TKS520司机控制器技术规范

1、 株洲威森机车配件有限公司司机控制器TKS520Master controller TKS520第一版 Issue: - 1.0 -批准 Released: 桂勇 GuiYong R & D depart 2010-02-04 Sgd. GuiYong 校核 Checked: 凌锦灿LingJinCan R & D depart 2010-02-04 Sgd. LingJinCan编制 Created: 全湘乾 QuanXiangQian R & D depart 2010-02-04 Sgd. QuanXiangQian姓 名 Name 部门 Devision 日期

2、Date 签 名 Signature更改清单List of changes版本号Issue日期Date更改理由Reason for change页面Page(s)1 04.02.2010第一版First issue 全部All234567891011121314151617181920目录Table of contents1 用途/功能Purpose / function.52 说明Description.52.1 技术参数Purposes of use/ technical data.62.2 技术说明Technical description .73 安全说明Safety instruct

3、ions .173.1 与安全有关的拧紧转矩Safety relevant tightening torque.174 操作手册Instruction manual.174.1 操作Operation .185 组装和调试Assembly and commissioning .185.1 运输/装船/储存Transportation / shipment / storage .185.1.1 运输/装船Transportation / shipment.185.1.2 储存Storage.185.2 安装Installation .195.3 调试Commissioning.215.3.1 调

4、试前检查Check-up before commissioning.215.3.2 调试Commissioning.225.4 维修Maintenance.235.4.1 维修等级Maintenance steps .235.4.2 维修计划Maintenance plan .245.4.3 维修工作Maintenance works.255.5 故障处理、更换设计维修Trouble shooting, exchange concept / maintenance.265.5.1 故障处理Trouble shooting.265.5.2 组装Assembly.285.5.3 投入使用/功能试验

5、Return to service / Function test.285.6 专用工具、设备，测量和试验设备Special tools, devices, measuring and test devices .285.6.1 测量和试验设备Measuring and test devices.285.6.2 易损件和备件Wearing und spare parts .295.7 废弃物处理方案Waste management concept .291 用途/功能Purpose / function司机控制器是机车的主令控制电器，用来转换机车的牵引与制动工况，改变机车的运行方向，设定机车运

6、行速度，实现机车的起动和调速等工况。Master controller is a kind of master apparatus used to control locomotive running.It used to convert the locomotives working modes of traction and braking, to change its direction, to set its velocity, to perform locomotive starting and speed regulation.122 说明Description31Traction

7、/brake controller2Direction switch3Key switch图 1：司机控制器总图Figure 1: Master controller overview 司机控制器是机车的主令控制电器，用来转换机车的牵引与制动工况，改变机车的运行方向，设定机车运行速度，实现机车的起动和调速等工况。各主要部件的功能参看表2.2。Master controller is a kind of master apparatus used to control locomotive running.It used to convert the locomotives working mo

8、des of traction and braking, to change its direction, to set its velocity, to perform locomotive starting and speed regulation. The function of each components see table2.2.2.1 技术参数 technical data司机控制器的机械寿命 2×106 次Master controllers mechanical lifetime 2×106cycles辅助触头盒电寿命 2×105 次Auxil

9、iary contacts Electrical life 2×105 cycles司机控制器的质量 10kgMaster controllers mass 10kg辅助触头盒的防护等级 IP67（依照IEC60529）Auxiliary contacts degrees of protection IP67(according to IEC60529)辅助触头盒标称电压 DC 110VAuxiliary contacts nominal voltage DC 110V辅助触头盒约定发热电流 10AAuxiliary contacts rated thermal current 10

10、A最小电气间隙 3mmMin electrical clearance 3mm最小爬电距离 4mmMin creeping length 4mm2.2 技术说明Technical description 司机控制器的结构见图2和表2.2。The structure of master controller see Fig 2 and table2.2.8721121615141317111069345图 2：司机控制器结构 Fig 2:Structure of master controller序号Item名称Designation备注Remarks1面板panel2牵引/制动控制器Drive

