Balance adjusting method for bogie of motor train unit and related system
By constructing a load distribution and prediction model and combining it with nylon pad compensation, the problem of low efficiency in bogie balance adjustment of EMU trains was solved, achieving efficient and precise bogie leveling and improving the stability and safety of train operation.
Patent Information
- Application Number
- CN202511132471.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-13
- Publication Date
- 2025-11-18
AI Technical Summary
In existing technologies, the efficiency of bogie balance adjustment for high-speed trains is low, which cannot meet the needs of advanced maintenance capacity, resulting in unstable train operation and safety hazards.
By collecting static load test data of the bogie, a load distribution model and a prediction model were constructed. Combined with the stiffness characteristics of the spring group, the pre-deformation of the spring group was calculated, and nylon adjusting shims were used for pre-compensation to level the bogie.
It improves the leveling accuracy and efficiency of bogies, reduces manual adjustment errors, extends the service life of spring assemblies, provides a standardized leveling method, and ensures the stability of train operation.
Smart Images
Figure CN120974753A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application belongs to the field of EMU equipment maintenance technology, and particularly relates to an EMU bogie balance adjustment method and related system. BACKGROUND
[0002] In today's era, the rapid development of the transportation field is remarkable. From bustling cities to remote towns, the tentacles of high-speed rail and EMUs gradually extend, weaving a dense and efficient transportation network. With the increasing number of high-speed rail and EMU lines, high-speed rail and EMU vehicles, with their fast, convenient, and comfortable characteristics, quickly occupy an important position in people's daily life and are increasingly popular.
[0003] In order to ensure the safety of passengers traveling and prevent accidents, the periodic inspection and maintenance of high-speed rail and EMU vehicles are placed in a crucial position by the railway department. Among these many inspection and maintenance projects, the balance detection of the vehicle is an essential key link. Because the balance of the vehicle directly affects the stability and safety of the train, once the balance of the vehicle is problematic, it may cause the train to sway and jolt during operation, or even cause more serious safety accidents.
[0004] Currently, in the railway industry, the efficiency of platform advanced repair EMU bogie balance adjustment is generally low. The bogie, as a key component of the EMU, directly affects the running state of the entire train. However, in actual advanced repair operations, due to the complex structure of the bogie and the large number of parts, a large amount of time and effort is often required for balance adjustment. This problem is increasingly highlighted in the contradiction between the growing capacity of EMU advanced repair and the increasing number of EMUs. With the increasing number of EMUs, the advanced repair task is also increasingly heavy, but the existing bogie balance adjustment efficiency cannot meet the demand for capacity growth, seriously restricting the capacity improvement of EMU advanced repair and causing certain obstacles to the efficient operation of railway transportation.
[0005] In the process of three, four-level repair of the existing three-type vehicle platform EMU bogie, due to the instability in the assembly process of the bogie mechanical parts, the balance of the four corners of the bogie may deviate, therefore, the present application proposes a method to solve this problem. SUMMARY
[0006] The purpose of the present application is to overcome the above-mentioned deficiencies, and to provide an EMU bogie balance adjustment method and related system.
[0007] In order to achieve the above-mentioned purpose, the present application adopts the following technical solutions: In a first aspect, the present application provides an EMU bogie balance adjustment method, comprising the following steps: Collect and accumulate the past motor train unit bogie static load test data; Based on the static load test data, the actual load force of the bogie on the static load test bench is obtained, and a load distribution model is constructed; Based on the constructed load distribution model, combined with the stiffness characteristics of the bogie spring group, a prediction model is constructed, and the pre-deformation of the spring group is calculated based on the constructed prediction model; Based on the pre-deformation of the spring group, the corresponding nylon adjusting gasket is used for supplement, the height of the spring group is pre-compensated, and the bogie is leveled.
[0008] In the step of constructing the load distribution model based on the static load test data, the method of constructing the load distribution model is as follows: Collect the load data of different car types and repair processes in the history test; According to the bogie design parameters and the weight distribution of the car body, a load distribution formula is established:
[0009] Among them, is the axle load, is the total weight, is the wheelbase weight, is the dynamic correction term. The wheelbase weight
[0010] is calculated according to the bogie wheelbase distribution and the weight distribution ratio of the car body.
