Joint module motor-driven train coupler correcting system

Abstract

The invention discloses a train coupler correcting system driven by a joint module motor, and relates to the technical field of railway freight equipment, the train coupler correcting system comprises two sets of correcting devices symmetrically arranged at two ends of a car dumper platform, the two sets of correcting devices are respectively fixed at two ends of a track of the car dumper platform, and two sets of correcting working parts are mirror images of each other. The push plates are all arranged on one side of the car dumper in the rotating direction and used for positioning and righting the car coupler drooping due to gravity caused by rotation of the car dumper. Each set is composed of a lower box body moving module, an upper box body overturning module, a car coupler push plate module, a double-cable guide rod module, an eccentric wheel locking module, a touch sensing module and an integrated control module, and all the modules are driven by an integrated joint module motor to be in linkage; the lower box body moves through a gear rack and is positioned through three points of an eccentric depended wheel; the upper box body is hinged to the lower box body; the push plate comprises a touch plate and double springs and stops when making contact with the coupler. The size is reduced through integration of the joint modules, cables are simplified, the assembly difficulty is reduced through factory calibration, the positioning precision and reliability are improved through cooperation of multiple modules, and the device is suitable for multiple vehicle types.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of railway freight equipment, and particularly relates to a train coupler positive hook system driven by a joint module motor. BACKGROUND

[0002] In the bulk cargo unloading link of railway freight, the dumper is the core equipment for realizing efficient unloading of the carriage, and the train coupler positive hook equipment, as a key matching component of the dumper, directly determines the precise docking and operation safety of the carriage and the dumper. The positive hook equipment is usually arranged in the middle of the two tracks of the dumper platform, and is installed horizontally at the bottom of the train carriage, and needs to complete the actions of walking back and forth, 90° turning and coupler righting, etc., to accurately limit and fix the coupler, so as to prevent the coupler from derailing or colliding due to gravity or inertia offset when the carriage is turned over.

[0003] The severe limitation of the operation space is the primary problem faced by the design of the positive hook equipment. The space from the bottom of the train carriage to the dumper platform is already narrow, and a safety margin needs to be reserved, which puts high requirements on the volume and integration of the equipment. The existing positive hook equipment is mostly driven by traditional industrial servo motors or stepping motors. Such motors are large in size and individually occupy a large amount of space. Moreover, the motor controller, driver, PLC module and other control elements cannot be integrated in the equipment body, and need to be connected to an independent external control cabinet, resulting in a scattered overall layout of the equipment. At the same time, multiple cables such as power lines, encoder lines and brake lines need to be connected between the motor and the driver, which makes the wiring complex and messy, further occupies the limited space, and increases the risk of cable drag, kinking and wear and tear during the back-and-forth movement of the equipment, directly affecting the operation stability of the equipment.

[0004] The assembly and debugging complexity and reliability defects of the existing technology further restrict the efficiency of the equipment. In the traditional motor driving scheme, the motor and the speed reducer need to be selected respectively, and it is necessary to ensure that the two are accurately matched in terms of inertia, torque and other performance parameters. In the assembly process, it is also necessary to ensure a high alignment accuracy, otherwise vibration, noise and mechanical wear may occur. The whole design and assembly cycle is long, and the dependence on the professional knowledge of the designers and the technical level of the assembly workers is very high. Poor assembly can significantly reduce the system life and control accuracy. In addition, the performance of the servo motor also depends on the quality of the external components and the on-site PID parameter setting level. The debugging process is complicated and it is difficult to achieve the best matching state, resulting in insufficient positioning accuracy and poor motion stability of the equipment. In high-frequency operation, faults occur frequently, which not only increases the maintenance cost, but also may cause the dumper operation to be interrupted due to the failure of the positive hook, affecting the freight turnover efficiency.

[0005] With the development of railway freight to heavy load and high frequency, higher demands are put forward for the adaptability and durability of the straight hook equipment. The traditional equipment has many cables exposed outside, which is easy to be eroded by dust and debris in the operation environment of the dumper, leading to signal interference or power interruption. At the same time, its fixed driving and control parameters are difficult to adapt to the differences of the coupler structure of different car types, and frequent manual adjustment is needed, which further reduces the operation efficiency. These problems superimpose, so that the existing straight hook equipment is difficult to meet the core needs of modern railway freight, such as "small, accurate, reliable and efficient", and becomes the key bottleneck restricting the improvement of the operation efficiency of the dumper. SUMMARY

[0006] The joint module motor-driven train coupler straight hook system provided by the present application solves the problems mentioned in the prior art.

[0007] In order to achieve the above purpose, the present application adopts the following technical scheme: a joint module motor-driven train coupler straight hook system, comprising the following modules:

[0008] The lower box moving module comprises a lower box body, a gear and rack mechanism and a walking joint module motor. The walking joint module motor integrates a motor, a speed reducer, a driver, a controller and a multi-turn absolute value encoder. The driving gear and rack drives the lower box to reciprocate along the track. Eccentric guide wheels are arranged on both sides of the gear and rack. The lower box bottom guide wheel cooperates with the track. After power failure, it is reset;

[0009] The upper box overturning module comprises an upper box body, a hinge shaft and a flap joint module motor. The upper box is connected with the lower box through the hinge shaft. The flap joint module motor drives the upper box to overturn by 90 degrees. The encoder monitors the overturning angle. After overturning, the electromagnetic brake is automatically locked to maintain the vertical working state;

[0010] The coupler push plate module comprises a push plate body, a touch plate, a rotating shaft, a limiting shaft, a built-in double spring, a travel switch and a push plate joint module motor. The push plate joint module motor drives the push plate to move vertically to the track through a screw nut mechanism. The touch plate is installed at the front end of the push plate through the rotating shaft. The limiting shaft limits the rotating range. When contacting the coupler, the spring is compressed to make the push plate stop;

[0011] The double cable guide rod module comprises two groups of parallel telescopic guide rods, a separation plate, a spring wire and a dustproof sealing ring. The two groups of guide rods guide the power cable and the signal cable respectively. The spring wire provides length compensation when the equipment moves. The dustproof sealing ring is arranged at the entrance of the guide rod to prevent dust from entering;

[0012] The eccentric wheel locking module is composed of an eccentric wheel, a guide wheel, an eccentric wheel shaft and a locking screw. The gap between the guide wheel and the rack is adjusted by rotating the eccentric wheel rotating hole through a special tool. The locking screw fixes the position of the eccentric wheel;

[0013] Touch sensing module, including car hook touch rod and push plate pressure sensor, car hook touch rod is installed on the side of the upper box and is connected with travel switch, when contacting car hook, trigger switch control lower box stop, push plate pressure sensor monitor contact force, data synchronization to integrated control module.

[0014] Integrated control module, PLC controller, driver, signal processor integrated in the lower box, communication with each joint module motor and sensor, only connect a power line and a network cable, plug and play.

[0015] Further, it also includes push plate contact force adaptive adjustment sub module, which carries pressure sensor and double spring displacement acquisition unit, pressure sensor real-time acquisition of contact pressure and double spring compression of touch plate and car hook, contact force calculation follows F=k1x1+k2x2, wherein F is the contact force of push plate and car hook, k1 is the main spring stiffness coefficient, k2 is the secondary spring stiffness coefficient, x1 is the main spring compression, x2 is the secondary spring compression; sub module will collect data and calculation results to push plate joint module motor controller, adjust motor output torque through pulse width modulation technology.

[0016] Further, it also includes lower box moving speed adjustment sub module, which walks joint module motor multi-turn absolute value encoder, encoder real-time acquisition of lower box moving displacement data to calculate the distance from the track end point to adjust the speed, during speed adjustment, sub module synchronously receives the compression force data of eccentric wheel locking module, when the compression force fluctuation exceeds 50N, additional reduce the speed by 20%, and control the guide wheel to increase the adhesion to the track, combined with three-point positioning structure to further eliminate the motion deviation.

