Speed ​​detector wear detection system

Abstract

To provide a system capable of detecting an abrasion state of a drive plate or the like without depending on a periodic maintenance work concerning a contact-type speed detector.SOLUTION: An abrasion detection system X is applied to a speed detector (tachometer generator) G installed on one end side of an axle A. The system includes: an output value detection section 1 for detecting an output value based on an output signal of a speed detector body (tachometer body) B in order to detect presence / absence of abrasion of a drive plate L which has grooves L2 for permitting insertion of a drive pin P and transmits rotation of the axle A to the tachometer body B by rotating with a rotating movement of the drive pin P inserted to the groove L2; and an abrasion estimation section 2 for comparing the output value detected by the output value detection section 1 with a predetermined threshold so as to estimate whether the drive plate L being an abrasion determination object part J is in an abrasion state. The abrasion state of the abrasion determination object part J is detected based on an estimation result by the abrasion estimation section 2.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a system for detecting the state of components of a speed generator or a contact-type speed sensor (collectively referred to as a speed detector) used for detecting speed.

Background Art

[0002] Conventionally, in the field of railways, speed generators have been used to detect speed. Speed generators can be broadly classified into contact-type and non-contact-type. As a contact-type speed generator, a mode is adopted in which a driving disk (hereinafter referred to as a driving plate) and a driving pin are provided and speed is detected by bringing them into contact.

[0003] The contact-type speed generator is connected to one end side of a train axle, and a driving plate and a driving pin are arranged between the main body of the speed generator and the axle. Specifically, a driving pin is provided on one end side of the axle so as to be integrally rotatable with the axle at a position eccentric from the axial center of the axle, a groove into which the driving pin can be inserted is formed in the driving plate, and the driving plate is connected to the main body of the speed generator by a connecting shaft. When the axle rotates with the driving pin inserted into the groove of the driving plate, the driving pin also rotates integrally. As a result, the driving plate also rotates following the driving pin, and the rotation of the axle is transmitted to the main body of the speed generator (speed generator side) (for example, Patent Document 1 below).

[0004] In this way, by maintaining contact between the drive pin and the drive plate, the rotation of the axle can be transmitted to the main body of the speed generator via the drive pin and drive plate. The main body of the speed generator rotates and generates electricity, providing an output signal to a higher-level device corresponding to the train's speed. Furthermore, a configuration is known in which the main body of a speed sensor, which does not have a power generation function, is used instead of the main body of the speed generator, and the rotation of the axle is transmitted to the main body of the speed sensor via the drive pin and drive plate by maintaining contact between the drive pin and the drive plate. Even with such a configuration, an output signal corresponding to the train's speed can be provided to a higher-level device. Hereafter, such speed generators and speed sensors will be collectively referred to as speed detectors. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Patent No. 4543508 [Overview of the project] [Problems that the invention aims to solve]

[0006] Incidentally, in railway maintenance, the amount of wear on drive plates and drive pins is checked periodically, and if the amount of wear exceeds the acceptable range, the drive plates and drive pins are replaced. Wear on drive plates and drive pins occurs depending on the train's operating speed and distance, and until now, the wear condition was only checked at the time of maintenance work. For example, even if the amount of wear exceeded the acceptable range during train operation, the parts were not replaced and continued to be used until the next maintenance work.

[0007] This invention was made in view of these problems, and its main objective is to provide a system for a contact-type speed sensor that can detect the wear condition of the drive plate and drive pin without requiring periodic maintenance. [Means for solving the problem]

[0008] In other words, the wear detection system according to the present invention is applicable to a speed generator provided on one end of an axle. The speed generator comprises a drive pin provided on one end of an axle and capable of rotating integrally with the axle, a drive plate that rotates in accordance with the drive pin, and a speed detector body connected to the drive plate. The drive plate has a groove that allows the drive pin to be inserted, and transmits the rotation of the axle to the speed detector body by rotating in accordance with the rotational movement of the drive pin inserted in the groove. The wear detection system according to the present invention comprises an output value detection unit that detects an output value based on the output signal of the speed detector body, and a wear estimation unit that estimates whether or not a wear-determined part, which is at least a part that the drive pin contacts and is subject to wear determination, is worn by comparing the output value detected by the output value detection unit with a preset threshold, and is characterized by detecting the wear state of the wear-determined part based on the estimation result by the wear estimation unit.

[0009] In the present invention, the "output value detected by the output value detection unit" can be the voltage value which is the output signal of the speed generator itself if the speed detector body is the speed generator body, or the frequency of the signal obtained by shaping the output signal of the speed generator body into a pulsed signal. If the speed detector body is the speed sensor body, it can be the frequency of the pulsed signal which is the output signal (sensor output) of the speed sensor body.

[0010] With the wear detection system according to the present invention, the wear condition and presence or absence of damage to the wear-detection target parts can be detected while the vehicle is running, without requiring periodic maintenance work on the contact-type speed sensor. Furthermore, if the drive plate, which is the part that the drive pins contact, is identified as the wear-detection target part and the system outputs an estimated result that wear has occurred to the point where replacement is required, maintenance of the parts surrounding the drive plate, specifically the drive pins, can be performed at the same time as the drive plate replacement work. If necessary, the drive pins can also be replaced, thereby maintaining the performance of the speed sensor at the desired standard level.

[0011] Recently, speed generators have been developed that incorporate resin bushings at the contact points between the metal drive plate and the metal drive pin to prevent contact between the drive plate and the drive pin, thereby reducing wear. However, with the recent trend of modal shift, the amount of freight and luggage handled by railway operations is increasing, and an increase in the frequency of vehicle operation is expected. Consequently, if the wear of the resin bushings increases, the work required to check the wear level of the resin bushings and replace them will increase, which is expected to necessitate a review of vehicle maintenance.

[0012] Therefore, in this invention, a resin bush can be set as a wear detection part, and the wear state of the resin bush can be detected based on the estimation result by the wear estimation unit. This makes it possible to detect the wear state of the resin bush while the vehicle is running, avoiding situations where the amount of wear of the resin bush increases and the amount of work required to replace the resin bush increases, and allowing the replacement of the resin bush to be carried out in a planned manner.

[0013] Furthermore, when reinstalling the resin bushings during vehicle inspections, it is anticipated that the resin bushings may slip and fall off due to gravity. Since the vehicle can still operate even with the resin bushings detached, the drive pins may come into direct contact with the drive plate during operation, leading to wear on the drive plate. Additionally, if the resin bushings fall into the axle box, they will be jostled around inside the axle box.

[0014] Considering this situation, if the wear detection system according to the present invention is configured to include an installation estimation unit that estimates whether or not a resin bush is interposed between the drive pin and the groove of the drive plate by comparing the output value detected by the output value detection unit with a preset second threshold, it will be possible not only to detect the wear state of the resin bush but also to estimate the installation state of the resin bush. If it is possible to detect that the resin bush has fallen out based on the estimation result, this will be useful information for the business operator.

[0015] Furthermore, the wear detection system according to the invention includes a wear amount estimation unit that estimates the amount of wear of the wear target part based on the output value detected by the output value detection unit. [Effects of the Invention]

[0016] According to the present invention, a speed detector wear detection system (speed generator wear detection system, speed sensor wear detection system) can be provided that allows for the detection of the wear status of parts subject to wear detection while the vehicle is running, without relying on periodic maintenance work in speed detectors such as contact-type speed generators and speed sensors, thereby enabling more planned maintenance. [Brief explanation of the drawing]

[0017] [Figure 1] A control block diagram of a train to which the speed generator wear detection system according to the first embodiment of the present invention is applied. [Figure 2] Overall configuration diagram of the speed generator in the same embodiment. [Figure 3] Schematic cross-sectional view along line aa in Figure 2 and an enlarged view of its main parts. [Figure 4] A schematic diagram showing that the output waveform of the speed generator differs depending on whether or not the wear-affected parts are worn or not. [Figure 5] This figure shows the state of the drive pin moving in the wear region of the drive plate in the same embodiment. [Figure 6]Flowchart showing the wear detection processing procedure in the same embodiment. [Figure 7] Diagram showing the resin bush attached to the drive pin in the second embodiment of the present invention. [Figure 8] Diagram showing the resin bush attached to the groove of the drive plate in the same embodiment. [Figure 9] Control block diagram of a train to which the speed generator wear detection system according to the same embodiment is applied. [Figure 10] Diagram showing the state of the drive pin moving in the wear area of the resin bush and the state of the drive pin moving in the area where the resin bush is not installed in the same embodiment. [Figure 11] Flowchart showing the wear detection processing procedure in the same embodiment. [Figure 12] Control block diagram of a train to which the speed generator wear detection system according to the third embodiment of the present invention is applied. [Figure 13] Flowchart showing the wear detection processing procedure in the same embodiment. [Figure 14] Control block diagram of a train to which the speed generator wear detection system according to the fifth embodiment of the present invention is applied. [Figure 15] Flowchart showing the wear detection processing procedure in the same embodiment. [Figure 16] Control block diagram of a train to which the speed generator wear detection system according to the sixth embodiment of the present invention is applied. [Figure 17] Flowchart showing the wear detection processing procedure in the same embodiment. [Figure 18] Control block diagram of a train to which the speed generator wear detection system according to the seventh embodiment of the present invention is applied. [Figure 19] Flowchart showing the wear detection processing procedure in the same embodiment.

