EP3721013A1

EP3721013A1 - Method and system for monitoring the loading of a tamping unit

Info

Publication number: EP3721013A1
Application number: EP18806991.8A
Authority: EP
Inventors: Bernhard Maier; Alexander PUCHMAYR; Johannes MAX-THEURER
Original assignee: Plasser und Theurer Export Von Bahnbaumaschinen GmbH
Current assignee: Plasser und Theurer Export Von Bahnbaumaschinen GmbH
Priority date: 2017-12-07
Filing date: 2018-11-09
Publication date: 2020-10-14
Anticipated expiration: 2038-11-09
Also published as: AT520698A1; JP2021505795A; US20200370248A1; DK3721013T3; EP3721013B1; PL3721013T3; EA202000143A1; CA3079624A1; AT520698B1; CN111417756B; ES2941534T3; WO2019110239A1; JP7179851B2; CN111417756A

Abstract

The invention relates to a method for monitoring the loading of a tamping unit (2) of a track-building machine (1), wherein at least one sensor (3) is arranged to detect loading of the tamping unit (2). Here, measurement data detected by means of the sensor (3) are stored in an evaluation device (5) over a time period (T), wherein at least one loading time profile for cyclical penetration operations (17) of the tamping unit (2) into a ballast bed (10) is derived from the stored measurement data. It is thus possible to draw conclusions on the loading situation of the tamping unit (2) and on the nature of the ballast bed (10).

Description

description

Method and system for monitoring the loading of a tamping unit

Field of engineering

[01] The invention relates to a method for monitoring the load of a

Stopfaggregates a track construction machine, wherein at least one sensor is arranged to detect a load on the Stopfaggregates. In addition, the invention relates to a system for carrying out the method.

State of the art

From EP 2 154 497 A2 a device for bearing diagnosis on an eccentric shaft of a tamping unit by means of a

Known vibration transducer. In this case, the vibration sensor is arranged on a housing of an eccentric drive. Only free oscillations of the eccentric drive in a phase during which the tamping unit is located outside of a ballast bed are detected. Based on changes in the data recorded at intervals, the wear state of the bearing of the eccentric shaft is determined

closed.

Summary of the invention

[03] The invention is based on the object, for a method and a

System of the type mentioned to indicate an improvement over the prior art.

[04] According to the invention, these objects are achieved by a method

according to claim 1 and a system according to claim 12. Advantageous developments of the invention will become apparent from the dependent

Claims.

[05] In the process, measured data acquired via the sensor are transmitted via a

Spaced time in an evaluation, wherein from the stored measurement data at least one load-time course for cyclic penetration of the tamping in a Ballast bed is derived. External or internal forces acting on the tamping unit or tamping unit parts are taken into account in this way in the course of a load size. On the one hand, this leads to conclusions about the load situation of the

Stopfaggregats to maintenance measures or

Specify maintenance intervals. On the other hand, evaluations of a ballast bed processed by means of the tamping aggregate are possible because it is possible to deduce from the progression of the detected load size to the forces acting on the tamping aggregate from the ballast bed.

In one embodiment of the invention it is provided that from the

Stress-time course a load collective is calculated. The

Load collective indicates directly which loads the tamping unit was exposed to over the recorded period of time. Through a

Adjustment with time stability specifications results from this

Predictable life of the tamping unit or of

Stopfaggregatteilen.

[07] For a current assessment of the stress situation by a

Operator, it is advantageous if by means of an output device from the load-time history derived load condition is displayed. In this way, it is possible to react directly to violations of predetermined load limits.

[08] In an advantageous method, one in a lifting and

Countersinking the tamping unit arranged hydraulic cylinder monitored, being detected as measurement data, a piston travel and hydraulic pressures acting in the hydraulic cylinder. Based on this

Measurement data is carried out by means of the evaluation device for each

Penetration a calculation of a penetration force. The corresponding stress-time profile forms an evaluation basis for the

Stopfaggregatbelastung or the ballast bed condition.

[09] A further development of the method provides that a penetration energy introduced when the tamping unit enters the ballast bed is calculated. As a corresponding load-time curve, a course of the penetration energy over several stuffing cycles is mapped. In this case, an averaging can be useful to mitigate any anomalies that may occur during the measurement data acquisition. The intrusion energy to be applied for penetration into a ballast bed is a meaningful rating for the

Ballast condition.

Furthermore, it is advantageous if an intrusion of the

Stopfaggregats acting in the ballast penetration power is calculated. From the course of the penetration over a continuous working period across conclusions about the nature of a processed track can be drawn. In addition, the

applied penetration a meaningful evaluation size for Stopfaggregatbelastung.

