CN104180767B - steel-rail wear measurement device based on machine vision and grinding strategy method thereof - Google Patents
steel-rail wear measurement device based on machine vision and grinding strategy method thereof Download PDFInfo
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- CN104180767B CN104180767B CN201310196977.0A CN201310196977A CN104180767B CN 104180767 B CN104180767 B CN 104180767B CN 201310196977 A CN201310196977 A CN 201310196977A CN 104180767 B CN104180767 B CN 104180767B
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Abstract
The invention provides a steel-rail wear measurement device based on machine vision, which comprises a main control panel, a power panel, a laser control panel, and a video panel. The power panel is used for providing a stable direct-current voltage for the main control panel, the laser control panel and the video panel. The laser control panel is electrically connected with two high-power lasers. The video panel is electrically connected with two CCD cameras. The main control panel is connected with the power panel, the laser control panel, and the video panel, and used for controlling the on-off and intensities of the two high-power lasers and controlling the shooting actions of the two CCD cameras. The invention also provides a grinding strategy method for steel-rail wear according to the measurement device. According to a planned grinding quantity, a proper grinding speed of a steel-rail grinding car, the grinding power, and the motor distribution of different angles are calculated, and the steel rail is grinded. The steel-rail wear measurement device based on machine vision has the beneficial effects that the planned grinding area of the steel rail on side can be calculated according to different zones, and shortcomings of large amount of labor, poor environment, low efficiency and the like of the measurement mode of manual and mechanical contact can be overcome.
Description
Technical field
The present invention relates to rail fields of measurement, and in particular to a kind of rail abrasion measurement apparatus based on machine vision and its
Polishing strategy process.
Background technology
Railway is the large artery trunks of national communication transport, assume responsibility for the passenger and freight task of China more than 70%, the shape of rail
Whether state is intact, and can directly affect train by safe, the steady and continual operation of speed of regulation.The high speed of train,
Heavy duty, high density operation, accelerate the abrasion of rail.When abrasion is more than certain limit, rail and train car on the one hand will be changed
The contact relation of wheel tread, increases train running resistance, further speeds up the abrasion of rail, great shadow is caused to traffic safety
Ring；The hunting aggravation of another aspect train, it may occur that acutely wave, have a strong impact on the comfort level of passenger.So needing to determine
Phase is detected to rail abrasion degree, arranges steel rail grinding construction in good time, repair profile of steel rail, improve wheel rail relation, to protect
Demonstrate,prove the stable and safe of train.
In terms of rail abrasion detects and polish measurement technique, common rail profile gauge can be divided into machinery and connect
Touch, electronic type and non-contact optical formula.Mechanical contact rail profile gauge operates comparatively laborious, hand labor intensity
Greatly, efficiency is low, be easily damaged；Electronic type rail profile gauge has compared with much progress than mechanical contact, but accuracy of detection is not high,
Have not been achievable online automatic detection；Non-contact optical formula rail profile gauge performance is more advanced than both the above, detection essence
Degree is higher, it is possible to achieve online automatic detection, but also no manufacturer of the country, depends on from external import.And state
Outer non-contact optical detecting system major part is all arranged on track checking car, and requires detecting system binding pin supporting with track checking car
Sell, this greatly improves the purchase cost and maintenance cost of equipment.At present in the rail abrasion detection work of China's railway in operation
Mainly estimated or detected using mechanical calliper by veteran workman, exist that detection efficiency is low, accuracy of detection is not high
The problems such as, oneself can not meet the development need of high-speed railway.How accurately and efficiently to detect that rail abrasion is state, inside and outside railway
One important research topic of department.
