Method for carrying out inspections of safety-relevant states

Abstract

The invention relates to a method for carrying out inspections of safety-relevant states of elements in a switch construction or crossing construction, the distance between said elements being changeable relative to one another. In order to ensure that measures on site, such as securing switch components or adjusting the travel path of the tongue rail, are only necessary when the elements that can be adjusted relative to one another no longer meet specified requirements, according to the invention at least one second element, the position of which can be changed relative to a stationary first element, is detected in its designated inspection position by means of at least one contactless first sensor in order to determine an actual value, which is compared with a target value or a limit value associated with the target value, and, if the actual value reaches or exceeds the target or limit value, an impermissible state is signalled, and / or the temporal progression of the actual value is determined in comparison with a target or limit value, wherein said progression is used to derive a tendency to carry out activities or expected changes in state of the switch construction or crossing construction, and wherein signals characterising the inspection are forwarded to a central evaluation unit, wherein the transfer occurs over a network via a secure protocol.

Description

[0001] Description

[0002] Procedures for conducting inspections of safety-relevant conditions

[0003] The invention relates to a method for carrying out inspections of safety-relevant conditions of elements of a switch or crossing structure, in particular a switch, whose distance can be adjusted relative to one another.

[0004] Switch or crossing constructions have, for example, stock rails, tongue rails, switch drive, locking unit and / or wing rails.

[0005] The switch is a critical element in the track system, and failures can lead to disruptions to rail traffic. Therefore, it is necessary not only to perform regular maintenance to keep equipment in a safe condition, for example, by regularly cleaning and lubricating it or checking hydraulic levels, but also to conduct inspections to determine the current condition and assess any deficiencies. During inspections, no action may be required as long as the system functions as required.

[0006] Any necessary intervention will only be determined on-site during current inspection work on the superstructure. For example, the test clearance, i.e., the distance between the tongue rail and the stock rail, must be checked regularly using a sheet gauge. If the gap exceeds a specified value, the tongue rail movement must be readjusted.

[0007] According to EP 4299408 A1, the inspection clearance does not need to be measured directly between the switch rail and the stock rail, but rather via the travel of the control rod in a switch machine. However, this does not simplify the inspection itself; it merely relocates the inspection location.

[0008] EP 0 514 365 A2 relates to a method for monitoring the condition of a rail switch. A sensor is mounted on a stock rail, which detects premature wear in the area of ​​the switch's tongue rails. The data is evaluated when the switch is being used.

[0009] DE 20 2021 000 395 UI refers to a device for the non-contact monitoring of railway infrastructure. This requires the use of two thin-film magnetometers.

[0010] DE 26 30 387 A1 relates to a monitoring device for the end positions of pivoting rails. For this purpose, rail switches with associated ferromagnetic counterparts are used to detect the position of the tongue rail. The rail switches themselves can be located in the tongue rail or in the stock rail. The monitoring device comprises several rail switches, whose signals are fed to an evaluation device. Evaluation occurs when all rail switches signal a position that requires monitoring.

[0011] DE 20 2019 101 386 U1 relates to a device for obtaining information from a mechanical or electromechanical interlocking system. A signal transmitter can be coupled to a push rod, to which a sensor is assigned to detect the position. A plurality of mechanical actuating and / or safety elements are provided, each of which can assume at least two switching positions. A track is only released when a predetermined switching combination of the safety elements is detected. The subject of DE 43 44 288 A1 is a safety device for a railway switch. The locking of a switch is monitored using inductive sensors, which can also be replaced by other proximity sensors.

[0012] The present invention is based on the object of developing a method of the type mentioned at the outset in such a way that the disadvantages of the prior art are avoided and that, in principle, on-site measures, such as the fastening of switch components or adjusting the travel of the tongue rail, are only necessary when the elements which are adjustable relative to one another no longer meet specified specifications.

[0013] To achieve the object, it is essentially proposed that at least one second element, the position of which can be changed relative to a stationary first element, is detected in its position predetermined for the inspection by means of at least one contactless first sensor for determining an actual value which is compared with a target value, and that if the actual value reaches or exceeds the target value, an inadmissible state is signaled.

