Multifunctional test system for testing composite material floor of railway passenger car and control method of multifunctional test system

Abstract

The invention relates to a multifunctional test system for testing a composite material floor of a railway passenger car. The multifunctional test system comprises a hydraulic power assembly, a test execution system and a measurement and control system, the hydraulic power assembly is used for providing adjustable pressure and flow output for a test execution mechanism of the test execution system; the test execution system is integrated with a plurality of load simulation mechanisms and is used for installing a tested workpiece and implementing a performance test; the measurement and control system comprises a sensor data acquisition and processing system, and the sensor data acquisition and processing system is used for monitoring and controlling key parameters of pressure, flow, temperature and displacement of the hydraulic power assembly and the test execution system in real time. The system has the advantage that the spanning from single-function equipment to a multifunctional integrated system is realized.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of test devices for rail passenger cars and their accessories, and in particular relates to a multifunctional test system for testing a rail passenger car composite floor and a control method thereof. BACKGROUND

[0002] With the rapid development of intelligent rail transit in China, phenolic carbon fiber composite heating floor has become a key material for improving the comfort of the car environment in extreme climates due to its lightweight, high strength, and intelligent temperature control characteristics. Through the integration of carbon fiber conductive network and intelligent temperature control module, this material realizes efficient electric heating conversion and space weight reduction while meeting the requirements of high strength, impact resistance, and long service life of rail vehicles. Traditional single-factor testing methods cannot effectively simulate the thermal-mechanical-electrical multi-field coupling mechanism during actual service, resulting in significant deviations in material performance evaluation. The multifunctional test system for the rail passenger car composite floor precisely simulates high-frequency vibration, temperature change impact, and other special conditions during vehicle operation, providing a scientific basis for the design optimization and performance improvement of phenolic carbon fiber composite heating floor.

[0003] Currently, to replicate the complex load environment that rail vehicles experience during actual operation, six types of tests are required: static / dynamic loading, random / sinusoidal vibration, transient impact, high-heeled shoe stepping simulation, drop ball impact testing, and environmental coupling testing. During testing, the phenolic carbon fiber composite heating floor is subjected to coupling interference from multiple physical fields, including nonlinear response of the mechanical system, sensor noise, actuator coupling effects, and others. These factors can affect the accuracy and repeatability of test data. The commonly used single-function vibration test systems or static loading devices on the market require dispersed testing in multiple locations using multiple devices in a step-by-step manner.

[0004] For example, in the field of aircraft structure strength testing, to simulate the complex working conditions of the floor structure in the main cabin airtight area simultaneously bearing airtight load and coordinated deformation load, corresponding test device schemes have been proposed in the prior art. For example, a typical structure is described in Chinese Patent No. CN120084628A, entitled "Aircraft floor structure test device". The device mainly includes a fixed base, an airtight and coordinated deformation loading frame, a hydraulic transmission cylinder, and a side support device.

[0005] In this scheme, the airtight and coordinated deformation loading frame is composed of a rectangular frame, a floor test piece and an airtight box cover plate to form a closed airtight box, an air bag is arranged inside, and the airtight load is simulated by inflating the air bag. The top corner of the rectangular frame is connected with a hydraulic transmission cylinder, and the horizontal displacement load is applied through the output shaft of the hydraulic transmission cylinder, so that the frame produces translation and rotation to simulate the coordinated deformation load. The side support device is used to provide out-of-plane support for the airtight box cover plate during the test to prevent unintended deformation.

[0006] Although the prior art scheme can realize the combined application of airtight and coordinated deformation loads, its functional design mainly focuses on specific types of static or quasi-static load simulation, and the structure is relatively fixed. The loading mode and frame structure are designed for a single test purpose, and lack of modularity and scalability, making it difficult to efficiently and conveniently complete diversified comprehensive performance tests such as vibration excitation, dynamic fatigue, impact and multi-directional loading on the same machine. In addition, the hydraulic system is usually designed as a single function circuit, which is difficult to meet the different technical requirements of high-precision steady-state loading and high-dynamic response vibration excitation, and has limitations in test efficiency, functional integration and system adaptability.

[0007] For example, in the field of floor material mechanical property testing, especially for special test devices for impact resistance, there are also corresponding representative designs. For example, the Chinese utility model patent "Floor Impact Resistance Tester" with the publication number CN214334559U discloses a typical impact test equipment. The device mainly includes a base, left and right columns, a liftable cantilever, an electromagnet attraction mechanism, a test sample support assembly and a force sensor.

[0008] In this scheme, the cantilever is lifted by a motor and screw mechanism, and an electromagnet is installed at the lower end of the cantilever for attracting a steel impact object. The test sample is placed on the test sample bottom plate at the bottom, and a support assembly with an impact force sensor is arranged below the bottom plate. During the test, the electromagnet is controlled to release the impact object, which falls vertically along the guide cylinder to impact the test sample, and the sensor collects impact force data in real time. The device supports replacing different specifications of electromagnets and impact objects, and can adjust the impact height, with certain operation automation and measurement accuracy.

[0009] The prior art scheme realizes the standardized test of floor materials under vertical impact load, has the characteristics of simple structure, relatively convenient operation, quantifiable impact force and the like. However, the functional range is strictly limited to a single drop hammer type impact test, and the integration of various test items such as vibration excitation, multidirectional fatigue loading, bearing test or drop ball impact cannot be realized on the same equipment. In addition, the loading mode is a simple free-fall impact, which is difficult to simulate the multidirectional composite load, vibration-impact coupling and dynamic mechanical environment with boundary constraints existing in actual service, so there are obvious limitations in the diversity of test items, the authenticity of working condition simulation and the multifunctional integration degree of equipment, which cannot meet the needs of comprehensive performance evaluation of structures such as aviation composite materials floor under complex comprehensive load.

[0010] For example, in the mechanical property test of wooden floor, there is also a special test device for surface rolling load performance. For example, a typical test equipment is provided in the Chinese Utility Model Patent with the Patent No. CN221405205U, "Wood-Plastic Composite Floor Load Test Mechanism". The device mainly consists of a base, a top plate, a support column, a hydraulic cylinder, a bearing plate, a rotating table, a tray and a moving mechanism with test wheels.

[0011] In this scheme, the wood floor to be tested is placed on the rotatable tray and is lightly limited by the periphery screw and bolt. The hydraulic cylinder drives the bearing plate to move downward, so that the test wheel installed on the wheel support presses the floor surface with a certain pressure. During the test, the operator can manually rotate the rotating table to make the floor rotate, and at the same time, the test wheel is driven to reciprocate along the long hole on the bearing plate through the operating lever, so as to simulate the longitudinal and transverse loading of the rolling wheel on the floor surface, and the load size is monitored through the pressure sensor in the tray. The mechanism realizes the rolling load test under manual operation by reducing the moving friction through the ball structure.

[0012] The prior art scheme has a relatively simple structure, and the operation is intuitive, which can qualitatively or semi-quantitatively evaluate the compression resistance and wear resistance of the floor surface under the action of rolling load. However, its function is limited to a single static or quasi-static surface rolling test, the loading mode is manual operation, the efficiency is low, the repeatability is limited, and the accurate control and complex time sequence simulation of the load cannot be realized. More importantly, the device cannot test the overall mechanical properties of the floor structure (such as vibration response, impact resistance, multidirectional bearing, connection point strength, etc.), and cannot simulate the dynamic and composite load conditions that may exist in the use environment, so there are obvious deficiencies in the comprehensiveness of test functions, the accuracy and automation degree of loading mode, and it is difficult to meet the high standard requirements of the overall performance system evaluation of composite material floor under complex working conditions in fields such as aviation and rail transportation.

[0013] Based on the analysis of the existing technical solutions above, the following limitations exist in the field of floor structure and material performance testing devices. These shortcomings highlight the improvement direction and technical advantages of the present invention:

[0014] 1. Limited functionality and lack of comprehensive testing capabilities.

[0015] Existing devices are mostly designed for a single load type or testing purpose. For example, CN120084628A focuses only on simulating airtightness and coordinated deformation loads, CN214334559U can only perform vertical drop hammer impact tests, and CN221405205U is limited to surface rolling load testing. These devices operate independently, making it impossible to integrate multiple testing items such as vibration, impact, fatigue, load bearing, and multi-directional loading on a single testing platform. This results in cumbersome testing procedures, high equipment investment, large space requirements, and difficulty in systematically evaluating the overall performance of specimens under complex combined loads.

[0016] 2. Fixed structure, insufficient modularity and expandability.

[0017] Existing testing equipment typically employs an integrated or dedicated design, such as the frame-airbag integrated structure of CN120084628A and the column-cantilever impact mechanism of CN214334559U. Such structures make it difficult to flexibly adjust or expand functional modules according to testing requirements, and also hinder the replacement of different fixtures, actuators, or sensors. This limits their adaptability to different specimen specifications and loading scenarios, resulting in poor equipment versatility and low efficiency.

[0018] 3. The loading method is simple, making it difficult to simulate real-world complex working conditions.

