Research And Development Of Control System For Train Windshield Curve Passing Capability Test Bench

With the continuous development of Chinese railway scale and operation speed,the running environment of each connecting part at the end of the train has become more and more harsh.As one of the important components of the connecting structure at the end of the train,the quality of the train windshield will directly affect the safety and comfort of the train.The ability of curve passing is an important part in the quality inspection of windshield,which is used to test the bearing capacity of the windshield under various extreme positions.At present,the existing simulation test benches at home and abroad have some shortcomings,such as complex control system,inconvenient operation,high cost of equipment,and fewer types of windshield to be tested.Therefore,it is of great significance to design a windshield curve passing capacity test bench which can be used for different types of windshield under different operating conditions and suitable for small and medium-sized enterprises.Based on the analysis of the design requirements of the test bench,the overall structure and control system scheme of the test bench are designed.The overall structure of the test bench is a three-coordinate linear movement platform and a three-coordinate rotating platform,driven by servo motors.The control system uses PC as the upper computer and PLC as the lower computer.The modularization idea is adopted to realize the automatic control of the test.Through the analysis of the actual movement of the windshield and the study of the quality inspection documents of the Ministry of Railway,the path of the train under the limit position of the curve entrance,curve arc top,S-shaped curve,linear stretching compression,roll and climbing path is transformed and solved.In terms of control system hardware,according to the structure design and control requirements of the test bench,the core hardware of the control system is selected and configured,then the electrical system is designed according to the selected hardware,and the control cabinet is completed.In terms of control system software,the software design framework is proposed,which is mainly divided into PC and PLC.The software design of the lower computer includes three parts: the design of servo communication,the establishment of coordinate system and the control execution program.The control function of the servo system is realized.The upper computer software adopts the modularization idea and is designed from four core aspects: communication module,automatic running program,path algorithm design and database design.It provides a powerful logic thinking for the whole test bench control system.Finally,simple and easy-to-operate man-machine interface is designed to realize the friendly interaction between man and control system.In order to ensure the normal and stable work of the test bench,the system debugging and the overall experiment of the test bench are carried out to ensure the stability of its motions and the logic of the program.Through a series of debugging and experiments,the test bench has passed the third party and the Academy of Iron Sciences test certification,which has been put into normal use in enterprises.