[0014] According to the invention, a contactless inspection of an element in the switch or crossing area, particularly in the switch area, is carried out that is movable relative to a stationary element. "Movable" includes not only the targeted adjustment of the second element, but also the unintentional detachment of the second element from the first element, such as the wing rail to the frog point.

[0015] Inadmissible condition means that the first and second elements are not assigned to each other in such a way that the switch or crossing structure can be used properly.

[0016] When measuring the test clearance, an impermissible condition means that the gap between the tongue rail and the stock rail is impermissibly wide. In the case of mechanical connections, for example, this means that the connection has become impermissibly loose. In particular, the invention provides that an actual position of the second element is determined as the actual value, which is then compared with a target position as the target value.

[0017] The target value is, for example, the maximum permissible gap between the stock rail as the first element and the tongue rail as the second element. If the actual position deviates from the specified target value, i.e., the gap is too wide, this can be detected at a higher-level location, such as the signal box, so that the necessary work can be carried out.

[0018] In particular, it is intended that a sensor from the group of Hall sensors, preferably 3D Hall sensors, inductive sensors, capacitive sensors, acceleration sensors, vibration sensors and sound sensors, is used as the contactless sensor.

[0019] The non-contact sensor is assigned to the first element without contact.

[0020] Preferably, a Hall sensor or a 3D Hall sensor is used as the sensor.

[0021] In particular, the invention provides that at least one inspection from the group of tester air, covering of a switch drive, engagement of a tester bar, detachable connection is carried out.

[0022] If it is to be checked whether a mechanical connection between switch or crossing components requires inspection, an acceleration or vibration sensor or structure-borne sound sensor can be used as a sensor.

[0023] The signals from the sensors are forwarded via an interface, such as a microcontroller, in the network using a secure protocol to a central evaluation unit, such as a signal box, in order to initiate inspection work depending on the signals.

[0024] The sensor signals are analyzed and correlated to provide information about the inspection work to be performed. Correspondence takes place via a network, reducing cabling and hardware costs and enabling remote maintenance of the switches and crossings.

[0025] In particular, it is intended that the Hall sensor generates a signal to be used when the sensor detects a magnetic field of a predetermined signature.

[0026] This ensures that only those signals can be processed that allow conclusions to be drawn about maintenance or activities to be carried out, such as replacing components.

[0027] In particular, it is provided that the elements to be inspected are not checked directly, but indirectly by means of at least one sensor. In particular, it is provided that the sensor detects the travel of an actuating element directly or indirectly connected to the second element, such as a piston rod, cylinder, test rod, spindle, or actuating rod.

[0028] The invention is also characterized by a method for inspecting the test air in a switch, comprising two stock rails as first elements and tongue rails adjustable relative to these as second elements, each tongue rail being connected to a test rod, characterized in that at least one sensor is assigned to each test rod and the travel of the test rod is determined from changes in the signal generated by the sensor.

[0029] In particular, a Hall sensor, in particular a 3D Hall sensor, is used as the sensor, by means of which a magnetic field emanating from the test rod is detected, whereby the travel of the test rod is determined from the change in the measured magnetic flux density.

[0030] The invention is also characterized by a method for inspecting a lockable locking piece of a point drive connected to control rods, wherein at least one sensor is assigned to the locking piece such that, when the locking piece is locked, a signal corresponding to the locking is generated. The teaching of the invention makes it possible, in principle, to avoid on-site inspections, since the electronically conducted inspection by at least one contactless sensor makes it possible to determine when work on elements, in particular the point, needs to be carried out, such as adjusting the inspection air. An intelligent system for maintaining point or crossing elements, i.e., the point or crossing itself, is provided.

[0031] A superstructure design is available that offers high reliability and eliminates human error during inspections. It reliably determines when work needs to be carried out.

[0032] Based on the teachings of the invention, inspection criteria such as air pressure measurements, which are currently only performed directly at the switch, are digitized and carried out remotely. Downtimes due to inspection work are avoided.