Mode for Carrying Out the Invention

[0018] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. 〈First Embodiment〉 As shown in Figure 1, the speed detector wear detection system X according to this embodiment can be used, for example, to detect the wear condition of components of a speed generator G installed in a railway vehicle T. In the wear detection system X according to the first to seventh embodiments, a speed generator G is used as the speed detector, and the speed generator body B corresponds to the speed detector body of the present invention. Therefore, hereinafter, the speed detector wear detection system X will be referred to as the speed generator wear detection system X.

[0019] As shown in Figure 2, the speed generator G is connected to one end of the axle A of the train T (Figure 1) in order to detect the speed of the train T, etc., and comprises a drive pin P that is integrally rotatable with the axle A, a drive plate L that rotates in accordance with the drive pin P, and a speed generator body B connected to the drive plate L.

[0020] The drive pin P is positioned eccentrically from the axis center A1 of the axle A, and as shown in Figure 2(b), it has a mounting portion P1 at its base end for attachment to the axle A, and a predetermined area from the mounting portion P1 to the tip is set as a cylindrical pin body P2.

[0021] The drive plate L is plate-shaped with a predetermined thickness and is connected to the speed generator body B by a connecting portion L1 provided in the center. As shown in Figure 3, the drive plate L has a groove L2 that opens from near the center (connecting portion L1) toward the outer circumference, and is mounted coaxially with the axle A with the drive pin P inserted into the groove L2. Figure 3(a) is a schematic cross-sectional view of aa in Figure 2. The opening width of the groove L2 is set to be slightly larger than the diameter of the drive pin P (diameter of the pin body P2), and the drive pin P is fitted into this groove L2. As a result, the drive plate L rotates due to the drive pin P, which rotates integrally with the axle A as the axle A rotates. In this way, the drive plate L is mounted coaxially with the axle A and rotates at the same speed as the axle A.

[0022] As shown in Figure 2, the speed generator body B rotates integrally with the drive plate L via a connecting part L1, and detects the speed of the train T by detecting the rotational speed of the drive plate L. The speed generator body B has a cylindrical housing part B1 arranged coaxially with the axle A, and the power generation mechanism and the like are arranged inside the housing part B1. The power generation mechanism inside the housing part B1 is a known one, and for example, it comprises an inductor that is rotatably mounted coaxially with the axle A of the train T and rotates integrally with the drive plate L, and a power generation part provided on the outer circumference of the inductor with a predetermined gap between them. When the inductor rotates, an electromotive force is generated in the power generation part by the magnetic field generated between the inductor and the power generation part. By detecting the amount of electromotive force, which is a value corresponding to the rotational speed of the inductor, the rotational speed of the inductor, that is, the rotational speed of the axle A, can be detected. The generated electromotive force is supplied to the brake control unit C (BCU) via appropriate wires or the like.

[0023] Figure 1 schematically shows the control configuration of a train T to which the speed generator wear detection system X according to this embodiment is applied. The train T includes a speed generator G mounted on the axle A of the wheels, a brake control unit C that receives the output signal of the speed generator G (a signal corresponding to the rotation of the axle A, and may hereafter be referred to as the "speed generator output signal") and sends a brake signal to the speed generator G, and an onboard control unit Y (train control unit) which is a higher-level controller of the brake control unit C.

[0024] The brake control unit C includes a waveform shaping unit C1 that shapes the output signal of the speed generator G into a pulsed signal, and a speed detection unit C2 that calculates the running speed of the train T based on the pulsed signal shaped by the waveform shaping unit C1. The speed signal (running speed of the train T) calculated by the speed detection unit C2 is sent to the on-board control unit Y. In railway vehicles, a speed generator G and a brake control unit C are provided for each vehicle or bogie. The waveform shaping unit C1 and the speed detection unit C2 may be directly incorporated into the brake control unit C, or they may be configured separately from the brake control unit C, or they may be built into the speed generator G.

[0025] The on-board control unit Y sends a brake command to the brake control unit C based on the speed signal received from the speed detection unit C2. Based on these commands, the brake control unit C sends a brake signal to the speed generator G, thereby controlling the travel speed of axle A.

[0026] Under this control, the speed generator G is connected to the drive plate L by inserting and fitting a drive pin P into the groove L2 of the drive plate L, thereby transmitting the rotation of axle A to the speed generator body B. In other words, the output signal of the speed generator G corresponding to the rotation of axle A is used as information related to the running speed of the railway vehicle.

[0027] Furthermore, as the axle A of train T rotates at high speed, the force applied to the contact area between the groove L2 of the drive plate L and the drive pin P also increases, and wear due to contact necessitates replacement with a new part.

[0028] Previously, the procedure involved checking for wear and tear (the degree of wear) only during periodic maintenance, and replacing parts with new ones if necessary. With this procedure, even if a part had reached a state of wear requiring replacement before maintenance, it would continue to be used until the maintenance work was performed.

[0029] Therefore, as shown in Figure 1, the speed generator wear detection system X according to this embodiment includes an output value detection unit 1 that detects an output value based on the output signal (speed generator output signal) of the speed generator body B, a wear estimation unit 2 that estimates whether or not the wear target part J, which is a part that at least the drive pin P contacts and is subject to wear determination, is worn by comparing the output value detected by the output value detection unit 1 with a preset threshold, and a wear amount estimation unit 10 that estimates the amount of wear of the wear target part J based on the output value detected by the output value detection unit 1 when the wear estimation unit 2 estimates that the wear target part J is worn. In this embodiment, the wear target part J is the drive plate L, and more specifically, the wear target part is the groove L2 of the drive plate L. Here, Figure 3(b) shows the state in which the drive plate L, which is the wear target part J, is not worn, and Figure 3(c) shows the state in which the drive plate L, which is the wear target part J, is worn.

[0030] In this embodiment, the output value detection unit 1 detects the frequency of the pulsed signal formed from the output signal of the speed generator body B by the waveform shaping unit C1 of the brake control unit C as the output value.

[0031] The wear estimation unit 2 can be further subdivided into a wear determination unit 21 that determines whether the output value detected by the output value detection unit 1 is smaller than a preset threshold, and a wear state estimation output unit 22 that outputs the wear state estimated based on the determination result of the wear determination unit 21. The wear determination unit 21 and the wear state estimation output unit 22 may be directly incorporated into the brake control unit C, or they may be configured separately from the brake control unit C, or they may be built into the speed generator G.

[0032] The wear determination unit 21 determines whether the output value (frequency) detected by the output value detection unit 1 is smaller than a preset threshold. The threshold is, for example, a value set based on the relationship between the running speed of the train T when there is no wear on the drive plate L and drive pin P, and the frequency of the output signal of the speed generator G corresponding to the running speed, and can be a theoretical value or a measured value (for example, a measured value when the speed generator G is rotated in accordance with the running speed of the train T, or a measured value when the train T is running with the speed generator G installed). Here, the frequency of the output signal of the speed generator G when there is no wear on the groove L2 of the drive plate L, which is the wear target part J, gradually increases as the running speed of the train T increases. That is, as shown in the first row from the top of Figure 4 (no wear on the wear target part), the frequency gradually increases as the running speed of the train T increases, as in A0...A5...A10.

[0033] On the other hand, if wear occurs in the groove L2 of the drive plate L, which is the part J subject to wear detection, then, for example, the drive pin P alternates between a state in which it approaches and contacts one end of the worn portion of the groove L2 (see Figures 5(a) and (c)) and a state in which it floats without contacting the end of the worn portion (see Figure (b)). That is, when the train T is running, the drive pin P behaves as if it is moving back and forth in the worn portion (a back and forth movement in the order of Figure (a) → (b) → (c) → (b) → (a)), and alternately moves from one end to the other of the worn portion, using both ends of the worn portion as turning points. As shown in the second row from the top of Figure 4 (wear detected in the part subject to wear detection), the frequency when the drive pin P approaches and contacts one end of the worn portion of the groove L2 (area A in the figure) is the same as or approximately the same as the frequency when there is no wear, and this value (frequency) changes according to the running speed of the train T. On the other hand, the frequency when the drive pin P is floating without contacting the end of the worn portion (region B in the figure) is lower than the frequency when there is no wear in the groove L2 of the drive pin P, and this value (frequency) changes according to the running speed of the train T.

[0034] The wear determination unit 21 compares a predetermined threshold value based on such events with the output value (frequency) actually detected by the output value detection unit 1 to determine whether the output value is smaller than the threshold value.

