command input, parameter setting, and data display, enabling automated control and data analysis. The physical hardware control unit utilizes self-locking / self-resetting mechanical buttons and multi-color indicator lights for the most direct manual control and status feedback, and can simulate non-interlocking abnormal signals through physical circuits.

[0020] Preferably, the control module is configured to implement at least three control modes: hardware control mode, software control mode, and fatigue test mode. These three modes have a preset priority, configured as "hardware control mode > software control mode > fatigue test mode," ensuring that manual operation has the highest priority to ensure operational safety.

[0021] Preferably, the fatigue test mode is used to control the periodic and uninterrupted automatic operation of the passenger compartment door system according to the number of door opening and closing times preset by the user, with one complete door opening and closing action being counted as a cycle, and key parameters such as the operating voltage and current of the door motor being monitored and recorded in real time during the test. A test report can be automatically generated after the test is completed.

[0022] Preferably, the integrated control cabinet is equipped with a switching circuit that, through an intermediate relay group, enables rapid switching between two door controllers under test (e.g., one standard device and one under test). Without changing other wiring, the operator can use a single switch to control the vehicle door system with different door controllers, thereby performing performance comparison and verification under identical operating conditions.

[0023] Preferably, this platform also defines interfaces for expanding functional modules. The maintenance operation platform and integrated control cabinet reserve mounting space and power supply interfaces, providing support for third-party testing instruments such as the door controller dedicated maintenance terminal (PTU), four-channel digital oscilloscope, RS485 protocol analyzer, and MVB protocol analyzer, facilitating more in-depth fault analysis and component repair.

[0024] The beneficial effects of the present invention are:

[0025] 1. High Safety: By building a platform separate from the actual train, the safety and quality risks associated with conducting training and maintenance on operating trains are completely eliminated. The training platform design allows operators to operate the upper door mechanism directly from a stable surface without the need for a heightened stool, eliminating the risk of falls.

[0026] 2. Good economic efficiency: The platform has the functions of component failure analysis and post-repair testing. It can perform in-depth repairs and functional verification on faulty components, so that the repaired components can be put into use again, significantly reducing the purchase demand for spare parts and effectively lowering operating costs.

[0027] 3. Highly Efficient: The platform conducts secondary quality inspection and functional verification of newly purchased parts, ensuring the quality and reliability of onboard components. This improves the overall quality and reliability of trains and reduces mainline failure rates. Furthermore, training no longer requires operating trains, improving train utilization and operational efficiency.

[0028] 4. High efficiency: The platform's optimized spatial layout and elevated operating height make the training space spacious, supporting multiple trainees to observe and operate at the same time. Compared with single-person training in a narrow compartment, this greatly improves training efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 The present invention is a schematic structural diagram of a comprehensive maintenance test platform for passenger compartment doors of urban rail vehicles.

[0030] Figure 2 It is a structural schematic diagram of the passenger compartment door mounting frame of the present invention.

[0031] Figure 3 It is a structural diagram of the integrated control cabinet, maintenance operation platform and training podium in an embodiment of the present invention.

[0032] Figure 4 Schematic diagram of a maintenance service object in an embodiment of the present invention. DETAILED DESCRIPTION

[0033] The following will clearly and completely describe the technical solutions of the present invention in conjunction with the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all 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.

[0034] It should be understood that it should also be noted that in the embodiments, the functions / actions that appear may be different from the order in which the figures appear. For example, depending on the functions / actions involved, they may actually be performed substantially concurrently, or two figures shown in succession may sometimes be performed in the reverse order.

[0035] like Figure 1 As shown, the present invention provides a comprehensive maintenance test platform for passenger compartment doors of urban rail vehicles, which adopts a modular design as a whole and mainly includes a basic function platform module, a maintenance service object module and an expansion function module.

[0036] The maintenance service object module refers to the passenger compartment door system to be tested, such as Figure 4 The double-leaf, electrically controlled, electric toothed belt-driven interior door on Chengdu Metro Line 3, shown here, includes a passenger compartment door mechanism 5, door panels, a door controller, and other components. This platform design is universally adaptable; by adjusting the dimensions of the mounting frame and platform, it can accommodate passenger compartment door systems of varying styles and sizes, including interior doors, sliding plug doors, and exterior doors.

