Dynamic set wheel set on-line detection system

Abstract

The utility model belongs to the field of rail train flaw detection, and discloses an on-line detection system for a movable set wheel set. Comprising a data center, a ground operation platform, an axle data network unit and dynamic set flaw detection equipment, according to the utility model, a top rotating wheel mode is adopted, a robot is utilized to carry an ultrasonic carrier, and ultrasonic flaw detection of a dynamic set train wheel set is realized through automatic control. Aiming at the situation that existing equipment cannot adapt to simultaneous detection of locomotive wheel sets and passenger car wheel sets, wheel jacking of different wheel diameters is achieved by changing the structure of a wheel jacking mechanism and adding an automatic block-up block. The application range of equipment is widened, the dispatching period of flaw detection of the dynamic train is shortened, and the on-line rate of the dynamic train is increased.

Description

Technical Field

[0001] This utility model belongs to the field of flaw detection for railcars, and specifically relates to an online detection system for moving wheelsets. Background Technology

[0002] Wheel flaw detection is a crucial step in ensuring safe train operation. Traditional flaw detection methods require manual operation by workers. The wheels remain stationary while a person manually scans the wheel rim using transverse wave ultrasonic waves to detect radial defects. This process often requires multiple people working together and 2-3 trips of the train to scan the entire wheel. This inevitably leads to missed defects and requires a large amount of manual work.

[0003] The 160km / h power-centralized EMU (Electric Multiple Unit) consists of Harmony electric locomotives (HXD3G or HXD1 locomotives) and 25T passenger cars, arranged in a 1Mc+7T+1Tc or 1Mc+16T+1Mc configuration. Therefore, the EMU train is characterized by its modularity, wide range of wheel diameters, and broad applicability for wheel flaw detection. Currently, there is no equipment in the railway field capable of automating flaw detection for all wheels of the power-centralized EMU. For wheel flaw detection in EMUs, current methods involve separate flaw detection for the locomotive and passenger cars, which presents significant scheduling and operational challenges for maintenance workshops.

[0004] Furthermore, due to the significant difference in wheel size between locomotives and passenger cars (locomotive wheel diameter 950mm–1250mm, passenger car wheel diameter 790mm–915mm), current locomotive flaw detection equipment is unable to perform flaw detection on passenger car wheels. For wheel flaw detection requirements of EMU trains, online flaw detection is not performed by disassembling the trains. Therefore, currently, for EMU flaw detection, the trains need to be dispatched from passenger car maintenance bases to locomotive maintenance bases to conduct flaw detection operations on both passenger cars and locomotives separately. This maintenance and dispatching process is complex and requires a large number of personnel to ensure wheel flaw detection operations can be carried out. Utility Model Content

[0005] In view of this, the present invention provides an online detection system for moving hub wheelsets to solve the above problems.

[0006] To solve the above technical problems, this utility model provides an online detection system for wheelsets of powered trains, comprising:

[0007] Data center, ground operation platform, axle data network unit and dynamic flaw detection equipment;

[0008] The data center is used to collect and store flaw detection data; the ground operation platform is used to control the moving flaw detection equipment to perform detection tasks; the axle data network unit is used to build a local area network, enabling information interaction and command control between the data center, the ground operation platform and the moving flaw detection equipment;

[0009] The moving flaw detection equipment includes a data acquisition and analysis unit, a top wheel unit, a flaw detection robot, a drive unit, an ultrasonic flaw detection unit, a coupling water supply system, and an electrical control unit. The drive unit forms a mobile platform that supports multiple units and can move along the track. The top wheel unit is mounted on the drive unit and is used to lift and rotate the train wheelsets, providing movement space for the flaw detection robot and the ultrasonic flaw detection unit.

[0010] As an alternative, the top roller unit includes an integrated rigid structure load-bearing arm, a roller mechanism, a lifting mechanism, and a pad block mechanism.