[0035] The wear state estimation output unit 22 estimates that at least the drive plate L is worn if the determination result from the wear determination unit 21 is Yes, that is, if the output value is less than the threshold, and outputs the estimation result. The wear state estimation output unit 22 also estimates that at least the drive plate L is not worn if the determination result from the wear determination unit 21 is No, that is, if the output value is not less than the threshold, and outputs the estimation result.

[0036] The wear amount estimation unit 10 can be further subdivided into a wear amount determination unit 101 that determines whether the wear amount of at least the drive plate L is less than a preset threshold based on the determination result of the wear determination unit 21, and a wear amount estimation output unit 102 that outputs the wear state estimated based on the determination result of the wear amount determination unit 101. The wear amount determination unit 101 and the wear amount estimation output unit 102 may be directly incorporated into the brake control unit C, or they may be configured separately from the brake control unit C, or they may be built into the speed generator G.

[0037] The wear amount determination unit 101 estimates the wear amount of the drive plate L when the determination result from the wear determination unit 21 is Yes, that is, when the output value is smaller than a threshold. Specifically, the wear determination unit 21 sets a threshold (wear amount determination threshold) that is smaller than a predetermined threshold and corresponds to a predetermined amount of wear (amount of wear requiring replacement), and determines whether the value is below that threshold (wear amount determination threshold). The threshold (wear amount determination threshold) is, for example, a value set based on the relationship between the running speed of the train T and the frequency of the output signal of the speed generator G corresponding to the running speed when a predetermined amount of wear has occurred on the drive plate L and no wear has occurred on the drive pin P, and the drive pin P is floating without contacting the edge of the worn part of the drive plate L. This can be a theoretical value or a measured value (for example, a measured value when the speed generator G is rotated in accordance with the running speed of the train T, or a measured value when the train T is running with the speed generator G installed).

[0038] The wear amount estimation output unit 102 estimates that the wear amount of the drive plate L has reached a predetermined wear amount if the determination result by the wear amount determination unit 101 is Yes, that is, if the output value is less than or equal to the threshold (threshold for wear amount determination), and outputs the estimation result. The wear amount estimation output unit 102 estimates that the wear amount of the drive plate L has not reached a predetermined wear amount if the determination result by the wear amount determination unit 101 is No, that is, if the output value is not less than or equal to the threshold (threshold for wear amount determination), and outputs the estimation result.

[0039] Furthermore, instead of using the above-mentioned threshold (threshold for determining the amount of wear) as a reference for the wear amount estimation unit 10, the following configuration can also be adopted. Specifically, when the drive plate L is worn, and the output signal of the speed generator G alternates between a state in which the drive pin P is approaching and in contact with one end of the worn portion of the groove L2, and a state in which it is floating without contacting the end of the worn portion, the amount of movement of the drive pin at a predetermined speed of the train T is calculated based on the frequency of the output signal in the state in which the drive pin P is floating without contacting the end of the worn portion and the time that this state occurs. When the calculated amount of movement of the drive pin becomes the same as or approximately the same as a predetermined amount of wear (amount of wear requiring replacement), the wear amount of the drive plate L is estimated to have reached the predetermined amount of wear, and the estimation result is output.

[0040] Here, the output value detection unit 1, wear estimation unit 2, and wear amount estimation unit 10 of the speed generator wear detection system X according to this embodiment can be configured by a circuit incorporated into the brake control unit C, as shown in Figure 1. Furthermore, the output value detection unit 1, wear estimation unit 2, and wear amount estimation unit 10 may be directly incorporated into the brake control unit C, configured separately from the brake control unit C, or built into the speed generator G.

[0041] Next, the processing procedure for wear detection by the speed generator wear detection system X according to this embodiment (speed generator wear detection method) will be explained with reference to Figure 6.

[0042] First, the control unit (which may be a dedicated controller for this system, but in this embodiment it is the brake control unit C itself) receives the output signal (raw signal) from the speed generator G of the moving train T using the output value detection unit 1 (output signal acquisition process S1), shapes a pulsed signal from the acquired output signal (signal shaping process S2), and detects the frequency of the shaped signal (frequency detection process S3). These three steps (output signal acquisition process S1, signal shaping process S2, and frequency detection process S3) can be collectively considered as the output value detection process SA.

[0043] Next, the control unit C determines whether the output value (frequency of the formed signal) detected in the output value detection process SA is smaller than a threshold (wear determination process S4). If the output value (frequency of the formed signal) is smaller than the threshold (wear determination process S4; Yes), it outputs a wear state estimation result (wear signal) indicating that wear has occurred in the drive plate L, which is the wear target part J (wear signal output process S5A). On the other hand, if the output value (frequency of the formed signal) is not smaller than the threshold (wear determination process S4; No), it outputs a wear state estimation result (wear signal) indicating that wear has not occurred in the drive plate L, which is the wear target part J (wear signal output process S5B). The wear determination process S4 and the wear signal output processes S5A and S5B can be considered together as the wear state estimation process SB.

[0044] Furthermore, if the output value (frequency of the formed signal) is smaller than the threshold (wear determination process S4; Yes), the control unit C determines whether the wear amount of the drive plate L, which is the wear target part J, has reached a predetermined amount (wear amount determination process S10). If the wear amount has reached the predetermined amount (wear amount determination process S10; Yes), it outputs a wear amount estimation result (wear amount signal) indicating that the wear amount of the drive plate L, which is the wear target part J, has reached a predetermined amount (wear amount signal output process S10A). On the other hand, if the wear amount has not reached the predetermined amount (wear amount determination process S10; No), it outputs a wear amount estimation result (wear amount signal) indicating that the wear amount of the drive plate L, which is the wear target part J, has not reached a predetermined amount (wear amount signal output process S10B). The wear amount determination process S10, and the wear amount signal output processes S10A and S10B can be considered together as the wear amount estimation process SB'.

[0045] By following these processing steps, the train T's operation management (operator) can determine in real time whether or not the drive plate L is worn based on the output of the wear state estimation process SB, and further, whether or not it has reached a wear level requiring replacement (or whether or not it is damaged) based on the output of the wear amount estimation process SB'. This makes it possible to replace the drive plate L as early as possible (for example, during the train T's daily inspection).

[0046] Furthermore, generally, drive pins P are often hardened by surface treatment or coating, resulting in less wear than drive plates L, and requiring less frequent replacement. Therefore, if wear is detected by applying the speed generator wear detection system X according to this embodiment at a time after the drive plate L has been replaced, it will be considered that wear of the drive pins P has been detected. Thus, similar to the wear detection of drive plate L, the wear estimation unit 2 may detect wear of the drive pins P, or a predetermined amount of wear of the drive pins P (the amount of wear requiring replacement) and a corresponding threshold (a threshold for determining the amount of wear) may be set in advance, and the wear amount determination unit 101 may determine whether the drive pins P have reached the predetermined amount of wear.

[0047] Thus, according to the wear detection system X of this embodiment, the wear condition of at least the drive plate L can be detected while the vehicle T is running, without requiring periodic maintenance work in a contact-type speed generator G. When the wear detection system X outputs an estimated result that the drive plate L is worn, maintenance of surrounding parts, specifically the drive pins P, can be performed when the drive plate L is replaced, and if necessary, the drive pins P can also be replaced, thereby maintaining the performance of the speed generator G at a desired standard level.

[0048] Furthermore, the introduction of the wear detection system X does not require the installation of dedicated hardware on the train T. As described in the above embodiment, it is possible to operate the system by, for example, partially utilizing and improving the existing brake control unit C. Therefore, the cost of introducing this system X can be reduced.

[0049] <Second Embodiment> The wear detection system X according to the second embodiment differs from the wear detection system X according to the first embodiment in that, as shown in Figures 7 and 8, it is applied to a speed generator G in which a resin bush R is interposed between the groove L2 of the drive plate L and the drive pin P to avoid direct contact between the groove L2 of the drive plate L and the drive pin P, the wear target part J is the resin bush R, and as shown in Figure 9, it is equipped with a mounting estimation unit 3. In other words, the first embodiment described above employs a method of directly inserting the drive pin P into the groove L2 of the drive plate L, while the second embodiment employs a method of indirectly inserting the drive pin P into the groove L2 of the drive plate L via the resin bush R rather than directly.

[0050] Here, the resin bush R may be attached to the drive pin P as shown in Figure 7, or it may be attached to the groove L2 of the drive plate L as shown in Figure 8.

[0051] The resin bush R, which is attached to the drive pin P, is a one-piece molded resin product with an outer shape slightly smaller than the opening width of the groove L2 of the drive plate L, and having an insertion hole R1 in the center into which the pin body P2 of the drive pin P can be inserted. The total length of the resin bush R along the axial direction of the drive pin P may be sized to cover the entire pin body P2 of the drive pin P, or it may be sized to cover the portion near the tip of the pin body P2 that fits into the groove L2. Such a resin bush R can be attached to the drive pin P by inserting the drive pin P into the insertion hole R1, and by fitting the drive pin P with the resin bush R attached into the groove L2 of the drive plate L, a speed generator G is formed with the resin bush R interposed between the groove L2 and the drive pin P. Figures 7(a) and 7(b) show an overall view of the resin bush R, with figure 7(b) showing the resin bush R attached to the drive pin P. Figure 7(c) is a schematic diagram of the resin bush R attached to the drive pin P and fitted into the groove L2 of the drive plate L.

