CN103017645B - Standard specimen relative method detects adapter equipment automatically - Google Patents
Standard specimen relative method detects adapter equipment automatically Download PDFInfo
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- CN103017645B CN103017645B CN201210469927.0A CN201210469927A CN103017645B CN 103017645 B CN103017645 B CN 103017645B CN 201210469927 A CN201210469927 A CN 201210469927A CN 103017645 B CN103017645 B CN 103017645B
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Abstract
This adapter automatic checkout equipment relates to railway freight-car application technology equipment, is mainly used in the automatic detection of car repair in depot to bogie adapter, replaces existing manual detection method.Solve model to detect that the manpower consumption brought is large, efficiency is low, of poor qualityly cannot record the problems such as Detection Information, this art situation of radical change, eliminates safe hidden trouble.The present invention adopts the standard specimen relative method detection technique of innovation, detects adapter abrasion value; Adopt constant chord high measurement arc diameter technology, detect saddle face circular arc abrasion value; Adopt feeler detection technique and intelligent clamp equivalence indirect measurement method, the detection module that exploitation is novel, solution adapter is complex-shaped, narrow space etc. measures a difficult problem; Use the rotation of first air inlet pressure, line slideway exploitation detection module three dimensions adjustment detent mechanism, solve and applicability needs are detected to various adapter; Adopt microcomputer and PLC to jointly control, exploitation dedicated test software, solves the technical barrier of railway long-standing problem.
Description
Technical field
The present invention relates to a kind of for freight train loader saddle utilization overhaul, is automatically detect adapter Apparatus and method for the standard specimen relative method that various adapter abrasion value carries out automatically detecting.
Technical background
Adapter is the vitals of railway goods train bogie, is arranged between freight car wheel set rolling bearing and truck sideframe pedestal, bears the effect of freight car wheel set bearing seat.The Inner arc saddle face of adapter is closely connected to rolling bearing with wheel, and end face and side frame guide lower plane close contact mainly bear and communicate wheel heavy load and Wheel/rail shock load; Between the medial surface of adapter drawing strickle guide and side frame guide corresponding surface, keep rational gap, the hunting produced when running suppressing vehicle high-speed has good effect, also can meet bogie and rotate requirement flexibly when curve motion.The workplace of adapter has adapter to support end face, bearing circle arc saddle face and bearing shoulder block inner ring surface, drawing strickle guide shelves limit medial surface, drawing strickle guide bottom surface, above-mentioned workplace is bearing load axle weight, wheel-rail impact and oscillating load effect in vehicle operating, the each workplace of adapter produces phase mutual friction with side frame guide corresponding surface, maintain the dynamic performance of bogie and the normal operation of vehicle, each workplace of adapter also produces the abrasion that work accordingly simultaneously.According to design and safety operating requirement, the Ministry of Railways assigns " lorry maintenance procedure ", and the maximum abrasion value to each workplace of adapter proposes clear and definite bound requirements, detects above-mentioned position when car inspection and repair, carries out repairing or changing when exceeding prescribed limit.
Current national lorry maintenance still adopts manual model detection method, and corresponding position adopts the measurement instruments such as different clamp, gauge and inspection chi, and often kind of model adapter has a set of special measuring tool.Current National railway freight-car recoverable amount about 600,000, the lorry that after annual utilization, the section of needs is repaiied is about hundreds of thousands, and each car is equipped with 8 adapters, annual adapter maintenance total amount about more than 300 ten thousand.Every part is about 18kg, manual upset detect and carrying for several times, work numerous and diverse, do not have metrical information record by model range estimation, Detection job is low, make maintenance and the car assembling that falls without according to complying with, become the bottleneck that vehicle safety uses modern management; The keeping of various gauge, working service and regularly check and correction etc. are also very complicated.In a word, manual detection efficiency is low, and labour intensity is large, and cost is high; Sometimes make detection operation become a mere formality, cause the hidden danger of safety operating.
Railway leading department and technology exploration and test are carried out to exploitation adapter checkout equipment about professional technique department in recent years:
1. disclosed in May, 2002, patent name is " detection equipment for freight train loader saddle ", patent No. 01259363(Tangshan), brief introduction mechanical part adopts hydraulic system, rotary teeth disc mechanism etc., detects station and is provided with stepper motor wheel measuring bar and hydraulic pressure slip test rod.This statutory status: in Cessation of patent right for not paying annual fees on October 08th, 2003;
2. " Intelligent detector for bearing saddle of goods train " patent No. 02247984 disclosed in August, 2003, (Lanzhou Xinpu Photoelectromechanical Integrated Technology Co., Ltd.) brief introduction mechanical part adopts cylinder-driven, and testing agency is provided with all directions measuring head and displacement transducer etc.Statutory status: in Cessation of patent right for not paying annual fees on October 17th, 2007;
3. in August, 2004 publication title " bearing saddle dimension inspector " patent No. CN2632627, patentee: Lianyun Harbour Jiu Zhou Power control Equipment Co., Ltd, brief introduction adopts line production, workpiece is longitudinal stepping on streamline, testing is separated into two platform positions to carry out, PLC is adopted to control, MICROCOMPUTER PROCESSING displacement transducer testing result etc.; 2005 " rail truck " the 05th the phase deliver " CZA-II type adapter automatic detecting machine ", write based on preceding paragraph " bearing saddle dimension inspector " patent content, this system requirements workpiece is located respectively two monitor station positions and is added positioning difficulty, testing process sensor assembly frequently moves up and down and also has impact to the repeatable accuracy of detection, and the program does not have successful field conduct use case;
4. adapter detects and also causes the outer other industry scientific and technical personnel of railway to note, 03rd phase in 2008 " industrial instrument and automation equipment " has delivered " train adapter detects the development of sorting system automatically ", propose to adopt displacement transducer to make contact sonde to measure, image data calculation process etc. is responsible for ADAM5510 industrial computer, but not to the detailed construction design content of adapter detection system.
