Method for diagnosing fault in channel and softness valve of type 483 air distributor and device for implementing it

Abstract

FIELD: railway transportation.SUBSTANCE: invention relates to diagnostics of braking equipment of rolling stock, namely to methods and devices for diagnosing a malfunction of a channel and a softness valve of an air distributor of type 483, 483M, 483A after spontaneous activation of the brakes of a rolling stock in a train or during a control test of the brakes and maintenance of the rolling stock. The method for diagnosing a malfunction of the channel and the softness valve of the air distributor of type 483 consists in that the pressure in the brake line is reduced by moving the handle of the driver's valve from position I to position II at a constant rate of softness to 0.3-0.4 kgf / cm2 per 1 min, whereas the air outlet through the atmospheric hole is recorded by a differential pressure sensor and converted into an internal digital signal transmitted via the PC interface to the microcontroller, and the microcontroller receives and processes the measurement data in accordance with the embedded algorithm, including filtering the measured signal and comparing it with a specified threshold value. The microcontroller interprets exceeding the threshold level as a sign of an air leak and a malfunction of the air distributor, whereas visual indication is implemented via a graphic OLED display. The diagnostic device comprises a housing comprising a differential pressure sensor, a microcontroller mounted on a debug board, a graphic OLED display, a battery, and a power switch. The housing comprises a tip with a through channel for connecting the atmospheric opening of the two-chamber tank with the measuring channels of the differential pressure sensor.EFFECT: increasing the accuracy of diagnosing a malfunction of the channel and the softness valve of the type 483 air distributor, improving the clarity of visualization of the device's operation, increasing the reliability of the device's operation and, as a result, increasing the efficiency of diagnostics.3 cl, 5 dwg

Description

[0001] The invention relates to the field of diagnostics of braking equipment of rolling stock, namely to methods and devices for diagnosing a malfunction of the channel and the softness valve of the air distributor of type 483, 483M, 483A after spontaneous activation of the brakes of a rolling stock in a train or during a control check of the brakes and technical maintenance of the rolling stock.

[0002] Type 483 air distributors are universal air distributors installed on all freight cars, regardless of their purpose. These air distributors are equipped with a channel and a softening valve to prevent the air distributor from applying brakes when the brake line pressure slowly decreases. If the channel or softening valve is faulty, particularly if the softening valve is stuck closed, the softening valve diaphragm is faulty, or the channel (calibrated opening 0.9 mm) is clogged, the type 483 air distributor becomes sensitive to longitudinal dynamic forces and, under jerking and impacts, may inadvertently apply brakes, especially when the train is starting.Moreover, after the spontaneous activation of a single faulty air distributor, a pressure drop propagates throughout the entire rolling stock due to the discharge of the brake line, and all air distributors are activated, causing an unscheduled train stop. Such malfunctions are hidden, and identifying the specific car with the faulty air distributor that caused the train stop by external inspection or brake testing is difficult and time-consuming, leading to train delays and resulting in losses and damages due to disruptions to the train schedule.

[0003] A test bench (device) for testing brake air distributors of railway rolling stock is known (RU No. 125530, IPC B60T 17 / 22, G01L 5 / 28, published 03.10.2013), comprising a housing with an electric control unit, while pneumatic reservoirs are located inside the housing: a working chamber reservoir, a spool chamber reservoir, a spare reservoir, a main and a brake reservoir. The pneumatic clamping mechanism of the main part and the main part of the air distributor are part of the mode switching unit. The mating flange of the main part of the air distributor is connected by a connecting channel to the pneumatic main reservoir through a pressure control unit. Pressure monitoring is performed by a pressure sensor.

[0004] The disadvantage of the well-known stand is the limited use of the stand, namely only in the manufacture of air distributors or in wagon and locomotive depots, and the impossibility of diagnosing air distributors installed on freight cars during operation.

[0005] An indicator is known for identifying faulty air distributors when checking the brakes of rolling stock (RU No. 2846344, IPC B60T 17 / 22, G01F 1 / 38, G01F 3 / 02, G01F 3 / 14, published 04.09.2025) containing a polymer hollow body, a polymer hollow rod and a hose connected to the body, wherein the hose is designed with the possibility of its installation in the atmospheric opening of a two-chamber reservoir of the air distributor.

[0006] The advantage of the well-known indicator is the ability to identify faulty air distributors during a control check of the brakes of rolling stock in operation.

