RU180938U1 - WAGON BRAKE RECEIVER - Google Patents

Abstract

The utility model relates to the field of railway transport, mainly to diagnostic systems for brake equipment of freight and passenger cars, and is intended for testing and acceptance of brakes of a car that leaves a repair. The car brake acceptance device comprises a functional unit with specialized software installed in it, a pneumatic unit, at least four compressed air pressure sensors, a battery, a charger, a feed pneumatic pipe, a brake pneumatic pipe. In this case, one pressure sensor is installed on the brake line, the second on the supply line, the third on the brake cylinder, the fourth on the second brake cylinder or on the brake reservoir. An analog-to-digital converter with the ability to measure and register current and voltage parameters in the electro-pneumatic brake circuit is included in the function block. The software algorithm is designed to take into account the characteristics of the acceptance of brake systems of various types, including disc brakes and systems with separate braking. A non-return valve is included in the pneumatic unit, while all the elements of the pneumatic unit have a 1/2 inch flow area. The technical result is to increase the versatility of the design of the device. 2 s.p. f-ly, 1 ill.

Description

The utility model relates to the field of railway transport, mainly to diagnostic systems for brake equipment of freight and passenger cars, and is intended for testing and acceptance of brakes of a car that leaves a repair.

A device for testing brake equipment of freight cars (Patent RU 68996 U1 В60Т 17/22, В60Т 13/26, В60Т 15/60, publ. 10.12.2007), consisting of two independently functioning parts: a mobile unit and a stationary unit. The mobile unit includes pressure, displacement, force, control unit, electro-pneumatic unit, air release device, recording device, power board, power source and indicator. The stationary unit includes a reader, a personal computer and a printer. Pressure sensors are installed on the air reservoir, brake line and on the brake cylinder of the car. Displacement sensors are installed on the brake cylinder and on the auto-regulator of the brake system of the car. Force sensors are mounted on the brake shoes of each wagon trolley. The pressure sensor and the displacement sensor mounted on the brake cylinder are placed in one housing, which is attached to the control hole in the brake cylinder housing. The device includes a radio channel designed to organize the exchange of data between the sensors, the control panel and the controller. The device controls all the parameters of the brake system, the force of pressing the brake pads in all modes of operation of the air distributor and the action of the autoregulator.

The disadvantage of this device is the limited functionality, since the design of the device is able to experience the usual brakes of a freight car, without separate braking, and is absolutely not suitable for testing the braking equipment of passenger cars.

A device for receiving an automatic brake of a freight car (UPTV-GR) is known (Patent RU 97098 U1 В60Т 17/22, published on 08.27.2010), the input of which is connected to the mains and the output to the brake line of the car. The device comprises a pneumatic actuating unit, a pressure sensor of the supply line installed in the supply part of the pneumatic execution unit, a pressure sensor of the brake line mounted on the pneumatic execution unit, a pressure sensor of the brake cylinder mounted on the brake cylinder of the car, a battery and a functional unit. Moreover, all structural elements of the device are made frost-resistant. The pneumatic actuating unit contains a charge pressure reducer, the input of which is connected to an air purification filter, and the output is with an electro-pneumatic power relay.

The disadvantage of this device is also the limited functionality. The design of the device is capable of testing only ordinary brakes of a freight car, without separate braking, and is absolutely not adapted to testing the braking equipment of passenger cars.

The closest technical solution, selected as a prototype, is the installation of the car brake acceptance (UPTV) (Brake equipment of freight and passenger cars: method. Directions / KM Kolyasov, AN Antropov - Yekaterinburg: UrGUPS, 2016. - 46 [2] p. 6-12) (https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=14&ved=0a hUKEwiQ8oWvorXVAhXSbVAKHbnnAVc4ChAWCDkwAw & url = 2% 2% 2%% 3% 2% 2% 2% 2% .ru% 2Fcgi-bin% 2Firbis64r_13% 2Fcgiirbis_64.exe% 3FC21COM% 3D2% 26I21DBN% 3DKN% 26P21DBN% 3DKN% 26Z21ID% 3D% 26Image_file_name% 3Dumm% 255Cumm_73jfjfjfjfjfjfjfjfjfjfjfjfjffg_fi_fjfj_fj_fj_fj_fj_faid_fid