5. the 03rd phase in 2003 " railway technology innovation " delivers " application of Optical Non contact Measurement Technology in adapter detects automatically " and the 02nd phase " China Mechanical Engineering " in 2005 delivers papers such as " the automatic detect delay of truck carrying saddle vision ", and in 2005 by department scientific research personnel such as University Of Tianjin's Precision Inspection and instrument state key researchs department, explore and utilize the ray structure illumination of several groups of laser projecting apparatuss to penetrate tested surface formation image, by several groups of stereoscopic vision optical sensors, image is gathered again, i.e. measuring three-dimensional morphology technology, detect delay is carried out to adapter abrasion, and develop video vision detection components and corresponding software etc., adapter is detected and develops demonstration and experimental study, but it is large to there is optical sensor system volume, require high to ambient brightness, be difficult to reach accuracy of detection requirement, adopt Software for Design compensation etc. again, add technical difficulty and equipment cost.All this kind, nearly 1,000,000 yuan of some unit manufacturing expenses costs, though give to expect and concern through each side, all could not reach the objective effect of on-the-spot practical application.
6. applicant was once the automatic checkout equipment that the depot design exploitation of east, Chengdu is used for " turning 8A " type adapter in 2005, adopted standard sample relative method to detect adapter first; Measuring sonde adopts current vortex non-contact sensor composition detection module, MICROCOMPUTER PROCESSING testing result; Tentatively solve the three-dimensional workplace abrasion value of this type adapter and detect a difficult problem, obtain initial success and pay on probation.But be difficult to adjustment owing to there is non-contact sensor preset clearance; Sensor needs to carry out compensation data to different materials current vortex, and testing product model is single to be waited not enough, has failed exploitation of following up further.
China Railway Freight heavy duty in recent years, speed-raising are rapidly developed, and speed is that the Heavy-haul Freight speed Train Development of the heavy 25t of the speed-up railway freight of 120km/h and axle is rapid, has become the lorry main force and developing direction.In the task that the whole nation each lorry utilization overhaul section is born, turning K2 type, turn K4 type and turning K5 type, turn K6 type adapter and occupied maintenance leading position based on E axle based on D axle, proposes higher technical requirement to the exploitation of novel bearing saddle checkout equipment.And at present, on-the-spot at lorry utilization overhaul, that detects adapter falls behind equipment and mode, increasing with the service technique gap of the miscellaneous part in existing MTU depot bogie repair assembly line, become the weak link of lorry maintenance.
Summary of the invention
This adapter automatic checkout equipment object of invention is that the general standard specimen relative method detected for existing various adapter detects adapter equipment automatically.Adapter its essence is the open rolling bearing pedestal of freight car wheel set, and bear and transmit side frame guide and the various load of bearing, its surface of contact certainly leads to wearing and tearing; Through " Railway Freight Car Repair code " that design and devdlop practice summary is formulated, the reasonable wear and tear amount limit at each position of clear stipulaties, the value that goes beyond the limit will impact normal utilization.But because of the complex-shaped workplace dispersion of adapter, dimensional measurement difficulty is large, adds again adapter kind many, different, not yet develops applicable checkout equipment so far.
Development test Problems existing had in the past: demarcating the prototype reference dimension of each workplace abrasion value of detected workpiece has disappearance, does not provide substantive standard sample block and adopts the detection method contrasted, and is difficult to realize the detection to abrasion value; Select to combine closely with detection process flow in the Workpiece fixing mode adopted and benchmark position, positioning precision is not enough; Testing agency and detection method single, do not carry out the exploitation of effective detection technique for privileged sites and innovation structure is designed and developed, the narrow and small complex-shaped difficult problem of workpiece could not be solved; To the type selecting of detecting sensor with to install and use research dark, accuracy of detection is inadequate; Workpiece conveying mechanism kinematic accuracy is low, causes repetitive positioning accuracy low; The position adjustments of testing agency is poor, and detection kind is single.All problems are all solved in this project above.
The technical solution used in the present invention is:
Freight train loader saddle automatic checkout equipment, it comprises: respectively detect position dimensional data for equipment to standard specimen and carry out acquisition process and the standard sample of the accurate mach various adapter of the process of memory retention; Described equipment also comprises:
-workpiece feeding, location and detection conveying mechanism; Workpiece is delivered to equipment Inspection position, rely on workpiece conduct oneself with dignity material loading locate;
-complete workpiece secondary location center module; For jacking workpiece, before and after center module, " wedge locating block " is installed, center module upper water safety dress " constant chord locating piece ", at center module uphill process, the left and right crest line of " constant chord locating piece " and workpiece saddle face arc contact complete second time and locate, and the workpiece jacking detecting position is sent into saddle face pick-up unit, drawing strickle guide pick-up unit and end face pick-up unit and carried out comprehensive detection by center module;
-microprocessor system; Each road detecting sensor sampled data is processed, automatically carries out being separated defective products and qualified workpiece according to testing result;
-existing each model adapter is detected automatically and the drawing strickle guide detection module position adjusting mechanism established.
Further: described workpiece feeding, location and detection conveying mechanism, adopt the Workpiece fixing conveying sliding table that cylinder and ball line slideway form, slide unit is the rectangular frame-shaped construction of steel, sky shape is made in centre, is the station conveying slot milling before and after " center module " jacking location, detection and slide unit.
Further: described equipment comprises pneumatic drive system further, comprise by the integrated Pneumatic control module formed of solenoid directional control valve, the action of each execution cylinder is driven by working routine requirement, each cylinder two ends are provided with attached Magnetic Sensor, feedback cylinder location signal, realize closed-loop automatic control requirement, the import and export of each cylinder is provided with one-way throttle valve, can make operation switching motion exactly, the motion of cylinder-driven all adopts ball slider line slideway.
Further: described saddle face pick-up unit is takeed on testing agency by An Mian circular-arc detection mechanism and bearing guard and formed, be arranged on two three axle cylinders of synchronization lifting, Dang Jian testing agency adopts two groups of symmetrical equiarm long lever mechanisms of installing, lever upper outside and adapter shelves are takeed on medial surface and are contacted, lever bottom respectively with sensor contacts, sensor is arranged in center module, and its sensor mask line guides transmitter into by conduit.
Further: described drawing strickle guide pick-up unit is provided with and detects intelligent clamp module, every side of clamp adopts equiarm right angle bending leverage, lever one end is contacted with workpiece wearing surface by cantilever bearings roller, the other end is by feeler acquisition testing face physical size, the full swing angle of lever work is all less than ± and 4 °, lever two ends measurement point perpendicular displacement length is equal, ensures displacement transducer image data true and accurate.
