RU2782290C1 - Stand for vibration diagnostics of axle boxes of wheel pairs of rolling stock - Google Patents

Abstract

FIELD: vehicles repair and maintenance.

SUBSTANCE: invention relates to the field of repair and maintenance of rail vehicles. The stand for vibration diagnostics of axlebox units of wheelsets of rolling stock contains a base recessed relative to the technological rail track, supports for axleboxes placed on it, drive grips for fixing the axleboxes, a positioning platform installed with the possibility of vertical movement with a section of the rail track corresponding to a break in the technological rail track, a means of rotation a pair of wheels in the form of rollers associated with the drive of their rotation and movement, vibration transducers associated with a measuring device, and a drive control unit. The stand is equipped with a device for centering the wheelset relative to the longitudinal axis of the rail track of the stand during rolling, made in the form of guides placed on the positioning platform, and a group of non-contact sensors, including sensors for the presence of axle boxes on the supports and sensors for the extreme positions of the positioning platform, grips and rollers of the rotation means, while all sensors are connected to the drive control unit.

EFFECT: increased reliability of the stand operation and increased reliability of diagnostic results.

13 cl, 11 dwg

Description

The technical field to which the invention belongs

The invention relates to railway transport, and in particular to the field of repair and maintenance of rail vehicles.

State of the art

A well-known complex for vibration diagnostics of axleboxes of wheelsets of rolling stock, containing a frame buried in a well under the rail track, carrying support racks for axle boxes and a vertically movable upper frame with rail inserts for rolling the wheelset, a mechanism for accelerating the wheelset, including rollers mounted on the shafts of electric motors and pneumatic cylinders for bringing the rollers to the wheelset, as well as vibration transducers connected to the measuring system (see patent RU 84559, Cl. G01M 17/10, publ. 10.07.2009). The upper frame takes over the wheel pair and lowers it with axle boxes onto the support legs, after which the mechanism for accelerating the wheel pair comes into action and its diagnosis is carried out. Braking of the wheelset is performed by means of rail inserts of the movable frame pressed against the wheels.

The disadvantages of the known device include the uncertainty of the position of the wheelset relative to the support legs, due to the possibility of misalignment of its axis when knurling on the stand, as well as the possibility of shifting axleboxes in the diagnostic process. All this negatively affects the operation of the equipment and the reliability of the obtained diagnostic data, due to the lack of ensuring the same conditions for diagnosing. In addition, the use of rail inserts for braking the wheelset leads to the development of their rolling surface and deterioration of the stand.

The problem of displacement of axleboxes in the process of diagnostics is solved in the complex for vibration diagnostics of axleboxes of the wheelset of a freight car (patent RU 117627 U1, IPC: G01M 17/10, published on February 10, 2010), the design of which is accepted as the closest analogue for the proposed technical solution .

Signs of the closest analogue, similar to the essential features of the proposed solution, are that the well-known complex contains a base in the form of a spatial frame, recessed relative to the technological rail track of the workshop, supports for the axle boxes and mechanisms for fixing the axle boxes, each of which includes a pair of rotary levers grips associated with the power cylinders of their movement, a positioning platform installed with the possibility of vertical movement with a section of the rail track corresponding to a break in the technological rail track, a means of rotation (rotation) of the wheel pair, including rollers fixed on the shafts of electric motors associated with the drive of their movement, vibration transducers associated with the measuring device, and a drive control unit.

In the closed position, the grips keep the axle boxes from moving, ensuring a fixed position of the wheelset during the diagnostic process. Rising, the grippers shift the axleboxes along the supports until their movement is stopped by an adjustable limiter, which ensures the correct angular position of the wheelset.

To securely hold the box, each grip must, when closed, fall into the groove between the technological protrusions on its body. However, in the well-known complex there are no mechanisms that ensure the centering of the wheelset relative to the longitudinal axis of the rail track, and therefore there is a high probability of deviation of the position of the wheelset from symmetrical. As a result, grips located symmetrically with respect to the longitudinal axis of the rail track may not close completely, hitting the protrusion of the axle box body, which will lead to instability of the wheelset position during measurements, while the lack of control over the operation of the drive mechanisms excludes the possibility of tracking the correct closing of the grips.