[0052] The resin bush R, which is fitted into the groove L2 of the drive plate L, is a one-piece molded resin product having a pair of clamping parts R2 that sandwich the drive plate L in the thickness direction when fitted into the groove L2 of the drive plate L, and an insertion hole R1 into which the pin body P2 of the drive pin P can be inserted. Figure 8(a) is a diagram of the location corresponding to Figure 7(c), and Figure 8(b) is a cross-sectional view taken along line bb in Figure 8(a).

[0053] The following explanation uses as an example a configuration in which a resin bushing R attached to the drive pin P is inserted into a groove L2 on the drive plate L.

[0054] When using a speed generator G with a resin bush R interposed between groove L2 and drive pin P, if the drive pin P is not significantly eccentric in the direction of the opening of groove L2 in the drive plate L while the train T is running, the high-speed rotation of the train T's axle A maintains the insertion state of the resin bush R into groove L2 of the drive plate L. As a result, the surface R3 of the resin bush R facing groove L2 (hereinafter referred to as the opposing surface R3) experiences less wear. However, due to the eccentricity of the drive pin P, significant wear occurs in the insertion hole R1 of the resin bush R, causing the insertion hole R1 to become wider than it was initially. In other words, as the drive pin P moves within the insertion hole R1 due to the high-speed rotation of the axle A, the insertion hole R1 tends to reach a predetermined wear amount (the amount of wear requiring replacement) faster than the opposing surface R3. Here, Figure 7(c) shows the state in which the resin bush R, which is the wear-determined part J, is not worn, and Figure 7(d) shows the state in which the resin bush R, which is the wear-determined part J, is worn.

[0055] On the other hand, if the drive pin P is significantly eccentric towards the opening direction of the groove L2 of the drive plate L while the train T is running, the high-speed rotation of the train T's axle A prevents the resin bush R from being properly fitted into the groove L2 of the drive plate L due to the eccentricity. As a result, the opposing surface R3 of the resin bush R experiences significant wear, while the insertion hole R1 of the resin bush R tends to experience less wear. In other words, the opposing surface R3 is more likely to reach a predetermined wear level (the amount of wear requiring replacement) sooner than the insertion hole R1.

[0056] When the resin bush R is worn, as shown in Figure 10, the drive pin P moves back and forth over the worn portion when the train T is running (a back and forth movement in the order of (a)→(b)→(c)→(b)→(a) in the same figure), and moves alternately from one end to the other of the worn portion, with both ends of the worn portion acting as turning points. As a result, the output signal of the speed generator G alternates between the state when the drive pin P is in contact with one end of the worn portion and the state when the drive pin P is floating without contacting either end of the worn portion, as shown in an example in Figure 4.

[0057] Therefore, by detecting the signal during non-contact situations, it is possible to detect the presence or absence of wear. Furthermore, it is also possible to estimate the amount of wear from the waveform during contact.

[0058] Therefore, the wear detection system X according to the second embodiment is configured to estimate the wear state of the resin bush R by a wear estimation unit 2 having a wear determination unit 21 and a wear state estimation output unit 22 that are substantially the same as those in the first embodiment.

[0059] The wear determination unit 21, similar to the first embodiment, determines whether the output value (frequency) detected by the output value detection unit 1 is smaller than a preset threshold. The first threshold is, for example, a value set based on the relationship between the running speed of the train T and the frequency of the output signal of the speed generator G corresponding to the running speed when there is no wear on the resin bush R, drive plate L, and drive pin P, and can be a theoretical value or an actual measured value (for example, a measured value when the speed generator G is rotated in accordance with the running speed of the train T, or a measured value when the train T is running with the speed generator G installed). Here, the frequency of the output signal of the speed generator G when there is no wear on the insertion hole R1 or opposing surface R3 of the resin bush R, which is the wear determination target part J, gradually increases as the running speed of the train T increases. That is, as shown in the first row from the top of Figure 4 (no wear on wear determination target part), the frequency increases as the running speed of the train T increases, such as A0...A5...A10.

[0060] The wear amount determination unit 101 estimates the wear amount of the resin bush R when the determination result from the wear determination unit 21 is Yes, that is, when the output value is smaller than a threshold. Specifically, the wear determination unit 21 sets a threshold (wear amount determination threshold) that is smaller than a preset threshold and corresponds to a predetermined amount of wear (amount of wear requiring replacement), and determines whether the value is below that threshold (wear amount determination threshold). The threshold (wear amount determination threshold) is, for example, a value set based on the relationship between the running speed of the train T and the frequency of the output signal of the speed generator G corresponding to the running speed when a predetermined amount of wear has occurred in the resin bush R and no wear has occurred in the drive plate L or drive pin P, and when the drive plate L is not in contact with the end of the worn part of the resin bush R or when the drive pin P is floating without contacting the end of the worn part of the resin bush R. The threshold (wear amount determination threshold) can be a theoretical value or a measured value (for example, a measured value when the speed generator G is rotated in accordance with the running speed of the train T, or a measured value when the train T is running with the speed generator G installed).

[0061] The wear amount estimation output unit 102 estimates that the wear amount of the resin bush R has reached a predetermined wear amount if the determination result by the wear amount determination unit 101 is Yes, that is, if the output value is less than or equal to the threshold (threshold for wear amount determination), and outputs the estimation result. The wear amount estimation output unit 102 estimates that the wear amount of the resin bush R has not reached a predetermined wear amount if the determination result by the wear amount determination unit 101 is No, that is, if the output value is not less than or equal to the threshold (threshold for wear amount determination), and outputs the estimation result.

[0062] Furthermore, since the wear state of the resin bush R tends to differ due to the eccentricity of the drive pin P toward the opening direction of the groove L2 of the drive plate L while the train T is running, the above threshold (threshold for determining the amount of wear) may be set taking into account the effect of eccentricity. For example, when the drive pin P is not eccentric toward the opening direction of the groove L2 of the drive plate L while the train T is running, the insertion hole R1 of the resin bush R is more likely to reach a predetermined amount of wear (amount of wear requiring replacement) at the insertion hole R1 than the opposing surface R3. On the other hand, when the eccentricity is large, the opposing surface R3 of the resin bush R is more likely to reach a predetermined amount of wear (amount of wear requiring replacement) at the opposing surface R3 than the insertion hole R1. Therefore, the above threshold (threshold for determining the amount of wear) may be divided into a predetermined amount of wear at the insertion hole R1 and a predetermined amount of wear at the opposing surface R3, and each may be set separately.

[0063] Furthermore, the wear amount estimation unit 10 may employ a configuration that, instead of the above threshold (threshold for determining the amount of wear), for example, when the resin bush R is worn, and the output signal of the speed generator G alternates between a state in which the drive plate L and drive pin P are approaching and in contact with one end of the worn portion of the resin bush R, and a state in which they are floating without contacting the end of the worn portion, the unit calculates the amount of movement of the drive plate and drive pin at a predetermined speed of the train T based on the frequency of the output signal in the state in which the resin bush R is floating without contacting the end of the worn portion and the duration of that state. If the amount of movement of the drive pin is the same as or approximately the same as a predetermined amount of wear (amount of wear requiring replacement), the unit estimates that the amount of wear of the resin bush R has reached the predetermined amount of wear and outputs the estimation result. Alternatively, the predetermined amount of wear (amount of wear requiring replacement) may be divided into a predetermined amount of wear at the insertion hole R1 and a predetermined amount of wear at the opposing surface R3, depending on the effect of the eccentricity of the drive pin P in the opening direction of the groove L2 of the drive plate L while the train T is running.

[0064] As shown in Figure 11, the control unit C determines whether the output signal detected by the output signal detection process SA is smaller than a threshold (referred to as the first threshold in the figure to distinguish it from the second threshold described later) (wear determination process S4). If the output value (frequency of the molded signal) is smaller than the threshold (wear determination process S4; Yes), it outputs a wear state estimation result (wear signal) indicating that wear has occurred in the resin bush R, which is the part J to be determined for wear (wear signal output process S5A). On the other hand, if the output value (frequency of the molded signal) is not smaller than the threshold (wear determination process S4; No), it outputs a wear state estimation result (wear amount signal) indicating that wear has not occurred in the resin bush R, which is the part J to be determined for wear (wear signal output process S5B). Furthermore, if the output value (frequency of the molded signal) is smaller than the threshold (wear determination process S4; Yes), the control unit C determines whether the amount of wear of the resin bush R, which is the wear target part J, has reached a predetermined amount (wear amount determination process S10). If the amount of wear has reached a predetermined amount (wear amount determination process S10; Yes), it outputs a wear amount estimation result (wear amount signal) indicating that the amount of wear of the resin bush R, which is the wear target part J, has reached a predetermined amount (wear amount signal output process S10A). On the other hand, if the amount of wear has not reached a predetermined amount (wear amount determination process S10; No), it outputs a wear amount estimation result (wear amount signal) indicating that the amount of wear of the resin bush R has not reached a predetermined amount (wear amount signal output process S10B). Through this process (wear state estimation process SB via wear determination process S4 and wear signal output processes S5A, S5B, and wear amount estimation process SB' via wear amount determination process S10 and wear amount signal output processes S10A, S10B), the train T operation management side (operator) can detect in real time whether the resin bush R is worn, and furthermore, whether the wear amount has reached a level that requires replacement. If wear is detected, the resin bush R can be replaced as soon as possible.

