铁路捣固车设备状态与作业质量在线监测方法及应用
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摘要
抄平起拔道捣固车(简称捣固车),是铁路线路的新线施工、旧线大中修清筛作业和运营线路维修作业的必备装备,能对轨道进行自动抄平起、拨道、道碴捣固作业,使轨道线路达到线路设计标准和线路维护要求,确保列车的安全运行。由于我国铁路列车的提速、重载和高密度运行,我国既有的捣固车已不能完全满足现代铁路线路维护的要求。现有08-32型捣固车是目前铁路线路大修、维修作业的主力车型,铁道部广州铁路集团公司提出了对其进行技术改进的要求,在现有08-32型捣固车上增加设备状态与作业质量在线监测系统,提高现有08-32型捣固车线路作业性能和设备维护水平。捣固车设备状态与作业质量在线监测系统,对设备运行状态实时监测,掌握设备运转状况,对其故障实时告警、早期诊断并处理；对作业质量信息实时采集处理,采用精确作业新方法,提高作业效率和作业精度。本文以捣固车设备状态与作业质量在线监测系统的设计与开发为主线,对设备状态在线监测方法、线路作业新方法、多功能混合I/O模块和远程监控系统通信服务器等关键技术进行了深入研究。
(1)根据项目的研究目的、内容及要求,总结了捣固车在线监测系统的研究现状及发展趋势,给出了项目实施方案和技术路线,确定了研究的重点和攻克的难点。
(2)针对捣固车设备状态在线监测方法及技术实现的问题,分析了捣固车的结构与运行工况,确定了在线监测系统的监测点,建立了捣固车在线监测系统模型和监测数据库,提出了监测系统故障告警与故障诊断算法,实现了设备故障实时告警、故障诊断和远程实时控制。
(3)针对捣固车线路作业新方法与技术实现问题,建立了作业圆形竖曲线的数学模型,采用激光长弦精确测量竖曲线,消除残余偏差,实现竖曲线精确起道作业；建立了精测精捣新方法的模型,捣固车采集精测数据,采用最小二乘法拟合曲线,重新设计目标曲线线型,为精确捣固提供线路理论参数,实现数字化精确起拨道控制。
(4)通过分析捣固车在线监测系统对I/O模块的需求,设计实现了一种多种形态的多功能混合I/O模块。该模块具有模拟量输入、模拟量输出、开关量输入、开关量输出、脉冲计数量输入等多种功能,I/O端口可软件配置为上述五功能之一。采用该模块,可减少采集设备成本、提高系统可靠性和缩减安装空间。
(5)针对捣固车远程监控系统通信服务器的设计与要求,设计了一种非阻塞NIO模式的通信服务器。建立了铁路捣固车远程监控系统的时延模型,对车载终端与远程服务器通信的GPRS链路部分进行了时延性分析,给出了优化GPRS寸延和恢复GPRS中断数据的措施；设计了服务器与车载终端、服务器与监控客户端的实时并发通信协议。
(6)分别在实验室和现场恶劣环境下对捣固车在线监测系统进行了运行实测,完成对GPRS通信功能、通信性能和数据采集的测试。实测结果表明本系统工作正常,达到系统设计目的和性能指标。
本文提出的捣固车设备状态和作业质量在线监测方法,有效解决了铁路线路捣固车常规作业过程中作业效率低、作业质量差和设备维护困难等技术难题,显著地提高了现有捣固车线路作业技术水准和装备信息化程度,为设计开发其它大型工程机械在线监测系统提供了重要理论依据和技术实现途径。本课题设计开发的捣固车设备状态与作业质量在线监测系统已于2009年11月通过了广州铁路集团公司的科技成果鉴定,认为该系统技术先进、设计合理、运行可靠,在整体技术和应用理论上达到国内领先水平。
Hydraulic tamping machine (abbreviated as tamping machine) is an essential equipment for constructions of new railways, major or medium overhauls and ballast screenings of old railways, and maintenance of railways in use. It is able to automatically lift and line railway and tamp railway ballast, which enables railways to meet railway design standards as well as railway maintenance requirements for the sake of security. Especially with the development of implement of increasing speed, over-loading and high-density, the existing tamping machine can not fully meet the requirements of the maintenance of railways. The08-32tamping machine is the main force vehicle of maintenance, Guangzhou Railway ask for the technical improvement in increasing the on-line monitoring system of device condition and operation quality of08-32tamping machine to improve operating performance and equipment maintenance level.Via the real-time monitoring of device operation, the on-line monitoring system of device condition and operation quality of tamping machine can tell whether the device is running well and can alarm as soon as the failure is detected. Thus, attendant early diagnosis is made and correspondent repair follows. It can glean and process the operation quality information, and efficiency as well as accuracy should be improved through the employment of a accurate new method. The system can greatly ameliorate the performance of existing tamping machine s and escalate the device maintenance level to satisfy the requirement of acceleration of trains. In this paper, on the basis of the design and development of on-line monitoring system of device condition and operation quality of tamping machine, in-depth research is made on such key technologies as method of on-line monitoring of device condition, new method of railway work, multi-functional mixed I/O module and communication server based on remote monitoring system.
