Intelligent maintenance car and maintenance method for gearbox of motor train unit

Abstract

The invention relates to the technical field of motor train unit maintenance equipment, and discloses an intelligent motor train unit gearbox maintenance car which comprises a car body. A sampling bottle storing and conveying unit, a sampling bottle cap processing unit, a laser marking unit, a sampling bottle collecting unit, an old oil collecting unit, an oil plug tightness processing unit, a first mechanical arm, a sampling bottle taking and oil injection assembly execution module, a second mechanical arm, an oil plug screwing and cleaning assembly execution module and a new oil plug and unqualified oil plug storing unit are arranged on the vehicle body. An oil plug scraping unit; a third manipulator; and an oil plug visual identification execution module. The overhauling method comprises the steps that the oil plug tightness treatment unit acts, and the first mechanical arm acts and the second mechanical arm act alternately. The motor train unit gearbox intelligent maintenance car and the maintenance method have the advantages of being high in automation degree, high in continuous working capacity, high in maintenance efficiency and good in safety.

Description

Technical Field

[0001] The present invention relates to the technical field of EMU maintenance equipment, and in particular to an EMU gearbox intelligent maintenance vehicle and a maintenance method. Background Art

[0002] The gearbox of an EMU (Electric Multiple Unit) is a key component of the running gear, directly driving the train. To ensure consistent lubrication, the gearbox requires regular lubrication oil replacement. Currently, gearbox oil changes are primarily performed manually, both domestically and internationally. This manual process typically involves cleaning the drain plug, fill plug, and surrounding area with a wire brush. Then, using a hexagonal socket to remove the fill plug, the drain plug is removed again with a hexagonal socket to drain any remaining oil from the gearbox into a waste oil container. After draining, the drain plug is tightened with a hexagonal socket. A grease gun is then used to inject lubricant into the gearbox through the fill port. After lubrication, the fill plug is tightened with a hexagonal socket. Finally, the drain and fill plugs and surrounding area are cleaned with detergent and a non-woven fabric. The entire manual process is complex and inefficient, and the poor working environment makes it prone to safety incidents. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to overcome the deficiencies of the existing technology and provide an intelligent maintenance vehicle and maintenance method for EMU gearboxes with high degree of automation, strong continuous working capability, high maintenance efficiency and good safety.

[0004] In order to solve the above technical problems, the present invention adopts the following technical solutions: An intelligent maintenance vehicle for a gearbox of an EMU train comprises a vehicle body, on which a main control panel for the engine head, a mid-section oil change panel, and a main control panel for the engine tail are arranged. The main control panel for the engine head is provided with a sampling bottle storage and conveying unit, a sampling bottle cap processing unit, a laser marking unit, a sampling bottle collection unit, and a first main control unit. The middle section oil change platform is provided with a used oil collection unit, an oil plug tightness processing unit, a first manipulator, a sampling bottle and oil filling assembly execution module connected to the first manipulator, a second manipulator, an oil plug tightening and cleaning assembly execution module connected to the second manipulator, and a position identification unit; The tail console body is provided with a new oil plug and unqualified oil plug storage unit, an oil plug scraping unit, a third manipulator, an oil plug visual recognition execution module connected to the third manipulator, and a second main control unit.

[0005] As a further improvement of the above technical solution: The sampling bottle storage and conveying unit includes an inclined bottom plate, several groups of limit plates fixedly connected to the bottom plate, and a cover plate fixedly connected to the limit plates. A sampling bottle slide is formed between any two adjacent groups of limit plates. The lower end of the bottom plate is provided with several groups of air-avoiding grooves with one side open, and the cover plate is provided with several groups of observation grooves. The air-avoiding grooves and the observation grooves correspond one-to-one to the sampling bottle slides. The lower end of the bottom plate is bent to form a bottle blocking portion.

[0006] The sampling bottle cap processing unit includes a first mounting base, on which is provided a bottle positioning sleeve, a first driving motor for driving the bottle positioning sleeve to rotate, a bottle cap positioning assembly, and a first driving cylinder for driving the bottle cap positioning assembly to move up and down. The bottle cap positioning assembly includes a first gripper cylinder and a first gripper for gripping the bottle cap, and a cap pressing plate for pressing the bottle cap is fixedly connected to the first gripper cylinder; The laser marking unit includes a UC ultraviolet laser marking machine fixedly connected to the first mounting base; The sampling bottle collection unit includes a collection tray.

[0007] The oil plug tightness processing unit includes a lifting column, which is escalably disposed within the middle oil exchange platform. A first sleeve for engaging with the oil plug, a first displacement sensor, and a first industrial camera are disposed on the left and right sides of the lifting column in a mirror-like manner. A second drive motor for driving the first sleeve to rotate is disposed within the lifting column. Oil receiving pans are mirror-mounted on the left and right sides of the top of the lifting column. The oil receiving pans are connected to an oil guide pipe, and the output end of the oil guide pipe is located above the used oil collection unit.

