The operational data of various parts of the diesel locomotive, especially the dynamic parameters in the locomotive operation, is the basis for analyzing and evaluating the operating state of the locomotive. At present, the new locomotives in China have been equipped with a certain function of the locomotive vehicle information monitoring system, but the locomotives produced earlier did not have this equipment, and the different management modes have different requirements for the vehicle information monitoring system. The original locomotive safety information comprehensive detection device (referred to as TAX box) of DF4B/4C locomotive recorded some vehicle operation data, but the vehicle maintenance data record is very small, that is, the locomotive is in the traction operation state, the locomotive data of each working condition is dynamic. The lack of records is not conducive to the comprehensive use of various monitoring data to comprehensively analyze the various conditions reflected in the operation of the locomotive. Therefore, we have developed a real-time monitoring system for DF4B/4C locomotive running information, together with the original TAX recorder on the locomotive, to record the working condition data of the oil, electricity and water systems when the vehicle is being used. Through the data analysis software, the locomotive operation data is analyzed and judged, and the technical status of equipment and components is mastered, which provides a real basis for preventive maintenance and overhaul of the locomotive.
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1 design ideas
At present, some of the locomotive operation information detecting devices that have been loaded are mostly designed with single-chip microcomputers, with fixed functions, simple performance, no flexibility and expandability, and it is impossible to analyze the operational data on-site while the locomotive is running. A system composed of a plurality of single-chip microcomputers does not form a modularity, which causes difficulty in repairing the failure of the device itself.
With the application-centric embedded system cost-effective, the use of general-purpose industrial-grade embedded controllers for locomotive applications can greatly improve system development cycles, improve system reliability and work efficiency.
The real-time detection system (device) of the locomotive operation information is mainly applied to the front of the vehicle. The design idea is to use standard industrial-grade embedded controller hardware, use standard embedded operating system, and use conventional external devices, such as standard keyboards, general-purpose displays, U disk, CF card, etc. Use a universal visualization development tool to take advantage of a networked development environment and standard industrial I/O channels to fully modularize the unit. The modular system design is flexible, fast, powerful, and scalable. The software can be commissioned on-demand for on-board expansion, data analysis can be performed on the locomotive running site, and the modular structure makes the maintenance of the device itself very convenient.
2 system hardware design
2.1 System function requirements
The TAX monitoring device on the original DF4B locomotive recorded some locomotive operating parameters, such as time scale, vehicle speed, signal number, public time scale, total quantity, gauge length, quantity, local machine, cargo, vehicle, train, section. No., station number, driver number, passenger number, locomotive number, model and other information. This project installs a real-time monitoring device for locomotive operation information on the DF4B locomotive console to record various real-time operating conditions of the locomotive. In addition to retaining the various locomotive operating parameters provided by the TAX monitoring device on the original vehicle, according to the needs of maintenance, increase the differential pressure, idling, grounding, total overcurrent, fault excitation, fixed power generation, vehicle unloading, water temperature, oil temperature, Collecting parameters such as fuel pressure, sliding pressure, auxiliary voltage, charge and discharge current, 6 motor shunt, main voltage, main current, etc. The dynamic operation data of the locomotive is detected and recorded in real time during the running of the train.
2.2 System hardware structure
According to the system function requirements, the overall structure of the designed system hardware is shown in Figure 1.
2.3 System hardware equipment design
2.3.1 Embedded Core Controller
According to the system design idea, the core controller must be able to replace the conventional PC and PLC, support standard display, provide a complete high-level language development environment and tools, have strong data processing capability and speed, have network interface and USB interface, allow Connect a storage device such as a CF card. After comparing several embedded controllers, we chose ICP DAS's WinCon-8000 embedded industrial controller system. The controller host uses W-8331 module, built-in Intel Strong ARM 32-bit CPU, clock 2.06 MHz, memory 64. MB SDRAM, 32 MB FLASH Memory, using CF card for electronic disk, using 3 expansion slot bottom plate.
