GB/T 14894-2026Rules for the inspection and testing of urban rail transit vehicles after completion of construction (English PDF)

4.1 General Rules

4.1.1 The process of vehicle manufacturers inspecting and testing vehicles should include test outlines, test specifications, process standards, and test records. The content should include recording, calibration of testing instruments and equipment, document control, control of nonconforming products, and personnel training, and should comply with GB/T 19001. Regulation.

4.1.2 All equipment or systems integrated into the vehicle shall be subject to appropriate inspection and testing. If the vehicle is not equipped with the equipment covered in this document... If the equipment or function is not required, corresponding checks and tests may not be necessary.

4.1.3 The contents related to reliability, availability, maintainability and safety shall comply with the provisions of GB/T 21562.

4.2 Test Outline

4.2.1 Before inspection and testing, a test outline should be prepared and reviewed.

4.2.2 The test outline shall include at least the following.

a) Experimental procedures;

b) Experimental plan;

c) Test methods;

d) The test categories and implementation conditions for each test;

e) Evaluation criteria for each test or vehicle design requirements.

4.2.3 The test outline may include referenced test specifications.

4.2.4 The test plan can be adjusted according to the actual situation.

4.3 Test Report After all tests are completed, a test report should be prepared, which should include at least the following.

a) The name and address of the organization that prepared the test report;

b) The name and address of the vehicle manufacturer;

c) Identification information of the vehicle and its major components, including name, type, model and related supplementary information;

d) Standards or normative documents referenced in the test outline;

4.4 Third-party testing institutions

4.4.1 Testing may be conducted by a third-party testing organization independent of the vehicle manufacturer. When a third-party testing organization is used, the testing organization should... The certification system details are declared and agreed upon.

4.4.2 When vehicle testing is conducted at a third-party testing site, it may be carried out by a third-party testing organization.

4.4.3 Third-party testing organizations shall meet the requirements of GB/T 27025.

5.1 General Rules

5.1.1 Before conducting tests on each vehicle, component or equipment tests should be completed. When the supplier's factory lacks suitable conditions, tests can be conducted on the entire vehicle. Perform static or dynamic routine tests on the components.

5.1.2 If the same test is conducted using test facilities of different specifications, the user should be informed of the impact of the test facilities on this type of test.

5.2 Test Categories

5.2.1 The various inspections and tests conducted on the vehicle after assembly and before it is put into use shall include.

a) Adjustment test;

b) Acceptance testing, including type testing and routine testing;

c) Research-based experiments.

5.2.2 Static tests shall comply with the following requirements.

a) Static testing shall be conducted at the vehicle manufacturer's factory or at another location agreed upon by the user;

b) Static tests should check whether the vehicle's safety meets the requirements of dynamic tests;

c) When static testing is conducted at a third-party testing facility, the test vehicle shall be transported safely.

5.2.3 Dynamic tests shall comply with the following provisions.

a) Dynamic tests should preferably be conducted at the vehicle manufacturer's factory; tests subject to track conditions should preferably be conducted on the track where the vehicle will be used. If the test is not available on the test line, it can be conducted on a line with similar characteristics or at a dedicated test site.

b) The test location and arrangements should be specified in the test outline;

c) The requirements for conducting the experiment shall comply with the regulations of the location where the experiment is conducted;

d) The test conditions should include all necessary facilities, equipment, and materials provided for dynamic testing;

e) The responsibilities of all parties involved in the dynamic trial should be clearly defined;

5.3 Test Implementation Conditions

5.3.1 Test Environment The inspection and testing environment conditions shall comply with the following requirements.

a) The altitude should not exceed 1400m;

b) The ambient temperature should be between -25°C and 45°C;

c) The average relative humidity of the wettest month should not exceed 90%, and the average minimum temperature of that month should be 25°C.

d) Due to the different climatic conditions in different cities, the test environment conditions can be specified separately in the test outline.