[0017] Further, it also includes lower box positioning accuracy correction sub module, which pre-stores gear rack drive error curve and track flatness parameters, through positioning correction formal As=kAvAt to dynamically compensate the final position of the lower box, wherein As is the positioning correction, k is the speed-displacement correction coefficient, Av is the deviation of the actual speed of the walking joint module motor from the set speed, At is the speed deviation duration, sub module collects speed feedback data of encoder every 10ms, calculates Av and At, combined with the trigger signal of track end point travel switch and real-time displacement data of encoder, automatically generates correction instruction, when the positioning deviation exceeds 0.8mm, control walking joint module motor to execute single ±0.2mm fine adjustment action, during fine adjustment process, eccentric wheel relies on constant compression force, guide wheel real-time correction of walking track, finally the positioning error is controlled within 0.5mm.

[0018] Further, it further includes a cable tension monitoring submodule, which is arranged with a metal foil strain gauge every 1m along the length direction of the double cable guide rod, and real-time collection of tension data of the power cable and the signal cable, with the power cable tension threshold set to 150N and the signal cable set to 80N; when the tension exceeds the threshold by 10%, the submodule first controls the guide rod driving mechanism to extend the telescopic length of the guide rod, and the adjustment amount is calculated according to 1.2 times the tension deviation; if the tension still exceeds the standard for 200ms, a speed reduction instruction is sent to the walking joint module motor, and the spring wire is controlled to increase the elastic compensation amount, the isolation plate between the guide rods is made of insulating polycarbonate material, the dustproof sealing ring at the entrance of the guide rod is made of fluororubber material, and the submodule generates a cable tension curve report at regular intervals.

[0019] Further, it further includes an upper box body overturning angle calibration submodule, and the angle calibration follows Δθ=mΔp+nΔa, wherein Δθ is an angle correction amount, m is an encoder resolution coefficient, Δp is a pulse count deviation, n is an acceleration correction coefficient, and Δa is a deviation between actual acceleration and theoretical acceleration; the calibration period is dynamically adjusted, and double-channel data are fused through a Kalman filtering algorithm; when it is detected that the angle deviation exceeds 0.3°, a correction pulse is immediately sent to the turnover plate joint module motor to adjust the overturning speed.

[0020] Further, it further includes a dustproof and waterproof submodule, which optimizes the sealing structure according to the turnover machine working environment, and double-lip sealing rings are arranged at the hinge joints of the upper box body and the lower box body and are made of oil-resistant nitrile rubber; an elastic silica gel sealing pad is arranged at the connection between the push plate contact plate and the push plate body, and the dustproof sealing ring of the double-cable guide rod is upgraded to a combined structure; the interface of the integrated control module is provided with a waterproof aviation plug, the interface is filled with sealing glue, and the surfaces of various sealing components are coated with a wear-resistant coating.

[0021] Further, it further includes a fault diagnosis and response submodule, which monitors the current, voltage, temperature and sensor data of each joint module motor in real time, and divides a three-level fault response mechanism according to the severity; mild fault: contact force fluctuation of 50-100N and angle deviation of 0.3°-0.5°, the submodule automatically adjusts the push plate motor torque by ±50N·m and the turnover motor angle by ±0.1°; moderate fault: motor overload and sensor signal loss, starting standby control logic, switching to redundant sensor data, and positioning the lower box body according to the pre-stored track; severe fault: motor temperature > 80℃, insulation resistance < 100MΩ, and positioning deviation > 1mm, immediately cutting off the motor power, triggering the electromagnetic brake to lock all moving parts, pushing the fault package to the operation and maintenance terminal, and starting the local sound and light alarm at the same time, and all fault processing processes automatically generate logs.

[0022] Further, it further includes a multi-vehicle type adaptive adjustment sub-module, the sub-module is built-in 12 kinds of mainstream vehicle coupler parameter database, through the coupler touch rod of touch sensing module and push plate pressure sensor, the contact position and pressure distribution characteristics of coupler are collected, cosine similarity algorithm is used to compare with database, after successful matching, corresponding parameters are automatically called;For new coupler, parameters are manually input through network connection terminal, after input, feature template is automatically generated and stored in database, sub-module updates database every quarter, and new vehicle type parameters are added.

[0023] Further, it further includes a running state monitoring and tracing sub-module, the sub-module collects data of each module through integrated control module, including lower box positioning accuracy, upper box overturning angle, push plate contact force, cable tension and motor operating parameters, the data is stored in local SD card after AES-256 encryption, and is uploaded to cloud server in real time through network line, three kinds of reports are automatically generated every week: equipment operation daily report, performance trend report and maintenance reminder report;Supporting inputting time range through terminal to trace fault track, the sub-module has remote diagnosis function, and operation and maintenance personnel can modify control parameters through network.

[0024] Compared with the existing technology, the beneficial effects of the present application are:

[0025] The equipment integration and space adaptability are significantly improved. The integrated joint module motor is used as the driving core, and the motor, speed reducer, driver, controller and encoder are highly integrated. Compared with the traditional dispersed motor, the volume is greatly reduced, and it is perfectly adapted to the narrow operation space between the carriage bottom and the platform. At the same time, the PLC controller and signal processor are directly arranged in the device body, and only one power line and one network line are needed, which completely eliminates the external control cabinet and complex wiring, effectively avoids the disadvantages of cable drag and kink, realizes plug and play convenient deployment, greatly improves the space utilization efficiency and equipment layout rationality.

[0026] The assembly and debugging difficulty is reduced, and the running reliability is greatly improved. The joint module motor has completed the precision matching, calibration and test of all parts before leaving the factory, without the need for on-site selection and matching of motor and speed reducer, and the design and manufacture of mounting structures such as brackets and couplings are also saved, which significantly shortens the mechanical design and assembly cycle, reduces the assembly difficulty and error rate. The fully enclosed structure can effectively prevent dust and debris from entering, avoid the life attenuation and performance decline caused by on-site assembly errors (such as concentricity and perpendicularity deviation), and compared with the traditional servo motor, the running stability and durability are essentially improved, which greatly reduces the frequency and cost of later maintenance.

[0027] The precision and coordination of the car hook straight hook operation are significantly enhanced. Each module is driven by a joint module motor, cooperates with a perception element such as an encoder, a pressure sensor, a travel switch, and realizes precise control of the movement of the lower box, the overturning of the upper box and the extension of the push plate. The multi-turn absolute value encoder of the walking joint module motor ensures that it can be accurately reset without zero reset after power failure, the plate joint module motor cooperates with the angle calibration mechanism to realize high-precision positioning of 90° overturning, and the push plate joint module motor adjusts the contact force to ensure reliable fixing of the car hook. The integrated control module coordinates the action timing of each module, so that the movement, overturning and righting actions are smooth, effectively avoiding positioning deviation and action conflict, and protecting the precise docking of the car and the car dumper, and fundamentally reducing the operation safety risk.

[0028] The versatility and operation convenience of the device are comprehensively optimized. The multi-vehicle type adaptive adjustment function can automatically match the corresponding operation parameters through the built-in different vehicle hook parameter database and the feature collection and comparison of the touch sensing module, without manual debugging, which can adapt to multiple vehicle types, greatly improving the application range of the device. The operation state monitoring and tracing sub-module realizes the whole process recording and fault trajectory backtracking of the operation data, which is convenient for quickly locating the problem source; the fault diagnosis and response mechanism can handle various abnormalities in time, reducing the risk of operation interruption. Overall, the versatility, maintainability and operation continuity of the device are significantly improved, providing a strong guarantee for the efficient and stable operation of railway freight transportation. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 A schematic block diagram of the joint module motor driven train car hook straight hook system according to the present application is shown in the figure;

[0030] Figure 2 A self-adaptive adjustment curve diagram of the movement speed of the lower box is shown in the figure;

[0031] Figure 3 A comparison bar chart of the success rate of multi-vehicle type car hook righting is shown in the figure;

[0032] Figure 4 A curve diagram of the change of cable tension with the movement distance of the box is shown in the figure. DETAILED DESCRIPTION

[0033] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0034] In the description of the present application, it is understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, which are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0035] In addition, the terms "first", "second" are only for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Therefore, the features defined with "first", "second" can explicitly or implicitly include one or more of the features. In the description of the present application, the meaning of "multiple" is two or more, unless otherwise specifically limited. In addition, the terms "mounting", "connecting", "connecting" should be broadly understood, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium, or it can be the communication between two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances, and the present application will be further described in detail below with reference to the drawings.

