Locomotive pneumatic rearview mirror performance detection tool and method

Abstract

The invention discloses a locomotive pneumatic rearview mirror performance detection tool and method, and belongs to the technical field of rail locomotive overhaul, the locomotive pneumatic rearview mirror performance detection tool comprises a hardware structure and a control system, the hardware structure comprises a rearview mirror fixing tool, a clamping structure, an angle detection module, a switching power supply, a sensor, an S7-200PLC, an MCGS embedded configuration touch screen and an electromagnetic valve; the control system adopts a framework of'an upper computer and a lower computer ', the lower computer is an S7-200PLC, and the upper computer is an MCGS embedded configuration touch screen. The device has the advantages that the device is simple in structure and convenient to operate, the problem of low efficiency of repeated disassembly and assembly is solved, flexible programming configuration of test parameters such as the cycle index, the reciprocating time and the angle threshold value is supported, and when the angle exceeds a set range, the system automatically triggers an alarm; the touch screen displays test state information such as movement times, a current angle, clamping stagnation alarm and the like in real time, so that an operator can master the test progress in real time conveniently.

Description

Technical Field

[0001] This invention belongs to the field of rail locomotive maintenance technology, specifically relating to a tooling and method for testing the performance of a locomotive pneumatic rearview mirror. Background Technology

[0002] During the maintenance of locomotive pneumatic rearview mirrors, a rigorous performance test must be conducted. The test standards are as follows: the rearview mirror is connected to an air pressure range of 350kPa to 800kPa and reciprocates once every 15 seconds for 100 consecutive reciprocating cycles. The mirror should operate smoothly without any jamming, produce a uniform and harmonious sound, and have a rotation angle between 60° and 70°.

[0003] In the existing maintenance process, the maintenance station lacks dedicated pneumatic rearview mirror testing fixtures. After maintenance, the rearview mirror must be directly installed on the vehicle for testing. If the test fails, it must be removed and returned to the maintenance station for repair or replacement of parts. This repeated disassembly and assembly method is not only time-consuming and labor-intensive, but also leads to low maintenance efficiency, increased maintenance costs and labor intensity. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the present invention aims to provide a tooling and method for testing the performance of a locomotive pneumatic rearview mirror, enabling performance testing and rotation angle testing of the pneumatic rearview mirror, and solving the problems of lack of dedicated testing equipment and low efficiency due to repeated disassembly and assembly in the current maintenance process.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a locomotive pneumatic rearview mirror performance testing fixture, comprising a hardware structure and a control system. The hardware structure includes a rearview mirror fixing fixture, a clamping structure, an angle detection module, a switching power supply, a sensor, an S7-200 PLC, an MCGS embedded configuration touch screen, and a solenoid valve. The control system adopts a "host computer + slave computer" architecture, wherein the slave computer is an S7-200 PLC and the host computer is an MCGS embedded configuration touch screen.

[0006] The rearview mirror fixing fixture adopts a frame structure formed by welding square tubes and steel plates, and is a dual-station symmetrical test bracket, which is also compatible with the synchronous test of left and right rearview mirrors.

[0007] The clamping structure uses wing bolts and nuts, heavy-duty clamps, or I-beam clamps to clamp and fix the rearview mirror bottom frame.

[0008] The angle detection module is a "mechanical measuring ruler + electronic sensor dual verification structure"; the mechanical measuring ruler is a pull-out angle measuring ruler with a measuring range of 60° to 70°. The ruler body is equipped with a center positioning mark and an observation opening. When not in use, it is suspended on the cylindrical hanging rod of the bracket. The electronic sensor is a Hall sensor, installed at the rearview mirror pivot, and communicates with the S7-200 PLC in real time.

[0009] The switching power supply outputs 24V to power the MCGS embedded configuration touchscreen and S7-200 PLC.

[0010] The S7-200 PLC is used to control the solenoid valve to drive the reciprocating motion of the rearview mirror and to collect and analyze the signals from the angle detection module; the MCGS embedded configuration touch screen is used to input test parameters, display test status and alarm information.