5.3.2 Vehicle Load Condition

5.3.2.1 When conducting inspections and tests, the load condition shall meet the following requirements.

a) The unloaded load (AW0) should be the vehicle's own weight load condition;

b) Seating load (AW1) shall be the vehicle mass when the passenger compartment is fully occupied and there are no standing passengers;

c) The rated passenger load (AW2) shall be the sum of the vehicle's tare weight and the rated passenger capacity;

d) Overload (AW3) shall be the overload at which the vehicle can operate safely, that is, the sum of the vehicle's own weight and the maximum passenger weight.

5.3.2.2 For inspection and test items specified in this document, where no specific load requirement is specified, the tests may be conducted under no-load conditions.

5.4 Adjustment Test

5.4.1 Adjustment tests may be conducted as needed before acceptance testing. These adjustments should preferably be completed at the vehicle manufacturer's factory. If further adjustments are required... If adjustments and tests are to be conducted on the customer's line, all static tests should be completed first.

5.4.2 Before the type test, the maximum operating mileage of the test should not exceed 5000km.

5.5.1 Type Testing

5.5.1.1 A type test shall be conducted on a vehicle under any of the following circumstances.

a) Newly designed and manufactured vehicles;

b) Mass-produced vehicles undergo significant technological upgrades, resulting in substantial changes to their performance, structure, materials, and components;

c) After a certain number of vehicles have been manufactured in mass production, it is necessary to re-verify their performance and conduct sampling tests.

d) This model of vehicle was produced for the first time;

e) Vehicles produced after the factory transfer.

5.5.1.2 Type testing shall comply with the following requirements.

a) The inspection and testing items shall comply with the provisions of Appendix A;

b) Static tests shall comply with the provisions of Chapter 6, and dynamic tests shall comply with the provisions of Chapter 7;

c) It should be carried out on the first train or on a train or rolling stock of the given design;

d) The test conditions shall comply with the provisions of 5.3;

e) It is advisable to complete the process within one year of vehicle assembly.

5.5.2 Routine Tests Routine tests shall comply with the following requirements.

a) The inspection and testing items shall comply with the provisions of Appendix A;

6.1.1 Dimensional Inspection

6.1.1.1 For all types of vehicles, their external shape and installation dimensions shall be inspected and measured according to the design requirements, and the following conditions shall be taken into account.

a) Adjustment range for all applicable components, including air springs;

b) Wear condition of the tread surface, etc.

c) Load conditions;

d) Range of motion in case of failure or damage to suspension components, etc.;

e) The worst-case combination of

6.1.1.2 For components such as doors that may exceed the vehicle's clearance limits under working conditions, dimensional checks should be performed according to design requirements.

6.1.1.3 Dimensions determined by calculation methods shall be listed in the test plan and shall be verified by inspection.

6.1.1.4 At least the following dimensional measurements shall be performed under the load conditions and straight track specified in the design, and the measurement results shall meet the design requirements.

a) The distance between the car body and the bogie or suspension frame;

b) Spacing between adjacent vehicles;

c) Height of the floor surface from the rail surface;

d) Working height of primary and secondary springs.

6.1.1.5 The length tests of hoses and cables shall be conducted under the most unfavorable load conditions and line conditions specified in the design, and the measurement results shall conform to the design specifications. Design requirements stipulate that at least the lengths of hoses and cables between the bogie or suspension and the relatively moving parts on the vehicle body should be measured.

6.1.4 Inspection of the sealing of the vehicle body and external equipment enclosure

6.1.4.1 The installation of protective panels, louvers, filters, dust separators, and other equipment used to filter the air drawn into the vehicle body and equipment compartment should be checked to ensure they are installed correctly. Accuracy and effectiveness.

6.1.4.2 After the dynamic test is completed, all parts of the vehicle shall not be subject to dust or damage.

6.1.4.3 When vehicles are running on tracks with foreign objects such as sand or snow, the devices preventing the intrusion of sand, snow, or other foreign objects should be checked.