[0008] The first manipulator includes a first movable seat, and the first manipulator is movably arranged on the middle oil exchange platform through the first movable seat; The sampling bottle and oiling assembly execution module includes a second mounting base, on which are provided a bottle clamping assembly, an oiling gun, a second driving cylinder for driving the oiling gun to move, a second displacement sensor and a second industrial camera. The bottle clamping assembly includes a second clamping cylinder and a second clamping hand for clamping the bottle body.

[0009] The second manipulator includes a second movable seat, and the second manipulator is movably arranged on the middle oil exchange platform through the second movable seat; The oil plug tightening and cleaning assembly execution module includes a third mounting base, on which are provided a second sleeve for being sleeved with the oil plug, a third driving motor for driving the second sleeve to rotate, a third driving cylinder for driving the third driving motor and the second sleeve to move, a cleaning brush head, a third displacement sensor, and a third industrial camera; The position identification unit includes a fourth mounting base, on which a fourth displacement sensor, a fourth industrial camera, and a fifth displacement sensor are arranged.

[0010] The new oil plug and unqualified oil plug storage unit includes a positioning plate, which is provided with a plurality of placement holes for placing the oil plugs, and the placement holes are provided with internal threads. Handles are respectively provided on both sides of the positioning plate.

[0011] The oil plug scraping unit includes a fifth mounting base, on which is provided a clamping plate for clamping with the oil plug, an inclined material drop trough and a material baffle plate. The clamping plate is provided with a clamping slot open on one side, and a collection box is provided under the material baffle plate.

[0012] The third manipulator includes a third movable base, and the third manipulator is movably arranged on the tail console body through the third movable base; The oil plug visual recognition execution module includes a sixth mounting base, on which a sixth displacement sensor and a fifth industrial camera are provided.

[0013] A maintenance method for the above-mentioned EMU gearbox intelligent maintenance vehicle comprises the following steps: (S1) The vehicle moves, the position recognition unit recognizes the position of the gearbox, and the vehicle stops after reaching the gearbox position; (S2) The second manipulator moves to tighten the oil plug and clean the assembly execution module to clean the surface of the oil drain plug and the oil filling plug; (S3) The oil plug tightness processing unit is activated, and the oil plug tightness processing unit loosens the oil drain plug and the oil filling plug; (S4) The second manipulator moves, the oil plug unscrewing and cleaning component execution module first removes the oil filling plug, and visually identifies the oil filling plug with the oil plug visual recognition execution module. If the visual recognition is qualified, the oil filling plug is scraped off on the oil plug scraping unit. If the visual recognition is unqualified, the oil filling plug is stored on the new oil plug and unqualified oil plug storage unit; after unscrewing the oil plug and cleaning component execution module, the oil drain plug is removed, and visually identifies the oil drain plug with the oil plug visual recognition execution module. If the visual recognition is qualified, the oil drain plug is scraped off on the oil plug scraping unit. If the visual recognition is unqualified, the oil drain plug is stored on the new oil plug and unqualified oil plug storage unit; (S5) The first manipulator moves, takes the sampling bottle and the oil filling assembly execution module, and clamps the sampling bottle from the sampling bottle storage and conveying unit. The sampling bottle cap processing unit opens the bottle cap. After the sampling bottle is filled with oil, the sampling bottle cap processing unit installs the bottle cap. The laser marking unit marks the sampling bottle, and the sampling bottle is placed on the sampling bottle collection unit. (S6) The second manipulator moves, the oil plug unscrewing and cleaning component execution module takes out a new oil plug from the new oil plug and unqualified oil plug storage unit, and installs the new oil plug into the oil drain port; (S7) The first manipulator moves to take the sampling bottle and the oil filling assembly execution module to add oil to the gear box; (S8) The second manipulator moves, the oil plug unscrewing and cleaning component execution module takes out a new oil plug from the new oil plug and unqualified oil plug storage unit, and installs the new oil plug into the oil filling port; (S9) The oil plug tightening processing unit is activated, and the oil plug tightening processing unit tightens the new oil drain plug and the new oil filling plug; (S10) The second manipulator moves to tighten the oil plug and clean the component execution module to take a visual photo and upload it.

[0014] Compared with the prior art, the advantages of the present invention are: 1. The intelligent maintenance vehicle for the gearbox of an EMU of the present invention includes a vehicle body, on which a first manipulator, a second manipulator and a third manipulator are provided. The first manipulator is connected to a sampling bottle and an oil injection assembly execution module to complete the sampling and oil injection processes. The second manipulator is connected to an oil plug tightening and cleaning assembly execution module to complete the cleaning and oil plug tightening processes. The third manipulator is connected to an oil plug visual recognition execution module to realize the process of judging the oil blockage situation. Through the intelligent collaboration between the manipulators, the intensity of manual operation can be effectively reduced. It has the advantages of high degree of automation, strong continuous working ability, high maintenance efficiency and good safety.

[0015] 2. The maintenance method of the intelligent maintenance vehicle for the EMU gearbox of the present invention is performed alternately through multiple actions between the oil plug tightness processing unit, the first manipulator and the second manipulator. The action response is fast and the accuracy is high, which can effectively improve the maintenance efficiency and maintenance quality of the EMU gearbox oil change. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a structural diagram of the EMU gearbox intelligent maintenance vehicle.

[0017] Figure 2 It is a structural diagram of the machine head main console body.

