About CRH5 type EMU towing handle failure analysis and related measures

2013-07-11 15:19:02

Ning Zhiqiang

(Zhengzhou, Henan Province, Zhengzhou Bus Depot EMU as 450,000)

Abstract: In this paper, Zhengzhou EMU actual use of the overhaul of CRH5 type EMU traction brake handle common failures are analyzed in detail and make some actual Hotbox system failure emergency treatment and preventive measures. Mainly from the brake lever traction control principle, structure and parts of the failure analysis, combined with the use of maintenance experience, the reason for the fault-prone from the principle of the design process, maintenance requirements and other aspects of the development of relevant measures. Judging from the actual operation, through continuous optimization measures, the failure rate has decreased significantly, to ensure the safety and stability of EMU operation.

Keywords: CRH5 type EMU Hotbox detection system false alarm

For the train, the traction brake handle is a very important equipment, traction brake handle failure affects directly back to traffic safety, especially for high-speed operation of the EMU is a top priority.

CRH5 type EMU CDB dependence in Zhengzhou, the failure rate is higher, to mention under CRH5 type EMU brake handle failure analysis.

One, CRH5 type EMU traction control principle brake lever

As shown below, CRH5 type EMU traction, braking command lever; This lever is used to control the traction / braking systems, traction or produce the desired braking force. The lever to an intermediate position (with a recess for positioning) and the intermediate position of two adjacent work area.

The handle located six stalls, divided into five zones, ahead of the traction area, back to the braking zone, and finally as an emergency braking zone.

● traction traction zone area includes two fan zones, the control handle to move forward l O. , The smallest available traction, continue to push the lever forward, traction will push forward with the lever angle increases in proportion gradually increased until maximum traction.

● braking zone pulling back the control handle can be obtained braking force, braking zones can be divided into two sectors zone and an emergency brake position.

First sector: only the movable shaft to electrical braking force, the first end of a fan-shaped region most effective electrical system for maximum force. In this region there is a recess at the end.

The second slice of the pie: dynamic electric braking force applied to the shaft still while dragging air braking force applied to the shaft. In this region there is a recess at the end.

Emergency brake position: the most rearward position, in this position, the movable shaft electric brake is disabled, emergency safety loop is opened, then the exhaust pipe and the brake for emergency braking.

Second, the traction control command transmission brake handle

As shown below, the brake lever traction traction / brake command, respectively, by the brake buses, network TCMS bus transfer. Wherein the brake command to an analog signal sent to each of the bus by the brake braking the car Confucius and unit BCU, the BCU control unit of the vehicle brake; traction command to a digital signal through the signal generator TCMS pulling each bus TCU vehicle traction control unit, and then by the TCU traction control unit controls the vehicle traction. Issued traction traction brake handle / brake signal is divided into two-way redundancy, to ensure safety.

Third, pulling the brake lever signal detection

Towing handle is actually a cam-controlled encoder, traction brake signal when the drawbar in different positions according to the cam control the micro switch is closed to generate the encoded data of a brake traction control. Drawbar from emergency brake position to the maximum traction angle artificially defined bits 0-90 degrees, traction rod in different positions have different encoding amount corresponding to different angles. Brake lever traction test is based on the software metering handle in the corresponding position at the correct angle to determine the traction brake handle is in good condition. Specific measured as follows:

1, the measurement position determination

Shown above: abscissa position angle value, the vertical axis is a numeric variable; To ensure accurate measurements, were used to measure the position of the maximum traction (90, 368), the first sector of traction (65 degrees, 265 ), neutral position (55 °, 225), braking the first sector (32.5 degrees, 133), the maximum brake position (10 degrees, 41), the emergency brake position (O °, 0).

2, measurement method

1: Activate the cab master key a laptop connected serlink98-MPU-TRA-choice Serdeb98-open the towing handle test file LC. Sdb file a select Trace random, began towing handle Test:

September 1, 2008 D141 (CRH5036A) times CRH503600 master, the driver can not find traction continuous output, the 2nd back library checked and found 00 cars pushed to the maximum towing towing handle, the output angle transitions, the bank replaced 00 vehicle traction brake handle, the fault disappears.

September 28, 2008 D133 (CRH5036A + CRH5042A) runs on the way CRH504200 owners control, traction maximum output of running the way 40KN, 28 日 library checked and found CRH504200 car towing brake handle encoder output signal failure, the replacement library After the test is normal.

October 2, 2008 D136 (CRH5036A + CRH4042A) times CRH504200 owners control, the driver found constant instability, 3 night back after 00 vehicle traction Zhengzhou library brake lever, run observation, follow-up observations after three cross-road fault disappears.

November 21, 2008 D132 times (CRH5038A + CRH5037A) and November 22, 2008 D136 times (CRH5038A + CRH5037A) running on the way 5038AOO cab owners control the brake pressure gauge appears insufficient, bank checks CRH503800 vehicle traction , brake handle encoder output angle and actual angle difference of 14 degrees, 25 November 2008 replaced properly.

At 7:22 on April 11, 2009, by the Zhengzhou to Beijing West D134 Hom (CRH5036A + CRH5041A, CRH503600 owners control) appeared in Zhengzhou station made car full column traction blockade (traction 4KN), library check for the traction brake handle encoder output signal failure, the 11th replacement brake lever replacement CRH503801 vehicle traction test after properly.

July 12, 2009, by the Beijing West to Hankou D123 times (CRH5038A + CRH5040A heavy linkage EMU, CRH503801 owners control) 14:43 arrive on station in Zhengzhou, 14:48 distribute car driver instruction given traction , traction after rising instantly disappear, bank check for the traction brake handle encoder sudden intermittent faults. The 12th replacement library

CRH503801 car rear brake lever traction test is normal.

Five, towing handle failure processor precautions

According to the typical failure cases can be seen:

1, CRH5 traction handle the failure rate is high, there is a big security risk.

2, can be found by the software detects a fault pulling the brake lever.

In the ordinary course of the repair process, we must do the traction brake handle fault prevention, identify problems early advance replacement. First, the use of software testing is a very good way. Therefore, in a repair job, the use of software fault detection can be found in advance, early treatment. The second is based on towing handle failure points to transform. So as to achieve effective prevention traction parking brake handle failure caused the accident late goal.

LoginName:
Password:
Verification: