CN110425126B - Portable air compressor testing device and testing method and application thereof - Google Patents
Portable air compressor testing device and testing method and application thereof Download PDFInfo
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- CN110425126B CN110425126B CN201910823620.8A CN201910823620A CN110425126B CN 110425126 B CN110425126 B CN 110425126B CN 201910823620 A CN201910823620 A CN 201910823620A CN 110425126 B CN110425126 B CN 110425126B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
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Abstract
The invention provides a portable air compressor testing device, a testing method and application thereof, so that a portable tool convenient to carry can be provided for detection personnel of the existing air compressor and a drying system thereof, and the portable air compressor testing device can be used for detecting the air compressor at any time and any place. The testing device comprises a testing host, a sensor box and a portable computer with testing software. By using the testing device, when the train is regularly maintained, the disassembly of the air compressor and the processing system thereof can be avoided. Compared with the traditional detection mode, the device and the method provided by the invention can obviously reduce the maintenance cost of the air compressor of the train and the drying system thereof, and greatly improve the overhauling efficiency and the turnover rate of the train.
Description
Technical Field
The invention relates to a detection device and a detection method for an air compressor and a drying system thereof, in particular to a detection device and a detection method for an air compressor and a processing system thereof used on a train in the rail transit industry.
Background
At present, trains, subways, high-speed rails, electric buses and trucks in the rail transit field all use compressed air to realize final braking. In order to ensure the safety of traveling, the air compressor for generating compressed air and the drying system thereof must be maintained frequently, however, unlike the fixed air compressor system installed in factories, construction sites, hospital mines, etc., in the field of rail transportation, the air compressor and the drying system thereof are installed on trains and are moved. Especially when the air compressor fails, the braking system of the vehicle may be disabled, thereby rendering the vehicle immobile.
From the first train run two hundred years ago to date, there has been no effective tool to address this problem. In view of the above circumstances, there is a need to develop a novel detection device and method for an air compressor and a processing system thereof used on a rail vehicle.
Disclosure of Invention
The invention provides a detection device and a detection method for an air compressor and a processing system thereof used on a train in the rail transit industry, so that a convenient tool can be provided for detection personnel of the existing air compressor and a drying system thereof, the detection device can be used for detecting the air compressor at any time and any place, and a large amount of manpower and material resources are saved.
When the train is in a running state, if the air compressor fails, the train needs to be stopped nearby, however, the nearest stop point does not necessarily have the overhauling capacity of the air compressor. For convenient detection, the detection device provided by the invention has the advantages of small volume, light weight and portability, and simultaneously, the detection device also has the advantages of water resistance, dust resistance and shock resistance in consideration of the running environment of a train. The more important technical difficulty is that because the air compressors and the drying systems of the air compressors of the trains have various forms and brands, a large amount of preliminary research work is needed to find out the detector suitable for detecting all the air compressors and the drying systems of the air compressors.
According to the specific implementation mode of the invention, the portable air compressor detection device which can be carried by engineering technicians is provided, so that a brand new concept is brought to the rail transit industry: when the train is maintained regularly, the disassembly of the air compressor and the processing system thereof can be avoided, and particularly on a locomotive, the disassembly of the air compressor is a very complicated process due to space limitation; when the brake system of the vehicle breaks down, in order to eliminate or determine the problem of the air compressor or other air handling systems, most faults can be detected by using 5 temperature sensors, one dew point sensor and two pressure sensors, in case of doubt about the flow of the air compressor, the air compressor can be detected only by disconnecting the interface of the air compressor and a main pipeline such as a main air pipe and connecting a flow sensor in the detection device of the invention, so that the air compressor does not need to be specially sent to a special overhaul place. Compared with the traditional detection mode, the device and the method provided by the invention can obviously reduce the maintenance cost of the air compressor of the train and the drying system thereof, and greatly improve the overhauling efficiency and the turnover rate of the train.
The equipment is divided into three parts, namely a portable computer, a mainframe box and a sensor box according to various parameters of an air compressor and an air drying system thereof. The portable computer is used for interface and man-machine interaction, and the customized test software is stored in the portable computer and is in limited or wireless communication with a Programmable Logic Controller (PLC). The results of the test are also transmitted to the designated server by wire or wirelessly. The mainframe box mainly comprises a power supply module, a PLC module, an input/output I/O module, a wireless module and various indicator lamps. The main function of the system is to execute customized software, convert, calculate, judge the result, generate and transmit the report to the human-computer interface of the computer. The sensor box is used for storing various sensors including a pressure sensor, a flow sensor, a temperature sensor, a current transformer and the like in a centralized manner, and is convenient to carry, store and manage.
