A dynamic signal detection-based car transfer platform tensioning device and a control method thereof

Abstract

The application discloses a kind of based on dynamic signal detection's migration station tensioner and control method thereof, including migration station, tensioning mechanism and control system, wherein signal detection system uses the proximity switch with being clamped vehicle wheel itself as dynamic response target, and preferably along the longitudinal parallel arrangement of redundancy multiple proximity switches of vehicle, the output signal of each group switch is connected into control system in parallel. Control method only uses the real physical signal generated by proximity switch as the only criterion of tensioning action completion;When any one group of proximity switch detects that wheel enters its response area, control system determines that tensioning is in place and allows migration, otherwise trigger safety locking and alarm. The application fundamentally solves the problem of signal loss or instability caused by wheel parking randomness, completely eliminates the major safety risk of vehicle derailment caused by signal misjudgment, with reliable signal, high safety, significant economic benefits and easy to implement.

Description

Technical Field

[0001] This invention relates to the field of railway tippler system safety technology, and in particular to a tensioning device for a car-moving platform based on dynamic signal detection and its control method. Background Technology

[0002] The wheel-shifting platform in a tippler system is used to move empty wagons. Its tensioning device (wheel tensioner) clamps the wheels with clamps to prevent the wagons from derailing during the shift. In existing technology, the tensioning signal typically relies on a fixed inductive switch (such as a proximity switch) to detect the position of a fixed sensing iron to determine if the clamp is in place. However, because the inner wheelbase of domestic railway freight wagons is 1353±3 mm, and the track gauge on the wheel-shifting platform is the standard railway gauge of 1435 mm, the wheels randomly stop within an 82±3 mm range along the railway in the tensioning area of ​​the wheel clamp. Since the effective sensing distance of the fixed inductive switch is generally 5-30 mm, this results in unstable or lost signals, severely affecting operational continuity and safety.

[0003] To address the signal loss problem, a temporary solution exists in existing technology: in the programmable logic controller (PLC) program, a fixed delay (e.g., 8 seconds) is used as a virtual "tensioning signal" after the clamping plate signal disappears. While this method ensures the process continues, it poses a significant safety hazard: if the tensioning mechanism experiences a mechanical failure (e.g., the clamping plate slightly moves but does not actually clamp), the PLC program will still mistakenly interpret it as "tensioned" after the delay ends. In this case, relocating the vehicle will cause it to derail, resulting in substantial economic losses and safety accidents. Furthermore, there are solutions that involve adding horizontal or vertical switch groups for localized improvements, but these fail to fundamentally solve the problem of the disconnect between signal detection and mechanical action.

[0004] With increasingly stringent railway safety regulations, derailment accidents (usually classified as Class D accidents) can cause economic losses of up to several million yuan per incident. Therefore, there is an urgent need for a relocation platform tensioning signal detection technology that can completely eliminate safety hazards and provide stable and reliable signals. Summary of the Invention

[0005] In view of this, the purpose of this invention is to provide a vehicle relocation platform tensioning device and its control method based on dynamic signal detection, which fundamentally solves the problem of signal loss or instability caused by the randomness of wheel positioning, completely eliminates the major safety risk of vehicles derailing due to signal misjudgment, and has the advantages of reliable signal, high safety, significant economic benefits and easy implementation.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a vehicle transfer platform tensioning device based on dynamic signal detection, comprising a vehicle transfer platform, a tensioning mechanism disposed on the vehicle transfer platform, and a control system; the tensioning mechanism includes a signal detection system, the signal detection system including at least one set of proximity switches, the proximity switches being arranged near the clamping plate of the tensioning mechanism, and configured to use the clamped vehicle wheel itself as the dynamic sensing target to generate a tensioning signal.

[0007] In a preferred embodiment: the proximity switch is a redundant set of multiple proximity switches arranged parallel to the longitudinal direction of the vehicle, including a first set of proximity switches arranged longitudinally along the first clamping plate and a second set of proximity switches arranged longitudinally along the second clamping plate. The output signals of the first set of proximity switches and the second set of proximity switches are connected in parallel to the input module of the control system.