[0018] Figure 3 It is a schematic diagram of the internal structure of the machine head main console.

[0019] Figure 4This is a structural diagram of the sampling bottle storage and transportation unit.

[0020] Figure 5 This is a schematic diagram of the disassembly of the sampling bottle storage and transportation unit.

[0021] Figure 6 This is a structural diagram of the sampling bottle cap processing unit and the laser marking unit.

[0022] Figure 7 A schematic diagram of the structure of the sampling bottle cap processing unit and the laser marking unit from another angle Figure 8 Schematic diagram of the structure of the sampling bottle collection unit.

[0023] Figure 9 This is a structural diagram of the middle section oil change platform.

[0024] Figure 10 This is a schematic diagram of the internal structure of the middle section oil change platform.

[0025] Figure 11 It is a structural diagram of the oil plug tightness processing unit.

[0026] Figure 12 This is a front view of the oil plug tightening processing unit.

[0027] Figure 13 This is a schematic diagram of the structure of the first manipulator and the second manipulator on the middle section of the oil change platform.

[0028] Figure 14 This is a structural diagram of the sampling bottle and oil filling assembly execution module.

[0029] Figure 15 This is a structural diagram of the oil plug unscrewing and cleaning component execution module.

[0030] Figure 16 Schematic diagram of the structure of the position recognition unit.

[0031] Figure 17 This is a structural diagram of the tail console.

[0032] Figure 18 This is a structural diagram of the tail console from another angle.

[0033] Figure 19 This is a structural diagram of the storage unit for new oil plugs and unqualified oil plugs.

[0034] Figure 20 This is a structural diagram of the oil blockage scraping unit.

[0035] Figure 21 This is a structural diagram of the oil blockage visual recognition execution module.

[0036] Legend: 100, vehicle body; 200, nose control panel; 300, mid-section oil change panel; 400, tail control panel; 1. Sampling bottle storage and transport unit; 101. Bottom plate; 102. Limit plate; 103. Cover plate; 104. Sampling bottle slide; 105. Air avoidance slot; 106. Observation slot; 107. Bottle blocking unit; 2. Sampling bottle cap processing unit; 201. First mounting base; 202. Bottle positioning sleeve; 203. First drive motor; 204. Bottle cap positioning assembly; 2041. First gripper cylinder; 2042. First gripper; 2043. Cover pressing plate; 205. First drive cylinder; 3. Laser marking unit; 301. UC UV laser marking machine; 4. Sampling Bottle collection unit; 401, collection tray; 5, first master control unit; 6, used oil collection unit; 7, oil plug tightness processing unit; 701, lifting column; 702, first sleeve; 703, first displacement sensor; 704, first industrial camera; 705, second drive motor; 706, oil receiving tray; 707, oil guide pipe; 8, first manipulator; 801, first moving base; 9, sampling bottle and oil filling assembly execution module; 901, second mounting base; 902, bottle clamping assembly; 9021, second gripper cylinder; 9022, second gripper; 903, injection Oil gun; 904, second drive cylinder; 905, second displacement sensor; 906, second industrial camera; 10, second manipulator; 1001, second movable base; 11, oil plug tightening and cleaning component execution module; 1101, third mounting base; 1102, second sleeve; 1103, third drive motor; 1104, third drive cylinder; 1105, cleaning brush head; 1106, third displacement sensor; 1107, third industrial camera; 12, position recognition unit; 1201, fourth mounting base; 1202, fourth displacement sensor; 120 3. Fourth industrial camera; 1204. Fifth displacement sensor; 13. Storage unit for new oil plugs and unqualified oil plugs; 1301. Positioning plate; 1302. Placement hole; 1303. Handle; 14. Oil plug scraping unit; 1401. Fifth mounting base; 1402. Card plate; 1403. Blanking chute; 1404. Baffle plate; 1405. Collection box; 15. Third manipulator; 1501. Third moving base; 16. Oil plug visual recognition execution module; 1601. Sixth mounting base; 1602. Sixth displacement sensor; 1603. Fifth industrial camera. DETAILED DESCRIPTION

[0037] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0038] like Figures 1 to 21As shown, the EMU gearbox intelligent maintenance vehicle of this embodiment includes a car body 100, on which a head control panel body 200, a mid-section oil change panel body 300 and a tail control panel body 400 are arranged. The head control panel body 200 is provided with a sampling bottle storage and conveying unit 1, a sampling bottle cap processing unit 2, a laser marking unit 3, a sampling bottle collection unit 4 and a first control unit 5; the mid-section oil change panel body 300 is provided with an old oil collection unit 6, an oil plug tightness processing unit 7, a first manipulator 8, a sampling bottle removal and oil filling assembly execution module 9 connected to the first manipulator 8, a second manipulator 10, an oil plug tightening and cleaning assembly execution module 11 connected to the second manipulator 10, and a position recognition unit 12; the tail control panel body 400 is provided with a new oil plug and unqualified oil plug storage unit 13, an oil plug scraping unit 14, a third manipulator 15, an oil plug visual recognition execution module 16 connected to the third manipulator 15, and a second control unit. The EMU gearbox intelligent maintenance vehicle includes a vehicle body 100, on which a first manipulator 8, a second manipulator 10 and a third manipulator 15 are provided. The first manipulator 8 is connected to a sampling bottle and oil injection assembly execution module 9 to complete the sampling and oil injection processes. The second manipulator 10 is connected to an oil plug tightening and cleaning assembly execution module 11 to complete the cleaning and oil plug tightening processes. The third manipulator 15 is connected to an oil plug visual recognition execution module 16 to realize the process of judging the oil blockage situation. Through the intelligent collaboration between the manipulators, the intensity of manual operation can be effectively reduced. The vehicle has the advantages of high degree of automation, strong continuous working ability, high maintenance efficiency and good safety.