In one aspect, the present invention provides a portable air compressor testing device, including:
the test host comprises a power supply module, a PLC module, an I/O module at an inlet and an outlet end and a wireless communication module;
the sensor box comprises a pressure sensor, a temperature sensor, a dew point sensor, a flow sensor, an oil level sensor, a current transformer and a vibration sensor; and
a portable computer with customized software for interface and man-machine interaction, said computer being capable of communicating with a Programmable Logic Controller (PLC) via wire or wirelessly and also capable of transmitting the test results to a designated server via wire or wirelessly;
the test host mainly has the function of executing the customized software, converting, calculating, judging results, generating reports and transmitting information acquired by various sensors to a human-computer interface of the computer.
According to an embodiment, the power module in the testing apparatus may include a mobile power supply element and a power conversion element.
According to one embodiment, the PLC module in the testing device can collect the information returned by the sensor module according to the instructions of the customized software and convert the information into digital quantity, and process the digital quantity, including comparing the record with a standard value, and further directly generate a report or transmit the processed result to the computer to make a report and store the report.
According to one embodiment, the I/O module at the inlet and outlet end of the testing device can receive the signal of the external sensor and transmit the signal to the PLC module.
According to one embodiment, the wireless communication module in the testing device can facilitate communication between the PLC module and the computer and timely and safely transmit the testing result to a designated server
According to one embodiment, the temperature sensors in the testing device comprise temperature sensors for detecting the ambient temperature, the compressed air outlet temperature, the compressor head temperature, respectively.
According to one embodiment, the vibration sensors in the test apparatus comprise vibration sensors for detecting vertical, horizontal and axial vibration amplitudes of the compressor, respectively.
According to one embodiment, the computer in the testing device serves as a human-computer interface, and can issue instructions from a user to the PLC module and also return the operation results of the PLC module to the interface.
According to one embodiment, the test host and the sensor box of the test device are separately disposed, so that the sensors in the sensor box can be selectively used with the test host.
According to one embodiment, the customized software in the test device is divided into two parts, wherein: the first part is used for testing, so that corresponding testing software compiled according to the requirements of users and different models of air compressors is used for detecting and displaying a detection result and forming a detection report, signals transmitted by sensors are converted into digital quantity according to the air compressors and drying systems of different models and then are compared with a standard value, and the comparison result is stored in a storage unit of the PLC module or is transmitted to a designated person or a designated server through the wireless communication module according to the requirements of customers; the second part is database management, which is installed on a remote server and manages the air compressor in the form of a database.
In another aspect, the present invention further provides a testing method using the portable air compressor testing device, including:
(a) selecting a test item according to the models and the running conditions of the train and the air compressor;
(b) starting the testing device and selecting a proper sensor by using a detection program of the computer to detect the test item;
(c) judging whether a fault exists according to the detection result, finding out a fault component and indicating the component needing to be updated if necessary;
(d) repeating the steps (b) and (c) for different test items, so as to completely detect the air compressor;
(e) determining that the air compressor has no fault according to the complete detection result of the air compressor;
(f) a test report is generated, wherein the report may be stored in a storage unit or transmitted to a designated server according to the test requirements and further used for database management of the air compressor.
In still another aspect, the invention further provides the application of the portable air compressor testing device, wherein the testing device is used for detecting the air compressor on the equipment such as trains, subways, high-speed rails, electric buses, trucks and the like.
The detector has the following functions:
1. temperature, the inventor has designed three temperature sensors to simultaneously detect ambient or inlet temperature, compressed air outlet temperature, and compressor head temperature. Whether the air cooling system in the air compressor is normal or not can be detected through the temperature difference between the temperature of the compressed air output port and the normal temperature.
2. Oil temperature (cylinder surface test): the inventors have additionally designed two temperature sensors for sensing the input and output temperatures of the internal oil. Whether the operation is normal or not is judged by detecting the oil temperature during the operation, and the lubricating oil is invalid due to the overhigh temperature.
3. Flow rate: thereby the operating efficiency and the ability of filling wind of air compressor machine are judged to the output data of air compressor machine through the flowmeter collection. The air charging capacity of the air compressor is expressed in the time required for sufficient air of a brake system, the current test uses a positive displacement calculation mode, a large container is required for testing and a space of dozens of square meters, a large amount of calculation is also needed, the operation is very inconvenient, each measurement needs to be carried out by one air discharging, air charging, stable waiting and recalculation process, the time is generally consumed to 1-2 hours, in order to achieve the purpose of quick and accurate detection, the principle of a pitot tube flowmeter is adopted, the air compressor is not required to be disassembled, a connector of the air compressor and a main air pipe is opened on a train, and the air compressor and the main air pipe are connected into the flowmeter in series,
(on the flowmeter, different connectors are designed to adapt to different pipe diameters), the flow value of the air compressor can be obtained within a few minutes, and repeated measurement can be carried out.