[0065] Furthermore, since the drive plate L and drive pin P are harder than the resin bush R, they wear less and require less frequent replacement. Therefore, if the speed generator wear detection system X according to this embodiment is applied to detect wear after the resin bush R has been replaced, it will indicate that wear has been detected on the drive plate L and drive pin P. Thus, similar to the wear detection of the resin bush R, the wear estimation unit 2 may detect wear on the drive plate L and drive pin P, or a predetermined amount of wear (amount of wear requiring replacement) and a corresponding threshold value for the drive plate L and drive pin P may be set in advance, and the wear amount determination unit 101 may determine whether the drive plate L and drive pin P have reached the predetermined amount of wear.

[0066] Furthermore, the wear detection system X according to the second embodiment includes an installation estimation unit 3 that estimates whether or not a resin bush R is installed.

[0067] If the resin bushing R falls off during maintenance or immediately after replacement, or if it falls off during operation due to damage, etc., as shown in Figures 10(d), (e), and (f), the drive pin P moves alternately from one end to the other of the opening edge of the groove L2 of the drive plate L (a reciprocating motion moving in the order of (d)→(e)→(f)→(e)→(d) in the same figure). The output signal of the speed generator G will alternately consist of a state where the drive pin P is in contact with either side edge of the groove L2 of the drive plate (region A in the same figure) and a state where the drive pin P is floating without contacting the groove L2 of the drive plate (a signal with a different frequency from the contact state, region C in the same figure). The signal during the non-contact state is more distorted than the waveform when the resin bushing R is worn (region B). Therefore, by processing such signals, it is possible to detect whether the resin bushing R is installed or not (fallen off, dropped).

[0068] The fitting estimation unit 3 can be further subdivided into a fitting determination unit 31 that determines whether the output value detected by the output value detection unit 1 is less than or equal to a preset second threshold, and a fitting state estimation output unit 32 that outputs the fitting state estimated based on the determination result by the fitting determination unit 31 (see Figure 9).

[0069] The mounting determination unit 31 determines whether the output value (frequency) detected by the output value detection unit 1 is below a preset second threshold. The second threshold is a value set based on the relationship between the running speed of the train T and the frequency of the output signal of the speed generator G corresponding to the running speed in the non-contact state described above, when there is no wear on the resin bush R, drive plate L, and drive pin P, and the resin bush R has fallen off (when the resin bush R is not interposed between the drive pin P and the groove L2 of the drive plate L). This can be a theoretical value or a measured value (for example, a measured value when the speed generator G is rotated in accordance with the running speed of the train T when the resin bush R is not installed). Here, when the resin bush R is installed (when the resin bush R is interposed between the drive pin P and the groove L2 of the drive plate L), the frequency of the output signal of the speed generator G is the same as or approximately the same as the frequency of the signal of the speed generator G when there is no wear in the groove L2 of the drive plate L as described in the first embodiment, and the frequency of the output signal of the speed generator G corresponding to the running speed when there is no wear in the resin bush R, drive plate L, and drive pin P, i.e., the frequency in the setting of the first threshold, and it gradually increases as the running speed of the train T increases. That is, as shown in Figure 4, the frequency gradually increases as the running speed of the train T increases, such as A0, A1, A2...A10.

[0070] On the other hand, when the resin bush R is not installed, the output signal of the speed generator G alternates between a state where the drive pin P is in contact with the opening edge of the groove L2 and a state where it is floating without contacting the opening edge of the groove L2. The frequency of the output signal when the drive pin P is in contact with the opening edge of the groove L2 is the same as or approximately the same as the frequency when the resin bush R is installed, and this value (frequency) changes according to the running speed of the train T. The frequency of the output signal when the drive pin P is floating without contacting the opening edge of the groove L2 is smaller than the frequency of the output signal when the drive pin P is in contact with the opening edge of the groove L2, and because the drive pin P moves more than when the resin bush R is installed and worn, it becomes smaller than the frequency of the output signal when it is floating without contacting the worn edge of the resin bush R, and this value (frequency) changes according to the running speed of the train T. In other words, the second threshold is smaller than the first threshold when the running speed of the train T is the same.

[0071] The mounting determination unit 31 compares a second threshold value predetermined based on such events with the output value (frequency) actually detected by the output value detection unit 1 to determine whether the output value is less than or equal to the second threshold value.

[0072] The mounting status estimation output unit 32 estimates that the resin bush R is not mounted (detached) when the determination result by the mounting determination unit 31 is Yes, that is, when the output value is below the second threshold, and outputs the estimation result. The mounting status estimation output unit 32 also estimates that the resin bush R is mounted (not detached) when the determination result by the mounting determination unit 31 is No, that is, when the output value is not below the second threshold, and outputs the estimation result.

[0073] As shown in Figure 9, the mounting estimation unit 3 of the speed generator wear detection system X according to this embodiment can be configured by a circuit or the like that is incorporated into the brake control unit C, similar to the output value detection unit 1 and the wear estimation unit 2.

[0074] The processing procedure for wear detection and mounting (detachment) detection by the speed generator wear detection system X according to this embodiment, which is equipped with such mounting estimation unit 3 (speed generator wear and detachment detection method), will be explained with reference to Figure 11.

[0075] First, the procedure for performing the output value detection process SA (output value acquisition process S1, signal shaping process S2, frequency detection process S3) is the same as in the first embodiment described above. Following the output value detection process SA, the control unit C determines whether the output value (frequency of the shaped signal) detected in the output value detection process SA is less than or equal to the second threshold (installation determination process S6). If the output value (frequency of the shaped signal) is less than or equal to the second threshold (installation determination process S6; Yes), it outputs an estimated installation state result (installation signal) indicating that the resin bush R is not installed (detached) (installation signal output process S7). In this embodiment, as shown in Figure 11, if the output value (frequency of the shaped signal) is less than or equal to the second threshold (installation determination process S6; Yes), it outputs an estimated installation state result (installation signal) indicating that the resin bush R is not installed (detached) (installation signal output process S7). This results in the output of an installation signal indicating that the resin bushing R is not installed, and a wear signal indicating that the resin bushing R is not worn. However, for the train T operation management side (operator), once the information that the resin bushing R is not installed is identified, the presence or absence of wear of the resin bushing R is irrelevant, so the output result from the above processing is sufficient.

[0076] On the other hand, if the output value (frequency of the molded signal) in the mounting determination process S6 is not below the second threshold (mounting determination process S6; No), the process proceeds to the wear state estimation process SB and the wear amount estimation process SB' described above. Alternatively, if the output value (frequency of the molded signal) is not below the second threshold (mounting determination process S6; No), the process may be configured to output a mounting state estimation result (mounting signal) indicating that the resin bush R is mounted (not detached) (mounting signal output process, not shown in the diagram). The mounting determination process S6 and the mounting signal output process S7 can be considered together as the mounting state estimation process SC.

[0077] By following these processing steps, the train T's operation management side (operator) can detect in real time whether the resin bush R is not installed (lost) based on the output result (installation signal) of the installation status estimation process SC. If it is detected that the resin bush R is not installed (lost), it becomes possible for an operator to install the resin bush R as soon as possible. Furthermore, according to the wear detection system X of this embodiment, if the installation status estimation process SC estimates that the resin bush R is installed (not lost), the wear status estimation process SB is executed following the installation status estimation process SC. Therefore, it is possible to detect in real time whether the resin bush R is in a worn state from the output result (wear signal) of the wear status estimation process SB, and by outputting an estimated result that it is in a worn state, it is possible to prompt an operator to replace the resin bush R.

[0078] Furthermore, in introducing this system X, which can detect the mounting and wear status of such resin bushings R, there is no need to install dedicated hardware on the train T. As described in the above embodiment, it can be operated by, for example, partially utilizing and improving the existing brake control unit C.

[0079] <Third Embodiment> The wear detection system X according to the third embodiment can be considered as a modified example of the wear detection system X according to the second embodiment. As shown in Figure 12, it is characterized by having a second wear estimation unit 4 in addition to the wear estimation unit 2 described above, and is configured to detect the wear state of the resin bush R, which is the wear target part, more accurately using a two-stage judgment criterion.