The Car Brake Acceptance Installation (UPTV) is used to test and accept the brake of a passenger car that exits repair. The installation contains a functional unit connected by a cable to a direct current source (battery), an executive unit connected to a supply line and connected by a flexible pipe to a brake line, a charge pressure reducer, an electro-pneumatic power relay, an electro-pneumatic braking relay. The pneumatic input of the installation is connected to the supply line, and the pneumatic output to the brake line. The functional unit (controller) is designed to perform monitoring and control operations in manual and automatic modes. Executive pneumatic unit is designed to control the pressure of compressed air in the brake network of the car. The function block is connected to the pressure sensor of the supply line, to the pressure sensor of the brake line and to the pressure sensor of the brake cylinder. Along the pipeline laid an electric cable containing the working and control wires.

However, this installation has the following disadvantages:

- limited functionality, since the design of the installation allows testing only shoe brakes of passenger cars;

- the installation is not able to register the parameters of current and voltage in the circuit of the electro-pneumatic brake;

- insufficient reliability of the installation, since its functional unit does not withstand overloads, because of which its electronics often fail.

The technical task of the proposed utility model is to create a car brake acceptance device (UPTV), which is able to test the brakes of freight cars of all types, including freight cars with separate (emergency) braking, the brakes of passenger and mail-baggage cars of all types, including shoe, disc, pneumatic and electro-pneumatic, brakes of passenger cars with separate (chest) braking, ensuring careful monitoring of the braking system of the car for leaks of the brake line, as well as having the ability to measure and record the current and voltage parameters in the electric air brake circuit.

The technical result is an increase in the universality of the design of the device.

To solve the problem and achieve a technical result in the car brake acceptance device (UPTV), which contains a functional unit with specialized software installed in it, a pneumatic unit, three compressed air pressure sensors, each of which is installed on the brake line, feed line and on the brake line cylinder, battery, charger, pneumatic feed pipe, brake pneumatic pipe, according to a utility model, contains at least one additional A compressed air pressure sensor installed on the second brake cylinder or on the brake reservoir, an analog-to-digital converter is included in the function block with the ability to measure and record current and voltage parameters in the electro-pneumatic brake circuit, and the software algorithm is designed to take into account the characteristics of acceptance of brake systems various types, including disc brakes and systems with separate braking, in addition, a check valve is included in the pneumatic unit, while all electric cops pneumatic blocks have a through 1/2 inch section.

The essence of the utility model is illustrated by a figure.

The figure shows a block diagram of a device for receiving car brakes (UPTV).

The car brake acceptance device (UPTV) is a mobile installation on wheels, in the housing of which are located: a functional unit 1, a pneumatic unit 2, compressed air pressure sensors 3, a battery 4, a charger 5, a feed pneumatic pipe 6, a brake pneumatic pipe 7. One the compressed air pressure sensor 3 is installed on the brake line, the second on the supply line, the third on the brake cylinder, the fourth pressure sensor 3 is installed, depending on the design of the car, or on the second torus brain cylinder, or on the brake reservoir. The fourth sensor is designed for receiving cars with separate braking, as well as for receiving some passenger cars with disc brakes. It is connected when the number of brake cylinders in a car is more than one, because passenger cars with a shoe brake and freight cars with a conventional (standard) braking system have one brake cylinder each, mail, baggage, mail-baggage cars and freight cars with separate braking, two brake cylinders each, and some passenger cars with disc brakes have more than two brake cylinders. The presence of four pressure sensors allows you to measure the pressure of the brake line and brake cylinders of any brake system of any type of car, which allows to increase the universality of the device design.

Function block 1 (controller) is designed to perform monitoring and control operations in manual and automatic modes. The functional unit 1 is connected by a cable to the battery 4 and to the pressure sensors 3, which are installed on the brake line, feed line and on the brake cylinders. The functional unit contains a housing on which are located: the UPTV power button, a display designed to inform the operator, a keyboard for entering information about the tested car and commanding to perform operations to test the car brakes, a USB connector for a flash drive. Inside the case of the functional block is a measuring and recording device based on microprocessor elements, which collects, processes and analyzes information.

In the functional block, unlike the prototype, a microprocessor (not shown) of the Microchip PIC32 family was used (the prototype uses an eight-bit AT Mega 32 microcontroller). PIC32 is a single-chip processor with MIPS architecture that has integrated flash memory and a complete set of microcontroller peripherals. The standard MIPS architecture (Microprocessor without Interlocked Pipeline Stages) meets all the requirements of microcontroller developers and surpasses the ARM Cortex-M family in speed, consumption and functionality.

