CN102788803A - On-line high-speed detection system of train wheel set tread and wheel rim and detection method thereof - Google Patents
On-line high-speed detection system of train wheel set tread and wheel rim and detection method thereof Download PDFInfo
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- CN102788803A CN102788803A CN2012102357438A CN201210235743A CN102788803A CN 102788803 A CN102788803 A CN 102788803A CN 2012102357438 A CN2012102357438 A CN 2012102357438A CN 201210235743 A CN201210235743 A CN 201210235743A CN 102788803 A CN102788803 A CN 102788803A
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Abstract
The invention discloses an on-line high-speed detection system of train wheel set treads and wheel rims and a detection method thereof. The detection system comprises a target detection unit, a speed measurement unit, a location determination unit and an image acquisition unit which are arranged at the outside of tracks in order, and an image processing unit and a control unit, wherein the image acquisition unit comprises multi-group line structure-light sources and a high-speed planar array camera, an intersecting line formed by intersecting the light plane with the wheel set is arranged between a train sand blasting pipe/braking unit and the track, and the imaging filed of the planar array camera covers and is slightly larger than the intersecting area. The detection method comprises: 1, judging whether the wheel set is defective by canny edge detection; 2, calculating the depth of the defects to obtain the size of the defects; and 3, splicing the light band portion of each image in order into an image. According to the invention, the influence of the train sand blasting pipe and braking unit on the detection is avoided, and the detection speed is fast; the system is suitable for 20-300km/h train on-line detection, the precision is high, the detection of the defects which are less than 1mm can be realized; the detection result is displayed in an image, thus the observation is convenient.
Description
Technical field
The present invention relates to a kind of detection system and detection method thereof, be specifically related to a kind of train wheel tread and online high-speed detection system of wheel rim and detection method thereof.
Background technology
Wheel is taken turns the traffic safety that right quality directly influences train to being one of most important parts of train.The defective of train wheel tread comprises flat sliding and shelled tread; These defectives can be brought extra impact shock in train operation; Having a strong impact on the serviceable life of the driving safety and the orbital facilities of train, is the detection technique problem of being badly in need of solution in the train development so how to detect the defective of train wheel tread accurately.
In recent years, along with China's rapid economy development, train running speed is progressively promoting; Be accompanied by the actual conditions of high speed and heavy duty; Train Wheel be to bearing bigger dynamic load, makes Train Wheel to phenomenon such as flat sliding very easily occurs, peel off, and then causes the train operation quality to descend.Train wheel tread wearing and tearing aggravation can cause axle fracture when serious, collapse wheel, even cause a serious accident.
The detection method that a lot of thread defects are arranged at present; Be in the patent of ZL200610155281.3 in the patent No. wherein, in the process that detects wheel tread, do not consider the influence of blast tube and brake gear, the optical plane of structured light group and orbit plane have angle and adopt the line-scan digital camera imaging; Because the structured light group can't all cover tread; So can only detect the part defect information of whole wheel tread, in addition, defect information is to obtain through doing difference after comparing with flawless picture; Do not consider the vibrations and the skew of locomotive, cause bigger detection error easily.
Summary of the invention
For solving the deficiency of prior art, the object of the present invention is to provide a kind of on-line detecting system and the detection method thereof of Train Wheel that be used to more accurately detect to defective.
In order to realize above-mentioned target, the present invention adopts following technical scheme:
Train wheel tread and the online high-speed detection system of wheel rim defective is characterized in that, comprising:
Be used to detect the object detecting device whether train gets into surveyed area,
Be used to detect the speed measuring device of train running speed,
Be used to judge whether train arrives the position judgment device of assigned address,
Be used to obtain the image collecting device of train wheel tread and wheel rim image information,
Be used to handle the image processing apparatus of the image information that aforementioned image collecting device obtains,
Be used to receive the information of aforementioned object detecting device, speed measuring device and position judgment device, and the system control device of image collecting device, image processing apparatus being controlled according to gained information;
Aforementioned image collecting device comprises: organize line structure light source and high-speed area array camera more; The optical plane of aforementioned line structure light source is positioned at the top of orbit plane and forms the angle of depression with orbit plane, and optical plane is parallel to orbit plane with wheel to crossing formed intersection and between train blast tube/brake gear and track; Aforementioned high-speed area array camera is positioned at the below of orbit plane, and the optical axis of camera and orbit plane form the elevation angle and form fixed angle with the aforementioned lights plane simultaneously; Each is provided with at least two covers to aforementioned image collecting device in the outside of two tracks.
