CRH_1 type EMU master handle Typical Fault Analysis and Countermeasures

A master handle functions

 

    Master handles EMU traction, brake master control command generator, the train started, the driver during normal operation achieved primarily through the operation of the master handle the operational control of the train.

 

1.1 Master handle stalls

 

Master handle a total of 16 stalls:

 

(1) - a neutral position (Figure 1, the "1" bit);

 

(2) - one constant bit (Figure 1, the "3");

 

    (3) three speed increment bit (Figure l interval "4"):

 

    (4) three velocity decrement bits (Figure 1 interval "2");

 

    (5) seven brake position (Figure 1 interval "5"):

 

    (6) - an emergency brake position (Figure 1, the "7" position).

 

    Front seven stalls traction file tip position is behind the eight brake file handle vertical position as neutral. Operations Master handle, the control rod end has a push-button switch, only press this switch, a lever to push the front of the towing gear, or only pull to the back of the brake file

 

2 master handle common faults

 

    CRH, type EMU since 2007 passenger car segment in Shanghai Action Army put into use since the emergence of the master handle various types of failures, stable operation for EMU caused a greater impact. Frequently Asked Questions can be summarized into the following categories: ① connector problem. ② brake safety circuit contacts problem. ③ loose rubber handrail problem. Here and analyzed for typical problems, and propose an improved method.

 

2.1 control handle loop connector problem

 

    Failure to pass: December 21, 2009, CRH, 050B play Shanghai - Zhengzhou D86 times cross-road, 00 owners control, IDU newspaper "master handle failure" (see Table 1, fault code 8205). IDU interlock interface displays "master in the brake lever position" while the target speed is displayed on the display device is a brake level, at which point the handle actual level bit is 0? Bow down to reactivate the train, IDU interlock interface is still shows "master in the brake lever position" and lead to the train brake test can not be started. Reactivate the train again, the fault disappears. And finally to the train station in Zhengzhou delayed 12 min.

 

    December 22, 2009, CRH, 050B play Shanghai - Zhengzhou D86 times cross-road, 00 owners control the way the master handle IDU reported failure fault (fault code 8209), after two re-activated, one-off battery reset processing, still valid, disconnected after 00 cars cyberspace open, re-activate the fault disappears. Subsequent runs on the way, the train and reported to handle faults (fault code 8205), many of the reset operation is invalid, the applicant rescue locomotive, speed limit 120 km / h. Arrived in Zhengzhou station late Sh13min. Emotionally intense travelers.

 

    Failure Analysis: For the 21 failures, according to the data analysis, IDU reported master grip handle failure is due to host two pairs of contacts are not synchronized, a difference of one or more locations. Thereafter, the driver applied an emergency brake, handle contact signal re-tested. 9:56 second reactivate the train driver, start braking test, two pairs of contacts signal display handles levels are consistent, both for 0, brake test is passed, the fault disappears, it is judged master handle failure, replace the main handle, after numerous tests, the fault is not reproduced.

 

    Since December 21 have been replaced 00 owners control handle, so you can initially ruled on December 22 as the main control handle failure phenomenon caused elapsed after careful investigation on the master loop handle and found the bottom right of the cab console C.A1 .2.2. Xl terminal block 76-82WAGO plug loose, this plug is re-seated fault disappears after several tests normal, fault conditions!

 

    For the complete elimination of hidden faults, technicians download failure data analysis, when the master handle on the 0 (Figure 3 and 4 range -7000 to 0), the main control lever A bit of contacts 4 feedback signals are normal , and specifically Figure 3. The contact B 1B, 2B, 3B is a normal position, in particular in Figure 4, but not correct feedback 4B bit, set to 0, the low level. B-position contact is exactly this combination of signals at a master handle the brake position feedback signal. This led to the handle when the master of the O position, the target speed is displayed as a brake position, and the impact 4B bit low for direct reason is the lower right of the cab console C. A 1.2.2.Xl terminal block 76-82WAGO plug loose, 79 points on the signal can not be correctly transferred to DXA4 module. Although this time the master handle in 0, due to safety principles, the train or the implementation of the Class I brake. It can be concluded, CRH, 0508 00 owners control handle direct cause of failure is due C. A1.2.2.Xl terminal block 76-82WAGO caused by loose plugs.

 

    Corrective measures: With CRH, type EMU transported weeks of years of increasing aging caused by the failure of the connector issues will become increasingly prominent. It is necessary to CRH EMU] type connectors to carry out regular inspection and found that the connector is abnormal change in time, especially to ensure EMU cab connector in good condition.

 

2.2 brake safety circuit contacts question

 

    Failure to pass: November 3, 2010, EMU CRH, 060B from Ningbo East are prepared to open D5591 entire passenger train, 01 owners control the emergency brake is applied when the full column can not be alleviated, 00 owners control the role of a good time all columns . Adopted a series of emergency measures invalid, for CRH, 060B for decommissioning process.

 

    Failure Analysis: Technical staff on the train for CRH, 0608 01 owners control handle checks, handle normal mechanical action, look no exception. Measured on the master loop handle

 

    Measurement results with the normal table does not match the master handle contacts are closed, the brake safety circuit inductive load more current is large, this loop series master controller on the 5th and the 10th contact welding adhesions leaving the string appears safe loop can not be closed is causing the main reason for this train outage.

 

  Corrective measures: recommended manufacturers enhance the capacity of the master handle the contacts and breaking capacity, improve the stability of the master handle. Emergency measures: handle emergency brake master position switch shorted. In the emergency brake master handle position, since all level digital signals are 0, TCMS will still be automatically applied the emergency brake, but in order to ensure reliable emergency brake is applied, the runtime for the emergency brake is applied, it is recommended directly by the emergency stop button.

 

    Manufacturers have pre-contact capacity on the main lever to improve and replace the existing master control lever, brake circuit has no contacts ignition and welding faults.

 

2.3 rubber handrail Loosening

 

    Failure to pass: July 23, 2010, EMU CRHi 059B served D5655 times cross-road, 00 owners control, not to mention drivers to reflect on the handle speed of the master, "O" position could not move, then you can handle a little activity Normal operation.

 

    Failure Analysis: examination revealed the master handle rubber handrail bit loose, rubber handrail under external force to move to a certain height, the upper part of the handle causes the button is not pressed, the handle can not be pushed to the traction.

 

  Corrective measures: the manufacturers of the master handle rubber handrail to transform, enhance motor car spare parts procurement and acceptance of the work to ensure that the master handle product quality.

 

3 Conclusion

 

    Master handles are CRH, type EMU major human manipulation interface, the function directly affects the stability of EMU safe and stable operation. To do handle failure investigation on the master control, we can only work from everyday use, carefully study various failure scenarios, careful analysis of the cause of the malfunction, constantly sum up, effective corrective measures proposed in order to better ensure the EMU Group Master handle reliable and stable operation, in order to better achieve high-speed railway passenger transport task.