[0080] In other words, the wear detection system X according to this embodiment has a second wear estimation unit 4 which includes a second wear determination unit 41 that, when the wear determination unit 21 determines that the output value (frequency) detected by the output value detection unit 1 is smaller than a preset threshold (hereinafter referred to as the "first threshold" as in the second embodiment), further determines whether the output signal of the speed generator G contains signals of two different frequencies periodically. Specific examples of the two different frequencies are, firstly, "a frequency that is the same as or approximately the same as the first threshold," and secondly, "a frequency that is smaller than the first threshold and larger than the second threshold."

[0081] The inventors of the present invention have considered the rare occurrence of cases where, even when the wear determination unit 21 determines that the output value (frequency) is smaller than a preset first threshold, the resin bush R is not actually worn to the extent expected. In order to prevent such occurrences, after diligent research, they have found that the wear state of the resin bush R can be more accurately identified by determining whether or not the two signals of different frequencies described above are periodically mixed together.

[0082] Here, "frequency that is the same as or approximately the same as the first threshold" means the frequency of the signal when the drive plate L or drive pin P is approaching and in contact with the edge of the worn portion of the resin bush R (the edge of the insertion hole R1 of the resin bush R or the opposing surface 3), as in the second embodiment, and "frequency that is less than the first threshold and greater than the second threshold" means the frequency of the signal when the drive pin P is floating without contacting the edge of the worn portion (the edge of the insertion hole R1 of the resin bush R). The periodic coexistence of signals of these two different frequencies confirms that the worn resin bush R is moving, and therefore, the wear detection system X according to this embodiment, which includes the second wear determination unit 41, can more accurately determine whether or not the resin bush R is in a worn state.

[0083] The second wear estimation unit 4, which has a second wear determination unit 41, includes a second wear state estimation output unit 42 that estimates that the resin bush R is worn when the determination result by the second wear determination unit 41 is Yes, that is, when the two signals of the two different frequencies mentioned above are periodically mixed, and outputs the estimation result (wear signal). The second wear state estimation output unit 42 also estimates that the resin bush R is not worn when the determination result by the second wear determination unit 41 is No, that is, when the two signals of the two different frequencies mentioned above are not periodically mixed, and outputs the estimation result (wear signal).

[0084] The second wear estimation unit 4, which includes a second wear determination unit 41 and a second wear state estimation output unit 42, can be configured by a circuit or the like that is incorporated into the brake control unit C, as shown in Figure 12.

[0085] The wear state detection processing procedure by the wear detection system X according to this embodiment is as shown in Figure 13. The control unit C determines whether the output value (frequency of the molded signal) detected in the output value detection process SA is greater than the second threshold and less than the first threshold (wear determination process S4). If the output value (frequency of the molded signal) is greater than the second threshold and less than the first threshold (wear determination process S4; Yes), the second wear determination unit 41 performs the second wear determination process S8. The second wear determination process S8 is a process that determines whether signals of two different frequencies, "the same or approximately the same value as the first threshold" and "a frequency less than the first threshold and greater than the second threshold," are periodically mixed. In the second wear determination process S8, if signals of the two frequencies are periodically mixed (second wear determination process S8; Yes), a wear state estimation result (wear signal) indicating that wear has occurred in the resin bush R, which is the wear target part J, is output (second wear signal output process S9A). On the other hand, in the second wear determination process S8, if the two frequencies mentioned above do not periodically coexist (second wear determination process S8; No), the wear state estimation result (wear signal) indicating that no wear has occurred in the resin bush R, which is the wear target part J, is output (second wear signal output process S9B).

[0086] By going through the second wear determination process S8 and the second wear signal output processes S9A and S9B, followed by the second wear state estimation process SD, the train T's operation management side (operator) can obtain estimation results based on the output results of the second wear state estimation process SD in addition to the output results of the wear state estimation process SB. This makes it possible to grasp information on whether or not the resin bush R is worn more accurately and in real time. For example, even if the wear progresses relatively slowly due to the low-speed operation of train T, it becomes possible to perform the replacement work of the resin bush R that truly needs replacing at an earlier timing. Furthermore, by preventing and suppressing false detections of wear, it is possible to avoid wasted work time and work processes (preparation time and work performed when attempting to replace based on false detection information that the bush is worn), contributing to improved work efficiency.

[0087] <Fourth Embodiment> The wear detection system X according to the fourth embodiment can be considered as a modified example of the wear detection system X according to the second and third embodiments, and is characterized by the addition of new requirements to the judgment criteria in the mounting estimation unit 3.

[0088] In other words, the threshold value, which is the judgment criterion value in the wear estimation unit 2 (this threshold is different from the second threshold and will be referred to as the first threshold hereinafter), can be set by focusing on the relationship in which the train's running speed and the frequency of the output signal of the speed generator G corresponding to that running speed are proportional. On the other hand, the second threshold value, which is the judgment criterion value in the mounting estimation unit 3, may not be set according to the second embodiment, depending on the relationship in which the force acting on the resin bush R when the train T is running may result in a state in which the drive plate L does not contact the resin bush R or a state in which the drive pin P floats without contacting the resin bush R. In such cases, the running speed of the train T and the frequency of the output signal of the speed generator G corresponding to that running speed may not necessarily be proportional, and in particular in the low-speed range of the train T, it may not be possible to set it according to the second embodiment. Therefore, in the speed range in which the above events may occur, it may not be possible to distinguish between the second threshold and the first threshold, and wear detection may not be accurate. For this reason, in this embodiment, the second threshold in the low-speed range of the second threshold is set by a different setting method than in the other speed ranges. Specifically, in the low-speed range where the above phenomenon occurs, the second threshold is set to zero or a value close to zero so that it can be distinguished from the first threshold, and the second threshold in other speed ranges is set based on the second embodiment.

[0089] By setting the second threshold to such a value, the problem of being unable to properly perform mounting state estimation processing and wear state estimation processing because it is not possible to distinguish between the second threshold and the first threshold in speed ranges where settings based on the second embodiment cannot be made can be resolved.

[0090] <Embodiments 5 through 7> The wear detection systems X according to the fifth to seventh embodiments are equipped with control block configurations similar to those of the wear detection systems X according to the first to third embodiments described above, as shown in Figures 14, 16, and 18, respectively. However, compared to the wear detection systems X according to the first to third embodiments, the output value detection unit 1 takes in the output signal of the speed generator G and detects the voltage (voltage value) of the output signal as the output value, and has a crucial difference in that it does not use the pulse-like frequency formed from the output signal as the output value.

[0091] Furthermore, as the voltage of the output signal of the speed generator G is detected as an output value, the judgment conditions in the wear determination unit 21, the mounting determination unit 31, the second wear determination unit 41, and the wear amount determination unit 101 also differ.

[0092] Specifically, the wear determination unit 21 determines whether the output value (voltage) detected by the output value detection unit 1 is greater than a preset threshold (the first threshold in the case of a configuration involving a resin bush R (sixth and seventh embodiments)) (see Figures 15, 17, and 19); the mounting estimation unit 3 determines whether the output value (voltage) detected by the output value detection unit 1 is greater than or equal to a preset second threshold (see Figures 17 and 19); and the second wear determination unit 41 determines whether "voltages with the same value as the first threshold" and "voltages smaller than the second threshold but greater than the first threshold" are periodically mixed (see Figure 19). These points differentiate it from the first to third embodiments described above.

[0093] Furthermore, in the wear detection system X according to the fifth to seventh embodiments, based on these differences, as shown in the flowcharts in Figures 15, 17, and 19, the number of processes from start to end is approximately the same as the number of processes in the corresponding first to third embodiments described above. However, in the output value detection process SA, the process of shaping a pulse-like frequency from the output signal acquired in the output value acquisition process S1 (signal shaping process S2) is unnecessary, and the process involves detecting the voltage of the output signal acquired in the output value acquisition process S1 (voltage detection process S3) (i.e., the output value detection process SA consists of only two processes: output value acquisition process S1 and voltage detection process S3). Also, the specific judgment processes of the wear judgment process SB, the mounting judgment process SC, and the second wear judgment process SD are different.