In terms of steel rail grinding strategy, as system-wide is equipped with advanced rail grinding train, steel rail grinding operation effect in a large number
Rate is obviously improved, but the polishing operation of rail grinding train places one's entire reliance upon the experience of operator, typically can by rule of thumb from
Used mode operations in the past, the veteran volume pattern that can show are selected to study industry in library.Steel rail grinding operation does not have
Clear and definite technological standardss, subjectivity, randomness are very big, and operation quality is unstable.The polishing of high-speed railway is mainly beaten by increase
Grind pass to meet prescription, there is unnecessary polishing in a large number, both increased the cost of steel rail grinding, shorten rail again
Service life.Therefore, carry out steel rail grinding technical research, formulate steel rail grinding technological standardss, be railway track repair work
In an important research topic.
The content of the invention
The technical problem to be solved in the present invention is, for deficiencies of the prior art, there is provided a kind of to be based on machine
The rail abrasion measurement apparatus and its polishing strategy process of vision.
The present invention for the solution technical scheme that adopts of above-mentioned technical problem is：
Based on the rail abrasion measurement apparatus of machine vision, including master board, power panel, laser controlling plate and video
Plate, power panel are used to provide galvanic current pressure for master board, laser controlling plate and video board；Laser controlling plate and two
High power laser is electrically connected；Video board is electrically connected with two ccd video cameras；Master board respectively with power panel, laser controlling
Plate and video board connection, for controlling the break-make and intensity of two high power lasers, and the bat of two ccd video cameras of control
Perturbation is made.
By such scheme, described two high power lasers are separately mounted to the left and right sides of tested rail, two big work(
The wire harness that rate laser instrument is projected on tested rail is generally aligned in the same plane, and vertical with the profile curve of tested rail.
By such scheme, described two ccd video cameras are correspondingly arranged at the side of two high power lasers, and each CCD
The optical axis of video camera is at 45 ° with the optical axis of the high power laser of homonymy respectively～60 ° of angles, with clearly complete shooting rail
Contour curve.
Present invention also offers a kind of polishing strategy process that rail abrasion is carried out according to above-mentioned measurement apparatus, including it is following
Step：
1）Using measurement apparatus to steel rail grinding before existing profile of steel rail measure, select the benchmark after polishing wide
Area difference between the existing profile of steel rail and benchmark profile of rail is set to the plan stock removal of polishing section by shape；
2）Rail is polished using rail grinding train, according to plan stock removal, with reference to the list of rail grinding train
All over maximum stock removal, polishing pass is calculated, polishing pass is rounded up divided by single pass maximum stock removal for plan stock removal
Integer；After polishing pass determines, distribute the initial buff amount of rail grinding train；
3）According to initial buff amount, in the polishing 12～18km/h of velocity interval of rail grinding train, rail is selected to beat
Polishing speed V of mill train；
4）According to the profile of steel rail area data surveyed by measurement apparatus of the present invention, by rail profile profile be divided into inner side,
Top surface and 3, outside region, the different plan stock removal of zones of different correspondence calculate steel under different angles according to different stock removals
The motor distribution number of rail polishing train, the motor of rail grinding train are distributed number according to motor total number and the ratio of angle
Distribution；
5）According in rail grinding train operation process, the total stock removal △ S of rail profile of N number of emery wheel of identical operating mode with
Relational expression between polishing power Ρ calculates the polishing power Ρ of rail grinding train；
6）According to plan stock removal, the polishing speed of rail grinding train, polish power, motor is selected to be distributed number, it is defeated
Go out polishing strategy, rail is polished using rail grinding train, be intended to stock removal and polish exactly complete, neither excessively
Polishing, does not owe polishing yet, makes the profile of steel rail after polishing consistent with benchmark profile.
By such scheme, the step 1）Middle measurement apparatus to steel rail grinding before existing profile of steel rail when measuring,
On the inside of rail, measurement apparatus pass through a horizontal brace rod and tested rail opposite to the high power laser of measurement apparatus
Another rail is connected, and is placed in what measurement apparatus were balanced on tested rail.