The arbitrariness of the position of the wheelset does not allow for repeatability of the diagnostic conditions, which negatively affects the reliability of the results obtained, while the symmetry of the load of the drive rollers is violated, which leads to increased wear of the drive elements of the wheelset and a reduction in the service life of the stand.

Thus, in order to obtain reliable data and ensure the reliability of the stand, not only the stability of the position of the wheelset during the measurement process is important, but also the initial accuracy of its installation in a given position corresponding to the symmetrical arrangement of the wheels of the wheelset relative to the longitudinal axis of the track of the stand.

The proposed invention is aimed at solving the above problems, and increasing the reliability of the stand and the reliability of the diagnostic results, by ensuring high accuracy and repeatability of the location of the axlebox units of the wheel pair relative to the functional equipment of the stand, reducing wear of the rotation drive elements, ensuring the control of the operation of the drive mechanisms and creating automation conditions diagnostic process.

Disclosure of the essence of the invention The above problem is solved, and the results are achieved in the proposed stand for vibration diagnostics of axlebox units of wheel sets of rolling stock, containing a base recessed relative to the technological rail track, supports for axleboxes placed on it, drive grippers for fixing the axleboxes, a positioning platform installed with the possibility of vertical movement with a section of the rail track corresponding to a gap in the technological rail track, a wheel pair rotation means in the form of rollers associated with the drive of their rotation and movement, vibration transducers associated with the measuring device, and a drive control unit. According to the claimed invention, the stand is equipped with a device for centering the wheelset relative to the longitudinal axis of the rail track during rolling, made in the form of guides placed on the positioning platform, and a group of non-contact sensors connected to the drive control unit, including sensors for the presence of axle boxes on the supports and sensors for the extreme positions of the drive mechanisms stand: positioning platform, grippers, rollers of the means of rotation.

Placed on the positioning platform along each rail, from its inner side, the guides, when rolling the wheelset onto the platform, interact with their working surface with the disk surface of the corresponding wheel, ensuring alignment of the position of the center of the wheelset relative to the longitudinal axis of the track of the stand, i.e. when the wheelset is rolled onto the platform, it is automatically centered.

As a result, a high accuracy of the location of the axleboxes (or shortly - axleboxes) of the wheel pair relative to the grips and other functional equipment of the stand is achieved. Firstly, this makes it possible to exclude the jamming of the grips on the elements of the axle boxes during closing and to increase the uniform distribution of the load on the rollers of the means of rotation, thereby increasing the durability of their service life and the reliability of the stand. Secondly, it provides an increase in the reliability of the diagnostic results due to the repeatability of the diagnostic conditions, because all wheel pairs in all cases of rolling onto the stand have the same position.

At the same time, the simplicity of the technological implementation of the centering device should be noted. So, each guide can be made in the form of a part, including an installation part with holes for fasteners and a working surface orthogonal to it, extended along the corresponding rail, made with the possibility of interacting with the inner disk surface of the corresponding wheel of the wheelset.

It is advisable to place guides at the inlet and outlet of the track section of the positioning platform, which will make it possible to roll the wheelset onto the platform from any side.

By equipping the stand with a group of non-contact sensors, including sensors for the presence of axle boxes on the supports and sensors for the extreme positions of the drive mechanisms, the operation of the drive mechanisms of the stand is monitored and the control of the correct execution of all stages of the work of the stand is ensured, which helps prevent possible breakdowns of mechanisms, eliminate possible downtime of the stand for these reasons and improve the reliability of its operation.

Receiving signals from sensors about the beginning and end of the operation, when the corresponding working body reaches the extreme position, the diagnostics control device, implemented by the measuring device associated with the drive control unit, can automatically switch from one operation to another.

