火车刹车片测试系统的研究
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摘要
制动装置是火车安全减速或停车的重要装置。为保证火车的安全，必须在各种条件下都能保证火车的制动性能。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，传统的闸瓦制动适应不了高速列车的发展。目前我国的铁路客车基本都已采用了盘形制动，火车刹车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。
火车刹车片测试系统是建立在刹车片制动试验台的基础上，测试火车刹车片的摩擦性能。论文根据《盘形制动试验大纲》要求，提出对火车刹车片制动试验台的设计方案，主要由电动机、联轴器、制动装置、支座、测试装置等几个部分构成。根据设计方案的总体布置，选取合适的交流电动机，采用变频控制方式控制电机转速。结合试验台的结构特点，进行测试系统的设计。
火车刹车片测试系统以总成试验的方式来测试刹车片的承载压力、表面温度、车轮运行速度等多项性能参数，结合实际选用合适的传感器。系统主要由上位机和下位机两部分组成。下位机采用ADuC841作为控制单元，控制压力、温度、速度的采集。上位机(即PC机)通过RS485串口通讯与下位机相连。上位机采用Visual Basic设计一个控制软件，对采集数据进行分析处理，最终生成刹车片的摩擦系数曲线图，可以直观的分析刹车片的摩擦性能。该软件还包括对变频器的控制模块，通过串口给下位机传送指令改变变频器的输出频率，实现对电机转速的控制。最后经过对测量结果的分析，可以看出火车的制动初速度与刹车片的表面温度都是影响火车刹车片的摩擦性能的重要因素。
Brake is an important equipment which offered emergency braking and safety deceleration when train run 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 no 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 pad 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 train brake pads are required to be developed.
The test system of train braking pad was built on the braking test-bed to measure the friction ability of the braking pad. A design proposal of train brake pads brake tester was introduced in this paper which based on the requirement of "outline of the brake pad performance test", mainly composed electric motor, shaft coupler, brake equipment, bearing, testing equipment and so on. According to the total arrangement of design proposal motor was selected, the motor was controlled by the frequency conversion. Then the testing system was established.
This essay explained the primary principle and the testing method of the test system. The test system contained the measuring modules of the pressure and the surface temperature of the braking pad, and the rotate speed of the wheel. It was composed of single chip system and computer system. The single chip system controlled the gathering of the parameter; the computer system communicated with the single chip system by serial interface. In the computer system there was a control software which can analyze the parameter and acquire the friction curve of the test pad. In the last part of the paper test result was analyzed, we received a conclusion that the friction of the train pad was influenced by the first rotate speed of the wheel and the surface temperature of the braking pad.
火车刹车片测试系统是建立在刹车片制动试验台的基础上，测试火车刹车片的摩擦性能。论文根据《盘形制动试验大纲》要求，提出对火车刹车片制动试验台的设计方案，主要由电动机、联轴器、制动装置、支座、测试装置等几个部分构成。根据设计方案的总体布置，选取合适的交流电动机，采用变频控制方式控制电机转速。结合试验台的结构特点，进行测试系统的设计。
火车刹车片测试系统以总成试验的方式来测试刹车片的承载压力、表面温度、车轮运行速度等多项性能参数，结合实际选用合适的传感器。系统主要由上位机和下位机两部分组成。下位机采用ADuC841作为控制单元，控制压力、温度、速度的采集。上位机(即PC机)通过RS485串口通讯与下位机相连。上位机采用Visual Basic设计一个控制软件，对采集数据进行分析处理，最终生成刹车片的摩擦系数曲线图，可以直观的分析刹车片的摩擦性能。该软件还包括对变频器的控制模块，通过串口给下位机传送指令改变变频器的输出频率，实现对电机转速的控制。最后经过对测量结果的分析，可以看出火车的制动初速度与刹车片的表面温度都是影响火车刹车片的摩擦性能的重要因素。
Brake is an important equipment which offered emergency braking and safety deceleration when train run 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 no 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 pad 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 train brake pads are required to be developed.
The test system of train braking pad was built on the braking test-bed to measure the friction ability of the braking pad. A design proposal of train brake pads brake tester was introduced in this paper which based on the requirement of "outline of the brake pad performance test", mainly composed electric motor, shaft coupler, brake equipment, bearing, testing equipment and so on. According to the total arrangement of design proposal motor was selected, the motor was controlled by the frequency conversion. Then the testing system was established.