[0011] As an alternative, the wheel mechanism includes a wheel swing hydraulic structure and a hydraulic drive wheel; the hydraulic drive wheel is located on both sides of the wheel swing hydraulic structure, and the structural part of the hydraulic drive wheel is movably fixed on the integrated rigid structure load-bearing arm. When the wheel swing hydraulic structure moves, it drives the hydraulic drive wheel to move.

[0012] As an alternative, the pad mechanism includes a pad drive cylinder and a pad block.

[0013] As an optional approach, the flaw detection robot includes at least two robots and two ultrasonic flaw detection units; wherein the flaw detection robot has at least 6 degrees of freedom.

[0014] As an optional approach, the ultrasonic flaw detection unit includes a phased array ultrasonic probe, a conventional ultrasonic probe, a sensor, a coupling water outlet structure, and a support arm.

[0015] As an optional approach, multiple phased array ultrasonic probes, conventional ultrasonic probes, and sensors are provided and configured in a matching set.

[0016] As an alternative, the electrical control unit includes a distribution box, a motion controller, and a motor driver.

[0017] As an alternative, the coupling water outlet structure is connected to the coupling water supply system.

[0018] As an optional approach, the data acquisition and analysis unit is used to collect, store, and distribute the data generated by ultrasonic flaw detection, and then upload it to the data center for analysis.

[0019] The beneficial effects of this utility model are as follows:

[0020] This invention employs a top-rotor mechanism, utilizing a robot to carry an ultrasonic carrier, and achieves ultrasonic flaw detection of train wheelsets through automated control. Addressing the limitation of existing equipment in simultaneously inspecting locomotive and passenger train wheelsets, the top-rotor mechanism is modified in structure, and automatic elevation blocks are added to accommodate top-rotor wheels of different diameters. This improves the equipment's adaptability, reduces the scheduling cycle for train flaw detection, and increases the operational rate of trains. Attached Figure Description

[0021] Figure 1 A schematic diagram of the structure of the online detection system for wheelsets of a moving train provided in this embodiment of the present invention;

[0022] Figure 2 A schematic diagram of the structure of the dynamic flaw detection equipment provided in this embodiment of the utility model;

[0023] Figure 3 This is a partial structural schematic diagram of the dynamic flaw detection equipment provided in an embodiment of the present utility model;

[0024] Figure 4 A schematic diagram illustrating the connection between the dynamic flaw detection equipment and the wheel, provided for an embodiment of this utility model;

[0025] Figure 5 This is a schematic diagram of the shim block structure provided in an embodiment of the present utility model;

[0026] Figure 6 This is a schematic diagram of the operation of the elevation unit during locomotive testing, provided in an embodiment of the present invention.

[0027] Figure 7 This is a schematic diagram illustrating the operation of the elevation unit during passenger vehicle testing, provided in an embodiment of the present invention.

[0028] Figure 8 A front view of the ultrasonic flaw detection unit provided in an embodiment of this utility model;

[0029] Figure 9 A side view of the ultrasonic flaw detection unit provided in an embodiment of this utility model;

[0030] Figure 10 This is a schematic diagram showing the connection between the ultrasonic flaw detection unit and the wheel, as provided in an embodiment of the present invention.

[0031] Figure labels and their correspondences:

[0032] 1-Data acquisition and analysis unit, 2-Top wheel unit, 21-Roller mechanism, 211-Roller swing hydraulic drive structure, 212-Hydraulic drive wheel, 22-Padded block structure, 221-Padded block drive cylinder, 222-Elevating block, 23-Lifting mechanism, 24-Integrated rigid structure load-bearing arm, 3-Ultrasonic flaw detection unit, 31-Sensor, 32-Phase array ultrasonic probe, 33-Conventional ultrasonic probe, 34-Support arm, 35-Coupled water outlet structure, 4-Flaw detection robot, 5-Drive unit, 6-Coupled water supply system, 7-Electrical control unit, 8-Inspected wheel, 9-Rail. Detailed Implementation

[0033] To enable those skilled in the art to better understand the technical solution of this utility model, the present utility model will be further described in detail below with reference to specific embodiments.