4. The pressure sensor is connected to a meter on a fixed device for displaying the pressure reading, and the great defect is that the pressure sensor is inconvenient to check. In order to achieve the aim of frequently checking and detecting pressure, the pressure sensor needs to be modified into a plug-in pressure sensor aiming at different test ports. For the test position, the premise is that the air compressor is not moved as much as possible, for this reason, the inventor designs and selects 2 pressure test points, one is near the outlet of the air compressor, the other is near the outlet of the drying system, the test ports of the outlet of the air compressor are provided with some air compressors, the railway bureau adds the air compressors without the test ports, and the test ports passing through the drying system can be provided with the air compressors. The two pressure values are important parameters of the air compressor, and the difference between the two pressure values is also the working feedback of the drying system. In addition, the pressure sensor can also complete the tightness test. The current leak test detects the leak by applying a soap-like liquid to each interface and observing whether air bubbles are generated within a specified time or by completely immersing the air compressor in water after removing the motor. The inventor uses the pressure sensor, and the computer can automatically remind the detector whether leakage exists or not by observing the change of the pressure in a period of time through a pressure maintaining test. The pressure value of the safety valve can also be detected by using a pressure sensor.
5. Dew point: in the case of air compressors, particularly in the field of rail traffic, compressed air is the key to braking, and if the compressed air contains too much moisture, the compressed air can be deposited in a brake pipe, so that the braking efficiency is reduced, and the safety is further compromised. The detection of the dew point of the air compressor can ensure that the content of the moisture in the compressed air does not exceed a normal value.
6. A pressure switch: the pressure switch is a main part of the air compressor and is responsible for starting and stopping the air compressor. Along with time, the start-stop value of the pressure switch can drift, and the tester is provided with a test port for the pressure switch, can test at any time and correct the start-stop value of the pressure switch.
7. The current and voltage of the air compressor and the voltage of the air compressor do not have large variation, but the current changes according to the load, the deviation of the rotating shaft of the air compressor, the lack of lubricating oil, the entering of obstacles and the like all cause the load change of the air compressor, and a detector can know whether the air compressor normally operates or not by detecting the current. In order to reduce the process of connecting and detaching a power line of an air compressor, the latest current and voltage transformer technology is adopted, and only buckles of a transformer are buckled on a cable; the test device is prevented from being connected in series or in parallel with the power supply, the test risk is reduced (the running voltage of the air compressor is 380VAC), and the fault of the power supply wiring is reduced.
8. Vibration, the inventor has designed three vibration sensor, can detect the vertical of compressor or fan like this simultaneously, horizontal and axial vibration amplitude, and it also satisfies the test to the air compressor machine of knoll simultaneously, because the air compressor machine of knoll has had two test points in the design.
9. And the detection of the oil content, namely the compressed air coming out from the air compressor can contain lubricating oil. The lubricating oil affects the quality of the compressed air, so that an oil-gas separation filter is arranged in the compressor to ensure the quality of the output air. The quality of the oil-gas separator in the air compressor can be deduced inversely through detecting the oil content in the air.
10. The paperless maintenance record is realized, and all information including the maintenance date, the operators, the maintenance process and the maintenance result are all stored by a computer.
11. And managing big data of the air compressor.
Drawings
Fig. 1 is a system block diagram illustrating a portable air compressor testing device according to an embodiment of the present invention.
Fig. 2 is a schematic diagram illustrating an operation scheme of a portable air compressor testing device according to an embodiment of the present invention.
Fig. 3 is a flowchart illustrating a portable air compressor testing apparatus according to an embodiment of the present invention.
Fig. 4 is a block diagram illustrating a troubleshooting module in a program structure of a portable air compressor testing device according to an embodiment of the present invention.
Fig. 5 is a block diagram illustrating a second part of the program structure diagram of the portable air compressor testing device according to an embodiment of the present invention with respect to database management.
Detailed Description
In order that the technical solution, novel features, objectives and effects of the invention will be readily understood, the invention will be further illustrated and described in the following detailed description, taken in conjunction with the accompanying drawings.