6.1.4.4 For urban express trains with airtightness requirements, under no-load conditions, when the doors, windows, and air conditioning equipment of a single car are closed... When the opening is external, the time for the air pressure inside the passenger compartment of a vehicle traveling at 160 km/h to drop from 2600 Pa to 1000 Pa should not be less than 18 seconds. For vehicles with a speed range of 120km/h to 140km/h, the time for the air pressure inside the passenger compartment to drop from 2100Pa to 1000Pa should not be less than 15 seconds.

6.2 Weighing Test

6.2.1 Weighing tests should preferably be conducted at the vehicle manufacturer's factory, or they may be conducted on the user's route.

6.2.2 Weighing tests should be conducted according to the determination method in TB/T 1740, and the accuracy of the measuring equipment should be attached. If the measuring equipment is in an open-air environment... When using this test, current environmental conditions such as wind and rain should not affect the test results.

6.2.3 Before the weighing test, the suspension device can be adjusted. During the adjustment process, only the dimensions need to be checked, and the load does not need to be measured.

6.2.4 Before weighing, the vehicle should be moved slowly or towed to the weighing position to check the primary and secondary springs of the bogie and the motor suspension system. There should be no jamming or interference, and the height should meet the design requirements. The primary and secondary springs of the bogie can be adjusted before weighing.

6.2.5 The load condition of the vehicle shall not be changed or adjusted during the entire weighing process. Impacts, shaking, or other methods shall not be used to alter the vehicle's load. The condition of the body and suspension system. During routine testing, wheel load and axle load should be measured twice consecutively. During type testing, the load should be measured continuously. Repeat 3 times, and meet the following requirements.

a) The weighbridge-type weighing test platform should be tested three times in each of two different directions, that is, the vehicle should be tested from either end of the weighing track in the same driver's cab. The instrument enters the measuring track three times each using either forward or backward motion, and the measured value is the arithmetic mean of the six records.

b) The standard gauge vehicle weighing and balancing test bench should be raised and lowered three times simultaneously, and the measured value should be the arithmetic mean of the three records;

c) The portable weighing device should be tested three times in each of two different directions, i.e., the vehicle or trailer vehicles should be weighed from either end of the weighing device. Enter the weighing device three times in the same driver's cab using either forward or backward methods, and take the arithmetic mean of the six recorded values. Mean.

6.2.6 The vehicle's mass, axle load, and wheel load shall meet the design requirements and shall take into account the following factors.

a) Permissible tolerances for the maximum and minimum vehicle mass and the total vehicle mass;

b) Maximum axle load of the vehicle and permissible tolerance for the load on each axle;

c) The difference in weight between one side and the other side of the vehicle;

d) Axle load difference of semi-towed and semi-motorized vehicles.

6.2.7 The difference between the measured vehicle mass and the design value should not exceed 3% of the design value; the axle load measured on each driving axle of the same motor car and... The difference in actual average axle load for each axle of the vehicle should be ±2% of the actual average axle load; the actual wheel load of each wheel should be ±2% of the average wheel load of the two wheels on that axle. The difference should be ±4% of the average wheel weight of the two wheels on the axle.

6.3 Clearance Inspection

6.3.1 The cross-section being inspected should not exceed the coordinate values required by the design.

6.3.2 Vehicle clearance checks should be performed under no-load conditions, preferably using a fixed profile inspection frame template.

6.3.3 Before vehicle inspection, the left-right symmetry and verticality of the bogie, car body, etc. should be adjusted.

6.3.4 The contour inspection rack shall meet the requirements of CJJ/T 96-2018.

6.3.5 The coordinate system of the inspection frame template shall be a reference coordinate system. The template coordinate values shall be based on the tolerance values and measurement error values specified in the design. Sure.

6.4.1 Static test of pantograph

6.4.1.1 When the vehicle is stationary, the nominal static contact force of the pantograph should meet the requirements of GB/T 21561.2 and operate well.