Key Benefits of MIPS over Cortex-M:

- M4K and M14K performance is 20% higher than Cortex-M3;

- The maximum clock frequency of M4K and M14K is 20% higher than Cortex-M3 cores;

- M14K spends 30% fewer cycles during interrupt processing;

- M14K prefetch buffer reduces flash access time, SRAM interface speeds up execution time;

- signal processing on the PIC32 is 14% faster than on the STM32F (for the FFT function);

- low consumption and high efficiency of energy consumption;

- A wide range of hardware and software design tools compatible with leading real-time operating systems (RTOS), middleware package (software), support for leading computer-aided design (CAD) systems.

The microcontrollers of this family of thirty-two bit controllers have an increased memory capacity for solving complex tasks for embedded applications.

The PIC32 microcontroller family is compatible with eight- and sixteen-bit Microchip controllers.

To display information on the display, a graphic indicator was used (not shown in the figure) (in the prototype, a four-line symbol) to more conveniently display information for the user.

To power the electric air brake circuit, a more powerful step-up converter (not shown) is used, which has an adjustable output voltage of up to 80 V, power of 800 W and a maximum load current of up to 15A, which helps protect the functional unit from failure (in the prototype a power source was used without the ability to adjust the output voltage and a maximum current of up to 3A).

An analog-to-digital converter (not shown in the figure) is used as part of the function block, which allows measuring and recording current and voltage in the electro-pneumatic brake circuit, which improves control, thereby increasing the universality of the device design. At the same time, a duplicated information storage system is provided, both on the Flash memory chip and on the Secure Digital Memory Card (SD).

The software of the function block contains an advanced algorithm that takes into account the acceptance features of various types of brake systems, including disc brakes and systems with separate braking.

An improved functional unit allows for data processing and brake processes of any brake system of any type of wagon. An improved test algorithm provides the ability to receive brakes of any brake system, any type of car in automatic mode with the registration of all necessary parameters. These features can improve the versatility of the device design.

Executive pneumatic unit 2 is designed to control the pressure of compressed air in the brake network of the car. The pneumatic unit 2 contains an air purification filter 8, the input of which is connected to the pneumatic feed line 6, and the output to the input of the charge pressure regulator 9. The output of the charge pressure regulator 9 is connected to the input of the electro-pneumatic power relay 10, the output of which is connected to the input of the non-return valve 11 The output of the non-return valve 11 is connected via a tee to the brake pneumatic conduit 7, with an electro-pneumatic brake relay 12 and with a sensor 3 mounted on the brake line.

The pneumatic input of the device is connected to the supply line by the supply pneumatic line 6, and the pneumatic output is connected to the brake line by the brake pneumatic line 7.

The charge pressure regulator 9 is designed to regulate the pressure in the brake line.

An electro-pneumatic power relay 10 is necessary to supply compressed air to the brake line.

The use of a non-return valve 11 in the pneumatic unit 2 is provided to exclude recharge of the brake system of the car in the overlap position after performing the braking stage. This improvement provides more thorough control of the brake system for leaks in the brake line of all types of cars, thereby increasing the versatility of the design of the device.

The electro-pneumatic brake relay 12 is designed to release compressed air from the brake line.

In cars with separate braking and in passenger cars with disc brakes, the volume of the brake system is increased by 3-5 times in comparison with the standard brake system of a passenger or freight car. Therefore, the use in the pneumatic block of elements with a cross section of 1/4 inch (as in the prototype) does not allow charging the brakes at the time established by regulatory requirements. In this regard, all the elements of the pneumatic unit are made with an enlarged bore - 1/2 inch. This improvement makes it possible to provide compressed air to any brake system of any type of wagon for the time set by the standards, which increases the universality of the device design.

The power supply of the functional unit 1 is provided by the rechargeable battery 4. The rechargeable battery 4 is recharged from a charger 5 connected to an AC voltage of 220 V.

The work of the functional unit 1 in terms of receiving commands, processing information, registering and issuing data, as well as submitting control commands to the executive elements is carried out using specialized advanced software.

Software designation, including its name, designation of its version:

Designation of the software: BF-UPTV-D.