[0033] The inventive teaching guarantees consistent quality of the field elements. Unplanned downtimes are essentially avoided.

[0034] Furthermore, the temporal progression of the change between target and actual values ​​can be evaluated in order to plan work at an early stage so that required material and downtimes can be calculated.

[0035] As mentioned above, on-site inspections could generally be avoided, resulting in cost savings.

[0036] An operator can obtain a remote overview of all switches and crossings within the infrastructure. Operations on the track are reduced. This also minimizes risks for the personnel deployed.

[0037] Further details, advantages, and features of the invention emerge not only from the claims and the features derived therefrom—alone and / or in combination—but also from the following description of preferred embodiments. They show:

[0038] Fig. 1 a system overview,

[0039] Fig. 2 a schematic diagram of a locking unit of a switch drive,

[0040] Fig. 3 shows a signal curve for monitoring a test air in normal condition,

[0041] Fig. 4 shows a signal curve for monitoring a test air in case of a change or a fault,

[0042] Fig. 5 a signal curve for monitoring a test air with generated messages for recommended actions and

[0043] Fig. 6 shows a signal curve for monitoring a test air after an adjustment.

[0044] The teaching of the invention is explained using a switch, without this limiting the teaching of the invention.

[0045] Fig. 1 shows a schematic diagram of a switch area. It includes a main track 10, a siding 12, a frog 14, stock rails 16, 18 of the main track, and adjustable tongue rails 20, 22, which are adjustable relative to the stock rails 16, 18 via a switch drive 24.

[0046] Corresponding switches must be maintained at regular intervals to keep work equipment in safe condition.

[0047] Independently of this, inspection measures must be conducted to determine whether any elements of the switch are in the prescribed condition to ensure operational safety. This includes, among other things, the gap between the tongue rail and the stock rail in the adjacent position, also known as the test clearance. Mechanical connections must also be checked for their strength at regular intervals. Corresponding inspections are carried out on-site, so the switch cannot be used during inspection activities.

[0048] According to the invention, inspection is carried out using sensors, eliminating the need for on-site inspection by humans. At the same time, the signals generated by the sensors are processed and analyzed, and then the signals indicating the inspection are forwarded to a control center, with transmission over the network taking place via a secure protocol.

[0049] The corresponding data can first be fed from the sensors to a control unit located in the area of ​​the switch, which can, for example, have an EULYNX architecture.

[0050] Thus, Fig. 1 shows a schematic diagram of a switch drive 24, i.e., its locking unit, containing several sensors that are assigned, for example, to test rods or locks in the locking unit. These sensors are used to inspect the test air between the tongue rail 20, 22 and the stock rail 16, 18, the end position of the tongue rail 20, 22, or the locking action in the locking unit. An electronic inspection is performed indirectly using sensors assigned to components that are, in turn, connected to elements of the switch to be inspected.

[0051] The corresponding signals generated by the sensors are then processed and analyzed in corresponding software and hardware components 27, located, for example, in a control cabinet 26, to then transmit digital signals to a control center 28. If the signals indicate that the elements to be inspected are not in the prescribed condition, work processes can be initiated on-site to restore the permissible condition.

[0052] The system overview shown in Fig. 1 also illustrates, in principle, that a mechanical connection, e.g., between wing rails 30, 32 and the frog 14, is electronically inspected by, for example, installing one or more acceleration sensors or sound sensors in the frog 14, which detect vibrations occurring when the connection between the wing rails 30, 32 and the frog 14 is loose. The fastening of the point drive can also be inspected using appropriate sensors.

[0053] With regard to the condition inspection of the tongue rails 20, 22 to the stock rails 16, 18, the invention provides for an indirect measurement of the conditions to be inspected, namely in the switch drive or its locking unit.

[0054] Fig. 2 shows the principle of a locking unit with a design similar to the applicant's UNISTAR HR point machine. In this regard, reference is made to the product description "General Revision No. 1.2 UNISTAR HR," which is current at the time of filing the application, particularly pages 41-59.

