CN-122015607-A - Data acquisition and quality control system for axle detection of railway freight car

CN122015607ACN 122015607 ACN122015607 ACN 122015607ACN-122015607-A

Abstract

The application relates to the technical field of mechanical engineering and intelligent detection, discloses a data acquisition and quality control system for axle detection of a railway wagon, and aims to solve the problems that in the prior art, manual recording is prone to error and leakage, data acquisition and quality judgment are disjoint, and closed loop control cannot be achieved. The system comprises a commercial digital display micrometer additionally provided with an external Bluetooth device, a portable small tablet and a quality management system, wherein a wireless transmission link is constructed through Bluetooth, static size data are transmitted to the small tablet in real time and uploaded to the system, a new data receiving, checking and storing module of the quality system is added, process standards are automatically compared, and visual identification is carried out on abnormal data. By adopting the technical scheme, the application can realize automatic acquisition, real-time verification and abnormality early warning of high-precision static size data, and remarkably improve detection accuracy, efficiency and quality traceability.

Inventors

CHEN YIHE
CHEN TAO
WANG SHIKUN
ZENG SHUANGSHUANG
XIE HONGQUN
WANG QI
SHAO CHENGYUN
YANG XINYI

Assignees

中车长江铜陵车辆有限公司

Dates

Publication Date: 20260512
Application Date: 20260123

Claims (7)

1. The system is characterized by comprising a handheld static size data wireless acquisition unit, a mobile data transfer and system access terminal and a quality management system deployed on an enterprise intranet server, wherein the handheld static size data wireless acquisition unit is composed of a commercial digital display micrometer with a data acquisition function, an external Bluetooth device and a special adapter cable, the external Bluetooth device is electrically connected with an output interface of the digital display micrometer through the special adapter cable and is paired with the mobile data transfer and system access terminal based on a Bluetooth communication protocol to form a wireless data transmission link from the digital display micrometer to the mobile data transfer and system access terminal through the external Bluetooth device, the mobile data transfer and system access terminal is an industrial portable small tablet, a client of the pre-installation quality management system is automatically started after the pairing with the external Bluetooth device is completed, an operator logs in through identity authentication, the small tablet serves as a data transfer node for detecting on site, and receives and caches the measured value of an axle from the digital display micrometer in real time, the quality management system comprises a data receiving module, a diameter data receiving module and a diameter calibration module, a diameter calibration module and a data receiving module, a diameter calibration module and a diameter calibration module are sequentially used for the data receiving the data in a diameter standard, and a diameter calibration standard is used for the data receiving the data in a diameter standard, and the data standard calibration standard is not required, the quality control system comprises a data storage module, a system support detection personnel, an API interface and a railway wagon manufacturing execution system MES, wherein the data storage module is used for automatically associating data meeting the standard with corresponding axle unique identification information according to a verification result to store the data into a database, and adding a visual identification attribute to the abnormal data when the data are stored, so that the data are presented in a red font in a system interface, the system support detection personnel maintain Bluetooth connection and data uploading when moving between multiple stations to automatically generate a quality control report containing abnormal items based on the abnormal identification, the quality control system is in butt joint with the railway wagon manufacturing execution system MES through the API interface, and when the axle has abnormal data, the API interface is used for sending a locking instruction containing the axle unique identification and the abnormal item code to the MES, and the MES is used for intercepting a work order station passing request corresponding to the identification until a retest qualification release instruction sent by the quality control system is received.
2. The system for data acquisition and quality control of axle detection of a railway wagon according to claim 1, wherein the output interface of the digital display micrometer accords with an RS232 standard protocol, the external bluetooth device is connected with the interface through a special adapter cable, and the special adapter cable integrates a level conversion circuit, a power isolation circuit and a signal filtering circuit without modifying a micrometer body structure.
3. The system for data acquisition and quality control of axle inspection of rail wagons according to claim 1, wherein the mobile data transfer and system access terminal is an industrial grade flat panel device with a weight of not more than 600 g, a screen size of 8 inches and an IP65 protection level, and the built-in battery supports continuous operation for more than 12 hours and is adapted to multi-station mobile inspection operation in a dusty and vibratory environment of a rail wagon inspection shop.
4. The system for data collection and quality control of axle inspection of rail wagons as claimed in claim 1, wherein the process standard database in the data verification module is configured with a plurality of critical dimension parameters for each axle model, each parameter is set with an upper and lower tolerance zone, the tolerance zone is determined according to the manufacturing technical conditions of the rail wagons axle, the data format specification defines the numerical types as floating point type, decimal number as three digits and unit as millimeter.
5. The system of claim 1, wherein the visual identification attribute is configured to highlight the entire row of records containing anomaly data in the axle list view in addition to controlling the display of the anomaly data in a red font, and to generate an anomaly number thermodynamic map in the day, week, or month dimension in the quality statistics sign and to support screening of the anomaly data by axle number, detection date, or operator dimension.
6. The system for data collection and quality control of axle detection of rail wagon according to claim 1, wherein the automatic quality inspection report generating module generates a structured report according to the stored detection data after measurement of all key parts of a single axle is completed, the report content comprises axle basic information, actual measurement values of all detection points, corresponding standard ranges, deviation values and abnormal identification states, the report format accords with the quality document specification of the rail wagon industry, and the report format can be exported as PDF or print archiving.
7. The system for data acquisition and quality control of axle detection of railway trucks according to claim 1, wherein the external bluetooth device adopts a bluetooth low energy 5.0 protocol, the communication distance is not less than 10 meters in an overhaul workshop environment, the data transmission rate is set to 9600 baud rate, the packet loss rate is lower than 0.1%, and a one-to-many connection mode is supported, so that a plurality of micrometers are allowed to be alternately connected into the same small plate.

