CN112033299A - Intelligent profile on-line detection system for steel rail - Google Patents
Intelligent profile on-line detection system for steel rail Download PDFInfo
- Publication number
- CN112033299A CN112033299A CN202010724385.1A CN202010724385A CN112033299A CN 112033299 A CN112033299 A CN 112033299A CN 202010724385 A CN202010724385 A CN 202010724385A CN 112033299 A CN112033299 A CN 112033299A
- Authority
- CN
- China
- Prior art keywords
- steel rail
- data
- profile
- detection system
- processing module
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Images
Classifications
-
- G—PHYSICS
- 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
Abstract
The invention discloses an intelligent steel rail profile online detection system, which is characterized in that profile sensors in an internal data acquisition module are used for acquiring three-dimensional multipoint data of steel rail profile; processing the data acquired by the data acquisition module through the internal signal acquisition and processing module to obtain and process the original data of the steel rail profile acquired by the profile sensor; the external signal acquisition and processing module is used for acquiring an initial signal of a steel rail entering the data acquisition module, a tachometer wheel encoder signal and other equipment signals on a steel rail production line, so that the safety interlocking between the intelligent profile on-line detection system of the steel rail and other equipment on the production line is realized; and the display of the steel rail outline dimension data, the alarm prompt and the viewing of historical data are realized through a man-machine interaction module. The invention can completely replace manual detection, and realizes the automation and the intellectualization of the detection.
Description
Technical Field
The invention belongs to the technical field of photoelectric detection, and particularly relates to an intelligent steel rail profile online detection system.
Background
At present, in the transportation system of China, railway transportation occupies an important position and bears most of the transportation volume of road transportation tasks of China. Rails are the main components of railway transportation systems, which are used to guide rolling stock forward while withstanding the tremendous stresses of the wheels. Along with the development of railway technology, the quality of the steel rail is more and more emphasized, and whether the parameters such as the appearance size of the steel rail meet the standards or not influences the safety, the stability, the comfort level and the speed of railway operation, so that the appearance geometric dimension of the steel rail is strictly controlled, relevant profile detection is carried out when the steel rail leaves a factory, and the problem that the steel rail is put into use is avoided. The manual detection method is a main detection means of various large steel rail, turnout and welded rail manufacturers at present. The method depends on the examination of experienced workers by adopting a template ruler, the detection personnel can go on duty only through professional training, and the defects of high labor intensity, low detection efficiency and the like exist in the detection; most importantly, the method has difficulty in measuring the total length of the steel rail, cannot quantitatively give a profile curve corresponding to a measuring position, is difficult to realize digital storage, cannot provide data support for the promotion of a subsequent steel rail production technology, and cannot meet the development requirement of efficient operation of railways.
Disclosure of Invention
Aiming at the problems, the invention provides an intelligent steel rail profile online detection system which can completely replace manual detection and realize automation and intellectualization of detection.
The invention relates to an intelligent steel rail profile online detection system, which collects three-dimensional multipoint data of steel rail profile through a profile sensor in an internal data collection module. And processing the data acquired by the data acquisition module through the internal signal acquisition and processing module to obtain and process the original data of the steel rail profile acquired by the profile sensor. The initial signal of the steel rail entering the data acquisition module, the signal of the tachometer wheel encoder and the signal of other equipment on the steel rail production line are acquired through the external signal acquisition and processing module, so that the safety interlocking between the intelligent profile on-line detection system of the steel rail and other equipment on the production line is realized. And the display of the steel rail outline dimension data, the alarm prompt and the viewing of historical data are realized through a man-machine interaction module.
The invention has the advantages that:
1. the intelligent steel rail profile on-line detection system can be installed on a steel rail production line, can quickly and accurately detect the steel rail profile automatically through the profile sensor, can completely replace manual detection, has the functions of real-time data processing and human-computer interaction, and realizes the automation and the intellectualization of detection.
2. According to the intelligent steel rail profile online detection system, various data reports can be finally formed according to the detection result, data reference is provided for actual production, and the production process of the steel rail is corrected in time.
Drawings
FIG. 1 is a block diagram of the structure of the intelligent steel rail profile on-line detection system.
FIG. 2 is a schematic view of a sensor mounting structure in the steel rail intelligent profile on-line detection system of the present invention.
In the figure:
1-data acquisition module 2-internal signal acquisition processing module 3-external signal acquisition processing module
4-human-computer interaction module 5-network switch 101-profile sensor
102-mechanical structure frame 201-angle correction unit 202-data reconstruction unit
203-mass analysis unit 301-PLC Power supply 302-CPU
303-digital input 304-encoder input unit 305-ethernet communication unit
Go out unit
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings.
The invention provides an intelligent steel rail profile online detection system which comprises a data acquisition module 1, an internal signal acquisition processing module 2, an external signal acquisition processing module 3, a man-machine interaction module 4 and a network switch 5, and is shown in figure 1.