[0055] To adjust the tongue rails 16, 18, they are connected to an adjusting rod 34 that extends through the end faces of the housing 36 of the switch drive 24. In a known manner, the adjusting rod 34 is connected to a sliding plate—also called a sliding piece—connected to a drive such as a hydraulic cylinder. These, in turn, are adjustable via locking prisms 38, 40 that can be moved perpendicular to the longitudinal movement by means of a locking plate 37, which simultaneously locks the prism. For this purpose, one of the prisms 38, 40 engages a recess in a stationary prism plate, depending on the tongue rail that rests against the associated stock rail, so that further movement of the adjusting rod 34 is no longer possible. The prism is additionally secured by covering the collapsed prism with the locking plate 37.

[0056] In this respect, reference is made to the function of the switch drive according to UNISTAR HR.

[0057] A locking actuator 42 extends from the locking plate 37, which interacts with its end sections 44, 46 with test bars 48 when the sliding plate is locked. The test bars 48 interact with test rods 50, 52, specifically with test plates 54 connected to them, in such a way that when one of the end sections 44, 46 acts on one of the test bars, the latter engages a recess 56 in the test plate 54, provided that proper locking has occurred. The drawing only shows the test plate 54 of the test rod 52 and the test bar 48, which is assigned to the test rod 50.

[0058] According to the invention, the travel of the test rods 50, 52, the closure when the sliding plate is locked and the positive engagement of the test bar in the associated recess of the test plate are now monitored by means of sensors, so that it can be analyzed from the signals whether the tongue rail 20, 22 in question is properly locked and the permissible test clearance is maintained.

[0059] The test air is measured based on the travel of the test rod 50 or 52. For this purpose, a sensor, such as a magnetic element 60, 62, e.g., in the form of a magnetic flag, extends from the test rod 50 or 52, which is moved past two spaced-apart sensors 64, 66 and 68, 70 when the test rod 50, 52 is adjusted.

[0060] The sensors 64, 66, 68, 70 are, in particular, Hall sensors, preferably 3D Hall sensors, for detecting the magnetic force flow in two directions. The Hall sensors 64, 66, 68, 70 are further programmed such that the further-processable signals are only generated when the Hall sensors 64, 66, 68, 70 detect magnetic fields originating from the associated magnetic element 60, 62. The signature of the magnetic field is used.

[0061] The sensors are calibrated to determine the distance in relation to the stock rail 16, 18, so that the distance measured by the sensors 64, 66 or 68, 70 can directly detect the gap between the tongue rail 20 and the stock rail 16 or 22 and 18 and thus the test air.

[0062] If, in the exemplary embodiment, the magnetic elements 60, 62 are attached to the test rods 50, 52, other possibilities are also available for detecting a magnetic field emanating from the respective test rod 50, 52 using the Hall sensors 64, 66, 68, 70. For example, magnetic elements can be present as inserts in the test rods 50, 52.

[0063] To determine the end position, i.e., to determine whether the tongue rail 20, 22 is locked in the predetermined end position relative to the stock rail 16, 18, Hall sensors 72, 74 are also preferably mounted on an intermediate wall in the housing 36, referred to as a switch plate 76. Magnetic elements 78, 80 connected to the respective test bar 48 are moved along the sensors 72, 74, so that, depending on the magnetic flux density detected by the respective sensor 72, 74, it can be sensed whether the test bar engages the recess in the test plate of the test bar, which is connected to the adjacent tongue rail.

[0064] Furthermore, using another sensor 82, which should also be a Hall sensor—in particular a 3D Hall sensor—it can be checked whether the required overlap of the closure plate 37 with the prism located in the prism holder has been achieved. For this purpose, a magnet 86 extends from the closure plate 37 and is moved toward the sensor 82.

[0065] From the signal detected by the respective sensor, it can then be deduced whether the locking is correct or not.

[0066] If the stock rail is used as a reference value for determining the travel, the bottom of the recess of the test plate is used for determining the end position and the location of the self-locking springs is used for inspecting the overlap, by means of which the locking plate is secured in a force-fitting manner when the collapsed prism is overlapped.

