机车闸片性能检测控制系统集成方法研究与实现
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摘要
制动装置是列车安全减速或停车的重要装置。为确保列车的安全,必须在各种条件下都保证列车的制动性能。随着列车运行速度的不断提高,对制动装置的制动性能要求也更高,。目前我国的铁路客车基本都已采用了盘形制动,机车闸片是盘形制动装置的重要组成部件,它对制动性能有着举足轻重的作用。为了研制出摩擦性能更好的机车闸片,闸片制动性能试验台的开发成为列车制动领域中的一个重要课题。机车闸片性能检测装置是模拟实际中的制动工况,对机车闸片的摩擦性能进行试验的装置。随着计算机技术、自动控制技术、微电子技术、现代检测传感技术的发展,逐渐形成和发展了工业计算机监控系统。本文介绍了该检测装置的控制检测系统的设计。
本文按照《盘形制动试验大纲》要求,提出了对机车闸片性能测试装置的测试与控制系统的设计方案。在详细分析闸片试验过程测控技术及其系统研究现状的基础上,研究基于PLC的闸片性能测控系统的集成,给出了系统的体系结构、控制功能描述和集成方法,对主轴转速、摩擦力、闸片及制动盘温度的测量方式进行设计和设备选型。结合机车闸片性能检测装置的试验过程及参数检测和控制的特点,集成了以FX-2N PLC为现场测控单元的智能化测控系统,给出了相应的软硬件设计。
硬件部分主要对上位机、下位机(PLC)、变频调速系统和供电系统进行硬件选型和硬件接线设计,并且设计了各个传感器同可编程控制器的接线及其数据传输方式。软件部分包括下位机和上位机的应用软件程序的编制。上位机运用组态软件(MCGS)作为用户可定制功能的软件开发平台工具,利用其良好的人机界面和通信能力,在PC机上开发出有好的人机界面。下位机采用三菱PLC的专用编程软件在PC机上编制控制机车闸片性能检测试验台运行的控制程序。实验结果表明,采用该控制系统,使机车闸片性能检测试验台工作可靠,使用方便,所集成的过程测控系统信号输入、输出模块配置合理,系统运行稳定可靠,满足了试验过程参数检测和控制要求。
Brake is the important equipment which offered emergency braking and safety deceleration when train runs on tracks.In order to ensure safety of the train,good brake performance should be provided under any condition.As the speed of operation is continually rising,traditional brake shoe braking be longer fit the high speed train's development,so good performance of brake equipment is to be request. At present,disc braking has applied almost in all our country's passenger train. Brake pads is an important composition part of disc brake equipment,it has pivotal function to the braking quality.Therefore,the exploitation of brake pad's braking ability test bed will become a vital topic in the domain of train braking;better locomotive brake pads are required to be developed.The test-equipment of locomotive braking pads is an apparatus which can simulate damped condition of the practice and prosecute a performance test about the friction.With the development of computer technology,automation technology,micro-electronics technology,modern measurement and sense technology,Industry Computer Supervisory Control system is gradually developed.The control-test system of the equipment is introduced in this paper.
A design proposal of test and control system of locomotive brake pads test-equipment was introduced in this paper,which based on the requirement of "outline of the brake pad performance test".On the basis of detailed analysis of research progress measurement technology and system in the test progress,the integration of measurement and control system based on PLC is researched.The system framework,control function description and integration method is given.And designed the measurement of the rotation speed of main axis,friction force, temperature of brake pad and the brake disc.According to the technical process and characteristic of parameter detection and control,the intelligent measurement and control system in the equipment is integrated and the software and hardware based on FX-2N PLC is designed.
We chose types and designed how to connect lines for the hardware system, which mainly includes location going to machine(industry touch-sensitive screen system),the next machine(PLC control system),frequency conversion system and power supply system.Designing the software system includes writing programs for IPC and PLC.The configuration software(MCGS)can customize the special function software platform for users,utilize its good man-machine interface and communication capacity,can develop the friendly man-machine interface on the PC. Operation control procedures for locomotive brake performance test-bed were prepared on the PC with Mitsubishi PLC programming software.The experimental results indicate,adopting this control system,it is reliable to make the equipment work and easy to use.Measurement and control system established in the testing process runs well and implements the task of parameter measurement and control.