[0034] Please see Figures 1-10 This embodiment provides an online detection system for wheelsets of moving trains, including:

[0035] Data center, ground operation platform, axle data network unit and dynamic flaw detection equipment;

[0036] The data center is used to collect and store flaw detection data; the ground operation platform is used to control the moving flaw detection equipment to perform detection tasks; the axle data network unit is used to build a local area network, enabling information interaction and command control between the data center, the ground operation platform and the moving flaw detection equipment;

[0037] The moving flaw detection equipment includes a data acquisition and analysis unit 1, a top rotating wheel unit 2, a flaw detection robot 4, a drive unit 5, an ultrasonic flaw detection unit 3, a coupling water supply system 6, and an electrical control unit 7. Among them, the drive unit 5 is used to form a supporting mobile platform that carries multiple units and can move along the track. The top rotating wheel unit 2 is installed on the drive unit 5 and is used to lift and rotate the train vehicle wheelsets, providing movement space for the flaw detection robot 4 and the ultrasonic flaw detection unit 3.

[0038] The data center comprises data storage and reporting services, while the data analysis center is primarily used for flaw detection data analysis. It includes flaw detection data servers, data analysis software, a video surveillance platform, and flaw detection data management and interconnection center management. It enables the storage and historical traceability of equipment inspection data, as well as the viewing of historical and current inspection data through reporting software, and facilitates electronic signing of flaw detection logs.

[0039] The ground operation platform consists of a ground control console, handheld control terminals, a data analysis host, a printer, network interfaces, and automated control and analysis software. The automated control and analysis software comprises a detection and control module, a data analysis and management module, and a performance monitoring and diagnostic module. Its main functions include controlling the movement of the trench flaw detection trolley, processing and analyzing equipment flaw detection data, and printing flaw detection logs. At the data analysis level, this operation platform functions similarly to a data center.

[0040] The axle data network unit consists of wireless APs, AP controllers, etc., which builds the local area network environment for the equipment to operate. It is used for flaw detection data transmission, control command interaction, and to realize flaw detection data aggregation and analysis in the data center.

[0041] In this embodiment, the drive unit 5 uses a high-precision servo motor to drive the track-walking steel wheels, and is equipped with an automatic positioning system for detection positions and safety protection devices. The top wheel unit 2 is mounted on the drive unit 5 and consists of an integrated rigid structure load-bearing arm 24, a wheel mechanism 21, a lifting mechanism 23, and a pad block mechanism. It realizes the lifting and rotation of locomotive wheelsets for wheelset flaw detection and wheelset maintenance.

[0042] Please refer to it again. Figure 3 In this embodiment, the rotating wheel mechanism 21 includes a rotating wheel swing hydraulic structure and a hydraulically driven rotating wheel 212. The hydraulically driven rotating wheel 212 is disposed on both sides of the rotating wheel swing hydraulic structure, and the structural part of the hydraulically driven rotating wheel 212 is movably fixed on the integrated rigid structure support arm 24. When the rotating wheel swing hydraulic structure moves, it drives the hydraulically driven rotating wheel 212 to move. Its working principle is as follows: the hydraulic lifting mechanism 23 drives the upper component to rise to a position close to the wheel 8 being inspected. At this time, the pad block mechanism is higher than the upper surface of the rail 9. Then the pad block mechanism passes over the rail 9, and the hydraulic lifting mechanism 23 descends until the pad block mechanism is completely pressed on the upper surface of the rail 9. At this time, the module composed of the pad block mechanism, the rotating wheel mechanism 21, and the integrated rigid structure support arm 24 can be regarded as a completely rigid body. The gravity and pressure on it are finally completely transferred to the rail 9 through the pad block mechanism. After the aforementioned pad mechanism fully presses against the rail 9, the rotating wheel swing hydraulic drive cylinder rotates the rotating wheel from swing position B to swing position A via a lever mechanism. At this time, the two rotating wheels are fully in contact with the wheel being tested and are lifted off the rail 9 by the rotating wheel mechanism 21. At this point, the rotation drive motor can drive the wheel to rotate to a specified angle as needed for testing and complete the wheel flaw detection.