Thus, due to the creation of feedback sensors with drive mechanisms and due to the high accuracy of the relative position of the equipment and the controlled object - the wheelset, it is possible to automate the diagnostic process. The exclusion of the human factor from the process also contributes to an increase in the reliability of the stand and the reliability of the diagnostic results obtained.

The high accuracy (certainty, repeatability) of the location of the wheelset at the working position and the stability of its position during the measurement process due to the reliable fixation of the axle boxes with grippers make it possible to use vibration transducers with automatic approach to the wheelset and control of their extreme positions in the stand.

In order to fully automate the diagnostic process, the stand can be equipped with a mechanism for ejecting the wheelset from the working position, including a pusher connected to the drive for its movement, and pusher extreme position sensors.

In preferred embodiments of the invention:

- piston pneumatic cylinders connected with the workshop pneumatic supply system through the receiver are used as drives for moving the grippers, rollers of the rotation means, pusher and vibration transducers;

- drive for vertical movement of the positioning platform is made in the form of a balloon (bellows) cylinder connected to the pneumatic supply system through the receiver;

- as sensors of the extreme positions of the grippers, rollers, pusher and vibration transducers, reed sensors are used that monitor the position of the pneumatic cylinder piston;

- eddy current sensors are used as sensors for the extreme positions of the positioning platform and as sensors for the presence of axle boxes on the supports;

- grips are made in the form of rotary L-shaped levers.

To rotate the friction rollers of the wheelset rotation means, mainly, an electric motor is used, connected to each of the rollers through a differential and a mechanism for transmitting rotation at an angle, while the latter is connected to the pneumatic cylinder rod, due to which the roller is moved and pressed against the wheelset.

The electric motor is connected to the drive control unit through a frequency converter. The speed of the wheelset is monitored by a non-contact speed sensor, the readings of which are visualized.

Such a design of the drive ensures the distribution of torque between the rollers during the transmission of rotation, which additionally contributes to an increase in the symmetry of their load and allows you to compensate for possible deviations in the position of the rollers and elements of the wheel pair, due, for example, to technological errors in the shape of the rollers, the presence of surfacing on the surface of the axle boxes, which causes deviation of the wheelset axle, etc. Increasing the symmetry of the load helps to reduce the wear of the rollers, increase the reliability and durability of their operation and the operation of the vibration diagnostic stand as a whole.

The use of one electric motor and one frequency converter leads to a reduction in the number of drives and improves the reliability of the stand.

Unlike the closest analogue, the means of rotation of the wheelset not only ensures its unwinding (acceleration), but is also used to stop the wheelset, carried out by the method of dynamic braking by an electric motor. The exclusion of specialized braking elements makes it possible to simplify the design of the stand and contributes to an increase in the reliability of its operation.

For the possibility of diagnosing axlebox units with cassette bearings, the stand is equipped with a set of adapters and a mechanism for loading the axlebox bearing in the axial direction with a hydraulic system for creating the load.

The design of the stand may include elements for fixing the upper position of the positioning platform, which will make it possible to use the technological rail track of the workshop for moving rolling stock without the risk of damage to the stand.

The essence of the proposed technical solution and the possibility of its industrial applicability are confirmed by the following examples of implementation and drawings, which show:

in fig. 1 - general view of the stand;

in fig. 2 - stand, top view;

in fig. 3 stand in cross section with a set of wheels installed on it;

in fig. 4 is view A of FIG. 2, the mechanism for fixing the axlebox assembly is shown;

in fig. 5 is view B of FIG. 4, an example of capturing;

in fig. 6 - positioning platform, isometry;

in fig. 7 - guide for centering the wheelset;

in fig. 8 - vibration transducer with a drive for its vertical movement;

in fig. 9 - ejector in two forms: isometry and longitudinal section;

in fig. 10 - an example of the placement of sensors of extreme positions on the pneumatic cylinder;

in fig. 11 - adapter.