[0019] Existing loading techniques are mostly static, unidirectional, or quasi-static, such as pneumatic loading, free-fall impact, or manual rolling loading. They lack the ability to apply multi-axis coordinated, dynamically coupled, and time-programmable composite loads. This makes it impossible to accurately simulate the complex mechanical environments that floor structures in aerospace, rail transportation, and other fields may experience in actual service, such as vibration-impact coordination, multi-directional fatigue, and aerodynamic-structural coupling. Consequently, the correlation between test results and actual working conditions is weak, limiting their engineering guidance value.

[0020] 4. Low level of automation, limiting testing efficiency and consistency.

[0021] For example, CN221405205U still relies on manual operation for rotation and reciprocating motion, while CN214334559U, although possessing some automation, has limited functionality. Existing devices generally have low levels of automation and intelligence in load control, data acquisition, and process execution, making it difficult to achieve high-precision, repeatable, and programmable testing processes, thus affecting testing efficiency, result consistency, and big data analysis capabilities.

[0022] 5. Low system integration, making it difficult to achieve resource sharing and collaborative control.

[0023] In existing solutions, subsystems such as hydraulics, control, and measurement are typically designed for single functions, failing to achieve multi-loop coordination and resource sharing. For example, the hydraulic system in CN120084628A only serves a single loading action and cannot simultaneously support high-precision static loading and high-dynamic vibration excitation under the same power source. This results in system redundancy, high energy consumption, and isolation between functions, making it impossible to form a collaborative testing capability. Summary of the Invention

[0024] In view of the above problems, the purpose of this invention is to provide a multifunctional test system and its control method for testing composite material floors of rail passenger vehicles. This system is used to continuously and collaboratively complete tests on the same platform, which not only greatly improves testing efficiency and site utilization, but more importantly, by simulating the spatiotemporal coupling effect of load, vibration and impact, it provides a more rigorous and scientific evaluation method for composite material floors that is closer to actual service conditions, filling the gap in comprehensive testing equipment in this field.

[0025] The present invention provides a multifunctional testing system for testing composite material floors of rail passenger vehicles, comprising: a hydraulic power assembly, a test execution system, and a measurement and control system;

[0026] The hydraulic power assembly is used to provide adjustable pressure and flow output for the test execution mechanism of the test execution system;

[0027] The test execution system integrates multiple load simulation mechanisms for mounting the test workpiece and conducting performance tests;

[0028] The measurement and control system includes a sensor data acquisition and processing system, which is used to monitor and control key parameters such as pressure, flow rate, temperature, and displacement of the hydraulic powertrain and test execution system in real time.

[0029] As a preferred embodiment of the present invention, the test execution system includes: a support frame, a three-degree-of-freedom vibration table installed within the support frame and located at the bottom, a vibration table surface installed on the three-degree-of-freedom vibration table, a first set of three-degree-of-freedom motion mechanisms installed on the support frame and located above the vibration table surface, and a second set of three-degree-of-freedom motion mechanisms installed on the support frame and located above the first set of three-degree-of-freedom motion mechanisms. The three-degree-of-freedom vibration table is used to perform random life vibration tests and triaxial random vibration tests on a test workpiece fixed on the vibration table surface. The first set of three-degree-of-freedom motion mechanisms is used for dynamic load fatigue tests, static load tests, and simulated high-heel shoe tests. The second set of three-degree-of-freedom motion mechanisms is used for applying horizontal tensile force tests and falling ball tests.

[0030] As a preferred embodiment of the present invention, the three-degree-of-freedom vibration table includes: a vibration table body and servo hydraulic cylinders arranged on the vibration table body along the XYZ directions. The servo hydraulic cylinders in the XY directions are connected to the vibration table body through a hinged connection structure. The hinged connection structure includes a hydraulic cylinder connecting hinge seat, one end of which is fixedly connected to the vibration table body, and the other end is hinged to a fisheye bearing at the end of the servo hydraulic cylinder. The servo hydraulic cylinders in the X and Y directions are fixedly connected to the support frame through trunnion supports. The housing of the servo hydraulic cylinder in the Z direction is mounted on the vibration table body, and the piston rod of the servo hydraulic cylinder in the Z direction is connected to the bottom of the vibration table surface. The vibration table body drives the vibration table surface to move through the servo hydraulic cylinders arranged in the XYZ directions.

[0031] As a preferred embodiment of the present invention, the vibration table surface includes: a table body and two sets of guide columns located at the bottom of the table body. Sample fixtures for fixing phenolic flooring are installed at the four corners of the upper surface of the table body. The sample fixtures include: hook clamps and height adjustment pins. The hook clamps constrain the phenolic flooring from above the edge, while the height adjustment pins provide support and positioning from below. Together, they form stable and controllable overlapping fixing points around the sample, keeping the central area of ​​the sample in a hollow state. The two sets of guide columns are slidably connected in a sliding sleeve fixed to the vibration table body.

[0032] As a preferred embodiment of the present invention, the first three-degree-of-freedom motion mechanism includes: two first Y-direction linear guides parallel to each other on a support frame along the Y-direction; a first linear guide slider slidably connected to the first Y-direction linear guides; a first positioning pin installed at the slot of the first linear guide slider; and a first linear guide clamp fixedly connected to the first linear guide slider. The first linear guide clamp is used to lock the first linear guide slider at any position within its sliding stroke on the first Y-direction linear guide. Parallel first transverse support seats and first guide posts are fixedly connected to the two first linear guide sliders. The two first linear guide sliders are used to drive the first transverse support seats along the first Y-direction linear guide. The linear guide rail extends linearly. A first X-direction linear guide rail is provided on the first transverse support. A first heavy-duty linear guide rail slider is slidably connected to the first X-direction linear guide rail. A first positioning mounting plate is fixedly connected to the first heavy-duty linear guide rail slider. A first guide sleeve fixedly connected to the upper end of the first positioning mounting plate is fitted onto a first guide post and slidably connected to the first guide post. A bidirectional double-outlet hydraulic cylinder is installed on the first positioning mounting plate. A loading seat is fixedly connected to the piston rod extending from the bidirectional double-outlet hydraulic cylinder. The first Y-direction linear guide rail and the first linear guide rail slider, as well as the first X-direction linear guide rail and the first heavy-duty linear guide rail slider, are all manually adjustable.

[0033] As a preferred embodiment of the present invention, the second set of three-degree-of-freedom motion mechanism includes: two second Y-direction linear guides parallel to each other on the support frame along the Y direction, a second linear guide slider slidably connected to the second Y-direction linear guides, a second positioning pin installed at the slot of the second linear guide slider, and a second linear guide clamp fixedly connected to the second linear guide slider. The second linear guide clamp is used to lock the second linear guide slider at any position within the sliding stroke of the second linear guide on the second Y-direction linear guide. Parallel second transverse support seats and second guide posts are fixedly connected to the two second linear guide sliders. The two second linear guide sliders are used to carry... The second transverse support seat is linearly displaced along the extension direction of the second Y-axis linear guide rail. The second transverse support seat is provided with a second X-axis linear guide rail arranged along the X-axis. A second heavy-duty linear guide rail slider is slidably connected to the second X-axis linear guide rail. A second positioning mounting plate is fixedly connected to the second heavy-duty linear guide rail slider. A guide sleeve fixedly connected to the upper end of the second positioning mounting plate is fitted onto the second guide post and slidably connected to the second guide post. A transverse loading hydraulic cylinder is installed on the second positioning mounting plate. The second Y-axis linear guide rail and the second linear guide rail slider, as well as the second X-axis linear guide rail and the second heavy-duty linear guide rail slider, are all adjusted by manual pushing control.

[0034] As a preferred embodiment of the present invention, the hydraulic powertrain adopts an integrated hydraulic pump station, which includes: a variable frequency motor, a hydraulic gear pump, an oil tank, a return oil filter, and oil temperature, oil pressure, and liquid level sensing and monitoring components. The variable frequency motor controls the pump station flow rate through the hydraulic gear pump, the return oil filter is used to filter impurities in the oil circuit, and the oil temperature, oil pressure, and liquid level sensing and monitoring components are used to provide real-time feedback on the operating parameters of the integrated hydraulic pump station.

[0035] As a preferred embodiment of the present invention, the hydraulic power assembly further includes a multi-stage pressure regulation system consisting of an electromagnetic relief valve and a pressure reducing valve, wherein the multi-stage pressure regulation system is used to control the load simulation mechanism to achieve precise step-wise adjustment of the loading pressure and vibration load.

[0036] As a preferred embodiment of the present invention, the integrated hydraulic pump station further includes an integrated valve block assembly for controlling the load simulation mechanism. The integrated valve block assembly integrates five parallel independent hydraulic circuits. The first and second independent hydraulic circuits are control circuits for servo hydraulic cylinders in the X and Y directions. The control circuits are equipped with electromagnetic directional valves and work in conjunction with switching valves to avoid motion interference caused by hinges in the X and Y directions of the servo hydraulic cylinders, prevent operational hazards caused by circuit closure, and achieve motion control of the vibration table in the X and Y horizontal directions. The third independent hydraulic circuit is the motion control circuit for the servo hydraulic cylinder in the Z direction. The fourth and fifth independent hydraulic circuits are motion control circuits for bidirectional double-rod hydraulic cylinders and lateral loading hydraulic cylinders. The motion control circuits are equipped with directional valves, and switching valves are set at the oil inlet and return ports of each vibration circuit to achieve independent on / off of each vibration branch. The integrated valve block centrally manages the five hydraulic circuits to achieve coordinated loading and vibration actions, accurately reproducing the load-bearing, vibration, and impact stress state of the composite material floor during actual use.

