Device for detecting thickness wear of locomotive brake shoe

Abstract

The utility model discloses a locomotive brake shoe thickness wear detection device which comprises a controller, a sensor 7 and a magnetic piston 6, the sensor 7 is installed on a brake cylinder 4 of a locomotive, and a piston 3 in the brake cylinder 4 is the magnetic piston 6 with magnetism; the controller is electrically connected with the sensor 7; the sensor 7 is a magnetic induction sensor; comprising industrial cameras, the industrial cameras are connected with a computer, the two industrial cameras 9 are installed on the two sides of a track of a maintenance workshop, a mark 13 is arranged on the side face of a to-be-detected brake shoe 8, and when the brake shoe enters the maintenance workshop, the industrial cameras rapidly record images of the mark 13 of the brake shoe 8. The brake shoe thickness detection speed and accuracy are effectively improved, the labor cost is reduced, and misjudgment caused by eye fatigue is prevented. The working efficiency is improved.

Description

Technical Field

[0001] The utility model relates to the field of locomotive brake shoe detection, in particular to a device for detecting the thickness wear of a locomotive brake shoe. Background Art

[0002] The most common braking method used in railway locomotives is shoe braking. The shoe-shaped brake pads made of cast iron or other materials hold the wheel tread tightly during braking, stopping the wheel from rotating through friction.

[0003] During braking, most of the heat load is borne by the wheels due to the small friction area of ​​the brake shoe. The higher the train speed, the greater the heat load on the wheels during braking. Especially during emergency braking, the large amount of heat generated by the high-speed friction on the brake shoe surface cannot be dissipated in time and accumulates on the surface, causing the surface temperature to rise sharply. Excessive temperature rise can easily cause a qualitative change in the properties of the brake shoe material, thereby causing a sudden change in its friction and wear properties, which will cause wear on the tread and affect driving safety.

[0004] The main form of failure of train brake shoes is wear. When the brake shoe thickness is less than the specified value, it must be replaced. When replacing brake shoes, all brake shoes on the same axis must be replaced.

[0005] The existing method of checking the wear thickness of the brake shoe of a locomotive is to draw a line on the brake shoe and manually observe the wear thickness of the brake shoe on site to determine whether it needs to be replaced. This method is inefficient, labor-intensive, and has large errors in the inspection results. Utility Model Content

[0006] The utility model provides a device for detecting the wear of the thickness of the brake shoe of a locomotive, which detects the wear degree of the thickness of the brake shoe of the locomotive. The wear degree of the brake shoe can be detected by adopting image detection technology and sensor technology, and the detection result is transmitted to the maintenance department. When the wear value of the brake shoe thickness reaches the limit value for replacing the brake shoe, an alarm signal is issued, and personnel are arranged to replace the scrapped brake shoe in time, thereby greatly ensuring the safety of train driving.

[0007] In order to achieve the above purpose, the utility model provides the following technical solutions:

[0008] A detection device for the wear of brake shoe thickness of a locomotive comprises a controller, a sensor 7 and a magnetic bellows 6, wherein the sensor 7 is mounted on a brake cylinder 4 of the locomotive, and a bellows 3 inside the brake cylinder 4 is a magnetic bellows 6 with magnetism; the controller is electrically connected to the sensor 7; and the sensor 7 is a magnetic induction sensor;

[0009] It also includes an industrial camera, which is connected to a computer. Two industrial cameras 9 are installed on both sides of the track in the maintenance workshop. There is a mark 13 on the side of the brake shoe 8 to be tested. When entering the maintenance workshop, the industrial camera quickly records the image of the mark 13 of the brake shoe 8.

[0010] The main components of the industrial camera are the CCD camera 11 and the fill light 12, and the installation height of the industrial camera is the same as that of the mark 13.

[0011] The power supply of the sensor and the controller is DC24V, and the output end of the sensor is connected to the digital input end of the controller; the controller has a variety of communication interfaces, including RS-232\RS-485\RJ45.

[0012] The technical effects and advantages of the present utility model:

[0013] Effectively improve the detection speed and accuracy of the brake shoe thickness, reduce the labor cost, and prevent misjudgment caused by eye fatigue.

