CN110954026A - On-line detection device for measuring geometric profile of steel rail - Google Patents
On-line detection device for measuring geometric profile of steel rail Download PDFInfo
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- CN110954026A CN110954026A CN201911133344.9A CN201911133344A CN110954026A CN 110954026 A CN110954026 A CN 110954026A CN 201911133344 A CN201911133344 A CN 201911133344A CN 110954026 A CN110954026 A CN 110954026A
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- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/245—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures using a plurality of fixed, simultaneously operating transducers
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Abstract
The invention relates to an on-line detection device for measuring the geometric profile of a steel rail, wherein a detection platform can support and level the measured steel rail in real time through the matching of a hydraulic lifting roller track line roller and a roller track line roller for supporting the steel rail; the laser profile sensor module is driven by the mechanical transmission module to move on the walking platform along the length direction of a measured steel rail and is used for scanning the geometric profile of the steel rail and converting the profile of the steel rail into two-dimensional coordinate data; the mounting positioning ring is connected with the rotating motor, and the spatial circumferential positions scanned by the four laser contourgraph instruments are adjusted under the driving of the rotating motor, so that the scanning of the measured steel rail without blind areas by real-time adjustment is realized.
Description
Technical Field
The invention relates to a steel rail outline detection device, in particular to a steel rail three-dimensional detection device for measuring the straightness, the torsion degree, the end face verticality, the appearance dimension error and the full-length rail body defect of a steel rail before welding 100m long steel rails on a rail base.
Background
At present, rail profile detection can be divided into two main categories.
The contact detection can be divided into two categories, ① adopts the equipment to directly contact the steel rail for measurement, ② mechanical and electronic technologies are related to the researched and developed equipment for electronically detecting the steel rail, the equipment and the steel rail need to be contacted when measuring the steel rail, and the measurement method is mostly adopted by the railway department in China currently.
The other is non-contact measurement methods, such as non-contact electronic measurement, image processing measurement, optical measurement, etc., which use equipment not in direct contact with the rail, and the appearance of these techniques relies on the rapid development of industrial automation technology in recent years. Most of the non-contact detection technologies are detection methods based on optical systems, and are commonly used for dynamic detection of the steel rail, namely, the steel rail and detection equipment are detected in a state of relative motion rather than a static state. Generally, a non-contact detection device is mounted on a rail inspection vehicle, and the state of a steel rail along the rail inspection vehicle is detected along with the movement of the rail inspection vehicle.
The existing electronic measuring equipment before steel rail welding mainly comprises an electronic flatness measuring scale for measuring the length of 1 meter, a passive measuring straightness ruler of 2.5 meters, a profile measuring caliper gauge and electronic measuring equipment for measuring the defects of no torsion, appearance size and rail body.
Disclosure of Invention
The invention provides an on-line detection device for measuring the geometric outline of a steel rail, which solves the problems that the existing steel rail detection before welding only has an electronic straightness measuring scale for measuring the length of 1 meter singly, a passive straightness measuring ruler of 2.5 meters, a profile measuring caliper gauge and electronic measuring equipment for measuring the defects of no torsion resistance, appearance size and rail body.