[0037] Another objective of this invention is to provide a control method for a multifunctional testing system for testing composite material flooring in rail passenger vehicles, comprising the following steps:

[0038] Step S1: Experimental process control,

[0039] Step S11: When conducting dynamic fatigue tests and static load tests, the first set of three-degree-of-freedom motion mechanism is used to drive the bidirectional double-outlet hydraulic cylinder to achieve full-plane loading motion without dead angles. The bidirectional double-outlet hydraulic cylinder achieves precise loading control of the force closed loop at the selected loading point. In conjunction with the three-degree-of-freedom vibration table, the dynamic fatigue test and static load test of the test specimen (composite phenolic floor) are realized.

[0040] Step S12: When conducting the simulated high heel test, the first set of three-degree-of-freedom motion mechanism drives the bidirectional double-outlet hydraulic cylinder to achieve full-plane loading motion without dead angles. The simulated high heel device is assembled by rigidly connecting the actuator end of the bidirectional double-outlet hydraulic cylinder, and the three-degree-of-freedom vibration table is used to simulate the high heel test on the test specimen.

[0041] Step S13: When conducting the installation test of the embedded parts of the test specimen, the transverse loading hydraulic cylinder of the second set of three-degree-of-freedom motion mechanism is used to apply a horizontal loading force to achieve the strength test of the embedded parts by rigidly connecting the transverse loading hydraulic cylinder with the embedded parts.

[0042] Step S14: By installing a ball drop test mechanism on the transverse loading hydraulic cylinder, the ball drop test mechanism realizes the remote release and free fall impact of the ball through electromagnetic control, and in conjunction with a three-degree-of-freedom vibration table, the ball drop test is realized on the test specimen.

[0043] Step S2: The measurement and control system adopts a three-layer architecture of sensing-acquisition-control for the test items of static / dynamic loading, vibration and transient impact, high heel simulation, falling ball impact, and embedded part installation strength, so as to realize the closed-loop management of the whole process from test command issuance, synchronous acquisition of multiple physical quantities to accurate reproduction of complex loads.

[0044] Step S21: Distributed sensor layout for multiple testing needs;

[0045] Step S211: In the static load, dynamic load fatigue test and simulated high heel shoe test, high-precision spoke-type tensile and compressive sensors, i.e. loading seats, are installed on the bidirectional double-outlet hydraulic cylinder and the preset load-bearing point of the floor of the first set of three-degree-of-freedom motion mechanism, and strain gauge sensors are installed in the central loading area of ​​the test specimen to monitor the total load and local stress and strain in real time.

[0046] Step S212: A vertical sensor drive rail slider assembly is set up for sensor installation. A pull rope displacement sensor and a laser displacement sensor are installed on it. The pull rope displacement sensor measures the precise position of the preset point to facilitate the recording of the test point. The laser displacement sensor is used to measure the deflection change of the test specimen during the test.

[0047] Step S213: During vibration and transient shock tests, a triaxial accelerometer interface is set on the vibration table body, and a triaxial accelerometer interface is arranged on the surface of the test specimen to measure the input excitation and the dynamic response of the test specimen.

[0048] Step S214: In the installation strength test of the embedded parts, a tension and compression sensor and a linear displacement sensor built into the transverse loading hydraulic cylinder are installed at the end of the piston rod of the transverse loading hydraulic cylinder to measure the pull-out force, shear force and transverse deformation deflection data of the handrail connector.

[0049] Step S215: During the drop ball test, stress strain gauges and high-speed cameras are placed in the test area of ​​the test specimen to capture transient impact force and contact morphology.

[0050] Step S22: High-synchronization, multi-channel data acquisition;

[0051] Step S221: Configure a multi-channel data acquisition subsystem based on the NI-CompactDAQ (cDAQ-9188) modular acquisition platform in the measurement and control system. This subsystem integrates four NI-9215 signal input acquisition cards with 16-bit analog input modules and bridge input modules for high-precision acquisition of quasi-static force and pressure signals from hydraulic pressure sensors and load cells, as well as precise displacement signal acquisition from the displacement sensor integrated into the hydraulic cylinder. Simultaneously, the multi-channel data acquisition subsystem is configured with one NI-9230 acquisition card with 24-bit dynamic signal acquisition capabilities. The 24-bit dynamic signal acquisition module has three differential input channels and is specifically designed for acquiring vibration acceleration signals from load simulation mechanisms. The acquired vibration acceleration time-domain data is driven by NI-DAQmx and linked with LabVIEW software to perform real-time Fast Fourier Transform (FFT) and Power Spectral Density (PSD) calculations, ultimately generating an acceleration spectral density curve to achieve frequency domain analysis of the vibration characteristics of the hydraulic system. Furthermore, the acquisition module is synchronized with the hardware clock of the cDAQ-9188 chassis to ensure the accuracy of time-domain-frequency domain correlation analysis between vibration acceleration signals and pressure and displacement signals.

[0052] Step S222: The measurement and control system is equipped with a direct-connect industrial computer using an RS485 serial communication module based on the Modbus-RTU protocol. The direct-connect industrial computer is used for the acquisition and recording of displacement data from the draw-wire displacement sensor and the laser displacement sensor. The 4-20mA current signal from the draw-wire displacement sensor is converted from analog to digital by the RS485 acquisition module and then uploaded to the industrial computer via the Modbus-RTU protocol. The laser displacement sensor directly outputs millimeter-level high-precision displacement data via the RS485 interface using the Modbus-RTU protocol. The direct-connect industrial computer is equipped with a communication and data analysis program written in LabVIEW to realize real-time acquisition and time-series storage of displacement data.

[0053] Step S3: Layered intelligent control and integrated monitoring;

[0054] Step S31: The measurement and control system utilizes an NI-cDAQ-9188 Ethernet chassis to build an analog output unit. The NI-cDAQ-9188 Ethernet chassis contains two 16-bit analog voltage output modules from NI-9263. Five channels within the NI-cDAQ-9188 Ethernet chassis are connected to the servo valves of five independent hydraulic circuits: the first to third channels output ±10V adjustable analog voltage signals as vibration excitation control signals, driving the servo valves of the servo hydraulic cylinders to achieve three-degree-of-freedom vibration signal output from the three-degree-of-freedom vibration table; the fourth and fifth channels output 0-10V analog voltage signals as loading control signals, adjusting the loading force of the hydraulic system through the servo valves; the two NI-9263 modules achieve hardware synchronization through the built-in timing engine and data acquisition subsystem of the NI-cDAQ-9188 chassis, ensuring that the output vibration and loading control signals match the acquired acceleration and pressure feedback signals in sequence, ultimately achieving coordinated and precise control of the test bench's vibration excitation and loading conditions.

[0055] Step S32: The measurement and control system is configured with a 16-channel digital output relay module, which is directly connected to the industrial control computer via an RS485 serial port. This module is used for the on / off control of ten switching valves in the integrated hydraulic pump station and the directional control logic of two directional valves. The relay module has a built-in opto-isolation circuit to achieve electrical isolation between the low-voltage control signals of the industrial control computer and the high-voltage drive circuit of the integrated hydraulic pump station. The RS485 serial port is based on the Modbus-RTU protocol to achieve data interaction, with a transmission distance of up to 1200 meters and differential signal transmission characteristics. At the same time, the industrial control computer uses a hardware timed triggering mechanism module to synchronize the valve group control commands of the relay module with the signal acquisition and servo valve control commands of the NI acquisition platform. This enables precise matching between the valve group actions of the hydraulic station and the vibration excitation and loading control conditions of the three-degree-of-freedom vibration table, achieving integrated and coordinated operation of the test system.

[0056] The beneficial effects of this invention are as follows:

[0057] 1. This invention represents a leap from a "single-function device" to a "multi-functional integrated system," thereby solving the efficiency and realism issues in existing testing solutions. Through innovative mechanical architecture and control strategies, it is the first to deeply integrate a three-degree-of-freedom vibration table, a multi-axis servo loading system, and a dedicated impact device into a single unit. It is particularly noteworthy that mainstream commercial vibration tables are mostly limited to two-degree-of-freedom (XY axis) translation, while the three-degree-of-freedom vibration table (XYZ axis) integrated in this system can reproduce a more realistic multi-dimensional spatial vibration environment. This combination of multi-dimensional hardware integration and software collaborative control allows for continuous and collaborative completion of previously fragmented tests that required multiple sites, multiple devices, and multiple steps, all on a single platform. This not only significantly improves testing efficiency and site utilization, but more importantly, by simulating the spatiotemporal coupling of load, vibration, and impact, it provides composite flooring with a more rigorous and scientific evaluation method that closely approximates actual service conditions, filling the gap in comprehensive testing equipment in this field.