[0014] Improve work efficiency. Since operators are prone to fatigue during long-term work, the quality and accuracy of manual vision are relatively low, while machine vision can greatly improve production efficiency and automation.

[0015] Reduce labor intensity. The installation position of the brake shoe is at the bottom of the locomotive and rolling stock, and the bottom structure of the vehicle is complex. When inspecting the brake shoe, it is necessary to bend down and lower the head, or enter under the vehicle, which is laborious and inconvenient, and even safety accidents may occur. The present utility model can effectively reduce accidents. Description of the drawings

[0016] Figure 1 It is a schematic diagram of the locomotive braking system and the sensor installation;

[0017] Figure 2 It is a wiring diagram of the sensor;

[0018] Figure 3 It is a process diagram of the sensor detection;

[0019] Figure 4 It is a schematic diagram of the CCD camera detection;

[0020] Figure 5 It is a schematic diagram of the image detection. Specific embodiments

[0021] The technical solutions in the embodiments of the present utility model will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present utility model, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present utility model without creative efforts shall fall within the protection scope of the present utility model.

[0022] The locomotive braking system includes: a wheel 1, an air duct 2, a piston 3, a brake cylinder 4, a piston rod 5, a magnetic piston 6, a sensor 7, and a brake shoe 8.

[0023] The basic braking principle of the locomotive is to increase the thrust of the piston 3 in the brake cylinder 4 through the lever system and then transmit it to the brake shoe 8 to press against the wheel tire, generating braking force through the adhesion between the wheel and the rail. The basic braking device consists of a lever system driven by the brake cylinder 4 and the brake shoe 8. The brake shoe is a standard cast iron brake shoe for freight cars. The basic braking adopts single-sided braking. There are two brake shoes for each wheel set, which are installed on the inner sides of the left and right wheels. Since the brake shoes are often worn, they need to be regularly inspected and the brake shoe clearance needs to be adjusted. When adjusting, loosen the locking nut and rotate the adjusting sleeve to make the brake shoe close to the wheel tread, keeping the brake shoe clearance at 6 - 8 mm. By tightening the brake shoe balance nut to compress the balance spring, the up and down clearance of the brake shoe can be adjusted to make the contact between the wheel and the shoe uniform; when adjusting the brake shoe clearance, the piston stroke of the brake cylinder should be 70 - 120 mm. A transverse connecting pull rod is installed on the brake lever plates on both the left and right sides of the same wheel set to limit the lateral movement of the brake shoe 8 during braking and prevent uneven wear of the brake shoe.

[0024] This utility model is divided into two parts. One is to detect the thickness wear degree of the brake shoe 8 by detecting the stroke change of the piston rod 5 of the brake cylinder 4. The other is to make marks on the side of the brake shoe 8 and calculate the thickness wear degree of the brake shoe 8 by detecting the wear degree of the marks through a CCD. By comprehensively comparing the detection results of the two, the degree of thickness wear is obtained, and then it is judged whether the brake shoe 8 needs to be replaced. Embodiment

[0025] The specific scheme is as follows:

[0026] A detection device for the thickness wear of the locomotive brake shoe includes a controller, a sensor 7 and a magnetic piston 6. The sensor 7 is installed on the brake cylinder 4 of the locomotive, and the piston 3 inside the brake cylinder 4 is a magnetic piston 6 with magnetism; the controller is electrically connected to the sensor 7; the sensor 7 is a magnetic induction sensor;

[0027] It also includes an industrial camera. The industrial camera is connected to a computer. Two industrial cameras 9 are installed on both sides of the track in the maintenance workshop. There is a mark 13 on the side of the brake shoe 8 to be detected. When entering the maintenance workshop, the industrial camera quickly records the image of the mark 13 of the brake shoe 8. By observing and comparing the real-time image and the original image on the computer display screen by the staff, the thickness wear result of the brake shoe 8 is obtained.

[0028] The main components of the industrial camera are a CCD camera 11 and a fill light 12. The installation height of the industrial camera is the same as the height of the mark 13.