Aforesaid train wheel tread and the online high-speed detection system of wheel rim defective is characterized in that aforementioned object detecting device, position judgment device and speed measuring device are Hall element.
Aforesaid train wheel tread and the online high-speed detection system of wheel rim defective; It is characterized in that; The imaging viewing field of aforementioned high-speed area array camera can be provided with, and the width of aforementioned imaging viewing field only contains the zone of existing wheel tread of lid and wheel-rim shape, and the height of imaging viewing field only contains the maximum intersection of lid zone.
Aforesaid train wheel tread and the online high-speed detection system of wheel rim defective is characterized in that, the optical axis of aforementioned high-speed area array camera and the size of fixed angle that optical plane becomes are in 5～20 degree scopes.
Utilize the online high-speed detection system of aforesaid train wheel tread and wheel rim defective to detect the method for wheel tread and wheel rim defective, it is characterized in that, may further comprise the steps:
(1) after wheel was to the entering surveyed area, object detecting device detected corresponding information, and system control device receives aforementioned information and also starts speed measuring device;
(2) after between wheel is to the entering speed trial ground, speed measuring device obtains the right velocity information of wheel, and system control device receives aforementioned velocity information and starts image collecting device;
(3) after wheel is to the image capture position that arrives appointment; Position judgment device detects the right positional information of wheel; System control device receives aforementioned location information and controls image collecting device wheel tread and wheel rim are carried out IMAQ, obtains a series of tread and wheel rim image information;
(4) image processing apparatus receives aforementioned image information and handles and analyze, and finally shows the defect information of wheel tread and wheel rim.
The method of aforesaid detection wheel tread and wheel rim defective is characterized in that, in abovementioned steps (4), the method for image processing apparatus processing image information is:
(1) judge whether wheel in the image to existing defective: utilize the method for canny rim detection obtain intersection on the pixel edge that places an order; Set a first threshold simultaneously; It is poor that pixel before pixel and its is done; When difference is then judged wheel to there being defective here greater than first threshold, otherwise then there is not defective;
(2), calculate the size of defective:
1., with tread and line structure light source intersection point reference point as single pixel edge; Set one second threshold value; It is poor that several single pixels of front and back of the estimated position of tread and wheel rim separately and reference point are done; Difference confirms that promptly this pixel is a separation of distinguishing tread and wheel rim during smaller or equal to second threshold value, obtains the actual pixels number A of wheel rim simultaneously;
2., the point in match tread zone, obtain straight line, match point p (x, y) with corresponding actual spot of measurement q (x, deviation y) is r (x; Y), and r (x, y)=p (x, y)-q (x; Y), the section of intersection position and the angle of optical plane are θ, and then depth of defect d is: and d=r (x, y) * tan θ;
3., according to wheel rim and the ratio that tread length is become, calculate not the theoretical number of pixels B of the wheel rim that wearing and tearing take place, B and A do and differ from the wear extent that promptly obtains wheel rim;
(3) generate figure as a result:
Light belt extracting section in every width of cloth image is come out, be spliced into piece image in order, and will take turns right defect part and come out with the color showing that is different from background.
The method of aforesaid detection wheel tread and wheel rim defective is characterized in that, aforementioned middle four pixels of being separated by of two poor pixels of doing.
Usefulness of the present invention is: the optical plane of image collecting device and wheel be to intersecting formed intersection between train blast tube/brake gear and rail, solved train blast tube/brake gear to the detection side of detection system to the problem that influences of scope; The optical plane of line structure light source is parallel to orbit plane with wheel to intersecting the intersection become, and the horizontal length of line structure light source covered and take turns right tread and wheel rim, really realizes all detections exhaustively of tread and wheel rim; The width of the imaging viewing field of high-speed area array camera only contains the zone of existing wheel tread of lid and wheel-rim shape, it is regional highly only to contain the maximum intersection of lid; Because of the part beyond the intersection zone does not collect in the image; So improved the arithmetic speed and the work efficiency of image processing apparatus greatly, native system is applicable to the online high speed detection of 20km/h ~ 300km/h train; Utilize method of the present invention to calculate the degree of depth of thread defect, need not to consider the vibrations and the skew of locomotive, reduced the error that detects greatly; Light belt in every width of cloth image partly is extracted out, and is spliced into piece image in order, takes turns right defect part and also is spliced in the aforesaid image more convenient observation testing result simultaneously.