[0058] 2. This invention achieves modular integrated design. The system adopts a highly integrated modular structure, integrating functional modules such as specimen clamping, multi-directional vibration excitation, lateral / vertical hydraulic loading, and drop ball testing onto a single platform, realizing the consolidation and functional synergy of the hardware platform. Multi-project testing compatibility: Relying on the modular design, the system can perform various tests such as impact vibration, dynamic load fatigue, embedded part strength, load-bearing capacity, and drop ball testing on the same frame at different times, significantly improving the flexibility and efficiency of testing and enhancing the realism of the working condition simulation. Intelligent control and data management: The system integrates a measurement and control unit based on NI-DAQ, combined with the functional differentiation design of the hydraulic circuit: the high-frequency vibration circuit uses a high-frequency response valve to achieve dynamic excitation, and the high-precision loading circuit uses a closed-loop servo proportional valve to achieve precise force control, realizing accurate and programmable control and data acquisition for different test modes. Safety redundancy structure: The hydraulic system is equipped with multiple safety mechanisms such as relief valves, emergency stop, and overload protection, and is equipped with oil temperature and liquid level warnings; the oil circuit adopts an isolation valve design to avoid interference between circuits, improving the reliability and safety of system operation. Attached Figure Description

[0059] Figure 1 This is a schematic diagram of the overall structure of this embodiment.

[0060] Figure 2 This is a schematic diagram of the overall structure of the test execution system in this embodiment.

[0061] Figure 3 This is a schematic diagram of the support framework in this embodiment.

[0062] Figure 4 This is a schematic diagram of the three-degree-of-freedom vibration table in this embodiment.

[0063] Figure 5 This is a schematic diagram of the integrated hydraulic pump station in this embodiment.

[0064] Figure 6 This is a schematic diagram of the second set of three-degree-of-freedom motion mechanisms in this embodiment.

[0065] Figure 7 This is a schematic diagram showing the connection between the vibration table body and the servo hydraulic cylinder in this embodiment.

[0066] Figure 8 This is a schematic diagram of the vibration table surface in this embodiment.

[0067] Figure 9 This is a schematic diagram of the ball-dropping test mechanism in this embodiment.

[0068] Figure 10 This is a schematic diagram of the first three-degree-of-freedom motion mechanism in this embodiment.

[0069] Figure 11 This is a side view schematic diagram of the high-heeled shoe fixture in this embodiment.

[0070] Figure 12 This is a schematic diagram of the guide rail slider for mounting the rope displacement sensor in this embodiment.

[0071] Figure 13 This is a schematic diagram of the hydraulic control principle of the hydraulic powertrain in this embodiment.

[0072] Figure reference numerals: 1. Hydraulic power assembly; 2. Test execution system; 3. Measurement and control system; 4. Support frame; 5. Three-degree-of-freedom vibration table; 5. Vibration table body; 501. Servo hydraulic cylinder; 502. Hydraulic cylinder connecting hinge; 503. Vibration table surface; 6. Table body; 601. Guide column; 602. Hook clamp; 603. Height adjustment pin; 604. Sliding sleeve; 605. First set of three-degree-of-freedom motion mechanism; 7. First Y-axis linear guide; 701. First linear guide slider; 702. Loading seat; 703. First linear guide clamp; 704. First transverse support seat; 705. First guide column; 706. First X-axis linear guide; 707. First heavy-duty linear guide... 708, rail slider, 709, first positioning mounting plate, 710, double-acting hydraulic cylinder, 8, second set of three-degree-of-freedom motion mechanism, 801, second linear guide rail, 802, transverse loading hydraulic cylinder, 803, second linear guide rail clamp, 804, second transverse support seat, 805, second guide post, 806, second X-axis linear guide rail, 807, second heavy-duty linear guide rail slider, 808, second positioning mounting plate, 809, ball drop test mechanism, 9, integrated hydraulic pump station, 10, variable frequency motor, 11, hydraulic gear pump, 12, oil tank, 13, rail slider assembly, 14, rope displacement sensor, 15, laser displacement sensor. Detailed Implementation

[0073] Example 1

[0074] See Figures 1-13 As shown in the figure, this embodiment provides a multifunctional testing system for testing composite material floors of rail passenger vehicles, including: a hydraulic power assembly 1, a test execution system 2, and a measurement and control system 3; the hydraulic power assembly 1 is used to provide adjustable pressure and flow output for the test execution mechanism of the test execution system 2; the test execution system 2 integrates multiple load simulation mechanisms, which are used to install the test workpiece and carry out various performance tests; the measurement and control system 3 includes: a NI-DAQ-based sensor data acquisition and processing system, which is used to monitor and control the key parameters of pressure, flow, temperature, and displacement of the hydraulic power assembly 1 and the test execution system 2 in real time.

[0075] The test execution system 2 in this embodiment includes: a support frame 4, a three-degree-of-freedom (X, Y, Z) vibration table 5 installed inside the support frame 4 and located at the bottom, a vibration table surface 6 installed on the three-degree-of-freedom vibration table 5, a first set of three-degree-of-freedom motion mechanisms 7 installed on the support frame 4 and located above the vibration table surface 6, and a second set of three-degree-of-freedom motion mechanisms 8 installed on the support frame 4 and located above the first set of three-degree-of-freedom motion mechanisms 7. The three-degree-of-freedom vibration table 5 is used to perform random life vibration tests and triaxial random vibration tests on the test workpiece (composite phenolic flooring) fixed on the vibration table surface 6; the first set of three-degree-of-freedom motion mechanisms 7 is used for dynamic load fatigue tests, static load tests, and simulated high-heel shoe tests; the second set of three-degree-of-freedom motion mechanisms 8 is used for applying horizontal tensile force tests and falling ball tests.

[0076] The three-degree-of-freedom vibration table 5 includes: a vibration table body 501, and servo hydraulic cylinders 502 arranged on the vibration table body 501 along the X, Y, and Z directions. The servo hydraulic cylinders 502 in the X and Y directions are connected to the vibration table body 501 through a hinged connection structure. The vibration table body 501 is mounted on a base inside the support frame 4 via an upper row of X-axis slide rail sliders and a lower row of Y-axis slide rail sliders. The hinged connection structure includes a CLCD_32 type hydraulic cylinder connecting hinge seat 503, one end of which is fixedly connected to the vibration table body 501, and the other end is connected to a CGM1MT4_63_3 type hydraulic cylinder connecting hinge seat 503. The servo hydraulic cylinder 502 of model 6_64A2X_B14CKUTWW_XV_193 is hinged to the end of a fisheye bearing. The X-axis servo hydraulic cylinder 502 and the Y-axis servo hydraulic cylinder 502 are fixed to the support frame 4 through a trunnion support of model CLTB_32. The housing (flange seat) of the Z-axis servo hydraulic cylinder 502 is mounted on the vibration table body 501. The piston rod of the Z-axis servo hydraulic cylinder 502 is connected to the bottom of the vibration table surface 6. The vibration table body 501 drives the vibration table surface 6 to move through the servo hydraulic cylinders 502 arranged in the X, Y, and Z directions. The connection structure design of the three-degree-of-freedom vibration table 5 ensures that the torque output by the servo hydraulic cylinder 502 is effectively transmitted to the vibration table surface 6, ensuring the power transmission efficiency of the vibration test. On the other hand, it can enhance the overall structural stability of the test table and provide reliable structural support for long-period, multi-directional random vibration tests.

[0077] The vibration table surface 6 includes: a table body 601, two sets of four guide columns 602 located at the bottom of the table body 601, and sample fixtures for fixing composite phenolic flooring installed at the four corners of the upper surface of the table body 601. The sample fixtures include: BJ131-16050 type hook clamps 603 and HJPHAWM12-L50-D30-W26-F30 type height adjustment pins 604. The hook clamps 603 provide restraint from above the edge of the phenolic flooring, and the height adjustment pins... 604 provides support and positioning from below, and together they form stable and controllable overlapping fixing points around the sample, keeping the central area of ​​the sample in a hollow state. Two sets of guide columns 602 are slidably connected in the sliding sleeves 605 fixed on the vibration table body 501. The table body 601 is based on an effective table with a size of 1250mm×1250mm. Its table is equipped with a special sample tooling fixture for reliably fixing the composite phenolic flooring test sample, providing basic installation conditions for subsequent tests. The sample fixture allows for flexible adjustment of clamping position and height, ensuring stable and repeatable clamping of test samples of different sizes. The design of the sample fixture not only realistically replicates the "overlapping" form of the floor in actual installation, that is, the support is achieved through edge connectors and the force characteristics of the central area are unrestrained, but also provides an installation foundation that conforms to the actual boundary conditions for subsequent tests such as vibration, impact and concentrated load, thereby ensuring that the test results can accurately reflect the mechanical behavior and performance of the composite floor in the real service environment.