[0036] Referring to Figures 1 to 4 A train coupler positive hook system driven by a joint module motor, comprising the following modules:

[0037] The lower box moving module comprises a lower box body, a gear and rack mechanism and a walking joint module motor. The walking joint module motor integrates a motor, a speed reducer, a driver, a controller and a multi-turn absolute value encoder. The driving gear and rack drive the lower box to reciprocate along the track. Eccentric guide wheels are arranged on both sides of the gear and rack. The pressure between the guide wheels and the back of the rack is adjusted by the eccentric shaft and the locking screw, forming three-point positioning. The guide wheels at the bottom of the lower box cooperate with the track to ensure the linearity and stability of the movement, and the lower box can be accurately reset without zero reset after power off.

[0038] The upper box turning module comprises an upper box body, a hinge shaft and a turning plate joint module motor. The upper box is connected to the lower box through the hinge shaft. The turning plate joint module motor drives the upper box to realize 90-degree turning. The encoder monitors the turning angle in real time. After turning to the position, the electromagnetic brake is automatically locked to maintain the vertical working state. The angle control precision error is not more than 0.5 degrees. The pressure sensor detects the brake adhesion after locking to ensure stability.

[0039] The car hook push plate module comprises a push plate body, a touch plate, a rotating shaft, a limiting shaft, a built-in double spring, a travel switch and a push plate joint module motor, the push plate joint module motor drives the push plate to move vertically to the track through a screw nut mechanism, the touch plate is installed at the front end of the push plate through the rotating shaft, the limiting shaft limits the rotating range, the spring is compressed when the touch plate contacts the car hook, the travel switch is triggered to make the push plate stop, and the touch plate is provided with a pressure sensor to realize real-time feedback of the contact state.

[0040] The double-cable guide rod module comprises two groups of parallel telescopic guide rods, an isolation plate, a spring wire and a dustproof sealing ring, the two groups of guide rods guide the power cable and the signal cable respectively, the isolation plate avoids winding and signal interference, the spring wire provides length compensation when the equipment moves, keeps the cable tension moderate, and the dustproof sealing ring is arranged at the inlet of the guide rod to prevent dust from entering.

[0041] The eccentric wheel locking module is composed of an eccentric wheel, a wheel, an eccentric wheel shaft and a locking screw, the gap between the wheel and the rack is adjusted by rotating the eccentric wheel rotating hole through a special tool, the locking screw fixes the position of the eccentric wheel, ensures that the wheel pressing force is stable when the lower box moves, and eliminates the movement shaking.

[0042] The touch sensing module comprises a car hook touch rod and a push plate pressure sensor, the car hook touch rod is installed on the side surface of the upper box and is connected with the travel switch, the switch is triggered to control the lower box to stop when the car hook is contacted, the push plate pressure sensor monitors the contact force in real time, and data is synchronously transmitted to the integrated control module. The integrated control module integrates the PLC controller, the driver and the signal processor in the lower box, communicates with each joint module motor and sensor, and is connected with only one power line and one network line, realizes plug and play, coordinates the action time sequence of each module, and guarantees the operation continuity.

[0043] In the application, a push plate contact force self-adaptive adjustment sub-module is also included, the sub-module is provided with a high-precision pressure sensor and a double-spring displacement acquisition unit, the pressure sensor is selected from a strain gauge type sensor with a range of 0-2000N and an accuracy of ±1%, and the contact pressure of the touch plate and the car hook and the compression amount of the double spring are acquired in real time. The contact force calculation follows F=k1*x1+k2*x2, wherein F is the contact force of the push plate and the car hook, k1 is the main spring stiffness coefficient, the value is 80N / mm, k2 is the auxiliary spring stiffness coefficient, the value is 30N / mm, x1 is the compression amount of the main spring, and x2 is the compression amount of the auxiliary spring. The sub-module transmits the acquisition data and the calculation result to the controller of the push plate joint module motor, adjusts the motor output torque through pulse width modulation technology, increases the torque to push the push plate to extend when the contact force is lower than 500N, reduces the torque to control the push plate to stop when the contact force is higher than 1000N, ensures that the contact force is stable in the range of 600-900N, avoids deformation of the car hook under stress, guarantees the fixing reliability, and adapts to the stress requirements of car hooks made of different materials such as cast steel and alloy steel.

[0044] In the application, the lower box moving speed adjusting sub-module is also included, which integrates the multi-turn absolute value encoder of the walking joint module motor (integrated in the motor, supporting power-off memory) and the speed closed-loop controller. The encoder collects the lower box moving displacement data in real time, and calculates the distance from the track end point through the displacement value. When the distance is greater than 5 m, the walking joint module motor runs at the rated speed of 1500 r / min, and the gear and rack transmission ratio of 1:20 realizes the moving speed of 0.5 m / s. When the distance is 1-5 m, the S-shaped acceleration and deceleration curve is started, the speed is linearly reduced to 800 r / min, and the corresponding speed is 0.27 m / s. When the distance is less than 1 m, the speed is reduced to 300 r / min, and the lower box is close to the track at a low speed of 0.1 m / s. During the speed adjusting process, the sub-module synchronously receives the pressing force data of the eccentric wheel locking module. When the pressing force fluctuation exceeds 50 N, the speed is additionally reduced by 20%, and the guide wheel is controlled to increase the adhesion to the track. Combined with the three-point positioning structure, the movement deviation is further eliminated, so that the lower box positioning process is efficient and stable, and the gear and rack wear caused by high-speed impact is avoided.

[0045] In the application, the lower box positioning precision correction sub-module is also included, which pre-stores the gear and rack transmission error curve and the track flatness parameter, and dynamically compensates the final position of the lower box through the positioning correction formal AS=kAvAt. Wherein, AS is the positioning correction amount, k is the speed-displacement correction coefficient, the value is 0.85, Av is the deviation between the actual speed and the set speed of the walking joint module motor, and At is the speed deviation duration. Combined with the trigger signal of the track end point travel switch (confirming that the lower box reaches the preset area) and the real-time displacement data of the encoder, the correction instruction is automatically generated. When the positioning deviation exceeds 0.8 mm, the walking joint module motor is controlled to perform a single ±0.2 mm fine adjustment action. During the fine adjustment process, the eccentric wheel relies on the wheel to maintain constant pressing force, and the guide wheel adjusts the walking track in real time, so that the positioning error is controlled within 0.5 mm. The correction data is stored in the integrated control module at the same time, which is used to optimize the subsequent positioning parameters and adapt to the mechanical wear changes after long-term operation.

[0046] In the application, a cable tension monitoring submodule is also included, a strain gauge is arranged every 1m along the length direction on the double-cable guide rod, the strain gauge selects a metal foil strain gauge with a sensitivity coefficient of 2.0 and an initial resistance of 120Ω, and the tension data of the power cable and the signal cable are collected in real time. The power cable tension threshold is set to 150N, and the signal cable is set to 80N, when the tension exceeds the threshold by 10%, the submodule first controls the guide rod driving mechanism to extend the telescopic length of the guide rod, and the adjustment amount is calculated according to 1.2 times the tension overproof value; if the tension still exceeds the standard for 200ms, a speed reduction instruction is sent to the walking joint module motor, the moving speed is reduced by 30%, and the spring wire is controlled to increase the elastic compensation amount. The isolation plate between the guide rods is made of insulating polycarbonate material with a thickness of 5mm, which effectively avoids the electromagnetic interference of the power cable and the signal cable, and the dustproof sealing ring at the entrance of the guide rod is made of fluororubber material with a lip diameter matched with the cable to prevent dust from entering and causing the tension sensor to fail. The submodule generates a cable tension curve report regularly to provide a basis for cable maintenance and replacement.