Version Number: 1.00

Description of the purpose of the software, its structure and functions:

The FB-UPTV software is intended for programming the functional block (FB) of the UPTV device. The software is made in the form of a head program and subprograms for working with various UPTV functional units. The software is intended for writing to the read-only memory (ROM) of the PIC18F microcontroller (single-chip microcomputer) from Microchip and can only be run on this device. The software performs the following functions:

- data input from the keyboard FB-UPTV;

- data output on the display FB-UPTV;

- data storage on the built-in medium;

- copying data to removable media;

- data exchange with pressure sensors;

- control of electro-pneumatic relays and voltage switches;

- manual test of the car brake;

- test the car brake in automatic mode;

- measurement of voltage and current in the circuit of the electro-pneumatic brake and battery.

The following calculation algorithms are implemented in the software:

- Calculation of a cyclic checksum (CRC16). The calculation algorithm allows to provide the required reliability of data during information exchange with pressure sensors;

- Conversion of floating point numbers (international standard IEEE754);

- Converting Floating-Point Conversion to decimal for display and storage on storage media.

Transfer and storage of data is carried out on a memory card MMS (multimedia cards). Next, the memory card is connected to a personal electronic computer (PC) and the file is copied to the PC using the PC operating system.

To protect the software, the hardware of the Microchip PIC18F series microcontrollers is used. After programming the microcontroller, protection bits are set that block unauthorized changes and copying of software. The measurement results are stored in the internal memory of the function block, which does not have other communication interfaces. Therefore, access to the measurement results is possible only using the software of the function block.

To store the measurement results, an internal non-volatile memory of the function block is used. Data is written to the memory chip sequentially using the SPI interface. After turning off the power to the function block, data is stored indefinitely. The storage time of data on the memory card is also unlimited.

Software can only be installed on a function block. The software does not require system software to run. The structure of the functional block includes specialized devices of non-volatile memory, timing, interface converters.

All structural elements of the car brake acceptance device (UPTV) are frost-resistant. The use of frost-resistant elements in the design of the device allows it to be operated in various temperature conditions, including in the open air when exposed to negative temperatures up to -60 ° C.

The device for receiving brakes of a car works as follows.

The initial state:

In the initial state, as shown in the figure, the electro-pneumatic power relay 10 and the electro-pneumatic braking relay 12 of the pneumatic unit 2 are de-energized, air from the supply line does not enter the charge pressure regulator 9, therefore, compressed air does not enter the output of the unit and the brake line . The pressure sensors 3 of the supply line, brake line and brake cylinders are also de-energized.

Preparation for work:

For testing and acceptance of car brakes, the UPTV rolls to the end of the test car. Before turning on the car brake acceptance device, sensors 3 are mounted on the brake cylinder, the supply pneumatic line 6 is connected to the supply line of the car, and the brake pneumatic line 7 is connected to the brake line of the car.

If the device is powered from the mains depot, it is necessary to connect the device’s line cable to the 220 V alternating current network. The device is turned on by the power button on the front panel of the function block 1. When the device is operating from the 220 V mains, the battery 4 is automatically recharged.

Car brake test:

When the unit is turned on, menu items appear on the display of function block 1.

The transition from the previous menu item to the next is carried out by pressing the corresponding buttons.

When you select the "Personnel number" item in the menu of function block 1, you must enter an eight-digit employee number for the purpose of subsequent registration.

When you select the item “Car number” in the menu of the functional block 1, enter the eight-digit number of the tested car for the purpose of subsequent recording of the results of all tests of the brakes of the car, the type of air distributor and electric air distributor installed on the car.

When you select the item "Density TM" on the display of the function block 1 appears the inscription "Turn off the disconnecting tap." To confirm the operation of checking the density of the brake line (TM), you must click the "Yes" (C) button, after which the density check of the brake line of the car will begin automatically according to the depot and overhaul standards.

When you select the item "Density TM - TO" on the display of the function block 1 appears the inscription "Turn off the disconnecting valve." To confirm the operation of checking the density of the brake line (TM), you must click the "Yes" (C) button, after which the density check of the brake line of the car will begin automatically according to the norms of the current uncoupling repair.

When you select in the menu of the functional block 1 of the item “Density of PMV and check valves”, the density check of the supply line of the car starts in automatic mode.

When the menu item "Checking the trolley disc brake" is selected in the menu of function block 1, the trolley disc brake test starts in automatic mode.

When you select the item "Pneumatics" in the menu of the functional block 1, the test of the pneumatic part of the brake system of the car in automatic mode begins according to the norms of depot and overhaul.

