CN-117233426-B - Failure analysis method of transverse acceleration sensor for motor train unit

CN117233426BCN 117233426 BCN117233426 BCN 117233426BCN-117233426-B

Abstract

The invention discloses a failure analysis method of a transverse acceleration sensor for a motor train unit, which comprises the steps of testing at room temperature and low temperature, screening to obtain a room temperature failure sensor sample and a low temperature failure and room temperature non-failure sensor sample, testing the low temperature failure and room temperature non-failure sensor sample before disassembly and testing in the disassembly process, removing potting adhesive after the disassembly is finished, testing the low temperature failure and room temperature non-failure sensor adhesive removing sample at room temperature, low temperature and low temperature-to-room temperature respectively, testing the room temperature failure and room temperature non-failure sensor adhesive removing sample at room temperature when the low temperature failure and the room temperature non-failure sensor adhesive removing sample pass at room temperature, testing the room temperature failure sensor sample after the low temperature failure and room temperature restoration pass, unsealing the room temperature failure sensor sample when the room temperature failure sensor sample passes, and testing the room temperature failure sensor adhesive removing sample again after the potting adhesive is removed when the air bubble exists, and analyzing to obtain failure reasons. The method can quickly, efficiently and accurately find out the deep fault failure reason of the sensor.

Inventors

LIN XUGUANG
WANG WENJUN
SUN PING
XU QIAOHONG
DOU ABO
WANG WEI

Assignees

华测检测认证集团股份有限公司
中车长客轨道客车股份有限公司

Dates

Publication Date: 20260508
Application Date: 20220818

Claims (8)

