A status monitoring system for train running gear

Abstract

This utility model provides a status monitoring system for train running gear that can solve the safety problems existing in the existing system, improve the safety of high-speed rail operation, and reduce secondary hazards caused by failures. It includes: a sensor unit comprising an axle temperature sensor, an instability sensor, a stability sensor, and a vibration sensor, used to collect axle temperature, instability, stability, and vibration data of the running gear; a pre-processing unit connected to each sensor in the sensor unit, used to convert the data collected by the sensor unit into digital signal data; and a diagnostic unit comprising a first diagnostic board and a second diagnostic board, each equipped with an MCU, and connected to the pre-processing unit. The first and second diagnostic boards receive the digital signal data converted by the pre-processing unit and output operating status signals, which are then sent to the upper-level safety monitoring system along with the collected data.

Description

Technical Field

[0001] This utility model relates to a rail transit safety monitoring system, specifically to a status monitoring system for the running gear of a train. Background Technology

[0002] With the rapid development of high-speed railways, train operation safety has become an increasingly important concern. As a critical component of the train, the running gear of a high-speed train directly affects train operation safety. Currently, high-speed train running gear safety monitoring systems primarily monitor parameters such as axle temperature, instability, stability, and vibration to achieve real-time monitoring and fault warnings of the train's running gear status.

[0003] In the existing technology, there are various safety monitoring system solutions for high-speed trains. For example, Chinese patent document with publication number CN112896237A discloses a hardware platform for a comprehensive safety monitoring system for high-speed train bogies. This system includes a multi-channel information acquisition unit, a host computer, and a train network control system. The host computer includes a main processing unit and multiple slave acquisition and processing units. The slave acquisition and processing units include axle temperature acquisition and processing unit, stability acquisition and processing unit, instability acquisition and processing unit, and vibration acquisition and processing unit, etc.

[0004] However, existing running gear condition monitoring systems still have some problems: the existing systems are not secure enough, the system architecture is not highly redundant, and a single point of failure can easily lead to the failure of the entire system, thereby increasing the risk of driving accidents. Utility Model Content

[0005] To address the aforementioned issues, this utility model provides a status monitoring system for train running gear, which can solve the safety problems existing in the current system, improve the safety of high-speed rail operation, reduce secondary hazards caused by malfunctions, and optimize operation and maintenance management.

[0006] The technical solution is as follows: a condition monitoring system for train running gear, comprising:

[0007] The sensor unit includes a shaft temperature sensor, an instability sensor, a stability sensor, and a vibration sensor, which are used to collect shaft temperature, instability, stability, and vibration data of the running gear, respectively.

[0008] A pre-processing unit is connected to each sensor of the sensor unit and is used to convert the data collected by the sensor unit into digital signal data.

[0009] The diagnostic unit includes a first diagnostic board and a second diagnostic board. The first diagnostic board and the second diagnostic board are each equipped with an MCU. The first diagnostic board and the second diagnostic board are respectively connected to the pre-processing unit. The first diagnostic board and the second diagnostic board respectively receive digital signal data converted by the pre-processing unit. The first diagnostic board and the second diagnostic board each output the running status signal of the traveling part and send it together with the collected data to the upper-level safety monitoring system.

[0010] Furthermore, the first diagnostic board and the second diagnostic board are each provided with two isolated Ethernet interfaces, both of which are connected to the upper-level safety monitoring system. The first diagnostic board and the second diagnostic board are each provided with a diagnostic board isolation power module, which is connected to an external power supply. The diagnostic unit is electrically isolated from the upper-level safety monitoring system, and the first diagnostic board and the second diagnostic board are electrically isolated from each other.

[0011] Furthermore, the instability sensor is a MEMS dual-axis accelerometer, the stability sensor is a MEMS triaxial accelerometer, the instability sensor is mounted on the bogie, and the stability sensor is mounted on the vehicle body.

[0012] Furthermore, the shaft temperature sensor and the vibration sensor are respectively installed on the shaft box, gearbox, motor stator, non-drive end of the motor, and drive end of the motor. The shaft temperature sensor is a PT1000 temperature sensor, and the vibration sensor is an IEPE vibration sensor.

[0013] Furthermore, the preprocessing unit includes at least one acquisition module, which includes an analog-to-digital converter chip, an FPGA chip, and a CPU processor connected to each other. The CPU processor is equipped with an Ethernet switching module and an Ethernet port.

[0014] Furthermore, the acquisition module has an isolated Ethernet port, which connects to the first diagnostic board and the second diagnostic board. Each acquisition module is equipped with an acquisition isolation power supply module, which is connected to the diagnostic board isolation power supply module. The preprocessing unit is electrically isolated from the diagnostic unit, and the acquisition modules are electrically isolated from each other.