[0047] In the application, a box body overturning angle calibration submodule is also included, which adopts a double-detection scheme of "encoder + three-axis acceleration sensor", the acceleration sensor selects a MEMS sensor with a measurement range of ±16g and an accuracy of ±0.01g, and the data is collected synchronously with the encoder. The angle calibration follows Δθ=mΔp+nΔa, wherein Δθ is the angle correction amount, m is the resolution coefficient of the encoder, the value is 0.001° / pulse, Δp is the pulse count deviation, n is the acceleration correction coefficient, the value is 0.05° / g, and Δa is the deviation between the actual acceleration and the theoretical acceleration. The calibration period is dynamically adjusted, the overturning start stage (0°-30°) and the braking stage (60°-90°) are 5ms / time, the middle stage (30°-60°) is 10ms / time, and the double-path data is fused through Kalman filtering algorithm. When the angle deviation is detected to be more than 0.3°, a correction pulse is immediately sent to the flap joint module motor to adjust the overturning speed, so that the angle error after 90° overturning is not more than 0.2°, and the electromagnetic brake is locked for 5s after calibration, and the angle fluctuation is ≤0.1° to confirm that the locking is effective.

[0048] In the application, a dustproof and waterproof submodule is also included, the submodule is aimed at the dust concentration (0-500μg / m 3) and relative humidity (30%-95%) optimization sealing structure. The lower box and the upper box hinge are provided with double lip-shaped sealing rings, which are made of oil-resistant nitrile rubber material, the lip diameter is 12mm, the compression amount is controlled in 2mm, the rotary sealing is realized; the elastic silica gel sealing pad with thickness of 3mm and shore hardness of 50HA is adopted at the connection between the push plate contact plate and the push plate body, which adapts to the rotating action of the contact plate. The dustproof sealing ring of the double-cable guide rod is upgraded to a combined structure, which integrates dustproof lip and waterproof lip, and the protection level reaches IP67; the interface of the integrated control module adopts a waterproof aviation plug with a pin pitch of 2.54mm, a plug-in life of ≥1000 times, and a sealing glue filled at the interface. The surfaces of all sealing components are coated with wear-resistant coating to prolong the service life in a dusty environment and reduce the maintenance frequency.

[0049] In the application, a fault diagnosis and response submodule is also included, which monitors the current (0-10A), voltage (220V±10%), temperature (-20℃-80℃) and sensor data of the motor of each joint module in real time, and divides a three-level fault response mechanism according to the severity. Mild fault: contact force fluctuation 50-100N, angle deviation 0.3°-0.5°, the submodule automatically adjusts the push plate motor torque ±50N·m and the overturning motor angle ±0.1°, without shutdown; moderate fault: motor overload (current>10A for 1s), sensor signal loss (for 50ms), start standby control logic, switch to redundant sensor data, push plate extends at a preset speed, and the lower box is positioned according to the pre-stored track; severe fault: motor temperature>80℃, insulation resistance<100MΩ, positioning deviation>1mm, immediately cut off the motor power, trigger the electromagnetic brake to lock all moving parts, push the fault package to the operation and maintenance terminal, including fault type, occurrence time, 10s parameter curve and processing guide, and start local sound and light alarm at the same time, the response time is less than 200ms. All fault handling processes automatically generate logs, and the storage period is not less than 2 years.

[0050] In the application, a multi-vehicle type adaptation adjustment sub-module is also included, which has a hook parameter database of 12 mainstream vehicle types such as C64, C70 and C80 built-in, containing characteristic parameters such as hook length, curvature radius and contact reference point. Through the hook touch rod of the touch sensing module and the push plate pressure sensor, the contact position and pressure distribution characteristics of the hook are collected, and the cosine similarity algorithm is used for database comparison, with an identification accuracy of not less than 98%. After successful matching, the corresponding parameters are automatically called: the C64 type hook push plate has an extension length of 180 mm and a contact force of 700 N; the C70 type has an extension length of 200 mm and a contact force of 800 N; and the C80 type has an extension length of 220 mm and a contact force of 900 N. For new hooks, parameters including hook type, characteristic size and stress threshold can be manually entered through a terminal connected by a network cable, and after input, a characteristic template is automatically generated and stored in the database, and subsequent operations can be automatically matched. The sub-module updates the database every quarter, adds parameters of new vehicle types, and improves the adaptability of the system.

[0051] In the application, a running state monitoring and tracing sub-module is also included, which collects data of each module at a frequency of 1 ms / time through the integrated control module, covering the positioning accuracy of the lower box body, the overturning angle of the upper box body, the contact force of the push plate, the cable tension and the motor operating parameters. The data is stored in a local SD card (capacity 64 GB) after AES-256 encryption, with a retention time of not less than 1 year, and is uploaded to a cloud server in real time through a network cable. Three types of reports are automatically generated every week: daily operation report, which counts the number of operations, average positioning time and failure rate in a day; performance trend report, which shows the change curve of positioning accuracy and contact force in the past 30 days; and maintenance reminder report, which marks parameters that need to be maintained, such as cable tension cumulative value and sealing element usage time. The terminal can be used to input a time range to trace the fault track, and the parameter change process 30 seconds before the fault occurs can be viewed to accurately locate the problem source. The sub-module also has a remote diagnosis function, and the operator can modify the control parameters through the network to optimize the operation performance of the equipment without on-site operation.

[0052] The specific implementation of the system is further described through two embodiments as follows:

[0053] Embodiment 1: 12,000-ton C80 type heavy haul train joint module motor drive positive hook system (application scenario of Datong coal freight station in Shanxi)

[0054] This embodiment is designed for 4 C-type dumper machines matched with 12,000-ton C80 type heavy haul trains in a large coal freight station in Datong, Shanxi. The station processes 300 carriages per day, and the rated processing capacity of a single dumper machine is 60 carriages per hour. The vertical space from the bottom of the carriage to the platform of the dumper machine is only 350 mm, and the daily average dust concentration reaches 300 μg / m 3, traditional positive hook equipment due to bulky, low integration, long-term operation space adaptation difficult, cable winding wear and tear, positioning accuracy is insufficient, etc. Problems, single positive hook operation time-consuming more than 30 seconds, daily average failure 2-3 times, seriously affect the freight turnover efficiency, the use of the scheme to realize the overall upgrade of the performance and operation efficiency of the equipment, the specific implementation process is as follows.

[0055] 1. System core component selection and overall configuration

[0056] The two sets of positive hook devices of the system are symmetrically arranged at both ends of the dumper platform. The core driving components of each set of device are all integrated joint module motors. The walking joint module motor selects Panasonic MBDHT2510 series, which integrates a 2.2kW AC servo motor, a planetary reducer with a transmission ratio of 1:30, a 24V DC driver and a 17-bit multi-turn absolute value encoder, has power-off memory function, and can be accurately reset without zero reset. The plate joint module motor adopts Delta ASD-A2-0421 type, power 0.4kW, reduction ratio 1:50, which is suitable for the lightweight overturning requirement of the upper box body; the plate joint module motor selects Yaskawa SGD7S-08A00A, power 0.75kW, reduction ratio 1:20, which realizes high-precision linear motion of the plate by cooperating with the ball screw nut mechanism.

[0057] The lower box body is made of Q235B low carbon steel plate and is welded into shape. The overall size is 1200mm long x 800mm wide x 300mm high. The inner cavity of the box body is integrated with Siemens S7-1200PLC controller, signal processor and power module through a partition type structure. Only one 3x4mm 2 Power cable interface and one super five category network interface are reserved to realize plug and play. The upper box body is made of aluminum alloy die casting, which is 40% lighter than the traditional steel structure. It is connected with the lower box body through a φ50mm 40Cr material hinge shaft, and a 10mm overturning gap is reserved at the hinge. The car hook push plate body selects 6061-T6 aluminum alloy, which is 300mm long x 150mm wide x 20mm thick. The front end touch plate is made of nylon material, and the built-in strain gauge pressure sensor has a range of 0-2000N.

[0058] The double-cable guide rod module adopts two groups of φ30mm 6063 aluminum alloy guide rods, which are arranged in parallel with a spacing of 50mm. A 5mm thick polycarbonate isolation plate is arranged between the guide rods to effectively avoid electromagnetic interference between the power cable and the signal cable. The guide rod end is connected with a 1.5m spring wire (power cable cross-sectional area 4mm 2, signal cable is 8-core shielded wire), with 0-1.5m extension to meet the needs of equipment movement; fluorine rubber material combination dustproof sealing ring is installed at the entrance of the guide rod, with IP67 protection level, which can effectively block the invasion of coal dust. Eccentric locking module is composed of φ40mm 45# steel eccentric, φ30mm nylon guide wheel, φ20mm eccentric shaft and M16 internal hexagonal locking screw, and the clearance is adjusted by rotating the φ8mm rotating hole on the eccentric wheel through the special wrench of ST-19 type.

