Passenger train power supply maintenance platform

Abstract

The utility model discloses a kind of passenger train power maintenance platform, belong to train maintenance equipment technical field, it includes simulation load test box, control cabinet;Simulation load test box is equipped with load one, load two, load three, load one connects measured single-phase inverter, load two connects measured charger, load three connects measured three-phase inverter;Control cabinet is equipped with control unit, relay output module, direct current electric quantity detection module, single-phase ac detection module, three-phase ac detection module, direct current electric quantity detection module and the line between measured charger and load two are connected, single-phase ac detection module and the line between measured single-phase inverter and load one are connected, three-phase ac detection module and the line between measured three-phase inverter and load three are connected;The utility model solves the problem that train power inverter and other equipment cannot be tested after maintenance.

Description

Technical Field

[0001] This utility model relates to the field of train maintenance equipment technology, and in particular to a power supply maintenance platform for passenger trains. Background Technology

[0002] Currently, the direct-powered air-conditioned buses adopt a full-train DC 600V power supply method, with the core components being the inverter power supply box and the charger box. Each workstation's inverter power supply box contains two three-phase inverters with a power capacity of 2×35kVA, responsible for converting DC 600V to three-phase AC 380V, primarily for powering the onboard air conditioning and electric kettles. The charger box contains an 8kW charger and a 3.5kVA single-phase inverter, converting DC 600V to DC 110V and AC 220V, mainly for charging the onboard battery packs, lighting, and power outlets.

[0003] Inverter power supply boxes and charger boxes, as the core of the passenger car power supply system, frequently malfunction during actual operation, causing them to fail and resulting in the shutdown of passenger car air conditioning systems, ventilation systems, electric kettles, etc., easily causing inconvenience to passengers and affecting the normal operation and efficiency of railway passenger services. According to statistics, in 2019 alone, a certain railway depot carried out more than 800 repairs on inverters, chargers, and single-phase inverters.

[0004] Existing testing methods and techniques are insufficient to ensure the quality of power-on testing of power supply equipment after maintenance, mainly due to the following issues:

[0005] First, it is impossible to conduct load tests on the repaired inverters and other equipment. They can only be tested when they are installed on the bus, which often results in failures and subsequent repairs.

[0006] Secondly, the original post-repair testing method relied solely on manual inspection and testing, which was labor-intensive, time-consuming, and the records could not be stored.

[0007] Third, it suffers from drawbacks such as low efficiency, poor standardization, and poor real-time performance.

[0008] Based on the above reasons, this utility model designs and develops a high-stability and high-reliability bus power supply simulated load test device. Utility Model Content

[0009] This utility model proposes a power supply maintenance platform for passenger trains. Through the design of a simulated load test box and control cabinet, it solves the problem that train power inverters and other equipment cannot be tested under load after maintenance.

[0010] To achieve the above objectives, the technical solution adopted by this utility model is as follows: a power supply maintenance platform for passenger trains, comprising a simulated load test chamber and a control cabinet; the simulated load test chamber is provided with load one, load two, and load three; load one is connected to contactor one, and contactor one has an access terminal one for connecting to a single-phase inverter under test; load two is connected to contactor two, and contactor two has an access terminal two for connecting to a charger under test; load three is connected to contactor three, and contactor three has an access terminal three for connecting to a three-phase inverter under test; the control cabinet is equipped with a control... The control unit includes a relay output module, a DC power detection module, a single-phase AC power detection module, and a three-phase AC power detection module connected to the control unit. The coils of contactors one, two, and three are each connected to a relay. The output terminal of the relay output module is connected to the coil of the relay. The DC power detection module is connected to the line between the charger under test and load two. The single-phase AC power detection module is connected to the line between the single-phase inverter under test and load one. The three-phase AC power detection module is connected to the line between the three-phase inverter under test and load three.

[0011] Preferably, each of the three-phase inverters under test is connected to a load bank containing two loads, and the output terminal of the three-phase inverter under test is simultaneously connected to both loads.

[0012] Preferably, the two three-phase AC power detection modules in the inverter power supply box located on the same workbench are respectively connected to two load cell groups.

