Research On Hardware-in-the-loop Simulation Of The Running System In Ballast Cleaner Machine

Ballast cleaner machine is a kind of large maintenance machinery, used to clean the ballast under the base of railway. With the large-scale acceleration of railway transportation and the increasing of the overloading train, the requirement of large maintenance machinery is becoming larger and larger. The maintenance time of ballast cleaner machine is inefficienry at present, and the high-speed running, an important part of auxiliary operation, will directly affect the operation efficiency of ballast cleaner machine and the safety of railway. Because of long development cycle, high cost and low efficiency, research on system simulation is of great significance. However, because the real-time simulation based on Matlab/Simulink lack of unified modularity and interface standardization, the model interface is disordered, which will lead to the low efficiency of model reusing and go against the maintenerance, expansion and portability.In this dissertation, according to analysis of high-speed running system in ballast cleaner machine and modular modeling method, real-time model is built and hardware-in-the-loop simulation station, based on xPC real-time system is finished, which can provide testing environment for the development of hydraulic system or controllers and lead to high-efficiency and low-cost. What’s more, in order to increase versatility of the modularity and interface standardization, modularity and interface standardization and coupled manners between models of electro-mechanical and hydraulic system are built. The chapters are organized as follows.In Chapter 1, the development, running system and maintenance mode of ballast cleaner machine are introduced. Also simulation technology and its application on ballast cleaner machine are summarized. Finally, the purpose and main contents of this project is put forward.In Chapter 2, based on the requirements analysis on real time of hardware in the simulation station and the features of xPC real time system, the hardware in the loop simulation of high-speed running system in ballast cleaner machine is designed, which is based on xPC real-time system and communicate with the host computer and 3-D display through Ethernet. The simulation model is built and parameterized encapsulated. The control interface of simulation under WinForm development framework and the 3-D display under Unity3D are proposed.In Chpater 3, modularity and interface standardization of electro-mechanical and hydraulic system is built. In order to increase versatility of the modularity and interface standardization, this chapter is research on electro-mechanical and hydraulic system, with the methods and principles of modularity in complex system, the modularity and interface standardization and coupled manners between models are built. And framework of module library with Matlab/Simulink is also built.In Chapter 4, according to the modularity and interface standardization of electro-mechanical and hydraulic system, the real-time models of high-speed running system in ballast cleaner machine are built, encapsulated and experimentally validated, including engine, variable pump, variable motor, displacement control mechanism, cartridge valves, pressure vessel, hydraulic pipe, mechanical systems and resistance module.In Chapter 5, the models of high-speed running system are intergrated and the simulation station is competed. The successful model inergrated validates the feasibility of modularity and interface standardization on electro-mechanical and hydraulic system. And the realization of the simulation station validates the real-time and feasibility. The development of control interface under WinForm is finished, realizing monitoring and controlling simulation, parameter regulation online, parameter saving, etc. The development of 3-D display under Unity3D is finished, realizing the real-tine display of ballast cleaner machine.In Chapter 6, the main conclusions and achievements are summarized, and the further.