By such scheme, the step 5）In identical operating mode N number of emery wheel the total stock removal △ S of rail profile with polishing work(
The relational expression of rate Ρ meets：
Wherein, Δ S-total stock removal of rail profile, unit mm2, S0- benchmark stock removal, unit mm2, Ρ-polishing work(
Rate, unit：Percentage ratio, Ρ0- benchmark polishing power, N-emery wheel number, V-polishing speed, unit km/h, V0The operation of-benchmark
Speed, unit km/h.
By such scheme, the rail grinding train is GMC96X shaped steel rails polishing train, benchmark polishing power Ρ0For
76%～77%, benchmark operating speed V0For 15km/h.
The operation principle of the present invention：（1）In terms of measurement, the measurement of the polishing amount that rail abrasion amount and rail reparation need
Based on machine vision, using two ccd video cameras and two high power laser emitters, master board control whole device；（2）
It is in the tactful output facet of polishing, according to measured plan stock removal and existing according to steel rail grinding work standard profile, rail
Profile, is analyzed with reference to rail grinding train performance and related operating condition, automatically generates polishing strategy（Including polishing speed
Degree, polishing power, motor distribution etc.）, simultaneously containing man-machine interaction link, meet special scheme and select demand.
Compared with prior art, the present invention has advantages below：
1st, the profile figure of CAD software drafting can be imported as benchmark profile, can be also selected by measurement apparatus in-site measurement
Profile of steel rail as benchmark profile, the wear extent of live rail can not only be detected, and the plan for needing rail grinding can be calculated
Stock removal, error are less than ± 0.1mm, overcome that manual measurement mode and the mechanical contact metering system amount of labour be big, environment is disliked
The low shortcoming of bad, efficiency；
2nd, can be with coordinate or the wear extent and plan stock removal of angle two ways displaying scene rail, can subregion calculating
The plan grinding area of live rail, error are less than ± 10%；And can be from the profile of steel rail several times measured by live same section
In, select a profile to represent, and automatically generate polishing strategy on this basis（Including polishing speed, polishing power, different angles
Degree motor distribution etc.）, simultaneously containing man-machine interaction link, meet special scheme and select demand.
Description of the drawings
Fig. 1 is the structured flowchart of measurement apparatus of the present invention.
Fig. 2 is the signal connection diagram of measurement apparatus of the present invention.
Fig. 3 is the laser instrument of measurement apparatus of the present invention and ccd video camera scheme of installation.
Fig. 4 is the use schematic diagram of measurement apparatus of the present invention.
Fig. 5 is the polishing amount schematic diagram of present invention polishing strategy process.
Fig. 6 is the polishing subregion schematic diagram of present invention polishing strategy process.
Fig. 7 is present invention polishing strategy process schematic flow sheet.
Fig. 8 is the tactful output result schematic diagram of present invention polishing.
Specific embodiment
With reference to the accompanying drawings and examples technical scheme is further described in detail.
As shown in figure 1, the rail abrasion measurement apparatus based on machine vision of the present invention, including master board, electricity
Source plate, laser controlling plate and video board, power panel are used to provide stable direct current for master board, laser controlling plate and video board
Voltage；Laser controlling plate is electrically connected with two high power lasers；Video board is electrically connected with two ccd video cameras；Master board
It is connected with power panel, laser controlling plate and video board respectively, for controlling the break-make and intensity of two high power lasers, and
The shooting action of two ccd video cameras of control.
As shown in Fig. 2 the signal connection figure of the embodiment of measurement apparatus of the present invention, the power panel be used for voltage stabilizing and
Voltage conversion is carried out to the DC source of outside, is powered master board is supplied after the cell voltage voltage stabilizing of external 12V, while will
The cell voltage of external 12V is powered to video board and laser controlling plate after being converted into 5V voltage stabilizing respectively；Master board is used as this
The core circuit plate of invention measurement apparatus, by output switching signal to laser controlling plate controlling two high power lasers
Break-make；By output intensity signal to laser controlling plate controlling the intensity of two high power lasers；Letter is shot by exporting
Number to video board controlling the shooting action of two ccd video cameras；By output image access signal to video board with by two
The profile data that ccd video camera shoots are returned to master board.