11、 of power-/brake controller3牵引/制动控制器油浸电位器Oil potentiometer of power-/brake controller与株洲威森机车配件有限公司联系Contact Zhuzhou VEE.SUN motor accessories Co.，Ltd4螺钉及弹垫Set of screws and spring lock washers包含在序3 中Included in item35联轴器Coupling包含在序2 中Included in item26沉头螺钉Set of countersunk screws包含在序2 中Included in

12、 item27方向转换开关Direction switch8螺钉及弹垫Set of screws and spring lock washers包含在序2、7 中Included in item2、79圆柱齿轮Spur gear 包含在序2、7 中Included in item2、7 10VS847 辅助触头盒Auxiliary contact type VS847 与株洲威森机车配件有限公司联系Contact Zhuzhou VEE.SUN motor accessories Co.，Ltd11螺钉及弹垫Set of screws and spring lock washers包含在序10

13、中Included in item1012钥匙开关Key switch13联锁机构Mechanical interlocking system包含在序12中Included in item1214螺钉及弹垫Set of screws and spring lock washers包含在序13中Included in item1315电阻Resistance包含在序2中Included in item216警惕按钮辅助触头盒Alert buttonAuxiliary contact type17警惕按钮Alert button18电连接器和连接电缆Connector and connecting

14、 cables 表 2.2 司机控制器部件清单 Table 2.2 Components list of Master controller2.2.1 牵引/制动控制器Drive of power-/brake controller牵引/制动手柄（图2，序2）位于司机控制器右侧，用于调节机车的牵引和制动工况。可前后推动，具有“T” （牵引）、“0”（停止）、“B”（制动）和“快制”四个区域。牵引/制动手柄（图2，序2）垂直时为“0”位，向前推进入“牵引”区，推动41°后到达“牵引”最大位；向后拉进入“制动”区，拉动36°后到达“制动”最大位；拉动41°后到达“快制

15、”位。牵引/制动手柄上的警惕按钮在任何角度都可以操作。Driving/braking lever（Fig 2,list 2） is at the right of master controller, used to convert thelocomotives working modes of traction and braking. Driving/braking lever（Fig 2,list 2）can bepushed forward and be draught backward, and it has four positions: “T”(Traction) 、“0”(Co

16、ast)、“B”(Braking) and "Quick braking". When it is vertical, indicating “0” (Coast). If push forward, driving/brakinglever in driving range, and after be pushed forward 41°, driving/braking lever will arrive theposition of driving max; If draw backward, driving/braking lever in braking

17、 range, and after bedraught backward 36°,driving/braking lever will arrive the position of braking max. and after bedraught backward 41°,driving/braking lever will arrive the position of Quick braking.Driving/braking lever's vigilance button in any Angle can operate.2.2.2 牵引/制动控制器油浸电位器

18、 Oil potentiometer of power-/brake controller牵引/制动控制油浸电位器（图2，序3）共有一个，外形结构如图3所示：There is one Oil potentiometer （Fig 2,list 3）of the Drive-/brake controller.The structure of Oil potentiometer see Fig 3.图3 油浸电位器外形图 Fig 3 The structure of Oil potentiometer牵引/制动手柄（Fig 2,list 2）在各位置的手柄角度及油浸电位器输出值见表2.2.2：输

19、入电压：15VDC Driving/braking levers position and its deflection and Oil potentiometer output valeues see table 2.2.2 ：The input voltage: 15VDC牵引/制动手柄（图2，序2）位置Driving/braking levers（Fig 2,list2） position手柄角度deflection of lever油电位器输出数值Oil potentiometer output values牵引最大位Driving max+41°8.3±0.15V

20、DC0 位Coast 0° 3±0.1VDC制动最大位Braking max -36°8±0.1VDC快制位 Quick braking-41°8.3±0.15VDC 表 2.2.2 牵引/制动手柄角度及油浸电位器输出Table 2.2.2 Driving/braking levers position and Oil potentiometer output valeues2.2.3 方向转换开关控制器Direction switch方向转换开关（图2，序7）位于司机控制器左侧，方向转换开关有三个位置：向前、0、向后，且每个位置均有

21、定位。每个位置之间开关的转动角度为20°。钥匙开关（图2，序12）具有“ON”和“OFF”两个位置。 Direction switch（Fig 2,list 7） is at the left of master controller, The direction switch has 3 positions namely ：”forward”, ”0”and “backward” , and each location are positioning. The switch turned 20°from one position to another. Keyswitch