1. The failure analysis method of the transverse acceleration sensor for the motor train unit is characterized by comprising the following steps of: Acquiring fault data of faults of the actuator train caused by faults of the transverse acceleration sensor in a fault site; detecting the damage to the appearance of all the transverse acceleration sensors corresponding to the fault data to obtain a sensor without appearance damage; Respectively carrying out functional tests on the sensors without appearance damage at room temperature and low temperature, and screening to obtain a room-temperature failure sensor sample and a low-temperature failure sensor sample without room-temperature failure; Performing a functional test before disassembly and a functional test in the disassembly process on the sensor sample which fails at low temperature and does not fail at room temperature, and observing whether bubbles exist in the pouring sealant after the disassembly is completed; When the pouring sealant of the sensor sample which is failed at the low temperature and is not failed at the room temperature has bubbles, removing the pouring sealant of the sensor sample which is failed at the low temperature and is not failed at the room temperature, and obtaining a glue removing sample of the sensor which is failed at the low temperature and is not failed at the room temperature; Performing functional tests on the sensor adhesive removing samples which fail at the low temperature and are not failed at the room temperature at room temperature, low temperature and low temperature-to-room temperature respectively; When the low-temperature failure and room-temperature failure sensor gel removal sample passes the function test at room temperature, and the function test at low temperature fails, but the function test passes after the room temperature is restored, unsealing and observing the room-temperature failure sensor sample; when bubbles exist in the pouring sealant of the room temperature failure sensor sample, removing the pouring sealant of the room temperature failure sensor sample to obtain a room temperature failure sensor gel removing sample; performing a functional test on the room temperature failure sensor photoresist removing sample at room temperature again; And when the room temperature failure sensor gel removal sample passes the function test at room temperature, deducing that the bubble exists in the sensor pouring sealant as the failure cause of the transverse acceleration sensor.
2. The failure analysis method of the lateral acceleration sensor for a motor train unit according to claim 1, wherein the step of detecting the breakage of the appearance of all the lateral acceleration sensors corresponding to the failure data to obtain a sensor free from the breakage of the appearance comprises: cleaning all the transverse acceleration sensors corresponding to the fault data; Removing the lateral acceleration sensors corresponding to the loss of waterproof putty of the plugs in all the lateral acceleration sensors; checking other appearance surfaces of each lateral acceleration sensor with waterproof putty on the plug; when other appearance surfaces of the transverse acceleration sensor are complete and not cracked, the glue filling treatment is adopted in the transverse acceleration sensor, so that the possibility of faults caused by water inflow is eliminated, and the sensor without appearance damage is obtained.
3. The method for analyzing the failure of the lateral acceleration sensor for the motor train unit according to claim 1, wherein the step of performing the functional test on each of the sensors without the appearance failure at room temperature and at low temperature, respectively, and screening to obtain a room-temperature failure sensor sample and a low-temperature failure sensor sample without the room-temperature failure comprises the steps of: The room temperature testing step is that at room temperature, room temperature function testing, dynamic acceleration testing and vertical vibration interference testing are carried out on the sensors without appearance damage, and the output voltage of each sensor without appearance damage in the sensors without appearance damage is synchronously recorded; A low-temperature test step of performing a low-temperature test on each sensor without appearance damage at a low temperature and synchronously recording the output voltage of each sensor without appearance damage in each sensor without appearance damage; A low-temperature room temperature test, namely taking out each sensor without appearance damage from low temperature, standing for a preset time, recovering room temperature, and then carrying out room temperature function test, dynamic acceleration test and vertical vibration interference test on each sensor without appearance damage again, and synchronously recording the output voltage of each sensor without appearance damage in each sensor without appearance damage; And a screening step, namely taking out the sensor mark which is invalid in the room temperature testing step according to the output voltage, taking out the sensor mark which is invalid in the low temperature testing step, and recovering to be effective in the low temperature to room temperature test.
4. The method for analyzing the failure of the lateral acceleration sensor for a motor train unit according to claim 3, wherein the step of performing the unsealing observation process on the room temperature failure sensor sample comprises: disassembling the metal shell of the room temperature failure sensor sample, and exposing pouring sealant of the room temperature failure sensor sample; Scanning and detecting the appearance surface of the pouring sealant of the room temperature failure sensor sample by using a surface groove scanning device, and judging whether the appearance surface of the pouring sealant of the room temperature failure sensor sample is flat and has no groove; If so, bubbles exist on the surface of the pouring sealant of the room temperature failure sensor sample; If not, carrying out X-rayCT scanning on the pouring sealant of the room temperature failure sensor sample, and judging whether a gap exists in the pouring sealant of the room temperature failure sensor sample; if so, bubbles exist in the pouring sealant of the room temperature failure sensor sample.
5. The method for analyzing the failure of the lateral acceleration sensor for the motor train unit according to claim 1, wherein the step of performing the functional test again on the room temperature failure sensor gel removal sample at room temperature includes: at room temperature, performing room temperature function test, dynamic acceleration test and vertical vibration interference test on the room temperature failure sensor photoresist removing sample, and synchronously recording the output voltage of each sensor; Judging whether the output voltages of the sensors before and after pouring sealant for removing the room temperature failure sensor sample are consistent or not; if yes, the room temperature failure sensor gummosis sample passes the function test at room temperature.
6. The method for analyzing the failure of the lateral acceleration sensor for the motor train unit according to claim 1, wherein the step of performing the functional test before the disassembly and the functional test in the disassembly process on the sensor sample which fails at the low temperature and does not fail at the room temperature, and observing whether the pouring sealant has bubbles after the disassembly is completed, comprises the steps of: carrying out room temperature function test, dynamic acceleration test and vertical vibration interference test on the sensor sample which fails at low temperature but does not fail at room temperature before disassembly, and synchronously recording the output voltage of each sensor; In the disassembly process, carrying out room temperature function test, dynamic acceleration test and vertical vibration interference test on the sensor sample which fails at low temperature but does not fail at room temperature, and synchronously recording the output voltage of each sensor; After the disassembly is completed, scanning and detecting the appearance surface of the pouring sealant of the sensor sample which fails at low temperature and does not fail at room temperature by using a surface groove scanning device, and judging whether the appearance surface of the pouring sealant of the sensor sample which fails at low temperature and does not fail at room temperature is flat and has no groove; if yes, bubbles exist on the surface of the pouring sealant of the sensor sample which is failed at the low temperature and is not failed at the room temperature; If not, carrying out X-rayCT scanning on the sensor sample which is failed at the low temperature and is not failed at the room temperature, and judging whether a gap exists in the pouring sealant of the sensor sample which is failed at the low temperature and is not failed at the room temperature; if so, bubbles exist in the pouring sealant of the sensor sample which is failed at low temperature and is not failed at room temperature.
7. The method for analyzing the failure of the lateral acceleration sensor for the motor train unit according to claim 1, wherein after the step of deducing that the presence of the air bubble in the sensor pouring sealant is the cause of the failure of the lateral acceleration sensor when the room temperature failure sensor gel removing sample passes the function test at the room temperature, further comprising: performing X-ray perspective inspection on the room temperature failure sensor photoresist-removing sample to obtain a first X-ray perspective detection chart; checking and analyzing welding conditions of components in the first X-ray perspective detection diagram; When the room temperature failure sensor gumming sample is subjected to gumming, gumming the gumming position; Slicing the desoldering position after the gluing treatment to obtain a first slice sample; observing a first desoldering crack texture at a desoldering position in a first slice sample using a microscope; And analyzing and obtaining a failure mechanism of the transverse acceleration sensor by the first desoldering crack texture.
8. The method for analyzing the failure of the lateral acceleration sensor for a motor train unit according to claim 7, further comprising the step of: Performing X-ray perspective inspection on the sensor gel removal sample which fails at low temperature but does not fail at room temperature to obtain a second X-ray perspective detection chart; checking and analyzing the welding condition of each component in the second X-ray perspective detection diagram; When the low-temperature failure occurs and the room-temperature non-failure sensor gumming sample is subjected to gumming, gumming the gumming position; Slicing the desoldering position after the gluing treatment to obtain a second slice sample; Observing a second desoldering crack texture at a desoldering position in a second slice sample using a microscope; and comparing and analyzing the first desoldering crack texture and the second desoldering crack texture, and verifying the consistency of failure mechanisms of the transverse acceleration sensor.

