RU75048U1 - DIAGNOSTIC SYSTEM FOR A WHEEL PAIR OF A PASSENGER WAGON WITH A VISUALIZATION OF A DEFECT - Google Patents

Abstract

1. A system for diagnosing a wheelset of a passenger car with a visualization of a defect, comprising a diagnostic station, consisting of a portal, a cabinet for controlling a station for diagnostics, a drive for loading / unloading a wheel pair, axle and wheel scanners, rotary drives for installing a pair of scanners, a contact fluid supply system, and drive control panel; rack diagnostic post, consisting of a system unit, consisting of a housing, an interface module for displacement sensors and an analog-to-digital module with installed software, characterized in that it contains wheel scanners incorporating transducers that implement an acoustic control circuit with ultrasound input from surfaces middle and open sections of the undercut parts of the axle, the inner surfaces of the rims and wheel disks. 2. The system according to claim 1, characterized in that the system unit includes a motion sensor interface module and an analog-to-digital module that manage the diagnostic post during data recording. The system according to claim 1, characterized in that a software package is installed in the system unit that provides processing, storage and visualization of the control results.

Description

The utility model relates to test equipment for ultrasonic non-destructive testing and can be used to detect defects in the axles and wheels of non-motorized carriage wheelsets and determine their location.

A well-known stand for ultrasonic testing of wheelsets (description to the patent of the Russian Federation No. 2243532, class C 27 G01M 17/10, 05/28/2001), containing a fixed base with supports for axle boxes of the test wheelset, a drive with a friction roller, located with the possibility interactions with the side surface of the wheel of the tested wheelset, two immersion baths, a lifting and turning device for lifting and turning the wheelset.

The disadvantages of the known stand should include the fact that it carries out control of the wheels only, without axle control. In addition, it is not possible to control the axles with the gear drive the generator from the middle part.

The closest analogue is an automated installation for flaw detection of wheel sets of wagons (description to the patent of the Russian Federation No. 2289128, class G01N 29/04, 07/07/2005), comprising a wheel pair feed device with a reversal mechanism, a control zone cleaning device, a rotation device wheelsets, a diagnostic tool consisting of a computing unit, a preliminary information processing unit and an amplifier unit, a control panel and a carriage for placing ultrasonic transducers.

The disadvantage of this installation is the impossibility of monitoring wheelsets with non-turned wheels, a generator drive gearbox, unmounted axle box or inner bearing rings, brake discs, detecting defects in the pre-access parts of the axle and their fillets, and the internal parts of the access part, the need to turn the wheelset in the process control, lack of control of the axle on the soundability and accessory zones of the wheels, low sensitivity of control, poor visibility desired control results.

The technical result consists in increasing the reliability of detection and accuracy of measuring the coordinates of defects, reducing the number of cases of rejection, there is no need to use the surfaces of the necks to enter ultrasound and turning the wheelset in the process of monitoring, using water as a contact liquid; less control time, providing the ability to control wheelsets in the presence of various equipment: axle box, inner rings of bearings, generator drive gearbox, brake discs; ensuring control over the entire volume of the axis, rims, flanges and wheel disks, including the near and frontal zones; visualization of the results of the control in the form of a schematic visualization of defects in a three-dimensional image of the wheelset with the possibility of printing and storing the control protocol with the coordinates of defects in the database.

The technical result is achieved by the fact that the composition of the diagnostic system of a wheelset of a passenger car with visualization of a defect containing a diagnostic post, consisting of a portal, a control cabinet for a diagnostic post, a drive for loading / unloading a wheelset, a drive for rotating a wheelset, electric drives for installing scanners, a contact feed system fluid and drive control panel, introduced a movable axis scanner, fixed axis scanners, wheel scanners, incorporating acoustic transducers a control circuit with ultrasound input from the surfaces of the middle and open sections of the axle axle parts, the inner surfaces of the rims and wheel disks, into the system block of the diagnostic post rack, consisting of a housing, a displacement sensors interface module, a monitor, a keyboard, a printer, and an uninterruptible power supply, a package is installed programs that manage the post of diagnostics, processing, storage and visualization of the results of control.

Figure 1 shows a General diagram of a diagnostic system for a wheelset of a passenger car.

Figure 2 shows an embodiment of a diagnostic post.

Figure 3 shows an embodiment of the rack diagnostic post.

Figure 4 shows an embodiment of a system unit.

The system contains a diagnostic post 1, designed to accommodate the test object (wheelset) and monitoring, a diagnostic post stand 2, to control the control process, and a remote control 3, designed to control the electric motors of the vertical and horizontal drives of the scanners.

The diagnostic post includes an installation stand 4, on which a pair of wheels is mounted 5. The wheels are mounted on two shafts, one of which is a drive shaft that provides rotation of the wheelset. 6 indicates ultrasonic transducers.

The transducers generate ultrasonic vibrations and receive reflected echoes. Scanners 7 and 8 provide scanning by the transducers during the control process and include clamps, which are hinged mechanisms for fixing the transducers 6, ensuring reliable contact between the transducers and the control object. A movable axis 8 scanner located above the middle of the wheel pair axis moves the transducers along the axis along the axis and is made on the basis of a horizontally moving drive, for example, a stepper motor, the control signals of which are generated by the scanner control unit 11. Side axle scanners located near the wheel hubs, and wheel scanners 9 are fixed motionless.

