Development Of Integrated Test System For Operational Reliability Of High-speed Train Window Wiper

High-speed Train Window wipers are the key devices to remove obstructions such as rain,fallen leaves and dust from the windshield of an EMU and to help the driver gain a clear view.The complexity of the service environment of the EMU leads to many factors that threaten the safe operation of the train,such as rain and snow,bird impact,high-speed driving into the tunnel and the EMU and other working conditions,the wiper has typical problems such as blockage,loss of control,floating or even rupture of the scraper arm and scraper,resulting in frequent accidents in the safe operation of the EMU.Conventional electric wiper testing mostly uses the static electrical parameters of the wiper for fault diagnosis,and such methods have problems such as insufficient coverage of test conditions and poor diagnostic effect.In addition,conventional wiper motors and controllers cannot be used directly in reliability test benches.Because the motor and controller are standard design,whether its software or hardware in the design process is designed to specifically meet the various working conditions of the train operation,and does not provide all kinds of acquisition interfaces and analysis modules required for comprehensive online diagnosis and analysis of various complex and unexpected failures,it is necessary to design a special motor and controller in the test bench,so that its operating performance is standard motor assembly,and at the same time,it can meet its various fault diagnosis and comprehensive analysis needs in various complex working conditions,accidents and extreme scenarios.In this paper,the comprehensive test system for the operation reliability of electric wipers of EMUs is designed,including the development of special wiper motor assemblies and the development of working conditions simulation subsystem for testing,so as to realize the monitoring analysis and fault diagnosis of the operation reliability of the wiper.The main tasks done are as follows:（1）According to the industry standard and system requirements analysis of the High-speed Train Window wiper,the design of the overall scheme of the electric wiper operation reliability comprehensive test system and the design of each functional subsystem were completed,including the design of the 3D model of the mechanical structure of the test bench,the design of the data acquisition subsystem,the design of the rainfall and load simulation subsystem,etc.（2）Design and development of special test motors for wipers.Based on the synchronous rotation coordinate system and the space vector pulse width modulation technology,the double closed-loop I_d=0 vector control strategy of the wiper test motor is formulated,and the motor vector control simulation experiment and operation analysis are carried out by MATLAB/Simulink software,so as to determine the design parameters of the test motor,and the customized processing and parameter calibration of the motor are completed accordingly.（3）Design and development of wiper special test motor controller.Analyze the functional requirements of the wiper test motor controller and design the hardware system architecture,and use Altium Designer software to design the control and drive circuits of the motor controller.According to the I_d=0 vector control strategy,the motor control program is designed based on the interrupt mechanism of the master control chip TMS320F28335.（4）Developed and completed the wiper test bench machine control system,to achieve the flexible addition and reduction of test content and equipment,flexible adjustment of test sequences,flexible loading of various preset working conditions of the test requirements.（5）Working condition experiments and data analysis were carried out.Through the simulation of the host computer control test system to generate various working conditions,including normal operating conditions and fault conditions,real-time collection of relevant diagnostic information during the dynamic operation of the wiper test motor,including busbar voltage,phase current,angle,speed,torque and scraper arm pressure and other operating data,to achieve the simulation function and acquisition function of the test system for complex working conditions,verified that the wiper test motor operation has stability and reliability under environmental conditions such as durability test,extreme precipitation test,etc.It provides a proven solution to this important engineering problem prevalent in the industry.