[0078] For the dynamic fatigue test, simulated high-heel shoe test, and static load test of composite phenolic flooring, all tests were performed using the first set of three-degree-of-freedom motion mechanism 7. Addressing the technical requirements of uncertain loading points on the test specimen (1000mm×1000mm composite phenolic flooring), the need to complete loading in multiple areas of the specimen, and the technical problem of the loading device's stability being easily affected by overturning moment during vertical loading, this device employs two sets of guide rail slider mechanisms in conjunction with auxiliary components to form a solution. Specific technical features are as follows:

[0079] The first three-degree-of-freedom motion mechanism 7 includes: two aluminum profiled first Y-axis linear guides 701 fixedly connected to the support frame 4 in parallel along the Y-axis; a QWW35CC1R1200Z0C type first linear guide slider 702 slidably connected to the first Y-axis linear guides 701; a first positioning pin installed at the slot of the first linear guide slider 702; and a first linear guide clamp 704 of model SVCK42 (knob type) fixedly connected to the first linear guide slider 702. The first linear guide clamp 704 is used to lock the first linear guide slider 702 at any position within the sliding stroke of the first Y-axis linear guide 701. The first linear guide clamp 704 adopts a C-type clamp and screw locking method. The two first linear guide sliders 702 are fixedly connected with parallel first transverse support seats 705 and first guide posts 706. The two first linear guide sliders 702 are used to drive the first transverse support seats 705. The linear guide rail 701 extends linearly along the first Y-axis. A first X-axis linear guide rail 707 is fixedly connected to the first transverse support 705. A first heavy-duty linear guide rail slider 708 (model EGW30CB1R1140Z0C) is slidably connected to the first X-axis linear guide rail 707. A first positioning mounting plate 709 is fixedly connected to the first heavy-duty linear guide rail slider 708. A first guide sleeve fixedly connected to the upper end of the first positioning mounting plate 709 is fitted onto the first guide post 706 and slidably connected to the first guide post 706. A bidirectional double-outlet hydraulic cylinder 710 is installed on the first positioning mounting plate 709. A loading seat 703 is fixedly connected to the piston rod extending from the bidirectional double-outlet hydraulic cylinder 710. The loading seat 703 is a vertical loading spoke-type tension and compression sensor. The first Y-axis linear guide rail 701 and the first linear guide rail slider 702, and the first X-axis linear guide rail 707 and the first heavy-duty linear guide rail slider 708 are all manually adjustable.

[0080] The second set of three-degree-of-freedom motion mechanism 8 includes: two second Y-direction linear guides 801 fixedly connected to the support frame 4 in parallel along the Y direction; a QWW35CC1R1200Z0C type second linear guide slider 802 slidably connected to the second Y-direction linear guides 801; a second positioning pin installed at the slot of the second linear guide slider 802; and a second linear guide clamp 804 of model SVCK42 (knob type) fixedly connected to the second linear guide slider 802. The second linear guide clamp 804 is used to lock the second linear guide slider 802 at any position within the sliding stroke of the second Y-direction linear guide 801. The second linear guide clamp 804 adopts a C-type clamp and screw locking method. Parallel second transverse support seats 805 and second guide posts 806 are fixedly connected to the two second linear guide sliders 802. The linear guide slider 802 is used to drive the second transverse support 805 to linearly displace along the extension direction of the second Y-direction linear guide 801. The second transverse support 805 is provided with a second X-direction linear guide 807 arranged along the X-direction. A second heavy-duty linear guide slider 808 of model EGW30CB1R1140Z0C is slidably connected to the second X-direction linear guide 807. A second positioning mounting plate 809 is fixedly connected to the second heavy-duty linear guide slider 808. A guide sleeve fixedly connected to the upper end of the second positioning mounting plate 809 is fitted onto the second guide post 806 and slidably connected to the second guide post 806. A transverse loading hydraulic cylinder 803 is installed on the second positioning mounting plate 809. The second Y-direction linear guide 801 and the second linear guide slider 802, and the second X-direction linear guide 807 and the second heavy-duty linear guide slider 808 are all adjusted by manual pushing control. To address the issue of overturning moment generated by the loading device under force during vertical loading, a second guide post 806 is added. The second guide post 806 is in sliding engagement with the loading device, which can effectively counteract the overturning moment and ensure the attitude stability of the loading device during vertical movement.

[0081] Through the orthogonal displacement adjustment of the two sets of guide rail slider mechanisms, combined with the auxiliary functions of positioning pins, linear guide rail clamps, and guide pillars, the loading device can achieve full-plane loading without dead angles on 1000mm×1000mm test specimens, and the adjustment accuracy and position fixation reliability of the loading points are both guaranteed.

[0082] In this embodiment, when conducting dynamic load fatigue tests and static load tests, the bidirectional double-rod hydraulic cylinder 710 can achieve precise force closed-loop loading control and quantitative loading control of displacement at the selected loading point.

[0083] In this embodiment, when conducting a simulated high-heeled shoe test, it is only necessary to assemble the simulated high-heeled shoe device at the actuator end of the bidirectional double-outlet hydraulic cylinder 710 using a rigid connection method to meet the performance index requirements of the test.

[0084] In this embodiment, the technical matching design of the loading force is as follows: the test sample is a composite phenolic flooring with a vertical handrail device mounted on its surface; the transverse loading hydraulic cylinder 803 of the second set of three-degree-of-freedom motion mechanism 8 is rigidly connected to the handrail device through a special connecting tool to apply a horizontal loading force. According to the test requirements, the handrail device needs to withstand a bending moment load of 1000 N·m. The vertical distance between the handrail installation position and the loading position of the test sample in the test bench is 1000 mm. According to the moment calculation formula M=F×L (where M is the bending moment, F is the horizontal loading force, and L is the vertical lever arm), only a horizontal loading force of 1000 N needs to be applied to the handrail device to meet the technical requirement of a bending moment load of 1000 N·m.

[0085] In this embodiment, the ball-dropping test mechanism 9 on the second set of three-degree-of-freedom motion mechanism 8 is specifically used for ball-dropping tests on composite phenolic flooring. The ball-dropping test mechanism 9 achieves remote release and free-fall impact of the ball through electromagnetic control to meet the performance requirements of the ball-dropping test. Its specific technical features and implementation logic are as follows:

[0086] (1). Selection and configuration of electromagnetic control components,

[0087] The ball drop test mechanism 9 is equipped with a custom-made 50mm ring electromagnet (outer diameter 50mm, inner diameter 16mm) as the actuating element for ball adsorption and release. It is also equipped with a signal receiving device of model KGS-B10-4. This signal receiving device is electrically connected to the ring electromagnet and is used to receive remote control signals and convert them into on / off commands for the electromagnet, so as to realize remote and precise control of ball release and avoid interference with test accuracy by manual operation.

[0088] (2). Assembly and fixing design of the mechanism,

[0089] The ball drop test mechanism 9 is assembled and connected with the second set of three-degree-of-freedom motion mechanism 8 through a non-standard customized ball drop device tooling: the ball drop test mechanism 9 serves as a transitional connection component, with one end fixedly connected to the annular electromagnet and signal receiving device, and the other end rigidly connected to the second positioning mounting plate 809, which can flexibly adjust the impact point of the ball drop as the second set of three-degree-of-freedom motion mechanism 8 moves.

[0090] (3) Matching design of falling ball test parameters,

[0091] During the design phase of the test bench, the installation benchmark of the drop ball test mechanism was determined through precise measurement: the vertical distance between the lowest point of the ball released by the annular electromagnet and the surface of the test sample (composite phenolic flooring) was 0.8m. This height design perfectly matches the required drop height of the ball in the test. During the test, an iron ball with a mass of 324g±5g and a diameter of 42.8mm±0.2mm was attracted by the annular electromagnet. After receiving the remote release signal, the electromagnet was de-energized, causing the iron ball to fall freely in the vertical direction and impact the surface of the test sample, thereby meeting the performance requirements of the drop ball test.

[0092] Through the above structural design, the ball drop test mechanism can realize remote automated control of ball release, and the falling height and impact point of the ball can be precisely adjusted to ensure that the test data of the ball drop test meets the standard requirements, while improving the convenience and safety of the test operation.

[0093] In this embodiment, the hydraulic power assembly 1 adopts the form of an integrated hydraulic pump station 10. The integrated hydraulic pump station 10 includes: a YVF2-160L-4-15-2-1 type variable frequency motor 11, an HGO-20-01R-VPC type hydraulic gear pump 12, an oil tank 13, a multi-stage pressure regulation system composed of a DBW10B-1-30B / 200G24NZ5L type electromagnetic relief valve and a ZDR6DP2-40 / 150YM type pressure reducing valve, an integrated valve block assembly, an RFB-100×10Y type return oil filter, and other core components. It is also equipped with oil temperature, oil pressure, and liquid level sensing and monitoring components. The variable frequency motor 11 controls the pump station flow through the hydraulic gear pump 12. The return oil filter is used to filter impurities in the oil circuit to ensure the cleanliness of the oil and maintain the stable operation of the system. The oil temperature, oil pressure, and liquid level sensing and monitoring components are used to provide real-time feedback on the operating parameters of the integrated hydraulic pump station. The hydraulic power assembly also includes: a multi-stage pressure regulation system used to control the load simulation mechanism to achieve precise step-wise adjustment of loading pressure and vibration load, thereby meeting the multi-condition simulation requirements of bearing pressure and fatigue load in the test. At the power regulation level, a multi-stage pressure regulation mechanism is built based on the DBW10B-1-30B / 200G24NZ5L electromagnetic relief valve and the ZDR6DP2-40 / 150YM pressure reducing valve. Combined with the control of the hydraulic actuator by the upper computer measurement and control system, precise step-wise adjustment of loading pressure and vibration load is achieved, thereby meeting the multi-condition simulation requirements of bearing pressure and fatigue load in the test.