In order to achieve the purpose, the technical scheme of the invention is as follows: the utility model provides a measure on-line measuring device of rail geometric outline, walks capable platform, mechanical transmission module, laser profile sensor module, data acquisition measurement module, storage module including, its characterized in that: the running platform is arranged on the detection platform through running wheels, and roller line rollers of a detected steel rail are arranged on the two sides of the detection platform; hydraulic lifting roller track line rollers are arranged on two sides of the upper surface of the walking platform, and the measured steel rail can be supported and leveled in real time through the cooperation of the hydraulic lifting roller track line rollers and the roller track line rollers for supporting the steel rail; the laser contour sensor module is driven by the mechanical transmission module to move on the walking platform along the length direction of the measured steel rail, is used for scanning the geometric contour of the steel rail and converting the steel rail contour into two-dimensional coordinate data, and the two-dimensional coordinate data is subjected to data processing to obtain a complete steel rail section at any position and restore a three-dimensional image of the steel rail; the laser profile sensor module consists of a mounting seat, a mounting positioning ring, four laser profilometers, a swing motor and a rotating motor, wherein the mounting seat is sleeved outside a measured steel rail, the mounting seat is connected with the four laser profilometers through the mounting positioning ring, and the laser profilometers on the left side and the right side are mounted on the swing motor and can perform end surface measurement aiming at the end surface of the steel rail so as to realize the measurement of the verticality between the rail end and the rail bottom; the mounting positioning ring is connected with a rotating motor, and under the driving of the rotating motor, the spatial circumferential positions scanned by the four laser contourgraph instruments are adjusted, so that the scanning of the measured steel rail without blind areas by real-time adjustment is realized; a grating ruler displacement sensor is fixedly connected to the walking platform, and when the laser profile sensor module translates, the grating ruler displacement sensor records the motion displacement data of the laser profile sensor module in real time; the data acquisition, measurement and storage module acquires data of the laser profile sensor and the grating displacement sensor by using a computer, calculates the section size, the straightness and the surface defects of the measured steel rail and stores the measurement results into a database; the storage module stores the processing results of the section size, the straightness and the torsion data of the steel rail into a database, and the generated profile curve is stored in an OPJ and STL format so as to facilitate management and query of management personnel on the data.
Furthermore, when the steel rail is measured, a part of the rail head end of the steel rail is lapped on the hydraulic liftable roller line roller on the left, when the rail head end of the steel rail is positioned in the middle of the scanning table, the laser profiler on the left swings by an angle a from the state of being vertical to the axis of the steel rail, and obliquely irradiates on the vertical central line of the head end of the steel rail, so that the measurement of the head end of the steel rail is realized; when the rail tail end is measured, a part of the rail tail end of the steel rail is lapped on the hydraulic lifting roller way line roller on the right side, when the rail tail end is positioned in the middle of the scanning table, the laser profilometer on the right side swings by an angle of-a from the state of being vertical to the axis of the steel rail, and obliquely irradiates on the vertical central line of the tail end of the steel rail, so that the measurement of the rail tail end is realized.
Further, the mechanical transmission module comprises a rack, a motor, a synchronous belt, a guide rail pair, a proximity switch and a photoelectric switch, the rack supports, protects and fixes the laser profile sensor module, the motor moves back and forth on the guide rail pair at a stable and uniform speed along the length direction of the steel rail through the synchronous belt laser profile sensor module, the proximity switch ensures that the movement of the laser profile sensor module is in a certain range, and the photoelectric switch controls the transmission of the measured steel rail, so that the measured steel rail stops at a specified position to wait for detection.
Furthermore, the high-precision ball screw nut pair and the linear rolling guide rail pair are used as the hardware basis of the whole scanning platform of the walking platform, so that the stability and reliability of the measurement result can be ensured.
Furthermore, the steel rail geometric outline on-line detection device adopts a three-dimensional scanning technology to carry out full-outline on-line scanning and comprehensive parameter measurement on the end parts of the two ends of a 100m long steel rail within a range of 3 m.
Further, the steel rail geometric outline on-line detection device adopts a three-dimensional dynamic scanning technology to perform high-speed dynamic surface defect extraction and key parameter detection on the middle 94 meters of the steel rail with the length of 100 meters.
Furthermore, the steel rail geometric outline on-line detection device displays a three-dimensional graph of a three-meter measurement area at the rail end of the measured steel rail, the flatness, the torsion degree, the end face verticality, the appearance dimension error and a two-dimensional coordinate curve diagram of the measured steel rail in the horizontal and vertical directions, and the dimension and the position of the defect of the full-length rail body of the steel rail through the display module.
The invention has the beneficial effects that:
the invention relates to a steel rail outline detection device, which is used for a steel rail three-dimensional detection center for measuring the straightness, the torsion degree, the end face verticality, the appearance size error and the full-length rail body defect of a steel rail before welding 100m long steel rails on a rail base. The five items of detection contents are completed by adopting four sets of high-precision three-dimensional laser profilometers, so that the problems that only a single electronic flatness measuring scale for measuring the length of one meter is used before the current steel rail is welded, and no electronic measuring equipment for measuring the torsion resistance, the appearance size and the rail body defects exists can be solved.