To install the converters on a pair of wheels, a movable axis 8 scanner and wheel scanners 9 include drives that provide vertical feed. Wheel scanners also include a horizontal feed drive, which provides converters to the inner faces of the rims and the inner surfaces of the wheel disks.

Power is supplied to the drives through the control unit of the diagnostic station 12. The buttons for controlling the drives are located on the remote control 3, which is connected to the block 12 of the diagnostic station 1.

The diagnostic station also includes a wheel pair loading drive 16, designed to load a wheel pair for monitoring and unloading it after monitoring.

The transducers 6 are connected via a transceiver path to the analog-to-digital module 18 through the switching unit 10. Unit 10, upon the command of the analog-digital module 18, switches the generated ultrasonic signal to the given transducers 6. From the transducers 6, the received signal through the switching unit 8 is fed back to the analog digital module 18.

Block 13 is designed to supply contact liquid (water) to the contact zone of the transducers with the studied object to ensure acoustic contact. The block contains:

1. circulation pump;

2. feed tubes;

3. straight-through solenoid valves of direct action, designed to block the supply of contact liquid under the currently unused groups of converters.

The drive 15 is based on a step module. It is designed to rotate the test object (wheelset) around its axis in the control process.

The angular displacement transducer 14 provides readout, conversion to a digital code and transmission to the analog-digital module 18 of the position of the wheelset during rotation relative to the zero position specified by the zero position sensor.

The diagnostic post 1 contains a computer 17 and an analog-to-digital module 18 (FIG. 3). The computer controls the control process and contains the following elements (Figure 4):

1. system unit 19;

2. monitor 20;

3. the keyboard 23;

4. printer 22;

5. uninterruptible power supply 21.

A preferred circuit of this block is shown in FIG. 4.

The block of the analog-to-digital module 18 performs the following functions:

1. amplification of echo signals coming from the switching unit, converting them into digital form, digital processing and storing in the buffer memory for subsequent data transfer to a PC,

2. the formation of the probe signal in the form of a bipolar pulse with adjustable duration and amplitude,

3. the formation of commands for controlling the drive of the movable axis scanner,

4. the formation of commands to control the preliminary amplification and switching channels of the switching unit 8,

5. receiving and transmitting commands over a serial channel, in accordance with the exchange protocol defined by the RS-422 standard.

The device operates as follows. A pair of wheels 5 with a loading drive of a pair of wheels 16 is installed on an installation stand 4. In the presence of various equipment on the middle part of the axis of the wheelset (brake disks or a gearbox of the drive of the generator from the middle part of the axis), scanners 7 and 9 are brought into operation, and in case of monitoring the wheels pairs with the free middle part of the axis — scanners 8 and 9. The contact fluid supply unit 13 and the wheel pair rotation device 15 are turned on. The data recording process is carried out — converters 6 connected through

the switch 10 to the analog-to-digital module 18, alternately emit and receive ultrasonic pulses.

In the control using the movable scanner of axis 8, the transducers scan both along the axis by moving the scanner and around the circumference by rotating the wheelset from the surface of the middle part of the axis. When monitoring the axis using fixed scanners 7, scanning is carried out only around the circumference of the surface of the approach and / or middle part of the axis.

The axis control is carried out using eight transducers in the case of using a movable scanner 8 or using twelve transducers (six in each scanner) in the case of using stationary scanners 7. The transducers are located symmetrically relative to the middle of the axis. Each transducer monitors a specific axis area. The transducers emit and receive shear waves at a frequency of 2.5 MHz and operate in a range of input angles of 15-72 degrees.

The wheels are scanned by scanners 9 from the inner surfaces of the rim and disk. Scanning by converters is provided by rotation of the wheelset. The transducers emit and receive transverse and longitudinal waves at a frequency of 2.5 MHz and operate in a range of input angles of 0-50 degrees.

After the data registration is completed, the process of automatic processing of the registered data is carried out. During processing, the type of wheelset is first determined, then defects in the axle and wheels are detected. In case of detection of defects, a three-dimensional image of the wheelset is automatically generated, on which defects in the axle and defective areas of the wheels are schematically displayed, and a control protocol.

Claims (3)

1. A system for diagnosing a wheelset of a passenger car with a visualization of a defect, comprising a diagnostic station, consisting of a portal, a cabinet for controlling a station for diagnostics, a drive for loading / unloading a wheel pair, axle and wheel scanners, rotary drives for installing a pair of scanners, a contact fluid supply system, and drive control panel; rack diagnostic station, consisting of a system unit, consisting of a housing, a motion sensor interface module and an analog-to-digital module with installed software, characterized in that it contains wheel scanners incorporating transducers that implement an acoustic control circuit with ultrasound input from surfaces middle and open sections of the under-axle parts, inner surfaces of rims and wheel disks. 2. The system according to claim 1, characterized in that as part of the system unit there is a motion sensor interface module and an analog-to-digital module that manage the diagnostic post during data recording. 3. The system according to claim 1, characterized in that a software package is installed in the system unit that provides processing, storage and visual representation of the control results.