CN111469882B - Using method of portable modularized self-correcting rail three-dimensional detection system - Google Patents
Using method of portable modularized self-correcting rail three-dimensional detection system Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61K—AUXILIARY EQUIPMENT SPECIALLY ADAPTED FOR RAILWAYS, NOT OTHERWISE PROVIDED FOR
- B61K9/00—Railway vehicle profile gauges; Detecting or indicating overheating of components; Apparatus on locomotives or cars to indicate bad track sections; General design of track recording vehicles
- B61K9/08—Measuring installations for surveying permanent way
Abstract
The invention belongs to the technical field of railway safety transportation, and relates to a use method of a portable modularized self-correcting rail three-dimensional detection system. When the device is used, firstly, the device is quickly assembled on site, and the manual operator is connected with the two detection units in a wireless manner to finish the integral initialization of the device; scanning the marker of the calibration rod to obtain a 3D image, comparing the left and right factory calibration reference 3D images to judge whether the error range exists, and further reading the reading of the level detection sensor if no fault detection exists, and respectively correcting the three-dimensional space coordinate system of the unit; correcting the whole coordinate system according to the calibration rod, establishing a coordinate system based on the ground level as a reference through the factory calibration information of the horizontal detection sensor, and starting to integrally scan the 3D image of the railway track; identifying characteristic information of the rail, the rail top surface and the rail edge, and calculating characteristic information of the rail gauge, the rail height, the rail extension angle and the rail profile; the detection unit acquires GPS positioning information and acquires walking information of a walking encoder.
Description
Technical field:
the invention belongs to the technical field of railway safety transportation, relates to a rail automatic correction system and a rail automatic correction method, and particularly relates to a use method of a portable modularized self-correction rail three-dimensional detection system, which can realize rapid assembly and detection.
The background technology is as follows:
railway transportation is one of the main transportation modes in China. The rail performance status directly affects railway traffic safety. The geometric parameter measurement of the rail is one of important basis for verifying the performance parameters of the rail. The most commonly used detection means on the railway at present is manual measuring tool detection, needs different measuring tools of manual operation, and the detection result is directly influenced by the level of operators, so that the manual interference is easy to introduce. The automatic detection equipment is relatively large in size, inconvenient to manually transport, complex in assembly and calibration process and high in maintenance difficulty. The precision of equipment easy to be assembled rapidly on site is difficult to ensure due to the influence of assembly errors. The problem is not solved, chinese patent application number CN209605771U discloses a track profile inspection device convenient to disassemble and assemble, a clamping component is connected to the bottom of the inspection box, an operation rod and a display screen are detachably connected and fixed through a locking piece, a hand-held rod is connected to the operation rod, the operation rod can rotate along a vertical plane relative to a conversion head and is detachably connected with the conversion head and a connector holder, the connector holder and a folding seat are respectively fixed on a connecting rod through locking pieces, and the connecting plate is respectively detachable from the connecting rod and the inspection box; although this profiler can dismantle through self structure, the equipment is simple, installs the detector at the rail fast when railway detects, can the dismantlement of the device of being convenient for, improves detection effect and efficiency to rail damage. However, simultaneous detection of multidimensional data such as track height, track gauge, track profile and the like cannot be realized. The Chinese patent with the application number of CN201610813938.4 discloses a high-precision rail geometric outline detection method, wherein a combined measurement system is constructed by adopting a plurality of lasers and a plurality of cameras, and rail geometric outline feature points in two non-overlapped dynamic three-dimensional coordinate systems are obtained with high precision through the combined calibration of the measurement system and the comprehensive processing of acquired data. The detection equipment is simple and flexible to install, high in detection precision, capable of calibrating world coordinates of the double-side rail at the same time and effectively completing three-dimensional detection of the geometric outline of the rail. The invention has the characteristics of simple and flexible installation, high detection precision, capability of calibrating the world coordinates of the bilateral rails and the like. However, the detection operation is heavy, and errors are easily introduced by manual operation. The Chinese patent with the application number of CN106114553A discloses a photoelectric dynamic measurement method for shaking of a railway detection vehicle platform, and relative displacement at a plurality of points on a rail can be obtained by utilizing a plurality of sets of rail displacement precision photoelectric measurement systems installed on the detection vehicle equipment platform to jointly work, so that dynamic measurement of relative position and attitude information of a rail surface and a measurement platform is realized. The rail displacement precise photoelectric measurement system consists of a line laser, a point laser and a camera, adopts a precise photoelectric displacement measurement method combining a point laser displacement measurement technology and a line laser displacement profile triangulation technology to measure the precise displacement of a laser point, obtains the rail section profile by utilizing line laser triangulation, and determines the position of the laser point on the rail surface profile according to the image relationship between the point laser and the line laser. However, when the invention is installed, a fit clearance is easy to be reserved between installation parts, errors are introduced in assembly, measurement results are affected, and meanwhile, the test equipment is large and inconvenient to move, and is complex in installation and debugging. Accordingly, the present invention seeks to devise a method of using a portable modular self-correcting rail three-dimensional inspection system that effectively addresses the above-described problems.
The invention comprises the following steps:
the present invention aims to overcome the above-mentioned drawbacks, and seeks to devise a method of using a portable modular self-correcting rail three-dimensional inspection system, which is capable of simultaneously performing rail geometric feature inspection in one inspection, comprising: the invention synchronously records the geographic coordinates of the detection points and is used for tracing and searching the detection records.