According to an embodiment of the present invention, as shown in fig. 1, the portable air compressor testing device of the present invention includes the following modules:
1. the power module comprises two parts, wherein one part is a mobile power supply and consists of a battery, whether the mobile power supply is equipped or not can be selected according to different applications, the other part is power conversion, external 220V alternating current is converted into 24V or 12V or 36V power supply required by PLC and other wireless modules, and the power module is responsible for supplying power to all external sensors.
A PLC module: the PLC module is the executor of the customized software. According to the instruction of software it collects the information returned by sensor module and converts them into digital quantity, then processes these digital quantities including comparison of recorded and standard values, and thirdly directly generates report or transmits the processed result to computer, and makes various reports and stores them. The WAGO can be designed by the user or can purchase the ready-made mature products in the market as long as the products required by the automatic control can be met, and in the project, the WAGO controller is adopted.
3. And an I/O module at the inlet and outlet, wherein the I/O ports comprise digital signals and analog signals. The function of the part is to receive signals of various external sensors and transmit the signals to the PLC, so that the modules are selected to be matched with the PLC. In which a mutual inductor is used for testing current, firstly, a circuit breaker is added in the invention to ensure safety, and secondly, the current value on the air compressor is in ampere level, so that the inventor adds a conversion module to convert the current quantity in ampere level into milliampere level so that an I/O terminal can accept the current.
4. The wireless communication module: the role of this module is primarily to facilitate communication between the PLC and the computer. Secondly, the test result is transmitted to the designated server safely in time.
5. A sensor module: the intelligent oil level sensor comprises a pressure sensor, a temperature sensor, a dew point sensor, a flow sensor, an oil level sensor, a vibration sensor and the like, and is used for collecting various external information such as temperature, pressure and the like and transmitting the information to the PLC. In design, the modules can be collectively placed in another suitcase, and the corresponding sensors can be taken out to be accessed when the portable electronic device is used. Or may be integrated in the mainframe box. In addition, the inventor also puts other external devices such as a current transformer, a detection joint of a pressure switch and the like into the module.
6. The customized software is the operation and operation core of the system. The air compressor testing system is divided into two parts, wherein the first part is used for testing, corresponding testing software is compiled according to the requirements of users and different models of air compressors, operators complete detection step by step according to software prompts, and finally, detection results are displayed, and detection reports can be automatically filed. The air compressors and the drying systems of different models take standard values of the air compressors and the drying systems as input, and signals transmitted by the sensors are converted into digital values to be compared with the standard values. And then the comparison result is stored in a storage module of the PLC or transmitted to a designated person or a server through a wireless module according to the requirement of a client. The second part is database management, which is installed on a remote server and manages the air compressor in the form of a database.
7. A computer: the computer is mainly used as a human-computer interface, and can issue human instructions to the PLC through the computer and return the calculation results of the PLC to the interface, including the final test report.
According to an embodiment of the present invention, an operation scheme of the portable air compressor testing device of the present invention is shown in fig. 2.
In the scenario shown in FIG. 2, the inventors chose to use CODESYS as the programming language. PLC the inventor has selected WAGO, and the mainframe box is externally connected with a 220V power supply, and the power supply is converted into 24V direct current to supply power to the PLC, and all sensors are concentrated in the sensor box, and are taken out when in use and connected to the I/O module of the mainframe box through a quick interface. The PLC executes the edited software, or collects the sensor information or calculates and compares and returns the result to the human-computer interface module of the computer. The connection between the computer and the PLC can be realized through an interface connected to the mainframe box through a wire or through a wireless module arranged in the mainframe box.
Fig. 3 and 4 are software program structure diagrams of the portable air compressor testing device according to an embodiment of the present invention, wherein:
201 automatically or manually selecting a test item according to the fault information;
202 executing relevant test items for troubleshooting;
203, intelligently positioning the fault module according to the empirical data and the test result;
204 prompting the process steps of replacing the fault module;
205 re-executing the complete detection process of the air compressor;
206 automatically generates a troubleshooting test report (including the location of the failure, the method of troubleshooting, and the final complete test).