Implementation of the invention Vibrodiagnostics stand for axleboxes of wheel pairs of rolling stock, see Fig. 1-3, includes a base 1 in the form of a prefabricated-welded spatial frame, buried relative to the technological rail track 2 workshops, placed along the edges of the support frame 3 for axle boxes, mechanisms for fixing the axle boxes, each of which includes a pair of oppositely placed relative to the corresponding support 3 rotary Г- shaped grippers 4 associated with pneumatic cylinders 5 of their movement (see Fig. 4, 5), positioning platform 6 installed between the supports 3 with the possibility of vertical movement, means of rotation of the wheelset in the form of friction rollers 7, each of which is connected to the electric motor 8 through the differential D and the mechanism M for transmitting rotation at an angle, the ejection mechanism (hereinafter referred to as the pusher) 9, the vibration transducers 10 connected to the measuring device 11, and the drive control unit 12 connected by a data bus to the measuring device 11 and placed together with it in a common housing 13.

On the positioning platform 6 (see Fig. 6) there are a pair of rails 14, forming a section of the rail track corresponding to a break in the technological rail track 2, and guides 15 for centering the wheel pair during rolling. To raise and lower the platform 6 is a balloon (bellows) pneumatic cylinder 16 (see Fig. .3).

Each guide 15 (see Fig. 7) is made in the form of a part containing the mounting part 17 with holes 18 for fasteners and a working surface 19 orthogonal to it, which performs the proper guiding functions.

For the manufacture of guides 15 can be used rolled corner profile of appropriate dimensions.

Preferably, the guides 15 are installed at the entrance and exit of the section of the rail track for the possibility of rolling the wheelset onto the platform 6 from any side.

As vibration transducers 10, vibration sensors with a needle (see Fig. 8) can be used, installed by means of pneumatic cylinders 20, leading the sensors to the axleboxes through the technological holes 21 in the supports 3 (see Fig. 1, 3).

This does not exclude the possibility of using other vibration transducers with mechanisms for their automatic approach to the measurement site.

To press the rollers 7 to the wheelset, pneumatic cylinders 22 are used, the rod of which interacts with the rotation transmission mechanism M at an angle (see Fig. 3). The pusher drive 9 is made in the form of a pneumatic cylinder 23 (see Fig. 9).

All pneumatic cylinders 5, 16, 20, 22 and 23 are connected to the workshop pneumatic supply system through a receiver (not shown in the drawings), which allows smoothing air pulsations and contributes to the uninterrupted operation of the stand.

The stand is equipped with a group of non-contact sensors that monitor the extreme positions of the drive mechanisms and the presence of axle boxes on the supports. All sensors are connected to the drive control unit 12.

Reed sensors 24 (see Fig. 10) mounted on the bodies of piston pneumatic cylinders 5, 20, 22 and 23, two on each body, can be used as sensors for the extreme positions of the grippers 4, rollers 7, pusher 9 and vibration transducers 10. The sensors 24 monitor the position of the rod (piston) of the pneumatic cylinder, corresponding to the extreme positions of the respective elements, which is ensured by pre-setting the sensors.

To track the extreme positions of the positioning platform 6, eddy current sensors 25 are installed in the support legs of the base 1 (see Fig. 3).

In the holes of the supports 3 there are sensors 26 for the presence of an axle box on the support (see Fig. 1), also made in the form of eddy current sensors.

The use of inductive proximity sensors based on magnetic phenomena is preferred because they do not require mechanical contact with the moving part. However, the examples given do not exclude the possibility of using other sensors, for example, optical, generator, magneto-reed, photoelectronic, etc.

To be able to diagnose axlebox units with cassette bearings, the stand is equipped with a set of adapters 27 (see Fig. 11) placed on supports 3 for axleboxes, and a mechanism for loading the axlebox bearing in the axial direction with a hydraulic system for creating a load (not shown in the drawings).

The base 1 can be provided with places for placing the receiver and the hydraulic station, as well as elements for fixing the upper position of the positioning platform.

The drive control unit 12 and the measuring device 11 associated with it are software and hardware units made on the basis of electronic computing technology using known methods. At the same time, the functionality of the blocks is provided by the corresponding software.