Description

Failure analysis method of transverse acceleration sensor for motor train unit Technical Field The invention relates to the technical field, in particular to a failure analysis method of a transverse acceleration sensor for a motor train unit. Background The high-speed motor train unit plays an important role in high-speed, safe and large-batch transportation, and has high requirements on safety and systemization of the high-speed motor train unit. The sensor is equipment for converting measurement parameters into electric signals or other needed information output according to a certain rule, is an indispensable important part in a safety control system of the whole rail traffic industry, and is a fusion mechanism of a high-speed train pedigree product platform to form a high-speed train pedigree product technology platform facing fault prediction and health management (Prognostics AND HEALTHMANAGEMENT, PHM), and is also very dependent on real-time monitoring of the sensor. At present, a transverse acceleration sensor is arranged on a bogie of a high-speed motor train unit, and the high-speed motor train unit is monitored in real time by using the transverse acceleration sensor, so that the train is ensured to run in a normal state or an optimal state. However, when the transverse acceleration sensor fails, the motor train unit needs to limit speed or even stop, so that the operation is greatly influenced, and the planning of later-stage health management is also influenced. However, in the current analysis and detection operation of the failed lateral acceleration sensor, an analysis flow for efficiently and rapidly performing test on the failed sensor is not formed, and after the failure occurs, a deep failure mechanism of the sensor is difficult to accurately find, so that a manufacturer is difficult to correspondingly improve a production process, and further, the phenomenon of shutdown caused by the failure of the lateral acceleration sensor frequently occurs in the running process of the high-speed motor train unit. Disclosure of Invention Based on the above, it is necessary to provide a method for analyzing the failure of the lateral acceleration sensor for a motor train unit, aiming at the technical problem of how to quickly and efficiently analyze and find out the failure reason of the lateral acceleration sensor. A failure analysis method of a lateral acceleration sensor for a motor train unit includes: Acquiring fault data of faults of the actuator train caused by faults of the transverse acceleration sensor in a fault site; detecting the damage to the appearance of all the transverse acceleration sensors corresponding to the fault data to obtain a sensor without appearance damage; Respectively carrying out functional tests on the sensors without appearance damage at room temperature and low temperature, and screening to obtain a room-temperature failure sensor sample and a low-temperature failure sensor sample without room-temperature failure; Performing a functional test before disassembly and a functional test in the disassembly process on the sensor sample which fails at low temperature and does not fail at room temperature, and observing whether bubbles exist in the pouring sealant after the disassembly is completed; When the pouring sealant of the sensor sample which is failed at the low temperature and is not failed at the room temperature has bubbles, removing the pouring sealant of the sensor sample which is failed at the low temperature and is not failed at the room temperature, and obtaining a glue removing sample of the sensor which is failed at the low temperature and is not failed at the room temperature; Performing functional tests on the sensor adhesive removing samples which fail at the low temperature and are not failed at the room temperature at room temperature, low temperature and low temperature-to-room temperature respectively; When the low-temperature failure and room-temperature failure sensor gel removal sample passes the function test at room temperature, and the function test at low temperature fails, but the function test passes after the room temperature is restored, unsealing and observing the room-temperature failure sensor sample; when bubbles exist in the pouring sealant of the room temperature failure sensor sample, removing the pouring sealant of the room temperature failure sensor sample to obtain a room temperature failure sensor gel removing sample; performing a functional test on the room temperature failure sensor photoresist removing sample at room temperature again; And when the room temperature failure sensor gel removal sample passes the function test at room temperature, deducing that the bubble exists in the sensor pouring sealant as the failure cause of the transverse acceleration sensor. In one embodiment, the step of detecting the damage to the appearance of all the lateral acceleration sensors corresponding to the fault data to obtain a sensor w