Drawings
FIG. 1 is a schematic structural diagram of an on-line detection device according to the present invention;
FIG. 2 is a cross-sectional view of a sensor layout of the present invention;
FIG. 3 is a system block diagram of the on-line detection device of the present invention;
FIG. 4 is a flow chart of the on-line detection device of the present invention.
Detailed Description
The invention is further described with reference to the following figures and examples.
The invention relates to an on-line detection device for measuring the geometric outline of a steel rail, which adopts 4 laser outline sensors to scan the complete section of a large member in the aspect of hardware to obtain the geometric dimension of the section of the large member, and dynamically scans the end part of the large member (the steel rail) under the transmission of a guide rail and a synchronous pulley to obtain the verticality, surface scratch and flatness parameters of the end part.
As shown in fig. 1 and 2, the on-line detection device for measuring the geometric profile of the steel rail is composed of a walking platform 8, a mechanical transmission module, a laser profile sensor module, a data acquisition and measurement module, a storage module, a grating displacement sensor and the like. The walking platform 8 is arranged on the detection platform 1 through the walking wheels 2, and the roller line rollers 4 of the detected steel rail 20 are arranged on the two sides of the detection platform 1; hydraulic lifting roller track line rollers 7 are arranged on two sides of the upper surface of the walking platform 8, so that the function of supporting and leveling the roller track line rollers 4 supporting the steel rail in real time during measurement can be realized; the mechanical transmission module is arranged on the walking platform 8 and connected with the laser contour sensor module, the laser contour sensor module is driven by the mechanical transmission module to move on the walking platform along the length direction of the steel rail and is used for scanning the geometric contour of the steel rail and converting the steel rail contour into two-dimensional coordinate data, and the two-dimensional coordinate data is subjected to data processing to obtain a complete steel rail section at any position and restore a three-dimensional image of the steel rail; a grating ruler displacement sensor is fixedly connected to the walking platform, and when the laser profile sensor module translates, the motion displacement data of the laser profile sensor module is recorded in real time; the data acquisition, measurement and storage module acquires data of the laser profile sensor module, the grating displacement sensor and the photoelectric switch by using a computer, calculates the section size, the straightness and the surface defects of the steel rail and stores the measurement results into a database; the storage module stores the processing results of the section size, the straightness and the torsion data of the steel rail into a database, and the generated profile curve is stored in an OPJ and STL format so as to facilitate management and query of management personnel on the data in the future.
(1) Mechanical transmission module is by frame 3, motor 5, the hold-in range, the guide rail is vice 6, proximity switch, photoelectricity is opened light etc. and is constituteed, frame 3 plays the support to laser profile sensor module, protection, the fixed action, motor 5 passes through hold-in range laser profile sensor module and goes on the guide rail is vice steady, at the uniform velocity come and go along rail length direction motion, proximity switch ensures that the motion of laser profile sensor module is in the certain limit, the conveying of photoelectric switch control rail, make the rail stop waiting to detect in the position of regulation.
(2) The laser profile sensor module consists of a mounting seat 10, a mounting positioning ring 11, laser profilers 12-1, 12-2, 12-3, 12-4, a swing motor 13 and a rotating motor 14, wherein the mounting seat 10 is sleeved outside a measured steel rail 20, the laser profilers 12-1, 12-2, 12-3 and 12-4 are fixedly connected to the mounting seat 10 through the mounting positioning ring 11, the laser profilers 12-1 and 12-3 on the left side and the right side are mounted on the swing motor 13, end face measurement can be carried out on the end face of the steel rail, and further perpendicularity measurement of the rail end and the rail bottom is realized; the mounting positioning ring 11 is connected with the rotating motor 14, and the scanning space circumferential positions of the laser profilometers 12-1, 12-2, 12-3 and 12-4 can be adjusted under the driving of the rotating motor 14, so that the functions of real-time adjustment and non-blind-area scanning of specific structural parts are realized.