The scheme of installation of laser as shown in Figure 3 and camera, described two high power lasers are separately mounted to tested
The left and right sides of rail, the wire harness that two high power lasers are projected on tested rail are generally aligned in the same plane, and with it is tested
The profile curve of rail is vertical.Described two ccd video cameras are correspondingly arranged at the side of two high power lasers, and each CCD
The optical axis of video camera respectively with the optical axis of the high power laser of homonymy into 60 ° of angles, with clearly complete shooting profile of steel rail
Curve.
As shown in figure 4, when measurement apparatus of the present invention work, by the high power laser of measurement apparatus on the inside of rail,
Measurement apparatus are connected with another rail on tested rail opposite by a horizontal brace rod, so as to the peace for balancing measurement apparatus
Put on tested rail.
Polishing amount schematic diagram as shown in Figure 5, using measurement apparatus to steel rail grinding before existing profile of steel rail survey
Amount, selects the benchmark profile after polishing, and the area difference between the existing profile of steel rail and benchmark profile of rail is set to polishing
The plan stock removal of section；According to plan stock removal, the polishing speed of rail grinding train, polish power, motor is selected to be distributed
And motor number, rail is polished using GMC-96x shaped steel rails polishing train, be intended to stock removal and polished exactly
Into, it is neither excessive to polish, polishing is not owed yet, makes the profile of steel rail after polishing consistent with benchmark profile.
GMC-96x shaped steel rails polishing motor angle of the polishing train above per share rail can adjust, straight along rail longitudinal direction
Row, each motor drive an emery wheel rotation, and during polishing train driving, single emery wheel is ground to the corresponding segmental arc of rail
Cut.GMC-96x shaped steel rails polishing train parameter be：Polishing power of motor range of accommodation is 50%～100%（22kW）.Rail is beaten
In mill operation process, passing ratio valve control pressurization oil cylinder working-pressure realizes that single polishing output power of motor is constant.Wheel grinding
Speed：Emery wheel equivalent diameter Ds=204mm, grinding wheel speed ns=3600r/min, average linear velocity vs=38m/s.Length feed speed
Spend for polish speed V, accepted value be 12≤V≤18km/h.According to field measurement data, grinding depth value is under normal circumstances
0.05≤ap≤0.1mm。
Polishing subregion schematic diagram as shown in Figure 6, according to the profile of steel rail area data surveyed by measurement apparatus of the present invention, will
Rail profile profile is divided into inner side, top surface and 3, outside region：1. inner side is profile of steel rail arc radius R13 and R80 section,
Comprising a areas（Polishing region, arc radius R13）With b areas（Polishing region, arc radius R80）；2. top surface is profile of steel rail circular arc
Radius R300 sections, comprising c areas（Polishing region）；3. outside is profile of steel rail arc radius R80 sections and inoperative side circular arc
Radius R13, comprising d areas（Polishing region, arc radius R80）With e areas（Non- polishing region, arc radius R13）.By internal
Side, top surface and 3, outside region are divided, the different plan stock removal of zones of different correspondence, are selected according to different stock removals
The motor distribution number of rail grinding train under different angles, the motor of rail grinding train are distributed number according to motor total number
It is distributed with the ratio of angle.
Determine will have for polishing train polishing stock removal：The setting operation cruise speed of polishing speed-rail grinding machine
Degree；Polishing motor is distributed-polishes the quantity and set angle of motor distribution；The setting work(of polishing power-single polishing motor
Rate；The specifications and models of grinding stone hardness-grinding stone, material hardness；The specifications and models of rail hardness-rail, material hardness.