[0029] The power supply for the sensor and the controller is DC24V. The output end of the sensor is connected to the digital input end of the controller; the controller has multiple communication interfaces, including RS - 232\RS - 485\RJ45. Embodiment

[0030] A sensor 7 is installed on the brake cylinder 4, and the piston 3 of the brake cylinder 4 is selected as a magnetic piston 6 with magnetism. The sensor 7 is selected as a magnetic induction sensor, which is a device that converts magnetic signals into electrical signals. Using the transformation relationship between magnetic quantities and other physical quantities, with the magnetic field as the medium, other non-electrical physical quantity signals can also be converted into electrical signals. The magnet is made into the moving part piston 3. Once the piston 3 approaches the magnetic induction sensor, it can be attracted to send out a signal. It is mostly used for control. If the electromagnetic coil is energized, the contact can be attracted. It has the characteristics of no contacts, low power consumption, long service life, high response frequency, etc. It is encapsulated in epoxy resin as a whole inside, can be installed in metal, can be installed closely side by side, and can detect through metal, so it can work reliably in various harsh environments. Therefore, it is used as a signal sending device for the piston 3 of the brake cylinder 4 to reach the position. Figure 1 。

[0031] The magnetic induction sensor is a contact sensor, which is composed of two alloy reed switches with high magnetic permeability and low coercive force and is sealed in a glass tube filled with inert gas. There is a certain overlap and appropriate gap between the two reed switches. The ends are gold-plated as contacts, and the fuse is welded outside the tube. When the magnetic induction intensity at the position where the sensor is located is large enough, the two reed switches attract each other and the contacts are turned on; when the magnetic field weakens to a certain extent, it is released under the action of the elastic force of the reed switch itself.

[0032] The magnetic induction sensor is used to detect the magnetic field, especially suitable for detecting the piston position in the cylinder. Through the electronic working principle, the magnetic field sensor can accurately detect permanent magnets of various intensities installed on all common cylinder pistons. The sensor adopts a non-wearing.

[0033] working mode, with short-circuit protection and being firm and durable.

[0034] The magnetic induction sensor is a contact sensor, which is composed of two alloy reed switches with high magnetic permeability and low coercive force and is sealed in a glass tube filled with inert gas. There is a certain overlap and appropriate gap between the two reed switches. The ends are gold-plated as contacts, and the fuse is welded outside the tube. When the magnetic induction intensity at the position where the sensor is located is large enough, the two reed switches attract each other and the contacts are turned on; when the magnetic field weakens to a certain extent, it is released under the action of the elastic force of the reed switch itself.

[0035] The power supply for the sensor and the controller is DC24V, and the output terminal of the sensor is connected to the digital input terminal of the controller. The controller has a variety of communication interfaces (RS-232\RS-485\RJ45). Figure 2 。

[0036] The principle of detecting the thickness wear of the brake shoe 8 through the sensor is that the stroke of the piston 3 in the brake cylinder 4 is fixed, the thickness of the brake shoe 8 installed at the top of the piston rod 5 is fixed, and the sum of the stroke of the brake cylinder 4 and the thickness of the brake shoe 8 is the original stroke. When the thickness of the brake shoe 8 wears and becomes thinner, the stroke of the piston 3 in the brake cylinder 4 increases. The sensor 7 is installed at the maximum safe position where the thickness of the brake shoe 8 wears. When the thickness of the brake shoe 8 wears to the maximum safe position, when the locomotive brakes, the magnetic piston 6 in the brake cylinder 4 moves to the position of the sensor 7, the sensor 7 detects that the contact of the magnetic piston 6 is closed and the indicator light is on, and sends a signal to the controller to remind the staff to replace the brake shoe 8 in time.

[0037] The installation position adjustment method of the sensor 7 Figure 3 In it, A is the initial position of the magnetic piston 6 when not braking. Fix the new brake shoe 8 and adjust the distance between the brake shoe 8 and the wheel to 6 mm to 8 mm. Start the air compressor, the gas enters the brake cylinder 4 through the air pipe, pushes the magnetic piston 6 to move, and the magnetic piston 6 pushes the brake shoe 8 to press against the wheel through the piston rod 5. At this time, the magnetic piston 6 is located at position B. Move the sensor to position B, the sensor detects the magnetic piston 6, and the detection indicator light is on. Mark the position B on the brake cylinder 4. If the maximum safe wear of the brake shoe 8.