[0043] Please see Figure 6 and Figure 7 , Figure 6This is a schematic diagram of the detection of the large vehicle (locomotive) wheel. When the large wheel is being detected at the current position, due to its large outer diameter, the angle at which the wheel is lifted changes little. The lifting height can be met by the rotation angle of the swing mechanism itself. Therefore, the lifting requirements can be met even when the pad block 222 of the pad block mechanism is in the retracted state. Figure 7 This is a schematic diagram of the trolley (bus) wheel inspection. When the trolley wheel is inspected at the current position, due to its small outer diameter, the angle at which the wheel is lifted changes significantly. The rotation angle of the swing mechanism itself cannot meet the lifting height, so an additional shim block 222 needs to be added at the shim block mechanism to meet the lifting requirements. At this time, the shim block 222 is in the raised position, and the height of the shim block 222 compensates for the height difference between the rail 9 and the shim block mechanism.

[0044] In some implementation scenarios, the diameter range of the inspected wheel 8 is 790mm to 1250mm, a large range that makes the existing top wheel structure unsuitable. To adapt to wheels with diameters from 790mm to 1250mm, the top wheel structure is dimensionally modified, and a miniature electric cylinder is used for automatic elevation. For wheels with diameters from 1050mm to 1250mm, no shim 222 is needed; for wheels with diameters from 790mm to 1050mm, shim 222 is required. The thickness of shim 222 is 12-15mm.

[0045] As an optional approach, the flaw detection robot 4 consists of two sets of robots with no less than six degrees of freedom and two sets of ultrasonic flaw detection units 3. Through arc-shaped / linear motion control and adaptive correction of wheel movement, it achieves correct and tight connection between the flaw detection carrier and the wheel tread, thus completing the wheelset flaw detection operation.

[0046] The ultrasonic flaw detection unit 3 consists of a phased array ultrasonic probe 32, a conventional ultrasonic probe 33, a phased array ultrasonic electronic unit, and a carrier and support arm 34, which realizes the acquisition and processing of wheelset ultrasonic data.

[0047] The ultrasonic carrier is used to mount phased array ultrasonic probes 32 and conventional ultrasonic probes 33 (for collecting defects in wheel rims and spokes). In addition to the two phased array ultrasonic probes 32 and five conventional ultrasonic probes 33 (five 0° straight probes, meaning the ultrasonic waves emitted from the probe are perpendicular to the probe surface) and one optional angled probe (the angled probe emits ultrasonic waves at an angle), it also includes a sensor 31 (for detecting whether the carrier is correctly attached to the wheel tread) and a coupling water outlet structure (for providing the coupling water required for ultrasonic flaw detection). The carrier support arm 34 has an irregular shape to prevent interference between the robot-mounted ultrasonic carrier and the locomotive's undercarriage space during the process of attaching to the wheel tread.

[0048] Data Acquisition and Analysis Unit 1: This unit acquires, stores, encapsulates, and processes ultrasonic flaw detection data, and also performs data analysis. Electrical Control System: Composed of a power distribution box, motion controller, and motor driver hardware, this system controls equipment movement, robot motion, and the top wheel device. Electrical Control Unit 7 uses a power battery to provide power to the entire flaw detection trolley, enabling the equipment to automatically navigate through trenches and achieve automatic positioning and flaw detection functions for locomotive and passenger car wheelsets.

[0049] The key point of this embodiment, based on the above solution, is to break away from the traditional ultrasonic flaw detection methods used in locomotive and EMU (Electric Multiple Unit) trains. It proposes a top-wheel method for EMU trains, utilizing a robot carrying an ultrasonic carrier to achieve ultrasonic flaw detection of the train wheelsets through automated control. Addressing the inability of existing equipment to simultaneously inspect locomotive and passenger train wheelsets, this embodiment modifies the top-wheel mechanism structure and adds an automatic elevation block 222 to accommodate top-wheels of different wheel diameters. This improves the equipment's adaptability, reduces the scheduling cycle for EMU train flaw detection, and increases the EMU train's operational rate.