This essay explained the primary principle and the testing method of the test system. The test system contained the measuring modules of the pressure and the surface temperature of the braking pad, and the rotate speed of the wheel. It was composed of single chip system and computer system. The single chip system controlled the gathering of the parameter; the computer system communicated with the single chip system by serial interface. In the computer system there was a control software which can analyze the parameter and acquire the friction curve of the test pad. In the last part of the paper test result was analyzed, we received a conclusion that the friction of the train pad was influenced by the first rotate speed of the wheel and the surface temperature of the braking pad.
引文
[1] 赵小楼，程光明等．摩擦材料摩擦磨损性能试验的现状与发展。润滑与密封．2006，10(182)：200～203
[2] 林敏．列车制动．北京：中国铁道出版社，1998
[3] 孙新海．盘形制动及其配套技术．北京：中国铁道出版社，1998
[4] 程安宁，尚爱琴．电机车制动类型及摩擦制动材料．起重运输机械．2006，2：6～8
[5] 张嗣伟．基础摩擦学．山东：石油大学出版社，2001
[6] Bochet B. Nouvelles recherches experimentales sur le forttement de glissement. Annales desMines, 1861, 19(38): 27～120
[7] Frank G. uber die Abhangigkeit der Glertenden Reibung vonder Geschwindigkeit. Civilingenieur, Band 23, 1882, s. 206
[8] N．B克拉盖尔斯基著，汪一麟等译，摩擦磨损计算原理．北京：机械工业出版社，1982
[9] 戴雄杰．摩擦学基础．上海：上海科学技术出版社，1984
[10] Coulumb CA. The theory of simple machines. Mem. Math Phys Acad Sci, 1785, 10: 161～331
[11] 谢关恒，丰向．摩擦工作表面温度的有限元分析．锻压机械．1989，2：P33～35
[12] 马保吉，韩莉莉．盘式制动器的温度场分析．西安：西安工业学院学报，1998，18(4)：311～315
[13] 梁爽，陈光雄等．四种车辆制动闸瓦材料摩擦特性试验研究．润滑与密封．2006，3：62～66
[14] 胡汉才．单片机原理及其接口技术．北京：清华大学出版社，2000
[15] 杨成美．高速列车制动方式的比较研究．上海铁道科技，2005，6：37～40
[16] Selecting Temperature Sensors for System Measurement and Protection, Maxim Integrated Products, APP3229, May 11, 2004
[17] Cold-Junction-Compensated K-Thermocouple-to-Digital Converter(0℃ to +1024℃), Maxim Integrated Products, 19-2235, Rev 1
[18] 雷亚平，沈春林．嵌入式系统的组成、设计与调试．航空计算技术，2003，3
[19] 张晶，曾宪云．嵌入式系统的应用．电气时代，2002，5
[20] 三菱变频调速器FR—E500使用手册
[21] 曹茂永，王霞，孙农亮。仪用放大器AD620及其应用．电测与仪表，2000，10(418)49～52
[22] 彭友湘．摩擦焊机液压、转速测控系统的研制：[硕士学位论文]．重庆：材料加工工程系，2003
[23] 于庆广，刘葵等．光电编码器选型及同步电机转速和转子位置测量．电气传动，2006， 4：17～21
[24] 刘洪萍，卢博友．应变式压力传感器在离散介质压力测量中误差的试验分析．甘肃农业大学学报，2001，2：35～38
[25] 李国屏．热电偶测温系统的误差分析．无锡商业职业技术学院学报，2004，3：20～23
[26] 马保吉，朱均．摩擦制动器接触表面温度计算模型．西安工业学院学报，1999(3)
[27] 崔德祥，苏广平．ATE-Krauss摩擦试验机的结构特点及其发展．大众科技，2005，11：250～252
[28] 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，2003．4(16)23～2S
[29] D. M Rowson, the Interfacial Surface Temperature of a Disc Brake, Wear, 1978(2)
[30] 凌善康，李浩然．温度测量基础．北京：北京中国标准出版社，1998
[31] 汪本强，凌玉华，廖力清．摩擦试验机计算机测试系统的设计与应用．中国仪器仪表，2006，7：41～43