[0039] Preferably, the sampling bottle storage and transport unit 1 includes an inclined base plate 101, several groups of limiting plates 102 fixedly connected to the base plate 101, and a cover plate 103 fixedly connected to the limiting plate 102. A sampling bottle slide 104 is formed between any two adjacent groups of limiting plates 102. The lower end of the base plate 101 is provided with several groups of air-avoiding grooves 105 with one side openings, and the cover plate 103 is provided with several groups of observation grooves 106. The air-avoiding grooves 105 and the observation grooves 106 correspond one-to-one to the sampling bottle slide 104. The lower end of the base plate 101 is bent to form a bottle blocking portion 107. In this embodiment, before the EMU gearbox intelligent maintenance vehicle works, the sampling bottle is manually placed in from the upper end of the bottom plate 101, and the sampling bottle rolls down in the sampling bottle slide 104 to the bottle blocking portion 107 until multiple sampling bottles fill the sampling bottle slide 104, thereby storing multiple sampling bottles. After the sampling bottle and oil filling assembly execution module 9 takes the bottle from the air avoidance groove 105, the next sampling bottle automatically rolls down to the bottle blocking portion 107 under gravity and waits for the next bottle to be taken, thereby realizing automatic transportation and replenishment of the sampling bottle, without the need for manual repeated sampling bottle operations. At the same time, the operator can understand the number of sampling bottles in the sampling bottle slide 104 by observing the through groove 106, which is more convenient to use.

[0040] Preferably, the sampling bottle cap processing unit 2 includes a first mounting base 201, on which is provided a bottle positioning sleeve 202, a first driving motor 203 for driving the bottle positioning sleeve 202 to rotate, a bottle cap positioning assembly 204, and a first driving cylinder 205 for driving the bottle cap positioning assembly 204 to move up and down. The bottle cap positioning assembly 204 includes a first clamping cylinder 2041 and a first clamping hand 2042 for clamping the bottle cap. The first clamping cylinder 2041 is fixedly connected to a cover pressure plate 2043 for pressing the bottle cap. In this embodiment, after the sampling bottle and oil filling assembly execution module 9 takes out two sampling bottles from the sampling bottle storage and conveying unit 1, the first manipulator 8 moves the sampling bottles to the sampling bottle cap processing unit 2, the sampling bottles are fixed on the bottle positioning sleeve 202, the bottle cap positioning assembly 204 descends to the cap pressing plate 2043 and abuts against the bottle cap, the first clamping hand 2042 clamps the bottle cap under the drive of the first clamping hand cylinder 2041, and then the first drive motor 203 drives the bottle positioning sleeve 202 to rotate, so that the bottle body rotates, thereby separating the bottle body from the bottle cap, and the bottle cap remains on the bottle cap positioning assembly 204, and the first manipulator 8 moves the sampling bottle body to the gear box oil discharge port for gear oil sampling; after the sampling is completed, the first manipulator 8 fixes the sampling bottle body on the bottle positioning sleeve 202, the bottle cap positioning assembly 204 and the bottle cap thereon descend to the sampling bottle mouth, and the first drive motor 203 drives the bottle positioning sleeve 202 to rotate, so that the bottle body rotates, thereby tightening the bottle body and the bottle cap.

[0041] Preferably, the laser marking unit 3 includes a UC ultraviolet laser marking machine 301 fixedly connected to the first mounting base 201 .

[0042] Preferably, the sampling bottle collection unit 4 includes a collection tray 401. In this embodiment, after the sampling bottle body and bottle cap are tightened, the UC UV laser marking machine 301 marks the corresponding gearbox number and date on the bottle body to facilitate later tracking. The first robot 8 then moves the sampling bottle to the collection tray 401 for storage, thus completing the sampling process. The remaining used oil falls into the used oil collection unit 6 for collection.