[0067] In general, the acquisition, processing and display of signals equivalent to a virtual inspection is carried out as follows.

[0068] Using the example of the switch drive 24, the sensors 64, 66, 68, 70 are physically connected to a hardware component (not shown) that can be mounted both in and on the housing 36 of the switch drive 24.

[0069] Preferably, the hardware component has additional on-board sensors (not shown), such as shock sensors, vibration sensors or, in particular, temperature sensors, and is used, if necessary, to connect additional safety-relevant and non-safety-relevant sensors, such as the sensors for electronic end position evaluation.

[0070] The signals SI, S2 emitted by the sensors are processed and sent via a secure protocol via a network connection, in particular via a long-distance Ethernet connection, to the software and hardware component 27, in particular a central controller unit (UNILOCK OCP).

[0071] In the software and hardware component 27, the signals SI and S2 are prepared and processed by a software algorithm. The software algorithm can be installed directly on the software and hardware component 27, as shown in Fig. 1, or on a server or in a cloud, which is particularly useful for larger systems.

[0072] The signals are evaluated by the software algorithm, as shown in Figs. 3 to 6 using the example of indirect monitoring of the test air.

[0073] Figures 3 to 6 each show a curve of signals corresponding to the test air between tongue rail 20 and stock rail 16 or 22 and 18 over time. The course of the test air is recorded indirectly by sensor monitoring, e.g., the test rod, in particular by detecting the travel of the test rod.

[0074] The test air is thus indirectly represented by a signal curve S1 of the at least one sensor 64, 66 and by a signal curve S2 of the at least one sensor 68, 70 over time, wherein the sensors 64, 66, 68, 70 are calibrated to determine the distance in relation to the stock rail 16, 18, so that the distance measured by means of the sensors 64, 66 or 68, 70 directly corresponds to the gap between the tongue rail 20 and the stock rail 16 or 22 and 18 and thus to the test air.

[0075] Extreme values ​​EW (peaks) of the signals SI, S2 in the positive and negative range are assigned to the end position of an element in a switch arrangement. The resulting absolute measured values ​​are subjected to a trend analysis. External influencing factors, such as temperature changes, should also be taken into account in the trend analysis. This should preferably be mandatory. The temperature T is plotted over time.

[0076] Fig. 3 shows the signals SI, S2 when monitoring the test air under normal conditions. A trend analysis of the extreme values ​​in the positive and negative ranges (absolute measured values) shows that a trend curve TI of the measured values ​​from sensors 64, 66 and a trend curve T2 of the measured values ​​from sensors 68, 70 are constant, which indicates that the trend of the test air is also constant.

[0077] Fig. 4 shows signals SI and S2 from the sensors for indirect monitoring of the test air, showing deviations from the normal range. The absolute measured values ​​of the sensors increase according to trend curve TI or decrease according to trend curve T2. This indicates that the test air is increasing or decreasing.

[0078] From the deviations, a message Ml, M2, M3 can be generated when limit or target values ​​are exceeded and / or a prediction can be made as to when a failure is to be expected in the future or when maintenance is to be carried out, as shown in Fig. 5.

[0079] Figures 4 and 5 show signals that indicate a trend in relation to, for example, failure or maintenance.

[0080] The inclusion of weather / temperature forecasts from external data sources is also taken into account.

[0081] After the mechanical readjustment of the system, the measured values ​​return to the target range, as shown in Fig. 6. This representation allows the quality of the work performed to be recorded.

[0082] The information can be displayed on any authorized device and can, for example, be displayed in the area of ​​the digital or conventional interlocking system 28.

Claims

Patent claims 1. A method for carrying out inspections of safety-relevant conditions of elements of a switch or crossing structure whose distance from one another can be varied, characterized in that at least one second element whose position can be changed relative to a stationary first element is detected in its position predetermined for the inspection by means of at least one contactless first sensor for determining an actual value, which is compared with a target value or a limit value assigned to the target value, and that if the actual value reaches or exceeds the target value or limit value, an inadmissible condition is signaled and / or the temporal course of the actual value is determined in comparison to a target value or limit value,whereby a tendency to carry out activities or expected changes in the condition of the switch or crossing structure are derived from the history, and whereby signals characterising the inspection are forwarded to a central evaluation unit, whereby transmission in a network takes place via a secure protocol.