[0059] 2. Operation mechanism and technical details of each functional module

[0060] 2.1 Lower box moving module and precision control

[0061] In the gear and rack mechanism of the lower box moving module, the gear is made of 40CrNiMoA material, with a modulus of 5mm, 20 teeth, and a tooth surface hardness of HRC58-62. The rack is made of 20CrMnTi material, with a length of 8m, installed in the T-shaped groove inside the 60kg / m steel rail. The walking joint module motor drives the gear to rotate through key connection, driving the lower box to move back and forth along the track. The eccentric guide wheels on both sides of the gear and rack adjust the rotation angle of the eccentric shaft to stabilize the pressing force of the guide wheels on the back of the rack at 800N, forming a three-point positioning structure. Combined with the 4 groups of φ80mm polyurethane guide wheels at the bottom of the lower box (with a gap of ≤0.5mm between the track side), the straightness deviation of the movement is ensured to be ≤0.8mm.

[0062] The lower box moving speed adjustment submodule relies on the 17-bit multi-turn absolute value encoder integrated with the walking joint module motor (Panasonic MBDHT2510 series, displacement accuracy ±0.1mm) to collect the moving displacement in real time, and calculate the distance from the track endpoint. When the distance is greater than 5m, the motor runs at a rated speed of 1500r / min, combined with the gear and rack transmission ratio of 1:20, achieving a moving speed of 0.5m / s. When the distance is 1-5m, the S-shaped acceleration and deceleration curve is started, and the speed is linearly reduced to 800r / min, corresponding to a speed of 0.27m / s. When the distance is less than 1m, the speed is reduced to 300r / min, with a low speed of 0.1m / s for peristalsis. At the same time, the track is installed with Schneider XCK-M121 travel switches at the 5m and 1m distance nodes. When the encoder feedback displacement reaches the corresponding value, the travel switch triggers a signal for verification, avoiding the speed deviation caused by the cumulative error of the encoder.

[0063] The positioning accuracy correction sub-module pre-stores the gear and rack transmission error curve (obtained by laser interferometer measurement, maximum error 0.3 mm) and the track flatness parameter (1 point per meter is measured, maximum fluctuation 0.2 mm). The rotational speed feedback data of the encoder is collected every 10 ms, and the correction amount is calculated by the formula Δs=kΔvΔt, wherein k=0.85 is the speed-displacement correction coefficient, Δv is the deviation of the actual speed from the set speed, and Δt is the speed deviation duration. For example, when Δv=50 r / min and Δt=0.2 s, Δs=0.85×50×0.2=8.5 mm, the sub-module immediately sends a fine adjustment instruction to the walking joint module motor, controls the motor to rotate forward or reverse corresponding to the number of pulses, and finally controls the positioning error of the lower box body to be within 0.4 mm.

[0064] 2.2 Upper box body turnover module and angle calibration

[0065] Before the upper box body turnover module is started, the integrated control module first detects the lower box body positioning signal, confirms that the positioning error is ≤0.5 mm, and then sends a turnover instruction to the flap joint module motor. The motor drives the hinged shaft to rotate through the flange connection, and the encoder feeds back pulse signals to the control module every 10 ms. The turnover angle is calculated as θ=k·Δp (k=0.001° / pulse, Δp is the number of pulses). During the turnover starting stage (0°-30°) and the braking stage (60°-90°), the motor speed is controlled below 50 r / min, and the speed is increased to 100 r / min in the middle stage (30°-60°) to balance the turnover efficiency and stability.

[0066] The upper box body turnover angle calibration sub-module adopts a "encoder + Bosch BMI055 three-axis acceleration sensor" double detection scheme. The acceleration sensor measures a range of ±16g with an accuracy of ±0.01g, and the data is collected synchronously with the encoder data. The calibration formula is Δθ=mΔp+nΔa, wherein m=0.001° / pulse is the encoder resolution coefficient, Δp is the pulse count deviation, n=0.05° / g is the acceleration correction coefficient, and Δa is the deviation of the actual acceleration from the theoretical acceleration. For example, when Δp=200 pulses and Δa=0.2g, Δθ=0.001×200+0.05×0.2=0.3°, the sub-module immediately enables the Kalman filter algorithm to fuse the data and sends a correction pulse to the motor, so that the angle error after the 90° turnover is controlled within 0.2°. After the turnover is completed, the DC24V electromagnetic brake is immediately activated, with a braking torque ≥10 N·m. The pressure sensor (Hedek HDA4745, range 0-5 MPa) detects the brake disc adhesion pressure. When the pressure is ≥2 MPa, it is confirmed that the locking is effective, and the angle fluctuation within 5 s is ≤0.1°, ensuring that the upper box body remains in a stable vertical working state.

[0067] 2.3 Car coupler push plate module and contact force adjustment

[0068] The ball screw of the car coupler push plate module is selected as SFU2505 type, with a lead of 5 mm and a positioning accuracy of C3 level. The motor of the push plate joint module drives the screw to rotate through a shaft coupling, realizing the linear motion of the push plate perpendicular to the track direction, with a maximum stroke of 250 mm. The touch plate at the front end of the push plate is installed through a φ

[0069] 12 mm stainless steel rotating shaft, and the limit shaft limits the rotation angle of the touch plate to be less than or equal to 15°. A double spring structure is built between the touch plate and the push plate body. The main spring is selected from 60Si2Mn material, with a stiffness coefficient of 80 N / mm. The auxiliary spring is made of 50CrVA material, with a stiffness coefficient of 30 N / mm.

[0070] The push plate contact force self-adaptive adjustment sub-module collects pressure sensor data and double spring compression amount in real time, and calculates the contact force through the formula F=k1x1+k2x2, where k1 is the stiffness coefficient of the main spring, x1 is the compression amount of the main spring, k2 is the stiffness coefficient of the auxiliary spring, and x2 is the compression amount of the auxiliary spring. For C80 type cast steel car coupler (surface hardness HB230-250), the contact force control threshold is set to 600-900 N. When x1=6 mm and x2=4 mm are detected, F=80x6+30x4=600 N. The sub-module adjusts the motor output torque through pulse width modulation technology, so that the contact force is stabilized at about 750 N. If the contact force suddenly increases to 1000 N due to the existence of protrusions on the surface of the car coupler, the motor will immediately stop extending and maintain the current position, avoiding deformation of the car coupler under stress. When the touch plate contacts the car coupler and compresses the spring, the travel switch (Schneider XCK-M121) is triggered when the compression amount reaches 10 mm, and the push plate stops moving, with a response delay of less than or equal to 10 ms.

[0071] 2.4 Auxiliary module operation and protection mechanism

[0072] Strain gauges (Huachu HSTL-6 / 120, sensitivity coefficient 2.0, initial resistance 120Ω) are arranged every 1 m along the length of the guide rod, and real-time cable tension data is collected. The power cable tension threshold is set to 150 N, and the signal cable is set to 80 N. When the tension exceeds the threshold by 10%, the sub-module first controls the guide rod drive mechanism to extend the guide rod extension length, and the adjustment amount is calculated as 1.2 times the tension deviation. If the tension still exceeds the threshold for 200 ms, a speed reduction instruction is sent to the walking joint module motor to reduce the moving speed by 30%, and at the same time, the spring wire is controlled to increase the elastic compensation amount to avoid cable wear and tear.

[0073] The dustproof and waterproof sub-module is designed for the high dust environment of the coal freight station: double-lip nitrile rubber sealing rings are arranged at the hinged part of the lower box body and the upper box body, the lip diameter is 12 mm, the compression amount is controlled to be 2 mm, and rotation sealing is realized; a 3 mm thick silica gel sealing gasket (Shore hardness 50HA) is arranged at the connection part between the push plate contact plate and the push plate body to adapt to the rotating action of the contact plate; the interface of the integrated control module adopts a waterproof aviation plug (WEIPU WF16 series), the pin pitch is 2.54 mm, the plug-in life is greater than or equal to 1000 times, and the interface is filled with silicone sealant. The fault diagnosis and response sub-module monitors the current (normal range 0-8A), voltage (220V±10%) and temperature (-20℃-80℃) of the motor of each joint module in real time. When the motor overload (current > 8A for 1s) is detected, the redundant sensor data is switched to immediately, the push plate is extended at a preset speed, and the operation interruption is avoided; if the motor temperature is greater than 80℃, a severe fault response is triggered, the power is cut off within 150ms, the electromagnetic brake locks all moving parts, and a fault package is pushed to the operation and maintenance terminal.