[32] 李云堂．干式制动片摩擦材料的研制和性能试验．试验与研究，2000，1：19～22
[33] AT89C51 In-Circuit Programming, Rev: 0287D-B-9/97
[34] 李霞，许志庆，杨勇．高速摩擦磨损试脸机的总体设计．中国仪器仪表，2003，10：19～23
[35] Bates, Introduction to scheduling and timing analysis, The Use of Ada in Real Time System, IEE Conference Publication
[36] Bennett, Real-Time Computer Control, Prentice Hall, New Jersey
[37] Huang, H-W(2000) Using the MCS-51 Microcontroller, Oxford University Press, New York
[38] Intel(1985)Microcontroller Handbook 1986, Infel Corporation
[39] S. Ramousse J. W. Haj O. T. Sarensen, Thermal Characterisaton of Brake Pads, Akademiai Kiado, 2001, 6: P171～177
[40] 凌善康，李浩然．温度测量基础．北京：北京中国标准出版社，1998
[41] Differential Two-Wire Hall Effect Sensor-IC for Wheel Speed Applications, Infineon Technologies AG, data sheet, V2. 1, February 2005
[42] 100kPa On-Chip Temperature Compensated & Calibrated Silicon Pressure Sensors, MPX2100 SERIES, Motorola, Inc. 2002
[43] 庄光山，王成国等．混杂纤维增强制动闸片的制动性能研究．铁道学报，2003，1(25)：43～47
[44] 程安宁，尚爱琴．电机车制动类型及摩擦制动材料．起重运输机械，2006，2：6～8
[45] 张元民．摩擦材料最近进展．北京：中国建筑下业出版社，1991
[46] 浦昭邦，王宝光．测控装置设计．北京：机械工业出版社，2001
[47] 刘玉广等．新型传感器技术及应用．北京：北京航空航天大学出版社，2004
[48] TORUMIYAUCHI等．窄轨列车用制动盘和闸片的摩擦磨损特性．国外机车车辆工 艺，1999．7(1)：37～42
[49] Griffin J. H, Meng C. H. Friction Damper of circular Motion and its Implication to Vibration control[J]. Transactions of ASME Journal of Vibration and Acoustics. 1991: 225～229
[50] 和田雄一等．开发的制动闸片和制动盘．国外铁道车辆．1997(1)：4～6
[51] Griffin J. H, Friction Damping of Resonant Stresses in Gas Turbine Engineering Airfoils. ASME Journal of Engineering for Power. 1980, 102: 329～333
[52] Meng C. H , Griffin J. H, Bielak J. The Forced Response of Shrouded Fan Stages[J]. ASME Journal of Vibration, Acoustics Stress, and Reliability in Design. 1980(108): 50～55
[2] 林敏．列车制动．北京：中国铁道出版社，1998
[3] 孙新海．盘形制动及其配套技术．北京：中国铁道出版社，1998
[4] 程安宁，尚爱琴．电机车制动类型及摩擦制动材料．起重运输机械．2006，2：6～8
[5] 张嗣伟．基础摩擦学．山东：石油大学出版社，2001
[6] Bochet B. Nouvelles recherches experimentales sur le forttement de glissement. Annales desMines, 1861, 19(38): 27～120
[7] Frank G. uber die Abhangigkeit der Glertenden Reibung vonder Geschwindigkeit. Civilingenieur, Band 23, 1882, s. 206
[8] N．B克拉盖尔斯基著，汪一麟等译，摩擦磨损计算原理．北京：机械工业出版社，1982
[9] 戴雄杰．摩擦学基础．上海：上海科学技术出版社，1984
[10] Coulumb CA. The theory of simple machines. Mem. Math Phys Acad Sci, 1785, 10: 161～331
[11] 谢关恒，丰向．摩擦工作表面温度的有限元分析．锻压机械．1989，2：P33～35
[12] 马保吉，韩莉莉．盘式制动器的温度场分析．西安：西安工业学院学报，1998，18(4)：311～315
[13] 梁爽，陈光雄等．四种车辆制动闸瓦材料摩擦特性试验研究．润滑与密封．2006，3：62～66
[14] 胡汉才．单片机原理及其接口技术．北京：清华大学出版社，2000
[15] 杨成美．高速列车制动方式的比较研究．上海铁道科技，2005，6：37～40
[16] Selecting Temperature Sensors for System Measurement and Protection, Maxim Integrated Products, APP3229, May 11, 2004