When the steel rail is measured, the steel rail has a rail head end test state, a part of the rail head end of the steel rail is lapped on the hydraulic lifting roller line roller 7 on the left, when the rail head end of the steel rail is positioned in the middle of the scanning table, the laser profiler 12-3 swings by an angle a from the state of being vertical to the axis of the steel rail, and obliquely irradiates on the vertical central line of the rail head end of the steel rail, so that the measurement of the rail head end is realized; when the rail tail end is measured, one part of the rail tail end of the steel rail is put on the right hydraulic lifting roller track line roller 7, the rail tail end is arranged in the middle of the scanning platform, the laser profiler 12-1 swings by an angle of-a from the state of being vertical to the axis of the steel rail, and obliquely irradiates the vertical central line of the tail end of the steel rail, so that the measurement of the rail tail end is realized.
(3) The data acquisition, measurement and storage module acquires data of the laser profile sensor, the grating displacement sensor and the photoelectric switch by using a computer, calculates the section size, the straightness and the surface defects of the component, and automatically stores the measurement result into a database.
(4) The storage module stores the processing results of the section size, the straightness and the torsion data of the steel rail into a database, and the generated profile curve is stored in an OPJ and STL format so as to facilitate management and query of management personnel on the data in the future.
(5) One end of a displacement sensor of the grating ruler is fixed on the walking platform, and when the contourgraph module translates, the movement displacement data of the displacement sensor is recorded in real time, and the precision can reach 0.03 mm.
(6) A walking platform. The high-precision ball screw nut pair and the linear rolling guide rail pair are used as the hardware basis of the whole scanning platform, so that the stability and reliability of the measurement result are ensured.
(7) By adopting the detection feedback system, the scanned outline measurement data and the defect position of each steel rail can be recorded in the terminal database, and simultaneously, the detection feedback system can be coordinated with the welded rail foundation steel rail database, so that the aim of optimizing and matching the steel rails is fulfilled, and the production efficiency is improved.
The detection process of the on-line detection device of the invention, as shown in fig. 3 and 4, comprises the following steps:
(1) and (3) carrying out full-profile online scanning and comprehensive parameter measurement on the end parts of the two ends of the long rail of 100m within a range of 3m by adopting a three-dimensional scanning technology.
(2) And (3) performing high-speed dynamic surface defect extraction and key parameter detection on the middle 94-meter rail body of the 100-meter long steel rail by adopting a three-dimensional dynamic scanning technology.
(3) Comprehensive measurement parameters obtained by adopting a high-precision three-dimensional laser profilometer meet the technical requirements of national standard TB/T2344 '43 kg/m-75 kg/m steel rail ordering technical condition' and TB/T3276 'steel rail for high-speed railway'.
(4) Laser three-dimensional profile scanning measurement software suitable for rail welding bases is researched and developed according to actual working conditions on site, and production and quality screening work of the steel rails on site is guided according to three-dimensional scanning measurement results to be completed according to the three-dimensional scanning results: 1) displaying a three-dimensional graph of a three-meter measuring area at the rail end of the measured steel rail; 2) displaying the flatness, the torsion degree, the end face verticality, the appearance dimension error and a two-dimensional coordinate curve chart of the measured steel rail in the horizontal and vertical directions; 3) and displaying the size and the position of the defect of the full-length rail body of the steel rail.
The invention relates to a steel rail geometric outline data processing method which comprises the following steps:
(1) single profile data:
data processing is a key link in the measurement process, the quality of data processing is directly related to the measurement result, and reasonable and effective data processing means can not only ensure the accuracy and reliability of measurement, but also improve the measurement precision. In the measuring process, due to the influence of factors such as transmission clearance of a measuring mechanism, sensor errors, external random interference and the like, the obtained profile data points are often scattered, disordered, uneven in distribution, few in noise points and incapable of being directly fitted, and the actually measured profile data points need to be correspondingly preprocessed through a proper algorithm. The data collected by the sensor can be accurate to 4 bits behind the decimal point, and the measurement requirement of the steel rail profile can be completely met. However, the data collected by the sensor cannot be directly compared with the reference profile to calculate the rail wear, and the rail wear can be corrected and calculated after certain rotation transformation. For accidental errors caused by external environmental factors, a limiting filtering method is adopted, and the change amplitude of the acquired data is judged through a program, so that the gross errors are eliminated. And for the second error, smoothing the data by adopting a weighted recursive average filtering method.