Further: described drawing strickle guide detection module position adjusting mechanism is symmetrical set, cylinder, ball slider, line slide rail is adopted to form three layers of three dimensions adjusting mechanism, the adjustment to different model adapter drawing strickle guide rib (longitudinal direction), drawing strickle guide bottom surface (transverse direction) and drawing strickle guide height and position has been controlled by industrial computer, the each detection module completing six detecting sensor compositions is located in three-dimensional position, realizes detecting versatility functional requirement.
Further: the position that the bascule mechanism of described clamp contacts with displacement transducer contact is provided with an adjustable detection round platform, round table surface is parallel with lever shaft, vertical with sensor displacement direction, detect round platform afterbody mounting rod and be provided with screw thread, be screwed into lever one end, and be locked with jam nut.
Beneficial effect of the present invention:
-adopt adapter standard specimen relative method detection technique, directly obtain true testing result.
-constant chord high measurement saddle face diameter technique, simplify arc measuring mechanism, measuring accuracy reaches technical regulation requirement;
-developing intellectual resource caliper measurements technology, in conjunction with the unique testing agency of actual invention, solves the narrow and small technical barrier of detection space.
-by workpiece twice location technology and jacking centralized detecting organic composition one, innovation Workpiece fixing conveying new method, determines workpiece crossfeed direction, adopts accurate conveying sliding table locate and send mode to, the corresponding gordian techniquies such as exploitation automatic manipulator discharging, realize line production.Adopt high precision line slideway and advanced pneumatic system to combine, workpiece is accurately located, accurately carries, a jack-up completes the testing of whole workplace abrasion value.
-adopt contact displacement sensor, the leverage of design equal arms, carry out dynamic no-interval measurement, testing result can reflect the virtual condition of workpiece, improves Detection job.
-exploitation detects position adjustment, and according to the detection status requirement of different model adapter, the detection space of tens road transducer detecting mechanism composition three-dimensional layouts, realizes a tractor serves several purposes.
This equipment has good adaptability, reliability and versatility, and mechanism stable is reasonable, measuring accurately, can increase substantially adapter detection technique level, is a brand-new advanced detection technique equipment, can the current detection technique looks of radical change, solve the technical barrier of railway long-standing problem.The raising of adapter Detection job, can give full play to adapter using function, to guaranteeing that Freight Transport has vital role safely.The machine operates according to 2 people, every part sense cycle about 50 seconds, and capacity of equipment per tour can detect about 50 lorries.The present invention has good social benefit.
Accompanying drawing explanation
Fig. 1 is a kind of adapter (turning K2 type) standard sample figure, makes by equipment and technology standard;
Fig. 2 is equipment side schematic view, and arrow indication is process flow direction; Its piece number is described as follows table:
Piece number | Title | Explanation |
1 | Preliminary examination platform | To preliminary examination before workpiece sensing and reorganize and outfit |
2 | Pneumatic hoisting material loading crane | Manual gas valve controls |
3 | Device body worktable | Testing agency's reference for installation parts |
4 | Center module | Centralized detecting parts |
5 | Blanking conveyer | Procedure auto-control |
6 | Workpiece separating mechanism | Automatic malsegregation product part |
7 | Industrial computer system | Control, detection, Output rusults |
Fig. 3 overlooks acquired equipment top view downwards above Fig. 2;
Fig. 4 is the cut-open view at checkout equipment core position intercepted by I-I direction of Fig. 2; Exhibition centre module location centralized detecting and apparatus characteristic situation, select this figure as specification digest accompanying drawing;
Fig. 4 piece number is described as follows table:
Piece number | Title | Explanation |
8 | Detected adapter workpiece | Location and centralized detecting state |
9 | Conveying sliding table | Cross-sectional configuration is illustrated |
10 | Material loading locating piece | |
11 | Synchronization lifting mechanism | Two three axle cylinder rigidity are installed |
12 | Shelves shoulder locating piece | Totally 4 |
13 | Constant chord locating piece | Diagram: fixing chord length 2k=130mm |
14 | Action detecting sensor | |
15 | Shelves shoulder lever detection module | |
16 | Drawing strickle guide detection module | Four groups, six sensors |
17 | End face detecting sensor | |
18 | Transverse shifting slide block | Totally two groups, left and right |
19 | Vertically move slide block | All around be symmetrical arranged |
20 | Height adjusting slider | Totally four groups |
Fig. 5 is the center module structural representation intercepted by II-II direction of Fig. 4; Left and right two parts illustrate the adjusting mechanism situation detected D axle and E axle two type adapter bearing guard shoulder;
Fig. 5 piece number is described as follows:
Piece number | Title | Explanation |
21 | Loose piece | Its mounting means numbers 15 |
22 | A/F pad | Totally 4 |
23 | Detect round platform | Totally 8 |
Fig. 6 is by the A direction view of Fig. 4, observes drawing strickle guide detection module schematic diagram from inside to outside; Represent bell crank preloading condition and equivalent testing agency;
Fig. 6 piece number is described as follows table:
Piece number | Title | Explanation |
24 | Bell crank | Both sides brachium is equal |
25 | Cantilever bearings roller | |
26 | Compress Spring | |
27 | Dog screw |
Fig. 7 is the mathematical functional expression detecting saddle face circular arc: y=x+k
2/ x geometric relationship sketch.Wherein k=65 is constant, and x value is independent variable (fixing action), and numerical value is gathered by displacement transducer; Y value is corresponding saddle face arc diameter, is drawn according to x value and the computing of mathematical functional expression special software by computing machine.
Embodiment
The present embodiment solves a relevant technologies difficult problem:
1. checkout equipment overall plan is designed, adhere to Aulomatizeted Detect and the principle that people-oriented, Workpiece fixing, station are sent to, cluster sampling output detections result and after detecting the key link such as automatic blanking conveying, defective products isolation complete by auto-programming, minimizing human intervention; Defective products workpiece after being separated with detection the preliminary examination before workpiece feeding, needs by the process of operator's necessity, to ensure the normal management of equipment input and output material.
2. equipment advance and applicability requirement is adhered to, by the comparative analysis to different schemes, be optimized and innovative design, adhere to modular design principle, sensor measurement assembly module is designed respectively to saddle face and shoulder block position, drawing strickle guide and end face, solve sensor install and adjust problem, the requirement changed check point three-dimensional space position when meeting workpiece model change, solves the narrow and small mechanical interferences problem that may occur of detection space.