Description

Data acquisition and quality control system for axle detection of railway freight car Technical Field The invention belongs to the technical field of mechanical engineering and intelligent detection, and particularly relates to a data acquisition and quality control system for axle detection of a railway wagon. Background With the rapid development of the railway transportation industry, the axle of a railway wagon is used as a key bearing and transmission part, and the dimensional accuracy in the manufacturing and overhauling processes of the axle is directly related to the operation safety and the service life. In the final inspection and segment repair links of axle manufacturing, the high-precision detection of static geometric dimensions of key parts such as axle journals, dustproof seats, wheel seats and the like is a core quality control step for ensuring that the axle accords with the process standard. The existing axle size detection is carried out by manually operating an display micrometer, and data are imported into a quality management system in a paper recording or manual recording mode. The method is low in efficiency, and is extremely easy to cause data misplacement, drop-out or unit confusion due to human negligence, so that the accuracy and traceability of quality judgment are seriously affected. Although some schemes attempt to introduce automatic sensing technology, such as a laser dynamic diameter measuring system, the method is mainly suitable for online detection scenes in an operation state, and is difficult to meet specific requirements of an end-of-manufacturing detection link on offline, static and high-precision dimension measurement, while a health monitoring method based on acoustic emission or vibration analysis focuses on dynamic fault modes such as cracks and fatigue and cannot cover quality control of static geometric parameters. The problems of disjoint detection means and business flow, data acquisition and quality judgment and splitting in the field of railway wagon axle static dimension quality inspection generally exist in the prior art, namely, on one hand, a commercial high-precision digital display micrometer has excellent metering performance but lacks seamless butt joint capability with an informatization system, and on the other hand, a quality management system has a data storage function but does not integrate real-time standard comparison, format verification and abnormal visualization mechanisms, so that detection data cannot be immediately converted into effective quality decision basis. The defects enable axle size quality inspection to stay in an inefficient mode of acquisition, input and post-check, and closed-loop management and control from data acquisition to quality judgment to abnormal early warning are difficult to realize, so that a data acquisition and quality management and control system which is oriented to a manufacturing final inspection scene and integrates a high-precision handheld measuring tool and an intelligent quality system is needed. Disclosure of Invention The invention aims to provide a data acquisition and quality control system for railway wagon axle detection, which can effectively solve the problems in the background technology. In order to achieve the above purpose, the technical scheme adopted by the invention is as follows: The data acquisition and quality control system for axle detection of railway wagon comprises the following specific modules, namely, a handheld static size data wireless acquisition unit is constructed, namely, an external Bluetooth device is additionally arranged on a commercial digital display micrometer with a data acquisition function, so that the external Bluetooth device is stably electrically connected with the digital display micrometer and is paired with a portable small flat plate through a Bluetooth communication protocol, and a wireless data transmission link from the digital display micrometer to the small flat plate through the external Bluetooth device is formed; step (2) configuring a mobile data transfer and system access terminal, wherein after the small flat plate is paired with an external Bluetooth device, the small flat plate automatically starts a preassembled quality management system client, an operator uses an identity authentication login system to enable the small flat plate to become a data transfer node of a detection site to receive and cache axle dimension measurement values from a digital micrometer in real time, step (3) establishes a quality system intelligent checking and storing mechanism, wherein the quality system intelligent checking and storing mechanism comprises a data receiving module, a data checking module and a data storing module, the data receiving module is used for receiving metering values uploaded by the small flat plate, a process standard database of railway wagon axles of different types is prestored in the data checking module, the standard range a