Integrated brake device without internal piping system and air cylinder maintenance

Abstract

The invention relates to the technical field of railway vehicle brake systems, aims to solve the problems that an existing integrated brake device is insufficient in piping connection integration degree, poor in sealing performance, high in piping strength, large in number of parts and large in weight, and provides an integrated brake device without an internal piping system and free of air cylinder maintenance, which comprises a middle body and a maintenance-free air cylinder. A cavity and a gas path are arranged in the middle body, and the maintenance-free air cylinder is communicated with the corresponding gas path; the maintenance-free air cylinder is directly connected in a sealed mode and fixedly connected to the middle body, or the maintenance-free air cylinder and the middle body are of an integrated casting forming structure; the intermediate is provided with an external test maintenance interface; according to the integrated brake device, a piping-system-free and maintenance-free air cylinder integrated design is adopted, a piping system between an existing air cylinder and a middle body is omitted, and a direct sealing and fixed connection or integrated casting forming structure is adopted, so that the sealing performance of the integrated brake device is improved, meanwhile, piping system suffocation is eradicated, the number of parts and the overall weight of the device are reduced, and the integration degree of the device is improved.

Description

Technical Field

[0001] This invention relates to the field of rail vehicle braking system technology, and more specifically, to an integrated braking device without internal piping and maintenance-free air cylinder. Background Technology

[0002] With the increasing demands for integrated braking systems in rail vehicles, integrated braking devices for rail vehicles have emerged. These devices use pipe connection components to connect the air cylinder to the intermediate body. However, this pipe connection method suffers from insufficient integration and poor sealing, failing to reduce the overall number of leakage points in the braking system. Furthermore, it also has problems such as pipe congestion, numerous components, heavy weight, and the need for regular replacement and maintenance of the sealing rings of the pipe connection components. Summary of the Invention

[0003] The present invention aims to provide an integrated braking device without internal piping and maintenance-free air cylinder, in order to solve the problems of insufficient integration of piping connections, poor sealing performance, piping congestion, numerous parts, and heavy weight in existing integrated braking devices.

[0004] This invention is achieved using the following technical solution: The present invention provides an integrated braking device without internal piping and maintenance-free air cylinder, comprising an intermediate body and a maintenance-free air cylinder. The intermediate body has a chamber and an air passage inside, and the maintenance-free air cylinder is connected to the corresponding air passage. The maintenance-free air cylinder is directly and sealed to the intermediate body, and the maintenance-free air cylinder is fixedly connected to the intermediate body; or, the maintenance-free air cylinder and the intermediate body adopt an integral casting structure. The intermediate is equipped with an external testing and maintenance interface.

[0005] Among them, "gas path" refers to gas pipeline.

[0006] The integrated braking device of this invention adopts an integrated design of a pipeless, maintenance-free air cylinder, eliminating the pipe connection between the air cylinder and the intermediate body in the prior art. The maintenance-free air cylinder is directly and sealed to the intermediate body and fixedly connected to it. Alternatively, the maintenance-free air cylinder and the intermediate body adopt an integral casting structure, forming a single unit for complete sealing. This design improves the sealing performance of the integrated braking device. Because the pipe connection is eliminated, problems such as pipe congestion, the need for regular replacement and maintenance of sealing rings in pipe connection components, and poor sealing performance of pipe connections are eliminated, effectively improving the overall sealing performance. It fundamentally reduces leakage points, facilitating troubleshooting and maintenance. Simultaneously, it reduces the number of parts in the integrated braking device, lightens the overall weight, and improves the integration level. The maintenance-free air cylinder itself in the integrated braking device of this invention has no external interface, eliminating the need for regular maintenance of pipe connection interfaces and drain outlets as required by existing air cylinders.

[0007] As a preferred technical solution: When the maintenance-free air cylinder is fixedly connected to the intermediate body, the maintenance-free air cylinder is welded to one side of the intermediate body.

[0008] As a preferred technical solution: A cylinder mounting base is provided on one side of the intermediate body. The cylinder mounting base and the intermediate body are an integral structure. The maintenance-free cylinder is welded to the cylinder mounting base.