Description of drawings
Fig. 1 is the vertical view of Train Wheel of the present invention to the total arrangement of defective on-line detecting system;
Fig. 2 is that Train Wheel among Fig. 1 is to the right view of defective on-line detecting system;
Fig. 3 is the optical plane of line structure light source and the relative position synoptic diagram of intersection section, place and blast tube/brake gear;
The implication of Reference numeral: 1-wheel is right among the figure, 2-track, 3-object detecting device, 4-position judgment device; 5-line structure light source, 6-high-speed area array camera, 7-speed measuring device, 8-optical plane; The 9-section, the 10-blast tube, θ-angle, arrow represent that This train is bound for XXX.
Embodiment
Below in conjunction with accompanying drawing and specific embodiment the present invention is done concrete introduction.
With reference to Fig. 1; Train Wheel of the present invention is to the online high-speed detection system of defective; Comprise: be used to detect the object detecting device 3 whether train gets into surveyed area; Be used to detect the speed measuring device 7 of train running speed; Be used to judge whether train arrives the position judgment device 4 of assigned address, be used to obtain Train Wheel to 1 the tread and the image collecting device of wheel rim image information, the information that image processing apparatus (not shown) that the image information that image collecting device is obtained is handled and receiving target pick-up unit 3, speed measuring device 7, position judgment device 4 transmit is also sent the system control device (not shown) of control command to image collecting device.Details are as follows for the total arrangement of this on-line detecting system:
In the outside of track 2 near the position of track 2, be placed with successively along track 2 bearing of trends: object detecting device 3, speed measuring device 7, position judgment device 4, image collecting device.Whether object detecting device 3 detects at first has train to get into surveyed area; Whether the travelling speed behind the speed measuring device 7 detection trains entering surveyed areas can satisfy image collecting device collects effective and complete image information; After train gets into surveyed area and exercises the image capture position of appointment; Position judgment device 4 sends signal and gives system control device, and then the startup image collecting device carries out the collection of image.
If train running speed is very fast, be unfavorable for that image collecting device collects effective and complete image information, the Flame Image Process that tends to cause image processing apparatus to be done is an idle work.So, speed measuring device 7 and system control device are set up signal contact, when detected train speed during less than a certain value, system control device receives information and sends the order of startup to image collecting device, and IMAQ is carried out in preparation; When detected train speed surpassed this value, speed measuring device 7 did not send signal and gives system control device, and image collecting device is not worked yet, and has avoided image collecting device and image processing apparatus to flog a dead horse.
Image collecting device comprises: the many groups line structure light source 5 and the high-speed area array camera 6 of forming array.With reference to Fig. 2 and Fig. 3; The optical plane 8 of line structure light source 5 is positioned at the top of orbit plane and forms the angle of depression with orbit plane; Optical plane 8 and wheel intersect to 1 that formed intersection is parallel to orbit plane and between train blast tube 10/ brake gear and track 2, solved train blast tube 10/ brake gear to the detection side of detection system to the problem that influences of scope; High-speed area array camera 6 is positioned at the below of orbit plane, and the optical axis of camera and orbit plane form the elevation angle, forms fixed angle with optical plane 8 simultaneously.
As a kind of preferred scheme, the size that the optical axis of high-speed area array camera 6 becomes fixed angle with 8 of optical planes is in 5～20 degree scopes.Because angle is big more, the characteristic that the defective of tread surface shows is just obvious more, but considers the quantity of the line structure light source 5 of installation, and angle can not be excessive, so through overtesting, the size of angle is confirmed in 5～20 degree scopes the most at last.
As a kind of preferred scheme, position judgment device 4 is corresponding one by one with image collecting device, is divided into two groups and the symmetrical outermost that is arranged on two tracks 2.In order to make image collecting device obtain whole all images information of taking turns, just collect wheel to all images information in 1 one weeks, the number of the outermost image collecting device of every siding track 2 >=2 to 1.A plurality of image collecting devices are arranged at different positions but work simultaneously, can obtain whole complete image information of taking turns 1, have increased the scope that detects greatly.
As a kind of preferred scheme, object detecting device 3, position judgment device 4 and speed measuring device 7 are Hall element.It not only to magnetic-field-sensitive, volume is little, response speed is fast, and long service life can be made accurately and being judged, and signal is passed to system control device, thereby guarantees the high-quality completion testing of on-line detecting system of the present invention.