In order to achieve the above purpose, the use method of the portable modularized self-correcting rail three-dimensional detection system is realized by the following technical scheme:
the main body structure of the portable modularized self-correcting rail three-dimensional detection system comprises two detection units for detection, a mounting bracket for supporting and connecting and a manual operator, wherein the main body structure of the detection unit comprises a running mechanism, a scanning mechanism, a control unit, a horizontal detection sensor, a power supply unit and a temperature and humidity sensor, and the running mechanism is connected with the scanning mechanism to realize running and scanning at the same time; the horizontal detection sensor is arranged at the rear side of the scanning mechanism; the control unit is communicated with the running mechanism, the scanning mechanism and the horizontal detection sensor to collect and process the information of the components; the power supply unit supplies power to the running mechanism, the scanning mechanism, the control unit and the horizontal detection sensor;
the main structure of the running mechanism comprises a power wheel, a bracket, an auxiliary wheel and an encoder; the power wheel is a servo wheel, the running distance can be accurately controlled, the encoder is arranged in the power wheel, the auxiliary wheel is horizontally arranged on the front side of the power wheel, the support is of a double-framework side mounting plate structure, and the power wheel and the auxiliary wheel are positioned in the middle of the support and are positioned at the lower part of the support and are connected with the double support plates of the support; the power supply and the servo controller are arranged in the middle of the frame side plate, wherein the servo controller is connected with the power wheel for control;
the main structure of the scanning mechanism comprises a sliding table and laser 2D/3D sensors, wherein three groups of laser 2D/3D sensors are arranged at the front part of the upper part between two double-framework side plates and are positioned at the upper part of the sliding table, and the sliding table can drive the laser 2D/3D sensors to longitudinally move so as to adjust the angle of the laser 2D/3D sensors;
the main structure of the control unit comprises an industrial personal computer, a GPS positioning module, a 4G module and a wireless communication module which form an integrated package, and the control unit can communicate with a computer through the GPS positioning module, the 4G module and the wireless communication module;
the main structure of the mounting bracket comprises a bearing frame, a locking mechanism and a reference rod piece, wherein the bearing frame in a plug-in type is in a triangular arrangement structure, two ends of the bearing frame are respectively connected with a side mounting plate of the framework in a plug-in type, the reference rod piece is positioned at the lower side of the bearing frame and is connected with the unit bracket through the locking mechanism, the main structure of the locking mechanism comprises a magnetic concave plate, a top spring and a base, the magnetic concave plate is connected with the base through the top spring to form an integral locking mechanism, the base of the locking mechanism is connected with the unit bracket, and the base is connected with a side plate of the member; the magnetic concave plate and the top spring structure can realize quick installation, and meanwhile, the installation accuracy and stability are ensured;
the manual operator is a tablet personal computer in the market, and a related program is arranged in the tablet personal computer;
further, the main structure of the bracket comprises two vertically arranged frame side plates, a frame stabilizing link rod for connecting the two frame side plates and bracket assembly members, wherein the frame stabilizing link rod and the bracket assembly members are positioned between and connected with the frame side plates at two sides, and the three mounting bracket assembly members are arranged in a triangular mode to ensure the integral mounting precision and stability of the system and realize quick assembly and disassembly; the bracket assembly component is matched with the mounting bracket, so that errors caused by system equipment are reduced;
furthermore, the control unit and the power supply unit are arranged in the detection unit and are close to the upper part, wherein the control unit is positioned at the front side of the power supply unit, and the temperature and humidity sensor is positioned at the front side of the control unit so as to be free from shielding and interference of other components during measurement;
the specific operation method of the invention is carried out according to the following steps:
step one, self-calibration is carried out
S1, rigidly connecting the sliding table, the movable laser 2D/3D sensor and the horizontal detection sensor, calibrating the component of the movable laser 2D/3D sensor, comparing the obtained contour with a reference contour, and if the obtained contour is matched with the reference contour, indicating that the movable laser 2D/3D sensor has no fault;
s2, the calibration parts are positioned on the reference rod piece and are rigidly connected, so that the spatial relative position relation between the calibration parts is fixed, the detection unit can obtain the outline spatial coordinates of the reference calibration parts through detection, calculate the relative spatial posture position of the detection unit relative to the calibration parts, and detect the outline spatial coordinates of the rail to be used as a reference object, thereby eliminating and correcting the installation error caused by rapid installation fit clearance;
s3, mutually verifying the detection result of the horizontal detection sensor according to the correction calibration, and correcting the whole system according to the reading of the horizontal detection sensor;
step two, a specific operation method is as follows:
the left side and the right side of the reference rod piece are provided with reference calibration parts, the calibration parts are triangular prisms, the straight lines of the protruding edges of the prisms are coplanar, and the straight lines of the protruding edges of the prisms on the left side and the right side are parallel to the straight lines of the protruding edges of the prisms on the left side and the right side; the distance between the line 2 and the line 3 is D, and the distance between the parallel lines 1 and the line 4 calibrated at the two ends and the distance between the parallel lines 5 and the line 8 calibrated at the two ends are equal to D1;
s1, forming matrix array by left 3D image scanning coordinates
S2, the horizontal coordinate sensor collects that the inclination angle is alpha 1 around the X axis, the inclination angle is beta 1 around the Y axis, and the horizontal coordinate sensor obtains the rotation coordinate system according to the alpha 1 and the beta 1
S3, dividing A2 n into the following three area coordinate matrix arrays according to x coordinates
A21[ i ] takes the value A2[ n ] (P2.ltoreq.x1 [ n ])
A22 j is a value A2 n (x 1 n is less than or equal to P1)
A23[ k ] is a value A2[ n ] (P1 < x1[ n ] < P2)
S4, at A21[ i ]]In which the resolution in Y-axis direction is 2 times as large as the step Deltay, and n Deltay < Y1[ i ] is searched]Z21[ i ] within Δy (n+1)]The point with the maximum value is obtained to form a new matrix array by the high points in the planeThe matrix array point prism protruding edge is positioned at the point where the straight line 1 passes through;
s5, solving a plane projection straight line of the matrix array B1[ r ] in z=0
Solving a projection equation of a straight line 1 when the projection equation of the plane with z=0 is y=b1x+a1;
s6, obtaining a projection straight line y=b11z+a11 of the B1[ r ] on the x=0 plane according to the method of the step S5;