A second part of the program structure diagram for describing the portable air compressor testing device according to an embodiment of the present invention is shown in fig. 5, which is a structure diagram related to database management, wherein:
301 the device automatically stores data module, storing picture, storing test result, storing trend graph and other test information;
302 additional information to be manually input, such as the number of the train, the model of the air compressor, the number of the tester, etc.;
303, a local database for temporarily storing test data, and having the functions of automatically saving power failure, automatically generating a report and the like;
the 304 data uploading module uploads the data to a database in a ssl encryption mode;
305 network module including but not limited to network communication module through 4G, wifi, etc.;
306 a big data management module;
307 remote database MySQL, automatically pushing custom alarm information;
308 artificial intelligence learning module;
309 maintaining and managing an air compressor;
310, managing spare parts;
311, a handheld device retrieval module, wherein the IOS or Andriod system mobile phone retrieves the detection information and receives pushing;
312, a web page terminal retrieval module, a computer or a notebook, etc. for retrieving the detection information and receiving the push,
313 other terminal modules;
314, encrypting and pushing the data to be pushed to the terminal user;
315 push the data of different categories to managers, maintainers, purchase managers, etc.
The features of the product of the invention include:
1. this tester is portable check out test set to the air compressor machine. The novel railway sensor integrates the latest sensor technology and the PLC technology in the world, has small volume and light weight, and meets the requirements of the railway industry on water resistance, dust resistance and shock resistance. The tester combines special conditions of the rail transit industry, and in the detection process, except for special conditions, the flow meter is required to be connected in series between the air compressor and the drying system, the air compressor and/or the drying system thereof are not required to be disassembled, the integrity and the original installation of the air compressor and/or the drying system are ensured to the maximum extent, and the performance of the tester is not influenced by detection. This has also very big extension this tester user's scope, has reduced the threshold of marcing into: in the field of rail transit, an unqualified person cannot drive the air compressor system because it involves braking and driving safety.
2. The tester integrates sensors or equipment required by main items detected by the air compressor, so that an operator can solve the problems related to all air compressors at one time. According to the maintenance requirements of the air compressor, particularly the air compressor on the train, appointed data are collected, the data are recorded, and the quality of the air compressor is judged through comparison with correct data.
3. The detector is used for detecting all air compressors, so that the selection of the types of the sensors, the selection of the number of the sensors and the selection of the detection positions are very important characteristics of the product different from fixed test equipment. The inventor conducts deep research and a large number of experimental certifications on various air compressors and the layout thereof, optimizes the air compressors for many times, and achieves the aim of conveniently detecting all the air compressors. For example, the temperature sensors are in a contact type, a non-contact type, a resistance type galvanic couple type and the like, theoretically, the contact type temperature meter is the most reliable, the air compressor which is detached can be used, but the detection is inconvenient, the air compressor needs to be opened, the sensors are placed in the air compressor, a specific closed interface is found, and the like, and the non-contact type temperature meter generates deviation due to different habits of users, different test points and different test distances. Through research on different air compressors, a test point is selected on the outer diameter of an input/output air pipe, a contact type metal sensor is selected and bound on the outer diameter of the input/output air pipe, and verification is carried out on a large amount of data in a laboratory, so that the temperature difference between the temperature of air in the pipe and the temperature difference between the outer wall of the pipe diameter is 3 degrees. Therefore, the temperature sensor can measure all air compressors very conveniently, and meanwhile, the accuracy of measured data is guaranteed.
4. Because the device is attached with various sensors and the power needed by the sensors is inconsistent, another important characteristic of the tester is that the power of all the sensors is provided by the main case, and the sensors can be effectively powered by connecting the sensors to the main case through a standard interface.
5. The number selection and the sequence of the sensors of the device are also the conclusion after a large number of studies. The temperature of the input and output air pipe relates to an air pipe cooling system, the input and output of the oil temperature indicate an oil way cooling system, and the temperature of the machine head indirectly monitors the oil temperature in a high-pressure state, so that the quality of the machine oil is monitored. The pressure sensor shows the output pressure of the air compressor, and is an important parameter of the air compressor, the tightness can be detected, and the dew point sensor reflects the working condition of the drying system. The system comprises 5 temperature sensors, two pressure sensors, an air compressor output pressure sensor, a pressure sensor after passing through a drying system, and a dew point sensor, wherein most faults of the air compressor system can be solved by adding a flow sensor. Further detection can be realized by additionally arranging a vibration sensor, a current-voltage transformer and a particle sensor in the air, so that the comprehensive detection of the air compressor is completed.
6. The data acquisition of the tester to the detected object is linear rather than point. For example, for the output pressure value and temperature value, the current testing mode is a handheld device, so the obtained result is at a certain time point, and the tester detects all changes of the pressure value from 0KPA to 100KPA for a certain time period. The test of the operating current also records all data for a certain period of time, so that the detector finds those occasional faults.