[0011] A testing method for a locomotive aerodynamic rearview mirror performance testing fixture based on any of the above includes the following steps: S1: Tooling preparation, connect 24V power supply, and check the connection status of each component; S2: Workpiece installation: Fix the rearview mirror on the double workstation and secure it firmly using the clamping structure; S3: Parameter settings, input the reciprocating time, number of reciprocations and angle threshold through the MCGS embedded configuration touch screen; S4: Angle calibration, manually open the rearview mirror to the limit position, mark the center position and calibrate the mechanical measuring ruler and electronic sensor; S5: Test execution, start the test, S7-200PLC controls the solenoid valve to drive the reciprocating motion of the rearview mirror, and the angle detection module collects angle data in real time; S6: Data monitoring and alarm, real-time display of test status, alarm when the angle exceeds the threshold or the movement is abnormal; S7: Test judgment: The test is qualified if the set number of reciprocating movements is completed without alarm; otherwise, it is unqualified. S8: Disassemble the workpiece, turn off the power, and remove the rearview mirror.

[0012] In step S3, the reciprocating time is set to 15 seconds, the number of reciprocations is 100, and the angle threshold is 60° to 70°.

[0013] The beneficial effects of this invention are: the device has a simple structure and is easy to operate, which solves the problem of low efficiency due to repeated disassembly and assembly. It supports flexible programming configuration of test parameters such as the number of cycles, reciprocating time, and angle threshold. When the angle exceeds the set range, the system automatically triggers an alarm. The touch screen displays test status information such as the number of movements, current angle, and jamming alarm in real time, which makes it easy for operators to keep track of the test progress in real time. Attached Figure Description

[0014] Figure 1 This is a block diagram of the railway locomotive aerodynamic rearview mirror performance testing system of the present invention; Figure 2 This is a schematic diagram of the overall structure of the testing fixture of the present invention; Figure 3This is a schematic diagram of the clamping structure of the testing fixture of the present invention; Figure 4 This is a schematic diagram of the mechanical measuring ruler measurement method of the testing fixture of the present invention; Figure 5 This is a schematic diagram illustrating the positioning of the center of the measuring ruler in this invention; Figure 6 This is a flowchart of the PLC program processing of the present invention; Figure 7 This is a flowchart of the touch screen program processing of the present invention. Detailed Implementation

[0015] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. It should be noted that the described embodiments are only some embodiments of the present invention, and 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.

[0016] Please see Figures 1-7 The detection fixture of this invention mainly consists of a hardware structure and a control system. The hardware structure of the inspection fixture includes a rearview mirror fixing fixture, a clamping structure, an angle detection module, a switching power supply, a sensor, an S7-200 PLC, an MCGS embedded configuration touch screen, and solenoid valves, etc. The components work together to achieve the inspection function.

[0017] Rearview mirror fixing fixture: The main body of the fixture is welded from square tubing and steel plates. To accommodate both left and right rearview mirrors, this fixture adopts a "dual-station symmetrical test bracket" design. The frame structure, formed by welding square tubing and steel plates, allows for simultaneous testing of both left and right rearview mirrors, effectively improving testing efficiency. Its specific structure is as follows: Figure 2 As shown.

[0018] Clamping Structure: To simplify the installation and removal process of the rearview mirrors, the bottom frames of the left and right rearview mirrors are clamped using wing bolts and nuts instead of traditional ordinary bolts and nuts, significantly saving installation and removal time. In addition, other convenient clamping methods such as heavy-duty clamps and I-beam clamps can be used according to actual needs, and their specific structures are as follows... Figure 3 As shown.

[0019] Angle detection module: To ensure the accuracy of rotation angle detection, this invention designs a "mechanical measuring ruler + electronic sensor dual verification structure", which improves the reliability of detection results through dual protection of mechanical measurement and electronic detection.

[0020] Mechanical end: Equipped with a retractable angle measuring scale, its range is set to 60°~70°, precisely matching the angle range required for the test. The scale body has a "center positioning mark" and an "observation opening," and can be hung on the cylindrical hanging rod of the bracket for easy storage when not in use. Before the test, manually open the rearview mirror to its extreme position, and measure its rotation angle using the movable angle measuring scale above to see if it is within the range of 60°~70°. The specific measurement method is as follows... Figure 4 As shown. Since the opening limits of different rearview mirrors vary, the corresponding rotation angles and the center position of the measuring scale will also differ. Therefore, after the rearview mirror is fully opened, the center position can be marked on the cylindrical hanger. The opening at the center position of the measuring scale facilitates observation of whether the measuring scale is aligned with the marked center position on the cylindrical hanger, ensuring accurate measurement reference. Its specific structure is as follows... Figure 5 As shown.