22、（ Fig 2,list 12） has two positions: “ON”、“OFF”.机械联锁要求：Mechanical interlocking system：2.2.3.1 钥匙开关（图2，序12）在“OFF”位置时，方向转换开关（图2，序7）和牵引/制动手柄（Fig 2,list 2）被锁在”0“位。 钥匙开关（图2，序12）在“ON”位置时，方向转换开关（图2，序7）可在“F”（向前）、“N”（关闭）、“B”（向后）之间转换。Keyswitch（ Fig 2,list 12）in “OFF”-position Direction switch（Fig 2,list 7）andd

23、riving-/braking lever（Fig 2,list 2） blockedin Coast. Keyswitch（ Fig 2,list 12）in “ON”-position Direction switch（Fig 2,list 12）can be transformed among “F”、 “N”and “B”.2.2.3.2 当方向转换开关（图2，序7）在“0”（关闭）位时，牵引/制动手柄（图2，序2）被锁在“0”（停止）位。Direction switch（Fig 2,list 7） in 0-position driving-/braking lever（Fig 2,

24、list 2） blockedin Coast.2.2.3.3 当方向转换开关（图2，序7）在“F”（向前）位或“B”（向后）位时，牵引/制动手柄（图2，序2）可自由推动。Direction switch（Fig 2,list 7）either in F-or in B-position Driving-/braking lever（Fig 2,list2） free to move.2.2.3.4 牵引/制动手柄（图2，序2）在“0”（停止）位时，方向转换开关（图2，序7）可在“F”（向前）、“N”（关闭）、“B”（向后）之间转换。Driving-/braking lever（Fig 2,l

25、ist2） blocked in Coast Direction switch（Fig 2,list7） can be transformed among “F”、 “N”and “B”.2.2.3.5 牵引/制动手柄（图2，序2）在“T”（牵引）或“B”（制动）区域时，方向转换开关（图2，序7）被锁在“F”（向前）位或“B”（向后）位。Driving-/braking lever （Fig 2,list 2） either in driving-or in braking range-Direction switch （Fig2,list 7） blocked either in F-or

26、in B-position.2.2.4 电连接器和连接电缆Connector and connecting cables所有触头盒的接线都连接到46 芯的Harting电连接器, 电连接器外罩型号为HAN16B,电连接器型号为HAN46EE，见图4，导线长1.1m。电位器导线接到5芯的Harting电连接器, 电连接器型号为HAN3HPR。All switches are wired to a 46-pole Harting connector according to wiring diagram ,the type of the Hood is HAN16B and the Harting

27、 connector is HAN46EE and the configuration ofconnector see Fig 4, cable length is 1.1m. Potentiometer wires to a 5-pole Harting connector.the Harting connector is HAN3HPR.图4 电连接器 Fig 4 Connector3 安全说明Safety instructions注意 NOTE司机控制器连接插头未连接时，触头可能无电。Not with the master controller connected plugs may l

28、ead in the contacts novoltage.严重警告CAUTION辅助触头盒（图2，序10）的额定工作电压为DC110V，小心触电。The auxiliary contacts （Fig 2,list 10） rate voltage is DC110V, be careful!3.1 与安全有关的拧紧转矩Safety relevant tightening torque位置Location螺纹公称尺寸Screws size拧紧转矩(Nm)Tighteningtorque (Nm)扳手尺寸Wrenchsize (SW备注Remark面板（ 图2 ，序1）panel（Fig 1,

29、list 1）M82613所标明的拧紧转矩取决于紧固方式(螺纹连接等级)，并根据德国25202 标准化机构制定。制动柜部件的螺纹连接：参见Knorr 检修手册The indicated tighteningtorques are depending onthe method of tightening(screw connection class) to German Institute forStandardization 25202.Screw connections ofcomponents of the brakepanel: see respective overhaulinstru