s7, according to the methods of the step S4 and the step S6, obtaining A22[ j ]]In-plane high-point matrix arrayThe matrix array points the straight line 4 where the convex edge of the prism is located passes through; obtaining z=of the matrix arrayA projection equation of the 0 plane projection straight line y=b2x+a2, and the x=0 plane projection straight line y=b22z+a22, namely the straight line 4;
s8, obtaining A23[ k ] according to the method of step S4 and step S6]In-plane high-point matrix arrayThe matrix array point prism protruding edge is positioned at the point where the straight line 3 passes through; obtaining a projection equation of the matrix array in a z=0 plane projection straight line y=b3x+a3, and in an x=0 plane projection straight line y=b33z+a33, namely a straight line 3;
s9, if y=b1x+a1 and y=b2x+a2 are not parallel and do not match with the reference profile characteristic attribute, the system cannot pass the self-check, and if the y=b1x+a1 and y=b2x+a2 are parallel, the rotation angle gamma 1 around the Z axis is calculated
γ1＝arccot(b1)；
S10. taking a straight line with equal distance y=b1x+a1 and y=b2x+a2Plane projection equation of the straight line 2 in z=0;
s11 is a straight line with the distance y=b11x+a11 equal to y=b22x+a22The projection equation of the straight line 2 on the x=0 plane;
s12, calculatingThe intersection point with y=b3x+a3 is solved
S13, taking the X1 value in the step S10 into y=b33z+a33 to obtain
S14, comprehensively obtaining left coordinate system correction parameters, wherein the rotation angles around X Y Z are alpha 1, beta 1 and gamma 1, the translation amounts are X1, Y1 and Z1,
s15, according to the method from the step S1 to the step S14, three projection straight lines y=c1x+d1 in the z=0 plane of the projection straight line equation can be obtained by processing the matrix array formed by the right 3D image scanning coordinates, and the projection straight line y=c1z+d11 in the x=0 plane of the projection straight line equation, namely the projection equation of the straight line 5;
projection equation for projection of straight line y=c2x+d2 on z=0 plane and straight line y=c22z+d22 on x=0 plane, i.e. straight line 8; projection equation for projection straight line y=c3x+d3 on z=0 plane and straight line y=c33z+d33 on x=0 plane, i.e. straight line 7; the parallelism self-test of y=b11x+a11 and y=b22x+a22 is performed, and if the parallelism self-test is not performed, the self-test of the unit cannot be performed;
by self-checking, it can be deduced that a straight line is projected on the z=0 planeProjecting a straight line in the x=0 planeThe projection equation of the straight line 6; the right coordinate system correction parameters can be deduced: rotation angles around X Y Z are alpha 11, beta 11 and gamma 11, and translation amounts are X11, Y11 and Z11;
s16. find the distance between y=b1x+a1 and y=b2x+a2
Find y=c1x+d1 to y=c2x+d2 distance
If D1 and e1 are not equal, the deformation of the standard rod piece or the deformation inclination deflection of the mechanical mechanism of the scanning unit is described, the whole system cannot pass the self-test, and if the deformation and the self-test are equal, the offset parallel to X of the center of the left 3D image coordinate system and the center of the right 3D image coordinate system is obtained
S17. find the distance difference between y=b11x+a11 and y=b22x+a22
The difference between the distances y=c11x+d11 and y=c22x+d22 is calculated
If D11 and e11 are not equal, the deformation of the standard rod or the deformation inclination deflection of the mechanical mechanism of the scanning unit is described, the whole system cannot pass the self-test, if the deformation and the self-test are equal, the offset parallel to Z of the center of the left 3D image coordinate system and the center of the right 3D image coordinate system is calculated
In summary, system self-checking and mutual verification are completed, and parameters obtained by the mutual verification are obtained, wherein the rotation angles of the self-calibration parameters X Y Z of the left 3D image are alpha 1, beta 1 and gamma 1, the rotation angles of the self-calibration parameters X Y Z of the right 3D image are alpha 11, beta 11 and gamma 11, the translation quantities X11, Y11 and Z11, and the translation quantities X12 and Z12 of the right 3D image relative to the left 3D image are corrected by the parameters obtained by the complaints, so that the installation errors caused by rapid installation fit clearances are corrected;
step three, rail contour detection:
after the self calibration is completed, the scanning mechanism scans the 3D contour of the rail, and the test results of all units are registered according to the calibration results to form an integral detection contour;
s1, track gauge: the edge of the rail profile on one side is taken as a datum line to vertically extend to the edge of the rail on the other side, the length is taken as a track gauge, and the multipoint detection avoids the error caused by the fact that the measuring tool cannot be vertically measured with the rail manually, and the degree of accuracy of the multipoint detection is increased, and meanwhile the parallelism of two rail detection sections can be simultaneously verified;
s2, rail height: calculating rail height by taking the multipoint track gauges and the rail contour edges as datum lines and vertically extending the rail edges to the other side and horizontally obtaining included angles between the rail edges and the ground in the S1;
s3, included angle of track extension: an included angle is obtained by the track extending direction and the ground level;
s4, rail outline: after coordinate correction, the rail profile can be obtained by taking the vertical plane of the rail as a tangent plane, and meanwhile, the horizontal position relation of the rail relative to the ground can be obtained, so that horizontal information is provided for further analysis of rail abrasion;
s5, other steps: the profile space 3D information of the two steel rail detection sections and the ground horizontal relation can further extract data according to the needs;
step four, measuring:
s1, rapidly assembling and detecting a portable modularized self-correcting rail three-dimensional detection system in the field, wherein the manual operator 3 is connected with two detection units in a wireless manner to finish the integral initialization of equipment;
s2, a left unit detection unit and a right unit detection unit respectively control a sliding table and a front section scanning calibration rod marker of a mobile laser 2D/3D sensor to obtain a 3D image;
s3, comparing the obtained data with factory calibration reference 3D images on the left side and the right side to judge whether the data are in an error range, deducing which sensor is likely to have faults through mutual verification of the data of the three laser 2D/3D sensors, and if the faults are reported to the exit;
s4, further reading readings of a horizontal detection sensor when no fault detection is performed, and respectively correcting a three-dimensional space coordinate system of the unit;
s5, comparing the left and right detection unit data with calibration standard rod data before delivery, judging whether the calibration rod deforms or not, and if the deformation fault alarm exits;
s6, correcting the whole coordinate system according to the calibration rod, establishing a coordinate system based on the ground level as a reference through the factory calibration information of the horizontal detection sensor, and starting to integrally scan the railway track 3D image;
s7, detecting the current temperature and humidity by a temperature and humidity sensor;
s8, identifying characteristic information including the rail, the rail top surface and the rail edge, and further calculating characteristic information including the rail gauge, the rail height, the rail extension angle and the rail profile according to temperature and humidity correction;
s9, the detection unit acquires GPS positioning information and walking encoder walking information, and the control unit uploads the information through the 4G module;
s10, automatically walking and moving to the next detection point for detection.