[0050] This embodiment employs a miniaturized ultrasonic carrier. Through mechanical layout, the ultrasonic carrier can adapt to wheel diameters ranging from 790mm to 1250mm. Simultaneously, the layout of the ultrasonic probe is modified (differentiating it from existing ultrasonic carrier probe layouts) to meet the ultrasonic coverage requirements of the locomotive and customer wheelsets' rims and spokes. The layout carrier support arm 34 ensures that the ultrasonic carrier's fitment to the wheel avoids the risk of interference from the undercarriage space.

[0051] The difference between this embodiment and the existing vehicle flaw detection system is that it uses battery power (no drag chain power supply system), which can realize fully automated operation in the trench. The equipment is equipped with a coupling water tank to assist in ultrasonic flaw detection.

[0052] The above are merely preferred embodiments of this utility model. It should be noted that the above preferred embodiments should not be considered as limitations on this utility model, and the scope of protection of this utility model should be determined by the scope defined in the claims. For those skilled in the art, several improvements and modifications can be made without departing from the spirit and scope of this utility model, and these improvements and modifications should also be considered within the scope of protection of this utility model.

Claims

1. An online detection system for moving wheelsets, characterized in that, include: Data center, ground operation platform, axle data network unit and dynamic flaw detection equipment; The data center is used to collect and store flaw detection data; The ground operation platform is used to control the dynamic flaw detection equipment to perform detection tasks; The axle data network unit is used to build a local area network, enabling the data center, ground operation platform and dynamic flaw detection equipment to achieve information interaction and command control; The moving flaw detection equipment includes a data acquisition and analysis unit, a top wheel unit, a flaw detection robot, a drive unit, an ultrasonic flaw detection unit, a coupling water supply system, and an electrical control unit. The drive unit forms a mobile platform supporting multiple units and can move along a track. The top wheel unit, mounted on the drive unit, is used to lift and rotate the train wheelsets, providing movement space for the flaw detection robot and the ultrasonic flaw detection unit.

2. The online detection system for moving wheelsets according to claim 1, characterized in that, The top rotating wheel unit includes an integrated rigid structure load-bearing arm, a rotating wheel mechanism, a lifting mechanism, and a pad block mechanism.

3. The online detection system for moving wheelsets according to claim 2, characterized in that, The rotating wheel mechanism includes a rotating wheel swing hydraulic structure and a hydraulic drive rotating wheel; the hydraulic drive rotating wheel is disposed on both sides of the rotating wheel swing hydraulic structure, and the structural part of the hydraulic drive rotating wheel is movably fixed on the integrated rigid structure load-bearing arm. When the rotating wheel swing hydraulic structure moves, it drives the hydraulic drive rotating wheel to move.

4. The online detection system for moving wheelsets according to claim 2, characterized in that, The pad mechanism includes a pad drive cylinder and a pad block.

5. The online detection system for moving wheelsets according to claim 1, characterized in that, The flaw detection robot includes at least two robots and two ultrasonic flaw detection units; wherein the flaw detection robot has at least 6 degrees of freedom.

6. The online detection system for moving wheelsets according to claim 1, characterized in that, The ultrasonic flaw detection unit includes a phased array ultrasonic probe, a conventional ultrasonic probe, a sensor, a coupling water outlet structure, and a support arm.

7. The online detection system for moving wheelsets according to claim 6, characterized in that, The phased array ultrasonic probe, conventional ultrasonic probe and sensor are provided in multiple sets and are configured in a matching manner.

8. The online detection system for moving wheelsets according to claim 1, characterized in that, The electrical control unit includes a distribution box, a motion controller, and a motor driver.

9. The online detection system for moving wheelsets according to claim 6, characterized in that, The coupling water outlet structure is connected to the coupling water supply system.

10. The online detection system for moving wheelsets according to claim 1, characterized in that, The data acquisition and analysis unit is used to collect, store, and distribute the data generated by ultrasonic flaw detection, and upload it to the data center for analysis.

Images