The data acquisition module 1 is used for acquiring three-dimensional multipoint data of the steel rail profile, and comprises a profile sensor 101 and a mechanical structure frame 102.
As shown in fig. 2, the mechanical structure frame 102 is a rectangular frame structure, and the middle part is used for steel rails to pass through. The profile sensors 101 are installed on the circumferential direction of the mechanical structure frame 102 by adopting a laser ranging principle, the specific installation number and the installation positions are determined according to the steel rail production working condition, the use environment, the measurement precision and the installation distance requirements, so that the detection visual fields of the profile sensors 101 are in the same plane, and the movement direction of the steel rail is perpendicular to the plane of the annular closed visual field.
Each profile sensor 101 can only detect a part of profile data of the section of the steel rail due to the vision range, so after the plurality of profile sensors 101 are installed, the vision of all the profile sensors 101 is ensured to cover the whole profile of the section of the steel rail, and a multi-sensor annular closed vision for non-contact measurement is formed. And then the complete original profile data acquisition of the steel rail is realized through a plurality of profile sensors 101. Because the detection data volume of the steel rail profile is large, the data acquisition of all the steel rails cannot be realized, and therefore, the invention sets each profile sensor 101 to perform interval sampling in an equidistant mode through the steel rail production running speed signal, and realizes efficient and reliable measurement. Each profile sensor 101 is connected with an external power supply through a sensor power supply cable to realize power supply of the profile sensor 101, and is connected with the internal signal acquisition processing module 5 through an Ethernet communication cable to realize data exchange between the data acquisition module 101 and the internal signal acquisition processing module 5.
The internal signal acquisition processing module 2 is developed based on Csharp, adopts a multi-thread mode, and is connected with the human-computer interaction unit 4 developed by Csharp through a network switch 5 (kilomega) to realize data communication between the internal signal acquisition processing module and the human-computer interaction unit. The internal data acquisition processing module 2 includes an angle correction unit 201, a data reconstruction unit 202, and a quality analysis unit 203.
The angle correction unit is developed based on Csharp software, and is communicated with the internal data acquisition and processing module 2 among processes by adopting a memory read-write function, and is used for processing the steel rail outline original data acquired by the outline sensors 101. Because the data acquired by each contour sensor 101 is in its own coordinate system, the angle correction algorithm unit 2 realizes data fitting under the multi-coordinate system of the plurality of contour sensors 101, and the angle correction algorithm based on coordinate transformation realizes high-precision data registration under the multi-coordinate system, and the specific method is as follows:
A. and performing Gaussian filtering processing on the acquired steel rail contour raw data detected by each contour sensor 101.
B. And D, converting the gray value of the data processed in the step A to obtain a coordinate data form.
C. The coordinate data is divided.
D. And carrying out rigid transformation on the segmented data to obtain coarse configuration data.
E. And (3) realizing high-precision registration of the complete profile of the steel rail by adopting a least square method (ICP), and realizing the establishment of a data model of the complete profile of the section of the steel rail for extracting the characteristic points.
The data reconstruction unit 3 is developed based on Csharp software, based on a steel rail section full-contour data model established by an angle correction algorithm unit, steel rail characteristic points are extracted according to railway standards (TB/T2344, TB/3276, TB3109) and the like, corresponding dimension measurement (steel rail height, steel rail bottom edge width, steel rail waist thickness and the like) is carried out, measurement data are displayed on the human-computer interaction module 4, the measurement data and the steel rail section full-contour data model are stored, and the steel rail section full-contour data model is converted into a CAD drawing to be stored. Due to the fact that vibration deviation conditions (X axis, Y axis and rotation) exist in the steel rail production motion process, a characteristic curve is selected through a steel rail section full-profile data model, the X axis, the Y axis and the rotation deviation caused by vibration are analyzed according to the characteristic curve, regression compensation is conducted on the measured data, and the detection precision of the intelligent steel rail profile on-line detection device is improved.
The quality analysis unit 203 performs profile difference calculation by using the size measurement data after regression compensation and corresponding standard steel rail section reference data in the standard steel rail profile model according to a standard steel rail profile model generated by a steel rail finished product judgment standard (TB/T2344, TB/3276, TB3109 and the like) based on csharp development, and performs quality judgment according to a calculation result. And finally displaying the judgment result in a man-machine interaction unit, and storing the final contour difference calculation data in a data storage mode.
The external signal acquisition and processing module 3 is composed of a series of PLCs (or other types of PLCs) of S7-400 of SIEMENS company, and comprises a PLC power supply 301, a CPU302, a digital quantity input and output unit 303, an encoder input unit 304 and an Ethernet communication unit 305.