Compared with the prior art, the invention has the following beneficial effects:
1. the invention can complete the detection of the geometric features of the rail at the same time by one detection, and comprises the following steps: the invention synchronously records the geographic coordinates of the detection points and is used for tracing and searching the detection records.
2. The module design is adopted, the on-site assembly is simple and quick, the automatic calibration function is realized after the assembly, the assembly error is eliminated, and the detection error caused by manual assembly or assembly looseness of similar portable products is overcome.
3. The detection result can form a three-dimensional image, and the automatic correction and calibration are matched, so that the overall measurement precision and accuracy of the equipment are greatly improved.
4. The rail movement detection can be automatically performed on the rail, and the movement distance can be recorded.
5. The invention has the advantages of modularized structure, convenient carrying and assembly, reference rod piece, self-correction verification of the system and error elimination according to the matching of the 3D profile imaging of the reference rod piece and the inclination sensor.
6. The self-calibration verification method is complete, self-checking can be achieved through calibration of results obtained by detecting the reference components through each unit and standard results, and integral correction is achieved through matching the reference components.
7. The invention realizes the detection of each characteristic relation of the rail by means of 3D detection, and can effectively eliminate the error introduction which is difficult to avoid manual operation in the traditional method.
8. The invention can more specifically provide complete space 3D geometric information of the steel rail, and can more comprehensively realize the space relationship of the steel rail, and the invention comprises the following steps: the spatial horizontal vertical relationship, the rail transverse longitudinal inclination relationship, the rail parallelism relationship and the like correspond to rail wear, so that the rail wear degree can be detected, and basic data can be provided for wear factor analysis.
In addition, the device has the advantages of ingenious main body conception, scientific and reasonable structural design, convenient, quick and accurate use and measurement, environment-friendly application and wide market prospect.
Description of the drawings:
fig. 1 is a schematic view of the relative positional relationship with a rail according to the present invention.
Fig. 2 is a schematic diagram of the principle of the main structure of the present invention.
Fig. 3 is a schematic diagram of the main structure of the detection unit according to the present invention.
Fig. 4 is a schematic diagram of a positional relationship of a laser 2D/3D sensor according to the present invention.
Fig. 5 is a schematic diagram of the principle of the main structure of the running mechanism according to the present invention.
Fig. 6 is a schematic diagram of the principle of the main structure of the locking mechanism according to the present invention.
Fig. 7 is a schematic diagram of the internal structure of the detection unit according to the present invention.
Fig. 8 is a schematic workflow diagram of a method of using the portable modular self-correcting rail three-dimensional inspection system of the present invention.
Fig. 9 is a schematic diagram of the self-calibration principle involved in the present invention.
The specific embodiment is as follows:
in order to clearly illustrate the technical features of the present invention, the present invention will be further described with reference to examples.
Example 1
The main structure of the portable modularized self-correcting rail three-dimensional detection system comprises two detection units 1 used for detection, a mounting bracket 2 used for supporting and connecting and a manual operator 3, wherein the main structure of the detection unit 1 comprises a running mechanism 1.1, a scanning mechanism 1.2, a control unit 1.3, a horizontal detection sensor 1.4, a power supply unit 1.5 and a temperature and humidity sensor 1.6, and the running mechanism 1.1 is connected with the scanning mechanism 1.2 so as to realize running and scanning; the horizontal detection sensor 1.4 is arranged at the rear side of the scanning mechanism 1.2; the control unit 1.3 is communicated with the running mechanism 1.1, the scanning mechanism 1.2 and the horizontal detection sensor 1.4 to collect and process information of the components; the power supply unit 1.5 supplies power to the running mechanism 1.1, the scanning mechanism 1.2, the control unit 1.3 and the horizontal detection sensor 1.4;
the main structure of the running mechanism 1.1 in the embodiment comprises a power wheel 1.1.1, a bracket 1.1.2, an auxiliary wheel 1.1.3 and an encoder 1.1.4; the power wheel 1.1.1 is a servo wheel, the running distance can be accurately controlled, the encoder 1.1.4 is arranged in the power wheel 1.1.1, the auxiliary wheel 1.1.3 is horizontally arranged on the front side of the power wheel 1.1.1, the bracket 1.1.2 is of a double-framework side plate 1.1.2.1 structure, and the power wheel 1.1.1 and the auxiliary wheel 1.1.3 are positioned in the middle of the bracket 1.1.2 and are connected with double support plates; the power supply 1.7 and the servo controller 1.8 are arranged in the middle of the side mounting plate 1.1.2.1 of the framework, wherein the servo controller 1.8 is connected with the power wheel 1.1.1 for control;
the main body structure of the scanning mechanism 1.2 comprises a sliding table 1.2.1 and laser 2D/3D sensors 1.2.2, wherein three groups of laser 2D/3D sensors 1.2.2 are arranged between the two double-framework side mounting plates 1.1.2.1 at the front part of the upper part and at the upper part of the sliding table 1.2.1, and the sliding table 1.2.1 can drive the laser 2D/3D sensors 1.2.2 to move longitudinally so as to adjust the angle of the laser 2D/3D sensors;
the main body structure of the control unit 1.3 comprises an industrial personal computer, a GPS positioning module, a 4G module and a wireless communication module which form an integrated package, and the GPS positioning module, the 4G module and the wireless communication module can communicate with a computer;
