RU56611U1 - DIAGNOSTIC SYSTEM OF MECHANISMS ОМСД-01 (02) - Google Patents

Abstract

The utility model relates to railway transport and can be used to detect defects (malfunctions) in the wheel-motor blocks of rolling stock locomotives by measuring vibro-acoustic signals and analyzing them using computer technology. The diagnostic system of mechanisms includes a diagnostic stand for axle box bearings, a diagnostic stand for traction engines, a diagnostic stand for a wheel-motor block (KMB), a diagnostic stand for a KMB under a locomotive for sequential and comprehensive diagnostics of the mentioned units. As a result, the quality of diagnostics of the locomotive wheel-motor unit is improved.

Description

The utility model relates to railway transport and can be used to detect defects (malfunctions) in the wheel-motor blocks of rolling stock locomotives by measuring vibro-acoustic signals and analyzing them using computer technology.

The problem of creating technical means for diagnosing bearing assemblies in the operation and repair of locomotives and freight cars in railway transport has always been quite relevant. Floor heating control devices for axlebox assemblies (PONAB, Disk-2, KTSM, Lozinsky S.N., Alekseev A.G., Karpenko P.N. Equipment for automatic detection of overheated axleboxes in trains. - M.: Transport, 1978, p. 16-19, 23-30) malfunctions of traction rolling stock bearings are not reliably detected due to the strong interfering effect of regular heating of traction electric motors (TED), the influence of changing external conditions, etc. For this reason, the assistants to the parking lots are obligated to touch the “back of the hand” to check the heating temperature of the axle box covers. In the technology of locomotive repair, listening to the operation of the gear transmission with a stethoscope was introduced. A simple medical device experienced repair technicians tried to detect extraneous noise during operation of the gear and bearing assemblies.

Against the background of using a stethoscope and an assistant’s hand as “diagnostic” tools, the introduction of vibro-acoustic devices has become a clearly progressive step. Currently, railway transport uses more than 15 different types of vibroacoustic devices, both domestic and foreign manufacturers.

The most common of them (known) are devices for detecting defects in bearing and gear units of locomotives and freight cars of the Prognoz-1 rolling stock (State Unitary Enterprise Transport Center, Omsk), Vector-2000, and KPA-1V ( JSC VAST, St. Petersburg), Tereshkin L.V., Zelenin I.G., Mechanization and automation of production processes in the repair of passenger cars, M., "Transport", 1974 p.163-165. With all the differences between these devices, they have much in common. Previously, they were used in other industries, including military-industrial complex (MIC). To expand the market, spontaneous attempts were made to adapt them to rolling stock. They, as a rule, use standard methods of processing the frequency spectra of vibroacoustic signals taken from objects and identifying them with reference spectra for specific types of malfunctions.

In addition, the above devices are used for vibration diagnostics of individual nodes of the rolling stock only at certain stages of the repair repair cycle. For example, when repairing locomotives, diagnosis is made only as part of the locomotive, i.e. on the final repair operation. The above vibration diagnostics devices are measuring systems that do not have technological devices (stands) for diagnosing parts and assemblies during the entire technological cycle of rolling stock repair.

Disadvantages: The inability to control the quality of the nodes that make up the mechanism, for example, a wheel-motor block of a locomotive, using unified methods and means (vibration diagnostics).

As a result, an unacceptably low level of reliability of the results is not more than 40-60%, which corresponds to the usual statistical sample. Diagnostic results completely depend on subjective factors - the experience and intuition of the diagnostic engineer. As a result, “predictions” of the type appear: “defect development level of 80% with a probability of 60%”, i.e. complete uncertainty. The same is true in the convergence of the results.

When creating a system of diagnostics of mechanisms ОМСД-01 (02) (single-channel multifunctional diagnostic system), it was necessary to solve the following problems:

- identify with reliability not less than 92% and unequivocally (valid / defective) all unacceptable defects in bearing and gear units, eliminating the influence of the human factor;

- to provide comprehensive diagnostics throughout the entire process chain from the bearing to the wheel-motor block under the locomotive;

- minimize the number of sensors and the time of diagnosis;

- provide the ability to electronically transmit diagnostic information to road or regional centers in real time;

The created single-channel multifunctional diagnostic system - ОМСД-01 (02) fully complies with the stated technical requirements.

The technical result, which the claimed utility model is aimed at, is to improve the quality of diagnostics of the locomotive wheel-motor unit by using 4 stands and a unified system of vibration diagnostics, which allows implementing the method of operational control of assembly operations and diagnosing the bearings and units that they enter at all stages the technological process of assembling wheel-motor blocks (KMB) of locomotives along the entire technological chain from the bearing to the wheel-motor block under the lock motive subject to the unity of measurement methods and tools that improves the quality of their manufacturing and maintenance and improves safety.

The technical task and the technical result achieved by its solution are realized due to the fact that:

The diagnostic system of mechanisms includes a diagnostic stand for axle box bearings, a diagnostic stand for traction engines, a diagnostic stand for a wheel-motor block (KMB), a diagnostic stand for a KMB under a locomotive for sequential and comprehensive diagnostics of the mentioned units.

Besides:

These stands contain vibration acceleration sensors, each of which is connected to an amplifier, the signals from which are fed to a multi-channel analog-to-digital converter (ADC) and then to a computer.