[0009] As a preferred technical solution: The external testing and maintenance interface is equipped with a detachable maintenance plug.

[0010] As a preferred technical solution: The outer side of the intermediate body is provided with multiple brake valves, and the interior of the intermediate body is provided with multiple chambers and multiple air passages; Part of the brake valve is connected to the intermediate body, and the brake valve is connected to the corresponding chamber and the air passage inside the intermediate body; Some of the brake valves are connected and communicate with their corresponding brake valves.

[0011] As a preferred technical solution: The intermediate body is connected to a bent pipe for external connection. One end of the bent pipe is connected to the intermediate body, and the other end of the bent pipe serves as a brake cylinder interface. Part of the brake valve is connected to the bend in the intermediate body via the corresponding air passage.

[0012] As a preferred technical solution: The bent pipe is connected to the intermediate body by bolts, and a sealing gasket is provided between the bent pipe and the intermediate body.

[0013] As a preferred technical solution: A dust collector is connected to the outside of the intermediate body, and the dust collector is connected to the corresponding air passage. One end of the dust collector is connected to the intermediate body, and the other end of the dust collector serves as a train pipe interface.

[0014] As a preferred technical solution: The intermediate body is provided with an external air passage interface.

[0015] As a preferred technical solution: The external air circuit interface includes a weighing mechanism interface, which is disposed on the intermediate body.

[0016] As a preferred technical solution: The intermediate body is provided with a pedestal mounting base and a hanging mounting base, and the pedestal mounting base and the hanging mounting base are integral with the intermediate body.

[0017] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are: 1. The integrated braking device of the present invention adopts an integrated design of a pipeless, maintenance-free air cylinder, eliminating the pipe connection between the air cylinder and the intermediate body in the prior art. The maintenance-free air cylinder is directly and sealed to the intermediate body, and the maintenance-free air cylinder is fixedly connected to the intermediate body (e.g., by welding). Alternatively, the maintenance-free air cylinder and the intermediate body adopt an integral casting structure, making them a single unit and achieving complete sealing. This design improves the sealing performance of the integrated braking device. Since the pipe connection is eliminated, problems such as pipe congestion, the need for regular replacement and maintenance of the sealing rings of pipe connection components, and poor sealing performance of pipe connections are eliminated, effectively improving the overall sealing performance. It fundamentally reduces leakage points, facilitating fault diagnosis and maintenance. At the same time, it reduces the number of parts in the integrated braking device, lightens the total weight of the integrated braking device, and improves the integration level of the integrated braking device.

[0018] 2. The integrated braking device of the present invention has external interfaces (external test and maintenance interface and external air circuit interface) on the intermediate body, while the maintenance-free air cylinder has no external interface, so it does not require regular maintenance of the pipe connection interface and drain outlet as in the existing air cylinder. Attached Figure Description

[0019] Figure 1 This is a front view of the integrated braking device of the present invention, which has no internal piping and requires no air cylinder maintenance.

[0020] Figure 2 This is a schematic diagram of the rear of the integrated braking device of the present invention, which is free of internal piping and requires no air cylinder maintenance.

[0021] Icons: 1: Brake valve one, 2: Brake valve two, 3: Brake valve three, 4: Brake valve four, 5: Maintenance-free air cylinder, 6: Bend, 7: Intermediate body, 8: Dust collector, 9: Inspection plug, 10: Brake cylinder interface, 11: Train pipe interface, 12: Weighing mechanism interface. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] Example 1 like Figure 1 and Figure 2 As shown, this embodiment proposes an integrated braking device without internal piping and maintenance-free air cylinder, including an intermediate body 7 and a maintenance-free air cylinder 5. The intermediate body 7 has a chamber and an air passage inside, and the maintenance-free air cylinder 5 is connected to its corresponding air passage. The maintenance-free air cylinder 5 is directly and sealed to the intermediate body 7, and the maintenance-free air cylinder 5 is fixedly connected to the intermediate body 7; or, the maintenance-free air cylinder 5 and the intermediate body 7 adopt an integral casting structure. The intermediate body 7 is provided with an external testing and maintenance interface, which is used to install a rapid testing and maintenance device. The rapid testing and maintenance device can be used to quickly test and maintain the intermediate body 7 or the air cylinder. The maintenance-free air cylinder 5 itself has no external interface.

