Design And Realization Of The Digital Rail Car Master Controller Based On Non-Contact Sensor

After 30 years of technology introduction and independent innovation, domestic rail cars are no long the simple combination of flat wagon and crane, it has evolved into a series of railway construction machinery to satisfy different demands. Although on-board equipment had achieved great development, the master controller of rail car still needs to be improved.Existing rail car master controllers mostly based on potentiometer and encoder technology, however, both of them have shortages. Master controller based on potentiometer can reach a higher level of accuracy with smaller installation size, but it has lower reliability since the existence of friction between brush and resistor film. Master controller based on encoder provides high reliability but it has deficiencies of complex structure, low output precision. Moreover, there is a general lack of digitalization among existing rail car master controllers. Thus, it has great significance in research and realization of a new type of digital rail car master controller which has the merits such as simple structure, small dimension, high precision, high reliability, etc.This thesis introduces the status of rail car master controllers development firstly, also some kinds of non-contact position sensor technology are reviewed, especially for hall sensor, which is most likely to be used in rail car master controller. The new generation hall sensor IC based on Triaxis(?) hall technology, MLX90360 was finally chosen after a technical tradeoff. Then, the paper introduces the design and realization of the digital rail car master controller based on MLX90360 from aspects of structure, hardware, firmware and upper monitor.In structure, the thesis described a single handle design of the new rail car master controller which complete the lock and unlock features.For reliability considerations, an FAE was developped on main force bearing part. In hardware work, the author analyzed and identified relevant electrical parameters of the master controller, then designed the schematics and PCB on Altium Designer. Limited to paper space, in software work the thesis only gave some important flow charts instead of source codes.At last, a prototype was manufactured by machining and tested. The test result shows that the digital rail car master controller based on non-contact sensor can meet the requirement of the engineering application.