After the denoising is carried out by the algorithm, due to the influence of rough burrs and slight jitter, the reconstructed railhead contour curve has the phenomenon of unsmooth, and the required measurement precision cannot be achieved. Therefore, within the error range of the precision requirement, the data points are processed by a spatial smoothing filter algorithm, and the premise of ensuring the reconstruction of the actual contour curve of the railhead is provided. The core idea of the algorithm is to divide the original array by using subarrays with different structures twice, so as to ensure that the number of subarrays divided for the 1 st time is equal to the number of subarray elements divided for the 2 nd time, and similarly, the number of subarray elements divided for the 1 st time is also equal to the number of subarrays divided for the 2 nd time. The two times of taking methods of the number of the spatial smoothing submatrices and the number of the array elements are used for ensuring that the number of the elements of the weighting matrix is equal to the number of the weighting spatial smoothing matrixes, and the weighting factors correspond to the weighted matrixes one by one. And summing and averaging the autocorrelation covariance matrixes of all the sub-matrixes obtained by the 1 st division to obtain a weighting factor, and applying a weighted spatial smoothing algorithm to all the autocorrelation and cross-correlation covariance matrixes obtained by the 2 nd division to realize the estimation of the direction of arrival of the information source.
(2) Splicing of multi-contour data:
the scanning range of the laser profile sensor is a trapezoidal area, the profile of a partial steel rail section can be obtained, and the whole steel rail section can be completely scanned by skillfully combining four laser sensors. Each sensor has an independent image coordinate system, and the acquired rail outline is scattered. The four image coordinate systems can be unified in a pairwise conversion mode, and the problem of splicing the four curves can be simplified into conversion of the two coordinate systems.
Because the geometric shape of the steel rail profile is complex and the measuring stroke is large, the measuring instrument cannot complete the measuring work of the whole surface at one time, and the steel rail section needs to be measured by dividing the edge twice. To ensure the integrity of the measured data points, the two measured data points need to be spliced to form a complete data point set. Therefore, data splicing has important significance for perfecting the measured data to each subsequent link of the reconstruction of the geometric outline of the steel rail.
In the reverse engineering, the data point set is spliced by mainly using the characteristic points of the object to be measured or the characteristic mark points added artificially to carry out superposition matching splicing. The specific measurement and analysis of the steel rail shows that the steel rail superposition measurement part has no characteristic mark points, and the artificial mark cannot be applied to actual measurement, so that the method cannot be adopted. In the actual steel rail edge-dividing measuring process, a first joint point of the two-connecting-rod measuring mechanism is fixed, and the misalignment of edge-dividing measuring sections is caused by the misalignment of a reference coordinate system caused by mechanism errors. Therefore, the measuring instrument can be calibrated and measured, and the measuring reference coordinate systems on the two sides are coincided through compensation calculation, so that the contour data points of sectional measurement can be directly spliced.
The reference coordinate system matching calibration of the measuring instrument is that under the condition that the instrument and an object to be measured are fixed relatively, the profile instrument is adopted to respectively measure the same measuring section of the object to be measured with known shape and size repeatedly, the obtained measuring data points are analyzed and calculated to obtain the deviation of the reference coordinate systems measured at two sides, the measuring data is compensated and calculated in the actual process to enable the measuring reference coordinate systems to be overlapped, and the profile data points measured in sections can be directly spliced to form a whole.
