Research And Application Of Train Composite Insulators Cleaning And Hydrophobic Measure Systems

Composite insulator is widely used in railway transportation, whose performance is good or bad has an important influence for the safe operation of the train. At present, the insulator in rail transit line catenary system and the train mostly are washed by artificial. This offline cleaning method has many disadvantages, such as investing a lot of manpower, the big labor intensity, time consuming, and not guaranteeing the cleaning quality. In addition, the equipment for composite insulator performance level measurement is rarely at the scene of the servicing operations. And there are not explicit criteria for composite insulator replacement. Based on this, the purpose of this thesis is to design a set of equipment which can be used for composite insulator automatic cleaning and composite insulator hydrophobic level detection. Main contents include:(1) The overall design of composite insulator automatic cleaning equipment is complete. The system is mainly composed of monitor system, composite insulator storage tray system, carrying mechanical arm system and cleaning system. And each subsystem adopts Siemens S7-200 PLC control. A monitoring system is developed based on Kingview. Also the overall of the control sequence of the system is determined;(2) The design of the composite insulator for turntable system is accomplished. The rotary table is designed to store insulator and realize the mechanical arm fixed-point handling. The material handling of the mechanical arm requires the precise coordination of the rotary table. Rotary table need to implement a closed loop control due to mechanical error and the external factors. This closed loop control of turntable is realized by PLC, stepper motor, and rotary encoder. Meanwhile, the output of the stepper motor is collected through the rotary encoder, and then the feedback information is uploaded to the PID module of PLC for error correction for achieving accurate closed-loop control.(3) The design of cleaning mechanism is completed. Cleaning mechanism is the main part of the system, whose design mainly includes the cleaning brush, elevator, upper and lower limit mechanism, automatic door, hydraulic system, transmission system and other parts. The purpose of it is moving around the insulator in the elevator by robotic arm, fixing the insulator on the cleaning station through the coordination between the elevator and the upper and lower limit, and finishing cleaning work of the insulator through the auxiliary institutions to cooperate.(4) Complete the design of the mechanical arm system. The mechanical arm designed is replacing workers with machines to achieve automatic cleaning. The mechanical arm selected in this dissertation is cylindrical coordinate type 3 degree of freedom mechanical arm, whose movement form is step by step successively and calculating the trajectory function of each joint. Then, the path planning of the mechanical arm is completed.(5) Based on image processing, the detection system of hydrophobicity of composite insulator is designed. Hydrophobic detection of composite insulator is an important means to judge the quality of the insulator. This method is greatly disturbed by the environment. the cleaning device is designed in a relatively closed space in this thesis, which is less disturbed by the external environment. So the detection system can be integrated into the cleaning system to improve the function of the system. In this thesis, the water spray classification method and the improved shape factor method are jointly used to detect the hydrophobicity and the PC interface of detection system is designed.