本文按照《盘形制动试验大纲》要求,提出了对机车闸片性能测试装置的测试与控制系统的设计方案。在详细分析闸片试验过程测控技术及其系统研究现状的基础上,研究基于PLC的闸片性能测控系统的集成,给出了系统的体系结构、控制功能描述和集成方法,对主轴转速、摩擦力、闸片及制动盘温度的测量方式进行设计和设备选型。结合机车闸片性能检测装置的试验过程及参数检测和控制的特点,集成了以FX-2N PLC为现场测控单元的智能化测控系统,给出了相应的软硬件设计。
硬件部分主要对上位机、下位机(PLC)、变频调速系统和供电系统进行硬件选型和硬件接线设计,并且设计了各个传感器同可编程控制器的接线及其数据传输方式。软件部分包括下位机和上位机的应用软件程序的编制。上位机运用组态软件(MCGS)作为用户可定制功能的软件开发平台工具,利用其良好的人机界面和通信能力,在PC机上开发出有好的人机界面。下位机采用三菱PLC的专用编程软件在PC机上编制控制机车闸片性能检测试验台运行的控制程序。实验结果表明,采用该控制系统,使机车闸片性能检测试验台工作可靠,使用方便,所集成的过程测控系统信号输入、输出模块配置合理,系统运行稳定可靠,满足了试验过程参数检测和控制要求。
Brake is the important equipment which offered emergency braking and safety deceleration when train runs on tracks.In order to ensure safety of the train,good brake performance should be provided under any condition.As the speed of operation is continually rising,traditional brake shoe braking be longer fit the high speed train's development,so good performance of brake equipment is to be request. At present,disc braking has applied almost in all our country's passenger train. Brake pads is an important composition part of disc brake equipment,it has pivotal function to the braking quality.Therefore,the exploitation of brake pad's braking ability test bed will become a vital topic in the domain of train braking;better locomotive brake pads are required to be developed.The test-equipment of locomotive braking pads is an apparatus which can simulate damped condition of the practice and prosecute a performance test about the friction.With the development of computer technology,automation technology,micro-electronics technology,modern measurement and sense technology,Industry Computer Supervisory Control system is gradually developed.The control-test system of the equipment is introduced in this paper.
A design proposal of test and control system of locomotive brake pads test-equipment was introduced in this paper,which based on the requirement of "outline of the brake pad performance test".On the basis of detailed analysis of research progress measurement technology and system in the test progress,the integration of measurement and control system based on PLC is researched.The system framework,control function description and integration method is given.And designed the measurement of the rotation speed of main axis,friction force, temperature of brake pad and the brake disc.According to the technical process and characteristic of parameter detection and control,the intelligent measurement and control system in the equipment is integrated and the software and hardware based on FX-2N PLC is designed.
We chose types and designed how to connect lines for the hardware system, which mainly includes location going to machine(industry touch-sensitive screen system),the next machine(PLC control system),frequency conversion system and power supply system.Designing the software system includes writing programs for IPC and PLC.The configuration software(MCGS)can customize the special function software platform for users,utilize its good man-machine interface and communication capacity,can develop the friendly man-machine interface on the PC. Operation control procedures for locomotive brake performance test-bed were prepared on the PC with Mitsubishi PLC programming software.The experimental results indicate,adopting this control system,it is reliable to make the equipment work and easy to use.Measurement and control system established in the testing process runs well and implements the task of parameter measurement and control.
引文
[1]赵田臣,孟凡爱,樊云昌.高速列车闸片材料制动试验机的研制.石家庄铁道学院学报,2003.16(4):23-25
[2]田莉.列车提速与制动装置.铁道技术监督,2005(2):22-23
[3]熊谷,则道等(日).新型制动试验台.国外铁道车辆,1994(2):45-49