[0024] The integrated braking device of this invention adopts an integrated design of a pipeless, maintenance-free air cylinder 5, eliminating the pipe connection between the air cylinder and the intermediate body in the prior art. The maintenance-free air cylinder 5 is directly and sealed to the intermediate body 7, and the maintenance-free air cylinder 5 and the intermediate body 7 are fixedly connected. Alternatively, the maintenance-free air cylinder 5 and the intermediate body 7 adopt an integral casting structure, forming a single unit for complete sealing. This design improves the sealing performance of the integrated braking device. Because the pipe connection is eliminated, problems such as pipe congestion, the need for regular replacement and maintenance of sealing rings in pipe connection components, and poor sealing performance of pipe connections are eliminated, effectively improving the overall sealing performance. It fundamentally reduces leakage points, facilitating fault diagnosis and maintenance. Simultaneously, it reduces the number of parts in the integrated braking device, lightens the overall weight of the integrated braking device, and improves the integration level. The maintenance-free air cylinder 5 in the integrated braking device of this invention has no external interface, eliminating the need for regular maintenance of pipe connection interfaces and drain outlets as required by existing air cylinders. The integrated braking device of this invention can be used in rail vehicles.

[0025] Preferably, the external air circuit interface includes a weighing mechanism interface 12, which is disposed on the intermediate body 7. The weighing mechanism interface 12 is used to connect to the output port of the weighing mechanism to realize the diversion of brake cylinder pressure when the vehicle is empty.

[0026] The integrated braking device of the present invention has an external interface (the external test and maintenance interface and the external air circuit interface) on the intermediate body 7, while the maintenance-free air cylinder 5 has no external interface, so it does not require regular maintenance of the pipe connection interface and drain outlet as in existing air cylinders.

[0027] Preferably, a maintenance plug 9 is detachably installed at the external test and maintenance interface. The external test and maintenance interface is used to install a rapid testing and maintenance device. The rapid testing and maintenance device is an existing product. The rapid testing and maintenance device can be used to quickly test and maintain the intermediate body 7 or the air cylinder. When the air cylinder or the intermediate body 7 is not tested and maintained, the external test and maintenance interface is blocked by the maintenance plug 9.

[0028] Preferably, when the maintenance-free air cylinder 5 is fixedly connected to the intermediate body 7, the maintenance-free air cylinder 5 is welded to one side of the intermediate body 7. This invention integrates the maintenance-free air cylinder 5 with the existing intermediate body 7, fixing them together by welding or directly casting them as a single unit. This not only eliminates the need for piping connections but also provides high sealing performance and structural integration through welding or integral casting. The intermediate body 7 can be welded to air cylinders of different volumes as needed, resulting in a high degree of product integration and strong adaptability to various application scenarios.

[0029] Preferably, a cylinder mounting base is provided on one side of the intermediate body 7, the cylinder mounting base and the intermediate body 7 are integral structures, and the maintenance-free cylinder 5 is welded to the cylinder mounting base.

[0030] Preferably, the outer side of the intermediate body 7 is provided with multiple brake valves, the interior of the intermediate body is provided with multiple chambers and multiple air passages, some of the brake valves are connected to the intermediate body 7, and the brake valves are connected to the corresponding chambers and air passages inside the intermediate body 7; some of the brake valves are connected and communicate with their corresponding brake valves.

[0031] Preferably, a dust collector 8 is connected to the outside of the intermediate body 7, and the dust collector 8 is connected to the corresponding air passage. The dust collector 8 is used to filter impurities in the compressed air. One end of the dust collector 8 is connected to the intermediate body 7, and the other end of the dust collector 8 serves as a train pipe interface 11. The train pipe interface 11 is used to connect to the train pipe to provide air source input for the railway freight car braking system.

[0032] Preferably, the dust collector 8 and the intermediate body 7 are connected by bolts, and a sealing gasket is provided between them.