The PLC power supply 301 is used for connecting an external power supply, and provides power support for the external signal acquisition and processing module 3, and the voltage is 220V AC.
The CPU302, the digital input/output unit 303, the encoder input unit 304, and the ethernet communication unit 305 are mounted on the PLC frame. The digital quantity input/output unit 303 is used for acquiring an initial signal when the steel rail enters the profile detection device (namely, when the steel rail reaches the data acquisition module 1); the encoder input unit 304 is used for reading encoder signals on the speed measuring wheel, and further acquiring the production running speed of the steel rail. The ethernet communication unit 305 is connected to other devices on the steel rail production line, so as to implement data communication between the external signal acquisition and processing module 3 and other devices on the steel rail production line, and implement network communication between the external signal acquisition and processing module and the human-computer interaction module 4 through the network switch 5. The CPU302 is configured to process the acquired signals, and includes: 1) judging the actual running condition (running direction and running speed) of the steel rail production line; 2) judging whether the steel rail enters a detection position or not according to a photoelectric detection switch in the profile detection equipment; 3) raising the speed measuring wheel to a working position (the speed measuring wheel is normally in a standby position; the speed measuring wheel is contacted with the lower surface of the steel rail, and the steel rail runs to drive the speed measuring wheel to move, so that the running speed of the steel rail is detected; 4) setting the acquisition frequency of the profile sensor according to the running direction, the running speed and whether the detection position is reached, and starting an equidistant mode to acquire an image; 5) after the steel rail passes through the profile detection device, returning the speed measuring wheel to the original position; the collected signals comprise initial signals of the steel rail entering the profile detection device, signals of a speed measuring wheel encoder and signals of other devices on the steel rail production line, so that the intelligent steel rail profile on-line detection system and the other devices on the production line are safely interlocked, and unnecessary loss caused by mechanical collision between the intelligent steel rail profile on-line detection system and the steel rail running at high speed in a maintenance or fault state is avoided. The data exchange among the modules adopts a memory read-write function to realize the inter-process communication.
The human-computer interaction module 4 is used for displaying the steel rail outline size data, giving an alarm and checking historical data; and the angle correction unit 201, the data reconstruction unit 202 and the quality analysis unit 203 adopt OPC communication to realize data exchange, and the external signal acquisition and processing module adopts TCP/IP to realize data exchange. The invention adopts a human-computer interaction interface, has good interactivity, has different functions realized by a plurality of HMI graphs, can realize the display of the outline size data of the steel rail and the display of the related equipment and the environmental temperature of the steel rail production line, and sets an alarm prompting function, a user authority setting function, a historical data recording function, a historical data viewing function and the like aiming at the key outline size data.
Claims (10)
1. The utility model provides an intelligent profile on-line measuring system of rail which characterized in that: acquiring three-dimensional multipoint data of the steel rail profile by a profile sensor in an internal data acquisition module; processing the data acquired by the data acquisition module through the internal signal acquisition and processing module to obtain and process the original data of the steel rail profile acquired by the profile sensor; the external signal acquisition and processing module is used for acquiring an initial signal of a steel rail entering the data acquisition module, a tachometer wheel encoder signal and other equipment signals on a steel rail production line, so that the safety interlocking between the intelligent profile on-line detection system of the steel rail and other equipment on the production line is realized; and the display of the steel rail outline dimension data, the alarm prompt and the viewing of historical data are realized through a man-machine interaction module.
2. The steel rail intelligent profile on-line detection system of claim 1, characterized in that: the contour sensor adopts a laser ranging principle and is arranged in the circumferential direction of the mechanical structure frame; the middle part of the mechanical structure frame is used for steel rails to pass through; the profile sensors enable detection visual fields of the plurality of profile sensors to be in the same plane, the visual fields cover the whole rail section profile of the steel rail, a multi-sensor annular closed visual field for non-contact measurement is formed, and the moving direction of the steel rail is perpendicular to the plane of the annular closed visual field.
3. The steel rail intelligent profile on-line detection system of claim 2, characterized in that: the profile sensor is sampled at intervals in an equidistant pattern.
4. The steel rail intelligent profile on-line detection system of claim 1, characterized in that: the internal data acquisition and processing module comprises an angle correction unit, a data reconstruction unit and a quality analysis unit;
the angle correction unit is used for data fitting under a multi-coordinate system of the contour sensor, and high-precision data registration under the multi-coordinate system is realized through an angle correction algorithm based on coordinate transformation;
the data reconstruction unit is used for establishing a steel rail section full-profile data model, extracting steel rail characteristic points and measuring the size of the steel rail;
and the quality analysis unit is used for generating a standard steel rail profile model and carrying out profile difference calculation on the standard steel rail profile model and the measured steel rail size data to obtain profile difference data.