[0011] In the step of constructing the prediction model based on the constructed load distribution model, combined with the stiffness characteristics of the bogie spring group, the prediction model constructed is as follows:
[0012] Among them, C represents the design reference height of the bogie; represents the pre-deformation of the spring, represents the compression height of the steel spring under the standard test load, represents the compression height of the laminated spring under the standard test load, is the axle load predicted based on the load distribution model, is the measured load of the static load test bench, is the equivalent stiffness of the spring group.
[0013] The empty load spring height is measured by using a laser range finder, and and are recorded after applying the standard load.
[0014] The equivalent stiffness of the spring group is calibrated by a step loading test.
[0015] If the pre-deformation of the spring is greater than the pre-deformation threshold , it is determined that the spring group is invalid and needs to be replaced.
[0016] In a second aspect, the present application provides a balance adjustment system for a bogie of a motor train unit, comprising: A data acquisition module is configured to collect and accumulate static load test data of past bogies of motor train units. A load distribution model construction module is configured to obtain actual load forces borne by the bogie on a static load test bench based on the static load test data, and construct a load distribution model. A prediction model construction module is configured to construct a prediction model based on the constructed load distribution model and in combination with stiffness characteristics of the spring group of the bogie, and calculate the pre-deformation of the spring group based on the constructed prediction model. A shim adjustment module is configured to use corresponding nylon adjustment shims to supplement and pre-compensate the height of the spring group based on the pre-deformation of the spring group, and level the bogie.
[0017] In a third aspect, the present application provides an electronic device comprising a memory and a processor, wherein the memory stores a computer program, and the processor implements the steps of the balance adjustment method for a bogie of a motor train unit when executing the computer program.
[0018] In a fourth aspect, the present application provides a storage medium having a computer program stored thereon, wherein the computer program implements the steps of the balance adjustment method for a bogie of a motor train unit when executed by a processor.
[0019] Compared with the prior art, the present application has the following beneficial effects: The present application provides a balance adjustment method for a bogie of a motor train unit, comprising the following steps: collecting and accumulating static load test data of past bogies of motor train units; obtaining actual load forces borne by the bogie on a static load test bench based on the static load test data, and constructing a load distribution model; constructing a prediction model based on the constructed load distribution model and in combination with stiffness characteristics of the spring group of the bogie, and calculating the pre-deformation of the spring group based on the constructed prediction model; using corresponding nylon adjustment shims to supplement and pre-compensate the height of the spring group based on the pre-deformation of the spring group, and leveling the bogie. The static load test data of the bogie is collected by the system to construct the load distribution model, the prediction model is established in combination with the stiffness characteristics of the spring to accurately calculate the pre-deformation, and the height of the spring group is pre-compensated by using the nylon adjustment shims, thereby effectively improving the leveling accuracy and efficiency of the bogie, reducing the error risk of manual adjustment, and simultaneously buffering the dynamic load impact by the elastic characteristics of the nylon shims, thereby prolonging the service life of the spring group and providing a standardized and data-based leveling method for the static load test of the bogie of the motor train unit. BRIEF DESCRIPTION OF DRAWINGS
[0020] Figure 1 This is a flowchart of the method of the present invention; Figure 2 This is a schematic diagram of the technical parameters in Embodiment 2 of the present invention; Figure 3 This is a schematic diagram of the pre-adjustment value generated in Embodiment 2 of the present invention; Figure 4 This is a schematic diagram of wheel weight data displayed on the static load test bench in Embodiment 2 of the present invention; Figure 5 This is a schematic diagram of the height difference at the four corners of the bogie and the wheel weight difference in Embodiment 2 of the present invention; Figure 6 This is a system diagram of Embodiment 4 of the present invention. Detailed Implementation
[0021] To further understand the content of this invention, the invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the embodiments are merely illustrative and not limiting of the invention.
[0022] Example 1 like Figure 1 As shown, a method for balancing a bogie of a high-speed train includes the following steps: S1: Collect and accumulate static load test data of bogies from previous EMU trains; S2: Based on the static load test data, obtain the actual load force on the bogie on the static load test bench and construct a load distribution model; S3: Based on the constructed load distribution model and combined with the stiffness characteristics of the bogie spring group, a prediction model is constructed, and the pre-deformation of the spring group is calculated based on the constructed prediction model. S4: Based on the pre-deformation of the spring assembly, supplement with corresponding nylon adjusting shims to pre-compensate the height of the spring assembly and level the bogie.