[0094] The integrated valve block assembly controls the load simulation mechanism. The integrated valve block assembly integrates five parallel independent hydraulic circuits. The first and second independent hydraulic circuits are control loops for the servo hydraulic cylinders 502 in the X and Y directions. Each control loop is equipped with a 4WE6M60BCG24NZ5L type solenoid directional valve, which works in conjunction with a switching valve to avoid motion interference caused by the hinge connection of the servo hydraulic cylinders 502 in the X and Y directions, preventing operational hazards caused by circuit closure, and achieving motion control of the vibration table body 501 in the X and Y horizontal directions. The third… The first independent hydraulic circuit is the motion control circuit of the Z-direction servo hydraulic cylinder 502. The fourth and fifth independent hydraulic circuits are the motion control circuits of the bidirectional double-rod hydraulic cylinder 710 and the lateral loading hydraulic cylinder 803. The motion control circuit is equipped with a reversing valve. Switch valves are set at the oil inlet and oil return ports of each vibration circuit to realize the independent on / off of each vibration branch. The integrated valve block centrally manages the five oil circuits to achieve the coordinated operation of loading and vibration actions, accurately reproducing the load-bearing, vibration and impact stress state of the composite material floor in actual use.

[0095] Example 2

[0096] This embodiment provides a control method for a multifunctional test system for testing composite material flooring in rail passenger vehicles, including the following steps:

[0097] Step S1: Experimental process control,

[0098] Step S11: When conducting dynamic fatigue tests and static load tests, the first set of three-degree-of-freedom motion mechanism 7 drives the bidirectional double-outlet hydraulic cylinder 710 to achieve full-plane loading motion without dead angles. The bidirectional double-outlet hydraulic cylinder 710 achieves precise loading control of the force closed loop at the selected loading point. In conjunction with the three-degree-of-freedom vibration table, the dynamic fatigue test and static load test of the test specimen (composite phenolic floor) are realized.

[0099] Step S12: When conducting the simulated high heel test, the first set of three-degree-of-freedom motion mechanism 7 drives the bidirectional double-outlet hydraulic cylinder 710 to achieve full-plane loading motion without dead angles. The simulated high heel device is assembled by using a rigid connection at the actuator end of the bidirectional double-outlet hydraulic cylinder 710, and the simulated high heel test is realized on the test sample in conjunction with the three-degree-of-freedom vibration table.

[0100] Step S13: When conducting the installation test of the embedded parts of the test specimen, the transverse loading hydraulic cylinder 803 of the second set of three-degree-of-freedom motion mechanism 8 is used to apply a horizontal loading force to achieve the strength test of the embedded parts by rigidly connecting the transverse loading hydraulic cylinder 803 with the embedded parts.

[0101] Step S14: By installing the ball drop test mechanism 9 on the transverse loading hydraulic cylinder 803, the ball drop test mechanism 9 realizes the remote release and free fall impact of the ball through electromagnetic control, and together with the three-degree-of-freedom vibration table 5, the ball drop test is realized on the test specimen.

[0102] Step S2: Using the measurement and control system 3, a three-layer architecture of sensing-acquisition-control is adopted for the test items of static / dynamic loading, vibration and transient impact, high heel simulation, falling ball impact, and embedded part installation strength. This achieves closed-loop management of the entire process from issuing test commands and synchronously acquiring multiple physical quantities to accurately reproducing complex loads.

[0103] Step S21: Distributed sensor layout for multiple testing needs;

[0104] Step S211: In the static load, dynamic load fatigue test and simulated high heel shoe test, a high-precision wheel spoke type tension and compression sensor (DYLF-102 wheel spoke type), i.e. loading seat 703, is installed on the bidirectional double-outlet hydraulic cylinder 710 of the first set of three-degree-of-freedom motion mechanism 7 and the preset load point on the floor. Strain gauge type sensor is also installed in the center loading area of ​​the test specimen to monitor the total load and local stress and strain in real time.

[0105] Step S212: In order to record the deflection change of the test specimen during the loading process and the precise position of the test points, a vertical sensor drive rail slider assembly 14 dedicated to sensor installation is set up. A rope displacement sensor 15 with a range of 1m and a laser displacement sensor 16 of model PDL-50-485 are installed on it. The rope displacement sensor 16 measures the precise position of the preset point to facilitate the recording of the test points, and the laser displacement sensor 16 is used to measure the deflection change of the test specimen during the test.

[0106] Step S213: During vibration and transient shock tests, a triaxial accelerometer (BYDE30005) interface is set on the vibration table body 501, and a triaxial accelerometer interface is arranged on the surface of the test specimen to measure the input excitation and the dynamic response of the test specimen.

[0107] Step S214: During the installation strength test of the embedded parts, a tension and compression sensor from the Ocean series and a linear displacement sensor from the lateral loading hydraulic cylinder 803 are installed at the end of the piston rod of the lateral loading hydraulic cylinder 810 to measure the pull-out force, shear force and lateral deformation deflection data of the handrail connector.

[0108] Step S215: During the drop ball test, stress strain gauges and a high-speed camera (considered as an image sensor) are placed in the test area of ​​the test specimen to capture transient impact force and contact morphology.

[0109] Step S22: High-synchronization, multi-channel data acquisition;

[0110] Step S221: To address the need for high-synchronization acquisition of slow-changing quasi-static signals such as pressure and laser displacement, as well as high-speed switching signals such as valve group feedback and sensor status in the hydraulic powertrain, a multi-channel data acquisition subsystem based on the NI-CompactDAQ (cDAQ-9188) modular acquisition platform is configured in the measurement and control system 3. This multi-channel data acquisition subsystem integrates four NI-9215 signal input acquisition cards with 16-bit analog input modules and bridge input modules. It is used for high-precision acquisition of quasi-static force and pressure signals from hydraulic pressure sensors and load cells, as well as for accurate displacement signal acquisition from the displacement sensors integrated into the hydraulic cylinders. Simultaneously, the multi-channel... The data acquisition subsystem is equipped with a 24-bit dynamic signal acquisition module of an NI-9230 acquisition card. The 24-bit dynamic signal acquisition module has 3 differential input channels and is specifically used for the acquisition of vibration acceleration signals of the load simulation mechanism. The acquired vibration acceleration time-domain data is linked with LabVIEW software through NI-DAQmx driver to perform fast Fourier transform (FFT) and power spectral density (PSD) calculation in real time, and finally generate acceleration spectral density curve to realize frequency domain analysis of the vibration characteristics of hydraulic system. The acquisition module is synchronized with the hardware clock of cDAQ-9188 chassis to ensure the accuracy of time-domain-frequency domain correlation analysis of vibration acceleration signal and pressure and displacement signals.

[0111] Step S222: The measurement and control system 3 is equipped with an RS485 serial communication module (industrial-grade RS485 to USB converter) based on the Modbus-RTU protocol, which is directly connected to an industrial control computer. The industrial control computer is used for the acquisition and recording of displacement data from the draw-wire displacement sensor (analog output type) and the laser displacement sensor. The 4-20mA current signal of the draw-wire displacement sensor is converted from analog to digital by the RS485 acquisition module and then uploaded to the industrial control computer via the Modbus-RTU protocol. The laser displacement sensor directly outputs millimeter-level high-precision displacement data via the RS485 interface using the Modbus-RTU protocol. The industrial control computer is equipped with a communication and data analysis program written in LabVIEW to realize real-time acquisition and time-series storage of displacement data.

[0112] Step S3: Layered intelligent control and integrated monitoring;

[0113] Step S31: To achieve precise timing control of actuators such as solenoid directional valves, switching valves, and hydraulic station motors in the hydraulic system, the measurement and control system 3 utilizes an NI-cDAQ-9188 Ethernet chassis to build an analog output unit. The NI-cDAQ-9188 Ethernet chassis is equipped with two NI-9263 16-bit analog voltage output modules (each module contains 8 output channels). Five channels are selected from the NI-cDAQ-9188 Ethernet chassis and connected to the servo valves of five independent hydraulic circuits. The first to third channels output ±10V adjustable analog voltage signals. The first channel, acting as the vibration excitation control signal, drives the servo valve of the servo hydraulic cylinder to achieve the three-degree-of-freedom vibration signal output of the three-degree-of-freedom vibration table; the fourth and fifth channels output 0-10V analog voltage signals as loading control signals, which adjust the loading force of the hydraulic system through the servo valve; the two NI-9263 modules achieve hardware synchronization with the data acquisition subsystem through the built-in timing engine of the NI-cDAQ-9188 chassis, ensuring that the output vibration and loading control signals match the timing of the acquired acceleration and pressure feedback signals, and finally completes the coordinated and precise control of the vibration excitation and loading conditions of the test bench.