[0021] Electronic component: An angle sensor (such as a Hall sensor) is installed at the rearview mirror pivot. This sensor establishes real-time communication with the PLC, which can collect rearview mirror rotation angle data in real time and transmit it to the control system to realize real-time angle monitoring and data recording.

[0022] Control system of the inspection fixture: To achieve automated and precise testing of rearview mirror performance, this invention adopts a "host computer + slave computer" architecture, integrating modules such as PLC, touch screen, and angle sensor to precisely control the solenoid valve of the rearview mirror cylinder, implementing an opening and closing command every 15 seconds to complete the test requirement of 100 continuous reciprocating movements. Simultaneously, through touch screen configuration and PLC programming, the rearview mirror's round-trip time, number of round trips, and required rotation angle range can be flexibly input, adapting to the performance testing needs of rearview mirrors in different vehicle models.

[0023] Hardware control core: This hardware system uses a Siemens S7-200 PLC as its control core, responsible for receiving sensor signals, executing control commands, and processing data. Its system block diagram is as follows: Figure 1 As shown. The switching power supply is designed to be 24V, providing a stable power supply for the MCGS embedded configuration touch screen and Siemens S7-200 PLC.

[0024] Software functionality implementation: The software consists of two parts: a Siemens S7-200 PLC and an MCGS touchscreen display. These two components work together to automate the testing process and enable human-machine interaction. The Siemens S7-200 PLC controls the solenoid valve of the pneumatic rearview mirror, ensuring precise reciprocating motion, and simultaneously collects and analyzes signals from the angle sensor. The MCGS touchscreen serves as the human-machine interface, receiving user-inputted test parameters (such as round-trip time, number of round trips, and angle thresholds) and displaying real-time test progress (such as the number of movements), current angle data, and fault alarm information (such as alarm prompts when the angle exceeds the range). The specific process is as follows: Figure 6 and Figure 7 As shown.

[0025] Core control functions: This invention adopts a "lower-level control + upper-level interaction" architecture of "S7-200 PLC + MCGS embedded touch screen" to achieve the following core control functions: Programmable configuration: It supports flexible programming configuration of test parameters such as the number of cycles, reciprocating time, and angle threshold. For example, it can be set to reciprocate once every 15 seconds and execute continuously for 100 times. Real-time angle monitoring: The system collects rearview mirror rotation angle data in real time through an angle sensor. When the angle exceeds the range of 60°~70°, the system automatically triggers an alarm. Real-time status feedback: The touch screen displays real-time test status information such as the number of movements, current angle, and jamming alarms, allowing operators to keep track of the test progress in real time.

[0026] Based on the above-mentioned testing fixture, the present invention also provides a method for testing the performance of a locomotive aerodynamic rearview mirror, the specific steps of which are as follows: Tooling preparation: Connect the testing tooling to a 24V power supply and check the connection status of components such as S7-200PLC, MCGS touch screen, angle sensor and solenoid valve to ensure that each component is working properly; Workpiece installation: According to the left and right specifications of the rearview mirror, install it on the double station of the fixed fixture, and fix the bottom frame of the rearview mirror firmly by using wing bolts, nuts or other clamping methods; Parameter settings: Input test parameters via MCGS touch screen, including reciprocating time (e.g., 15 seconds), number of reciprocations (e.g., 100 times), and rotation angle threshold (60°~70°). Angle calibration: Manually open the rearview mirror to its limit position, mark the center position on the cylindrical hanger, adjust the position of the mechanical measuring ruler to ensure that its center is aligned with the marked position, and complete the calibration of the mechanical measurement; at the same time, the angle sensor is zero-point calibrated through PLC to ensure the accuracy of electronic detection; Test execution: Press the start button, the PLC controls the solenoid valve to move, driving the rearview mirror to reciprocate according to the set reciprocating time and number of times. The angle sensor collects the rotation angle data in real time and transmits it to the PLC. Data monitoring and alarm: During the test, the MCGS touch screen displays information such as the number of movements and the current angle in real time. The PLC analyzes the angle data in real time. If the rotation angle exceeds the set threshold or jamming occurs, causing abnormal movement, the system will immediately trigger an alarm and suspend the test. Test completion and judgment: When the rearview mirror completes the set number of reciprocating movements without alarm information, it is judged as qualified; if an alarm occurs during the test, it is judged as unqualified, and the rearview mirror needs to be repaired and retested. Workpiece disassembly: After the test, turn off the power, loosen the clamping structure, and remove the rearview mirror from the fixture.