[0033] Preferably, four brake valves are provided on the outer side of the intermediate body 7, namely brake valve 1, brake valve 2, brake valve 3, and brake valve 4. Brake valve 1 is used to realize the emergency braking function of railway freight cars, brake valve 2 is used to realize the braking and release function of railway freight cars, brake valve 3 is used to realize the manual release function of the railway freight car braking system, and brake valve 4 is used to control the braking pressure output by brake valve 2. Brake valve 1, brake valve 2, and brake valve 4 are all connected to the intermediate body 7, and brake valve 3 is connected to brake valve 2.

[0034] Preferably, the intermediate body 7 is connected to a bent pipe 6 for external connection. One end of the bent pipe 6 is connected to the intermediate body 7, and the other end of the bent pipe 6 serves as a brake cylinder interface 10. The brake cylinder interface 10 is used to connect to the railway freight car brake cylinder and the weighing mechanism, providing input to the railway freight car brake cylinder and also providing input signals to the weighing mechanism.

[0035] Preferably, the brake valve 4 is connected to the bend 6 through the corresponding air passage within the intermediate body 7.

[0036] Preferably, the bend 6 is connected to the intermediate body 7 by bolts, and a sealing gasket is provided between the bend 6 and the intermediate body 7. When the brake valve is connected to the intermediate body 7, it is also connected by bolts, and a sealing gasket is provided between the two.

[0037] Preferably, the intermediate body 7 is a four-chamber intermediate body, which has four chambers inside, namely a local reduction chamber, an emergency chamber, a depressurization chamber and an accelerated relief chamber; The pressure reduction chamber is connected to the second brake valve 2; the emergency chamber is connected to the first brake valve 1; the pressure reduction chamber is connected to the fourth brake valve 4 and the weighing mechanism interface 12; the acceleration relief chamber is connected to the second brake valve 2; and the third brake valve 3 is connected to the second brake valve 2.

[0038] Preferably, the intermediate body 7 has 5 air passages inside, namely the train pipe air passage, the auxiliary air cylinder air passage, the local reduction chamber air passage, the upstream air passage of the brake cylinder, and the downstream air passage of the brake cylinder; The train air passage is connected to the dust collector 8, the brake valve 1, and the brake valve 2 respectively; the auxiliary air cylinder air passage is connected to the maintenance-free air cylinder 5 and the brake valve 2 respectively; the local reduction chamber air passage is connected to the local reduction chamber and the brake valve 2; the upstream air passage of the brake cylinder is connected to the brake valve 4 and the brake valve 2 respectively; the downstream air passage of the brake cylinder is connected to the brake valve 4 and the bend pipe 10.

[0039] The intermediate body 7 of this invention contains four chambers (emergency chamber, local reduction chamber, acceleration relief chamber, and pressure reduction chamber), and the auxiliary air cylinder is integrated with the intermediate body 7. In contrast, existing integrated braking devices use a plate-type intermediate body without internal chambers; the chambers (emergency chamber and local reduction chamber) are located on the outer surface of the plate-type intermediate body, and the external chambers are installed using sealing gaskets and threaded fasteners, resulting in poor sealing performance. The acceleration relief air cylinder, pressure reduction air cylinder, and auxiliary air cylinder are not integrated with the plate-type intermediate body and need to be fixed together using air cylinder clamps and fasteners. The internal air passage of the intermediate body needs to be connected to the air cylinder through three hose connection assemblies, i.e., a piping connection. This invention adopts an integrated design, eliminating the air cylinder clamps, external chambers, non-integrated air cylinders, and hose connection assemblies, resulting in a higher degree of integration and effectively reducing leakage points.

[0040] The intermediate body 7 of this invention has three brake valves, one dust collector 8, one bend 6, and one external interface (weighing mechanism interface 12) connected externally. All six locations are sealed at the end faces using rubber gaskets. Maintenance is only required at these six locations during repair. In contrast, the existing integrated braking device's plate-type intermediate body has three brake valves, one dust collector, one bend, three internal interfaces (connecting to the air cylinder), and one chamber (including an emergency chamber and a partial reduction chamber), all sealed at the end faces. Furthermore, the air cylinder also contains three internal interfaces (connecting to the intermediate body), one external interface (the external interface here functions the same as the weighing mechanism interface 12 of this invention), and three air cylinder maintenance drain ports. The chamber is installed in the gap between the intermediate body and the air cylinder, resulting in insufficient installation space and difficulties in maintenance after installation. This invention, however, has a higher degree of integration, fewer points requiring maintenance, and sufficient space for all components, making maintenance convenient.