In an alternative embodiment of the invention or as an extension of the aforementioned method, it is provided that an eccentric drive of the tamping unit is monitored by detecting a power of the eccentric drive over the working time span. With the course of the applied eccentric power as a load-time curve is on the load situation of Stopfaggregats or

Gravel bed quality closed back.

[12] It is advantageous if, in the case of a hydraulic eccentric drive of the tamping unit, a pressure or a pressure difference and a flow rate are detected as measured data and if a hydraulic power of the eccentric drive is derived therefrom. Alternatively, the power of the eccentric drive may be derived from a measured torque and speed.

[13] The same applies to an expression with an electrical eccentric drive of the tamping unit. This is advantageously monitored by an applied voltage and a current are detected as measured data, from which an electric power of the eccentric drive is derived.

For automated maintenance planning for the tamping aggregate, it is advantageous if, based on the load-time profile by means of a computing unit a maintenance or inspection interval of the

Stopfaggregats is specified.

In addition, it is for an automated evaluation of

Ballast bed texture advantageous if based on the

Stress-time course by means of a computer unit a classification of the stuffed ballast bed is performed.

In this case, an improvement of the procedure that in one

Output device the classification of the ballast bed associated with a performance time and / or a place of performance is displayed. In this way it becomes immediately apparent in which

Work sections which were ballast bed texture.

[17] In the system according to the invention for carrying out one of

the aforementioned method, the Stopfaggregat at least one sensor for detecting a load, wherein the sensor to the

Evaluation device is connected and wherein the

Evaluation device for determining the load-time history from the stored measurement data is set up. The evaluation device is located either on the tamping machine or in a remote system center. Depending on the measurement data via signal lines or via an internal vehicle bus system or a wireless communication device are transmitted to the evaluation.

In an advantageous embodiment of the system includes the

Evaluation device, a data acquisition unit, a microprocessor and a communication means for transmitting data to remote computer systems or output devices. The data acquisition unit (DAQ) digitizes analog sensor signals to determine the load-time profile from the digitized measurement data by means of the microprocessor. In particular, by means of

Microprocessor characteristic signal ranges identified and calculated relevant parameters.

A development of the system provides that a machine control with drives or control components of the tamping unit is connected and that the machine control, the measurement data are supplied to adjust control data. This is an efficient one

Control loop implemented to avoid overloading the tamping unit.

It makes sense, the machine control with the

Evaluation device connected to using the evaluation calculated parameters as control parameters for the

Specify machine control. In this way, for example, be reacted automatically to a change in the ballast bed condition.

Brief description of the drawings

[20] The invention will be described below by way of example

With reference to the accompanying figures explained. It show in

schematic representation:

Fig. 1 stuffing machine with Stopfaggregat

Fig. 2 Stopfaggregat

Fig. 3 waveforms during two stuffing cycles

Fig. 4 system structure

Fig. 5 performance curves over time

Fig. 6 display in an output device

Description of the embodiments

[21] The exemplary system includes a stuffing machine 1 having a

Stopfaggregat 2, at the multiple sensors 3 for detecting

Loads of Stopfaggregats 2 are arranged. Via signal lines 4, sensor signals are transmitted to an evaluation device 5. In the evaluation device 5, measurement data acquired by the sensors 3 are stored over a time period T and evaluated. The tamping machine 1 is movable on a track 6. The track 6 comprises a rail grid 9 formed from rails 7, sleepers 8 and rail fastenings, which is mounted on a ballast bed 10 (FIG. 1). When Unterstopfen the track 6 of the rail grid 10 is brought by means of a lifting-straightening unit 11 in a desired position. To stabilize this position, stuffing tools 12 penetrate the

Stopfaggregats 2 between the thresholds 8 in the ballast bed 10 a. The stuffing tools 12 are subjected to a vibratory movement 13. This vibratory movement 13 is produced by means of an eccentric drive 14. At this are auxiliary cylinders 15 are connected to provide the stuffing tools 12 in the lowered state, that is to move toward each other (Fig. 2). This order movement 16 remains the vibration movement 13 superimposed, the

Vibration frequency during a penetration 17 (e.g., 45Hz) is usually chosen to be higher than during a fitting process 18 (e.g., 35Hz).

In this way the penetration into the ballast is facilitated, because at an increased frequency the vibrated ballast resembles a flowing medium.

[23] The eccentric drive 14 is arranged on a tool carrier 19. On the tool carrier 19 also pivot arms 20 are mounted. These have the stuffing tools 12 at the lower ends. At upper ends of the pivot arms 20 on the Beistellzylinder 15 with a means of

Eccentric 14 coupled driven eccentric shaft. The

Tool carrier 19 is guided in an aggregate frame 21 and vertically movable by means of a lifting and lowering device 22. In this case, the lifting and lowering device 22 includes a hydraulic cylinder 23. Der

Hydraulic cylinder 23 is against a machine frame 24 of

Tamping machine 1 is supported and causes in operation a lifting and lowering force F _z on the tool carrier 19. The applied by the hydraulic cylinder 23 during a penetration process 17 lowering force F _z is a proportion of a penetration force F _E , which acts on the ballast bed 10.