[17] Cold-Junction-Compensated K-Thermocouple-to-Digital Converter(0℃ to +1024℃), Maxim Integrated Products, 19-2235, Rev 1
[18] 雷亚平，沈春林．嵌入式系统的组成、设计与调试．航空计算技术，2003，3
[19] 张晶，曾宪云．嵌入式系统的应用．电气时代，2002，5
[20] 三菱变频调速器FR—E500使用手册
[21] 曹茂永，王霞，孙农亮。仪用放大器AD620及其应用．电测与仪表，2000，10(418)49～52
[22] 彭友湘．摩擦焊机液压、转速测控系统的研制：[硕士学位论文]．重庆：材料加工工程系，2003
[23] 于庆广，刘葵等．光电编码器选型及同步电机转速和转子位置测量．电气传动，2006， 4：17～21
[24] 刘洪萍，卢博友．应变式压力传感器在离散介质压力测量中误差的试验分析．甘肃农业大学学报，2001，2：35～38
[25] 李国屏．热电偶测温系统的误差分析．无锡商业职业技术学院学报，2004，3：20～23
[26] 马保吉，朱均．摩擦制动器接触表面温度计算模型．西安工业学院学报，1999(3)
[27] 崔德祥，苏广平．ATE-Krauss摩擦试验机的结构特点及其发展．大众科技，2005，11：250～252
[28] 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，2003．4(16)23～2S
[29] D. M Rowson, the Interfacial Surface Temperature of a Disc Brake, Wear, 1978(2)
[30] 凌善康，李浩然．温度测量基础．北京：北京中国标准出版社，1998
[31] 汪本强，凌玉华，廖力清．摩擦试验机计算机测试系统的设计与应用．中国仪器仪表，2006，7：41～43
[32] 李云堂．干式制动片摩擦材料的研制和性能试验．试验与研究，2000，1：19～22
[33] AT89C51 In-Circuit Programming, Rev: 0287D-B-9/97
[34] 李霞，许志庆，杨勇．高速摩擦磨损试脸机的总体设计．中国仪器仪表，2003，10：19～23
[35] Bates, Introduction to scheduling and timing analysis, The Use of Ada in Real Time System, IEE Conference Publication
[36] Bennett, Real-Time Computer Control, Prentice Hall, New Jersey
[37] Huang, H-W(2000) Using the MCS-51 Microcontroller, Oxford University Press, New York
[38] Intel(1985)Microcontroller Handbook 1986, Infel Corporation
[39] S. Ramousse J. W. Haj O. T. Sarensen, Thermal Characterisaton of Brake Pads, Akademiai Kiado, 2001, 6: P171～177
[40] 凌善康，李浩然．温度测量基础．北京：北京中国标准出版社，1998
[41] Differential Two-Wire Hall Effect Sensor-IC for Wheel Speed Applications, Infineon Technologies AG, data sheet, V2. 1, February 2005
[42] 100kPa On-Chip Temperature Compensated & Calibrated Silicon Pressure Sensors, MPX2100 SERIES, Motorola, Inc. 2002
[43] 庄光山，王成国等．混杂纤维增强制动闸片的制动性能研究．铁道学报，2003，1(25)：43～47
[44] 程安宁，尚爱琴．电机车制动类型及摩擦制动材料．起重运输机械，2006，2：6～8
[45] 张元民．摩擦材料最近进展．北京：中国建筑下业出版社，1991
[46] 浦昭邦，王宝光．测控装置设计．北京：机械工业出版社，2001
[47] 刘玉广等．新型传感器技术及应用．北京：北京航空航天大学出版社，2004
[48] TORUMIYAUCHI等．窄轨列车用制动盘和闸片的摩擦磨损特性．国外机车车辆工 艺，1999．7(1)：37～42
[49] Griffin J. H, Meng C. H. Friction Damper of circular Motion and its Implication to Vibration control[J]. Transactions of ASME Journal of Vibration and Acoustics. 1991: 225～229
[50] 和田雄一等．开发的制动闸片和制动盘．国外铁道车辆．1997(1)：4～6
[51] Griffin J. H, Friction Damping of Resonant Stresses in Gas Turbine Engineering Airfoils. ASME Journal of Engineering for Power. 1980, 102: 329～333
[52] Meng C. H , Griffin J. H, Bielak J. The Forced Response of Shrouded Fan Stages[J]. ASME Journal of Vibration, Acoustics Stress, and Reliability in Design. 1980(108): 50～55