[0041] Preferably, the intermediate body 7 is provided with 5 external test and maintenance interfaces, of which 4 external test and maintenance interfaces are used for the test and maintenance of the intermediate body 7 chamber, and 1 external test and maintenance interface is used for the test and maintenance of the air cylinder, which facilitates maintenance.

[0042] Preferably, the intermediate body 7 is provided with a total of 5 detachable maintenance plugs 9, which are respectively located at the 5 external test and maintenance interfaces, and seal the external test and maintenance interfaces on the intermediate body 7 when no testing or maintenance is being performed.

[0043] Preferably, the intermediate body 7 is provided with a pedestal mounting base and a hanging mounting base, and the pedestal mounting base and the hanging mounting base are integral with the intermediate body 7 for easy loading.

[0044] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An integrated brake device without internal piping and free of air cylinder maintenance, characterized in that: an intermediate body and a maintenance-free air cylinder are included, the intermediate body is internally provided with a chamber and a gas path, and the maintenance-free air cylinder is connected in communication with the corresponding gas path of the intermediate body; the maintenance-free air cylinder is directly sealed and connected to the intermediate body, and the maintenance-free air cylinder is fixedly connected to the intermediate body, or the maintenance-free air cylinder and the intermediate body are integrally formed by casting; and the intermediate body is provided with an external test and maintenance interface.

2. The integrated brake device without internal piping and free of air cylinder maintenance according to claim 1, characterized in that: when the maintenance-free air cylinder is fixedly connected to the intermediate body, the maintenance-free air cylinder is welded to one side of the intermediate body.

3. The integrated brake device without internal piping and free of air cylinder maintenance according to claim 2, characterized in that: one side of the intermediate body is provided with an air cylinder mounting seat, the air cylinder mounting seat and the intermediate body are an integral structure, and the maintenance-free air cylinder is welded to the air cylinder mounting seat.

4. The integrated brake device without internal piping and free of air cylinder maintenance according to claim 1, characterized in that: a repair plug is detachably installed at the external test and maintenance interface.

5. The integrated brake device without internal piping and free of air cylinder maintenance according to claim 1, characterized in that: a plurality of brake valves are arranged on the outside of the intermediate body, the inside of the intermediate body is provided with a plurality of chambers and a plurality of gas paths; part of the brake valves are connected to the intermediate body, and the brake valves are connected in communication with the corresponding chambers and gas paths in the inside of the intermediate body; and part of the brake valves are connected in communication with the corresponding brake valves.

6. The integrated brake device without internal piping and free of air cylinder maintenance according to claim 5, characterized in that: a bend pipe for external connection is connected to the intermediate body, one end of the bend pipe is connected to the intermediate body, and the other end of the bend pipe serves as a brake cylinder interface; and part of the brake valves are connected in communication with the bend pipe through the corresponding gas paths in the intermediate body.

7. The integrated brake device without internal piping and free of air cylinder maintenance according to claim 1, characterized in that: a dust collector is connected to the outside of the intermediate body, and the dust collector is connected in communication with the corresponding gas path; one end of the dust collector is connected to the intermediate body, and the other end of the dust collector serves as a train pipe interface.

8. The integrated brake device without internal piping and free of air cylinder maintenance according to claim 1, characterized in that: an external gas path interface is arranged on the intermediate body.

9. The integrated brake device without internal piping and free of air cylinder maintenance according to claim 8, characterized in that: the external gas path interface includes a load measuring mechanism interface, and the load measuring mechanism interface is arranged on the intermediate body.

10. The integrated brake device without internal piping and free of air cylinder maintenance according to any one of claims 1-9, characterized in that: a seat mounting seat and a hanging mounting seat are arranged on the intermediate body, and the seat mounting seat and the hanging mounting seat are an integral structure with the intermediate body. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​

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