[0023] Specifically, in S2, the actual load force refers to the vertical force applied to the bogie spring assembly by the test bench during the static load test. It usually includes the car body weight, simulated load, etc., and is measured by the force sensor equipped on the static load test bench.
[0024] The method for constructing the load distribution model is as follows: Collect load data from different vehicle models and repair processes during historical tests; Based on the bogie design parameters and the car body weight distribution, the load distribution formula is established:
[0025] in, For the first Axial load, is a total weight, is an axle distance weight, is a dynamic correction term, such as track irregularity compensation, axle distance weight is calculated according to the bogie axle distance distribution and the body weight distribution ratio.
[0026] Specifically, in S3, based on the constructed load distribution model, a prediction model is constructed in combination with the stiffness characteristics of the bogie spring set, and the pre-deformation amount of the spring set is calculated based on the constructed prediction model.
[0027] The constructed prediction model is as follows:
[0028] wherein C represents a bogie design reference height, which is preferably 314 in the embodiment; represents the pre-deformation amount of the spring, represents the compression height of the steel spring under the standard test load, represents the compression height of the laminated spring under the standard test load, is the axle position load predicted based on the load distribution model, is the actual measured load of the static load test bed, is the equivalent stiffness of the spring set, which is calibrated through the step loading test.
[0029] The calibration method is as follows: A step load is applied to the spring set, and the slope of the load-deformation curve is fitted; When the spring set is a series connection of steel springs and laminated springs, the equivalent stiffness R satisfies:
[0030] Further, the unloaded spring height is measured using a laser range finder, and after the standard load is applied, the and are recorded; the is obtained through the force sensor of the static load test bed, and the is calculated in combination with the load distribution model.
[0031] Further, if , it is determined that the spring set is failed and needs to be replaced; if , the load distribution model optimization alarm is triggered.
[0032] Specifically, in S4, based on the pre-deformation amount of the spring set, the corresponding nylon adjusting gasket is used for supplement, and the spring set height is pre-compensated to level the bogie.
[0033] If the size of the nylon gasket is not enough, a combination of metal sheets can be used for compensation.
[0034] As the embodiment is preferably, certain motor train unit bogie static load test measured =120kN, model prediction =115kN, spring stiffness =25kN / mm, + =300mm; Calculate the pre-deformation amount:
[0035] Gasket adjustment: choose 13mm nylon gasket + 0.8mm metal sheet combination compensation.
[0036] Embodiment 2 The calculation method of the application is packaged in MATLAB GUI, and the software is deployed in Window system, and the key parameters required for calculation are input, and the height value can be generated by one key.
[0037] Using the method described in the application, as shown in the table in Excel, the height data of the four-corner primary steel spring and the laminated spring of the bogie is input in advance, the height calculation software is opened, the shaft box spring data table is imported, the platform of the train set belonging to the main factory is selected: Tangshan / Changkun, the corresponding repair process is selected: three-level repair / four-level repair, and the calculation is clicked to generate the deformation amount required for supplement, that is, the number of nylon adjustment pads required to be added, and the generated result is as shown in Figure 2 The on-site operator can place it according to the result generated by the calculation. Figure 3
[0038] Figure 4 After the software calculation Figure 2 data is pre-adjusted, the wheel load data displayed on the static load test bench.
[0039] As shown in Figure 5 , Figure 5 After the software calculation Figure 2 data is pre-adjusted, the difference between the four-corner height of the bogie and the wheel load under the static load test pressure application condition, through Figure 4 , Figure 5 It can be found that the difference between the four-corner height of the bogie and the wheel load after pre-adjustment can pass the test at one time, improving the maintenance efficiency.
[0040] The application can predict which axle position needs to be adjusted in advance through the bogie four-corner height calculation model before the train is tested, so that the bogie test data is qualified at one time, greatly improving the operation efficiency and reducing the labor intensity of the on-site operator.