[0007] A drawback of the known indicator is the lack of a reliable connection between the indicator and the air distributor. The connection is made through an atmospheric vent via a hose without any additional fastening devices. Furthermore, the device's low reliability and low fault detection accuracy are related to the fact that a faulty air distributor is detected by the indicator with its piston rod extended under the influence of compressed air. However, due to the piston rod blocking the connection of the additional discharge channel (ADC) to the atmosphere, there is a risk of the air distributor being triggered. Furthermore, if the piston rod is tightly fitted in the hollow polymer housing, the piston rod will not move due to friction against the housing walls even with a minor compressed air leak, leading to a missed fault.

[0008] The prototype of the claimed technical solution is a method for detecting a type 483 air distributor of a freight car with a faulty channel or soft valve using an "indicator" device (Sel'kin A.A., Mikhailov D.I., Nalabordin D.G., Volkov V.V. Improving methods for detecting a faulty air distributor during a control check of brakes / / "Wagons and Wagon Economy", No. 2, Q2 2023. - pp. 29-30). The device is an "indicator", which consists of an oil and petrol-resistant hose (GOST 10362) 50 mm long and 10 mm in diameter. A polyethylene packaging bag is attached to the hose at a distance of 25 mm from the end with insulating tape, with the ability to refill the bag cavity with air through the hose. The diagnostic method involves installing the device on the air distributor of a freight car by inserting a hose into the atmospheric opening of a two-chamber tank by 10-25 mm, while the air from the bag must be released.After securing the packages, a technique is used to induce spontaneous brake activation. By moving the driver's valve handle from position I to position II, the brakes automatically transition from the elevated pressure in the equalizing reservoir and brake line to normal charging pressure at a constant rate of 0.3-0.4 kgf / cm. 2 In 1 minute. If the air distributor's duct or softening valve is faulty, air will be released into the atmosphere through the atmospheric opening of the two-chamber reservoir, triggering the "indicator" (the bag will fill with air). "Indicators" installed on serviceable air distributors will remain in their previous state (without air). This is how a car with a faulty air distributor is identified.

[0009] The advantage of this method and device is the ability to identify an air distributor with a faulty channel or soft valve after spontaneous activation of the brakes of a rolling stock or during a control check of the brakes.

[0010] The disadvantage of the known method and device is the blocking of the opening connecting the air distributor to the atmosphere, which can lead to the activation of the brake when filling the bag, the lack of a reliable connection of the device with the air distributor, the vulnerability of the device to mechanical and natural influences and phenomena that can lead to its malfunction, unclear visualization of the operation of the "indicator", and, as a result, low reliability of the device, high labor intensity of the work.

[0011] The technical problem being solved is the low reliability of existing devices for diagnosing air distributor malfunctions, the lack of a reliable connection between the devices and the air distributor, unclear visualization of the device operation due to the lack of the ability to record diagnostic results in the devices, low accuracy in detecting a malfunction of the channel and the soft valve of the type 483 air distributor due to the blocking of the hole connecting the air distributor to the atmosphere during diagnostics, which together negatively affects the effectiveness of the diagnostics.

[0012] The technical result consists in increasing the accuracy of diagnosing a malfunction of the channel and the softness valve of the type 483 air distributor, improving the clarity of visualization of the device’s operation, increasing the reliability of the device’s operation and, as a result, increasing the efficiency of diagnostics.

[0013] The technical result is achieved due to the fact that the method for diagnosing a malfunction of the channel and the softness valve of the type 483 air distributor is based on the operating features of the air distributor and consists in the fact that the diagnostic device is connected to the atmospheric hole located in the two-chamber reservoir of the air distributor, then the pressure in the brake line is reduced by moving the handle of the driver's valve from position I to position II at a constant softness rate of up to 0.3-0.4 kgf / cm 2For 1 minute, the air flow exiting through the atmospheric vent is recorded by a differential pressure sensor. The differential pressure sensor converts the dynamic pressure caused by the air flow into an internal digital signal transmitted via a PC interface to the microcontroller. The microcontroller then receives and processes the measured data according to a preset algorithm, including filtering the measured signal and comparing it with a preset threshold. If the threshold is exceeded, the microcontroller interprets an air leak and, consequently, a malfunction of the air distributor. Visual indication is provided by activating a graphic OLED display, which records the air flow detection.

[0014] The diagnostic device comprises a housing in which a differential pressure sensor, a microcontroller mounted on a debug board, a graphic OLED display, a battery, a power switch and a permanent magnet are placed, while the housing of the device comprises a tip with a through channel designed for aerodynamic coupling of the atmospheric opening of the two-chamber air distributor tank with the measuring channels of the differential pressure sensor.