the main structure of the mounting bracket 2 comprises a bearing frame 2.1, a locking mechanism 2.2 and a reference rod piece 2.3, wherein the bearing frame 2.1 in a plug-in type is in a triangular arrangement structure, two ends of the bearing frame are respectively connected with a framework side mounting plate 1.1.2.1 in a plug-in type, the reference rod piece 2.3 is positioned at the lower side of the bearing frame 2.1 and is connected with a unit bracket 1.1.2 through the locking mechanism 2.2, the main structure of the locking mechanism 2.2 comprises a magnetic concave plate 2.2.1, a top spring 2.2.2 and a base 2.2.3, the magnetic concave plate 2.2.1 is connected with the base 2.2.3 through the top spring 2.2.2 to form an integral locking mechanism, and the base 2.2.3 of the locking mechanism is connected with a unit bracket 1.1.1.2.3 and a side plate of the 1.1.2.1 member; the magnetic concave plate 2.2.1 and the top spring 2.2.2 can realize quick installation, and meanwhile, the installation accuracy and stability are ensured;
the manual operator is a tablet personal computer in the market, and a related program is arranged in the tablet personal computer;
further, the main structure of the bracket 1.1.2 in the embodiment includes two vertically arranged frame side plates 1.1.2.1, a frame stabilizing link 1.1.2.2 for connecting the two frame side plates 1.1.2.1, and a bracket assembly member 1.1.2.3, wherein the frame stabilizing link 1.1.2.2 and the bracket assembly member 1.1.2.3 are both located between and connected to the two frame side plates 1.1.2.1, and the three mounting bracket assembly members 1.1.2.3 are arranged in a triangle manner to ensure the overall installation accuracy and stability of the system and realize quick assembly and disassembly; the bracket fitting member 1.1.2.3 in cooperation with the mounting bracket 2 can enable system equipment introduction errors to be reduced;
further, in this embodiment, the control unit 1.3 and the power supply unit 1.5 are disposed in the detection unit 1 and near the upper portion, where the control unit 1.3 is located at the front side of the power supply unit 1.5, and the temperature and humidity sensor 1.6 is located at the front side of the control unit 1.3, so that the measurement is not blocked and interfered by other components;
the specific operation method of the embodiment is carried out according to the following steps:
step one, self-calibration is carried out
S1, a sliding table 1.2.1, a movable laser 2D/3D sensor 1.2.2 and a horizontal detection sensor 1.4 are rigidly connected, the movable laser 2D/3D sensor 1.2.2 is calibrated, the obtained outline can be compared with a reference outline, and if the obtained outline is matched, the movable laser 2D/3D sensor 1.2.2 is fault-free;
s2, the calibration parts are positioned on the reference rod piece and are rigidly connected, so that the spatial relative position relation between the calibration parts is fixed, the detection unit 1 can obtain the outline spatial coordinates of the reference calibration parts through detection, calculate the relative spatial posture position of the detection unit relative to the calibration parts, and detect the outline spatial coordinates of the rail to be used as a reference object, thereby eliminating and correcting the installation errors caused by rapid installation fit clearance;
s3, mutually verifying the detection result of the horizontal detection sensor 1.4 according to the correction calibration, and correcting the whole system according to the reading of the horizontal detection sensor 1.4;
step two, a specific operation method is as follows:
as shown in fig. 9, reference calibration parts are arranged on the left and right sides of the reference rod piece, the calibration parts are triangular prisms, the straight lines of the protruding edges of the prisms are coplanar, and the straight lines of the protruding edges of the prisms on the left and right sides are parallel and parallel to the straight lines of the protruding edges of the prisms on the left and right sides; the distance between the line 2 and the line 3 is D, and the distance between the parallel lines 1 and the line 4 calibrated at the two ends and the distance between the parallel lines 5 and the line 8 calibrated at the two ends are equal to D1;
s1, forming matrix array by left 3D image scanning coordinates
S2, the horizontal coordinate sensor collects that the inclination angle is alpha 1 around the X axis, the inclination angle is beta 1 around the Y axis, and the horizontal coordinate sensor obtains the rotation coordinate system according to the alpha 1 and the beta 1
S3, dividing A2 n into the following three area coordinate matrix arrays according to x coordinates
A21[ i ] takes the value A2[ n ] (P2.ltoreq.x1 [ n ])
A22 j is a value A2 n (x 1 n is less than or equal to P1)
A23[ k ] is a value A2[ n ] (P1 < x1[ n ] < P2)
S4, at A21[ i ]]In which the resolution in Y-axis direction is 2 times as large as the step Deltay, and n Deltay < Y1[ i ] is searched]Z21[ i ] within Δy (n+1)]The point with the maximum value is obtained to form a new matrix array by the high points in the planeThe matrix array point prism protruding edge is positioned at the point where the straight line 1 passes through;
s5, solving a plane projection straight line of the matrix array B1[ r ] in z=0
Solving a projection equation of a straight line 1 when the projection equation of the plane with z=0 is y=b1x+a1;
s6, obtaining a projection straight line y=b11z+a11 of the B1[ r ] on the x=0 plane according to the method of the step S5;
s7, according to the methods of the step S4 and the step S6, obtaining A22[ j ]]In-plane high-point matrix arrayThe matrix array points the straight line 4 where the convex edge of the prism is located passes through; obtaining a projection equation of the matrix array on a z=0 plane projection straight line y=b2x+a2 and on a x=0 plane projection straight line y=b22z+a22, namely a straight line 4;
s8, obtaining A23[ k ] according to the method of step S4 and step S6]In-plane high-point matrix arrayThe matrix array point prism protruding edge is positioned at the point where the straight line 3 passes through; obtaining a projection equation of the matrix array in a z=0 plane projection straight line y=b3x+a3, and in an x=0 plane projection straight line y=b33z+a33, namely a straight line 3;
s9, if y=b1x+a1 and y=b2x+a2 are not parallel and do not match with the reference profile characteristic attribute, the system cannot pass the self-check, and if the y=b1x+a1 and y=b2x+a2 are parallel, the rotation angle gamma 1 around the Z axis is calculated
γ1＝arccot(b1)；
S10. taking a straight line with equal distance y=b1x+a1 and y=b2x+a2Plane projection equation of the straight line 2 in z=0;
s11 is a straight line with the distance y=b11x+a11 equal to y=b22x+a22The projection equation of the straight line 2 on the x=0 plane;
s12, calculatingThe intersection point with y=b3x+a3 is solved
S13, taking the X1 value in the step S10 into y=b33z+a33 to obtain
S14, comprehensively obtaining left coordinate system correction parameters, wherein the rotation angles around X Y Z are alpha 1, beta 1 and gamma 1, the translation amounts are X1, Y1 and Z1,