[0041] Embodiment 3 A motor train unit bogie balance adjustment system, comprising: The data collection module is configured to collect and accumulate the static load test data of the bogie of the motor train unit. The load distribution model construction module is configured to obtain actual load force of the bogie on the static load test platform based on the static load test data, and construct a load distribution model. The prediction model construction module is configured to construct a prediction model based on the constructed load distribution model and the stiffness characteristics of the spring set of the bogie, and calculate the pre-deformation of the spring set based on the constructed prediction model. The gasket adjustment module is configured to use the corresponding nylon adjustment gasket to supplement and pre-compensate the height of the spring set based on the pre-deformation of the spring set, and level the bogie.
[0042] Embodiment 4 As shown in the accompanying drawings, Figure 2 The electronic device 100 for the balancing adjustment method of the bogie of the motor train unit is also provided, which comprises a memory 101, at least one processor 102, a computer program 103 stored in the memory 101 and executable on the at least one processor 102, and at least one communication bus 104.
[0043] The memory 101 can be used to store the computer program 103, and the processor 102 can realize the steps of the balancing adjustment method of the bogie of the motor train unit by running or executing the computer program stored in the memory 101 and calling the data stored in the memory 101. The memory 101 can mainly include a program storage area and a data storage area, wherein the program storage area can store an operating system, at least one application required by a function (such as a sound playing function, an image playing function, etc.), and the like; and the data storage area can store data (such as audio data) created according to the use of the electronic device 100, etc. In addition, the memory 101 can include a non-volatile memory, such as a hard disk, a memory, a plug-in hard disk, a smart media card (SMC), a secure digital (SD) card, a flash card, at least one disk storage device, a flash memory device, or other non-volatile solid-state storage device.
[0044] The at least one processor 102 can be a central processing unit (CPU), and can also be other general-purpose processors, digital signal processors (DSP), application specific integrated circuits (ASIC), field programmable gate arrays (FPGA) or other programmable logic devices, discrete gates or transistor logic, discrete hardware components, etc. The processor 102 can be a microprocessor or can also be any conventional processor, etc., which is the control center of the electronic device 100 and connects all parts of the electronic device 100 through various interfaces and lines.
[0045] The memory 101 in the electronic device 100 stores a plurality of instructions to implement a motor train bogie balance adjustment method, and the processor 102 can execute the plurality of instructions to implement: Collect and accumulate past motor train bogie static load test data; Based on the static load test data, obtain the actual load force of the bogie on the static load test bench, and construct a load distribution model; Based on the constructed load distribution model, the stiffness characteristics of the bogie spring set are combined to construct a prediction model, and the pre-deformation amount of the spring set is calculated based on the constructed prediction model; Based on the pre-deformation amount of the spring set, the corresponding nylon adjustment gasket is used for supplement, the spring set height is pre-compensated, and the bogie is leveled.
[0046] Embodiment 5 The modules / units integrated in the electronic device 100, if realized in the form of a software function unit and sold or used as an independent product, can be stored in a computer readable storage medium. Based on this understanding, all or part of the processes in the above-mentioned embodiment methods of the present application can also be completed by a computer program instructing related hardware, and the computer program can be stored in a computer readable storage medium. The computer program can implement the steps of each method embodiment when executed by a processor. The computer program includes computer program code, which can be in the form of source code, object code, executable files or some intermediate forms, etc. The computer readable medium can include any entity or device capable of carrying the computer program code, recording medium, U disk, mobile hard disk, magnetic disk, optical disk, computer memory and read-only memory (ROM).
[0047] Those skilled in the art will appreciate that embodiments of the present application can be readily used as a method, apparatus such as a system, or computer program product. Accordingly, the present application can take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present application can take the form of a computer program product on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROMs, optical storage devices, etc.) embodying computer readable program code.
[0048] The present application is described in reference to the drawings using a flowchart and / or a block diagram of methods, apparatus (systems) and computer program products according to embodiments of the application. It will be understood that each block of the flowchart and / or block diagram, and combinations of blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general purpose computer, special purpose computer, embedded processing device or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart and / or block diagram block or blocks. Figure 1 one or more functions specified in one or more of the flowchart or block diagram block or blocks. Figure 1 means for carrying out each of the functionality specified in the flowchart or block diagram block or blocks.
[0049] These computer program instructions can also be stored in a computer- readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instructions which implement the flowchart or block diagram block or blocks. Figure 1 one or more functions specified in one or more of the flowchart or block diagram block or blocks. Figure 1 means for carrying out each of the functionality specified in the flowchart or block diagram block or blocks.