WinCon-8000 is an embedded controller with both regular PC and PLC functions running Windows CE.NET operating system. Windows CE.NET is a real-time multitasking embedded operating system widely used in smart devices. It can be customized for lightweight applications based on specific applications and supports multiple CPU architectures. Support development tools such as Visual Basic.NET, Visual C#, Embedded Visual C++. Windows CE inherits the traditional Windows graphical interface. The application software on the PC platform can be used continuously on the Windows CE platform with simple modification and porting. WinConSDK provided by WinCon-8000 is used by Microsoft on ordinary PCs. Visual Studio. The NET and Embedded Visual C++ development environment directly develops the application and then downloads it to WinCon-8000 for execution. The development environment is ready and convenient, providing the foundation for developing powerful graphics applications.
The WinCon-8000 has a VGA interface that allows the user to replace the HMI display with an LCD monitor that supports Ethernet, USB, keyboard, mouse and CF card. With RS 232, 485 serial port, support a variety of I / O modules, such as I-7000, I-8000, I-87K expansion I / O module, support timing counter / frequency meter. WinCon-8000 is selected as the main controller, which provides convenience for data analysis on the vehicle. The recorded data can be transmitted to the ground computer for analysis, or can be directly monitored and processed after the display is mounted on the locomotive and the keyboard, so that it can be easily maintained and debugged on the vehicle.
2.3.2 Analog input channel
The analog quantities that need to be measured in this system are: 1~6 motor divided current, main generating voltage, main generating current, water temperature, oil temperature, oil pressure, fuel pressure, auxiliary power generation, battery charge and discharge current, diesel engine speed, etc. 14 Analog quantity.
The analog input module used on the locomotive should be based on harsh environment and high reliability, and the price is a secondary factor. Therefore, we chose the I-7000 series I-7018 module from ICP DAS as the analog input channel. I-7018 is an 8-channel analog input module. It uses RS 485 protocol to connect with the WinCon-8000 host. In the application program, I-7018 is operated directly through the WinconSDK dynamic link library function. This machine uses two i-7018 modules to realize 14 analog inputs.
2.3.3 Switching Channel
The I-7000 series module has been selected as the analog input channel. For serialization, the I-8042 (16-channel isolated digital I/O) module is used as the digital input channel.
The switch quantity to be collected in the device has 8 switching amounts such as differential pressure, water temperature, fixed power generation, idling, main circuit grounding, main circuit overcurrent, vehicle unloading, and fault excitation. Eight channels of the I-8042 were used.
2.3.4 Speed â€‹â€‹acquisition channel
In order to collect the locomotive diesel engine speed, a speed acquisition channel is required. The ICP I-8080 (4-channel counting frequency device) module is selected to collect the pulse output from the locomotive diesel engine rotor, and the rotational speed is calculated according to the frequency.
2.3.5 Panel I/O Module
The controller includes four button switches, which are used to control the device to implement backup, dump, reset, local output and other operations, and set 8 indicators for the working status and alarm information of the device. Although the I-8042 has redundant I/O channels available, it is necessary to perform secondary relay amplification on its output due to its own output capability. We use I-7050 (7-channel digital input / 8-channel digital output module) as the panel I / O module, which can directly drive the panel indicator of 24 V.
2.3.6 485-232 converter
The collection instrument cooperates with the original TAX box on the locomotive to receive the TAX box data in time, avoiding sharing the bus with I-7018 and I-7050, and converting the TAX box output RS 485 data into RS 232 protocol by using the I-7520 module. The RS232 port on the WinCon-8000 backplane is received.
2.4 Power and Chassis Design
Other modules of the system include 1 power conversion module (ph75s 110-24), 1 speed switch quantity regulation board, 1 signal conditioning board, 1 chassis, 4 aviation sockets, 4 button switches and 8 indicator lights.