[0013] Preferably, the first load is a heating plate, and the second and third loads are both resistors.

[0014] Preferably, the simulated load test chamber is provided with a left mounting area, a middle mounting area and a right mounting area. Load 1 is installed in the left mounting area, load 2 is installed in the middle mounting area and load 3 is installed in the right mounting area. A power distribution cabinet is provided in the middle mounting area below load 2. Contactor 1, contactor 2 and contactor 3 are all installed in the power distribution cabinet. The power distribution cabinet is provided with an aviation socket interface for connecting to the device under test.

[0015] Preferably, a heat dissipation area is provided below the simulated load test chamber, and a heat sink is installed in the heat dissipation area.

[0016] Preferably, the DC power detection module, the single-phase AC power detection module, and the three-phase AC power detection module are all connected to the control unit via a communication module.

[0017] Preferably, the communication module is a 485 to 232 converter.

[0018] Preferably, the control unit is an industrial touch screen all-in-one machine.

[0019] Preferably, the control cabinet includes an upper mounting area, a middle mounting area, a lower mounting area, and a bottom storage area; the control unit is installed in the upper mounting area, and the front of the upper mounting area has an inclined operating surface, on which the operating part of the control unit is located; the relay output module and the relay are both installed in the middle mounting area; the DC power detection module, the single-phase AC power detection module, and the three-phase AC power detection module are all installed in the lower mounting area, and the lower mounting area also has an aviation socket interface for connecting the device under test to the detection module; the bottom storage area serves as a storage space for storing tools and spare parts.

[0020] By adopting the above technical solution, this utility model has the following beneficial effects:

[0021] 1. A simulated load test chamber and control cabinet for the bus power system were designed based on inverter model research, resistor network model, and automatic control circuit. This design met the routine test requirements for load testing of equipment after maintenance and solved the problem that train power inverters and other equipment could not be tested under load after maintenance.

[0022] 2. An automatic control and data acquisition system consisting of an industrial control touch screen all-in-one machine, an output control unit, and a detection module is used to realize automatic load switching, automatic workstation switching, and real-time data monitoring. This can reduce the workload of operators and prevent the influence of human factors during the test.

[0023] 3. By combining and sharing multiple loads and load cells, load tests on multiple inverters and chargers can be performed without testing them one by one, thus making fuller use of load capacity and maximizing efficiency. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the circuit connection structure of the passenger train power supply maintenance platform proposed in Embodiment 1 of this utility model;

[0025] Figure 2 This is a schematic diagram of the system architecture of the passenger train power supply maintenance platform proposed in Embodiment 1 of this utility model;

[0026] Figure 3 This is a schematic diagram of the partitioned structure of the simulated load test chamber proposed in Embodiment 1 of this utility model;

[0027] Figure 4 This is a schematic diagram of the partitioned structure of the control cabinet proposed in Embodiment 1 of this utility model.

[0028] The components in the attached diagram are labeled as follows: 1-Simulated load test chamber, 2-Control cabinet, 3-Load 1, 4-Load 2, 5-Load 3, 6-Contactor 1, 7-Single-phase inverter under test, 8-Single-phase AC power detection module, 9-Contactor 2, 10-Charger under test, 11-DC power detection module, 12-Contactor 3, 13-Three-phase inverter under test, 14-Three-phase AC power detection module, 15-Control module, 16-Communication module, 17-Relay output module, 18-Left mounting area, 19-Right mounting area, 20-Middle mounting area, 21-Heat dissipation area, 22-Upper mounting area, 23-Operating surface, 24-Middle mounting area, 25-Lower mounting area, 26-Bottom storage area. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0030] Example 1