6.4.1.2 The limit dimensions of the pantograph's lateral displacement shall meet the design requirements.

6.4.1.3 The automatic pantograph lowering device should be tested through simulation to ensure it functions properly.

6.4.2 Static Test of Current Collector

6.4.2.1 The installation dimensions of the current receiver and the swing position dimensions of the swing arm shall meet the design requirements.

6.4.2.2 The static contact pressure of the current collector in subway vehicles should be 120N~180N, and the contact pressure of self-guided tire vehicles should be 100N~. 140N; for other vehicle models, the static contact pressure should meet the design requirements.

6.4.2.3 The current receiver shall undergo at least one reciprocating mechanism operation test.

6.5 Rain Test

6.5.1 The water spray test shall be conducted in accordance with the water spray test method specified in TB/T 1802.

6.5.2 The water spray intensity should not be less than 6 mm/min, or the entire water spraying device should be able to achieve a uniform spray of

0.5 m^3/min, and the water pressure at the nozzle should be... It should not be less than

0.1 MPa, and for vehicles with a maximum operating speed of 120 km/h or above, it should not be less than

0.3 MPa.

6.5.3 During the test, the sealing of all openings, doors, covers, plates or gaps where water or rain may enter should be checked.

6.5.4 The waterproof and drainage properties of openings such as air inlets, doors, windows, and machine covers should be checked.

6.5.5 If neither the vehicle nor the water spraying system moves, the spraying time should not be less than 5 minutes, and there should be no leaks in any parts inside the vehicle. After the water spraying is completed... Within 10 to 20 minutes, check all components inside the passenger compartment for leaks.

6.5.6 If the vehicle moves relative to the water spray test device, either the vehicle or the water spray device should move at a constant speed not exceeding 30 mm/s. After the water spraying stops, check for leaks in all components inside the passenger compartment within 10 to 20 minutes.

6.6 Hydraulic System Test

6.6.1 All hydraulic equipment should be checked to ensure it is functioning properly, including.

a) Hydraulic pump;

b) Hydraulic motor;

c) Safety protection devices;

d) Pressure limiter;

f) Close the valve;

6.6.2 A pressure holding test should be performed on the hydraulic system. This test should measure the pressure reduction of each component when the hydraulic cylinder is at its maximum working pressure and isolated from the pump. It should not exceed the design value, and there should be no liquid leakage.

6.7.1 Insulation Test

6.7.1.1 Insulation tests of all circuits should be conducted immediately after vehicle assembly is completed.

6.7.1.2 When the test voltage is 500V, the minimum insulation resistance value should preferably be greater than the following specified values.

a) For DC circuits with a rated voltage of not less than 300V or AC circuits with a rated voltage of not less than 100V, the minimum insulation resistance value shall be 5MOmega;

b) For DC circuits with a rated voltage less than 300V or AC circuits with a rated voltage less than 100V, the minimum insulation resistance should be 1MOmega. Under special conditions such as wet conditions or the use of armored cables, a minimum insulation resistance value can be specified in the design, which can be less than 1MOmega.

6.7.1.3 When electrical equipment is double-insulated from the vehicle body, it should be verified that all parts of the insulation system meet the insulation test requirements in

6.7.1.1 and 6.7.1.2. Requirements for verification.

6.7.2 Pressure Resistance Test

6.7.2.1 Before the test, the electrical clearance of all cables and equipment should be checked.

6.7.2.2 For circuits consisting of multiple insulation classes, insulation checks and ground withstand voltage tests should be performed on each circuit separately. At this time, other circuits should not be tested. The road should be in a grounded state.

6.7.2.3 Contactors and switching devices shall be in a closed or short-circuited state, and necessary protective measures shall be taken.

6.7.2.4 Before the test, vulnerable static converters and electronic equipment should be disconnected or short-circuited.

6.7.2.5 During the whole vehicle insulation test, a rotating motor or other equipment that has already undergone insulation strength testing on a test bench and has passed the test can be used. resection.