[0074] 3. System assembly and operation effect

[0075] In the system assembly stage, since the motor, reducer and encoder of the joint module have been precisely matched and calibrated before leaving the factory, there is no need for on-site type selection, matching, alignment and debugging. Only the motor needs to be fixed on the preset mounting seat through the flange, and the motor power supply and communication line need to be connected. The assembly period of a single set of device is shortened from 12 hours of the traditional scheme to 3 hours, and the assembly error is controlled within 0.1 mm.

[0076] The continuous 30-day operation test shows that the performance indicators of the system are better than those of the traditional equipment, and the specific data are shown in the following table:

[0077] Table 1: Performance comparison between traditional positive hook equipment and system of the application

[0078] Performance indicators Conventional system Inventive system Overall height of the device 420 mm 300 mm Number of external cables 8 (power, coding, etc.) 2 (power supply, network cable) Positioning error of the lower box 2.1 mm 0.4 mm Turnover error of the upper box 1.3° 0.2° Time taken for a single positive hook operation 32 seconds 18 seconds Daily number of faults 2.5 times 0.2 times Single assembly cycle 12 hours 3 hours

[0079] The data in Table 1 is from the 30-day continuous operation statistics of the freight station. The traditional system adopts a split type servo motor and an external control cabinet, and the overall height reaches 420 mm, which exceeds the operation space limit and needs additional modification of the dumper platform. The 8 exposed cables are frequently entangled during equipment movement, with an average of 2.5 daily failures, of which cable wear accounts for 60%. The positioning and overturning accuracy is insufficient, resulting in misalignment of the push plate and the coupler, and the single operation time is 32 seconds. The application reduces the equipment height to 300 mm through the high integration of the joint module motor, perfectly adapting to the narrow space. The number of external cables is reduced to 2, completely solving the entanglement problem. The positioning and overturning accuracy is improved by 81% and 84.6%, respectively, and the operation time is shortened by 43.7%. The joint module factory calibration and the fully enclosed structure greatly reduce the failure rate, with an average of only 0.2 failures per day, and the assembly cycle is shortened by 75%. The daily coal unloading capacity is increased from 120,000 tons of the traditional system to 144,000 tons, significantly improving the freight efficiency.

[0080] Example 2: Joint module motor drive positive hook system for mixed train of multiple vehicle types (application scenario of Guangdong Zhanjiang port freight station)

[0081] This embodiment is designed for the Guangdong Zhanjiang port freight station, which mainly handles mixed trains of C64, C70 and C80 types, and cooperates with 3 dumper machines for operation. The operation environment has the characteristics of high humidity (85%-95%) and high salt mist concentration (50 mg / m 3 ). The traditional positive hook equipment has problems such as short equipment life (average service life less than 1 year), time-consuming parameter adjustment before operation (5 minutes for each vehicle type), and frequent failures. The application scheme realizes the dual improvement of environmental tolerance and multi-vehicle type adaptation ability of the equipment, and the specific implementation process is as follows.

[0082] 1. Selection and overall configuration of system core components

[0083] The lower box body of the two sets of positive hook devices in the system is made of 304 stainless steel with a thickness of 5 mm, and a 200 μm thick fluorocarbon anticorrosive coating is sprayed on the surface to effectively resist salt mist corrosion. The walking joint module motor is selected from the Mitsubishi HG-KR23J series, with a power of 2.0 kW and a reduction ratio of 1:25, and an IP67 rated corrosion-resistant fully enclosed housing. The power of the turning plate joint module motor is 1.0 kW, and the power of the push plate joint module motor is 0.8 kW, both of which adopt the same corrosion treatment process.

[0084] The integrated control module selects Rockwell CompactLogix L24ER PLC, supports Modbus TCP / IP communication protocol, and interacts with the cloud server in real time through a 4G module; the multi-vehicle type adaptive adjustment sub-module has a built-in 12-type mainstream vehicle hook parameter database, including the length, curvature radius, and contact force threshold of vehicle types such as C64 (hook length 400 mm, contact reference point 150 mm from the top), C70 (length 450 mm, reference point 100 mm from the top), C80 (length 500 mm, reference point 120 mm from the top), and the like; the running state monitoring and tracing sub-module is configured with a 64 GB industrial-grade SD card, with a data storage period of ≥1 year, and supports real-time running curve viewing through a Web terminal.

[0085] The guide rod of the double-cable guide rod module is made of 316L stainless steel, the surface is passivated, the isolation plate is a 10 mm thick glass fiber reinforced plastic plate, and the spring wire is an oil and salt mist resistant polyurethane sheathed cable; the eccentric wheel and the wheel of the eccentric wheel locking module are made of stainless steel to avoid adjustment jamming caused by salt mist corrosion; the hook touch rod of the touch sensing module is made of 304 stainless steel, and the travel switch is an Omron D4V-8108Z waterproof model with a protection level of IP65.

[0086] 2. Function mechanism and technical details of each functional module

[0087] 2.1 Multi-vehicle type adaptive adjustment and hook identification

[0088] The multi-vehicle type adaptive adjustment sub-module realizes automatic identification of the hook type through the touch sensing module: during the reverse movement of the lower box, the hook touch rod (length 200 mm, diameter 15 mm) on the side of the upper box first contacts the hook, triggering the travel switch and stopping the movement of the lower box; after the push plate is extended, the 16-point pressure sensor array (sampling frequency 100 Hz) built into the touch plate collects the pressure distribution characteristics of the hook surface, and the sub-module compares the collected data with the vehicle type characteristic template in the database based on cosine similarity, with an identification accuracy of ≥98%.

[0089] When a C70-type hook is detected, the similarity is 98.5%, and the sub-module automatically calls the preset parameters: the push plate is extended by 200 mm, the contact force threshold is 800 N, and the lower box is positioned 1200 mm away from the rail end; if a C64-type hook is detected, the push plate is extended by 180 mm, the contact force is 700 N, and the positioning distance is 1100 mm. When a new unknown hook is encountered, the operation and maintenance personnel can manually enter the vehicle type name, hook length 250 mm, contact force 850 N, etc. through the Web terminal, and the sub-module automatically generates a characteristic template and stores it in the database. Subsequent operations can be automatically matched, and the input process only takes 2 minutes, which is much faster than the 5-minute debugging time of traditional equipment.

[0090] 2.2 Cable tension monitoring and environmental compensation

[0091] Strain gauges of the cable tension monitoring submodule are arranged at every 0.5 m along the guide rod, with a higher density than that of Example 1 to adapt to the complex tension change environment of the port. The tension calculation is based on the resistance change of the strain gauge, which is realized through the formula AR = KER0, where AR is the resistance change amount, K = 2.0 is the sensitivity coefficient, ε is the cable strain value (power cable allowed range < 0.1%, signal cable < 0.08%), and R0 = 120 Ω is the initial resistance. For example, when the power cable strain ε = 0.09% is detected, AR = 2.0 x 0.09% x 120 = 0.216 Ω, and the tension is calculated to be 135 N, which is lower than the threshold of 150 N, and the system operates normally.

[0092] In view of the high humidity environment of the port, the submodule introduces a humidity compensation mechanism: the environmental humidity is monitored in real time by a Sensirion SHT31 temperature and humidity sensor, and when the humidity > 90%, the cable tension threshold is reduced by 10% (power cable reduced to 135 N), and at the same time, the guide rod driving mechanism is controlled to increase the extension frequency to avoid the cable from being overweight due to moisture, resulting in excessive tension. A cable tension curve report is automatically generated daily, marking the tension peak and cumulative change amount, and when the cumulative strain exceeds 0.5%, a replacement warning is pushed to the operation and maintenance terminal.