3. this equipment adopts and automatically detects the production line mode of production, and device action adopts programmed control pneumatic actuator system and straight line precise guide rail mechanism, reaches mechanism kinematic accurately and stability requirement; Adopt PLC electrically and industrial computer combined control system, equipment operating is easy, completes cycle detection line production, enhance productivity by working routine.4. detect data processing function perfect, difficult point exploitation dedicated test technology is detected to key position, establishment dedicated test process software; All detection record can be stored, can with the HMIS system group network of host computer, realize information sharing.Detection system sensor adopts anti-interference and that adaptive capacity to environment is strong " differential transformer type feeler ", and transmitter adopts linear transformer and transmission shielding line etc., guarantees data transmission stability; 5. equipment labor aptitude is good, does not have particular/special requirement to operating ambient temperature, humidity, supply voltage AV220 ± 10%, and consumed power is less than 0.5kw; Bleed pressure is used to be greater than 0.5MPa, air consumption about 0.05 cubic metre/per minute.Equipment is provided with photoelectric sensor safety alarm device, the interference preventing workpiece on production line because operation surprisingly produces.Device Host is arranged in facility floor, and industrial computer is installed separately, and equipment surrounding environment cleans, and is undertaken cleaning and removes detect position greasy dirt and burr etc. before workpiece sensing by existing regulation requirement.
The detection technique method that the present invention adopts and utility machine structure main contents are described below:
(1) the detection technique method adopting workpiece and adapter standard sample to contrast: be called for short " relative method " and detect.The standard that adapter detects is according to being the limit of wear that " railway maintenance procedure " specifies, and abrasion value refers to and to determine compared with original product design size, and judges that the qualified, to be added of workpiece is repaiied or scrap three kinds of states according to this, and is separated.This method is the standard sample that employing process is accurately processed, and be called for short standard specimen (Fig. 1), its material is identical with various adapter with shape, and the size detecting position is identical with prototype adapter product design figure correspondingly-sized, but makes precision raising 1-2 level.Equipment is before to workpiece sensing, and first demarcate standard specimen, equipment respectively detects position dimensional data to standard specimen and carries out acquisition process and memory retention; When subsequent workpiece detects, compare computing with the data that standard specimen is demarcated for benchmark, the detection numerical value of each workplace abrasion value of workpiece can be obtained.The superiority of relative method is: one, and directly can obtain the workplace wear loss data required in " railway maintenance procedure ", real result is reliable; Its two, due to standard specimen make precision high, except can detecting each workplace abrasion value, each workplace change in location situation (i.e. Form and position error) can also be detected, provide useful information to control workpiece quality comprehensively; While its three pairs of standard specimens are demarcated, also to equipment state, as confirmed the rational position of sensor probe, its essence is the effect core to equipment state, this point is very necessary.The range of the various sensors that equipment adopts is that reference work surface wear limit is determined, requires to make this range little as far as possible, to ensure that enough accuracy and own dimensions are not excessive, to make detection module miniaturization, prevents mechanical interferences.The position of each sensor probe when the state of demarcation, reserve the range that fully works (abrasion value), to ensure workpiece sensing needs, this work range can in timing signal collection, industrial computer screen display, thus the good working state of the equipment of guarantee.
The prerequisite condition of standard specimen relative method is adopted to have: 1. design determines that various adapter " standard sample " detects the standard size at position.When determining standard specimen corresponding site processing dimension tolerance, female surface size gets plus tolerance value, and male surface gets minus tolerance value, and average error value is less than 5% of limit of wear value, and surface accuracy improves 1-2 grade than originating in design; Standard specimen saddle face circular arc still adopts with bearing " excessively coordinating ", but dimensional accuracy improves a grade.Standard specimen material adopts former adapter material, can ensure Long-Time Service requirement.The detail of design of various adapter standard sample, includes in " adapter checkout equipment technical conditions ", passes through through expert's certification.2. standard specimen must be qualified through the detection of national standard metrological service after making, and opens proof, carry out mark.3. adopt standard specimen relative method to detect, after Workpiece fixing, the detection data of each workplace must be gathered simultaneously, objectively require to arrange accurate detent mechanism, adopt a centralized detecting station, to ensure accuracy of detection requirement.Adopt standard specimen relative method to detect adapter to be proposed by applicant, in east, Chengdu, rolling stock section tried out.
(2) method measuring constant chord height is adopted, detect An Mian garden arc dia abrasion value, in An Mian circular-arc detection mechanism, be provided with fixing chord length locating piece, the contact that high-precision sensor is installed in centre position contacts with measured workpiece arc surface, measure the height of constant chord, after constant chord left and right crest line contacts with saddle face, utilize the slight change of fixing action, saddle face arc diameter numerical value change can be detected, action is represented with variable x, variable y represents detected arc diameter, 2k represents fixing chord length and locating piece two crest line distance (see figure 7)s, according to fixing action formula: x/k=k/ (y-x), then there is mathematical functional expression: y=x+k
2/ x, when x, y get on the occasion of, and it is meaningful as x < k, the method is suitable for the detection to " D type " axletree saddle face (φ 230) and " E type " axletree saddle face (φ 250) abrasion value simultaneously, choose 2k value slightly larger than diameter one half (as 2k=130mm), be suitable for the detection and location requirement to various model adapter.In practical ranges, the increment size of variable y is about the 8-12 of variable x reduced value doubly, and x value is gathered by high-precision sensor, display precision reaches a μm level, the numerical value of y value presses mathematical model by microcomputer calculation process, and compare with " calibration value ", the detection to the face of cylinder, saddle face abrasion value can be completed.