1. The project implementation plan and technology roadmap are put forward in this paper according to research purposes, contents and requirements, and then points out the key and difficult points, summarizes the present research and developmental trends of the on-line monitoring system of s tamping machine.
2. The structure and operating conditions of tamping machine concerned with the on-line monitoring method and the technology issues of tamping machine are analysed. A measuring point of the on-line monitoring system, an on-line monitoring system model and a monitoring database are established. Hence, real-time alarm of device failure, fault diagnosis and remote real-time control are realized.
3. The mathematical model of round vertical curve is established in response to the new method of railway work and technology issues. The laser chord is adopted to accurately measure the vertical curve and remove the residual deviation to achieve accurate track-lifting. In the line difficult to operate, minimum mean square error fitting curve is used, and then the shape of target curve is re-designed for providing theoretical parameters for accurate tamping to achieve the digital precise track lifting and lining control.
4. A multi-functional mixed I/O module is designed and realized via the analysis of the requirement of the I/O module from the on-line monitoring system of tamping machine, The module has multiple functions such as analog input, analog output, digital input, digital output, counting statistic input, etc.. I/O ports can be configured to one of the five functions by the means of software. Using the module can reduce the cost of device acquisition, improve the system reliability and reduce the installation space
5. A non-blocking NIO mode of communication server is designed for server design and development issues of the remote monitoring system of tamping machine. A delay model of remote monitoring system is established; delay analyses of vehicle terminal and the GPRS link of remote server communication are made; measurements concerning how to optimize delay and recover interrupted data of GPRS are put forward; real-time concurrent communication protocols between server and vehicle terminal, server and monitoring client are designed. Results of performance and load pressure tests indicate that the communication server designed and developed by us can meet the need of real time and concurrence of the remote monitoring system of tamping machine.
6.The GPRS communication function, communication performance and data acquisition performance are all tested both in the laboratory and the field under the harsh circumstance, and results show that the system works properly and fully meets the system design requirements and performance indicators.
The method of monitoring device condition and operation quality of tamping wagon proposed in this paper effectively resolves technological problems such as low efficiency, poor operation quality, hard maintenance etc.. The informationization level and technical level of existing tamping wagon are escalated, which provides important theoretical basis and paves the way for the design and development of on-line monitoring system for large-scale construction machinery. The system of on-line monitoring on operation quality and equipment status of tamping has passed the technological achievement identification. The results indicate that the technique is advanced, and the design is reasonable and runs reliably. Both systemic technology and applied theory have reached the leading domestic level.
(1)根据项目的研究目的、内容及要求,总结了捣固车在线监测系统的研究现状及发展趋势,给出了项目实施方案和技术路线,确定了研究的重点和攻克的难点。
(2)针对捣固车设备状态在线监测方法及技术实现的问题,分析了捣固车的结构与运行工况,确定了在线监测系统的监测点,建立了捣固车在线监测系统模型和监测数据库,提出了监测系统故障告警与故障诊断算法,实现了设备故障实时告警、故障诊断和远程实时控制。
(3)针对捣固车线路作业新方法与技术实现问题,建立了作业圆形竖曲线的数学模型,采用激光长弦精确测量竖曲线,消除残余偏差,实现竖曲线精确起道作业；建立了精测精捣新方法的模型,捣固车采集精测数据,采用最小二乘法拟合曲线,重新设计目标曲线线型,为精确捣固提供线路理论参数,实现数字化精确起拨道控制。
(4)通过分析捣固车在线监测系统对I/O模块的需求,设计实现了一种多种形态的多功能混合I/O模块。该模块具有模拟量输入、模拟量输出、开关量输入、开关量输出、脉冲计数量输入等多种功能,I/O端口可软件配置为上述五功能之一。采用该模块,可减少采集设备成本、提高系统可靠性和缩减安装空间。
(5)针对捣固车远程监控系统通信服务器的设计与要求,设计了一种非阻塞NIO模式的通信服务器。建立了铁路捣固车远程监控系统的时延模型,对车载终端与远程服务器通信的GPRS链路部分进行了时延性分析,给出了优化GPRS寸延和恢复GPRS中断数据的措施；设计了服务器与车载终端、服务器与监控客户端的实时并发通信协议。
(6)分别在实验室和现场恶劣环境下对捣固车在线监测系统进行了运行实测,完成对GPRS通信功能、通信性能和数据采集的测试。实测结果表明本系统工作正常,达到系统设计目的和性能指标。
本文提出的捣固车设备状态和作业质量在线监测方法,有效解决了铁路线路捣固车常规作业过程中作业效率低、作业质量差和设备维护困难等技术难题,显著地提高了现有捣固车线路作业技术水准和装备信息化程度,为设计开发其它大型工程机械在线监测系统提供了重要理论依据和技术实现途径。本课题设计开发的捣固车设备状态与作业质量在线监测系统已于2009年11月通过了广州铁路集团公司的科技成果鉴定,认为该系统技术先进、设计合理、运行可靠,在整体技术和应用理论上达到国内领先水平。