[0093] 2.3 Calibration and corrosion protection of the upper box body overturning angle

[0094] The calibration period of the upper box body overturning angle calibration submodule is dynamically adjusted according to the overturning stage: the calibration frequency is 5 ms / time in the starting stage (0°-30°) and the braking stage (60°-90°), and 10 ms / time in the middle stage (30°-60°). The calibration formula is Δθ = mΔp + nΔa, where m = 0.001° / pulse and n = 0.05° / g. For example, when the overturning angle is 45°, the encoder detects Δp = 300 pulses, the acceleration sensor detects Δa = 0.3 g, and Δθ = 0.001 x 300 + 0.05 x 0.3 = 0.315°. The submodule immediately sends a correction pulse to the motor of the flap joint module to control the angle error within 0.25°. After the overturning is completed, the electromagnetic brake is locked, and the angle fluctuation is monitored for 5 s. When the angle fluctuation is ≤0.08°, the locking is confirmed to be effective.

[0095] Dustproof, waterproof, anticorrosive and protective sub-module: The double-lip seal ring at the hinge of the lower and upper boxes is made of fluororubber, resistant to oil and salt mist, with silicon grease lubrication on the lip. The push plate sealing gasket is made of chloroprene rubber, 3 mm thick, with a Shore hardness of 55HA. The dustproof sealing ring of the double-cable guide rod is upgraded to a combination structure of "dust lip + waterproof lip + oil scraping lip", with the interior of the guide rod filled with lubricating grease to prevent salt mist intrusion. The aviation plug interface of the integrated control module is filled with silicone sealant, and a drain hole is provided at the bottom of the box to prevent condensate accumulation. The sealing components are checked regularly every month, and there is no aging or deformation on the appearance. After 3 months of operation, there is no salt mist erosion trace inside.

[0096] 2.4 Fault diagnosis and operation state monitoring

[0097] The fault diagnosis and response sub-module divides faults into three levels: mild fault (contact force fluctuation 50-100 N, angle deviation 0.3°-0.5°), automatic adjustment of push plate motor torque ±50 N·m, and overturning motor angle ±0.1°; moderate fault (motor overload for 1s, sensor signal loss for 50ms), start standby control logic, switch to redundant sensor data; severe fault (motor temperature >80℃, insulation resistance <100MΩ), immediately cut off the power, electromagnetic brake locking, push fault package to operation and maintenance terminal, including fault type, occurrence time, 10s parameter curve and processing guide. In a certain operation, the temperature of the push plate motor increased to 82℃ due to the jamming of the lead screw, and the system triggered a severe fault response within 180ms. The maintenance personnel completed the repair within 10 minutes according to the guide, without causing operation interruption.

[0098] The operation state monitoring and tracing sub-module collects data at a frequency of 1ms / second, covering 12 parameters such as lower box positioning accuracy, upper box overturning angle, push plate contact force, and cable tension. The data is encrypted by AES-256 and stored in an SD card and uploaded to the cloud. Weekly automatic generation of three types of reports: device operation daily report (statistics of single day operation times 200 times, average positioning time 15 seconds, fault occurrence rate 0.1%); performance trend report (showing the positioning accuracy fluctuation from 0.45mm to 0.5mm in 30 days, prompting track cleaning); maintenance reminder report (marking cable tension cumulative value 0.3%, sealing component usage time 90 days, not reaching the warning threshold). Support input time range to trace fault trajectory, can view the parameter change process 30s before the fault occurs, accurately locate the problem source.

[0099] 3. System operation effect and environmental adaptability

[0100] The system has been continuously running for 45 days, and has shown excellent stability and adaptability in high humidity and high salt mist environment. The specific data is shown in the following table:

[0101] Table 2: Different working conditions and vehicle model adaptation performance

[0102] Working conditions / vehicle types Positioning error Turnover error Righting success rate Cable failure rate Time taken for vehicle type adaptation Moisture salt spray working conditions 0.5 mm 0.28° 99.7％ 0％ - Multi-machine collaborative working conditions 0.45 mm 0.25° 99.8％ 0％ - C64 type coupler 0.5 mm 0.3° 99.8％ - 0s C70 type coupler 0.4 mm 0.25° 99.9％ - 0s New unknown coupler 0.6 mm 0.35° 95％ - 2 min

[0103] Table 2 data from the port 45 days test, the traditional system in the wet salt spray working condition, the cable failure rate due to corrosion is 15%, the average service life of the equipment is only 10 months; each vehicle model needs to be manually debugged for 5 minutes, and the mixed train operation causes low efficiency due to frequent debugging, and the new type of car coupler righting success rate is only 70%. The application of 304 stainless steel material and corrosion resistant coating, combined with cable tension monitoring and sealing protection, reduces the cable failure rate to 0%, and the expected service life of the equipment is extended to 3 years; the multi-vehicle model adaptation sub-module realizes automatic identification of vehicle model, and the adaptation time is 0, the new type of car coupler can be adapted after manual input, and the success rate is 95%; under the working condition of multi-machine cooperation, the positioning and overturning precision is stable through PLC coordination of each equipment action time sequence, and the righting success rate is more than 99.7%, which completely solves the problems of poor environmental tolerance and low adaptability of traditional equipment, and the daily train handling capacity of the port is increased from 8 to 10, and the operation efficiency is improved by 25%.

[0104] Reference Figure 2 This figure clearly shows the core logic of the speed adjustment sub-module. Based on the "distance grading speed control" technical scheme in the file, the initial distance is 15 m, and the high-speed movement is 0.5 m / s to balance the operation efficiency; after 5 m, enter the deceleration transition section to avoid inertia impact; after 1 m, switch to 0.1-0.17 m / s fine docking, and cooperate with the positioning error correction formula Δs=kΔvΔt to control the positioning error within 0.4 mm. This adjustment mode solves the problem of "low efficiency at long distance and misalignment at short distance" caused by traditional fixed speed movement, lays a foundation for the precise linkage of subsequent box body overturning and push plate righting, and embodies the fine design of system motion control.

[0105] Reference Figure 3 The traditional system relies on manual preset parameters, and the success rate of C64-C80 vehicle model is only 90%-92%, and the success rate of new vehicle is reduced to 70% due to the lack of matching parameters, and the success rate of mixed working condition is 85% due to frequent parameter adjustment. The application automatically matches C64-C80 parameters by combining pressure distribution characteristics comparison and built-in 12 vehicle model parameter database, and the success rate is more than 99.8%; the new vehicle can be adapted after manual input, and the success rate is 95%; the mixed working condition does not need to be intervened, and the success rate is 99.7%, which highlights the advantages of the multi-vehicle model adaptation sub-module.

[0106] Reference Figure 4The traditional system cable winding and unwinding is asynchronous with the box movement, the cable tension exceeds the threshold of 150N after 4m, and reaches 250N after 8m, which easily leads to cable corrosion and rupture in a salt spray environment. The application calculates the tension in real time based on AR=K epsilon R0, adjusts the guide rod extension through feedforward control, and stabilizes the tension within the threshold after 8m, cooperates with the 316L stainless steel guide rod and the corrosion-resistant seal, and reduces the cable failure rate to 0%, which reflects the core value of the cable tension monitoring submodule.

[0107] The above specific embodiments do not constitute a limitation on the protection scope of the present application. Those skilled in the art should understand that various modifications, combinations, sub-combinations and substitutions can be made according to design requirements and other factors. Any modification, equivalent replacement and improvement made within the spirit and principle of the present application should be included in the protection scope of the present application.