Judge whether the diameter abrasion of saddle face reach the limit value of regulations stipulate, be required to meet two conditions, whether the abrasion of first saddle face are even, after abrasion, saddle face is still arc surface, it two is whether sensor detection display precision is enough, be described below: the first, the former design size in saddle face " D axle " saddle face diameter y=φ 230
+ 0.10 -0.05and " axle E " saddle face diameter y=φ 250
+ 0.10 -0.05adopt " transition fit " (9 class precision) with corresponding wheel set bearing cylindrical, according to bearing working principle, at wheel in operation, bearing inner ring and wheel are " interference fit face " to axletree, must rotate together with axletree; And cylindrical and saddle face " transition fit ", in utilization process, produce pole relatively rotates slowly, and produces even wear in a small amount, and can improve the serviceable life of bearing top circle, this is normal.Regulations stipulate locomotive repair limit is: the abrasion value 0.5mm of saddle face diameter, when close to this abrasion value, be equivalent to saddle face dimensional accuracy and be down to about 12 grades of dimensional accuracies by 9 class precisions, due to outer race and saddle face relative wear amount little, still can keep the uniform contact of arc surface transition fit, therefore saddle face still can keep the geometrical property of circular arc.The second, saddle face displacement transducer selected range is 3mm, and accuracy of detection is 0.1% grade, and its display precision is 0.003mm; As the fixing chord length 2k=130mm of locating piece, if when action x reduces 0.003mm, the increment of saddle face diameter y is about 0.03mm.The limit value of scrapping specified by maintenance procedure is 0.5mm, if it is feasible for leaving 0.05mm synthetic determination error, visible saddle face examine of diameter accuracy value 0.03mm can meet real requirement.
Adopt the high accuracy displacement sensor of small-range, the detection to D axle (φ 230) and the various adapter saddle face of E axle (φ 250) can be met simultaneously.Chord length 2k=130-0.1 is fixed in this case, can meet workpiece and accurately locate needs; Owing to adopting fixing chord length slightly larger than the half of bearing outside diameter, make measured circle cambered surface containing the main support face having covered bearing working roller, this scope circular arc quality is controlled, the contact stress on the bearing roller face of cylinder can be made to be controlled, extend the serviceable life of bearing, thus ensure that the repair quality of adapter.
(3) detection and location of workpiece feeding location, accurately conveying and center module:
1) workpiece conveying and orientation is chosen: adapter drawing strickle guide is positioned at the symmetric position of cylinder axis both sides, saddle face, and drawing strickle guide detection position is many, narrow space, auxiliary body's ability examinations must be set, for avoiding producing mechanical interferences, need by its dispersed placement in workpiece throughput direction both sides, and make throughput direction and adapter both sides drawing strickle guide in vertical state.Determine that the material loading of adapter is put orientation and is thus: left and right drawing strickle guide outward opening is laterally put, and corner level, saddle face down, and the detection faces of drawing strickle guide is vertical with slide unit horizontal location face, throughput direction consistent with adapter cylinder axis (see Fig. 1 vertical view).
2) selecting properly positioning datum: workpiece first time positioning datum, the plane choosing four angle compositions of adapter circular-arc bottom face is supporting surface, processing datum when this face was workpiece manufacture originally, and does not does not substantially wear and tear for non-working surface; To cross the 4 groups of right angle crest lines formed with bearing guard limit arc surface (Fig. 1 φ 210) and anchor ring (the 153+0.2 both sides of Fig. 1) and baseplane, corner again, as horizontal, longitudinal register benchmark, rely on workpiece material loading of having conducted oneself with dignity to locate; Workpiece fixing benchmark is machine work and is formed, and abrasion are less, can ensure material loading Position location accuracy.Preliminary examination platform (Fig. 2 is placed on after being cleared up by workpiece, piece number 1) on, adopt hand operated pneumatic lifting material loading crane (piece number 2), workpiece is hung workpiece conveying sliding table (Fig. 4, piece number 9) above material loading position, workpiece is steadily placed on locating piece (piece number 19) and completes material loading location (first time location); Workpiece conveying sliding table is made up of fixed journey system cylinder and ball line slideway and steel slide unit, slide unit is the frame-shaped construction of accurately processing, square hole-shaped is made in centre, is the station conversion slot milling before and after " center module " (Fig. 2, piece number 4) jacking location of monitor station position and slide unit.Behind workpiece first time location, accurately delivered to above monitor station position by conveying sliding table, make workpiece centre with immediately below jacking to detect " center module " vertical, complete the accurate conveying of workpiece, for the secondary accurate positioning of workpiece is ready;
3) complete when vertically risen by center module in the second time location of workpiece, before and after center module, " wedge locating block " (Fig. 4 is installed, piece number 12), first take on inner side for locating surface with workpiece bearing guard, four wedge shape location are fast in company with center module rising insertion front and back crosspiece shoulder inner side, moving forward and backward of restriction workpiece; Install " constant chord locating piece " (piece number 13) at center module top accurate degree, at center module uphill process, the left and right crest line that this location is fast and saddle face arc contact complete second time and accurately locate.
Accurate detection and localization location is by equipment moving mechanism realization accurately, except employing accurate conveying device, to device body worktable (Fig. 2, piece number 3) and conveying sliding table, center module installation component etc., through Precision Machining and installation, ensure verticality and the levelness accuracy requirement of each three-dimensional motion mechanism and fuselage axis line position, fastening with locating after calibrating indicating instrument.
The Second Positioning System that it is benchmark with bearing saddle face that this positioning system adopts, its advantage is: one, can adapt to the positioning requirements that each model adapter detects.Before and after center module, " loose piece " (Fig. 5 is set, piece number 21) and special " A/F pad " (piece number 22), module is provided with two horizontally-guided axles and retention mechanism, only need adjust installation site inside and outside A/F pad (as about Fig. 5 illustrates), center module shoulder block position width can be changed, (D axle shelves shoulder is apart from 153mm, E axle shelves shoulder apart from 163mm) can realize the general positioning requirements to " D profile shaft " series and " E profile shaft " serial Multiple Type adapter.Its two, saddle face is bearing top circle mating surface, uses middle even wear, can ensure the accuracy that secondary is located.Secondary location makes drawing strickle guide detection faces be in plumbness, for the centralized detecting of " center module " jacking provides condition.When jacking about 1/3 stroke time complete secondary location, workpiece depart from slide unit rely on deadweight be buckled in center module, when module continue rise time enter centralized detecting region, complete whole testing.Centralized detecting includes: saddle face and shoulder block detection system, left and right drawing strickle guide detection system and end face pick-up unit three part.
