Unit brake test stand
table of Contents
I. Overview 2
Second, the use of conditions 2
Third, the main structure of the composition 3
Fourth, the main technical parameters 3
V. Instructions for use 4
Sixth, security 6
Seventh, electric cabinet maintenance 6
Eight, electric cabinet operating procedures 7
I. Overview
1. The equipment is our company's dedicated research and development, design of special test equipment according to the overall design and maintenance process of the Harmony Electric Locomotive and the structural characteristics and working conditions of the unit brake.
2. Equipment Name: "Unit Brake Test Bench" Model: HZL-HH-01
3. The equipment can be applied to the brake devices of HXL1, HXL2 and HXL3 locomotives, with manual and automatic control functions; over-current, over-voltage, limit and other protective measures; simplified Chinese Windows XP operating interface; powerful data acquisition And processing functions.
4. The installation and commissioning of the equipment shall be completed by the supplier, and the initial test shall be completed by the supplier.
5, please read this manual carefully before use.
Second, the use of conditions
1, the altitude does not exceed 2000 meters.
2, the ambient temperature: 0 °C ~ +40 °C.
3. During the period when the device is stopped, the ambient temperature is not lower than -10°C.
4, relative humidity is not more than 85%.
5, the grid line voltage fluctuation is not more than ± 5%, the waveform span is not more than ± 10%.
6, in the absence of conductive, flammable, explosive dust, no corrosion of metal and destroy the insulation of gas and vapor applications.
7. Use indoors without strong vibration and impact.
Third, the main structure
1, test bench cabinet 2, industrial control machine and software
3, programmable controller 4, electronic control valve
5, sensor 6, spring tube pressure gauge
7, digital pressure gauge 8, low-voltage electrical appliances
Fourth, the main technical parameters
1. Rated power supply voltage: (AC380V AC220V); 50Hz
2, compressed air pressure: 1Mpa
V. Instructions
1. Power on: Close the Main Power switch and the power indicator light on the front panel.
2. Turn the key switch on, start the IPC, and display the Windows XP operation interface.
3. Double-click the QYB icon on the desktop to start the configuration project and present the human-machine interface;
4. Manual test: Set the (manual/automatic) selector switch on the panel to manual.
5. The brake cylinder inlet and the spring cylinder inlet on the back of the test bench are respectively connected to the brake cylinder and the spring cylinder.
6. Press the corresponding button according to the test requirements until you meet the requirements and release the button.
7, brake cylinder pressure test, when the pressure to the pressure value, the timer switch to the open position, start timing.
8. Automatic test: Turn the operation mode switch to automatic position: Click the corresponding button on the display interface as needed.
9, specific test reference unit brake detection standards.
The following items are for reference only
1, sensitivity test
The brake cylinder rushed into 50KPa pressure air and tested 3 times in a row.
2, brake shoe gap adjuster test
2.1 Determine a stable brake shoe clearance
Manually adjust the brake shoe and tread clearance to 25-28 mm, perform five brake-relief tests, and then perform ten brake-relief tests after finding that the clearance does not change. At this time, the stability value of the brake shoe and tread clearance is determined. The brake shoe clearance for this unit is a, and the stability shoe clearance should be between 6mm≤a≤12mm.
2.2 one-time adjustment test
In the condition of normal temperature relief, the brake shoe is adjusted to the shortest position, and the adjustment nut is used to push it forward from the shortest position by about 40mm, and the brake shoe is fixed at a fixed point to a fixed point of the brake unit Ha, and then proceed. In a brake-relief test, note the distance H from the same fixed point to the brake fixing point, then the value of H-Ha is the amount of brake adjustment. Perform five consecutive tests and take five averages as one adjustment. Quantity, once adjustment ≥ 6mm is qualified.
2.3 Total adjustment test
Under the condition of normal temperature relief, move the brake shoe to the shortest position, select the reference point on the brake, measure the distance L to the center point of the brake disk, and let the brake cylinder repeatedly inflate and exhaust the brake. When the launch volume is not increasing, the distance between the reference point and the center point of the brake wagon is measured in the state of relief. The difference between L and La is the total adjustment amount. The total adjustment amount is L-La ≥ 110mm.
2.4 manually adjust the gap test
Under normal temperature conditions, turn the adjusting nut in both positive and negative directions with the wrench. The brake vats should be able to adjust in both directions and be flexible.