[0015] Furthermore, the acquisition isolation power supply module is also connected to a DC voltage conversion module, which can convert the 24V voltage of the acquisition isolation power supply module into 5V, 3.3V, 9V, and 12V voltages.

[0016] This utility model discloses a status monitoring system for train running gear. By setting up two diagnostic boards, a first diagnostic board and a second diagnostic board, each outputs the running gear's operating status signal and they corroborate each other. Each diagnostic board has two Ethernet connections to the upper-level safety monitoring system, which can effectively avoid misjudgments or omissions caused by single-point failures. This meets the high requirements of railway systems for safety redundancy. Electrical isolation is adopted between the front-end processing unit and the diagnostic unit, between the diagnostic unit and the upper-level safety monitoring system, between the two diagnostic boards of the diagnostic unit, and between the acquisition modules within the front-end processing unit. Even if a single diagnostic board, front-end processing unit, or internal acquisition module fails, it will not affect the normal operation of the entire system. This greatly reduces the chain reaction of failures, helps to reduce the risk of secondary failures, and improves the reliability and stability of the system.

[0017] Compared to an architecture that centralizes all sensor data processing and diagnostic logic in a single central processing unit, this invention utilizes a distributed architecture with a preprocessing unit for preprocessing and an independent diagnostic board for diagnostics. This effectively distributes the computational load, improves data processing efficiency, and reduces communication bandwidth requirements when dealing with numerous sensors. Attached Figure Description

[0018] Figure 1 This is a block diagram of the system components of this utility model;

[0019] Figure 2 This is a block diagram of the pre-processing unit of this utility model;

[0020] Figure 3 The left half of a block diagram of a status monitoring system for a train running gear, as shown in the embodiment;

[0021] Figure 4 The right half of a block diagram of a status monitoring system for a train running gear, as shown in the embodiment;

[0022] Figure 5 The left half of a circuit block diagram of a pre-processing unit according to an embodiment;

[0023] Figure 6 The right half of a circuit block diagram of a preprocessing unit according to an embodiment is shown. Detailed Implementation

[0024] See Figures 1 to 4 This utility model discloses a status monitoring system for train running gear, comprising:

[0025] The sensor unit 100 includes a shaft temperature sensor 101, an instability sensor 102, a stability sensor 103, and a vibration sensor 104, which are used to collect shaft temperature, instability, stability, and vibration data of the running gear, respectively.

[0026] The pre-processing unit 200 is connected to each sensor of the sensor unit and is used to convert the data collected by the sensor unit into digital signal data.

[0027] The diagnostic unit 300 includes a first diagnostic board 310 and a second diagnostic board 320. Each of the first and second diagnostic boards 310 and 320 is equipped with an MCU. Both boards are connected to the pre-processing unit 200. The first and second diagnostic boards 310 and 320 receive digital signal data converted by the pre-processing unit 200. Each board outputs a running status signal of the traveling section and sends it along with the collected data to the upper-level safety monitoring system 400. The first and second diagnostic boards 310 and 320 are redundant, serving to verify the output running status signal of the traveling section against the collected data.

[0028] When a single diagnostic board fails, another diagnostic board can still work independently, ensuring the continuity and accuracy of the running status signals of the running gear and avoiding system failure due to a single point of failure. In this embodiment, the effect of hot backup is achieved through hardware redundancy and data cross-verification, which meets the high requirements of railway systems for safety redundancy. The mutual verification of the output results of the diagnostic boards can effectively identify diagnostic errors and improve the reliability of fault judgment.

[0029] In this embodiment, the instability sensor 102 is a MEMS dual-axis accelerometer, and the stability sensor 103 is a MEMS triaxial accelerometer. The instability sensor 102 is mounted on the bogie, and the stability sensor 103 is mounted on the car body, respectively monitoring the dynamic instability of the bogie and the stability of the car body. The axle temperature sensor 101 and the vibration sensor 104 are respectively installed on the axle box, gearbox, motor stator, non-drive end of the motor, and drive end of the motor, to monitor temperature changes with high precision. The vibration sensor 104 is an IEPE vibration sensor, covering all ends of the motor, to capture early signals of mechanical faults. By combining multiple high-precision sensors, this embodiment can achieve accurate monitoring of key parameters such as axle temperature, instability, stability, and vibration of the train running gear. Temperature data can provide early warnings of bearing overheating and gearbox lubrication failure; vibration data can identify bearing wear and gear meshing faults; and acceleration data can determine abnormal bogie swaying or car body swaying, providing multiple bases for fault early warning and improving the quality and reliability of data acquisition.