The measuring device 11, using a two-way data bus connecting them, interacts with the drive control unit 12 and automatically controls the diagnostic process, in accordance with the measurement algorithm embedded in it.

To be able to control the stand and visualize the results of diagnostics, the measuring device 11 is equipped with a display with a touch panel or a keyboard, a printer for the possibility of printing diagnostic results, and a communication unit for the possibility of transmitting data to an external device.

All these blocks, placed in one housing 13, form a stand control panel.

The stand works as follows.

In the initial state, the positioning platform 6 is raised, the rails 14 are located on the same level with the rails of the tramline 2 (see Fig. 1). The wheel pair 28 to be diagnosed rolls onto platform 6.

When moving from the technological track 2 to the section of the track of the positioning platform 6, the wheels of the wheelset 28 fall into the zone of action of the guides 15, which act with their working surface 19 on the side surface 29 of the corresponding wheel and ensure the alignment of the position of the center of the wheelset relative to the longitudinal axis 30 of the rail track of the stand (ideally coinciding with the axis of the tramline).

To facilitate the entry of the wheel into the area of action of the guide 15, the end sections 31 of the surface 19 are bent at a certain angle.

The wheel pair 28 installed on the platform 6 has a strictly defined symmetrical position relative to the longitudinal axis 30, which ensures high accuracy of the location of the wheels and axle boxes relative to the functional equipment of the stand.

After setting the wheel pair 28 to the diagnostic position, the positioning platform 6 smoothly lowers, maintaining its horizontal position, while the axle boxes 32 of the wheel pair 28 are placed in the cradles of the supports 3. (see Fig. 3).

Full lowering of the positioning platform 6 is controlled by sensors 25, which transmit a signal to the drive control unit 12. The presence of the axle boxes 32 on the supports 3 is controlled by sensors 26, the signal from which also enters the drive control unit 12. The combination of the mentioned signals is used to enable the operation of the pneumatic cylinders 5 to move the grippers 4.

Due to the high accuracy and symmetry of the position of the wheels and axleboxes relative to the functional equipment of the stand, each grip 4, when raised, freely enters between the ebb-limiters on the axlebox body, which ensures its reliable fixation and stability during the diagnostic process.

The movement of each gripper 4 is monitored by sensors 24 located on the pneumatic cylinders 5. After receiving signals from them about the completion and correctness of the operation, the block 11 through the block 12 sends a signal to the drive cylinders 22, which bring the friction rollers 7 to the wheels and press them against the inner side surface of the wheels. After receiving confirmation signals from the sensors 24 placed on the pneumatic cylinders 22, the electric motor 8 is turned on and the wheelset is untwisted, while the speed is controlled by the speed sensor 33 (see Fig. 3).

The rotational speed of the wheelset is automatically controlled by the electronic unit 11 using a frequency converter and brought to the nominal value. Indication of the rotational speed of the wheelset can be displayed on the control panel display.

After the rotation speed reaches the set value, the vibration sensors 10 are brought through the technological holes 21 of the supports 3 and measurements are taken. Due to the accuracy and repeatability of the location of the wheelset on the stand, the vibration sensor is brought to the same point of the axle box where the measurement is performed, i.e. the repeatability of diagnostic conditions is ensured, which contributes to an increase in the reliability of its results.

The supply and retraction of the vibration transducers 10 is controlled by the extreme position sensors 24 located on the pneumatic cylinders 20.

After completion of the measurements, the measuring device 11 sends a command to stop the wheelset, carried out by the method of dynamic braking by the electric motor.

After a complete stop of the wheelset, the rollers 7 are retracted, the grippers 4 are retracted, the positioning platform 6 is raised and the vibration sensors 10 are lowered, while the operation of each mechanism is controlled by the corresponding sensors. The wheel pair 28, raised on the same level with the rails of the technological track, is pushed out of the working position by the pusher 9.

After ejecting the diagnosed wheelset, the process is repeated with a new wheelset.

The use of sensors for feedback between the drive mechanisms and the drive control unit 12 creates the conditions for the stand to work in automatic mode, in accordance with the program embedded in the device 11.