[24] By measuring the hydraulic pressures acting in the hydraulic cylinder 23, the lowering force F _z can be determined in a simple manner. For detecting the penetration force F _E , the mass and the acceleration of the tool carrier 19 together with the parts arranged thereon are additionally taken into account.

The acceleration can be characterized by two differentiation calculate a measured piston travel x of the hydraulic cylinder 23. To determine the penetration force F _E is thus only a pressure and displacement measurement on the known mass of the moving parts

Hydraulic cylinder 23 performed.

[25] By acquiring the measurement data over a period of time T, the result is a progression of the penetration force F _E over time t. In this way you first get a simple load-time history. For further evaluations, in particular a plurality of stuffing cycles are monitored and in each case the highest penetration force is stored during the respective penetration process 17, so that the stress-time profile indicates the maximum penetration force over the time t, ie over a plurality of consecutive stuffing cycles. From the load-time curve or a load-time function, a load collective can be determined in a simple manner. Thus, it is immediately apparent what burdens over the considered period T away

appeared.

[26] The training of the stress-time course will be for everyone

Penetration 17 the penetration energy E _E calculated:

or (1)

with (2)

x ₀ ··· Start of a penetration route

x _x ··· End of a penetration path

t ₀ ··· Start of a penetration process 17

t _x ··· End of an intrusion process 17

Thus, by monitoring a plurality of penetrations 17 over the time period T across the course of the penetration energy E _E over the time t. An averaging over several penetrations 17 thereby leads to a mitigation of possibly occurring anomalies in the measurement data acquisition.

[27] In further consequence it can be meaningful, which during the respective

Penetrations applied penetration P _E to determine:

From a course of the penetration power P _E over a continuous working time T, conclusions can be drawn about the load situation of the tamping unit 2 as well as about the nature of the ballast bed 10 processed during the working time period T. Again, averaging is useful.

[28] In the case of multiple clogging, several stuffing operations (subcycles) occur at one point of the track 6 in order to achieve a given degree of compaction of the ballast bed 10. In this case, several

Stress-time courses formed, namely according to the sequence of subcycles. In a double tamping the course of the penetration force F _E, the penetration energy E _E P _E or the penetrating power of all first sub-cycles and for example, is determined separately for all of the second sub-cycles.

As eccentric 14 for vibration generation, for example, a hydraulic motor is provided. In this case, a pressure difference Dr between entry and exit of the hydraulic oil and a flow rate Q of the hydraulic oil are measured in order to determine a hydraulic power P _{H of} the eccentric drive 14:

P _H = Dr Q (4)

About the respective Stopfzyklus the eccentric power P _{H is} averaged.

For a coherent working time span T with numerous stuffing cycles, the result of this is the course of the eccentric power P _H over the time t as the vibration load time curve.

[30] The individual courses are shown in simplified form in FIG. The uppermost diagram shows a course of the penetration path x (penetration depth) over the time t. This corresponds to the detected piston travel x of

Hydraulic cylinder 23. At the beginning of the penetration path x _0, the tips of the tamping tools 12 touch the surface of the ballast bed 10 and at the end of the penetration path x _x , the tamping tools 12 have the

provided maximum penetration depth reached. In the diagrams below are the courses of the coincidental timeline

Flow rate Q, the pressure difference Dr, the resulting Eccentric power P _H and at the bottom of the course of the penetration force F _E shown.

[31] As shown in FIG. 4, the evaluation device 5 comprises a

Data acquisition unit 25, a microprocessor 26 and a

Communication means 27 (e.g., modem) for transmitting data to remote computer systems 28 and output devices 29, respectively

Caching of data is the microprocessor 26

Conveniently connected to a memory device 30. The remote computer system 28 also includes a database means 31 for storing historical data.

[32] A machine controller 32 is supplied with output signals from the sensors 3 to form a control circuit. In this way, an efficient adaptation of control signals to changing ones takes place

System conditions. Through digitization by means of the

Data acquisition unit 25 are selected from the output signals of

Sensors 3 digital measurement data and provided to the microprocessor 26. In this case, a storage of the measured data takes place over the intended time period T. By means of the microprocessor 26, a load-time curve is created and evaluated from the measured data. In this case, characteristic signal ranges are identified and relevant parameters are calculated, for example load collectives of the lifting and lowering device 22 and the eccentric drive 14 or classifications of the ballast bed 10. For the possible adaptation of

Control parameters are the parameters to the

Machine control 32 transmitted. In this way, for example, an adaptation of the stuffing parameters to a determined hardness of

Gravel bed 10.