[0114] Step S32: The measurement and control system 3 is configured with a 16-channel digital output (16DO) relay module, which is directly connected to the industrial control computer via an RS485 serial port. This module is used for the on / off control of ten switching valves in the integrated hydraulic pump station and the directional control logic of two reversing valves. The relay module has a built-in opto-isolation circuit to achieve electrical isolation between the industrial control computer's low-voltage control signals (5VTTL) and the integrated hydraulic pump station's high-voltage drive circuit (24VDC). This effectively blocks the reverse impact of high-voltage surges and voltage spikes on the industrial control computer, significantly improving the anti-interference capability and operational stability of the control system. The 16 output channels fully cover the ten switching valves (such as oil circuit on / off valves and hydraulic pump start / stop control valves) and two... The control requirements of directional valves (such as oil circuit direction switching valves) can be met by centrally managing the hydraulic station valve group without additional expansion modules, simplifying the system hardware architecture. The RS485 serial port, based on the Modbus-RTU protocol, enables data interaction with a transmission distance of up to 1200 meters and has differential signal transmission characteristics, making it suitable for long-distance cabling and strong electromagnetic interference environments in industrial sites. At the same time, the industrial control computer synchronizes the valve group control commands of the relay module with the signal acquisition and servo valve control commands of the NI acquisition platform through a hardware timed triggering mechanism module, realizing precise matching between the hydraulic station valve group actions and the vibration excitation and loading control conditions of the three-degree-of-freedom vibration table, and achieving integrated and coordinated operation of the test system.

[0115] The system's host computer uses LabVIEW software to develop a human-computer interaction interface, integrating a multi-dimensional real-time data display module (collected data such as vibration acceleration, displacement, and pressure), a parameter configuration unit (sampling rate, servo valve control threshold, valve group action sequence), a manual / automatic control switching interface (servo valve output, on / off valve), and embedding data analysis visualization components (acceleration spectral density curve, displacement trend graph) and data storage and export functions. The interface has a simple and intuitive layered layout, supporting real-time monitoring of the experimental process and historical data traceability.

[0116] The system's host computer settings are as follows:

[0117] (1) Safety protection devices,

[0118] The system integrates a multi-level safety protection mechanism: the main oil circuit is equipped with a pilot-operated relief valve to limit the maximum working pressure of the system; the electrical control box panel is equipped with a one-button emergency stop button, which can instantly cut off the power in case of abnormality; the motor and pump power circuit are equipped with overload protection relays to realize automatic power cut-off when the current exceeds the limit, forming a dual electrical-hydraulic protection.

[0119] (2) Oil temperature control and cooling system,

[0120] The hydraulic oil tank has a built-in PT100 temperature sensor to monitor the oil temperature in real time. When the oil temperature exceeds the set threshold, the air-cooled oil cooler automatically starts, using forced convection to lower the oil temperature, ensuring the hydraulic system is within a suitable operating temperature range and protecting oil performance and component lifespan.

[0121] (3) Leakage and contamination prevention and control system,

[0122] Pipeline connections widely employ O-ring face seals and 24° cone seal structures, with high-quality Step seals and Glyd rings selected for key dynamic sealing components. The oil tank features a fully enclosed structure, with air filters and high-pressure oil filters at the inlet and outlet ports to effectively isolate external impurities and control system contamination levels.

[0123] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A multifunctional testing system for testing composite material flooring in rail passenger vehicles, characterized in that, include: Hydraulic powertrain, test execution system, measurement and control system; The hydraulic power assembly is used to provide adjustable pressure and flow output for the test execution mechanism of the test execution system; The test execution system integrates multiple load simulation mechanisms for mounting the test workpiece and conducting performance tests; The measurement and control system includes a sensor data acquisition and processing system, which is used to monitor and control key parameters such as pressure, flow rate, temperature, and displacement of the hydraulic powertrain and test execution system in real time.

2. The multifunctional testing system for testing composite material floors of rail passenger vehicles according to claim 1, characterized in that, The test execution system includes: a support frame, a three-degree-of-freedom vibration table installed within the support frame and located at the bottom, a vibration table surface installed on the three-degree-of-freedom vibration table, a first set of three-degree-of-freedom motion mechanisms installed on the support frame and located above the vibration table surface, and a second set of three-degree-of-freedom motion mechanisms installed on the support frame and located above the first set of three-degree-of-freedom motion mechanisms. The three-degree-of-freedom vibration table is used to perform random life vibration tests and triaxial random vibration tests on a test workpiece fixed on the vibration table surface. The first set of three-degree-of-freedom motion mechanisms is used for dynamic load fatigue tests, static load tests, and simulated high-heel shoe tests. The second set of three-degree-of-freedom motion mechanisms is used for applying horizontal tensile force tests and falling ball tests.

3. The multifunctional testing system for testing composite material floors of rail passenger vehicles according to claim 1, characterized in that, The three-degree-of-freedom vibration table includes: a vibration table body and servo hydraulic cylinders arranged on the vibration table body along the XYZ directions. The servo hydraulic cylinders in the XY directions are connected to the vibration table body through a hinged connection structure. The hinged connection structure includes a hydraulic cylinder connecting hinge seat, one end of which is fixedly connected to the vibration table body, and the other end is hinged to a fisheye bearing at the end of the servo hydraulic cylinder. The servo hydraulic cylinders in the X and Y directions are fixedly connected to the support frame through trunnion supports. The housing of the servo hydraulic cylinder in the Z direction is mounted on the vibration table body, and the piston rod of the servo hydraulic cylinder in the Z direction is connected to the bottom of the vibration table surface. The vibration table body drives the vibration table surface to move through the servo hydraulic cylinders arranged in the XYZ directions.

4. The multifunctional testing system for testing composite material floors of rail passenger vehicles according to claim 2, characterized in that, The vibration table includes: a table body and two sets of guide columns located at the bottom of the table body. Sample fixtures for fixing phenolic flooring are installed at the four corners of the upper surface of the table body. The sample fixtures include: hook clamps and height adjustment pins. The hook clamps constrain the phenolic flooring from above the edge, while the height adjustment pins provide support and positioning from below. Together, they form stable and controllable overlapping fixing points around the sample, keeping the central area of ​​the sample in a hollow state. The two sets of guide columns are slidably connected in the sliding sleeves fixed to the vibration table body.

5. A multifunctional testing system for testing composite material floors of rail passenger vehicles according to claim 2, characterized in that, The first three-degree-of-freedom motion mechanism includes: two first Y-axis linear guides parallel to each other on a support frame along the Y-axis; a first linear guide slider slidably connected to the first Y-axis linear guides; a first positioning pin installed at the slot of the first linear guide slider; and a first linear guide clamp fixed to the first linear guide slider. The first linear guide clamp is used to lock the first linear guide slider at any position within its sliding stroke on the first Y-axis linear guide. Parallel first transverse support seats and first guide posts are fixed to the two first linear guide sliders. The two first linear guide sliders are used to drive the first transverse support seats along the first Y-axis linear guides. The linear displacement in the extension direction is as follows: a first X-direction linear guide rail is provided on the first transverse support seat along the X direction; a first heavy-duty linear guide rail slider is slidably connected to the first X-direction linear guide rail; a first positioning mounting plate is fixedly connected to the first heavy-duty linear guide rail slider; a first guide sleeve fixedly connected to the upper end of the first positioning mounting plate is fitted onto a first guide post and slidably connected to the first guide post; a bidirectional double-outlet hydraulic cylinder is mounted on the first positioning mounting plate; a loading seat is fixedly connected to the piston rod extending from the bidirectional double-outlet hydraulic cylinder; the first Y-direction linear guide rail and the first linear guide rail slider, as well as the first X-direction linear guide rail and the first heavy-duty linear guide rail slider, are all adjusted by manual pushing control.

6. A multifunctional testing system for testing composite material floors of rail passenger vehicles according to claim 2, characterized in that, The second three-degree-of-freedom motion mechanism includes: two second Y-axis linear guides parallel to each other on the support frame along the Y-axis; a second linear guide slider slidably connected to the second Y-axis linear guides; a second positioning pin installed at the slot of the second linear guide slider; and a second linear guide clamp fixed to the second linear guide slider. The second linear guide clamp is used to lock the second linear guide slider at any position within the sliding stroke of the second linear guide on the second Y-axis linear guide. Parallel second transverse support seats and second guide posts are fixed to the two second linear guide sliders. The two second linear guide sliders are used to drive the second transverse... The support base moves linearly along the extension direction of the second Y-axis linear guide. The second transverse support base is provided with a second X-axis linear guide along the X-axis. A second heavy-duty linear guide slider is slidably connected to the second X-axis linear guide. A second positioning mounting plate is fixedly connected to the second heavy-duty linear guide slider. A guide sleeve fixedly connected to the upper end of the second positioning mounting plate is fitted onto the second guide post and slidably connected to the second guide post. A transverse loading hydraulic cylinder is installed on the second positioning mounting plate. The second Y-axis linear guide and the second linear guide slider, as well as the second X-axis linear guide and the second heavy-duty linear slider, are all adjusted by manual pushing control.

7. A multifunctional testing system for testing composite material floors of rail passenger vehicles according to claim 1, characterized in that, The hydraulic powertrain adopts an integrated hydraulic pump station, which includes: a variable frequency motor, a hydraulic gear pump, an oil tank, a return oil filter, and oil temperature, oil pressure, and liquid level sensing and monitoring components. The variable frequency motor controls the pump station flow rate through the hydraulic gear pump, the return oil filter is used to filter impurities in the oil circuit, and the oil temperature, oil pressure, and liquid level sensing and monitoring components are used to provide real-time feedback on the operating parameters of the integrated hydraulic pump station.