30、ctions Knorr其余 OthersM5M66,310,8810表 3.1 与安全有关的拧紧转矩实例 Table 3.1 Sample safety relevant tightening torque4 操作手册Instruction manual4.1 操作Operation 用钥匙打开钥匙开关（图2，序12），旋转方向转换开关（图2，序7），选择“向前”或“向后”，向牵引方向推动牵引/制动手柄（图2，序2），机车将起动，并随着推动角度的增大，机车速度将增大。机车需要制动时，可将牵引/制动手柄（图2，序2）拉向制动区域。在行车过程中，如需要改变机车的工况时，必须将控制手柄放回“0”位

31、后，才可进行换向手柄的操作。如司机需要进行异端操作时，必须将本端司控器的控制手柄置“0”位，锁闭机械锁拔出钥匙，方可进行异端操作。 Use the key to open key switch（Fig 2,list 12）, then operate direction switch（Fig 2,list7）, select F(forward) or B(backward),push driving/braking lever（Fig 2,list 2） to“T”(Traction),locomotive will start, and the speed will rise with t

32、he pushing angle up.Whenlocomotive need brake,only draw driving /braking lever（Fig 2,list 2） to “B”(Braking). In driving process, such as the need to change the operation condition of the locomotive, must will driving/braking lever（Fig 2,list 2） to put it back after a "0", they are the rev

33、ersing handle operation. If the driver to heresy operation, the company will have to the control device driving/braking lever（Fig 2,list 2） buy "0", a mechanical lock key lock out, can heresy operation.5 组装和调试Assembly and commissioning5.1 运输/装船/储存Transportation / shipment / storage5.1.1 运输

34、/装船Transportation / shipment 司机控制器在运输时的环境条件（根据DIN EN 60721-3-2 的环境条件分级）： Ambient conditions of Master controller during transport（Classification of environmentalconditions according to DIN EN 60721-3-2）： 温度等级 Temperature class：2K4； 其他环境条件Other environmental conditions：2B2，2C3，2S3，2M3。 司机控制器由制造商进行包装和

35、发货。在收到包装后，客户必须检查交货是否受损和有故障，包括因运输而受损的，并把可能出现的问题通知制造商和转运商。如果通知迟了将不再考虑索赔。 Master controller is packed and dispatched by the manufacturer. After receiving the packing the customer is obliged to check the delivery for damaged and defects, including transport damaged and notify the manufacturer and forwar

36、der about possible shortcomings. Claims are not considered in cases of later notifications.5.1.2 储存Storage 司机控制器必须储存在下列条件下的封闭的空间内： Master controller must be stored in enclosed spaces under the following conditions: 储存温度的范围: -40到+50 Range of storage temperature : from 40 to +50 最大相对湿度（该月月平均最低温度不低于25）

37、： 95 Max. relative humidity：95 (the average lowest temperature of the month is above 25)5.2 安装Installation图5 开孔和安装尺寸图 Fig 5 The diagram of openings and installation 将司机控制器安装到司机操纵台上前，无需要先拆下牵引/制动控制器和速度设定控制器的控制手柄。（图5）直接从司机操纵台下部向上安装即可。锁开关安装要卸下后面的凸轮，取出锁芯才可以安装。 Before the Master Controller can be installe

38、d into the operators panel, the grip of thetraction power / brake control unit and speed setting-selector unit has not to be removed（Fig 5）.The installation can be directly from the operators panel upward. Lock switch installed to remove the back of the CAM, remove lock core can be installed.图6 司机控制

39、结构图Fig 6 Schematic diagram of structural profile for S335 master controller 司机控制器 (图6)需要从司机操纵台上侧用螺钉连接。因此司机操纵台需要预留四个安装螺钉的接口。在安装中将用到以下连接件： 内六角沉头螺钉M8 （GB/T70.3-2000） 4 个 As enlightens from Figure 6 the Master controller (Fig 64) has to be bolted against the desk platestop side. For that purpose the des

40、k plate is to be provided with the cutouts aswell as four thread screws as shown in dimensioned drawing no. TKS520. For thescrew joint the following elements are recommended: _ 4 x M8 Hex head sink screws according to GB/T70.3-2000 安装或拆卸时必须注意以下事项：1、司机控制器锁闭侧是通过锁来安装的，组装或拆卸时需注意：锁后面的凸轮必须移走，如果必要的话，可以移动拉丝