The detection device uses an industrial chassis of 31 cm Ã— 24.5 cm Ã— 19.5 cm, and all the external keyboard, display, mouse and other sockets are externally mounted on the chassis. Eight indicators on the panel indicate the operating status of the device, and four button switches on the panel control the data transcription operation. Connect all data collection points on site through 4 aviation outlets. In order to avoid affecting the original signal system of the locomotive, the signal acquisition uses a high-impedance input circuit, and takes a series of signal isolation, amplification, transformation and transmission measures. For example, in some high-speed, strong interference signal channels, an isolation transformer is added to isolate the signal source from the electrical circuit. By designing the filter circuit to suppress power supply interference, the possibility of device crash is greatly reduced, and the reliability of the device is improved.
The system changes the design idea of â€‹â€‹the traditional bus + data acquisition board and adopts a modular design. Each collection channel is isolated, and the channels with similar signals form a module. The modules are connected between the modules and the main control unit through a communication bus, which ensures the independence of each channel, each module and the main control unit. It is convenient for system expansion and upgrade, adapt to the access of various types of sensor information and facilitate troubleshooting. The front end takes the signal from the instrument terminal wiring, and after signal conditioning, it is sent to the main controller by the isolated channel module, and the watchdog design provided by W-8331 is used to improve the reliability of the system software.
3 system software design
The software consists of three parts: in-machine data acquisition software, on-board data analysis software and ground data analysis software.
3.1 In-machine data acquisition software
The in-machine data acquisition software and on-board data analysis software use Visual C# programming, and use WinConSDK function library to control and operate all the hardware of WinCon-8000, including I-8000/I-87K/I-7000 series I/O modules. The internal data acquisition program is directly developed on the ordinary microcomputer using Microsoft's Visual C# development environment, and then downloaded to WinCon-8000 for execution.
The in-machine data acquisition software drives each I/O channel to collect data of each information point every 1 s, and receives data of a TAX box to form a record with a frame length of 120 B. The time to be outputted by the TAX box is the standard time, and one frame of data is recorded every 1 to 10 s according to the accuracy. If the data collected twice does not change much, one frame of data is recorded every 10 s; if the data collected twice is large, one frame of data is recorded every 1 s. The storage space required to store one frame of data is 120 B. When the memory is almost full, the first recorded data is eliminated according to the first-in-first-out data backup strategy, so that the data of the last few days is always recorded.
3.2 Onboard data analysis software
Limited by the W-8331 module resources, the on-board data analysis software mainly displays the collected data in real time and judges the alarm. When the device is in operation, if it has a display, the display always displays real-time data of a main control interface and main signal points. When the collected signal is greater than the set value, the sound, map, and indicator light are used for alarm. The on-board data analysis software can retrospectively display the parameters at any time before the operation of the mouse, so that the crew can understand the running status of the locomotive at the vehicle running site for on-site maintenance analysis and processing decisions. The device can be equipped without a display and a mouse. At this time, the four button switches on the device operate the transcription control, and the indicator light and the sound alarm.
3.3 Ground Data Analysis Software
The data is transferred to the ground computer through U disk transcription, the ground computer runs the ground data analysis software, reads the original data of the U disk, performs data format verification, selects incomplete records, and performs locomotive operation according to the driver number or time segmentation. The working condition parameter curve is drawn. The software is developed by Delphi to draw the running curve of each parameter of the locomotive with time stamp. The recorded data can be searched and queried according to time, kilometer mark, and the like. The running curve provides various data playback analysis modes including horizontal and vertical data comparison, which makes the recorded data visual and truly reproduces various working condition information of the locomotive in the running state, so that the ground analyst can visually judge the running condition of the locomotive for the locomotive. The overhaul provides a scientific basis.
The data recorded by the collector can also be converted into the data format required by other ground processing software through the data format conversion program, which provides convenience for the user to use other commercial ground data processing software. At the same time, the ground data analysis software provides data to the maintenance information base.
Using a versatile and powerful industrial-grade microcontroller to form a system, despite the high cost, it is still an acceptable solution for critical equipment such as locomotives. The device was developed by Hami Xintong Company and is mainly used for the collection of front maintenance data. The operation test is carried out on the DF4B locomotive. The operation test shows that the system is stable and reliable, and the functions are well realized, which has reached the expected design goal. .
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