[0050] The computer program instructions can also be loaded into a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the flowchart or block diagram block or blocks. Figure 1 one or more functions specified in one or more of the flowchart or block diagram block or blocks. Figure 1 means for carrying out each of the functionality specified in the flowchart or block diagram block or blocks.
[0051] Finally, it should be noted that the above-mentioned embodiments are merely intended for describing and illustrating, not limiting, the technical solution of the present application. Although the present application has been described in detail with reference to the above-mentioned embodiments, those skilled in the art should understand that the specific embodiments of the present application can be modified or replaced by equivalents without departing from the spirit and scope of the present application, and any modification or equivalent replacement without departing from the spirit and scope of the present application should be covered in the protection scope of the claims of the present application.
Claims
1. A method for balancing adjustment of a bogie of a motor train unit, characterized in that, The method comprises the following steps: Collect and accumulate the static load test data of the bogie of the motor train unit in the past; Based on the static load test data, the actual load force of the bogie on the static load test bench is obtained, and a load distribution model is constructed; Based on the constructed load distribution model and the stiffness characteristics of the spring set of the bogie, a prediction model is constructed, and the pre-deformation of the spring set is calculated based on the constructed prediction model; Based on the pre-deformation of the spring set, the corresponding nylon adjusting gasket is used for supplement, the height of the spring set is pre-compensated, and the bogie is leveled.
2. The method for balancing adjustment of a bogie of a motor train unit according to claim 1, characterized in that, In the step of constructing the load distribution model based on the static load test data and obtaining the actual load force of the bogie on the static load test bench, the method of constructing the load distribution model is as follows: Collect the load data of different vehicle types and repair processes in historical tests; According to the design parameters of the bogie and the weight distribution of the car body, a load distribution formula is established: wherein, is the first is the total weight, is the axle weight, is the wheelbase weight, is the dynamic correction term.
3. The method of claim 2, wherein the step of adjusting the balance of the bogie of the motor train unit is characterized by, The wheelbase weight According to the bogie wheelbase distribution and the body weight distribution ratio.
4. The method of claim 1, wherein, In the step of constructing the prediction model based on the constructed load distribution model and the stiffness characteristics of the spring set of the bogie, and calculating the pre-deformation of the spring set based on the constructed prediction model, the constructed prediction model is as follows: C represents a bogie design reference height; represents a pre-deformation amount of the spring, represents a compression height of the steel spring under a standard test load, represents a compression height of the laminated spring under a standard test load, is an axle position load predicted based on a load distribution model, is a measured load of a static load test stand, is an equivalent stiffness of the spring set.
5. The method of claim 4, wherein the step of adjusting the balance of the bogie of the motor train unit is characterized by, Measure unloaded spring height using laser gauge, record after applying standard load and .
6. The method of claim 4, wherein, The equivalent stiffness of the spring set is calibrated through step loading test.
7. The method of claim 4, wherein the step of adjusting the balance of the bogie of the motor train unit is characterized by, If the predeformation of the spring is greater than 0.5 mm , it is determined that the spring set is defective and needs to be replaced.
8. A bogie balance adjustment system for a multiple unit train, characterized by, It comprises: A data acquisition module for collecting and accumulating the static load test data of the bogie of the motor train unit in the past; A load distribution model construction module for constructing a load distribution model based on the static load test data and obtaining the actual load force of the bogie on the static load test bench; A prediction model construction module for constructing a prediction model based on the constructed load distribution model and the stiffness characteristics of the spring set of the bogie, and calculating the pre-deformation of the spring set based on the constructed prediction model; A gasket adjustment module for adjusting the height of the spring set based on the pre-deformation of the spring set, using the corresponding nylon adjusting gasket for supplement, pre-compensating the height of the spring set, and leveling the bogie. 9.An electronic device comprising a memory and a processor, the memory storing a computer program, wherein, The processor executes the computer program to realize the steps of the motor train unit bogie balance adjustment method in any one of claims 1 to 7.
10. A storage medium having stored thereon a computer program, characterized in that The computer program is executed by the processor to realize the steps of the motor train unit bogie balance adjustment method in any one of claims 1 to 7.