[0043] Preferably, the oil plug tightness processing unit 7 includes a lifting column 701, which is movably arranged in the middle oil change platform 300. The left and right sides of the lifting column 701 are mirror-arranged with a first sleeve 702 for being sleeved with the oil plug, a first displacement sensor 703 and a first industrial camera 704. The lifting column 701 is provided with a second drive motor 705 for driving the first sleeve 702 to rotate; the left and right sides of the top of the lifting column 701 are mirror-arranged with an oil receiving pan 706, and the oil receiving pan 706 is connected to an oil guide pipe 707, and the output end of the oil guide pipe 707 is located above the used oil collection unit 6. In this embodiment, the bottom of the middle oil-changing platform body 300 is connected to the XY-axis movable seat, and has the freedom of movement in the front-back (X-axis) and left-right (Y-axis) directions. The lifting column body 701 can be lifted and lowered in the middle oil-changing platform body 300. Through the cooperation of the first displacement sensor 703 and the first industrial camera 704, the positions of the oil drain plug and the oil filling plug are automatically identified, so that the first sleeve 702 can be aligned with the oil drain plug and the oil filling plug; after the first sleeve 702 is respectively connected to the oil drain plug and the oil filling plug, the second drive motor 705 drives the first sleeve 702 to rotate to loosen (or tighten) the oil drain plug and the oil filling plug, thereby facilitating the subsequent process of tightening the oil plug and cleaning the assembly execution module 11. It should be noted that at a gearbox station, the gearboxes on both sides need oil change and maintenance. Therefore, the first sleeve 702, the first displacement sensor 703 and the first industrial camera 704 are arranged in a mirrored manner on the left and right sides of the lifting column 701. The output shaft of the second drive motor 705 is connected to the gearbox, and the two sides of the gearbox are respectively connected to the first sleeve 702 through couplings, which can achieve high torque output, thereby loosening (or tightening) the oil drain plug and the oil filling plug.

[0044] Preferably, the first manipulator 8 includes a first movable base 801, which is movably mounted on the middle oil-exchange platform 300. In this embodiment, the first movable base 801 is slidably connected to the middle oil-exchange platform 300 via a guide rail and slider mechanism. A rack and pinion transmission mechanism is provided between the first movable base 801 and the middle oil-exchange platform 300, enabling the first movable base 801 to move left and right (Y-axis) on the middle oil-exchange platform 300, thereby providing the first manipulator 8 with freedom of left and right (Y-axis) movement.

[0045] Preferably, the sampling bottle and oiling assembly execution module 9 includes a second mounting base 901, on which are provided a bottle clamping assembly 902, an oiling gun 903, a second driving cylinder 904 for driving the oiling gun 903 to move, a second displacement sensor 905 and a second industrial camera 906; the bottle clamping assembly 902 includes a second clamping cylinder 9021 and a second clamping hand 9022 for clamping the bottle body. In this embodiment, the first manipulator 8 cooperates with the second displacement sensor 905 and the second industrial camera 906 to automatically identify the positions of the oil filling port and the oil drain port (at this time, the oil drain plug and the oil filling plug on the gear box have been removed by the oil plug and cleaning component execution module 11), so that the oil filling gun 903 can be aligned with the oil filling port. The second driving cylinder 904 drives the oil filling gun 903 to extend. After the oil filling gun 903 is connected to the oil filling port, the air compressor in the middle oil changing platform body 300 delivers high-pressure air into the gear box to clean the residual oil in the gear box. The second driving cylinder 904 drives the oil filling gun 903 to retract. The oil drain plug is screwed onto the oil drain port by the oil plug and cleaning component execution module 11. Then, the second driving cylinder 904 drives the oil filling gun 903 to extend. After the oil filling gun 903 is connected to the oil filling port, the oil pump in the middle oil changing platform body 300 fills 5L of new oil into the gear box. The second driving cylinder 904 drives the oil filling gun 903 to retract.

[0046] Preferably, the second manipulator 10 includes a second movable base 1001, which is used to movably mount the second manipulator 10 on the middle oil-exchange platform 300. In this embodiment, the second movable base 1001 is slidably connected to the middle oil-exchange platform 300 via a guide rail and slider mechanism. A rack and pinion transmission mechanism is provided between the second movable base 1001 and the middle oil-exchange platform 300, enabling the second movable base 1001 to move left and right (Y-axis) on the middle oil-exchange platform 300, thereby providing the second manipulator 10 with freedom of left and right (Y-axis) movement.

[0047] Preferably, the oil plug and cleaning assembly execution module 11 comprises a third mounting base 1101, a second sleeve 1102 for sleeving with the oil plug, a third drive motor 1103 for driving the second sleeve 1102 to rotate, a third drive cylinder 1104 for driving the third drive motor 1103 and the second sleeve 1102 to move, a cleaning brush head 1105, a third displacement sensor 1106, and a third industrial camera 1107 are arranged on the third mounting base 1101. In the embodiment, after the oil drain plug and the oil injection plug are unscrewed, the second mechanical arm 10 cooperates with the third displacement sensor 1106 and the third industrial camera 1107 to move the oil plug and cleaning assembly execution module 11 to the oil drain plug and the oil injection plug, and then the cleaning brush head 1105 is used to clean the surface of the oil drain plug and the oil injection plug. Then the third drive cylinder 1104 is used to drive the second sleeve 1102 to extend, and after the second sleeve 1102 is sleeved with the oil drain plug and the oil injection plug respectively, the third drive motor 1103 is used to drive the second sleeve 1102 to rotate, so as to remove the oil drain plug and the oil injection plug. After the oil plug visual recognition execution module 16 performs visual recognition, it is judged whether the iron powder in the oil plug is within the qualified range. The unqualified oil plug is stored on the new oil plug and unqualified oil plug storage unit 13, and the qualified oil plug is separated from the second sleeve 1102 through the oil plug scraping unit 14. The second sleeve 1102 takes out the new oil plug from the new oil plug and unqualified oil plug storage unit 13 and screws the new oil plug on the oil drain port and the oil injection port.