Claims

1. A train coupler knuckle system driven by a joint module motor, characterized in that, The application relates to a device for automatically coupling and uncoupling a train, which comprises the following modules: a lower box moving module, which comprises a lower box body, a gear and rack mechanism and a walking joint module motor, the walking joint module motor is integrated with a motor, a speed reducer, a driver, a controller and a multi-turn absolute value encoder, a driving gear and rack drives the lower box to reciprocate along a track, eccentric guide wheels are arranged on the two sides of the gear and rack, a guide wheel at the bottom of the lower box is matched with the track, and the lower box is reset after power failure; an upper box overturning module, which comprises an upper box body, a hinged shaft and a flap joint module motor, the upper box is connected with the lower box through the hinged shaft, the flap joint module motor drives the upper box to overturn by 90 degrees, the overturning angle is monitored in cooperation with an encoder, an electromagnetic brake is automatically locked after the upper box is overturned to a position, and a vertical working state is maintained; a car hook push plate module, which comprises a push plate body, a touch plate, a rotating shaft, a limiting shaft, built-in double springs, a travel switch and a push plate joint module motor, the push plate joint module motor drives the push plate to move vertically relative to the track through a screw nut mechanism, the touch plate is installed at the front end of the push plate through the rotating shaft, the limiting shaft limits the rotating range, the spring is compressed when the touch plate contacts the car hook, the travel switch is triggered, and the push plate is stopped; a double-cable guide rod module, which comprises two groups of parallel telescopic guide rods, an isolation plate, a spring wire and a dustproof sealing ring, the two groups of guide rods guide power cables and signal cables respectively, the spring wire provides length compensation when the device moves, and the dustproof sealing ring is arranged at the inlet of the guide rod to prevent dust from entering; an eccentric wheel locking module, which is composed of an eccentric wheel, a guide wheel, an eccentric wheel shaft and a locking screw, the gap between the guide wheel and the rack is adjusted by rotating the eccentric wheel rotating hole through a special tool, and the locking screw fixes the position of the eccentric wheel; a touch sensing module, which comprises a car hook touch rod and a push plate pressure sensor, the car hook touch rod is installed on the side surface of the upper box and is connected with the travel switch, the switch is triggered when the car hook is contacted to control the lower box to stop, the push plate pressure sensor monitors the contact force, and data is synchronously transmitted to an integrated control module; an integrated control module, which integrates a PLC controller, a driver and a signal processor in the lower box, communicates with each joint module motor and sensor, and is connected with only one power line and one network line, and is plug and play.

2. The system according to claim 1, wherein the system is a positive coupling system of a train coupler driven by a motor of a joint module. The application further comprises a push plate contact force self-adaptive adjustment sub-module, which is equipped with a pressure sensor and a double-spring displacement acquisition unit, the pressure sensor collects the contact pressure of the touch plate and the car hook and the compression amount of the double springs in real time, contact force calculation complies with F=k1*x1+k2*x2, wherein F is the contact force of the push plate and the car hook, k1 is a main spring stiffness coefficient, k2 is a secondary spring stiffness coefficient, x1 is the compression amount of the main spring, and x2 is the compression amount of the secondary spring; the sub-module transmits the collected data and calculation results to the controller of the push plate joint module motor, and adjusts the output torque of the motor through pulse width modulation technology.

3. The system according to claim 1, wherein the system is a positive coupling system of a train coupler driven by a motor of a joint module. The application further comprises a lower box moving speed adjustment sub-module, which integrates the multi-turn absolute value encoder of the walking joint module motor, the encoder collects the displacement data of the lower box movement in real time to calculate the distance from the end point of the track and adjust the speed, during the speed adjustment process, the sub-module synchronously receives the pressing force data of the eccentric wheel locking module, when the pressing force fluctuation exceeds 50N, the speed is additionally reduced by 20%, and the guide wheel is controlled to increase the adhesion to the track, and three-point positioning structure is combined to further eliminate movement deviation.

4. The system according to claim 1, wherein, The lower box positioning accuracy correction submodule pre-stores the gear and rack transmission error curve and the track flatness parameter, and dynamically compensates the final position of the lower box through the positioning correction Δs=kΔvΔt, wherein Δs is the positioning correction amount, k is the speed-displacement correction coefficient, Δv is the deviation between the actual speed and the set speed of the walking joint module motor, and Δt is the speed deviation duration. The submodule collects the speed feedback data of the encoder every 10 ms, calculates Δv and Δt, combines the trigger signal of the track end travel switch and the real-time displacement data of the encoder, and automatically generates a correction instruction. When the positioning deviation exceeds 0.8 mm, the control walking joint module motor executes a single ±0.2 mm fine adjustment action. The eccentric wheel keeps constant pressure during the fine adjustment process, and the guide wheel real-time corrects the walking track, so that the positioning error is finally controlled within 0.5 mm.

5. The system of claim 1, wherein the system is a positive coupling system of a train coupler driven by a motor of a joint module. The cable tension monitoring submodule is arranged with a metal foil strain gauge every 1 m along the length direction of the double-cable guide rod, and real-time tension data of the power cable and the signal cable are collected. The power cable tension threshold is set to 150 N, and the signal cable is set to 80 N. When the tension exceeds 10% of the threshold, the submodule first controls the guide rod driving mechanism to extend the telescopic length of the guide rod, and the adjustment amount is calculated according to 1.2 times the tension deviation. If the tension still exceeds the standard for 200 ms, a speed reduction instruction is sent to the walking joint module motor, and the spring wire is controlled to increase the elastic compensation amount. The insulating polycarbonate material is used for the isolation plate between the guide rods, and the fluororubber material is used for the dustproof sealing ring at the entrance of the guide rod. The submodule generates a cable tension curve report regularly.

6. The system of claim 1, wherein the system is a positive coupling system for a train car coupler driven by a motor of a joint module. The upper box turnover angle calibration submodule is used for angle calibration, which follows Δθ=mΔp+nΔa, wherein Δθ is the angle correction amount, m is the encoder resolution coefficient, Δp is the pulse count deviation, n is the acceleration correction coefficient, and Δa is the deviation between the actual acceleration and the theoretical acceleration. The calibration period is dynamically adjusted, and the double-channel data is fused through the Kalman filtering algorithm. When the angle deviation is detected to exceed 0.3°, a correction pulse is immediately sent to the turnover plate joint module motor to adjust the turnover speed.

7. The articulated modular motor-driven train coupler knuckle system of claim 1, wherein, The dustproof and waterproof submodule optimizes the sealing structure according to the working environment of the dumper. Double-lip sealing rings are arranged at the hinge joints of the lower box and the upper box, and oil-resistant nitrile rubber material is selected. Elastic silica gel sealing pads are used at the connection between the push plate contact plate and the push plate body. The dustproof sealing rings of the double-cable guide rod are upgraded to a combined structure. The interfaces of the integrated control module adopt waterproof aviation plugs, the interfaces are filled with sealant, and the surfaces of each sealing component are coated with wear-resistant coating.

8. The system of claim 1, wherein the system is a positive coupling system for a train coupler driven by a motor of a joint module. Also includes fault diagnosis and response sub-module, the sub-module real-time monitoring of each joint module motor current, voltage, temperature and sensor data, according to the severity of three fault response mechanism, mild fault: contact force fluctuation 50-100N, angle deviation 0.3°-0.5°, the sub-module automatically adjust the push plate motor torque ± 50N·m, flip motor angle ± 0.1°; moderate fault: motor overload, sensor signal loss, start standby control logic, switch to redundant sensor data, the lower box according to the pre-stored trajectory positioning; severe fault: motor temperature > 80℃, insulation resistance < 100MΩ, positioning deviation > 1mm, immediately cut off the motor power, trigger electromagnetic brake locking all moving parts, to the operation and maintenance terminal push fault package, while starting local sound and light alarm, all fault handling process automatically generate log.

9. The system of claim 1, wherein the system is a positive coupler system for a train with an electric motor driven joint module. Also includes multi-vehicle type adaptive adjustment sub-module, the sub-module is built-in 12 kinds of mainstream vehicle coupler parameter database, through the touch sensing module coupler touch rod and push plate pressure sensor, the collection of coupler contact position and pressure distribution characteristics, using cosine similarity algorithm and database comparison, matching success after automatically call corresponding parameters; for new coupler, through the network terminal manual input parameters, after entering automatically generate feature template stored in the database, the sub-module database is updated every quarter, increase new vehicle parameters.

10. The articulated modular motor-driven train coupler knuckle system of claim 1, wherein, Also includes operation state monitoring and tracing sub-module, the sub-module through the integrated control module to collect data, covering the lower box positioning accuracy, upper box flip angle, push plate contact force, cable tension and motor operating parameters, data after AES-256 encryption stored in local SD card, at the same time through the network real-time upload to the cloud server, every week automatically generate three kinds of report: equipment operation daily report, performance trend report, maintenance reminder report; Support through the terminal input time range backtracking fault trajectory, the sub-module has remote diagnosis function, operation and maintenance personnel through the network to modify the control parameters.

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