[0008] In a preferred embodiment, the sensing surface of each set of proximity switches faces the wheel parking area.

[0009] In a preferred embodiment: the proximity switch is an inductive proximity switch, and the distance H between its sensing surface and the working surface of the clamp is set to the calibrated sensing distance L of the proximity switch minus 3mm, that is, H = L-3mm, in order to prevent wheel collision damage and ensure detection reliability.

[0010] In a preferred embodiment: the control system is a programmable logic controller (PLC), whose control logic is configured to discard the virtual tensioning signal generation logic based on a fixed delay, and use only the real physical signal from the proximity switch as the sole criterion for the completion of the tensioning action.

[0011] This invention provides a control method for a tensioning device for a car transfer platform based on dynamic signal detection, characterized by the following steps: Detection steps: Using proximity switches placed near the clamping plate, the vehicle wheels are used as dynamic sensing targets to detect in real time whether the wheels have entered the effective sensing area of ​​the proximity switches. Judgment Step: The control system determines whether the tensioning action has been truly completed based on whether it receives a valid electrical signal from any set of proximity switches; Execution steps: The control system will only allow subsequent vehicle relocation operations to be performed when it is determined that the tensioning action has been truly completed; otherwise, a safety lock and alarm signal will be triggered.

[0012] In a preferred embodiment: in the determination step, when any one of the multiple sets of proximity switches connected in parallel to the control system generates a valid electrical signal, it is determined that the tensioning action has been truly completed.

[0013] In a preferred embodiment, the system further includes a timeout protection step, wherein the control system presets a tensioning action time threshold. If no valid signal from any proximity switch is received within the threshold, the tensioning is deemed to have failed, vehicle relocation is prohibited, and a fault alarm is output.

[0014] Compared with the prior art, the present invention has the following beneficial effects: 1. Fundamentally improved signal stability and reliability: The innovative design uses vehicle wheels as moving "inductive electrodes," allowing the signal detection point to dynamically adjust according to the actual stopping position of the wheels, completely solving the signal loss problem caused by the randomness of wheel positioning. Redundant parallel design further ensures the absolute reliability of the signal.

[0015] 2. Completely eliminate major safety hazards: By abandoning the "virtual signal" that relies on PLC delay, the possibility of the system misjudging "tightened" in the event of mechanical hardware failure is eliminated, thus eliminating the risk of vehicle derailment accidents at the source.

[0016] 3. Significant economic benefits: With extremely low renovation investment (e.g., less than 10,000 yuan), it avoids potential accident losses of up to 2.2 million yuan per incident (including vehicle repair, line repair, production stoppage losses and accident fines), resulting in huge annualized safety and economic benefits.

[0017] 4. Systematic and Long-Term Effectiveness: This solution innovates systematically from two dimensions: equipment structure adaptability and signal detection mechanism, resolving long-standing problems. The upgraded hardware standard is unified, and the results can be incorporated into equipment maintenance procedures, forming a long-term effective safety mechanism that is easy to promote within the industry.

[0018] 5. Simple structure and easy implementation: No large-scale modification of the main mechanical structure of the vehicle transfer platform is required. The main modification involves optimizing the arrangement of standardized proximity switches and modifying the control logic near the existing clamping plate. The modification cycle is short and the results are quick. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of a preferred embodiment of the present invention. Detailed Implementation

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0021] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0022] It should be noted that the terminology used herein is for the purpose of describing particular implementations only and is not intended to limit the exemplary implementations according to this application; as used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise; furthermore, it should be understood that when the terms “comprising” and / or “including” are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0023] A tensioning device for a vehicle transfer platform based on dynamic signal detection, reference Figure 1 The system includes a vehicle transfer platform, a tensioning mechanism mounted on the vehicle transfer platform, and a control system. The tensioning mechanism includes a signal detection system, which includes at least one set of proximity switches. The proximity switches are arranged near the clamping plate of the tensioning mechanism and configured to use the clamped vehicle wheel itself as a dynamic sensing target to generate a tensioning signal.