(4) saddle face and shoulder block detect:
The main component of center module is processed into the hexahedron of hollow, installs constant chord locating piece (piece number 12) above, and center is upwards installed " action detecting sensor " (piece number 14), and complete saddle face circular-arc detection, principle is as aforementioned.Two sides, front and back is symmetrically installed with loose piece (piece number 21) and shelves shoulder lever detection module (piece number 15), annular face contacts inside clamp contact, top and shoulder block, isometric position, lever bottom contacts with sensor contact, the information of equivalent received clamp contact displacement, be called for short " intelligent clamp ", undertake the detection to the abrasion of bearing guard shoulder inner ring surface.Have three sensors in center module inside, its cable has protective conduit in company with center module one lifting, and the aviation plug of cable connects and is connected with the transmitter in mainframe box.Center module bottom is arranged on the top board of two three axle cylinders of synchronization lifting by the supporting plate that is rigidly connected, and forms six pillar synchronization lifting mechanisms (Fig. 4, piece number 11).When module rises to tip position, workpiece conveying sliding table (piece number 9) follow procedure returns to material loading position, prepare next workpiece feeding, the front position of slide unit is in the splicing state of center module, follow procedure time controling after workpiece comprehensive detection terminates, and center module band workpiece together falls, about during 2/3 stroke, workpiece both sides put off on slide unit blanking position, and center module continues to drop to the end, and top departs from workpiece completely; When next workpiece is carried, by the workpiece detected on slide unit, deliver to " going out material level after detection " (see figure 3), by follow-up automatic material blanking mechanism mechanical arm, follow procedure grabbing workpiece is also sent.
Lever lower end and displacement transducer contact be one little " detection round platform " (piece number 23), round table surface is vertical with sensor displacement, detect round platform afterbody mounting rod and make screw thread, be screwed into lever one end, and be locked with jam nut, make round platform position can carry out front and back to regulate in a small amount, solve a difficult problem for sensor installation and fine position.
(5) adapter drawing strickle guide detection system:
1) drawing strickle guide testing agency and detection mode: drawing strickle guide is "] [" opening shape of symmetria bilateralis layout, drawing strickle guide inner space is little, various adapter size is all not identical, and differ greatly, for improving testing agency's stability, drawing strickle guide " detection module " (Fig. 6) is positioned at corresponding position above workpiece drawing strickle guide, wait for that center module is by workpiece jacking, enters in the drawing strickle guide detection system behind location and completes detection (see figure 4).Because detected face is system vertical inner side plane, various workpiece size dispersion is large, inside drawing strickle guide, scope is 79 ~ 170mm, drawing strickle guide bottom surface scope is 181 ~ 309mm, drawing strickle guide height differs about 40mm, and size sensor is large, can not directly detect workplace, special testing agency must be designed, make symmetrical, synchronously adjustable drawing strickle guide testing agency.This drawing strickle guide testing agency is made up of two parts, and one is detection module part, and it two is drawing strickle guide detection module position adjusting mechanism, and two parts are combined closely, the problem such as solve that three dimensions is narrow and small, data collection point is concentrated and adjusting range is large.Drawing strickle guide testing agency is provided with 6 sensors altogether, is responsible for the detection to left and right drawing strickle guide medial surface and two drawing strickle guide bottom surfaces.
2) drawing strickle guide detection module: both sides are provided with symmetrical drawing strickle guide detection module and compound detection module (installing two cover detecting sensors).Each sensor detection module mechanism is made up of cantilever bearings roller (piece number 25) and equal length arm bell crank (piece number 24) and the part such as pressure spring (piece number 26) and dog screw (piece number 27), cantilever rollers is arranged on the sagging one end of bell crank, roller can go deep into contacting with detection faces inside drawing strickle guide, the horizontal level of bell crank is installed and is detected round platform (piece number 23), on round platform, plane contacts with sensor contact, and equivalence accepts the displacement information of roller contact.The drawing strickle guide of corresponding both sides detects bell crank and is in symmetrical horizontal level all the time, forms three altogether to " intelligent clamp " mechanism, detects the abrasion value of left and right drawing strickle guide medial surface abrasion value and drawing strickle guide bottom surface, left and right two respectively.Roller testing agency is positioned at workpiece top position, leaves about 30mm down suction with the workpiece drawing strickle guide top that slide unit is placed, when guaranteeing that workpiece is carried and mechanism do not interfere.Be somebody's turn to do the every while be equiarm bell crank mechanism of " intelligent clamp " mechanism, lever is contacted with workpiece wearing surface by cantilever bearings roller, adopt small-sized rolling bearing structure of contact terminal, can conveniently roll into corresponding detection faces, rolling bearing contact rolls in detected face and contributes to steadily completing testing process, and Compress Spring 26 and stop screw 27 are installed in lever shaft both sides, ensures that two ends check point is closely connected, and prevent pendulum angle excessive, guarantee to detect authenticity and reliability.Workpiece sensing data, compared with standard specimen nominal data, obtain the actual abrasion value of each workplace.The bascule mechanism of above-mentioned intelligent clamp, full swing angle during the work of its lever is all less than ± 4 ° of values, lever arm length can be kept substantially not change, and make lever two ends measurement point perpendicular displacement length substantially equal, ensure the true and accurate of displacement transducer image data.
3) drawing strickle guide detection module position adjusting mechanism: this mechanism is symmetrical set, adopts three layers of three dimensions adjusting mechanism that automatic control cylinder and ball slider line slideway form.Ground floor is symmetrical is provided with horizontal Mutli-station cylinder promotion transverse shifting slide block (Fig. 4, piece number 18), two groups, left and right slide block installs two layers of traversing platen, undertakes the adjustment of measuring position, drawing strickle guide bottom surface, left and right; The second layer is each on transverse moving left and right platen installs former and later two Mutli-station cylinders, promotes to vertically move slide block (piece number 19), slide block is installed vertical shift frame, undertake the adjustment that both sides drawing strickle guide medial surface detects position; Third layer is on left and right totally four vertical shift framves, symmetrical setting height(from bottom) adjusting slider (piece number 20) and height adjusting cylinders, top layer slide block is installed drawing strickle guide detection module (piece number 16), detection different model adapter drawing strickle guide high and low position is adjusted, keeps the adjustment positioning requirements of detection module and different workpieces drawing strickle guide.Above-mentioned three-layer stereo adjust structure, has promoted the adjustment of four groups of detection module three-dimensional space positions by three kinds of 10 cylinders, has realized versatility functional requirement.Ten adjustment cylinders divide three groups automatically to be controlled by solenoid valve, by different workpieces drawing strickle guide size positions, adjust locating piece on a small quantity, can realize location different model drawing strickle guide being detected to position.Whole cylinder is provided with attached Magnetic Sensor, and detection module can be provided in the feedback signal of this detection position, guarantees the steady operation requirement of drawing strickle guide detection system.
