The door pressure tester is a compact, handheld device designed for efficient and accurate testing of subway vehicle doors. It consists of a specialized pressure sensor and an integrated test management system, making it ideal for evaluating the closing force of passenger compartments, detecting minimum obstacles, and assessing the anti-pinch protection function of doors. The device allows users to set and record test parameters such as the number of tests, time, and specific test items. It can automatically complete the testing process and store results, significantly improving efficiency and accuracy.
In high-speed rail systems, the safety of vehicle doors is critical. These doors must meet strict performance standards to ensure safe operation. Manufacturers must test these parameters during production, and ongoing inspections and maintenance are essential to maintain safety. Traditional testing methods often rely on manual tools and human judgment, which can be time-consuming, inaccurate, and inefficient. This approach lacks automation, leading to inconsistencies in data collection and limited ability to track long-term performance.
Current door pressure testing methods typically involve inspectors using hand tools, which presents several challenges. First, the equipment is often bulky and difficult to carry, limiting its portability. Second, data must be recorded manually, which is not only labor-intensive but also prone to errors. Third, reliance on personal experience reduces the reliability of results. Fourth, manual procedures may pose safety risks. Finally, the overall testing process is slow and inefficient, making it unsuitable for large-scale or frequent inspections.
To address these issues, this paper introduces a portable door pressure detector that combines a specialized pressure sensor with a test management system. It is designed to accurately measure the closing force of subway vehicle doors, detect obstacles, and verify the anti-pinch protection mechanism. The device supports setting and recording test parameters, while the system automatically completes the tests and stores the results. Additionally, it features a USB interface for data transfer, enhancing usability and compatibility.
Overall System Design
The system is built around the ATmega32 microcontroller, serving as the central processing unit. The design includes a pressure acquisition system, a control and display interface, a power supply module, a data storage and import system, and an alarm module for abnormal conditions. A block diagram of the main system is shown in Figure 1.
Introduction to ATmega32
The ATmega32 is an 8-bit microcontroller based on the AVR RISC architecture, known for its low power consumption and high performance. With one instruction executed per clock cycle, it achieves near 16 MIPS/MHz performance. Key features include:
1) High-performance, low-power 8-bit AVR microcontroller
2) Advanced RISC architecture with 130 powerful instructions, most executed in a single clock cycle, and a hardware multiplier
3) On-chip memory: 32 KB FLASH (1000 erase cycles), 1024 bytes EEPROM (100,000 erase cycles), 2 KB SRAM, and program encryption
4) Multiple timers, PWM channels, ADCs, and an internal comparator
5) Power-on reset, programmable brown-out detection, and multiple interrupt sources
6) Low power consumption and high speed
In the ATMEL microcontroller family, the ATmega32 stands out due to its Harvard architecture, large memory capacity, and rich peripheral interfaces. Its combination of speed, low power, and cost makes it highly suitable for designing a portable door pressure detector.
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