[0037] The basic function platform module is the core of the present invention, providing the physical basis and control core for the realization of various functions. Figure 1 、 Figure 2 、 Figure 3 As shown, it mainly consists of a passenger compartment door mounting frame 1, a training podium 2, an integrated control cabinet 3, a maintenance operation platform 4, and a control module.

[0038] like Figure 2 As shown, the passenger compartment door mounting frame is the skeleton of the entire platform. It restores the installation interface and environment of the door on a real vehicle at a 1:1 ratio. The main frame 11 is welded with 50mm×50mm square steel profiles to ensure the rigidity and stability of the structure. The door opening size and external curve are designed according to the target vehicle model (such as Chengdu Metro Line 3) to simulate the real vehicle body. The mechanism mounting part 12 is precisely machined from steel plates and fully matches the installation dimensions of the passenger compartment door mechanism. The upper fixing foot 13 is fixed to the wall by expansion bolts, and the lower support leg 14 can be fine-tuned in height to ensure the stability and levelness of the mounting frame. The mounting frame also integrates an external equipment mounting frame 15 for installing an emergency unlocking device to facilitate related tests.

[0039] like Figure 1 and Figure 3 As shown, the training platform is located directly in front of the mounting frame. Constructed from multi-layered solid wood panels and an angle steel frame, the platform is elevated 500mm and connected to the ground via two steps. This elevates components requiring frequent operation and maintenance, such as the door drive mechanism, to a comfortable, ergonomic height. Operators can easily work without bending over or using a stool, ensuring safety and comfort. The spacious platform accommodates multiple trainees simultaneously, significantly improving training efficiency.

[0040] like Figure 1 and Figure 3 As shown, on the training podium, a comprehensive control cabinet and maintenance platform are symmetrically positioned on either side. The main body of the comprehensive control cabinet is constructed of multi-layer solid wood. The interior space is used to house electrical equipment such as the PLC, power modules (providing DC110V and DC24V, etc.), relays, and terminal blocks. Wiring is done in accordance with electrical specifications. The cabinet doors feature three hinged doors for easy maintenance.

[0041] The maintenance platform, located atop the control cabinet, features an innovative two-tier design. The first-tier platform 41 is wider (400mm) and houses a hardware control panel. The panel integrates mechanical buttons simulating train control signals (such as zero speed, enable, and door open / close commands) and status indicators. The second-tier platform 42, located above the first-tier platform and rearward, is 185mm higher and 200mm wider. It is designed specifically for accommodating test equipment (such as door controllers) and testing instruments.

[0042] The control module is the core component of the platform. Specifically, it uses a programmable controller (PLC) (e.g., programmed using GXWorks2) as the core control system, and is coupled with a human-computer interactive touch screen (e.g., configured and compiled using YKBuilder). The touch screen enables software-level door control, operating mode switching (manual, automatic, fatigue testing), real-time monitoring and display of key parameters (e.g., motor current, voltage, and door opening and closing times), and the recording and export of test data, among other advanced functions.

[0043] The platform is designed with three independent yet interrelated control systems and sets priorities.

[0044] a) Hardware control mode (highest priority): Through the physical buttons and indicator lights on the maintenance operation platform, the hard-wired command control method of the real train is 100% restored. The operation is intuitive and the response is fast. It is used for basic manual operation and fault simulation.

[0045] b) Software control mode (medium priority): Through touch screen operation, the PLC program controls the output signal of the relay group, which can realize more complex control logic and automation sequence.

[0046] c) Fatigue test mode (low priority): Activated in software control mode, after setting the target number of times, the PLC will automatically cycle the door open and close and record data throughout the process for component durability and reliability verification.

[0047] The integrated control cabinet utilizes ingenious circuit design and an intermediate relay group to implement a "dual-door controller quick switching" function. It can simultaneously connect a standard door controller and a door controller under test (or after repair). With a single switch, vehicle door control can be switched between the two, facilitating performance comparisons under the same conditions and enabling quick determination of component status.

[0048] Expanded function modules refer to third-party equipment that can be optionally installed based on specific testing requirements. This platform reserves ample space and power ports on the maintenance operation platform and control cabinet, allowing for easy integration of door controller PTU maintenance monitoring terminals, digital oscilloscopes, RS485 / MVB protocol analyzers, and other devices, providing powerful technical support for in-depth troubleshooting and component repair.