s15, according to the method from the step S1 to the step S14, three projection straight lines y=c1x+d1 in the z=0 plane of the projection straight line equation can be obtained by processing the matrix array formed by the right 3D image scanning coordinates, and the projection straight line y=c1z+d11 in the x=0 plane of the projection straight line equation, namely the projection equation of the straight line 5;
projection equation for projection of straight line y=c2x+d2 on z=0 plane and straight line y=c22z+d22 on x=0 plane, i.e. straight line 8; projection equation for projection straight line y=c3x+d3 on z=0 plane and straight line y=c33z+d33 on x=0 plane, i.e. straight line 7; the parallelism self-test of y=b11x+a11 and y=b22x+a22 is performed, and if the parallelism self-test is not performed, the self-test of the unit cannot be performed;
by self-checking, it can be deduced that a straight line is projected on the z=0 planeProjecting a straight line in the x=0 planeThe projection equation of the straight line 6; the right coordinate system correction parameters can be deduced: rotation angles around X Y Z are alpha 11, beta 11 and gamma 11, and translation amounts are X11, Y11 and Z11;
s16. find the distance between y=b1x+a1 and y=b2x+a2
Find y=c1x+d1 to y=c2x+d2 distance
If D1 and e1 are not equal, the deformation of the standard rod piece or the deformation inclination deflection of the mechanical mechanism of the scanning unit is described, the whole system cannot pass the self-test, and if the deformation and the self-test are equal, the offset parallel to X of the center of the left 3D image coordinate system and the center of the right 3D image coordinate system is obtained
S17. find the distance difference between y=b11x+a11 and y=b22x+a22
The difference between the distances y=c11x+d11 and y=c22x+d22 is calculated
If D11 and e11 are not equal, the deformation of the standard rod or the deformation inclination deflection of the mechanical mechanism of the scanning unit is described, the whole system cannot pass the self-test, if the deformation and the self-test are equal, the offset parallel to Z of the center of the left 3D image coordinate system and the center of the right 3D image coordinate system is calculated
In summary, system self-checking and mutual verification are completed, and parameters obtained by the mutual verification are obtained, wherein the rotation angles of the self-calibration parameters X Y Z of the left 3D image are alpha 1, beta 1 and gamma 1, the rotation angles of the self-calibration parameters X Y Z of the right 3D image are alpha 11, beta 11 and gamma 11, the translation quantities X11, Y11 and Z11, and the translation quantities X12 and Z12 of the right 3D image relative to the left 3D image are corrected by the parameters obtained by the complaints, so that the installation errors caused by rapid installation fit clearances are corrected;
step three, rail contour detection:
after the self calibration is completed, the scanning mechanism 1.2 scans the 3D contour of the rail, and registers the test results of each unit according to the calibration results to form an integral detection contour;
s1, track gauge: the edge of the rail profile on one side is taken as a datum line to vertically extend to the edge of the rail on the other side, the length is taken as a track gauge, and the multipoint detection avoids the error caused by the fact that the measuring tool cannot be vertically measured with the rail manually, and the degree of accuracy of the multipoint detection is increased, and meanwhile the parallelism of two rail detection sections can be simultaneously verified;
s2, rail height: calculating rail height by taking the multipoint track gauges and the rail contour edges as datum lines and vertically extending the rail edges to the other side and horizontally obtaining included angles between the rail edges and the ground in the S1;
s3, included angle of track extension: an included angle is obtained by the track extending direction and the ground level;
s4, rail outline: after coordinate correction, the rail profile can be obtained by taking the vertical plane of the rail as a tangent plane, and meanwhile, the horizontal position relation of the rail relative to the ground can be obtained, so that horizontal information is provided for further analysis of rail abrasion;
s5, other steps: the profile space 3D information of the two steel rail detection sections and the ground horizontal relation can further extract data according to the needs;
step four, measuring:
s1, rapidly assembling and detecting a portable modularized self-correcting rail three-dimensional detection system related to the embodiment on site, wherein a manual operator 3 is connected with two detection units 1 in a wireless manner to finish the integral initialization of equipment;
s2, a left unit detection unit 1 and a right unit detection unit 1 respectively control a sliding table 1.2.1 and a front section scanning calibration rod marker of a mobile laser 2D/3D sensor 1.2.2 to obtain a 3D image;
s3, comparing the obtained data with factory calibration reference 3D images on the left side and the right side to judge whether the data are in an error range, deducing which sensor is likely to have faults through mutual verification of the 1.2.2 data of the three laser 2D/3D sensors, and if the fault alarms and exits;
s4, further reading readings of the horizontal detection sensor 1.4 when no fault detection is performed, and respectively correcting a three-dimensional space coordinate system of the unit;
s5, comparing the data of the left and right detection units 1 with the calibration rod data before delivery, judging whether the calibration rod deforms or not, and if the deformation fails, giving an alarm and exiting;
s6, correcting the whole coordinate system according to the calibration rod, establishing a coordinate system based on the ground level as a reference through the factory calibration information of the horizontal detection sensor 1.4, and starting to integrally scan the railway track 3D image;
s7, detecting the current temperature and humidity by using a temperature and humidity sensor 1.6;
s8, identifying characteristic information including the rail, the rail top surface and the rail edge, and further calculating characteristic information including the rail gauge, the rail height, the rail extension angle and the rail profile according to temperature and humidity correction;
s9, the detection unit 1 acquires GPS positioning information and walking encoder walking information, and the control unit 1.3 uploads the information through the 4G module;
s10, automatically walking and moving to the next detection point for detection.