[0048] Preferably, the position recognition unit 12 comprises a fourth mounting base 1201, a fourth displacement sensor 1202, a fourth industrial camera 1203, and a fifth displacement sensor 1204 are arranged on the fourth mounting base 1201. In the embodiment, the vehicle body 100 is an RGV vehicle. When the RGV vehicle moves, the fourth industrial camera 1203 recognizes the left and right positions of the gear box and the position of the shaft, and the fourth displacement sensor 1202 and the fifth displacement sensor 1204 measure the equal distance on both sides of the shaft to determine the center line position of the shaft, so as to realize position recognition.

[0049] Preferably, the new oil plug and unqualified oil plug storage unit 13 comprises a positioning disc 1301, a plurality of placement holes 1302 for placing the oil plug are arranged on the positioning disc 1301, and an internal thread is arranged in the placement hole 1302. Handles 1303 are arranged on both sides of the positioning disc 1301. In the embodiment, two new oil plugs are needed for each gear box. Before the EMU gear box intelligent maintenance vehicle starts to work, the new oil plugs are manually installed in the placement holes 1302. After the new oil plugs are installed in the gear boxes, the empty placement holes 1302 will appear. When the oil plug visual recognition execution module 16 recognizes the unqualified oil plug, the second sleeve 1102 screws the unqualified oil plug into the empty placement hole 1302, so as to occupy small space and store large amount.

[0050] Preferably, the oil plug scraping unit 14 includes a fifth mounting base 1401, which is provided with a clamping plate 1402 for engaging with the oil plug, an inclined material drop chute 1403, and a material stopper 1404. The clamping plate 1402 has a clamping slot with an opening on one side, and a collection box 1405 is provided below the material stopper 1404. In this embodiment, the oil plug is magnetic and is magnetically attracted to the second sleeve 1102. The second manipulator 10 inserts a qualified oil plug into the clamping slot on the clamping plate 1402, thereby scraping the oil plug from the second sleeve 1102. The oil plug falls into the material drop chute 1403 and is collected by the collection box 1405.

[0051] Preferably, the third manipulator 15 includes a third movable base 1501, which is movably mounted on the tail console body 400. In this embodiment, the third movable base 1501 is slidably connected to the tail console body 400 via a guide rail and slider mechanism. A rack and pinion transmission mechanism is provided between the third movable base 1501 and the tail console body 400, enabling the third movable base 1501 to move left and right (Y-axis) on the tail console body 400, thereby providing the third manipulator 15 with freedom of left and right (Y-axis) movement.

[0052] Preferably, the oil plug visual recognition execution module 16 includes a sixth mounting base 1601, which is equipped with a sixth displacement sensor 1602 and a fifth industrial camera 1603. In this embodiment, the third robot 15 cooperates with the sixth displacement sensor 1602 and the fifth industrial camera 1603 to visually identify the oil plug on the second robot 10 and determine whether the iron powder inside the oil plug is within the acceptable range.

[0053] It should be noted that, in this embodiment, the first manipulator 8, the second manipulator 10 and the third manipulator 15 are all Wasu collaborative six-axis robots, which are existing technologies and will not be described in detail here.

[0054] The maintenance method of the EMU gearbox intelligent maintenance vehicle of this embodiment includes the following steps: (S1) The vehicle body 100 moves, the position recognition unit 12 recognizes the position of the gearbox, and the vehicle body 100 stops after reaching the gearbox position; (S2) The second manipulator 10 moves to tighten the oil plug and the cleaning component execution module 11 (i.e., through the cleaning brush head 1105) cleans the surface of the oil drain plug and the oil filling plug; (S3) The oil plug tightening processing unit 7 is activated, and the oil plug tightening processing unit 7 (i.e., through the first sleeve 702) loosens the oil drain plug and the oil filling plug; (S4) The second manipulator 10 moves, and the oil plug and cleaning component execution module 11 (i.e., through the second sleeve 1102) first removes the oil filling plug, and visually identifies the oil filling plug with the oil plug visual recognition execution module 16. If the visual recognition is qualified, the oil filling plug is scraped off on the oil plug scraping unit 14. If the visual recognition is unqualified, the oil filling plug is stored in the new oil plug and unqualified oil plug storage unit 13; after the oil plug and cleaning component execution module 11 is unscrewed (i.e., through the second sleeve 1102), the oil drain plug is removed, and visually identifies the oil drain plug with the oil plug visual recognition execution module 16. If the visual recognition is qualified, the oil drain plug is scraped off on the oil plug scraping unit 14. If the visual recognition is unqualified, the oil drain plug is stored in the new oil plug and unqualified oil plug storage unit 13; (S5) The first manipulator 8 moves to take the sampling bottle and oil filling assembly execution module 9 (i.e., through the bottle gripping assembly 902) and pick up the sampling bottle from the sampling bottle storage and conveying unit 1. The sampling bottle cap processing unit 2 opens the bottle cap. After the sampling bottle is filled with oil, the sampling bottle cap processing unit 2 installs the bottle cap. The laser marking unit 3 marks the sampling bottle and places the sampling bottle on the sampling bottle collection unit 4. (S6) The second manipulator 10 moves to remove the new oil plug from the new and unqualified oil plug storage unit 13 (i.e., through the second sleeve 1102) and install the new oil plug into the oil drain port. (S7) The first manipulator 8 moves to take the sampling bottle and the oil filling assembly execution module 9 (i.e., through the oil filling gun 903) to add oil to the gear box; (S8) The second manipulator 10 moves to remove the new oil plug from the new and unqualified oil plug storage unit 13 (i.e., through the second sleeve 1102) and install the new oil plug into the oil filling port. (S9) The oil plug tightening processing unit 7 is activated, and the oil plug tightening processing unit 7 (i.e., through the first sleeve 702) tightens the new oil drain plug and the new oil filling plug; (S10) Second manipulator 10 actuates, and oil plug tightening and cleaning component execution module 11 (i.e., via third industrial camera 1107) takes a visual image and uploads it. This intelligent maintenance vehicle for EMU gearboxes utilizes multiple actions, alternating between the oil plug tightening and loosening processing unit 7, first manipulator 8, and second manipulator 10. This method offers fast response and high accuracy, effectively improving the efficiency and quality of EMU gearbox oil change maintenance.