[0094] As a threshold value used in the wear determination unit 21, for example, in the configuration in which a resin bush R is not interposed between the drive plate L and the drive pin P (5th embodiment), a value set based on the relationship between the running speed of the train T when no wear occurs on the drive plate L and drive pin P, which are the wear target parts J, and the voltage of the output signal of the speed generator G corresponding to the running speed can be used. In the configuration in which a resin bush R is interposed between the drive plate L and the drive pin P (6th and 7th embodiments), a value set based on the relationship between the running speed of the train T when no wear occurs on the resin bush R, drive plate L, and drive pin P, which are the wear target parts J, and the voltage of the output signal of the speed generator G corresponding to the running speed can be used, and this can be a theoretical value or a measured value (for example, a measured value when the speed generator G is rotated in accordance with the running speed of the train T, or a measured value when the train T is running with the speed generator G installed, etc.). Here, the voltage of the output signal of the speed generator G when no wear occurs on the wear target parts J gradually increases as the running speed of the train T increases. On the other hand, if wear occurs in the wear-detection target part J, for example, in a configuration where a resin bush R is not interposed between the drive plate L and the drive pin P (5th embodiment), the drive pin P alternates between a state in which it approaches and contacts one end of the worn portion of the drive plate L, and a state in which it floats without contacting the end of the worn portion. Due to the fluctuations in the induced voltage of the speed generator G resulting from the alternating occurrence of these states, the voltage of the output signal when the drive pin P approaches and contacts one end of the worn portion becomes higher than the voltage of the output signal when no wear occurs, and this value (voltage) changes according to the running speed of the train T. Due to the above fluctuations in induced voltage, the voltage of the output signal when the drive pin P floats without contacting the end of the worn portion becomes lower than the voltage of the output signal when no wear occurs in the wear-detection target part J, and this value (voltage) changes according to the running speed of the train T. In other words, when wear occurs, the output value (voltage) fluctuates relative to the voltage (threshold) of the output signal of the speed generator G when no wear occurs, and the magnitude of this fluctuation increases as the wear increases.

[0095] In the wear determination unit 21 of the fifth to seventh embodiments, a preset threshold (a first threshold in the configuration involving a resin bush R (sixth and seventh embodiments)) is compared with the output value (voltage) detected by the output value detection unit 1 to determine whether the output value is greater than the threshold (first threshold). The voltage value used in setting the threshold is optimally the voltage peak value of the output signal of the speed generator G, but the effective value, average value, absolute value, etc., may also be used.

[0096] Furthermore, the wear state estimation output unit 22 of the fifth to seventh embodiments estimates that at least the wear target part J is worn if the determination result by the wear determination unit 21 is Yes, that is, if the output value is greater than a threshold (the first threshold if a resin bush R is interposed between the drive plate L and the drive pin P (sixth and seventh embodiments)), and outputs the estimation result. Also, the wear state estimation output unit 22 of the fifth to seventh embodiments estimates that at least the wear target part J is not worn if the determination result by the wear determination unit 21 is No, that is, if the output value is the same as or approximately the same as a threshold (the first threshold if a resin bush R is interposed (sixth and seventh embodiments)), and outputs the estimation result.

[0097] The wear amount estimation unit 10 estimates the wear amount of the drive plate L, which is the wear target part J, when the wear determination result from the wear determination unit 21 is Yes, that is, when the output value is greater than the threshold, in the case of a configuration in which a resin bush R is not interposed between the drive plate L and the drive pin P (fifth embodiment). Specifically, the wear determination unit 21 sets a threshold (wear amount determination threshold) that is greater than a preset threshold and corresponds to a predetermined wear amount (amount of wear requiring replacement), and if it is greater than or equal to that threshold, it estimates that the wear amount of the drive plate L, which is the wear target part J, has reached the predetermined wear amount, and outputs the estimation result. The threshold (a threshold for determining the amount of wear) is, for example, a value set based on the relationship between the running speed of the train T and the voltage of the output signal of the speed generator G corresponding to the running speed, in a state where a predetermined amount of wear has occurred on the drive plate L and no wear has occurred on the drive pin P, and the drive pin P is floating without contacting the edge of the worn portion of the drive plate L. This value can be a theoretical value or an actual measured value (for example, a measured value when the speed generator G is rotated in accordance with the running speed of the train T, or a measured value when the train T is running with the speed generator G installed).

[0098] Furthermore, in the configuration in which a resin bush R is interposed between the drive plate L and the drive pin P (sixth and seventh embodiments), the wear amount estimation unit 10 estimates the wear amount of the resin bush R, which is the wear target part J, when the determination result by the wear determination unit 21 is Yes, that is, when the output value is greater than the first threshold. Specifically, the wear determination unit 21 sets a threshold (wear amount determination threshold) that is greater than the first threshold set in advance and corresponds to a predetermined amount of wear (amount of wear requiring replacement). If the value is greater than or equal to the first threshold, it estimates that the wear amount of the resin bush R, which is the wear target part J, has reached a predetermined amount of wear, and outputs the estimation result. The threshold (threshold for determining the amount of wear) is, for example, a value set based on the relationship between the running speed of the train T and the voltage of the output signal of the speed generator G corresponding to the running speed, in a state where a predetermined amount of wear has occurred in the resin bush R, but there is no wear on the drive plate L and drive pin P, and the drive plate L and drive pin P are floating without contacting the end of the worn portion of the resin bush R. This value can be a theoretical value or an actual measured value (for example, a measured value when the speed generator G is rotated in accordance with the running speed of the train T, or a measured value when the train T is running with the speed generator G installed).

[0099] Furthermore, in the configuration in which a resin bush R is interposed between the drive plate L and the drive pin P (sixth and seventh embodiments), similar to the second embodiment, the wear state of the resin bush R tends to differ due to the effect of the drive pin P shifting toward the opening direction of the groove L2 of the drive plate L while the train T is running. Therefore, the above threshold (threshold for determining the amount of wear) may be set separately, taking into account the effect of eccentricity, for a predetermined amount of wear at the insertion hole R1 of the resin bush R and a predetermined amount of wear at the opposing surface R3.

[0100] Furthermore, instead of using the above-mentioned threshold (threshold for determining wear amount) as a reference for the wear amount estimation unit 10, the following configuration can also be adopted. Specifically, when the drive plate L and resin bush R are worn, and the output signal of the speed generator G alternates between a state where the drive pin P is approaching and in contact with one end of the worn portion of the groove L2, and a state where it is floating without contacting the end of the worn portion, the system may employ a configuration that calculates the amount of movement of the drive pin P and drive plate R at a predetermined speed of the train T based on the frequency corresponding to the voltage of the output signal when the drive pin P is floating without contacting the end of the worn portion, the frequency of the signal corresponding to the state where the drive pin P is in contact with the end of the worn portion, where the voltage peak value does not exceed a predetermined voltage (the threshold or first threshold mentioned above), and the difference in time when a predetermined voltage is detected before and after that output signal. If the calculated amount of movement is the same as or approximately the same as a predetermined wear amount (the amount of wear requiring replacement), the system may estimate that the amount of wear of the drive plate L has reached the predetermined wear amount and output the estimation result.

[0101] As shown in Figures 15, 17, and 19, the wear determination process S4 determines whether the output value (voltage) detected in the output value detection process SA is greater than a threshold (the first threshold in the sixth and seventh embodiments). If the output value (voltage) is greater than the threshold (the first threshold in the sixth and seventh embodiments) (wear determination process S4; Yes), it outputs a wear state estimation result indicating that wear has occurred in the wear target part J (wear signal output process S5A). If the output value (voltage) is not greater than the threshold (the first threshold in the sixth and seventh embodiments), that is, if it is the same as or approximately the same as the threshold (the first threshold in the sixth and seventh embodiments) (wear determination process S4; No), it outputs a wear state estimation result indicating that wear has not occurred in the wear target part J (wear signal output process S5B).

[0102] Furthermore, if the output value (voltage) is greater than the threshold (wear determination process S4; Yes), it is determined whether the amount of wear of the drive plate L and resin bush R, which are the wear target parts J, has reached a predetermined amount (wear amount determination process S10). If the amount of wear has reached a predetermined amount (wear amount determination process S10; Yes), the wear amount estimation result indicating that the amount of wear of the wear target parts J has reached a predetermined amount is output (wear amount signal output process S10A). On the other hand, if the amount of wear has not reached a predetermined amount (wear amount determination process S10; No), the wear amount estimation result indicating that the amount of wear of the wear target parts J has not reached a predetermined amount is output (wear amount signal output process S10B).

[0103] Furthermore, the mounting determination unit 31 of the sixth and seventh embodiments determines whether the output value (voltage) detected by the output value detection unit 1 is equal to or greater than a preset second threshold. The second threshold is a value set based on the relationship between the running speed of the train T and the voltage of the output signal of the speed generator G corresponding to the running speed when the resin bush R, drive plate L, and drive pin P are not worn, and the resin bush R has fallen off (when the resin bush R is not interposed between the drive pin P and the groove L2 of the drive plate L), and the drive pin P is in contact with either side edge of the groove L2 of the drive plate L. The second threshold can be a theoretical value or a measured value (for example, a measured value when the speed generator G is rotated in accordance with the running speed of the train T when the resin bush R is not installed). Here, when the resin bush R is installed (when the resin bush R is interposed between the drive pin P and the groove L2 of the drive plate L), the voltage of the output signal of the speed generator G is the same as or approximately the same as the voltage of the signal of the speed generator G when there is no wear in the groove L2 of the drive plate L as described in the fifth embodiment, and the running speed of the train T and the voltage of the output signal of the speed generator G corresponding to the running speed when there is no wear in the resin bush R, drive plate L, and drive pin P, i.e., the voltage in the setting of the first threshold, and it gradually increases as the running speed of the train T increases.