[0024] The clamping plate includes a first clamping plate 1 and a second clamping plate 2. The proximity switch is a redundant set of multiple proximity switches arranged parallel to the longitudinal direction of the vehicle, including a first set of proximity switches (L1, L2, L3) arranged longitudinally along the first clamping plate 1 and a second set of proximity switches (L4, L5, L6) arranged longitudinally along the second clamping plate 2. The output signals of the first set of proximity switches and the second proximity switch are connected in parallel to the input module of the control system.

[0025] Control Unit: The control system (such as a PLC) receives signals from the dynamic sensing unit and discards the original delayed virtual signal logic. The control logic is configured to determine that the tensioning action is complete and allow the transfer platform to perform subsequent transfer operations only when a real physical signal from the dynamic sensing unit is received; if the signal is not received, the tensioning is determined to have failed, an alarm is triggered, and the transfer platform is locked.

[0026] Meanwhile, a signal control method for the aforementioned car-transfer platform tensioning device is provided, comprising the following steps: S1: The vehicle transfer platform is in place, and the clamping plate of the tensioning mechanism begins to move towards the vehicle wheels.

[0027] S2: The relative position of the clamp and the wheel is detected in real time by a group of proximity switches arranged longitudinally with the wheel as the sensing target.

[0028] S3: When the clamp is actually in place and close to the wheel, the metal body of the wheel enters the sensing range of at least one proximity switch, generating a high-level signal.

[0029] S4: The control system collects this high-level signal in real time and uses it as the sole criterion for determining whether tensioning is complete.

[0030] S5: If a valid signal is acquired within the preset action time, the control system issues a vehicle relocation permission command; if no valid signal is acquired after the timeout, the control system issues a fault alarm and prohibits vehicle relocation.

[0031] This solution was implemented on the vehicle transfer platform of the company's tipper system. Three sets of normally open inductive proximity switches (sensing distance approximately 5-30mm) were installed parallel to each other at equal intervals on the longitudinal support of the tensioning clamp, with the sensing surfaces of the switches facing the area where the wheel might stop. The output lines of the three sets of switches were connected in parallel and then connected to a digital input point of the PLC. The original 8-second delay "tensioning signal" generation logic was removed from the PLC program, and the status of this input point was directly read. When the clamping cylinder pushes the clamping plate to press against the wheel, regardless of the wheel's lateral position, its rim or spokes will always enter the sensing area of ​​at least one proximity switch, triggering a signal. The PLC confirms this signal before issuing the vehicle transfer command. Furthermore, the redundant design of the three sets of switches fully considers the longitudinal positioning deviation of the vehicle caused by factors such as changes in the torque of the tipper mechanism. In this way, regardless of the wheel's lateral position or longitudinal positioning deviation, as long as the wheel is within the clamping area, the transfer can be completed, meaning this invention is universally applicable to various working conditions.

[0032] In practical application, the tension signal of the four tippler systems remained 100% stable after the modification, and there were no more work interruptions caused by signal problems. More importantly, the safety hazards caused by signal misinterpretation were completely eliminated, and the system is safe and reliable in operation.

[0033] The wheel sets are arranged with three proximity switches as shown in the figure above. They are evenly distributed longitudinally in the clamping section because the other sections of the clamping plate are empty after the vehicle arrives at the transfer platform. This arrangement can avoid the influence of randomness of the wheels in a certain range in the longitudinal direction due to the braking of the vehicle transfer mechanism. The switches are arranged laterally, with the distance between the switch sensing surface and the working surface of the clamping plate being H, where H = the rated sensing distance of the switch L - 3mm. This can prevent the wheels from damaging the switches and ensure the detection reliability of the proximity switches.