6.7.2.6 The withstand voltage test for the rooftop high-voltage wiring and through-type high-voltage cables of 25kV AC vehicles shall be applied for 5 minutes, and the test method shall be in accordance with... The requirements of GB/T 3048.8 shall apply. For vehicles with other power supply systems, the withstand voltage test between the cable circuit and ground shall be applied for 1 minute, and the test voltage value shall be... It should be GB/T 21413 (all parts), GB/T 25118, GB/T 25120, GB/T 25122 (all parts), GB/T 25123 (all parts). (Partial) The test voltage of individual equipment circuit components is 85% of the specified voltage.

6.7.2.7 When the vehicle operates at an altitude greater than 1400m, the selection of the pressure resistance correction factor should also comply with TB/T 3213 and GB/T 20626.1. According to the regulations.

6.7.3 Impact pressure resistance test Vehicles using pantographs for current collection shall undergo an impact withstand voltage test according to GB/T 16927.1.During the test, the vehicle's high voltage shall be disconnected. Surge arresters, high-voltage transformers, main transformers, high-voltage bus cables, and main circuit breakers should be connected to the impulse voltage generator output via conductors. The pantograph is connected to the vehicle, and a lightning strike is applied to the vehicle through the pantograph. The test voltage should meet the design requirements.

6.8 Inspection of grounding and return circuit connections

6.8.1 The inspection of the grounding and return circuit connections on the vehicle should include the following.

a) Functional grounding connections between the system and equipment and the grounding system;

b) Ensure the safety of the system or equipment and personal safety of exposed conductive parts such as metal casings, cable trays, and metal conduits, and their connection to the vehicle's mechanical components. Safety grounding connection wire;

c) Grounding connection wire for three-position switches, etc.;

d) Equipotential bonding wires between car bodies, between the through passage and the mechanical parts of the car body, between the bogie frame and the car body, and between couplers;

e) Ensure that the electromagnetic compatibility grounding connection does not degrade equipment performance or cause electromagnetic hazards or interference in the electromagnetic environment.

6.8.2 Wiring inspection shall meet the following requirements.

a) The length of the connecting line should meet the maximum allowable relative displacement between the connection points;

b) The wiring terminals, grounding terminals, and return terminals should be secure;

c) Protective grounding and return circuits shall comply with the provisions of GB/T 21414;

d) The cross-sectional area of the connecting wires should match the rated current to be carried.

6.9.1 Air compressor unit inspection

6.9.1.1 Each air compressor unit should be checked one by one with no air pressure in each air cylinder, and the air supply capacity should meet the design requirements.

6.9.1.2 The start-stop logic of the air compressor unit shall meet the design requirements.

6.9.1.3 All compressed air equipment, including dryers, pressure regulators, drain valves, pressure sensors, safety protection devices, and isolation valves, should be properly installed. Regular work.

6.9.2 Air tightness inspection of main air reservoir and other compressed air equipment

6.9.2.1 Main air reservoir and auxiliary devices When the compressed air equipment such as the braking system, door device, air spring, and pantograph is in a state of cut-off air supply and without pressure, the total When the air pressure is charged to its maximum value, the pressure drop after 5 minutes should not exceed 20 kPa.

6.9.2.2 Combination of main air reservoir and auxiliary devices with other air compression equipment Except for equipment with inherent air leakage, other compressed air equipment, under normal pressurization conditions, should be charged to the maximum total air pressure and then the air compressor should be shut off. After 20 minutes, the pressure should not be lower than the minimum pressure required for all equipment to operate normally.

6.9.2.3 Return train pipe The test methods and results for the airtightness of train pipes should meet the design requirements.

6.9.2.4 Brake cylinder and brake air reservoir During the test, the driver can operate the brake controller or use other methods to bring the pressure in the brake cylinder and brake reservoir to the maximum value and then cut off the brake. After 3 minutes, the pressure drop in the brake cylinder and brake reservoir should not exceed 10 kPa.