Hydraulic tamping machine (abbreviated as tamping machine) is an essential equipment for constructions of new railways, major or medium overhauls and ballast screenings of old railways, and maintenance of railways in use. It is able to automatically lift and line railway and tamp railway ballast, which enables railways to meet railway design standards as well as railway maintenance requirements for the sake of security. Especially with the development of implement of increasing speed, over-loading and high-density, the existing tamping machine can not fully meet the requirements of the maintenance of railways. The08-32tamping machine is the main force vehicle of maintenance, Guangzhou Railway ask for the technical improvement in increasing the on-line monitoring system of device condition and operation quality of08-32tamping machine to improve operating performance and equipment maintenance level.Via the real-time monitoring of device operation, the on-line monitoring system of device condition and operation quality of tamping machine can tell whether the device is running well and can alarm as soon as the failure is detected. Thus, attendant early diagnosis is made and correspondent repair follows. It can glean and process the operation quality information, and efficiency as well as accuracy should be improved through the employment of a accurate new method. The system can greatly ameliorate the performance of existing tamping machine s and escalate the device maintenance level to satisfy the requirement of acceleration of trains. In this paper, on the basis of the design and development of on-line monitoring system of device condition and operation quality of tamping machine, in-depth research is made on such key technologies as method of on-line monitoring of device condition, new method of railway work, multi-functional mixed I/O module and communication server based on remote monitoring system.
1. The project implementation plan and technology roadmap are put forward in this paper according to research purposes, contents and requirements, and then points out the key and difficult points, summarizes the present research and developmental trends of the on-line monitoring system of s tamping machine.
2. The structure and operating conditions of tamping machine concerned with the on-line monitoring method and the technology issues of tamping machine are analysed. A measuring point of the on-line monitoring system, an on-line monitoring system model and a monitoring database are established. Hence, real-time alarm of device failure, fault diagnosis and remote real-time control are realized.
3. The mathematical model of round vertical curve is established in response to the new method of railway work and technology issues. The laser chord is adopted to accurately measure the vertical curve and remove the residual deviation to achieve accurate track-lifting. In the line difficult to operate, minimum mean square error fitting curve is used, and then the shape of target curve is re-designed for providing theoretical parameters for accurate tamping to achieve the digital precise track lifting and lining control.
4. A multi-functional mixed I/O module is designed and realized via the analysis of the requirement of the I/O module from the on-line monitoring system of tamping machine, The module has multiple functions such as analog input, analog output, digital input, digital output, counting statistic input, etc.. I/O ports can be configured to one of the five functions by the means of software. Using the module can reduce the cost of device acquisition, improve the system reliability and reduce the installation space
5. A non-blocking NIO mode of communication server is designed for server design and development issues of the remote monitoring system of tamping machine. A delay model of remote monitoring system is established; delay analyses of vehicle terminal and the GPRS link of remote server communication are made; measurements concerning how to optimize delay and recover interrupted data of GPRS are put forward; real-time concurrent communication protocols between server and vehicle terminal, server and monitoring client are designed. Results of performance and load pressure tests indicate that the communication server designed and developed by us can meet the need of real time and concurrence of the remote monitoring system of tamping machine.
6.The GPRS communication function, communication performance and data acquisition performance are all tested both in the laboratory and the field under the harsh circumstance, and results show that the system works properly and fully meets the system design requirements and performance indicators.
The method of monitoring device condition and operation quality of tamping wagon proposed in this paper effectively resolves technological problems such as low efficiency, poor operation quality, hard maintenance etc.. The informationization level and technical level of existing tamping wagon are escalated, which provides important theoretical basis and paves the way for the design and development of on-line monitoring system for large-scale construction machinery. The system of on-line monitoring on operation quality and equipment status of tamping has passed the technological achievement identification. The results indicate that the technique is advanced, and the design is reasonable and runs reliably. Both systemic technology and applied theory have reached the leading domestic level.
引文
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