[0027] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

[0028] The parts of this invention not described in detail are prior art.

Claims

1. A tooling for testing the performance of a locomotive aerodynamic rearview mirror, comprising a hardware structure and a control system, characterized in that; The hardware structure includes a rearview mirror fixing fixture, a clamping structure, an angle detection module, a switching power supply, a sensor, an S7-200 PLC, an MCGS embedded configuration touch screen, and a solenoid valve; the control system adopts a "host computer + slave computer" architecture, where the slave computer is an S7-200 PLC and the host computer is an MCGS embedded configuration touch screen.

2. The locomotive aerodynamic rearview mirror performance testing fixture according to claim 1, characterized in that: The rearview mirror fixing fixture adopts a frame structure formed by welding square tubes and steel plates, and is a dual-station symmetrical test bracket, which is also compatible with the synchronous test of left and right rearview mirrors.

3. The locomotive pneumatic rearview mirror performance testing fixture according to claim 1, characterized in that: The clamping structure uses wing bolts and nuts, heavy-duty clamps, or I-beam clamps to clamp and fix the rearview mirror bottom frame.

4. The locomotive pneumatic rearview mirror performance testing fixture according to claim 1, characterized in that: The angle detection module is a "mechanical measuring ruler + electronic sensor dual verification structure"; the mechanical measuring ruler is a pull-out angle measuring ruler with a measuring range of 60° to 70°. The ruler body is equipped with a center positioning mark and an observation opening. When not in use, it is suspended on the cylindrical hanging rod of the bracket; the electronic sensor is a Hall sensor, which is installed at the rearview mirror pivot and communicates with the S7-200 PLC in real time.

5. The locomotive pneumatic rearview mirror performance testing fixture according to claim 1, characterized in that: The switching power supply outputs 24V to power the MCGS embedded configuration touchscreen and S7-200 PLC.

6. The locomotive aerodynamic rearview mirror performance testing fixture according to claim 1, characterized in that: The S7-200 PLC is used to control the solenoid valve to drive the reciprocating motion of the rearview mirror and to collect and analyze the signals from the angle detection module; the MCGS embedded configuration touch screen is used to input test parameters, display test status and alarm information.

7. A testing method for a locomotive aerodynamic rearview mirror performance testing fixture based on any one of the fixtures described in claims 1-6, characterized in that: Includes the following steps: S1: Tooling preparation, connect 24V power supply, and check the connection status of each component; S2: Workpiece installation: Fix the rearview mirror on the double workstation and secure it firmly using the clamping structure; S3: Parameter settings, input the reciprocating time, number of reciprocations and angle threshold through the MCGS embedded configuration touch screen; S4: Angle calibration, manually open the rearview mirror to the limit position, mark the center position and calibrate the mechanical measuring ruler and electronic sensor; S5: Test execution, start the test, S7-200PLC controls the solenoid valve to drive the reciprocating motion of the rearview mirror, and the angle detection module collects angle data in real time; S6: Data monitoring and alarm, real-time display of test status, alarm when the angle exceeds the threshold or the movement is abnormal; S7: Test judgment: The test is qualified if the set number of reciprocating movements is completed without alarm; otherwise, it is unqualified. S8: Disassemble the workpiece, turn off the power, and remove the rearview mirror.

8. The method for testing the performance of a locomotive aerodynamic rearview mirror according to claim 7, characterized in that: In step S3, the reciprocating time is set to 15 seconds, the number of reciprocations is 100, and the angle threshold is 60° to 70°.

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