3 braking force test
3.1 brake cylinder braking force test
When the brake shoe and the tread are in normal clearance, the brake cylinder is filled with compressed air of 350KPa. The output force of the brake shoe is measured and it should be ≥34.2KN±5%. When the brake cylinder is filled with compressed air of 450KPa, the brake shoe output is measured. Force should be ≥ 44KN ± 5%.
3.2 Spring parking brake force test
Fill the parking brake cylinder with 600KPa compressed air, then empty it, implement parking brake and measure the spring braking force. The spring braking force should be ≥31.5KN±5%
4 Spring parking device performance test
4.1 Spring Parking Brake, Mitigation Test
Under normal temperature conditions, the spring parking brake cylinder is filled with compressed air of 550-600KPa, and then the compressed air is discharged. The brake shoes should be braked, and 500KPa compressed air is filled into the spring parking brake cylinder, and the brake shoes should be able to relieve Repeat the test five times. Under normal temperature conditions, braking and relieving should be normal.
4.2 Spring Stop Minimum Relief Pressure Test
The spring parking brake cylinder is filled with compressed air of 550-600KPa, then the compressed air is discharged to brake the brake, and then the compressed air is filled into the spring stop and the pressure is gradually increased from 300KPa until the spring stop can be fully relieved. The pressure at this time is the minimum relieving pressure Pmin, and Pmin ≤460 KPa is acceptable.
4.3 Spring Stop Manual Relief Test
Under normal temperature conditions, charge 550-600KPa of compressed air into the spring stop, then empty the compressed air to brake the brake and pull the manual mitigation device. The unit brake should be completely relieved and repeat the test five times. Should be able to completely ease.
5 tightness test
5.1 Low-pressure air seal test
Under normal temperature conditions, 100KPa compressed air is charged into the spring brake cylinder or the spring parking cylinder respectively, and the pressure is kept for 3 minutes, and the leakage amount is not more than 2KPa.
5.2 High Pressure Airtightness Test
Under normal temperature conditions, respectively into the brake cylinder filled with 430-465KPa compressed air, spring parking tank filled with 600-650KPa compressed air, pressure for 3 minutes, the leakage is not more than 2KPa.
10, MCGS software is equipped with: start interface, sensitivity, gap adjustment test interface, adjustment amount test interface, airtightness test, data browsing, test report, help, etc. more than 10 window interface, to facilitate recording, query, print a variety of tests The data and results can be operated as prompted by the window menu. The window that cannot collect data is provided with a keyboard input function. The historical report can be used as a test result to automatically generate a standard Excel report and store it on the hard disk of the IPC. The report can be copied and uploaded to the server. And in the upper computer.
11. Shutdown: After the test is complete, shut down the IPC and the printer and disconnect the power switch and compressed air valve.
Sixth, security protection
1. When the test bench is decommissioned for a long time, the input power should be disconnected to ensure the safety of personnel and equipment.
2. Control interlock protection is set to prevent operation mistakes or equipment malfunction. Ensure safe and reliable operation.
3, with grounding protection, short circuit, and overload protection to ensure the safety of electricity.
4. The protection level of the console is IP54, and the protection level of the detection components and sensors is not lower than IP64.
5, the electrical components are selected domestic and international famous brand products, reliable quality. Imported electrical components, components through the CE certification; domestic electrical components in line with the national standard GB/T14048.1, GB/T14048.3, GB/T14048.
Seventh, the electric cabinet maintenance
According to the user's usage, use it frequently every three months, normal use every six
Monthly inspection
1) Inspection and maintenance project
1. Check the button switch for damage.
2. Check whether the instrument instrument is broken or not and whether the sensor cable is damaged.
3. Check whether the wiring in the power cabinet is tight, whether the cable is damaged, and whether the insulation is aging.
2) Inspection and maintenance methods
1. After the equipment fails, please ask the electrician to find out the reason and troubleshoot before restarting the test or contacting the company.
2. When the equipment is not in use for a long time, all power switches should be disconnected; do waterproof, moisture-proof, lightning-proof, anti-corrosion, dust-proof and other measures.
Eight, electric cabinet operation procedures
1. Those who have passed the training and hold the operation certificate shall conduct the operation. Operators must strictly abide by the safety and handover systems.
2, before the work should be strictly in accordance with the procedures.
3, check the instrument and power indicator is normal. If everything is normal, proceed to the next step.
4, in strict accordance with the order of operations.
5. After the test is completed, disconnect the power switch and compressed air valve. The equipment must be inspected and cleaned to perform daily maintenance work to achieve safety, orderliness and cleanliness.
Nine, the main display operating interface
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