In rail grinding train operation process, the total stock removal △ S of rail profile and each operation of N number of emery wheel of identical operating mode
Relation between each parameter of pattern is as follows：
Formula（1）In, the Δ S-total stock removal of rail profile, unit mm2；
S0- benchmark stock removal, unit mm2；
Ρ-polishing power (percentage ratio)；
Ρ0- benchmark polishing power（77%）；
Ν-emery wheel number；
V-polishing speed, unit km/h；
V0- benchmark operating speed（15km/h）.
Polishing output schematic flow sheet as shown in Figure 7, polishing output step are as follows：
1）Using measurement apparatus of the present invention to steel rail grinding before existing profile of steel rail measure, select polishing after base
Area difference between the existing profile of steel rail and benchmark profile of rail is set to the plan stock removal of polishing section by quasi- profile；
2）Rail is polished using GMC-96x shaped steel rails polishing train, according to plan stock removal, with reference to GMC-96x
The single pass maximum stock removal of shaped steel rail polishing train, selects polishing pass；After polishing pass determines, distribute GMC-96x shaped steel rails
The initial buff amount of polishing train；
3）According to initial buff amount, with reference to GMC-96x shaped steel rails polishing train apparatus performance, technological requirement, ground effect
And equipment application practical experience, select polishing speed V of GMC-96x shaped steel rails polishing train；
4）Check that rail profile profile is divided into inner side, top surface and 3, outside region by data analysiss according to profile instrument, no
With the different plan stock removal of region correspondence, GMC-96x shaped steel rails polishing train under different angles is selected according to different stock removals
Motor distribution number；
5）During according to GMC-96x shaped steel rails polishing train work, the rail profile of N number of emery wheel of identical operating mode always grinds
Relational expression between the amount of cutting △ S and polishing power Ρ（1）Calculate the polishing power Ρ of rail grinding train；
6）According to plan stock removal, the polishing speed of GMC-96x shaped steel rails polishing train, polish power, motor point are selected
Cloth and motor number, are polished to rail using GMC-96x shaped steel rails polishing train, are intended to stock removal and have polished exactly
Into, it is neither excessive to polish, polishing is not owed yet, makes the profile of steel rail after polishing consistent with benchmark profile.
The tactful output result of polishing is as shown in Figure 8.
The above is only presently preferred embodiments of the present invention, not makees any pro forma restriction to the present invention, this
Art personnel make a little simple modification, equivalent variations or modification using the technology contents of the disclosure above, all fall within this
In bright protection domain.
Claims (5)
1. based on machine vision rail abrasion measurement apparatus polishing strategy process, measurement apparatus include master board, power supply
Plate, laser controlling plate and video board, power panel are used to provide galvanic current for master board, laser controlling plate and video board
Pressure；Laser controlling plate is electrically connected with two high power lasers；Video board is electrically connected with two ccd video cameras；Master board point
It is not connected with power panel, laser controlling plate and video board, for controlling the break-make and intensity of two high power lasers, and control
The shooting action of two ccd video cameras of system, it is characterised in that：Polishing strategy process is comprised the following steps：
1) using measurement apparatus to steel rail grinding before existing profile of steel rail measure, select polishing after benchmark profile, will
Area difference between the existing profile of steel rail and benchmark profile of rail is set to the plan stock removal of polishing section；
2) rail is polished using rail grinding train, according to plan stock removal, with reference to rail grinding train single pass most
Big stock removal, calculates polishing pass, pass of polishing be plan stock removal divided by single pass maximum stock removal rounded up it is whole
Number；After polishing pass determines, distribute the initial buff amount of rail grinding train；
3) according to initial buff amount, in the polishing 12～18km/h of velocity interval of rail grinding train, steel rail grinding row are selected
Polishing speed V of car；
4) rail profile profile is divided into inner side, top surface and outside 3 by the profile of steel rail area data surveyed according to measurement apparatus
Individual region, the different plan stock removal of zones of different correspondence calculate rail grinding train under different angles according to different stock removals
Motor distribution number, rail grinding train motor distribution number according to motor total number and angle ratio be distributed；
5) according in rail grinding train operation process, the total stock removal △ S of rail profile and the polishing of N number of emery wheel of identical operating mode
Relational expression between power Ρ calculates the polishing power Ρ of rail grinding train；The rail profile of N number of emery wheel of identical operating mode is total
Stock removal △ S are met with the relational expression of polishing power Ρ：
Wherein, Δ S-total stock removal of rail profile, unit mm2, S0- benchmark stock removal, unit mm2, Ρ-polishing power, list
Position：Percentage ratio, Ρ0- benchmark polishing power, N-emery wheel number, V-polishing speed, unit km/h, V0- benchmark operating speed,
Unit km/h；
6) according to plan stock removal, the polishing speed of rail grinding train, polish power, motor is selected to be distributed number, using steel
Rail polishing train is polished to rail, is intended to stock removal and polishes exactly complete, neither excessive to polish, and does not also owe polishing,
Make the profile of steel rail after polishing consistent with benchmark profile.