[0031] like Figure 1 As shown, this embodiment takes the simultaneous load test of 8 inverters, 2 chargers, and 2 single-phase inverters as an example to provide a detailed description of a passenger train power supply maintenance bench. In this utility model, a passenger train power supply maintenance bench includes a simulated load test chamber 1 and a control cabinet 2. For example... Figure 2 The diagram shows the system architecture of a passenger train power supply maintenance platform. It mainly consists of a simulated load in the simulated load test chamber 1, an action unit, and an industrial control touch screen all-in-one machine, output control unit, DC power detection module 11, single-phase AC power detection module 8, and three-phase AC power detection module 14 in the control cabinet 2. The industrial control touch screen all-in-one machine mainly includes a human-machine interface and an industrial control computer. Various detection modules include voltage and current sensors and data acquisition modules, which collect electrical data from the simulated load and send it to the industrial control touch screen all-in-one machine for display. The output control unit is a relay output module 17, and the action unit is a general term for various types of relays. The control signals from the industrial control touch screen all-in-one machine control the action unit through the output control unit, thereby controlling the connection and disconnection between the simulated load and the device under test, thus achieving the purpose of testing according to the test requirements.

[0032] This invention designs a load simulation box for a bus power system from aspects such as inverter model research, resistor network model, and automatic control circuit, meeting the relevant routine test requirements for load testing of equipment after maintenance. Through automatic control and data acquisition technology, it realizes intelligent and comprehensive load performance testing of the bus's standardized inverter power supply device, which can reduce the workload of operators and prevent the influence of human factors during the test. Furthermore, the entire test process can be automatically controlled through an industrial control touch screen all-in-one machine, eliminating the need for on-site switching operations by personnel. It also has auxiliary functions for data acquisition, enabling the test data to be saved and retrieved, facilitating later traceability.

[0033] The following will provide a detailed description of the specific structure and connection method of each component in a passenger train power supply maintenance platform according to the utility model.

[0034] Regarding the simulated load test chamber 1, as follows: Figure 3 As shown, the device includes a left mounting area 18, a middle mounting area 20, and a right mounting area 19. Load 1 3 is installed in the left mounting area 18, load 2 4 is installed in the middle mounting area 20, and load 3 5 is installed in the right mounting area 19. Load 1 3 is a heating plate, while loads 2 4 and 3 5 are resistors. Regarding the selection of components, the heating plate selected in this embodiment has the following main performance parameters: Voltage: compatible with the device under test; Power: 700W; Dimensions: 200mm long, 300mm wide, 20mm thick; Material: Stainless steel casing, international nickel-chromium wire heating. The selected stainless steel resistor has the following main performance parameters: Voltage: compatible with the device under test; Rated current: 9.8A / 8.4A; Resistance: 58Ω / 80Ω; Material: Stainless steel, ceramic, wire-wound resistor.

[0035] A power distribution cabinet is located in the middle mounting area 20 below load 24, housing contactors 1 (6), 2 (9), and 3 (12). The cabinet also includes aviation socket interfaces for connecting to the device under test (DUT), such as charger 10, single-phase inverter 7, and three-phase inverter 13. The power distribution cabinet is an independent enclosure embedded within the simulated load test chamber 1. The relays within control the connection between the simulated load and the DUT, enabling the switching of loads in different areas within the chamber. The middle mounting area 20 has a separate cover with control signal indicator lights for easy maintenance and fault monitoring. Furthermore, a heat dissipation area 21 is located below the simulated load test chamber 1, equipped with heat sinks (such as cooling fans) to rapidly dissipate heat from easily heated components, ensuring the safe and stable operation of electronic components.

[0036] In this embodiment, the simulated load test chamber 1 has a rectangular structure and is made of stainless steel. The upper surface is a stainless steel panel, which is waterproof, beautiful, and durable. The other five sides are stainless steel mesh, which, together with the stainless steel frame, provides sufficient strength support while reducing the weight of the entire chamber. The stainless steel mesh also has excellent ventilation and heat dissipation functions, ensuring the heat dissipation of the entire load simulation chamber and meeting the requirements for stable operation under long-term load simulation. At the same time, it can also prevent rodents from damaging the wires and signal lines. The design is comprehensive, stable, and practical.