Claims (6)
1. The application method of the portable modularized self-correcting rail three-dimensional detection system is characterized by comprising the following steps of:
step one, self-calibration is carried out
S1, rigidly connecting the sliding table, the movable laser 2D/3D sensor and the horizontal detection sensor, calibrating the component of the movable laser 2D/3D sensor, comparing the obtained contour with a reference contour, and if the obtained contour is matched with the reference contour, indicating that the movable laser 2D/3D sensor has no fault;
s2, the calibration parts are positioned on the reference rod piece and are rigidly connected, so that the spatial relative position relation between the calibration parts is fixed, the detection unit can obtain the outline spatial coordinates of the reference calibration parts through detection, calculate the relative spatial posture position of the detection unit relative to the calibration parts, and detect the outline spatial coordinates of the rail to be used as a reference object, thereby eliminating and correcting the installation error caused by rapid installation fit clearance;
s3, mutually verifying the detection result of the horizontal detection sensor according to the correction calibration, and correcting the whole system according to the reading of the horizontal detection sensor;
step two, a specific operation method is as follows:
the left side and the right side of the reference rod piece are provided with reference calibration parts, the calibration parts are triangular prisms, the straight lines of the protruding edges of the prisms are coplanar, and the straight lines of the protruding edges of the prisms on the left side and the right side are parallel to the straight lines of the protruding edges of the prisms on the left side and the right side; the distance between the line 2 and the line 3 is D, and the distance between the parallel lines 1 and the line 4 calibrated at the two ends and the distance between the parallel lines 5 and the line 8 calibrated at the two ends are equal to D1;
s1, forming matrix array by left 3D image scanning coordinates
S2, the horizontal coordinate sensor collects that the inclination angle is alpha 1 around the X axis, the inclination angle is beta 1 around the Y axis, and the horizontal coordinate sensor obtains the rotation coordinate system according to the alpha 1 and the beta 1
S3, dividing A2 n into the following three area coordinate matrix arrays according to x coordinates
A21[ i ] takes the value A2[ n ] (P2.ltoreq.x1 [ n ])
A22 j is a value A2 n (x 1 n is less than or equal to P1)
A23[ k ] is a value A2[ n ] (P1 < x1[ n ] < P2)
S4, at A21[ i ]]In the method, according to delta Y steps, delta Y is 2 times of resolution in the Y-axis direction, and n delta Y is searched<y1[i]Z21[ i ] within Δy (n+1)]The point with the maximum value is obtained to form a new matrix array by the high points in the planeThe matrix array point prism protruding edge is positioned at the point where the straight line 1 passes through;
s5, solving a plane projection straight line of the matrix array B1[ r ] in z=0
Solving a projection equation of a straight line 1 when the projection equation of the plane with z=0 is y=b1x+a1;
s6, obtaining a projection straight line y=b11z+a11 of the B1[ r ] on the x=0 plane according to the method of the step S5;
s7, according to the methods of the step S4 and the step S6, obtaining A22[ j ]]In-plane high-point matrix arrayThe matrix array points the straight line 4 where the convex edge of the prism is located passes through; obtaining a projection equation of the matrix array on a z=0 plane projection straight line y=b2x+a2 and on a x=0 plane projection straight line y=b22z+a22, namely a straight line 4;
s8, according to the step S4Step S6, obtaining A23[ k ]]In-plane high-point matrix arrayThe matrix array point prism protruding edge is positioned at the point where the straight line 3 passes through; obtaining a projection equation of the matrix array in a z=0 plane projection straight line y=b3x+a3, and in an x=0 plane projection straight line y=b33z+a33, namely a straight line 3;
s9, if y=b1x+a1 and y=b2x+a2 are not parallel and do not match with the reference profile characteristic attribute, the system cannot pass the self-check, and if the y=b1x+a1 and y=b2x+a2 are parallel, the rotation angle gamma 1 around the Z axis is calculated
γ1＝arccot(b1)；
S10. taking a straight line with equal distance y=b1x+a1 and y=b2x+a2Plane projection equation of the straight line 2 in z=0;
s11 is a straight line with the distance y=b11x+a11 equal to y=b22x+a22The projection equation of the straight line 2 on the x=0 plane;
s12, calculatingThe intersection point with y=b3x+a3 is solved
S13, taking the X1 value in the step S10 into y=b33z+a33 to obtain
S14, comprehensively obtaining left coordinate system correction parameters, wherein the rotation angles around X Y Z are alpha 1, beta 1 and gamma 1, the translation amounts are X1, Y1 and Z1,
s15, according to the method from the step S1 to the step S14, three projection straight lines y=c1x+d1 in the z=0 plane of the projection straight line equation can be obtained by processing the matrix array formed by the right 3D image scanning coordinates, and the projection straight line y=c1z+d11 in the x=0 plane of the projection straight line equation, namely the projection equation of the straight line 5;
projection equation for projection of straight line y=c2x+d2 on z=0 plane and straight line y=c22z+d22 on x=0 plane, i.e. straight line 8; projection equation for projection straight line y=c3x+d3 on z=0 plane and straight line y=c33z+d33 on x=0 plane, i.e. straight line 7; the parallelism self-test of y=b11x+a11 and y=b22x+a22 is performed, and if the parallelism self-test is not performed, the self-test of the unit cannot be performed;
by self-checking, it can be deduced that a straight line is projected on the z=0 planeProjecting a straight line in the x=0 planeThe projection equation of the straight line 6; the right coordinate system correction parameters can be deduced: rotation angles around X Y Z are alpha 11, beta 11 and gamma 11, and translation amounts are X11, Y11 and Z11;
s16. find the distance between y=b1x+a1 and y=b2x+a2
Find y=c1x+d1 to y=c2x+d2 distance
If D1 and e1 are not equal, the deformation of the standard rod piece or the deformation inclination deflection of the mechanical mechanism of the scanning unit is described, the whole system cannot pass the self-test, and if the deformation and the self-test are equal, the offset parallel to X of the center of the left 3D image coordinate system and the center of the right 3D image coordinate system is obtained
S17. find the distance difference between y=b11x+a11 and y=b22x+a22
The difference between the distances y=c11x+d11 and y=c22x+d22 is calculated
If D11 and e11 are not equal, the deformation of the standard rod or the deformation inclination deflection of the mechanical mechanism of the scanning unit is described, the whole system cannot pass the self-test, if the deformation and the self-test are equal, the offset parallel to Z of the center of the left 3D image coordinate system and the center of the right 3D image coordinate system is calculated
In summary, the system self-checking and mutual verification are completed, and the left 3D image self-calibration parameters X Y Z rotation angles are alpha 1, beta 1 and gamma 1, translation amounts X1, Y1 and Z1, the right 3D image self-calibration parameters X Y Z rotation angles are alpha 11, beta 11 and gamma 11, translation amounts X11, Y11 and Z11 and the right 3D image relative to the left 3D image translation amounts X12 and Z12 are obtained, so that the installation errors caused by the rapid installation fit clearance are corrected by the obtained parameters;
step three, rail contour detection:
after the self calibration is completed, the scanning mechanism scans the 3D contour of the rail, and the test results of all units are registered according to the calibration results to form an integral detection contour;
s1, track gauge: the edge of the rail profile on one side is taken as a datum line to vertically extend to the edge of the rail on the other side, the length is taken as a track gauge, and the multipoint detection avoids the error caused by the fact that the measuring tool cannot be vertically measured with the rail manually, and the degree of accuracy of the multipoint detection is increased, and meanwhile the parallelism of two rail detection sections can be simultaneously verified;