8. A multifunctional testing system for testing composite material floors of rail passenger vehicles according to claim 7, characterized in that, The hydraulic powertrain also includes a multi-stage pressure regulation system consisting of an electromagnetic relief valve and a pressure reducing valve. The multi-stage pressure regulation system is used to control the load simulation mechanism to achieve precise step-wise adjustment of the loading pressure and vibration load.

9. A multifunctional testing system for testing composite material floors of rail passenger vehicles according to claim 7, characterized in that, The integrated hydraulic pump station also includes an integrated valve block assembly for controlling the load simulation mechanism. This assembly integrates five parallel independent hydraulic circuits. The first and second independent hydraulic circuits are control loops for servo hydraulic cylinders in the X and Y directions. These control loops are equipped with electromagnetic directional valves that work in conjunction with switching valves to prevent interference caused by hinged connections in the X and Y directions, thus preventing operational hazards caused by circuit closure and enabling control of the vibration table's horizontal X and Y directions. The third independent hydraulic circuit is the motion control loop for the servo hydraulic cylinder in the Z direction. The fourth and fifth independent hydraulic circuits are motion control loops for bidirectional double-rod hydraulic cylinders and lateral loading hydraulic cylinders. Each motion control loop is equipped with a directional valve, and switching valves are installed at the inlet and outlet of each vibration circuit to achieve independent on / off control of each vibration branch. The integrated valve block centrally manages the five hydraulic circuits, achieving coordinated loading and vibration actions and accurately replicating the load-bearing, vibration, and impact stress states experienced by the composite material floor during actual use.

10. The control method of a multifunctional test system for testing composite material flooring of rail passenger vehicles according to claim 7, characterized in that, Includes the following steps: Step S1: Experimental process control, Step S11: When conducting dynamic fatigue tests and static load tests, the first set of three-degree-of-freedom motion mechanism is used to drive the bidirectional double-outlet hydraulic cylinder to achieve full-plane loading motion without dead angles. The bidirectional double-outlet hydraulic cylinder achieves precise loading control of the force closed loop at the selected loading point. In conjunction with the three-degree-of-freedom vibration table, the dynamic fatigue test and static load test of the test specimen (composite phenolic floor) are realized. Step S12: When conducting the simulated high heel test, the first set of three-degree-of-freedom motion mechanism drives the bidirectional double-outlet hydraulic cylinder to achieve full-plane loading motion without dead angles. The simulated high heel device is assembled by rigidly connecting the actuator end of the bidirectional double-outlet hydraulic cylinder, and the three-degree-of-freedom vibration table is used to simulate the high heel test on the test specimen. Step S13: When conducting the installation test of the embedded parts of the test specimen, the transverse loading hydraulic cylinder of the second set of three-degree-of-freedom motion mechanism is used to apply a horizontal loading force to achieve the strength test of the embedded parts by rigidly connecting the transverse loading hydraulic cylinder with the embedded parts. Step S14: By installing a ball drop test mechanism on the transverse loading hydraulic cylinder, the ball drop test mechanism realizes the remote release and free fall impact of the ball through electromagnetic control, and in conjunction with a three-degree-of-freedom vibration table, the ball drop test is realized on the test specimen. Step S2: The measurement and control system adopts a three-layer architecture of sensing-acquisition-control for the test items of static / dynamic loading, vibration and transient impact, high heel simulation, falling ball impact, and embedded part installation strength, so as to realize the closed-loop management of the whole process from test command issuance, synchronous acquisition of multiple physical quantities to accurate reproduction of complex loads. Step S21: Distributed sensor layout for multiple testing needs; Step S211: In the static load, dynamic load fatigue test and simulated high heel shoe test, high-precision spoke-type tensile and compressive sensors, i.e. loading seats, are installed on the bidirectional double-outlet hydraulic cylinder and the preset load-bearing point of the floor of the first set of three-degree-of-freedom motion mechanism, and strain gauge sensors are installed in the central loading area of ​​the test specimen to monitor the total load and local stress and strain in real time. Step S212: A vertical sensor drive rail slider assembly is set up for sensor installation. A pull rope displacement sensor and a laser displacement sensor are installed on it. The pull rope displacement sensor measures the precise position of the preset point to facilitate the recording of the test point. The laser displacement sensor is used to measure the deflection change of the test specimen during the test. Step S213: During vibration and transient shock tests, a triaxial accelerometer interface is set on the vibration table body, and a triaxial accelerometer interface is arranged on the surface of the test specimen to measure the input excitation and the dynamic response of the test specimen. Step S214: In the installation strength test of the embedded parts, a tension and compression sensor and a linear displacement sensor built into the transverse loading hydraulic cylinder are installed at the end of the piston rod of the transverse loading hydraulic cylinder to measure the pull-out force, shear force and transverse deformation deflection data of the handrail connector. Step S215: During the drop ball test, stress strain gauges and high-speed cameras are placed in the test area of ​​the test specimen to capture transient impact force and contact morphology. Step S22: High-synchronization, multi-channel data acquisition; Step S221: Configure a multi-channel data acquisition subsystem based on the NI-CompactDAQ (cDAQ-9188) modular acquisition platform in the measurement and control system. This subsystem integrates four NI-9215 signal input acquisition cards with 16-bit analog input modules and bridge input modules for high-precision acquisition of quasi-static force and pressure signals from hydraulic pressure sensors and load cells, as well as precise displacement signal acquisition from the displacement sensor integrated into the hydraulic cylinder. Simultaneously, the multi-channel data acquisition subsystem is configured with one NI-9230 acquisition card with 24-bit dynamic signal acquisition capabilities. The 24-bit dynamic signal acquisition module has three differential input channels and is specifically designed for acquiring vibration acceleration signals from load simulation mechanisms. The acquired vibration acceleration time-domain data is driven by NI-DAQmx and linked with LabVIEW software to perform real-time Fast Fourier Transform (FFT) and Power Spectral Density (PSD) calculations, ultimately generating an acceleration spectral density curve to achieve frequency domain analysis of the vibration characteristics of the hydraulic system. Furthermore, the acquisition module is synchronized with the hardware clock of the cDAQ-9188 chassis to ensure the accuracy of time-domain-frequency domain correlation analysis between vibration acceleration signals and pressure and displacement signals. Step S222: The measurement and control system is equipped with a direct-connect industrial computer using an RS485 serial communication module based on the Modbus-RTU protocol. The direct-connect industrial computer is used for the acquisition and recording of displacement data from the draw-wire displacement sensor and the laser displacement sensor. The 4-20mA current signal from the draw-wire displacement sensor is converted from analog to digital by the RS485 acquisition module and then uploaded to the industrial computer via the Modbus-RTU protocol. The laser displacement sensor directly outputs millimeter-level high-precision displacement data via the RS485 interface using the Modbus-RTU protocol. The direct-connect industrial computer is equipped with a communication and data analysis program written in LabVIEW to realize real-time acquisition and time-series storage of displacement data. Step S3: Layered intelligent control and integrated monitoring; Step S31: The measurement and control system utilizes an NI-cDAQ-9188 Ethernet chassis to build an analog output unit. The NI-cDAQ-9188 Ethernet chassis contains two 16-bit analog voltage output modules from NI-9263. Five channels within the NI-cDAQ-9188 Ethernet chassis are connected to the servo valves of five independent hydraulic circuits: the first to third channels output ±10V adjustable analog voltage signals as vibration excitation control signals, driving the servo valves of the servo hydraulic cylinders to achieve three-degree-of-freedom vibration signal output from the three-degree-of-freedom vibration table; the fourth and fifth channels output 0-10V analog voltage signals as loading control signals, adjusting the loading force of the hydraulic system through the servo valves; the two NI-9263 modules achieve hardware synchronization through the built-in timing engine and data acquisition subsystem of the NI-cDAQ-9188 chassis, ensuring that the output vibration and loading control signals match the acquired acceleration and pressure feedback signals in sequence, ultimately achieving coordinated and precise control of the test bench's vibration excitation and loading conditions. Step S32: The measurement and control system is configured with a 16-channel digital output relay module, which is directly connected to the industrial control computer via an RS485 serial port. This module is used for the on / off control of ten switching valves in the integrated hydraulic pump station and the directional control logic of two directional valves. The relay module has a built-in opto-isolation circuit to achieve electrical isolation between the low-voltage control signals of the industrial control computer and the high-voltage drive circuit of the integrated hydraulic pump station. The RS485 serial port is based on the Modbus-RTU protocol to achieve data interaction, with a transmission distance of up to 1200 meters and differential signal transmission characteristics. At the same time, the industrial control computer uses a hardware timed triggering mechanism module to synchronize the valve group control commands of the relay module with the signal acquisition and servo valve control commands of the NI acquisition platform. This enables precise matching between the valve group actions of the hydraulic station and the vibration excitation and loading control conditions of the three-degree-of-freedom vibration table, achieving integrated and coordinated operation of the test system.

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