[0037] In terms of circuit structure, such as Figure 2 As shown, load 3 is connected to contactor 6, which has an access terminal 1 for connecting to the single-phase inverter 7 under test, used for simulating the test of the single-phase inverter 7. Load 4 is connected to contactor 9, which has an access terminal 2 for connecting to the charger 10 under test, used for simulating the test of the charger 10. Load 5 is connected to contactor 12, which has an access terminal 3 for connecting to the three-phase inverter 13 under test, used for simulating the test of the three-phase inverter 13. Because the output power of the three-phase inverter is relatively large, a unique design was used for its detection circuit in this embodiment. In this embodiment, each three-phase inverter under test 13 is connected to a load bank containing two loads 5, and the output terminal of the three-phase inverter under test 13 is simultaneously connected to two loads 5. That is, the output terminal of each three-phase inverter under test 13 is connected to two loads in parallel. This not only meets the testing requirements, but also improves the heat dissipation of the loads by reducing their size. In addition, since there are two three-phase inverters on the same workbench, to avoid excessive heat buildup caused by continuous use of the loads, the two three-phase AC power detection modules 14 in the inverter power supply box located on the same workbench are respectively connected to two load banks. That is, there are four loads 5 designed in this embodiment, and the two three-phase inverters are respectively connected to two different loads. In terms of layout, the following can be adopted: Figure 2 The diagram shows an intermittent layout. This not only avoids the problem of excessive heat buildup caused by continuous load use, but also enables load reuse when testing three-phase inverters in multiple workbenches simultaneously, greatly reducing the manufacturing cost of passenger train power supply maintenance benches.

[0038] It should be further clarified that during testing, each load bank can only connect to a maximum of one three-phase inverter at a time. Therefore, when testing three-phase inverters across multiple workstations, they must be tested in turn. When testing a three-phase inverter, for light-load testing, one load from the load bank can be used; for heavy-load testing, two loads from the load bank can be connected to a single three-phase inverter to achieve heavy-load testing. In other words, each three-phase inverter under test can be connected to a maximum of two load banks simultaneously: 0 unloaded, 1 light-load, and 2 heavy-load.

[0039] When more than four three-phase inverters need to be tested simultaneously, the load automatically switches between different devices according to the set time parameters, which saves hardware resources and enables load testing. Up to eight three-phase inverters can be connected, but only four can be used at the same time, and the switching can be set according to the time.

[0040] Regarding the workbench, such as Figure 1 In the text, A1-A3 and B1-B3 both represent worktables, such as worktable A1 and worktable B1.

[0041] Regarding control cabinet 2, to improve the flexibility of the maintenance bench and facilitate repair and maintenance, control cabinet 2 in this embodiment adopts a modular design concept and applies ergonomics, designing the control cabinet housing in the form of a test vehicle. The external structure of the control cabinet housing is as follows: Figure 4 As shown, the control cabinet 2 is divided into four spatial layers: upper, middle, lower, and bottom. The upper installation area 22 mainly houses the control module 15, i.e., the industrial control touch screen all-in-one machine, enabling digital automatic monitoring and simulation of load control tests on a passenger bus. Furthermore, the front of the upper installation area 22 has an inclined operating surface 23, on which the screen of the industrial control touch screen all-in-one machine is located for user convenience. The middle installation area 24 mainly houses the power devices for automatic load switching, i.e., the relay output module 17 and relays. The lower space mainly houses the DC power detection module 11, the single-phase AC power detection module 8, and the three-phase AC power detection module 14, used to collect key electrical parameters such as current, voltage, power, and frequency during the test process, providing a basis for device testing. The lower installation area 25 also has an aviation socket interface for connecting the device under test to the detection module. The bottom storage area 26 is a reserved functional expansion space that can be used as storage space for commonly used tools and components related to maintenance and repair.

[0042] Control cabinet 2 is constructed of stainless steel, making it aesthetically pleasing and durable. The box-type stainless steel structure also provides shielding protection. The back of control cabinet 2 is designed to be removable for easy maintenance and repair. Casters are installed at the bottom for easy relocation of the equipment.