s2, rail height: calculating rail height by taking the multipoint track gauges and the rail contour edges as datum lines and vertically extending the rail edges to the other side and horizontally obtaining included angles between the rail edges and the ground in the S1;
s3, included angle of track extension: an included angle is obtained by the track extending direction and the ground level;
s4, rail outline: after coordinate correction, the rail profile can be obtained by taking the vertical plane of the rail as a tangent plane, and meanwhile, the horizontal position relation of the rail relative to the ground can be obtained, so that horizontal information is provided for further analysis of rail abrasion;
s5, other steps: the profile space 3D information of the two steel rail detection sections and the ground horizontal relation can further extract data according to the needs;
step four, measuring:
s1, rapidly assembling and detecting a portable modularized self-correcting rail three-dimensional detection system in the field, wherein the manual operator 3 is connected with two detection units in a wireless manner to finish the integral initialization of equipment;
s2, a left unit detection unit and a right unit detection unit respectively control a sliding table and a front section scanning calibration rod marker of a mobile laser 2D/3D sensor to obtain a 3D image;
s3, comparing the obtained data with factory calibration reference 3D images on the left side and the right side to judge whether the data are in an error range, deducing which sensor is likely to have faults through mutual verification of the data of the three laser 2D/3D sensors, and if the faults are reported to the exit;
s4, further reading readings of a horizontal detection sensor when no fault detection is performed, and respectively correcting a three-dimensional space coordinate system of the unit;
s5, comparing the left and right detection unit data with calibration standard rod data before delivery, judging whether the calibration rod deforms or not, and if the deformation fault alarm exits;
s6, correcting the whole coordinate system according to the calibration rod, establishing a coordinate system based on the ground level as a reference through the factory calibration information of the horizontal detection sensor, and starting to integrally scan the railway track 3D image;
s7, detecting the current temperature and humidity by a temperature and humidity sensor;
s8, identifying characteristic information including the rail, the rail top surface and the rail edge, and further calculating characteristic information including the rail gauge, the rail height, the rail extension angle and the rail profile according to temperature and humidity correction;
s9, the detection unit acquires GPS positioning information and walking encoder walking information, and the control unit uploads the information through the 4G module;
s10, automatically walking and moving to the next detection point for detection.
2. The method for using the portable modularized self-correcting rail three-dimensional detection system according to claim 1, wherein the method is realized according to the portable modularized self-correcting rail three-dimensional detection system, the main structure of the system comprises two detection units for detection, a mounting bracket for supporting and connecting and a manual operator, wherein the main structure of the detection unit comprises a running mechanism, a scanning mechanism, a control unit, a horizontal detection sensor, a power supply unit and a temperature and humidity sensor, and the running mechanism is connected with the scanning mechanism to realize running and scanning at the same time; the horizontal detection sensor is arranged on the scanning mechanism; the control unit is communicated with the running mechanism, the scanning mechanism and the horizontal detection sensor to collect and process the information of the components; the power supply unit supplies power to the running mechanism, the scanning mechanism, the control unit and the horizontal detection sensor;
the main structure of the running mechanism comprises a power wheel, a bracket, an auxiliary wheel and an encoder; the power wheel is a servo wheel, the running distance can be accurately controlled, the encoder is arranged in the power wheel, the auxiliary wheel is horizontally arranged on the front side of the power wheel, the support is of a double-framework side mounting plate structure, and the power wheel and the auxiliary wheel are positioned in the middle of the support and are positioned at the lower part of the support and are connected with the double support plates of the support; the power supply and the servo controller are arranged in the middle of the frame side plate, wherein the servo controller is connected with the power wheel for control;
the main structure of the scanning mechanism comprises a sliding table and laser 2D/3D sensors, wherein three groups of laser 2D/3D sensors are arranged at the front part of the upper part between two double-framework side plates and are positioned at the upper part of the sliding table, and the sliding table can drive the laser 2D/3D sensors to longitudinally move so as to adjust the angle of the laser 2D/3D sensors;
the main structure of the control unit comprises an industrial personal computer, a GPS positioning module, a 4G module and a wireless communication module which form integrated package, and the control unit can communicate with a computer through the GPS positioning module, the 4G module and the wireless communication module.
3. The method for using the portable modularized self-correcting rail three-dimensional detection system according to claim 2, wherein the main structure of the mounting bracket comprises a bearing frame, a locking mechanism and a reference rod piece, wherein the bearing frame in a plug-in type is in a triangular arrangement structure, two ends of the bearing frame are respectively connected with a side mounting plate of the framework in a plug-in type, the reference rod piece is positioned at the lower side of the bearing frame and is connected with the unit bracket through the locking mechanism, the main structure of the locking mechanism comprises a magnetic concave plate, a top spring and a base, the magnetic concave plate is connected with the base through the top spring to form an integral locking mechanism, the base of the locking mechanism is connected with the unit bracket, and the base is connected with the side plate of the member; wherein magnetic force concave plate, top spring structure can realize quick installation, guarantee the accuracy and the stability of installation simultaneously.
4. The method of claim 2, wherein the hand-held device is a commercially available tablet computer having associated programs.
5. The use method of the portable modularized self-correcting rail three-dimensional detection system according to claim 2, wherein the main structure of the bracket comprises two vertically arranged frame side plates, a frame stabilizing link rod for connecting the two frame side plates and a bracket assembly member, wherein the frame stabilizing link rod and the bracket assembly member are positioned between and connected with the frame side plates at two sides, and the three mounting bracket assembly members are arranged in a triangular manner so as to ensure the integral mounting precision and stability of the system and realize quick dismounting; the bracket assembly member cooperates with the mounting bracket to enable system equipment introduction errors to be reduced.
6. The method of using a portable modular self-correcting rail three-dimensional inspection system according to claims 2-5, wherein the control unit and the power supply unit are located in the inspection unit and at the upper part, wherein the control unit is located at the front side of the power supply unit, and wherein the temperature and humidity sensor is located at the front side of the control unit, so as to be free from shielding and interference of other components during measurement.
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