[0055] The above is only a preferred embodiment of the present invention, and the scope of protection of the present invention is not limited to the above embodiment. For those skilled in the art, improvements and modifications obtained without departing from the technical concept of the present invention should also be considered as the scope of protection of the present invention.

Claims

1. An intelligent maintenance vehicle for a gearbox of an EMU, comprising a vehicle body (100), characterized in that: The vehicle body (100) is provided with a head control console (200), a mid-section oil change console (300), and a tail control console (400); the head control console (200) is provided with a sampling bottle storage and conveying unit (1), a sampling bottle cap processing unit (2), a laser marking unit (3), a sampling bottle collection unit (4), and a first control unit (5); The middle section oil change platform (300) is provided with a used oil collection unit (6), an oil plug tightness processing unit (7), a first manipulator (8), a sampling bottle and oil filling assembly execution module (9) connected to the first manipulator (8), a second manipulator (10), an oil plug tightening and cleaning assembly execution module (11) connected to the second manipulator (10), and a position recognition unit (12); The tail console body (400) is provided with a new oil plug and unqualified oil plug storage unit (13), an oil plug scraping unit (14), a third manipulator (15), an oil plug visual recognition execution module (16) connected to the third manipulator (15), and a second main control unit.

2. The EMU gearbox intelligent maintenance vehicle according to claim 1 is characterized in that: The sampling bottle storage and transport unit (1) includes an inclined bottom plate (101), several groups of limiting plates (102) fixedly connected to the bottom plate (101), and a cover plate (103) fixedly connected to the limiting plates (102), a sampling bottle slide (104) is formed between any two adjacent groups of limiting plates (102), the lower end of the bottom plate (101) is provided with several groups of air-avoiding grooves (105) with one side opening, the cover plate (103) is provided with several groups of observation grooves (106), the air-avoiding grooves (105) and the observation grooves (106) correspond one to one with the sampling bottle slide (104), and the lower end of the bottom plate (101) is bent to form a bottle blocking portion (107).

3. The EMU gearbox intelligent maintenance vehicle according to claim 2 is characterized in that: The sampling bottle cap processing unit (2) comprises a first mounting base (201), on which a bottle positioning sleeve (202), a first driving motor (203) for driving the bottle positioning sleeve (202) to rotate, a bottle cap positioning assembly (204), and a first driving cylinder (205) for driving the bottle cap positioning assembly (204) to move up and down are provided. The bottle cap positioning assembly (204) comprises a first gripping cylinder (2041) and a first gripping hand (2042) for gripping the bottle cap. A cap pressing plate (2043) for pressing the bottle cap is fixedly connected to the first gripping cylinder (2041); The laser marking unit (3) comprises a UC ultraviolet laser marking machine (301) fixedly connected to the first mounting base (201); The sampling bottle collection unit (4) comprises a collection tray (401).

4. The EMU gearbox intelligent maintenance vehicle according to claim 3 is characterized in that: The oil plug tightness processing unit (7) comprises a lifting column (701), the lifting column (701) being movably arranged in the middle oil exchange platform (300), a first sleeve (702) for being sleeved with the oil plug, a first displacement sensor (703) and a first industrial camera (704) being arranged in a mirror-like manner on the left and right sides of the lifting column (701), and a second driving motor (705) for driving the first sleeve (702) to rotate being arranged in the lifting column (701); Oil receiving pans (706) are mirror-mounted on the left and right sides of the top of the lifting column (701). The oil receiving pans (706) are connected to an oil guide pipe (707). The output end of the oil guide pipe (707) is located above the used oil collection unit (6).