(6) adapter end face Abrasion detecting:
The detection of adapter end face abrasion value, carries out to during uppermost position in center module jacking.Above the center module of device Host, be provided with fixing end face detect mounting structure frame, installation three top detecting sensors (piece number 17) on it, the displacement data that sensor reception workpiece end face transmits and standard specimen calibration value contrast, and can determine end face abrasion value and eccentric wear amount.Sensor 30mm effectively detects stroke, can adapt to various workpiece apical side height change requirement.
(7) workpiece automatic material blanking mechanism and separating mechanism:
As aforementioned, when being sent to blanking position by feeding slipway after workpiece sensing, by workpiece blanking conveyer (Fig. 2, piece number 5) workpiece is transported, workpiece is transported to (Fig. 2, piece number 6) top on seperator gantry position by clamp, according to Detection Information, being separated rod for stiring materials can preset material toggling direction, waits for that mechanical arm carries out separating action after putting down workpiece, carries out detections automatically be separated afterwards certified products, reprocessed products and waste product.
Workpiece automatic-separation mechanism and main frame are provided separately, and eliminate the impact of workpiece mask work to the impact of Host Detection, separating mechanism is made up of steel structure frame and pneumatic driving lever.
(8) pneumatic drive mechanisms and control system:
The master operation circulations such as workpiece conveying, center module detection, workpiece automatic blanking, workpiece separation, and detect different model time detection module locus conversion, various execution cylinder is all adopted to promote, comprising three axle cylinders, super-thin air cylinder, Mutli-station cylinder and Standard Cylinder 18, grouping is controlled by 9 two-position-five-way solenoid valves, each cylinder two ends are equipped with attached Magnetic Sensor, control cylinder working position; Cylinder import and export is provided with throttling valve, can make cylinder smooth working.Installing for solving numerous and diverse air pipe, adopting solenoid valve integrated package technology, pipeline crane span structure and pallet being set at device interior, pneumoelectric pipeline towing chain mechanism etc.Relating to the main movement mechanisms such as Workpiece fixing conveying, detection, all adopting accurate ball linear rail system, ensureing that straight, accurate, the nothing of each mechanism action swing, meet accuracy of detection requirement.All transmission components and parts all adopt advanced standard auxiliary equipment.Repeated accuracy of detection can be ensured, there is accurate and flexible, the general functions such as economy and durability that are in harmonious proportion.
(9) sensor detecting system:
Require that measurement point is many, detection space is narrow and small and the needs of measuring ability according to workpiece, this equipment adopts differential transformer type displacement feeler and transmitter, by order requirement, Miniaturization Design is carried out to No. 11 sensor profiles, sensor all adopts private mask line to protect to transmitter and transmitter to computing machine, transmitter adopts linear power supply and import accessory, improves accuracy of detection and stability.
(10) PLC and microcomputer automatic control system:
Equipment Inspection is undertaken by auto-programming requirement, comprises " calibrating procedure ", detects loop program and variety renovation position adjustment programme.Equipment has by job procedure closed-loop automatic control function, accurately complete Workpiece fixing conveying, jacking detection and localization, mechanical arm automatic capturing workpiece and send and detect the operations such as rear defective products is separated automatically, information feed back element is provided with between each process actions, composition automatic streamline production line, realize a push-botton operation, automatically complete the whole testing requirement of workpiece.Under industrial computer (Fig. 2, piece number 7) and PLC system jointly control, composition electromechanical integration automatic control system.
Microcomputer controls the data acquisition of each sensor, A/D conversion calculate by special software and detect numerical value and calibration value calculation process, display or printout testing result, send the automatic separation command of defective products etc., system has HMIS network data interface, can realize LAN Information and share.
To evaluation of the present invention:
-from detected adapter functional analysis, grasp the key link workplace and bearing fit saddle face, tightly around " Railway Freight Car Repair code " requirement, develops proprietary detection method and creative design design, effectively solve the practical problems.
-adopt the technology such as up-to-date pneumatics and line slideway, adopt sequencing the Automation Design, form complete processing line, novel structure, run smooth, adapt to on-the-spot needs.
-the present invention utilizes ripe detection technique element, adopts the program control and microcomputer untied simulated techniques of PLC, forms advanced and applicable checkout equipment, have electromechanical integration technology level, adapt to railway maintenance equipment Development needs.
-this invention provides the correct thinking and countermeasure solving actual techniques problem, and combine closely on-the-spot actual, by existing new technology and method conjunctive use, continue to optimize scheme, exploitation new method, creates best of breed, forms advanced technology equipment.The present invention jumps out the so-called high-tech occurred in recent years and detects thinking, avoid the many puzzlements for adapter 3 D stereo measuring surface, little space-closed face employing optical image detection technique: if measured object is that black side photonasty is poor, field illumination is uneven, and environmental interference is large; Optical calibrating technology and special part not yet have technological breakthrough etc.Comparatively speaking, technical measure is advanced, production reality of combining closely, applicability are good, reaches bleeding edge requirement.
Implement mode of the present invention:
Self-developing trial-production innovative product, meet market demand, patent value embodies in the product, and emphasis service railway freight-car section repaiies industry, according to market demand, transfer of technology mode can be adopted to accelerate market supply, but must focus on product function, improve quality.Concrete implementation step is as follows:
1) develop proprietary detection technique, research new detecting method and innovative design dedicated test modular structure, finishing equipment overall plan designs.
2) the research establishment of equipment and technology standard, the requirement of research railway maintenance procedure, fiducial mark master drawing is drawn, and is suitable for site inspection, to equipment applicability and versatility research.
3) product technology design, program design, industrial computer controls inspection software design, and crucial detecting element exploitation is ordered goods, and pneumatic system development and Design, element is ordered goods, Design of Electrical Controling System.