The remote computer system 28 is advantageously in one

System center 33 arranged to analyze currently collected and historical data and derived from maintenance or

Specify inspection intervals for the tamping unit 2. As a criterion, for example, an adjustment of a formed load spectrum with predetermined time-stability ranges can be used. [34] Exemplary curves of the eccentric power P _H and the penetration power P _E over a continuous working time period T are shown in FIG. 5. In this case, a similarity between the two courses can be recognized, because the quality of the ballast bed 10 affects both variables P _H , P _E. A harder ballast bed 10 with an already longer service life requires both a higher one

Eccentric power P _H and a higher penetration P _E. In a new situation with new gravel, however, the applied powers P _H , P _E are lower.

[35] In order to assign a given condition class (soft new position, medium, hard-old) to a respective processing section of a ballast bed 10, P _H , P _E are at least one of the two output quantities

corresponding value ranges specified. By comparing the ascertained performance curves with these predetermined value ranges, an automated classification of the processed data is carried out

Roadbed sections.

[36] Advantageously, the determined condition class is linked to an execution time and a performance location in one

Output device 29 (computer screen, tablet, etc.) is displayed. In the simplest case, this is done in tabular form with date,

Site description, condition class and average eccentric power P _H and average penetration P _E.

[37] A high information content display 34 is shown in FIG.

In this case, a construction site 35 in an electronic map 36

drawn, with individual construction site sections are assigned differently marked condition classes. The basis for this is formed by a predetermined hardness scale 37 for the ballast bed 10. In addition, date and time indications 38 are displayed at striking points on the construction site.

Claims

claims

1. A method for monitoring the load of a tamping unit (2) of a track construction machine (1), wherein at least one sensor (3) for detecting a load of Stopfaggregates (2) is arranged, dad u rch nets net, that by means of the sensor (3) detected Measurement data over a period of time (T) away in an evaluation (5) are stored and that from the stored measurement data at least one load-time history for cyclic penetration (17) of the tamping unit (2) is derived in a ballast bed (10).

2. Method according to claim 1, characterized in that a load collective is calculated from the load-time profile.

3. The method according to claim 1, characterized in that a hydraulic cylinder (23) arranged in a lifting and lowering device (22) of the tamping unit (2) is monitored and in that a piston travel (x) and in the measuring data is provided Hydraulic cylinder (23) acting hydraulic pressures are detected.

4. The method according to claim 1, characterized in that a penetration energy (E _e ) introduced into the ballast bed (10) when the tamping unit (2) enters the ballast bed (10) is calculated.

5. The method according to any one of claims 1 to 4, dad u rch geken nzeich net that a penetration of the tamping unit (2) into the ballast bed (10) acting penetration (P _E ) is calculated.

6. The method according to claim 1, characterized in that an eccentric drive (14) of the tamping unit (2) is monitored and that over the time span (T) a power of the eccentric drive (14) is detected.

7. The method according to claim 5, characterized in that a hydraulic eccentric drive (14) of the tamping unit (2) is monitored and in that a pressure (Dr) and a flow rate (Q) are detected as measured data and that therefrom is a hydraulic Power (P _H ) of the eccentric drive (14) is derived.

8. Method according to claim 5, characterized in that an electrical eccentric drive (14) of the tamping unit (2) is monitored and that as

Measured data voltage and current are detected and that an electrical power of the eccentric drive (14) is derived.

9. Method according to one of claims 1 to 8, characterized in that based on the load-time profile by means of a computer unit (28) a maintenance or inspection interval for the tamping unit (2) is provided.

is given.

10. The method according to any one of claims 1 to 9, dad u rch

Genken nzeich net that based on the load-time course by means of a computer unit (28) a classification of the stuffed ballast bed (10) is performed.

11. The method according to claim 10, characterized in that the classification of the ballast bed (10) associated with an execution time and / or a performance location is displayed in an output device (29).

12. A system for carrying out a method according to one of claims 1 to 11, wherein the tamping unit (2) has at least one sensor (3) for detecting a load, characterized in that the sensor (3) is connected to the evaluation device (3). 5) is connected and that the evaluation device (5) is set up to determine the load-time curve from the stored measurement data.

A system according to claim 12, characterized in that the

Evaluation device (5) comprises a data acquisition unit (25), a microprocessor (26) and a communication means (27) for transmitting data to remote computer systems (28) or output devices (29).

14. System according to claim 12 or 13, dad u rch geken nzeich net that a machine control (32) with drives or control components of the tamping unit (2) is connected and that the machine control (32), the measurement data are supplied to adjust control data.

15. System according to claim 14, characterized in that the

Machine control (32) with the evaluation device (5) is connected to the evaluation means (5) calculated characteristics as

Specify control parameters.