7. The tester has standardized test program and test steps, is convenient and simple, and can be operated by an operator only according to the prompt of a computer, thereby firstly ensuring the accuracy of the acquired data and secondly reducing the qualification threshold of maintenance personnel. Meanwhile, due to the fact that the wireless transmission module is installed, a professional of a maintenance headquarters can see maintenance contents and results in time, and when a fault occurs, a field operator can communicate with a more professional of the headquarters at any time to judge the result.
8. Scalability and compatibility. Compatibility is considered by software and hardware adopted by the design of the tester, and Siemens and STEP software or FESTO and CODESYS software can be selected as the PLC. This ensures the reliability of the product supply. Redundant inputs are reserved in the I/O module so that new test equipment or new sensors can be accessed directly in the future when new demands are made. For example, the noise is not detected in various tests at present, and in actual work, the ultrahigh noise is an expression that the operation of the air compressor is problematic.
9. The design of the tester separates the sensors from the test box, and allows an experienced operator to select the desired sensors to go to the field, thereby making the device more portable.
The advantages of the product provided by the invention include:
1. the portable air compressor machine can be carried to any place to overhaul any air compressor machine. The air compressor inspection method has the main characteristic that the air compressor is prevented from being detached from a train during primary and intermediate-level maintenance, and the air compressor can be completely inspected only by connecting the air outlet of the air compressor with the sensor provided by the invention and selecting different sensors. When the air compressor must be disassembled in advanced repair, the air compressor with the replaced parts can be detected on site, so that the air compressor is prevented from being returned to a major repair factory, and only fixed maintenance equipment for the air compressor is available at the air compressor manufacturer and a large repair base at present. In order to eliminate the possibility of failure of the air compressor when the brake system fails, the decision can only be heard and seen on site by an experienced engineer. The portable tester provided by the invention can be used for carrying out complete inspection on the air compressor on site according to national standards or railway bureau standards so as to determine the fault or no fault of the air compressor and avoid sending the intact air compressor to an original factory or an overhaul base.
2. And the maintenance cost is reduced. The disassembly of the air compressor from the train is time-consuming and labor-consuming, the stop time of the train is also increased, and the centralized maintenance by the original factory or the overhaul base is firstly high in cost and secondly time-consuming. More air compressors are required to maintain the turnover rate.
3. The turnover rate of the air compressor and even the train is accelerated due to the on-site maintenance.
4. The standardization of the maintenance procedure of the air compressor is realized, the report is paperless, all data come from sensors and are directly recorded by a computer, the accuracy of the data is improved, and the missing detection, manual reading and manual recording error rate are avoided. The prompt of image and characters in the test process simplifies the test, and reduces the technical threshold of the air compressor overhaul personnel.
5. The customer is provided with a portable acceptance tool to clear the responsibility between the supplier and the customer.
6. One machine is used for one file, and the report generated by the customized software actually provides a portable file for the air compressor and the drying system thereof, so that the management capability is improved. At present, in the railway industry, in order to provide train turnover rate, an air compressor is replaced in an assembly mode, the replacement of the assembly refers to the fact that the air compressor on a train is integrally disassembled and transferred to a supplier, the supplier provides an integral air compressor and a drying system which are maintained, the systems can be old and have no fault or have faults and then are maintained, and the systems can also be new.
7. The second part of the customized software is the establishment and management of an air compressor database, different from enterprises, the number of the air compressors is several or dozens, in the rail transit industry, each vehicle is provided with an air compressor, the number of the air compressors kept by the general Chinese railway company is more than 10 thousands, the service life of the air compressors reaches 20 years or even 30 years, and the management of the respectively established archives of the air compressors is very important. The customized software inputs each air compressor and the running state of the air compressor into the database in a wired or wireless mode, and further establishes files for the air compressors to form the database of the rail transit air compressors, so that the concept of big data can be used for management in the future, such as whether the air compressor of a certain type is more effective, the failure rate is lower, whether the air compressor of a certain type is defective, claims can be made and the like.
The above embodiments are provided for further description and illustration of the technical solution of the present invention, and are not intended to limit the scope of the present invention. Variations of equivalent structures or steps, which may be made by those skilled in the art using the description and claims of the present invention, are within the scope of the present invention.