2. polishing strategy process as claimed in claim 1, it is characterised in that：Described two high power lasers are separately mounted to
The left and right sides of tested rail, the wire harness that two high power lasers are projected on tested rail are generally aligned in the same plane, and with
The profile curve of tested rail is vertical.
3. polishing strategy process as claimed in claim 1, it is characterised in that：Described two ccd video cameras are correspondingly arranged at two
The side of high power laser, and the optical axis of each ccd video camera it is at 45 ° with the optical axis of the high power laser of homonymy respectively～
60 ° of angles.
4. polishing strategy process as claimed in claim 1, it is characterised in that：The step 1) in measurement apparatus to steel rail grinding
When front existing profile of steel rail is measured, on the inside of rail, measurement apparatus pass through one to the high power laser of measurement apparatus
Bar horizontal brace rod is connected with another rail on tested rail opposite, is placed in what measurement apparatus were balanced on tested rail.
5. polishing strategy process as claimed in claim 1, it is characterised in that：The rail grinding train is GMC96X shaped steel rails
Polishing train, benchmark polishing power P0For 76%～77%, benchmark operating speed V0For 15km/h.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
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| CN201310196977.0A CN104180767B (en) | 2013-05-24 | 2013-05-24 | steel-rail wear measurement device based on machine vision and grinding strategy method thereof |
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| CN201310196977.0A CN104180767B (en) | 2013-05-24 | 2013-05-24 | steel-rail wear measurement device based on machine vision and grinding strategy method thereof |
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| CN104180767B true CN104180767B (en) | 2017-05-10 |
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| 基于计算机视觉的钢轨磨耗测量系统的研究与实现;杨留君;《中国优秀硕士学位论文全文数据库 信息科技辑》;20080915;第25-31页 * |
| 激光锁定成像在钢轨磨耗测量系统中的应用;吴柯庆等;《激光技术》;20120531;第36卷(第3期);第353-356页 * |
| 钢轨磨耗测量系统中光带主曲线提取的研究;吴柯庆等;《计算机工程与设计》;20120630;第33卷(第6期);第2461-2465页 * |
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| CN104180767A (en) | 2014-12-03 |
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Address after: 430020 reentry section of 27 horizontal road, Hankou river bank, Wuhan City, Hubei Province, No. 268 Co-patentee after: Wuhan University of Technology Patentee after: Chinese Wuhan Railway Bureau Group Co. Ltd. Wuhan large maintenance machinery operation and maintenance period Address before: 430020 reentry section of 27 horizontal road, Hankou river bank, Wuhan City, Hubei Province, No. 268 Co-patentee before: Wuhan University of Technology Patentee before: WUHAN LARGE-SCALE ROAD MAINTENANCE MACHINERY RUNNING AND MAINTENANCE SECTION OF WUHAN RAILWAY BUREAU |
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Granted publication date: 20170510 Termination date: 20190524 |