[0030] In this embodiment, since there are a large number of sensors that need to be deployed, the front-end processing unit 200 is provided with two acquisition modules. The acquisition modules are completely identical in structure, except that they are connected to different sensors. The acquisition module includes an analog-to-digital converter chip 201, an FPGA chip 202, and a CPU processor 203 connected to each other. The CPU processor 203 is connected to an Ethernet port 205 through an Ethernet switching module 204.

[0031] In this embodiment, the acquisition module has an isolated Ethernet port 205, and the acquisition module is equipped with an acquisition isolation power supply module 206. The acquisition isolation power supply module 206 is connected to the diagnostic board isolation power supply module 302. The preprocessing unit 200 and the diagnostic unit 300 are electrically isolated from each other, and the acquisition modules are electrically isolated from each other. The acquisition isolation power supply module is also connected to a DC voltage conversion module, which can convert the 24V voltage of the acquisition isolation power supply module into 5V, 3.3V, 9V, and 12V voltages.

[0032] Specifically, in the embodiment, each car is equipped with two front-end processing units 200, both of which have the same function and interface, and each corresponds to a bogie. The front-end processing unit 200 contains two independent acquisition modules, which together complete the interface acquisition and conversion of the axle temperature, instability, stability, and vibration sensor signals of the corresponding bogie. Then, the converted axle temperature, instability, stability, and vibration digital data information are sent to the two first diagnostic boards 310 and the second diagnostic board 320 for processing through independent Ethernet buses.

[0033] The pre-processing unit converts the analog signals collected by the sensors into digital signal data, which facilitates subsequent processing and transmission. Each car is equipped with two pre-processing units, each containing two independent acquisition modules, which can efficiently complete the acquisition and conversion tasks of various sensor signal interfaces of the corresponding bogie. The data is sent to two diagnostic boards for processing through an independent Ethernet bus, which can improve the efficiency of data processing and ensure the timeliness of data transmission.

[0034] The first diagnostic board 310 and the second diagnostic board 320 are each equipped with two isolated Ethernet interfaces 301. Both Ethernet interfaces are connected to the upper-level safety monitoring system 400. With this configuration, the operating status signals and collected data of the traveling section output by the first diagnostic board 310 and the second diagnostic board 320 are also sent to the upper-level safety monitoring system 400 via redundant Ethernet through the two Ethernet interfaces 301. This multi-level redundancy design ensures that the system can still operate normally when some modules fail. The first diagnostic board 310 and the second diagnostic board 320 are each equipped with a diagnostic board isolation power supply module 302, which is connected to an external power supply. The diagnostic unit 300 is electrically isolated from the upper-level safety monitoring system 400, and the first diagnostic board 310 and the second diagnostic board 320 are also electrically isolated from each other.

[0035] The MCUs of the first diagnostic board 310 and the second diagnostic board 320 can be NXP's LS1043 or Rockchip's RK3568. Both the first diagnostic board 310 and the second diagnostic board can independently judge the running status signal of the traveling section by the shaft temperature, instability, stability, and vibration digital data collected and converted by the two pre-processing units 200. This judgment can be an anomaly judgment based on the collected real-time data and historical data, or an anomaly judgment based on the collected real-time data and a set threshold. Both can be achieved by simple settings of the MCU of the diagnostic unit. How to output the running status signal of the traveling section is a current technology method. Finally, the real-time temperature value, characteristic indicators, running section status and other information in the collected data are sent to the upper-level safety monitoring system via Ethernet.

[0036] In this embodiment, the two diagnostic boards of the diagnostic unit are electrically isolated from the upper-level safety monitoring system, the diagnostic unit is electrically isolated from the pre-processing unit, and the two diagnostic boards of the diagnostic unit are electrically isolated. The electrical isolation realizes power isolation and communication isolation, ensuring that the failure of a single diagnostic board does not affect the normal operation of the system and the other diagnostic board.

[0037] Electrical isolation between the four acquisition modules within the two front-end processing units ensures that a failure in a single front-end processing unit or one of its acquisition modules will not affect the normal operation of the front-end processor and other acquisition modules. Through the electrical isolation design between the diagnostic board and the upper-level intelligent safety monitoring system, between the diagnostic board and the front-end processing unit, between the two diagnostic boards, and between the acquisition modules within the front-end processing unit, the chain reaction of failures can be effectively reduced, and the risk of secondary failures can be lowered.

[0038] Traditional systems only perform simple filtering at the power supply end and do not achieve full-link electrical isolation, making them susceptible to interference from the complex electromagnetic environment on board. This invention, through multi-level isolation design, is particularly suitable for the strong interference scenarios of high-speed trains.