5. The EMU gearbox intelligent maintenance vehicle according to claim 4 is characterized in that: The first manipulator (8) comprises a first movable seat (801), and the first manipulator (8) is movably arranged on the middle oil exchange platform (300) via the first movable seat (801); The sampling bottle and oiling assembly execution module (9) includes a second mounting base (901), on which are provided a bottle clamping assembly (902), an oiling gun (903), a second driving cylinder (904) for driving the oiling gun (903) to move, a second displacement sensor (905) and a second industrial camera (906), and the bottle clamping assembly (902) includes a second clamping cylinder (9021) and a second clamping hand (9022) for clamping the bottle body.

6. The EMU gearbox intelligent maintenance vehicle according to claim 5, characterized in that: The second manipulator (10) comprises a second movable seat (1001), and the second manipulator (10) is movably arranged on the middle oil exchange platform (300) via the second movable seat (1001); The oil plug tightening and cleaning assembly execution module (11) comprises a third mounting base (1101), on which are provided a second sleeve (1102) for being sleeved with the oil plug, a third driving motor (1103) for driving the second sleeve (1102) to rotate, a third driving cylinder (1104) for driving the third driving motor (1103) and the second sleeve (1102) to move, a cleaning brush head (1105), a third displacement sensor (1106) and a third industrial camera (1107); The position recognition unit (12) comprises a fourth mounting base (1201), on which a fourth displacement sensor (1202), a fourth industrial camera (1203) and a fifth displacement sensor (1204) are arranged.

7. The EMU gearbox intelligent maintenance vehicle according to claim 6, characterized in that: The new oil plug and unqualified oil plug storage unit (13) comprises a positioning plate (1301), the positioning plate (1301) is provided with a plurality of placement holes (1302) for placing the oil plugs, the placement holes (1302) are provided with internal threads, and handles (1303) are respectively provided on both sides of the positioning plate (1301).

8. The EMU gearbox intelligent maintenance vehicle according to claim 7, characterized in that: The oil plug scraping unit (14) comprises a fifth mounting base (1401), on which a clamping plate (1402) for clamping with the oil plug, an inclined material drop trough (1403) and a material blocking plate (1404) are provided, wherein the clamping plate (1402) is provided with a clamping groove with an opening on one side, and a collecting box (1405) is provided below the material blocking plate (1404).

9. The EMU gearbox intelligent maintenance vehicle according to claim 8, characterized in that: The third manipulator (15) comprises a third movable seat (1501), and the third manipulator (15) is movably arranged on the tail console body (400) via the third movable seat (1501); The oil plug visual recognition execution module (16) comprises a sixth mounting base (1601), on which a sixth displacement sensor (1602) and a fifth industrial camera (1603) are arranged.

10. A maintenance method for an EMU gearbox intelligent maintenance vehicle according to any one of claims 1 to 9, characterized in that: The following steps are involved: (S1) the vehicle body (100) moves, the position recognition unit (12) recognizes the position of the gear box, and the vehicle body (100) stops after reaching the gear box position; (S2) The second manipulator (10) moves to tighten the oil plug and the cleaning component execution module (11) cleans the surface of the oil drain plug and the oil filling plug; (S3) The oil plug tightening processing unit (7) is actuated, and the oil plug tightening processing unit (7) loosens the oil drain plug and the oil filling plug; (S4) The second manipulator (10) moves, the oil plug screwing and cleaning component execution module (11) first removes the oil filling plug, and visually identifies the oil filling plug with the oil plug visual recognition execution module (16). If the visual recognition is qualified, the oil filling plug is scraped off on the oil plug scraping unit (14). If the visual recognition is unqualified, the oil filling plug is stored on the new oil plug and unqualified oil plug storage unit (13); after the oil plug screwing and cleaning component execution module (11) is removed, the oil drain plug is visually identified with the oil drain plug and the oil plug visual recognition execution module (16). If the visual recognition is qualified, the oil drain plug is scraped off on the oil plug scraping unit (14). If the visual recognition is unqualified, the oil drain plug is stored on the new oil plug and unqualified oil plug storage unit (13); (S5) The first manipulator (8) moves, and the sampling bottle and oil filling assembly execution module (9) takes the sampling bottle from the sampling bottle storage and conveying unit (1), and the sampling bottle cap processing unit (2) opens the bottle cap. After the sampling bottle is filled with oil, the sampling bottle cap processing unit (2) installs the bottle cap, and the laser marking unit (3) marks the sampling bottle, and the sampling bottle is placed on the sampling bottle collection unit (4); (S6) The second manipulator (10) moves, the oil plug is tightened and the cleaning component execution module (11) takes out a new oil plug from the new oil plug and unqualified oil plug storage unit (13), and installs the new oil plug into the oil drain port; (S7) The first manipulator (8) moves to take the sampling bottle and the oil filling assembly execution module (9) to add oil to the gear box; (S8) The second manipulator (10) moves, the oil plug is unscrewed, and the cleaning component execution module (11) takes out a new oil plug from the new oil plug and unqualified oil plug storage unit (13), and installs the new oil plug into the oil filling port; (S9) The oil plug tightening processing unit (7) is actuated, and the oil plug tightening processing unit (7) tightens the new oil drain plug and the new oil filling plug; (S10) The second manipulator (10) moves, tightens the oil plug and cleans the assembly, and the execution module (11) takes a visual photo and uploads it.

Images