[0043] Regarding the circuit structure, please refer to the connection details of the control module 15 in control cabinet 2, as well as the relay output module 17, DC power detection module 11, single-phase AC power detection module 8, and three-phase AC power detection module 14 connected to the control module 15. Figure 2 The coils of contactors 1-6, 2-9, and 3-12 are all connected to a relay. The output terminal of the relay output module 17 is connected to the relay coil, and the relay has an interlocking function. The DC power detection module 11 is connected to the line between the charger under test 10 and the load 2-4. The single-phase AC power detection module 8 is connected to the line between the single-phase inverter under test 7 and the load 1-3. The three-phase AC power detection module 14 is connected to the line between the three-phase inverter under test 13 and the load 3-5. The DC power detection module 11, single-phase AC power detection module 8, and three-phase AC power detection module 14 are all connected to the control module 15 via the communication module 16. In this embodiment, the communication module 16 is a 485 to 232 converter.

[0044] In this embodiment, the equipment selected in control cabinet 2 is as follows:

[0045] The main performance parameters of the industrial control touch screen all-in-one machine are as follows:

[0046] ● Intel Core i7 processor, 8GB RAM, 512GB SSD;

[0047] ● 17-inch capacitive touchscreen display;

[0048] ● Aluminum alloy panel, slim and compact design;

[0049] ● Front panel IP65 protection rating;

[0050] ● Abundant communication interfaces: COM, HDMI, VGA, USB, and Ethernet;

[0051] ●RS-485 serial port isolation protection;

[0052] ●Supports Microsoft Windows 7 / Windows 8 / Windows 10 / Linux and other operating systems;

[0053] ●Input voltage: DC12V;

[0054] ●Power consumption: 30W.

[0055] The main performance parameters of the relay output module 17 are as follows:

[0056] ● Wide operating temperature range and high noise immunity;

[0057] ●1kV surge protection voltage input;

[0058] ● Wide power input range: +10~+30V (DC).

[0059] ●Power consumption: 1.5 W;

[0060] ● Easy-to-monitor LED indicator lights;

[0061] ●Actuation time: 5ms;

[0062] ● Release time: 2ms;

[0063] ●Contact capacity: 1A@250VAC, 2A@30VDC.

[0064] The main performance parameters of the DC power detection module 11 are as follows:

[0065] ●Accuracy class: Voltage 0.2, Current 0.5;

[0066] ● Data update time: 20ms / 40ms / 60ms / 80ms / 100ms (default);

[0067] ●Overload capacity: Voltage and current overload of 1.2 times can be measured normally; voltage input terminal can withstand surge voltage impact;

[0068] ● Voltage range: 10V~450VDC selectable;

[0069] ● Current range: 1A~40ADC selectable;

[0070] ●Communication output: RS485;

[0071] ●Isolation withstand voltage: >DC 2.5kV;

[0072] ●Operating temperature: Industrial grade: -30℃~+70℃;

[0073] ●Frequency response: 0Hz~1KHz;

[0074] ● Wide power input range: +8~+30V (DC).

[0075] The main performance parameters of the AC current detection module are as follows:

[0076] ●Accuracy class: Voltage 0.2, Current 0.2;

[0077] ●Data update time: 40ms~1000ms;

[0078] ●Overload capacity: 1.4 times the range input can be measured correctly;

[0079] ● It will not be damaged even if the instantaneous (<10 cycles) current is 5 times or the voltage is 3 times the range;

[0080] ●Voltage range: 10V~500V selectable;

[0081] ● Current range: 1A~20A selectable;

[0082] ●Communication output: RS485;

[0083] ●Isolation withstand voltage: >DC 1kV;

[0084] ●Operating temperature: -20℃~+70℃;

[0085] ● Wide power input range: +8~+30V (DC).

[0086] The detection module transmits the collected signals to the industrial control touch screen all-in-one machine through the communication module 16 to complete the collection and processing of test data. The collected data can be displayed, and according to the test requirements of the load test, the tester can use the industrial control touch screen all-in-one machine to control the relay action through the relay output module 17 to realize automated test.

[0087] The above description is a detailed description of the preferred embodiments of the present utility model. However, the embodiments are not intended to limit the scope of the patent application of the present utility model. All equivalent changes or modifications made under the technical spirit of the present utility model should fall within the patent scope covered by the present utility model.