Claims (11)
1. A portable air compressor machine testing arrangement, it includes:
the test host comprises a power supply module, a PLC module, an I/O module at an inlet and an outlet end and a wireless communication module;
the sensor box comprises a pressure sensor, a temperature sensor, a dew point sensor, a flow sensor, an oil level sensor, a current transformer and a vibration sensor; and
a portable computer with customized software for interface and man-machine interaction, said computer being capable of communicating with a Programmable Logic Controller (PLC) via wire or wirelessly and also capable of transmitting the test results to a designated server via wire or wirelessly;
the test host is mainly used for executing the customized software, converting, calculating, judging results, generating reports and transmitting information acquired by various sensors to a human-computer interface of the computer;
the power supplies of all the sensors included in the power supply module are provided by the test host, so that an effective power supply can be obtained only by connecting the sensors to the test host through a standard interface, and the high-voltage arrangement required by the air compressor is prevented from entering the detector, so that the wiring is convenient and the power supply safety is improved;
the temperature sensor comprises a temperature sensor, an internal oil input temperature sensor and an internal oil output temperature sensor which are respectively used for detecting the ambient temperature, the compressed air outlet temperature and the compressor head temperature; all the temperature sensors do not need to open the air compressor or contact gas or oil in the air compressor, so that the convenience of testing and the safety of the air compressor are guaranteed; the internal oil input temperature sensor and the internal oil output temperature sensor are respectively used for detecting the input temperature and the output temperature of internal oil, so that whether the operation is normal or not is judged by detecting the oil temperature during the operation, and the lubricating oil is prevented from being invalid due to overhigh temperature; the outer diameter of an input/output air pipe is selected as a test point of the temperature sensor, and a contact type metal sensor is bound on the outer diameter of the input/output air pipe, so that all air compressors can be conveniently measured, and meanwhile, the accuracy of measured data is ensured; and the running state of the cooler is judged according to the temperature difference between the inlet and the outlet of the gas circuit and the oil circuit;
the current transformer inherits the principle of convenient detection and train safety guarantee, the working condition of a three-phase power supply can be obtained by only putting a cable containing an insulating layer into a button of the current transformer without disconnecting a power supply by using a button type current transformer, and a test device can be prevented from being connected in series or in parallel with the power supply, so that the power supply wiring fault and the test risk are reduced; and the air compressor can be detected without an electrical engineer;
the flow sensor adopts a pitot tube principle, the interfaces of the air compressor and a main air pipe are opened on the train under the condition that the air compressor is not detached from the train, the output of the air compressor is connected to the input of the flow sensor in an external connection mode, and the flow value of the air compressor can be obtained, so that the completeness, the original installation performance and the performance of the air compressor and/or a drying system can be furthest ensured not to be influenced by detection;
the pressure sensor is a plug-in type pressure sensor which is modified aiming at different test ports, and two pressure test points near the outlet of the air compressor and near the outlet of the drying system are selected when the pressure sensor is used, so that two pressure values are measured from the two pressure test points, important parameters of the operation of the air compressor are provided, and the difference value of the two pressure values is also a working feedback parameter of the drying system; in addition, the pressure sensor can also complete a tightness test, the pressure change is observed within a period of time through a pressure maintaining test, a tester can be automatically reminded whether leakage exists or not through the portable computer, and the pressure sensor can also detect the pressure value of the safety valve;
the testing positions of the pressure sensor and the dew point sensor can exactly reflect the standard parameters of the air compressor and can help the fault diagnosis of the air compressor;
the customized software is divided into two parts, wherein the first part is used for testing, so that corresponding testing software compiled according to the requirements of users and different models of the air compressor is used for detecting and displaying a detection result and forming a detection report, signals transmitted by the sensor are converted into digital quantity according to the air compressors and the drying systems of different models and then are compared with a standard value, and then the comparison result is stored in a storage unit of the PLC module according to the requirements of the users or is transmitted to a designated person or a designated server through the wireless communication module; the second part is used for managing a database, is arranged on a remote server and manages the air compressor in the form of the database; moreover, the customized software inputs each air compressor and the running state of the air compressor into the database in a wired or wireless mode, provides a portable historical file for each air compressor, improves the stability and predictability of detection and maintenance, reduces potential safety hazards, forms a large database of the rail transit air compressors at the same time, facilitates the overall optimization of the running, the detection and the maintenance of the rail transit air compressors, and improves the management efficiency;
the PLC module can collect the information transmitted back by the sensor module according to the instruction of the customized software and convert the information into digital quantity, and the digital quantity is processed, including the comparison between the record and the standard value, and in addition, the processed result is directly generated into a report or transmitted to the computer to be made into a report and stored;
the test host and the sensor box are separately arranged, so that the sensor in the sensor box can be selectively matched with the test host; meanwhile, as the measuring equipment is required to be regularly checked by a third party approved by the country, the single sensor box not only solves the problems of transportation and packaging in the process of sending and checking, but also avoids unnecessary idling of the main case and risks in transportation;
the portable computer and the test host are also separately arranged and can be connected by wire or wireless, thereby solving the problems of space and distance in the actual operation process; the data acquisition of the test device to the detected object is linear rather than point, so that all data in a certain time period can be set and recorded, and a detector can find accidental faults;
the testing device can be used for completely detecting the air compressor under the condition that the air compressor is not detached from the train, so that the air compressor can be prevented from being detached from the train during primary and intermediate-level maintenance, the air compressor can be completely detected as long as the air outlet of the air compressor is connected with a sensor which can be selected, even if the air compressor is required to be detached during high-level maintenance, the air compressor with replaced parts can be detected on site, the air compressor is prevented from being detached from the train and sent to a factory with fixed air compressor maintenance equipment or a maintenance base with a laboratory for maintenance, a user of the air compressor can check and accept a new air compressor or an air compressor which is completely maintained, the maintenance efficiency and the safety level can be improved for the rail transit industry, and the maintenance cost is reduced.