[0034] The PLC control logic is as follows: Address definition I0.0: Tightening Initiation I0.1: Tensioning in place detection (normally open, clamped = 1) I0.2: Vehicle relocation operation command Q0.0: Tensioner output - Q0.1: Vehicle relocation permitted Q0.2: Alarm (Timeout + Lost) T37: Tension Timeout Timer PT = 100 (10 seconds) Trapezoid diagram: I0.0 I0.1 Q0.0 |----[ ]------------[\]-------------( )----| Tightening initiation not yet in place, tightening output Q0.0 |----[ ]------------------------| Self-locking retention Q0.0 I0.1 T37 |----[ ]---------[\]-----------(TON)----| Tightening action not completed within 10 seconds PT=100 I0.1 T37 Q0.1 |----[ ]------------[\]---------------( )------| Vehicle relocation permitted if tension is tightened and time limit is not exceeded. I0.2 I0.1 Q0.2 |------[ ]---------[\]-------( )(If the tension signal is lost during vehicle relocation, an alarm signal will be output) Vehicle relocation tension alarm T37 Q0.2 |-------[ ]--------( ) (Tension timeout, output alarm signal) Timeout alarm This invention fundamentally solves the problem of signal instability caused by the randomness of wheel positioning, completely eliminates the major safety risk of vehicles derailing due to signal misjudgment, and has the advantages of reliable signal, high safety, significant economic benefits, and easy promotion.

Claims

1. A tensioning device for a car transfer platform based on dynamic signal detection, comprising a car transfer platform, a tensioning mechanism disposed on the car transfer platform, and a control system; characterized in that: The tensioning mechanism includes a signal detection system, which includes at least one set of proximity switches arranged near the clamping plate of the tensioning mechanism and configured to use the clamped vehicle wheel itself as a dynamic sensing target to generate a tensioning signal.

2. The tensioning device for a vehicle transfer platform based on dynamic signal detection according to claim 1, characterized in that: The proximity switches are redundant sets of proximity switches arranged parallel to each other along the longitudinal direction of the vehicle, including a first set of proximity switches arranged along the longitudinal direction of the first clamping plate and a second set of proximity switches arranged along the longitudinal direction of the second clamping plate. The output signals of the first set of proximity switches and the second set of proximity switches are connected in parallel to the input module of the control system.

3. The tensioning device for a vehicle transfer platform based on dynamic signal detection according to claim 2, characterized in that: The sensing surface of each proximity switch is facing the area where the wheels are parked.

4. A tensioning device for a vehicle transfer platform based on dynamic signal detection according to any one of claims 1 to 3, characterized in that: The proximity switch is an inductive proximity switch, and the distance H between its sensing surface and the working surface of the clamp is set to the calibrated sensing distance L of the proximity switch minus 3mm, that is, H = L-3mm, in order to prevent wheel collision damage and ensure detection reliability.

5. A tensioning device for a vehicle transfer platform based on dynamic signal detection according to claim 1, characterized in that: The control system is a programmable logic controller (PLC), whose control logic is configured to abandon the virtual tensioning signal generation logic based on a fixed delay, and use only the real physical signal from the proximity switch as the sole criterion for the completion of the tensioning action.

6. A control method for a tensioning device for a car transfer platform based on dynamic signal detection as described in any one of claims 1 to 5, characterized in that... Includes the following steps: Detection steps: Using proximity switches placed near the clamping plate, the vehicle wheels are used as dynamic sensing targets to detect in real time whether the wheels have entered the effective sensing area of ​​the proximity switches. Judgment Step: The control system determines whether the tensioning action has been truly completed based on whether it receives a valid electrical signal from any set of proximity switches; Execution steps: The control system will only allow subsequent vehicle relocation operations to be executed when it is determined that the tensioning action has been truly completed; Otherwise, a safety lock and alarm signal will be triggered.

7. The control method for a tensioning device for a car transfer platform based on dynamic signal detection according to claim 6, characterized in that: In the determination step, when any one of the multiple proximity switches connected in parallel to the control system generates a valid electrical signal, it is determined that the tensioning action has been truly completed.

8. A control method for a tensioning device for a car transfer platform based on dynamic signal detection according to claim 6 or 7, characterized in that: It also includes a timeout protection step, whereby the control system presets a tensioning action time threshold. If no valid signal from any proximity switch is received within this threshold, the tensioning is deemed to have failed, vehicle relocation is prohibited, and a fault alarm is output.

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