Claims

1. A power supply maintenance platform for passenger trains, characterized in that: The system includes a simulated load test chamber (1) and a control cabinet (2). The simulated load test chamber (1) is equipped with a load 1 (3), a load 2 (4), and a load 3 (5). The load 1 (3) is connected to a contactor 1 (6), which has an access terminal 1 for connecting to the single-phase inverter (7) under test. The load 2 (4) is connected to a contactor 2 (9), which has an access terminal 2 for connecting to the charger (10) under test. The load 3 (5) is connected to a contactor 3 (12), which has an access terminal 3 for connecting to the three-phase inverter (13) under test. The control cabinet (2) is equipped with a control module (15) and a control module (15) connected to the control module (15). The system includes a relay output module (17), a DC power detection module (11), a single-phase AC power detection module (8), and a three-phase AC power detection module (14). The coils of contactor one (6), contactor two (9), and contactor three (12) are all connected to a relay. The output terminal of the relay output module (17) is connected to the coil of the relay. The DC power detection module (11) is connected to the line between the charger under test (10) and load two (4). The single-phase AC power detection module (8) is connected to the line between the single-phase inverter under test (7) and load one (3). The three-phase AC power detection module (14) is connected to the line between the three-phase inverter under test (13) and load three (5).

2. The power supply maintenance platform for passenger trains according to claim 1, characterized in that: Each of the three-phase inverters under test (13) is connected to a load bank containing two loads (5), and the output of the three-phase inverter under test (13) is simultaneously connected to the two loads (5).

3. The power supply maintenance platform for passenger trains according to claim 2, characterized in that: Two three-phase AC power detection modules (14) in the inverter power supply box located on the same workbench are respectively connected to two load groups.

4. The power supply maintenance platform for passenger trains according to claim 1, characterized in that: The first load (3) is a heating plate, and the second load (4) and the third load (5) are both resistors.

5. A power supply maintenance platform for passenger trains according to any one of claims 1-4, characterized in that: The simulated load test chamber (1) is provided with a left mounting area (18), a middle mounting area (20) and a right mounting area (19). The first load (3) is installed in the left mounting area (18), the second load (4) is installed in the middle mounting area (20), and the third load (5) is installed in the right mounting area (19). A power distribution cabinet is provided in the middle mounting area (20) below the second load (4). The first contactor (6), the second contactor (9) and the third contactor (12) are all installed in the power distribution cabinet. The power distribution cabinet is provided with an aviation socket interface for connecting to the device under test.

6. A power supply maintenance platform for passenger trains according to claim 5, characterized in that: The simulated load test chamber (1) is also provided with a heat dissipation area (21) below, in which a heat sink is installed.

7. A power supply maintenance platform for passenger trains according to claim 1, characterized in that: The DC power detection module (11), the single-phase AC power detection module (8), and the three-phase AC power detection module (14) are all connected to the control module (15) through the communication module (16).

8. A power supply maintenance platform for passenger trains according to claim 7, characterized in that: The communication module (16) is a 485 to 232 converter.

9. A power supply maintenance platform for passenger trains according to claim 1, characterized in that: The control module (15) is an industrial control touch screen all-in-one machine.

10. A power supply maintenance platform for passenger trains according to claim 1, 7, 8 or 9, characterized in that: The control cabinet (2) is provided with an upper installation area (22), a middle installation area (24), a lower installation area (25), and a bottom storage area (26). The control module (15) is installed in the upper installation area (22), and the front side of the upper installation area (22) is provided with an inclined operating surface (23). The operating part of the control module (15) is located on the operating surface (23). The relay output module (17) and the relay are both installed in the middle installation area (24). The DC power detection module (11), the single-phase AC power detection module (8), and the three-phase AC power detection module (14) are all installed in the lower installation area (25). The lower installation area (25) is also provided with an aviation socket interface for connecting the device under test to the detection module. The bottom storage area (26) serves as a storage space for storing tools and spare parts.

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