The essence of the claimed utility model is illustrated by the presented graphic materials, where Fig. 1 shows the structural block diagram of the claimed utility model - "Diagnostic system of mechanisms ОМСД-01 (02)", which indicates the following:

1 - diagnostic stand for axle box bearings;

2 - diagnostic stand for traction engines;

3 - diagnostic stand wheel-motor unit (KMB);

4 - stand diagnosis KMB under the locomotive;

5 - multi-channel analog-to-digital converter (ADC);

6 - computer;

and ¹ a ² , a ³ , and ⁴ - vibration acceleration sensors;

b ¹ , b ² , b ³ , b ⁴ - amplifiers.

The claimed system operates as follows.

The axlebox bearing is diagnosed in order to detect mechanical defects of the parts included in it, for which the bearing

it is driven into rotation on stand 1. The vibrations arising from this are converted using the vibration acceleration sensor a ¹ into an electrical signal. The signal from the sensor is fed to the input of the amplifier b ¹ . From the output of the amplifier, the signal is fed to the first input of an analog-to-digital converter (ADC) 5, where it is converted to digital form. From the output of the analog-to-digital converter (ADC), the signal enters the computer 6, where it is processed and analyzed to detect bearing defects.

Suitable bearings are mounted in a traction electric motor (TED), which is driven to rotate on stand 2. The resulting vibrations are converted using the vibration accelerator sensor a ² into an electrical signal. The signal from the sensor is fed to the input of the amplifier b ² . From the output of the amplifier, the signal goes to the second input of the analog-to-digital converter (ADC) 5, where it is converted to digital form. From the output of the analog-to-digital converter (ADC), the signal enters the computer 6, where it is processed and analyzed to identify defects in the traction motor.

Suitable bearings and a traction motor are mounted in a wheel-motor unit (KMB) which is diagnosed to detect assembly and lubrication defects on a stationary stand 3. Vibrations arising from this are converted using the vibration acceleration sensor a ³ into an electrical signal. The signal from the sensor is fed to the input of the amplifier b ³ . From the output of the amplifier, the signal goes to the third input of the analog-to-digital converter (ADC) 5, where it is converted to digital form. From the output of the analog-to-digital converter (ADC), the signal enters the computer 6, where it is processed and analyzed to identify assembly defects and lubrication of the wheel-motor unit (KMB).

A serviceable wheel-motor unit (KMB) is mounted under a locomotive, which is diagnosed to detect assembly and lubrication defects on stand 4. Vibrations arising from this are converted using an acceleration sensor a ⁴ into an electrical signal. Signal with

the sensor goes to the input of the amplifier b ⁴ . From the output of the amplifier, the signal is fed to the fourth input of the analog-to-digital converter (ADC) 5, where it is converted to digital form. From the output of the analog-to-digital converter (ADC), the signal enters the computer 6, where it is processed and analyzed to detect assembly defects and lubrication.

Comparison of consumer properties of known systems and the proposed is shown in the table.

No. p / p Name complex Forecast-1 Vector-2000 complex OMSD-01 system (02) one 2 3 four 5 one Diagnosis (good / marriage) without the participation of the human factor. No, gives recommendations on a commission decision No, gives recommendations on a commission decision Unambiguously valid / defective 2 Information transfer via Internet communication channels to a single diagnostic center (hub, road, Russian Railways) for accumulation and development of a forecast of the remaining resource. No No Yes 3 The number of sensors for the diagnosis of KMB, units 6 6 2 four Diagnosis time of an electric locomotive, minutes. 118 72 twenty 5 Permissible deviations of the object’s rotation frequency from the nominal,%. one one 10 6 Qualification of specialists for working with systems. engineer engineer operator 7 Reliability of defect detection according to the actual data of long-term measurements,%. 65 62 not less than 92 8 Probability of false positives up to 65% up to 65% no more than 3% 9 Probability of missing a defect 32% (for individual depots up to 70%) 32% (for individual depots up to 70%) no more than 2%

The key element of the ОMSD-01 (02) system is the reliable determination of the threshold value for each defect. Achieving and even exceeding this parameter is a necessary and sufficient condition for an unambiguous rejection of the unit with an indication of the reason.

Comparing the diagnostic parameters with the threshold values for each malfunction during diagnosis, the depot not only makes a forecast regarding the further operation of each unit, but also plans to repair the locomotives taking into account the predicted resource.

Through the use of modern methods of mathematical processing of information taken, integrated integrated assessment of threshold values for each defect, the latest software, it was possible with one sensor (the second - control) to provide reliable (at least 92%) and unambiguous (valid / defective) diagnosis of bearing and gear units locomotive rolling stock.

Thus, the entire technological chain of repair of wheel-motor blocks of locomotives is controlled.

Claims (2)

1. Diagnostic complex for diagnosing a wheel-motor block of locomotive rolling stock, characterized in that it contains a diagnostic stand for axlebox bearings, a diagnostic stand for traction engines, a diagnostic stand for wheel-motor block (KMB), a diagnostic stand for KMB under the locomotive for sequential and comprehensive diagnostics of the aforementioned nodes. 2. The diagnostic complex according to claim 1, characterized in that said stands contain vibration acceleration sensors, each of which is connected to an amplifier, the signals from which are fed to a multi-channel analog-to-digital converter (ADC) and then to a computer.