2. Method according to claim 1, characterized in that the signals of the sensors are evaluated, whereby extreme values ​​(peaks) of the signals are assigned to a position of a component assigned for determining the test air, such as the end position of a test rod of a switch drive, and are subjected to a trend analysis.

3. Method according to claim 1 or 2, characterized in that external influencing factors, such as temperature changes, are taken into account in the trend analysis.

4. Method according to at least one of the preceding claims, characterized in that the extreme values ​​of the signals or a trend curve derived from the trend analysis are compared with at least one limit or target value.

5. Method according to at least one of the preceding claims, characterized in that when the at least one limit or target value is exceeded, a message M1, M2, M3 is generated and / or a prediction or recommendation for action is made as to when a failure is to be expected in the future or when maintenance must be carried out.

6. Method according to at least one of the preceding claims, characterized in that an actual position of the second movable element is determined as the actual value, which is compared with a desired position as the desired value.

7. Method according to at least one of the preceding claims, characterized in that the at least one sensor is assigned a transmitter, such as a magnetic element, which is detected by the at least one sensor.

8. Method according to at least claim 1, characterized in that a redundant comparison is made between the actual and target values.

9. Method according to at least one of the preceding claims, characterized in that that a sensor from the group of Hall sensors, preferably 3D Hall sensors, inductive sensors, capacitive sensors, acceleration sensors, vibration sensors and sound sensors, is used as the contactless sensor.

10. Method according to at least one of the preceding claims, characterized in that at least one inspection from the group of tester air, covering of a switch drive, engagement of a tester bar, detachable connection is carried out.

11. Method according to at least claim 10, characterized in that an acceleration or vibration or structure-borne sound sensor is used to inspect the detachable connection.

12. Method according to at least one of the preceding claims, characterized in that the signal from the sensor is sent to the central evaluation unit, such as a signal box, via the secure protocol.

13. Method according to at least claim 9, characterized in that a signal to be used is generated by the Hall sensor when the sensor detects a magnetic field of a predetermined signature.

14. Method according to at least one of the preceding claims, characterized in that the sensor detects the travel of an actuating element connected directly or indirectly to the second element, such as a piston rod, cylinder, test rod, spindle, or actuating rod.

15. Method according to at least one of the preceding claims for inspecting the test air in a switch, comprising two stock rails as first elements and to these adjustable tongue rails as second elements, wherein each tongue rail is connected to a test rod, characterized in that at least one sensor is assigned to each test rod and the travel of the test rod is determined from changes in the signal generated by the sensor.

16. Method according to at least claim 15, characterized in that a Hall sensor, in particular a 3D Hall sensor, is used as the sensor, by means of which at least one magnetic field emanating from the test rod is detected, the travel of the test rod being determined from changes in the measured magnetic field or the magnetic flux density.

17. A method for inspecting a lockable locking piece of a switch drive connected to actuating rods according to at least claim 1, characterized in that at least one sensor is assigned to the locking piece in such a way that when the locking piece is locked, a signal corresponding to the locking is generated.

18. Method for checking the end position of a tongue rail as a second element which is in contact with a stock rail as a first element, wherein the tongue rail is connected to a lockable closure piece of a point drive and a tester bar is adjustable via the closure piece and engages in a receptacle of the tester rod connected to the tongue rail when the tongue rail is in the end position, in particular for carrying out the method according to claim 1, characterized in that a sensor is assigned to the tester bar which generates a signal corresponding to the end position of the tongue rail when the tester bar engages in the receptacle.

19. Method according to at least claim 18, characterized in that at least one magnetic element is connected to the test bar.

20. Method according to at least claim 18 or 19, characterized in that signals from several sensors are fed to an interface, from which signals are forwarded via a network to a device, such as a signal box.

21. Method according to at least claim 1, characterized in that at least one magnetic element is fixedly connected to the second element or is embedded in the second element.

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