[0015] Improving the accuracy of diagnosing a fault in the duct and softening valve of the Type 483 air distributor is achieved through the use of a differential pressure sensor. A conventional pressure sensor cannot detect air leakage, so the proposed invention utilizes a differential pressure sensor sensitive specifically to air flow, effectively separating the useful signal (leak) from background changes in static pressure. Microcontroller processing of measurement data enables precise adjustment of the response threshold, interference filtering, and a flexible display format.

[0016] Improved visualization of device operation is achieved by the ability to record diagnostic results within the device. Visual indication is achieved by activating a graphic OLED display, which records the air flow detection, signaling the presence of an air leak.

[0017] The reliability of the diagnostic device is increased by the presence of a permanent magnet for secure fixation of the device on the air distributor body.

[0018] This is how the technical result is achieved.

[0019] The essence of the claimed invention is explained by graphic material:

[0020] - Fig. 1 shows a sectional view of the air distributor type 483;

[0021] - Fig. 2 shows a section of the diagnostic device;

[0022] - Fig. 3 shows the fixation of the diagnostic device on the air distributor of type 483;

[0023] - Fig. 4 shows a type 483 air distributor and shows the location of the atmospheric hole on the two-chamber tank;

[0024] - Fig. 5 shows a photograph of a prototype of a diagnostic device installed on the body of a two-chamber air distributor tank of type 483, manufactured in accordance with the claimed invention.

[0025] The method for diagnosing a malfunction of the channel and the softness valve of the air distributor type 483 is based on the operating features of the air distributor 1 (Fig. 1) when the pressure in the brake line 2 decreases at a rate of 0.3-0.4 kgf / cm 2in 1 min. If channel 3 and softening valve 4 are in good working order, air from the working chamber 5 flows into the spool chamber 6, and from there through channel 3 (calibrated opening 0.9 mm) into the main chamber 7. In this case, the pressure in the spool chamber 6 and the main chamber 7 are equalized and the displacement of the main diaphragm 8 does not occur. If channel 3 or the softness valve 4 is faulty, in particular if the softness valve 4 is jammed in the closed state, if diaphragm 9 is faulty, or if channel 3 is clogged (calibrated opening 0.9 mm), air from the spool chamber 6 does not have time to flow into the main chamber 7. The pressure in the main chamber 7 decreases faster than in the spool chamber 6, and the main diaphragm 8 bends and opens the additional discharge valve 10, the additional discharge channel 11 and the reserve softness channel, then the excess air is released through the atmospheric opening 12 of the air distributor 1.The release of air from the atmospheric opening 12 is a signal of a malfunction of channel 3 or the softness valve 4 of the air distributor 1.

[0026] The claimed method consists in that the pressure in the brake line 2 is reduced by moving the driver's valve handle from position I to position II at a constant softening rate of up to 0.3-0.4 kgf / cm 2 for 1 minute and determine the fact of air exit through the additional discharge channel 11, and then from the atmospheric opening 12 of the air distributor 1 using the differential pressure sensor 13 (Fig. 2).

[0027] The method for diagnosing a malfunction of the channel and the softness valve of the air distributor type 483 is implemented as follows: the diagnostic device 14 (Fig. 2, 3) is connected to the atmospheric hole 12 (Fig. 3, 4), located in the two-chamber reservoir 15 of the air distributor 1. The diagnostic device 14 is connected to the atmospheric hole 12 of the two-chamber reservoir 15 using the tip 16 (Fig. 3). The diagnostic device 14 is fixed on the two-chamber reservoir 15 of the air distributor 1 using a permanent magnet 17. The next step of diagnosis is the use of the technology of provoking spontaneous activation of the brakes. By moving the driver's valve handle (not shown in the figure) from position I to position II, an automatic transition from the increased pressure in the equalizing reservoir and brake line 2 to the normal charging pressure is ensured at a constant rate of softness up to 0.3-0.4 kgf / cm 2in 1 min. If channel 3 (Fig. 1) or softness valve 4 of air distributor 1 is faulty, then air under pressure is released from air distributor 1 through atmospheric opening 12, which causes an air flow entering through through channel 18 (Fig. 2) of tip 16 into the housing of diagnostic device 14. This air flow causes the appearance of dynamic pressure, which is recorded by differential pressure sensor 13 with a measurement range from -50 Pa to 50 Pa (for example, differential pressure sensor D6F-PH0505AD3) and converted into an internal digital signal transmitted via PC interface to microcontroller 19 (for example, microcontroller ESP8266). Microcontroller 19 receives and processes measurement data in accordance with a built-in algorithm, including filtering the measured signal and comparing it with a specified threshold value.Microcontroller 19 interprets exceeding the threshold level as an indication of an air leak and, accordingly, a malfunction of air distributor 1. Visual indication is provided by activating graphic OLED display 20, which records the air flow. In the event of inadvertent brake application, the driver's valve (not shown in the figure) discharges brake line 2 to the full service braking value, followed by moving the driver's valve handle to position IV to prevent brake release. If brake line 2 is not discharged, all diagnostic devices 14 will be triggered due to subsequent brake release.