[0038] If the thickness is X, then measure a length of X from position B in the braking direction and record it as C. Position C is the installation position of the sensor. Figure 3 。 Embodiment

[0039] It is to make marks on the side of the brake shoe 8 and calculate the thickness wear degree of the brake shoe 8 by detecting the wear degree of the marks through an industrial camera. Install two industrial cameras 9 and industrial camera 10 on both sides of the track in the maintenance workshop, and make marks 13 on the side of the brake shoe 8. When the locomotive enters the maintenance workshop, the brake shoes with marks 13 pass through the industrial cameras in turn. The industrial cameras quickly record the images of the marks 13 on the brake shoe 8, compare the detected mark 1 images with the original images, and obtain the thickness wear result of the brake shoe 8. The industrial camera has high image stability, high transmission ability and high anti-interference ability.

[0040] The main components of the industrial camera are the CCD camera 11 and the fill light 12. The installation height of the industrial camera is the same as the height of the mark 13.

[0041] The photocoupler CCD camera, the image of the mark 13 of the brake shoe 8 is focused onto the CCD chip through the lens. The CCD accumulates charges in corresponding proportions according to the intensity of light. The charges accumulated by each pixel are moved outward point by point under the control of the video timing. After filtering and amplification, a video signal is output. The video signal is connected to the video input end of the monitor to see the same video image as the original image. CCD converts light signals into electrical signals through its own electronic scanning, and its photoelectric conversion devices all use CCD devices. When the object reflects light, it propagates to the lens and is focused onto the CCD chip through the lens. The CCD accumulates corresponding charges according to the intensity of light, and generates electrical signals representing each picture through periodic discharge. After a series of processing such as filtering, amplification, shaping, DSP (digital signal processing), a standard composite video signal is output through the output terminal of the camera. It is characterized by high sensitivity, small distortion, long life, anti-vibration, anti-magnetic field, small size, no afterimage, etc.

[0042] The fill light 12 can effectively compensate for the defect of the dark main body of the picture when the camera is shooting in a backlit environment. When the compensation function is enabled, the camera only detects a sub-area of ​​the entire field of view, and determines the working point of the AGC circuit by calculating the average signal level of this area. Since the average level of the sub-area is very low, the AGC amplifier will have a higher gain, which increases the amplitude of the output video signal, thereby making the main body picture on the monitor clear. At this time, the background picture will be brighter, but the subjective brightness difference between it and the main body picture will be greatly reduced, and the visibility of the entire field of view will be improved. In the case of insufficient ambient light, the fill light 12 is needed to cooperate with the capture system to fill in the light to ensure that the feature image accurately captured is clear and complete. Figure 4 Two industrial cameras communicate with the computer via cables.

[0043] 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 in the protection scope of the present invention.

Claims

1. A device for detecting the thickness wear of a locomotive brake shoe, characterized in that: The invention comprises a controller, a sensor (7) and a magnetic bellows (6), wherein the sensor (7) is mounted on a brake cylinder (4) of a locomotive, and the bellows (3) inside the brake cylinder (4) is a magnetic bellows (6) with magnetism; the controller is electrically connected to the sensor (7); and the sensor (7) is a magnetic induction sensor; The invention comprises an industrial camera connected to a computer. Two industrial cameras (9) are installed on both sides of a track in a maintenance workshop. The side of a brake shoe (8) to be inspected has a mark (13). When entering the maintenance workshop, the industrial camera quickly records the image of the mark (13) on the brake shoe (8).

2. A locomotive brake shoe thickness wear detection device according to claim 1, characterized in that: The main components of the industrial camera include a CCD camera (11) and a fill light (12). The installation height of the industrial camera is the same as the height of the mark (13).

3. The device for detecting the thickness wear of a locomotive brake shoe according to claim 1, characterized in that: The sensor and controller are powered by DC24V, and the output of the sensor is connected to the digital input of the controller; the controller has a variety of communication interfaces, including RS-232\RS-485\RJ45.

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