[0049] Through innovative design integrating mechanical structure, electrical control, and ergonomics, this invention has created a comprehensive, safe, efficient, and practically applicable platform for inspecting and testing passenger compartment doors on urban rail vehicles. This platform effectively addresses numerous challenges currently faced in door maintenance and is of significant value in improving rail transit operations and personnel training. The design concept and modular architecture of this solution offer excellent versatility, allowing for adaptive adjustments and widespread application based on the door systems of different vehicle models.

[0050] The present invention is not limited to the above-mentioned optional implementation modes. Anyone can derive other forms of products under the inspiration of the present invention. However, no matter what changes are made in the shape or structure, any technical solution that falls within the scope defined by the claims of the present invention falls within the scope of protection of the present invention.

Claims

1. A comprehensive inspection and testing platform for passenger compartment doors of urban rail vehicles, characterized in that: include: The passenger compartment door mounting frame is used to simulate the urban rail vehicle body environment and install the passenger compartment door system to be inspected and tested; A training podium is provided in front of the passenger compartment door mounting frame and is used to provide a standing platform for operation and maintenance; An integrated control cabinet, which is arranged on the table of the training podium and has electrical components installed therein for driving and monitoring the passenger compartment door system; A maintenance operation platform is provided on the top of the integrated control cabinet and is used to place a control panel and components to be tested; The control module is arranged in the integrated control cabinet and is electrically connected to the control panel on the maintenance operation platform, and is used to control the operation of the passenger compartment door system, simulate faults, perform tests and monitor and record operation data.

2. The comprehensive maintenance test platform for passenger compartment doors of urban rail vehicles according to claim 1 is characterized in that: The passenger compartment door mounting frame comprises: The main frame is designed with door openings based on the actual door size and fits the curvature of the car body; Mechanism installation part, used for installing the passenger compartment door mechanism; An upper fixed foot extends from the upper portion of the main frame and is connected to a fixing plate; The lower support legs are arranged at the lower part of the main frame and are used to support the overall weight and adjust the flatness.

3. The comprehensive maintenance test platform for passenger compartment doors of urban rail vehicles according to claim 2 is characterized in that: The passenger compartment door mounting frame also includes an external equipment mounting frame.

4. The comprehensive maintenance test platform for passenger compartment doors of urban rail vehicles according to claim 1 is characterized in that: The bottom of the training platform is provided with a keel frame, and is transitioned to the ground through at least one step; the integrated control cabinet is arranged in a mirror image along both sides of the training platform surface.

5. The comprehensive maintenance test platform for passenger compartment doors of urban rail vehicles according to claim 1 is characterized in that: The maintenance operation platform is designed in layers and includes: A first-layer platform, located on the top of the integrated control cabinet, for installing a hardware control panel integrating mechanical buttons and indicator lights; The second-layer platform is located on the first-layer platform and is used for placing the door controller to be tested and other detection instruments.

6. The comprehensive maintenance test platform for passenger compartment doors of urban rail vehicles according to claim 1 is characterized in that: The control module includes a software control unit and a physical hardware control unit; The software control unit is based on a programmable controller (PLC) and uses a human-computer interactive touch screen for command input and data display. The physical hardware control unit includes mechanical buttons and indicator lights, which are used to send control instructions and reflect the instructions and door status.

7. The comprehensive maintenance test platform for passenger compartment doors of urban rail vehicles according to claim 6 is characterized in that: The control module is configured to implement at least three control modes, including a hardware control mode, a software control mode and a fatigue test mode; the three control modes have preset priorities, wherein the hardware control mode has the highest priority.

8. The comprehensive maintenance test platform for passenger compartment doors of urban rail vehicles according to claim 7 is characterized in that: The fatigue test mode is used to control the periodic automatic operation of the passenger compartment door system according to a preset number of door openings and closings, and to monitor and record key parameters during the test process.

9. The comprehensive maintenance test platform for passenger compartment doors of urban rail vehicles according to claim 1 is characterized in that: A switching circuit is provided in the integrated control cabinet, and the switching circuit realizes rapid switching of at least two door controllers to be tested through an intermediate relay, so as to perform comparative verification under the same working conditions.

10. The comprehensive maintenance test platform for passenger compartment doors of urban rail vehicles according to claim 1 is characterized in that: The platform also includes an expansion function module to provide mounting space and power supply support for third-party testing instruments.

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