[4]饶忠.列车制动.北京:中国铁道出版社,1998
[5]陈明,周伟,吴明江.基于虚拟仪器技术的火车闸片摩擦系数测试系统.电工技术杂志,2004.(8):49-51
[6]王颖,程明,周伟.Lab VIEW 7 Express在火车刹车控制系统中的应用.电工技术杂志,2004.(8)49-51
[7]吴晓等.计算机工业控制技术.厦门:厦门大学出版社,2005
[8]张学敏,付建中,王进军,瞿宏建.微机自动控制在JZ-7型机车制动机试验台上的应用.中国铁路,2003.(8):37-39
[9]廖常初.PLC编程及应用.北京:机械工业出版社,2002
[10]张蔚,徐华,丁学文,金大海.CAN总线在机车监控系统中的应用.测控技术与设备,2003.29(4):21-23
[11]王先锋.惯性制动器试验台的控制系统设计及数据处理与分析.[硕士论文]湖南:湖南大学机械与汽车工程学院,2006
[12]何小阳.计算机监控原理及技术.重庆:重庆大学出版社,2003
[13]马明建,周长城.数据采集与处理技术.西安:西安交通大学出版社,1998
[14]陈宁.可编程控制器基础及编程技巧.广州:华南理工大学出版社,2001
[15]张芳玺,彭学院,张成兵.基于PLC的机车空压机性能检测系统研制.压缩机技术,2005.(6):1-3
[16]袁秀英.组态控制技术.北京:电子工业出版社,2003
[17]谢志萍.传感器与检测技术.北京:电子工业出版社,2004
[18]浦昭邦,王宝光.测控装置设计.北京:机械工业出版社,2001
[19]马国华.监控组态软件及其应用.北京:清华大学出版社,2001
[20]MCGS工控组态软件用户指南.1999
[21]李贺桥,杨怀栋,黄战华,彭志强.监控系统控制的机车车辆制动动能自动检测技术.制造业自动化,2000.22(10):39-41
[22]梁风,宋宝玉,张锋,张欢.摩擦磨损实验软件测试系统的开发与应用.机械工程师.2005(12):42-44
[23]Dr.Xaver Wirth.Improving Performance of Disc Brakes on High-speed Rail Vehicles with a Novel Type of Brake Pad.ISOBAR.RTR.1998.2(1):24-29
[24]Gurin,l.V.Gurin,I.M.Neldyudov,etal.Carbon.carbon Composite Materials for Friction Purposes.Power Metallurgy and Metal Ceramics,2001.40(4):97-102
[25]West P.Weight saving carbon-carbon brakes gaining favor on commercial aircraft.Adv.Mater,1998.10(20):1-4
[26]Barry Smyth,Mark T Keane.Using adaptation knowledge retrieve and adapt design cases.Knowledge-Based System,1999(2):127-135
[27]Wang,J;Agrawal,P;Aiexander,L;Rajamani,R;American Control Conference,2003
[28]Thomas R Hinrichs,Janet L Kolodner.The Roles of Adaptation in Case-Based Design.Ninth National Conference,2001:28-33
[29]Mohamed EI-Mehalawi,R.Allen Miller.A database system of mechanical components based on geometric and topological similarity.Computer-Aided Design,2003(35):83-94
[30]Minami,M amura,A akura,T Evolutionary Computation,Proceedings of the 2002Congress,2002
[31]Edwards,M.C.;Donelson,J.,Ⅲ;Zavis,W.M.;Prabhakaran,A.;Brabb,D.C.;Jackson,A.S.;Improving freight rail safety with on-board monitoring and control systems.Rail Conference,2005.Proceedings of the 2005 ASME/IEEE Joint,16-18 March 2005 Page(s):117-122
[32]Thelen,G.A.;Tse,Y.H.;An automatic speed enforcement system for heavy freight trains.Railroad Conference,1990.,Technical Papers Presented at the 1990 ASME/IEEE Joint,17-19April 1990 Page(s):31-39
[33]Ludlow,C.C.;van Schoor,D.;Gipson,T.;Self powered wireless brake shoe force measurement system for train brakes.Rail Conference,2006.Proceedings of the 2006IEEE/ASME Joint,4-6 April 2006 Page(s):73-80
[34]Booth,G.;Prabhakaran,A.;Punwani,S.K.;Stewart,M.;Simplified representation of rigging efficiency in brake force calculation.Rail Conference,2006.Proceedings of the 2006IEEE/ASME Joint,4-6 April 2006 Page(s):61-71
[35]Andrew Petersen,Rod Barrett and Steven Morrison.Driver-training and emergency brake performance in cars with antilock braking systems.Safety Science,Volume 44,Issue 10,December 2006,Pages 905-917
[36] M. Chou and X. Xia. Optimal cruise control of heavy-haul trains equipped with electronically controlled pneumatic brake systems. Control Engineering Practice, In Press, Corrected Proof, Available online 27 October 2006
[37]Qi Xinbo, Chang Wenping. The Application of the Distribution Supervisory system of Computer in Substation of 500KV.Control&Automation,2005(3):4649
[38]K.J.Astrom.Automatic Tuning and Adaption for PID Controller-A Survey.Control Eng Practice,1993.1(4):351-364
[39]k.k.Tan,T.H.Lee.Enhenced Automatic Tuning Procedure for Process Control of PI/PID Controller.AICHEJournal,1996.42(9):2221-2253
[40]D.M.Dhamdhere.Systems Programing and Operating Systems.McGraw-Hill,2001
[2]田莉.列车提速与制动装置.铁道技术监督,2005(2):22-23