2. The apparatus of claim 1, wherein the power module comprises a mobile power element and a power conversion element.
3. The apparatus of claim 1, wherein the structure of the customization software comprises: automatically or manually selecting a test item according to the fault information; executing relevant test items for removing faults; intelligently positioning a fault module according to experience data and a test result; prompting the process step of replacing the fault module; re-executing the complete detection process of the air compressor; and automatically generating a fault removal detection report, wherein the fault removal detection report comprises a fault positioning method, a fault removal method and a final complete test, and the final complete test report also comprises all manual detection processes, so that the electronization of the detection report of the air compressor in the railway industry can be realized.
4. The apparatus of claim 1, wherein said inlet-outlet port I/O module is capable of providing sensors with various operating power required by it and receiving and transmitting external sensors' signals to said PLC module.
5. The apparatus of claim 1, wherein the wireless communication module facilitates communication between the PLC module and the computer and timely and securely transmits the test results to a designated server, wherein the communication between the PLC module and the computer enables a maintenance worker to operate the air compressor in the cab of the locomotive by operating a handle on the locomotive or a valve under the locomotive to check the operation state of the air compressor.
6. The apparatus of claim 1, wherein the vibration sensors comprise vibration sensors for detecting vertical, horizontal and axial vibration amplitudes of the compressor, respectively.
7. The device of claim 1, wherein the computer is used as a man-machine interface, and can issue a user's instruction to the PLC module and also return the operation result of the PLC module to the interface.
8. A testing method using the portable air compressor testing device of any one of claims 1 to 7, comprising the following steps:
(a) selecting test items according to the models and the operating conditions of the vehicle and the air compressor;
(b) starting the testing device and selecting a proper sensor by using a detection program of the computer to detect the test item;
(c) judging whether a fault exists according to the detection result, finding out a fault component and indicating the component needing to be updated if necessary;
(d) repeating the steps (b) and (c) for different test items, so as to completely detect the air compressor;
(e) determining that the air compressor has no fault according to the complete detection result of the air compressor;
(f) a test report is generated, wherein the report may be stored in a storage unit or transmitted to a designated server according to the test requirements and further used for database management of the air compressor.
9. Use of a portable air compressor testing device, wherein the portable air compressor testing device according to any one of claims 1-7 is used for testing an air compressor on a vehicle.
10. The use of claim 9, wherein the vehicle is a train, subway or high-speed rail that uses compressed air generated by an air compressor for braking.
11. The use according to claim 9, wherein the vehicle is an electric bus or truck using compressed air generated by an air compressor for braking.
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| CN2018110282619 | 2018-09-04 | ||
| CN201811028261.9A CN109268248A (en) | 2018-09-04 | 2018-09-04 | Portable air compressor test device and method |
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| CN113933001B (en) * | 2020-06-29 | 2024-04-30 | 广州地铁集团有限公司 | Main air pipe pressure leakage assessment method and device based on big data and electronic equipment |
| CN112326937B (en) * | 2020-11-04 | 2022-12-13 | 衢州学院 | Oil gas detection device of low-carbon screw air compressor |
| CN114112447B (en) * | 2021-11-24 | 2024-05-28 | 中车大连机车车辆有限公司 | Locomotive departure front function test method |
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| CN203009263U (en) * | 2012-12-11 | 2013-06-19 | 天津众恒控制工程有限公司 | Air compressor performance test board for vehicle |
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| CN102691651A (en) * | 2012-05-23 | 2012-09-26 | 上海昶嘉工业设备有限公司 | Energy-saving tester for air-compressor system |
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