In the automatic mode of operation, the operator gives only the initial and final commands: the “start measurements” command and the “push the wheelset” command at the end of the diagnostic process.

The possibility of automating the diagnostic process makes it possible to eliminate the influence of the human factor, which also contributes to improving the reliability of the stand and the reliability of the results obtained.

The proposed stand provides an automated process for diagnosing bearings of axleboxes with cylindrical roller, double and cassette bearings with the issuance of results in the form of "Good / Rejected" indicating a specific type of defect and automatically saving the results to the stand database, generating reports on the results of diagnosing and generating summary reports for a specified period; transferring the results of diagnosing wheel sets to the automated control system of the wagon repair company, while software tracking the repeatability of measurement results is provided, which excludes the possibility of entering the same diagnostic information (from one wheel set) into the database under different numbers.

Claims (13)

1. Stand for vibration diagnostics of axlebox units of wheel pairs of rolling stock, containing a base recessed relative to the technological rail track, supports for axleboxes placed on it, drive clamps for fixing the axle box, a positioning platform installed with the possibility of vertical movement with a section of rail track, corresponding to a gap in the technological rail track, a wheel pair rotation means in the form of rollers connected with a drive for their rotation and movement, vibration transducers associated with a measuring device, and a drive control unit, characterized in that the stand is equipped with a device for centering the wheel pair relative to the longitudinal axis of the rail track when rolling, made in the form of guides placed on the positioning platform, and a group of non-contact sensors connected to the drive control unit, including sensors for the presence of axle boxes on the supports and sensors for the extreme positions of the positioning platform, grips and rollers of the rotation means. 2. The stand according to claim 1, characterized in that the guides are installed on the inside of each rail of the rail track section, while each guide is made in the form of a part, including an installation part with holes for fasteners and a working surface orthogonal to it, extended along the corresponding rail, made with the possibility of interaction with the inner disk surface of the corresponding wheel of the wheelset. 3. The stand according to claim 2, characterized in that the guides are installed at the inlet and outlet of the rail track section. 4. Stand according to claim 1, characterized in that the vibration transducers are made with the possibility of automatic approach to the wheelset and control of their extreme positions. 5. Stand according to claim 1, characterized in that it is equipped with a mechanism for ejecting the wheelset from the working position, including a pusher connected to the drive for its movement, and pusher extreme position sensors. 6. Stand according to any one of paragraphs. 1, 4, 5, characterized in that as drives for moving the grippers, rollers of the rotation means, pusher and vibration transducers, piston pneumatic cylinders are used, connected to the pneumatic supply system of the shop through the receiver, while the sensors of the extreme positions of the grippers, rollers, pusher and vibration transducers are used reed sensors of the position of the piston of the pneumatic cylinder. 7. The stand according to claim 1, characterized in that the sensors for the presence of axle box on the support are made in the form of eddy current sensors installed in the holes of the support cradles. 8. Stand according to claim 1, characterized in that the drive for vertical movement of the positioning platform is made in the form of a balloon (bellows) cylinder connected to the pneumatic supply system of the workshop through the receiver, while eddy current sensors are used as sensors for the extreme positions of the positioning platform. 9. Stand according to claim 1, characterized in that the roller rotation drive is made in the form of an electric motor connected to each of the rollers through a differential and an angle transmission mechanism connected to a pneumatic cylinder for moving and pressing the roller to the wheel pair. 10. Stand according to claim 9, characterized in that the electric motor is connected to the drive control unit through a frequency converter, while the speed of the wheelset is monitored by a non-contact speed sensor, the readings of which are visualized. 11. Stand according to claim 1, characterized in that it is equipped with a set of adapters for axlebox units with cassette bearings and a mechanism for loading the axlebox bearing in the axial direction with a hydraulic system for creating a load. 12. Stand according to claim 1, characterized in that the grips are made in the form of L-shaped rotary elements. 13. Stand according to claim 1, characterized in that there are elements for fixing the upper position of the positioning platform.

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