41、组件。2、司机控制器的拉丝组件在发货之前已经调到合适的位置，如果在组装或者拆卸司机控制器的时候将其分开了，必须重新再作调整。要保护司机控制器的钥匙可以灵转动，锁牢固可靠。Install or remove must pay attention to the following items:1, the driver controller is through the lock to lock in the installation, assembly or remove the need to note: lock the back of the CAM must be moved, if n

42、ecessary, you can move the wire drawing components.2, the driver of the controller drawing components prior to shipment has been transferred to the right position, if in the assembly or remove the driver of the controller time to separate, have to be adjusted. To protect the driver controller can be

43、 the key to spirit rotation, lock strong and reliable.5.3 调试Commissioning5.3.1 调试前检查Check-up before commissioningNo.序号部件Components方法Measures注意NOTE交叉引用Crossreference1 牵引/ 制动手柄（ 图2 ， 序2 ）driving/braking lever（Fig 2,list 2）方向转换开关（图2，序7）direction switch（Fig 2,list 7）钥匙开关（图2，序12），key switch（Fig 2,list 12

44、）操作各手柄及开关，检查是否动作良好。Operate all levers andswitches, check themwhether they work well.2 机械联锁机构mechanical interlocking system检查机械联锁机构的联锁关系是否满足2.2.3的要求。Check mechanicalinterlocking systemwhether meet therequirements of 2.2.3.2.2.3 机械联锁要求2.2.3mechanicalinterlockingsystem表5.3.1 调试前检查实例 Table 5.3.1 Sample

45、checkups before commissioning5.3.2 调试CommissioningNo.序号部件Components方法Measures结果/指示器Effect / Indicator交叉引用Crossreference1油浸电位器（ 图2，序3）Oil potentiometer （ Fig2,list 3 ）调节油浸电位器（图2，序3）的联轴器，使得输出码值满足表2.2.2 和2.2.4的要求。Regulate coupling of Oil potentiometer（Fig 2list 3 and 8）, make Oil potentiometer output v

46、alues meet therequirements of table 2.2.2and table 2.2.4.油浸电位器测试仪Oil potentiometertesting pparatus2.2.2、2.2.4表5.3.2 调试实例 Table 5.3.2 Sample commissioning5.4 维修Maintenance5.4.1 维修等级Maintenance steps维修等级Maintenance stage说明Description运行里程数Running performance (km)间隔期Interval(Period)VI目检Visual inspection

47、10.000 km 2 周 2 weeksI1检查1 级Inspection 1100.000 km6 个月6 month I2 检查2 级Inspection 2200.000 km 1 年1 yearI3检查3 级Inspection 3400.000 km 2 年2 yearsR1 修正1 级Revision 1800.000 km 1.200.000 km 4 6 年4 6 yearsR2 修正2 级Revision 21.600.000 km 2.400.000 km 8 12 年8 12yearsR3 修正3 级Revison 33.200.000 km 3.600.000 km

48、16 18 年16 18yearsUM 计划外维修Unscheduled maintenance 表 5.4.1 中国机车项目维修等级 Table 5.4.1 Maintenance steps for Project China Sprinter5.4.2 维修计划Maintenance planNo.序号部件Components维修Maintenance维修等级Maintenance stage1牵引/制动手柄（图2，序2）driving/braking lever（Fig 2,list 2）方向转换开关（图2，序7）direction switch（Fig 2,list7）钥匙开关（图2

49、，序12），key switch（Fig 2,list 12）操作各手柄及开关，检查是否动作良好。Operate all levers and switches,check them whether they work wellI12 油浸电位器（图2，序3）Oil potentiometer（Fig 2,list 3）检查油浸电位器输出值是否满足表2.2.2和表2.2.4的要求。CheckOil potentiometer output values whether meetthe requirements of table 2.2.2 andtable 2.2.4.3 机械联锁机构mechanicalinterlocking system拆解机械联锁机构，对疲劳部件进行更换dismantle mechanicalinterlocking system,replace theweariness components.I2 表5.4.2 维修计划实例 Table 5.4.2 Sample maintenance plan5.4.3 维修工作Maintenance worksI1 级检修Maintenance stage I1No.序号部件Components检查Inspection交叉引用Cross