[0039] Figure 5 , 6The system block diagram of the pre-processing unit in the embodiment is shown. The analog-to-digital converter chip 201 includes ADS8343X2, MAX31865X20, and ADS1178X. ADS8343X2 corresponds to a stability sensor and an instability sensor, MAX31865X20 corresponds to a shaft temperature sensor, and ADS1178X1 corresponds to a vibration sensor. In this embodiment, an ADS7961 is also used to detect the open / short circuit status of three accelerometers: eight diagnostic sensors, two MEMS biaxial accelerometers, and one MEMS triaxial accelerometer. The FPGA chip 202 in this embodiment uses an LFE5U-25F-6BG256I, the CPU processor 203 uses an HG-IMX6-CORE-BRD, the Ethernet switching module 204 uses a KS8995MI, and the isolation power supply 206 uses a URB2424. The LD-20WR3 acquisition isolation power supply module is also connected to a DC voltage conversion module 207. The DC voltage conversion module 207 uses an RT8070ZSP to obtain a 3.3V voltage, uses a TPS5430 to realize the conversion of 24V to 5V voltage, and uses a URA2409YMD-10WR3 to realize the conversion of 24V to 9V voltage.

[0040] In practice, the sensor unit includes 8 IEPE vibration sensors, 20 PT1000 temperature sensors, two MEMS biaxial accelerometers and one MEMS triaxial accelerometer, for a total of 3 accelerometers. The sensor unit is powered by converting DC24V voltage to DC12V through the REC5-2412SRW DC voltage conversion module.

[0041] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0042] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A condition monitoring system for a train running gear, characterized in that, Comprising: A sensor unit, the sensor unit includes an axle temperature sensor, an instability sensor, a stability sensor, and a vibration sensor, which are respectively used to collect the axle temperature, instability, stability, and vibration data of the running gear; A preprocessing unit, the preprocessing unit is connected to each sensor of the sensor unit, and is used to convert the collected data of the sensor unit into digital signal data; A diagnosis unit, the diagnosis unit includes a first diagnosis board and a second diagnosis board, the first diagnosis board and the second diagnosis board are respectively provided with an MCU, the first diagnosis board and the second diagnosis board are respectively connected to the preprocessing unit, the first diagnosis board and the second diagnosis board respectively receive the digital signal data converted by the preprocessing unit, and the first diagnosis board and the second diagnosis board respectively output the running state signals of the running gear and send them to the superior safety monitoring system together with the collected data.

2. A condition monitoring system for a train running gear according to claim 1, characterised in that: The first diagnosis board and the second diagnosis board are respectively provided with two isolated Ethernet interfaces, and both of the two Ethernet interfaces are connected to the superior safety monitoring system.

3. A condition monitoring system for a train running gear according to claim 1, wherein: The first diagnosis board and the second diagnosis board are respectively provided with a diagnosis board isolation power supply module, the diagnosis board isolation power supply module is connected to an external power supply, the diagnosis unit is electrically isolated from the superior safety monitoring system, and the first diagnosis board and the second diagnosis board are electrically isolated from each other.

4. A condition monitoring system for a train running gear according to claim 1, wherein: The instability sensor uses a MEMS biaxial acceleration sensor, the stability sensor uses a MEMS triaxial acceleration sensor, the instability sensor is installed on the bogie, and the stability sensor is installed on the car body.

5. A condition monitoring system for a train running gear according to claim 1, wherein: The axle temperature sensor and the vibration sensor are respectively arranged on the axle box, gear box, motor stator, non-driving end of the motor, and driving end of the motor. The axle temperature sensor uses a PT1000 temperature sensor, and the vibration sensor uses an IEPE vibration sensor.

6. A condition monitoring system for a train running gear according to claim 3, wherein: The preprocessing unit includes at least one acquisition module, the acquisition module includes an analog-to-digital conversion chip, an FPGA chip, and a CPU processor connected to each other, and the CPU processor is provided with an Ethernet switching module and an Ethernet port.

7. A condition monitoring system for a train running gear according to claim 6, characterised in that: The acquisition module has an isolated Ethernet port, the acquisition module is connected to the first diagnosis board and the second diagnosis board through the Ethernet port, the acquisition module is respectively connected to an acquisition isolation power supply module, the acquisition isolation power supply module is connected to the diagnosis board isolation power supply module, the preprocessing unit is electrically isolated from the diagnosis unit, and the acquisition modules are electrically isolated from each other.

8. A condition monitoring system for a train running gear according to claim 7, characterised in that: The acquisition isolation power supply module is also connected with a DC voltage conversion module, and the DC voltage conversion module can convert the 24V voltage of the acquisition isolation power supply module into 5V, 3.3V, 9V, and 12V voltages.

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