When the item “Pneumatics maintenance” is selected in the menu of the functional block 1, the test of the pneumatic part of the car’s brake system begins automatically according to the norms of the current uncoupling repair.

When you select the "EPT" begins the test of the electro-pneumatic brake in automatic mode. When testing the electro-pneumatic brake, the circuit of the electro-pneumatic brake (working and control wires) of the car is checked.

When you select "Manual mode" in the menu of function block 1, the device enters the keyboard control mode, in which operations are performed by pressing the corresponding buttons.

When selecting the "View results" item, the program goes to the submenu (auxiliary menu), where you can see the test results of the brakes of any tested carriage for choice.

When you select the "Clear memory" item, the memory of function block 1 is cleared (deleting all test results). If the memory of functional block 1 is full, the test results will be recorded on the previously recorded results of previous tests until the memory is cleaned (memory capacity “1000 cars).

When you select the item "Date and time", the program enters the mode of setting the current date and time in order to register the test date of the car brakes (it is set once, further time measurement is automatic).

When you select the item "Self-diagnosis" starts the process of diagnosing the operation of the device UPTV. To perform self-diagnosis, you must first connect the device to a sealed tank of 20 l.

All test results recorded by the controller can be written to a computer as a file and then printed.

Unlike the prototype, the car brake acceptance device can test the brakes of freight cars of all types, including cars with separate (truck braking), the brakes of passenger and mail-baggage cars of all types, including shoe, disc, pneumatic and electro-pneumatic, as well as cars with separate (bodily) inhibition.

When testing the brakes of a passenger car, the device charges the brake network of a specified duration. It checks the density of the supply air duct of the car and check valves, checks the brakes of the trolley, the pneumatic brake of the car, the electro-pneumatic brake of the car.

When testing an automatic brake, the device performs the braking stage after fully charging and checks the operation of the brake during the braking stage; determines the compliance of the tightness of the brake line of the car with the established standards; determines the maximum pressure in the brake cylinder during emergency braking; determines the duration of the braking effect by the rate of pressure decrease in the brake cylinder after emergency braking; checks the action of the exhaust valve; controls the release of the brake when restoring the pressure in the brake line in accordance with the requirements of the General Guidelines for the repair of brake equipment of cars 732-CV-TsL.

When testing an electro-pneumatic brake (EPT), the device checks the integrity of the working and control wires of the EPT control circuit; performs braking steps of a certain duration; performs vacation steps of a specified duration; Performs full service braking and full vacation after full service braking.

When testing the brakes of a freight car, the device charges the brake network of a specified duration. When testing an automatic brake, the device performs the braking stage after fully charging and checks the operation of the brake during the braking stage; determines the compliance of the tightness of the brake line of the car with the established standards; determines the amount of pressure in the brake cylinder during full service braking; determines the duration of the braking effect by the rate of pressure decrease in the brake cylinder after braking; monitors brake release when pressure is restored in the brake line. All operations are carried out in accordance with the requirements of the General Guidelines for the repair of brake equipment of wagons 732-CV-TsL.

Thus, the proposed utility model allows:

- test the brakes of cars of all types;

- provide compressed air to any brake system of any type of car for the time specified by regulatory requirements;

- measure and record the current and voltage parameters in the circuit of the electro-pneumatic brake;

- carefully monitor the brake system of all types of cars for leaks in the brake line.

Claims (3)

1. A device for receiving car brakes, comprising a functional unit with specialized software installed in it, a pneumatic unit, three compressed air pressure sensors, each of which is installed on the brake line, supply line and brake cylinder, a battery, a battery charger, a pneumatic supply pipe , a pneumatic brake pipe, characterized in that it contains an additional compressed air pressure sensor, and an analog-to-digital converter is included in the function block with the ability to measure and record current and voltage parameters in the circuit of an electro-pneumatic brake, and the software algorithm is designed to take into account the specifics of acceptance of various types of brake systems, including disc brakes and systems with separate braking, in addition, a check valve is included in the pneumatic unit, while all elements of the pneumatic unit have a 1/2 inch bore. 2. The device for receiving car brakes according to claim 1, characterized in that the additional compressed air pressure sensor is installed on the second brake cylinder. 3. The car brake acceptance device according to claim 1, characterized in that the additional compressed air pressure sensor is mounted on the brake reservoir.

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