Claims (7)
1. The utility model provides a measure on-line measuring device of rail geometric outline, walks capable platform, mechanical transmission module, laser profile sensor module, data acquisition measurement module, storage module including, its characterized in that: the running platform is arranged on the detection platform through running wheels, and roller line rollers of a detected steel rail are arranged on the two sides of the detection platform; hydraulic lifting roller track line rollers are arranged on two sides of the upper surface of the walking platform, and the measured steel rail can be supported and leveled in real time through the cooperation of the hydraulic lifting roller track line rollers and the roller track line rollers for supporting the steel rail; the laser contour sensor module is driven by the mechanical transmission module to move on the walking platform along the length direction of the measured steel rail, is used for scanning the geometric contour of the steel rail and converting the steel rail contour into two-dimensional coordinate data, and the two-dimensional coordinate data is subjected to data processing to obtain a complete steel rail section at any position and restore a three-dimensional image of the steel rail; the laser profile sensor module consists of a mounting seat, a mounting positioning ring, four laser profilometers, a swing motor and a rotating motor, wherein the mounting seat is sleeved outside a measured steel rail, the mounting seat is connected with the four laser profilometers through the mounting positioning ring, and the laser profilometers on the left side and the right side are mounted on the swing motor and can perform end surface measurement aiming at the end surface of the steel rail so as to realize the measurement of the verticality between the rail end and the rail bottom; the mounting positioning ring is connected with a rotating motor, and under the driving of the rotating motor, the spatial circumferential positions scanned by the four laser contourgraph instruments are adjusted, so that the scanning of the measured steel rail without blind areas by real-time adjustment is realized; a grating ruler displacement sensor is fixedly connected to the walking platform, and when the laser profile sensor module translates, the grating ruler displacement sensor records the motion displacement data of the laser profile sensor module in real time; the data acquisition, measurement and storage module acquires data of the laser profile sensor and the grating displacement sensor by using a computer, calculates the section size, the straightness and the surface defects of the measured steel rail and stores the measurement results into a database; the storage module stores the processing results of the section size, the straightness and the torsion data of the steel rail into a database, and the generated profile curve is stored in an OPJ and STL format so as to facilitate management and query of management personnel on the data.
2. The on-line measuring device for measuring the geometric profile of a steel rail according to claim 1, wherein: when the steel rail is measured, a part of the rail head end of the steel rail is lapped on the hydraulic liftable roller line roller on the left, when the rail head end of the steel rail is positioned in the middle of the scanning table, the laser profiler on the left swings by an angle a from the state of being vertical to the axis of the steel rail, and obliquely irradiates on the vertical central line of the head end of the steel rail, so that the measurement of the head end of the steel rail is realized; when the rail tail end is measured, a part of the rail tail end of the steel rail is lapped on the hydraulic lifting roller way line roller on the right side, when the rail tail end is positioned in the middle of the scanning table, the laser profilometer on the right side swings by an angle of-a from the state of being vertical to the axis of the steel rail, and obliquely irradiates on the vertical central line of the tail end of the steel rail, so that the measurement of the rail tail end is realized.
3. The on-line measuring device for measuring the geometric profile of a steel rail according to claim 1, wherein: the mechanical transmission module comprises a rack, a motor, a synchronous belt, a guide rail pair, a proximity switch and a photoelectric switch, wherein the rack plays a role in supporting, protecting and fixing the laser profile sensor module, the motor moves back and forth along the length direction of the steel rail in a stable and uniform speed mode on the guide rail pair through the synchronous belt laser profile sensor module, the proximity switch ensures that the movement of the laser profile sensor module is in a certain range, and the photoelectric switch controls the transmission of the measured steel rail so that the measured steel rail stops at a specified position to wait for detection.
4. The on-line measuring device for measuring the geometric profile of a steel rail according to claim 1, wherein: the traveling platform is provided with a high-precision ball screw nut pair and a linear rolling guide rail pair as hardware bases of the whole scanning platform, and stable and reliable measuring results can be ensured.
5. The on-line measuring device for measuring the geometric profile of a steel rail according to claim 1, wherein: the on-line detection device for measuring the geometric profile of the steel rail adopts a three-dimensional scanning technology to carry out full-profile on-line scanning and comprehensive parameter measurement on the end parts of two ends of a long steel rail of 100m within a range of 3 m.
6. The on-line measuring device for measuring the geometric profile of a steel rail according to claim 1, wherein: the on-line detection device for measuring the geometric profile of the steel rail adopts a three-dimensional dynamic scanning technology to extract the high-speed dynamic surface defects and detect key parameters of the 94-meter rail body in the middle of the 100-meter long steel rail.
7. The on-line measuring device for measuring the geometric profile of a steel rail according to claim 1, wherein: the on-line detection device for measuring the geometric profile of the steel rail displays a three-dimensional graph of a three-meter measuring area at the rail end of the measured steel rail, the flatness, the torsion degree, the end face verticality, the appearance dimension error and a two-dimensional coordinate curve diagram of the measured steel rail in the horizontal and vertical directions, and the dimension and the position of the defect of the full-length rail body of the steel rail through the display module.
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