4) equipment trial-production, calibrating procedure and autotest, software and hardware uniting and adjustment, industrial computer PLC controls, and functions of the equipments comprise: equipment installs and uses requirement, equipment diagnosis techniques, safe operation, and operation instruction etc. is write in fault handling.Carry out equipment performance test, finishing equipment test examining report.
Claims (7)
1. freight train loader saddle automatic checkout equipment, it comprises: respectively detect position dimensional data for equipment to standard sample and carry out acquisition process and the standard sample of the accurate mach various adapter of the process of memory retention; It is characterized in that, described equipment also comprises
-workpiece feeding, location and detection conveying mechanism; Workpiece is delivered to equipment Inspection position, rely on workpiece conduct oneself with dignity material loading locate;
-complete workpiece secondary location center module; For jacking workpiece, before and after center module, wedge locating block is installed, center module upper water safety dress constant chord locating piece, at center module uphill process, the left and right crest line of " constant chord locating piece " and workpiece saddle face arc contact complete second time and locate, and the workpiece jacking detecting position is sent into saddle face pick-up unit, drawing strickle guide pick-up unit and end face pick-up unit and carried out comprehensive detection by center module;
-microprocessor system; Each road detecting sensor sampled data is processed, automatically carries out being separated defective products and qualified workpiece according to testing result;
-existing each model adapter is detected automatically and the drawing strickle guide detection module position adjusting mechanism established.
2. freight train loader saddle automatic checkout equipment as claimed in claim 1, it is characterized in that, described workpiece feeding, location and detection conveying mechanism, adopt the Workpiece fixing conveying sliding table that cylinder and ball-type line slideway form, slide unit is the rectangular frame-shaped construction of steel, sky shape is made in centre, centered by module jacking location, detect and slide unit before and after station conveying slot milling.
3. freight train loader saddle automatic checkout equipment as claimed in claim 1, it is characterized in that, described equipment comprises pneumatic drive system further, comprise by the integrated Pneumatic control module formed of solenoid directional control valve, the action of each execution cylinder is driven by working routine requirement, each cylinder two ends are provided with attached magnetic measurement sensor, feedback cylinder location signal, realize closed-loop automatic control requirement, the import and export of each cylinder is provided with one-way throttle valve, can make operation switching motion exactly, the motion of cylinder-driven all adopts ball slider line slideway.
4. freight train loader saddle automatic checkout equipment according to claim 1, it is characterized in that, described saddle face pick-up unit is takeed on testing agency by An Mian circular-arc detection mechanism and bearing guard and is formed, be arranged on two three axle cylinders of synchronization lifting, Dang Jian testing agency adopts two groups of symmetrical equiarm long lever mechanisms of installing, lever upper outside and adapter shelves are takeed on medial surface and are contacted, lever bottom contacts with detecting sensor respectively, detecting sensor is arranged in center module, and its detecting sensor shielding line guides transmitter into by conduit.
5. freight train loader saddle automatic checkout equipment according to claim 1, it is characterized in that, described drawing strickle guide pick-up unit is provided with and detects intelligent clamp module, every side of clamp adopts equiarm right angle bending leverage, lever one end is contacted with workpiece wearing surface by cantilever bearings roller, the other end is by contact-detection sensor acquisition testing face physical size, the full swing angle of lever work is all less than ± and 4 °, lever two ends measurement point perpendicular displacement length is equal, ensures displacement detecting sensor image data true and accurate.
6. freight train loader saddle automatic checkout equipment according to claim 1, it is characterized in that, described drawing strickle guide detection module position adjusting mechanism is symmetrical set, cylinder, ball slider, line slide rail is adopted to form three layers of three dimensions adjusting mechanism, the adjustment to different model adapter drawing strickle guide rib longitudinal direction, drawing strickle guide bottom surface transverse direction and drawing strickle guide height and position has been controlled by industrial computer, the each detection module completing detecting sensor composition is located in three-dimensional position, realizes detecting versatility functional requirement.
7. freight train loader saddle automatic checkout equipment as claimed in claim 5, it is characterized in that, the position that the bascule mechanism of described clamp contacts with displacement detecting sensor contact is provided with an adjustable detection round platform, round table surface is parallel with lever shaft, vertical with displacement detecting sensor sense of displacement, detect round platform afterbody mounting rod and be provided with screw thread, be screwed into lever one end, and be locked with jam nut.
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CN201210469927.0A CN103017645B (en) | 2012-09-06 | 2012-11-20 | Standard specimen relative method detects adapter equipment automatically |
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CN201320547305.5U Expired - Fee Related CN203426056U (en) | 2012-09-06 | 2013-09-05 | Automatic detection equipment for wagon adapter |
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CN108361502A (en) * | 2018-04-20 | 2018-08-03 | 深圳市晶向科技有限公司 | The camera calibration apparatus and method of glass cutting machine |
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CN111077167B (en) * | 2019-12-27 | 2023-10-31 | 四川国软科技集团有限公司 | Bearing saddle detecting system |
CN111189847B (en) * | 2019-12-27 | 2024-02-06 | 四川国软科技集团有限公司 | Temporary storage device and online detection system |
CN111069086B (en) * | 2019-12-30 | 2021-07-30 | 苏州协同创新智能制造装备有限公司 | Injection molding piece detection and material receiving method |
CN111854639B (en) * | 2020-07-28 | 2022-05-03 | 天津智通信息***集成有限公司 | High-speed railway side wall radian measuring equipment |
CN112720029B (en) * | 2020-12-24 | 2022-03-25 | 神华铁路装备有限责任公司 | Adapter transfer device |
CN113340186B (en) * | 2021-05-31 | 2022-08-12 | 常州伊贝基位移科技有限公司 | Error measuring device for linear displacement sensor |
CN115156070A (en) * | 2022-08-03 | 2022-10-11 | 西安国智电子科技有限公司 | Automatic testing device for bearing saddle |
CN115077388B (en) * | 2022-08-22 | 2022-11-18 | 成都岁生科技有限责任公司 | Railway freight car bogie slide wedge detection device |
CN115541401B (en) * | 2022-11-28 | 2023-02-28 | 中铁电气化局集团有限公司 | Rail qualification on-site verification and analysis equipment for construction |
CN116242284B (en) * | 2023-04-20 | 2023-08-18 | 慧铁科技有限公司 | Judgment method for damage of bearing saddle |
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