As a kind of preferred scheme, the imaging viewing field of high-speed area array camera 6 can be provided with, and the width of imaging viewing field only contains the zone of existing wheel tread of lid and wheel-rim shape, and the height of imaging viewing field only contains the maximum intersection of lid zone, can be slightly larger than the intersection zone.Owing to no longer make change after the imaging viewing field of high-speed area array camera 6 sets; With the wheel to 1 to image collecting device near; The intersection formed image in zone proportion in entire image is also increasing, so the imaging viewing field size of camera is advisable can contain lid or to be slightly larger than maximum intersection zone.Because of the most of scene beyond the intersection zone does not collect in the image; So image processing apparatus is when handling image; Only handle the image information in intersection zone; Improved arithmetic speed and work efficiency greatly, travel speed is taken turns the detection to defective at the train of 20km/h ~ 300km/h native system all capable of using.
Utilize the method for the online high-speed detection system detection wheel of above-mentioned train wheel tread and wheel rim defective, may further comprise the steps defective:
At first, after wheel got into surveyed area to 1, object detecting device 3 detected corresponding information, and sends signal and give system control device, starts speed measuring device 7 by system control device.Then, after wheel got between speed trial ground to 1, speed measuring device 7 detection wheels were to 1 speed; If speed is smaller or equal to a certain numerical value; Speed measuring device 7 passes to system control device with rate signal, starts image collecting device by system control device, carries out the preliminary work of images acquired information; If speed is imperfect for fear of the image information that image collecting device collects during greater than this numerical value, just can not get whole image information of taking turns to 1, speed measuring device 7 does not send signal and gives system control device, does not just start image collecting device.After image collecting device is activated; When wheel arrives the image capture position of appointment to 1; Position judgment device 4 detects relevant position information; And send signal and give system control device, by system control device control image collecting device wheel tread and wheel rim are carried out IMAQ, obtain a series of tread and wheel rim image information.At last, image processing apparatus receives image information and handles and analyze, and finally shows the defect information of wheel tread and wheel rim.
Wherein, the method for image processing apparatus processing image information is:
At first, judge that whether wheel in the image to existing defective.Concrete deterministic process is following: utilize the method for canny rim detection obtain intersection on the pixel edge that places an order, intersection be optical plane with wheel to intersecting formed intersecting lens; Set a first threshold, pixel edge is handled to placing an order on obtaining.As a kind of preferred scheme, each pixel is done poorly with the 5th pixel of this pixel front respectively, when this difference during greater than first threshold, then judges to have defective here, otherwise does not then have defective.
Then, calculate the size of defective.With tread and line structure light source intersection point reference point as single pixel edge; Set one second threshold value; Because the proportionate relationship of wheel rim and tread length is fixed, can confirm the estimated position that tread and wheel rim separate earlier through total pixel, when the difference of several single pixels and reference point is smaller or equal to second threshold value before and after this estimated position; Confirm that promptly this pixel is a separation of distinguishing tread and wheel rim, calculate the actual pixels number A of the shared pixel of wheel rim simultaneously; Point to the tread zone carries out match, obtains straight line, and (x is y) with corresponding actual spot of measurement q (x for tread match point p; Y) deviation be r (x, y), r (x; Y)=and p (x, y)-q (x, y); The section 9 of intersection position is θ with the angle of optical plane 8, and then depth of defect d is: and d=r (x, y) * tan θ; Become certain fixed proportion according to wheel rim with tread length, calculate not the theoretical number of pixels B of the wheel rim that wearing and tearing take place, it is poor then B and A to be done, and difference is exactly that part of number of pixels that wheel rim reduces because of wearing and tearing, thereby obtains the wear extent of wheel rim.
At last, image processing apparatus is with all images splicing and form a width of cloth testing result figure.Concrete joining method is: the light belt extracting section in every width of cloth image is come out; Be spliced into piece image in order; Take turns right defect part and also be spliced in above-mentioned image, in order to be convenient to observe more, defect part is represented with the background various colors with another kind of.
Need to prove that the foregoing description does not limit the present invention in any form, all employings are equal to the technical scheme that mode obtained of replacement or equivalent transformation, all drop in protection scope of the present invention.