[0028] The diagnostic device 14 (Fig. 2) consists of a housing 21, inside which a differential pressure sensor 13 with a measurement range from -50 Pa to 50 Pa (for example, a differential pressure sensor D6F-PH0505AD3), a microcontroller 19 (for example, an ESP8266 microcontroller) mounted on a Wemos D1 Mini debug board, a graphic OLED display 20 with a diagonal of 0.96 inches, a power switch 22, as well as a lithium-ion battery 23 of size 18650, which is closed with a cover 24, are placed. The housing 21 contains a tip 16 with a through channel 18, intended for aerodynamic coupling of the atmospheric opening 12 (Fig. 3, 4) of the two-chamber reservoir 15 of the air distributor 1 with the measuring channels 25 (Fig. 2) of the differential pressure sensor 13. The fixation of the diagnostic device 14 (Fig. 3) on the two-chamber reservoir 15 of the air distributor 1 is carried out by means of a permanent magnet 17.

[0029] Thus, the accuracy of diagnosing a malfunction of the soft air distributor valve type 483 is increased by using a differential pressure sensor 13, sensitive specifically to the air flow, which allows for the effective separation of the useful signal (leak) from background changes in static pressure, and microcontroller processing provides the ability to fine-tune the response threshold, filter interference, and a flexible display format.

[0030] Improving the clarity of visualization of the operation of the diagnostic device 14 is ensured by the ability to record the diagnostic results in the diagnostic device 14. In this case, visual indication is realized by activating the graphic OLED display 20, through which the fact of registration of the air flow, signaling the presence of an air leak, is recorded.

[0031] The increased reliability of the operation of the diagnostic device 14 is ensured by the presence of a permanent magnet 17 for reliably fixing the diagnostic device 14 on the two-chamber reservoir 15 of the air distributor 1.

[0032] This is how the technical result is achieved.

[0033] In accordance with the claimed invention, the applicant manufactured and tested a prototype device for diagnosing the duct and soft valve of a Type 483 air distributor. Tests were conducted at the PGUPS automatic brake laboratory and at the Vologda Carriage Repair Plant. Fig. 5 shows a photograph of the prototype diagnostic device mounted on the body of the two-chamber reservoir of a Type 483 air distributor. The test results confirmed the diagnostic device's compliance with the stated efficiency.

Claims

1. A method for diagnosing a malfunction of the channel and the softness valve of the type 483 air distributor, which consists in connecting the diagnostic device to the atmospheric hole located in the two-chamber reservoir of the air distributor, then reducing the pressure in the brake line by moving the driver's valve handle from position I to position II at a constant softness rate of up to 0.3-0.4 kgf / cm 2for 1 minute, characterized in that the air flow exiting through the atmospheric opening is recorded by a differential pressure sensor, which converts the dynamic pressure caused by the air flow into an internal digital signal transmitted via the PC interface to the microcontroller, and the microcontroller receives and processes the measurement data in accordance with a built-in algorithm, including filtering the measured signal and comparing it with a specified threshold value, wherein the exceeding of the threshold level is interpreted by the microcontroller as a sign of the presence of an air leak and, accordingly, a malfunction of the air distributor, wherein the visual indication is realized by activating a graphic OLED display, which records the fact of registration of the air flow.

2. A device for diagnosing a fault in the channel and the softness valve of a type 483 air distributor, comprising a housing, characterized in that the housing contains a differential pressure sensor, a microcontroller mounted on a debug board, a graphic OLED display, a battery, a power switch, and the housing of the device contains a tip with a through channel, intended for aerodynamic coupling of the atmospheric opening of the two-chamber reservoir of the air distributor with the measuring channels of the differential pressure sensor.

3. The device according to paragraph 2, characterized in that it contains a permanent magnet designed to fix the device on the air distributor.

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