[3]熊谷,则道等(日).新型制动试验台.国外铁道车辆,1994(2):45-49
[4]饶忠.列车制动.北京:中国铁道出版社,1998
[5]陈明,周伟,吴明江.基于虚拟仪器技术的火车闸片摩擦系数测试系统.电工技术杂志,2004.(8):49-51
[6]王颖,程明,周伟.Lab VIEW 7 Express在火车刹车控制系统中的应用.电工技术杂志,2004.(8)49-51
[7]吴晓等.计算机工业控制技术.厦门:厦门大学出版社,2005
[8]张学敏,付建中,王进军,瞿宏建.微机自动控制在JZ-7型机车制动机试验台上的应用.中国铁路,2003.(8):37-39
[9]廖常初.PLC编程及应用.北京:机械工业出版社,2002
[10]张蔚,徐华,丁学文,金大海.CAN总线在机车监控系统中的应用.测控技术与设备,2003.29(4):21-23
[11]王先锋.惯性制动器试验台的控制系统设计及数据处理与分析.[硕士论文]湖南:湖南大学机械与汽车工程学院,2006
[12]何小阳.计算机监控原理及技术.重庆:重庆大学出版社,2003
[13]马明建,周长城.数据采集与处理技术.西安:西安交通大学出版社,1998
[14]陈宁.可编程控制器基础及编程技巧.广州:华南理工大学出版社,2001
[15]张芳玺,彭学院,张成兵.基于PLC的机车空压机性能检测系统研制.压缩机技术,2005.(6):1-3
[16]袁秀英.组态控制技术.北京:电子工业出版社,2003
[17]谢志萍.传感器与检测技术.北京:电子工业出版社,2004
[18]浦昭邦,王宝光.测控装置设计.北京:机械工业出版社,2001
[19]马国华.监控组态软件及其应用.北京:清华大学出版社,2001
[20]MCGS工控组态软件用户指南.1999
[21]李贺桥,杨怀栋,黄战华,彭志强.监控系统控制的机车车辆制动动能自动检测技术.制造业自动化,2000.22(10):39-41
[22]梁风,宋宝玉,张锋,张欢.摩擦磨损实验软件测试系统的开发与应用.机械工程师.2005(12):42-44
[23]Dr.Xaver Wirth.Improving Performance of Disc Brakes on High-speed Rail Vehicles with a Novel Type of Brake Pad.ISOBAR.RTR.1998.2(1):24-29
[24]Gurin,l.V.Gurin,I.M.Neldyudov,etal.Carbon.carbon Composite Materials for Friction Purposes.Power Metallurgy and Metal Ceramics,2001.40(4):97-102
[25]West P.Weight saving carbon-carbon brakes gaining favor on commercial aircraft.Adv.Mater,1998.10(20):1-4
[26]Barry Smyth,Mark T Keane.Using adaptation knowledge retrieve and adapt design cases.Knowledge-Based System,1999(2):127-135
[27]Wang,J;Agrawal,P;Aiexander,L;Rajamani,R;American Control Conference,2003
[28]Thomas R Hinrichs,Janet L Kolodner.The Roles of Adaptation in Case-Based Design.Ninth National Conference,2001:28-33
[29]Mohamed EI-Mehalawi,R.Allen Miller.A database system of mechanical components based on geometric and topological similarity.Computer-Aided Design,2003(35):83-94
[30]Minami,M amura,A akura,T Evolutionary Computation,Proceedings of the 2002Congress,2002
[31]Edwards,M.C.;Donelson,J.,Ⅲ;Zavis,W.M.;Prabhakaran,A.;Brabb,D.C.;Jackson,A.S.;Improving freight rail safety with on-board monitoring and control systems.Rail Conference,2005.Proceedings of the 2005 ASME/IEEE Joint,16-18 March 2005 Page(s):117-122
[32]Thelen,G.A.;Tse,Y.H.;An automatic speed enforcement system for heavy freight trains.Railroad Conference,1990.,Technical Papers Presented at the 1990 ASME/IEEE Joint,17-19April 1990 Page(s):31-39
[33]Ludlow,C.C.;van Schoor,D.;Gipson,T.;Self powered wireless brake shoe force measurement system for train brakes.Rail Conference,2006.Proceedings of the 2006IEEE/ASME Joint,4-6 April 2006 Page(s):73-80
[34]Booth,G.;Prabhakaran,A.;Punwani,S.K.;Stewart,M.;Simplified representation of rigging efficiency in brake force calculation.Rail Conference,2006.Proceedings of the 2006IEEE/ASME Joint,4-6 April 2006 Page(s):61-71
[35]Andrew Petersen,Rod Barrett and Steven Morrison.Driver-training and emergency brake performance in cars with antilock braking systems.Safety Science,Volume 44,Issue 10,December 2006,Pages 905-917
[36] M. Chou and X. Xia. Optimal cruise control of heavy-haul trains equipped with electronically controlled pneumatic brake systems. Control Engineering Practice, In Press, Corrected Proof, Available online 27 October 2006
[37]Qi Xinbo, Chang Wenping. The Application of the Distribution Supervisory system of Computer in Substation of 500KV.Control&Automation,2005(3):4649
[38]K.J.Astrom.Automatic Tuning and Adaption for PID Controller-A Survey.Control Eng Practice,1993.1(4):351-364
[39]k.k.Tan,T.H.Lee.Enhenced Automatic Tuning Procedure for Process Control of PI/PID Controller.AICHEJournal,1996.42(9):2221-2253
[40]D.M.Dhamdhere.Systems Programing and Operating Systems.McGraw-Hill,2001