Claims (7)
1. train wheel tread and the online high-speed detection system of wheel rim defective is characterized in that, comprising:
Be used to detect the object detecting device whether train gets into surveyed area,
Be used to detect the speed measuring device of train running speed,
Be used to judge whether train arrives the position judgment device of assigned address,
Be used to obtain the image collecting device of train wheel tread and wheel rim image information,
Be used to handle the image processing apparatus of the image information that above-mentioned image collecting device obtains,
Be used to receive the information of above-mentioned object detecting device, speed measuring device and position judgment device, and the system control device of image collecting device, image processing apparatus being controlled according to gained information;
Above-mentioned image collecting device comprises: organize line structure light source and high-speed area array camera more; The optical plane of above-mentioned line structure light source is positioned at the top of orbit plane and forms the angle of depression with orbit plane, and optical plane is parallel to orbit plane with wheel to crossing formed intersection and between train blast tube/brake gear and track; Above-mentioned high-speed area array camera is positioned at the below of orbit plane, and the optical axis of camera and orbit plane form the elevation angle, form fixed angle with above-mentioned optical plane simultaneously; Each is provided with at least two covers to above-mentioned image collecting device in the outside of two tracks.
2. train wheel tread according to claim 1 and the online high-speed detection system of wheel rim defective is characterized in that above-mentioned object detecting device, position judgment device and speed measuring device are Hall element.
3. train wheel tread according to claim 1 and the online high-speed detection system of wheel rim defective; It is characterized in that; The imaging viewing field of above-mentioned high-speed area array camera can be provided with; The width of above-mentioned imaging viewing field only contains the zone of existing wheel tread of lid and wheel-rim shape, and the height of imaging viewing field only contains the maximum intersection of lid zone.
4. train wheel tread according to claim 1 and the online high-speed detection system of wheel rim defective is characterized in that, the optical axis of above-mentioned high-speed area array camera and the size of fixed angle that optical plane becomes are in 5～20 degree scopes.
5. utilize the online high-speed detection system of described train wheel tread of claim 1 and wheel rim defective to detect the method for wheel tread and wheel rim defective, it is characterized in that, may further comprise the steps:
(1) after wheel was to the entering surveyed area, object detecting device detected corresponding information, and system control device receives above-mentioned information and starts speed measuring device;
(2) after between wheel is to the entering speed trial ground, speed measuring device obtains the right velocity information of wheel, and system control device receives above-mentioned velocity information and starts image collecting device;
(3) after wheel is to the image capture position that arrives appointment; Position judgment device detects the right positional information of wheel; System control device receives above-mentioned positional information and controls image collecting device wheel tread and wheel rim are carried out IMAQ, obtains a series of tread and wheel rim image information;
(4) image processing apparatus receives above-mentioned image information and handles and analyze, and finally shows the defect information of wheel tread and wheel rim.
6. the method for detection wheel tread according to claim 5 and wheel rim defective; It is characterized in that; In above-mentioned steps (4); The method of image processing apparatus processing image information is: (one) judges whether wheel in the image to existing defective: utilize the method for canny rim detection obtain intersection on the pixel edge that places an order, set a first threshold simultaneously, it is poor that pixel and the pixel before it are done; When difference is then judged wheel to there being defective here greater than first threshold, otherwise then there is not defective;
(2), calculate the size of defective:
1., with tread and line structure light source intersection point reference point as single pixel edge; Set one second threshold value; It is poor that several single pixels of front and back of the estimated position of tread and wheel rim separately and reference point are done; Difference confirms that promptly this pixel is a separation of distinguishing tread and wheel rim during smaller or equal to second threshold value, obtains the actual pixels number A of wheel rim simultaneously;
2., the point in match tread zone, obtain straight line, match point p (x, y) with corresponding actual spot of measurement q (x, deviation y) is r (x; Y), and r (x, y)=p (x, y)-q (x; Y), the section of intersection position and the angle of optical plane are θ, and then depth of defect d is: and d=r (x, y) * tan θ;
3., according to wheel rim and the ratio that tread length is become, calculate not the theoretical number of pixels B of the wheel rim that wearing and tearing take place, B and A do and differ from the wear extent that promptly obtains wheel rim;
(3) generate figure as a result:
Light belt extracting section in every width of cloth image is come out, be spliced into piece image in order, and will take turns right defect part and come out with the color showing that is different from background.
7. the method for detection wheel tread according to claim 6 and wheel rim defective is characterized in that, above-mentioned middle four pixels of being separated by of two poor pixels of doing.
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