[0104] If the resin bushing R is not installed (fallen off), the output signal of the speed generator G alternates between a state where the drive pin P is in contact with the opening edge of groove L2 and a state where it is floating without contacting the opening edge of groove L2. The voltage of the output signal when the drive pin P is in contact with the opening edge of groove L2 becomes higher than the voltage of the output signal when there is no wear or when the resin bushing R is installed (not fallen off), due to fluctuations in the induced voltage of the speed generator G resulting from the alternating occurrence of these states, and this value (voltage) changes according to the running speed of the train T. On the other hand, the voltage of the output signal when the drive pin P is floating without contacting the opening edge of groove L2 becomes lower than the voltage of the output signal when there is no wear or when the resin bushing R is installed (not fallen off), due to fluctuations in the induced voltage of the speed generator G, and this value (voltage) changes according to the running speed of the train T. In other words, when the resin bushing R is not installed, the output value (voltage) fluctuates compared to the voltage of the output signal of the speed generator G when there is no wear or when the resin bushing R is installed (not detached). The magnitude of this fluctuation is greater than when the resin bushing R is installed because the drive pin P moves more than when the resin bushing R is installed and worn, resulting in a larger fluctuation in the induced voltage. That is, the second threshold value is greater than the first threshold value when the train T is traveling at the same speed.

[0105] The mounting determination unit 31 compares a second threshold value predetermined based on such events with the output value (voltage) actually detected by the output value detection unit 1 to determine whether the output value is equal to or greater than the second threshold value.

[0106] The mounting status estimation output unit 32 estimates that the resin bush R is not mounted (detached) when the mounting determination unit 31 determines it to be Yes, that is, when the output value is equal to or greater than the second threshold, and outputs this estimation result. Conversely, the mounting status estimation output unit 32 estimates that the resin bush R is mounted (not detached) when the mounting determination unit 31 determines it to be No, that is, when the output value is not equal to or greater than the second threshold, and outputs this estimation result.

[0107] Therefore, as shown in Figures 17 and 19, in the mounting determination process S6, it is determined whether the output value (voltage) detected in the output value detection process SA is equal to or greater than the second threshold. If the output value (voltage) is equal to or greater than the second threshold (mounting determination process S6; Yes), the mounting state estimation result that the resin bush R is not mounted (detached) is output (mounting signal output process S7). If the output value (voltage) is not equal to or greater than the second threshold (mounting determination process S6; No), the process proceeds to the wear state estimation process SB.

[0108] Furthermore, the second wear determination unit 41 of the seventh embodiment determines whether the output signal of the speed generator G periodically contains a mixture of "a voltage with the same value as the first threshold" and "a voltage that fluctuates between a voltage less than the second threshold and a voltage greater than the first threshold." "A voltage with the same value as the first threshold" means the voltage when the drive pin P or drive plate L is approaching and in contact with the edge of the worn part (the edge of the insertion hole R1 of the resin bush R or the opposing surface R3), while "a voltage that fluctuates between a voltage less than the second threshold and a voltage greater than the first threshold" means the voltage when the drive pin P or drive plate L is floating without contacting the edge of the worn part. The periodic mixture of these two different voltages confirms that the drive pin P or drive plate L is moving on the opposing surface R3 of the insertion hole R1 of the worn resin bush R. Therefore, the wear detection system X equipped with the second wear determination unit 41 can more accurately determine whether or not the resin bush R is in a worn state.

[0109] The seventh embodiment of the wear detection system X, which includes a second wear determination unit 41, includes a second wear state estimation output unit 42 that estimates that the resin bush R is worn when the determination result by the second wear determination unit 41 is Yes, that is, when the two different voltages described above are periodically mixed, and outputs the estimation result (wear signal). The second wear state estimation output unit 42 estimates that the resin bush R is not worn when the determination result by the second wear determination unit 41 is No, that is, when the two different voltages described above are not periodically mixed, and outputs the estimation result (wear signal).

[0110] Therefore, as shown in Figure 19, if the wear determination process S4 is less than the second threshold and greater than the first threshold (wear determination process S4; Yes), a second wear determination process S8 is performed to determine whether "voltages with the same value as the first threshold" and "voltages less than the second threshold and greater than the first threshold" are periodically mixed. In the second wear determination process S8, if the above two frequencies are periodically mixed (second wear determination process S8; Yes), a wear state estimation result (wear signal) indicating that wear has occurred in the resin bush R, which is the wear target part J, is output (second wear signal output process S9A). In the second wear determination process S8, if the above two frequencies are not periodically mixed (second wear determination process S8; No), a wear state estimation result (wear signal) indicating that wear has not occurred in the resin bush R, which is the wear target part J, is output (second wear signal output process S9B).

[0111] It should be noted that the present invention is not limited to the embodiments described above. For example, the thresholds (including the first threshold, the wear amount determination threshold, and the second threshold) can be set to values ​​defined as appropriate depending on the situation, such as changing "greater than or equal to" to "greater than" or setting "less than" to "less than or equal to" as specified in the embodiments described above. Furthermore, considering detection errors and noise in the output signal, it is also possible to set values ​​with a range, for example, by changing "greater than or equal to the first threshold" to "greater than or equal to the first threshold ± 5%".

[0112] Furthermore, with respect to the parts subject to wear determination, it is also possible to configure the system to estimate the amount of wear without detecting the presence or absence of wear (without performing wear state estimation processing). Moreover, although the embodiments described above illustrate a configuration in which the wear amount estimation processing is performed by the wear amount estimation unit after the determination result by the wear determination unit, it is also possible to adopt a configuration in which, after the determination result by the second wear determination unit, the second wear estimation unit specifically determines whether or not signals of two frequencies are periodically mixed, and outputs a determination result that they are mixed, and then performs the wear amount estimation processing. Furthermore, the system can be configured to perform an installation estimation process that estimates whether or not a resin bushing is interposed between the drive pin and the groove of the drive plate, without detecting the presence or absence of wear or estimating the amount of wear.

[0113] The information handled when operating the system according to the present invention (frequency, voltage, signal, threshold, etc.) may be collected outside the train, such as in an operation management system or the cloud.

[0114] Furthermore, the wear detection system according to the present invention can be applied not only to speed generators but also to contact-type speed sensors. The speed sensor body of the speed sensor has, for example, a cylindrical housing portion arranged coaxially with the train axle, and a Hall element and a permanent magnet are incorporated inside the housing portion. The sensing mechanism inside the housing portion is a known one, for example, comprising a magnetic gear that is rotatably mounted coaxially with the train axle and rotates integrally with the drive plate L, and a Hall element and a permanent magnet provided on the outer circumference of the gear, and is configured to detect the rotational speed of the gear, that is, the rotational speed of the axle, by converting the change in the magnetic field around the gear into an electrical signal when the gear rotates. When the wear detection system of the present invention (speed sensor wear detection system) is configured using such a speed sensor as the speed detector, since the sensor output is pulsed, it will be operated in accordance with the first to fourth embodiments described above, which treat frequency as input information, and the speed generator G in Figure 1 will be replaced with a contact-type speed sensor.

[0115] Furthermore, various modifications are possible without departing from the spirit of the present invention. [Explanation of Symbols]

[0116] 1...Output value detection unit 2…Wear estimation section 3...Estimation unit for attachment 10... Wear amount estimation unit A... Axle B... Speed ​​detector unit (speed generator unit) G... Speed ​​detector (speed generator) J...Parts subject to wear assessment L... Drive plate L2…Groove P...Drive pin R... Resin bushing X... Speed ​​detector wear detection system (speed generator wear detection system)

Claims

1. A wear detection system for a contact-type speed sensor, comprising a drive pin provided on one end of an axle and capable of rotating integrally with the axle, a drive plate that rotates in accordance with the drive pin, and a speed sensor body connected to the drive plate, The drive plate has a groove that allows the drive pin to be inserted, and transmits the rotation of the axle to the speed detector body by rotating in conjunction with the rotational movement of the drive pin inserted in the groove. An output value detection unit that detects an output value based on the output signal of the speed detector body, The system includes a wear estimation unit that compares the output value detected by the output value detection unit with a preset threshold value to estimate whether at least the part that the drive pin contacts and which is subject to wear determination is worn or not, A speed detector wear detection system characterized by detecting the wear state of the wear target part based on the estimation result by the wear estimation unit.

2. A resin bush is interposed between the drive pin and the groove of the drive plate, The speed detector wear detection system according to claim 1, wherein the wear target part is the resin bush.

3. The speed detector wear detection system according to claim 2, further comprising a mounting estimation unit that estimates whether or not the resin bush is interposed between the drive pin and the groove of the drive plate by comparing the output value detected by the output value detection unit with a preset second threshold.

4. A speed detector wear detection system according to any one of claims 1 to 3, further comprising a wear amount estimation unit that estimates the amount of wear of the wear target part based on the output value detected by the output value detection unit.

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