5. The steel rail intelligent profile on-line detection system of claim 4, characterized in that: the angle correction unit and the internal data acquisition and processing module adopt a memory read-write function to realize inter-process communication.
6. The steel rail intelligent profile on-line detection system of claim 4, characterized in that: the angle correction algorithm based on coordinate transformation is as follows:
A. performing Gaussian filtering processing on the acquired steel rail contour original data detected by each contour sensor;
B. b, converting the gray value of the data processed in the step A to obtain a coordinate data form;
C. dividing the coordinate data;
D. carrying out rigid transformation on the segmented data to obtain coarse configuration data;
E. and high-precision registration of the complete profile of the steel rail is realized by adopting a least square method, and the establishment of a full-profile data model of the section of the steel rail is realized for characteristic point extraction.
7. The steel rail intelligent profile on-line detection system of claim 4, characterized in that: the data reconstruction unit also selects a characteristic curve from the steel rail section full-profile data model, analyzes X-axis, Y-axis and rotation deviation caused by vibration according to the characteristic curve, and performs regression compensation on the steel rail size measurement data.
8. The steel rail intelligent profile on-line detection system of claim 8, characterized in that: the external signal acquisition and processing module comprises a PLC power supply, a CPU, a digital quantity input and output unit, an encoder input unit and an Ethernet communication unit;
the PLC power supply is used for providing power support for the external signal acquisition and processing module; the digital quantity input and output unit is used for acquiring initial signals when the steel rail enters the internal data acquisition module; the encoder input unit is used for reading a tachometer wheel encoder signal; the Ethernet communication unit realizes data communication between the external signal acquisition and processing module and other equipment on the steel rail production line; CPU is used for processing the collected signals
9. The steel rail intelligent profile on-line detection system of claim 1, characterized in that: the internal signal acquisition processing module and the external signal acquisition and processing module realize network communication with the human-computer interaction module through a network switch.
10. The steel rail intelligent profile on-line detection system of claim 1, characterized in that: and the human-computer interaction module and the internal signal acquisition and processing module adopt OPC communication, and the human-computer interaction module and the external signal acquisition and processing module adopt TCP/IP to realize data exchange.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010724385.1A CN112033299A (en) | 2020-07-24 | 2020-07-24 | Intelligent profile on-line detection system for steel rail |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010724385.1A CN112033299A (en) | 2020-07-24 | 2020-07-24 | Intelligent profile on-line detection system for steel rail |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN112033299A true CN112033299A (en) | 2020-12-04 |
Family
ID=73583130
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202010724385.1A Pending CN112033299A (en) | 2020-07-24 | 2020-07-24 | Intelligent profile on-line detection system for steel rail |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN112033299A (en) |
Citations (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH08261742A (en) * | 1995-03-27 | 1996-10-11 | Nippon Steel Corp | Measuring method for the shape of rail for railway |
| CN103759695A (en) * | 2013-12-27 | 2014-04-30 | 中国铁道科学研究院金属及化学研究所 | Detecting device and method for automatically measuring outline of steel rail |
| JP2014199208A (en) * | 2013-03-29 | 2014-10-23 | 株式会社日立ハイテクノロジーズ | Track inspection method and device |
| CN204405018U (en) * | 2014-12-19 | 2015-06-17 | 合肥市百胜科技发展股份有限公司 | Online contour outline measuring set |
| CN106441091A (en) * | 2016-08-31 | 2017-02-22 | 武汉汉宁轨道交通技术有限公司 | Steel rail automatic detection device and method |
| CN106840033A (en) * | 2017-03-13 | 2017-06-13 | 武汉理工大学 | A kind of profile of steel rail detection means and method based on image procossing |
| CN107632022A (en) * | 2017-08-30 | 2018-01-26 | 武汉理工大学 | A kind of detection method of surface flaw of steel rail and device based on data processing |
| CN108248634A (en) * | 2018-01-24 | 2018-07-06 | 西南交通大学 | Track switch and track full-sized abrasion vision measurer and its measuring method |
| CN110954026A (en) * | 2019-11-19 | 2020-04-03 | 上海理工大学 | On-line detection device for measuring geometric profile of steel rail |
-
2020
- 2020-07-24 CN CN202010724385.1A patent/CN112033299A/en active Pending
Patent Citations (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH08261742A (en) * | 1995-03-27 | 1996-10-11 | Nippon Steel Corp | Measuring method for the shape of rail for railway |
| JP2014199208A (en) * | 2013-03-29 | 2014-10-23 | 株式会社日立ハイテクノロジーズ | Track inspection method and device |
| CN103759695A (en) * | 2013-12-27 | 2014-04-30 | 中国铁道科学研究院金属及化学研究所 | Detecting device and method for automatically measuring outline of steel rail |
| CN204405018U (en) * | 2014-12-19 | 2015-06-17 | 合肥市百胜科技发展股份有限公司 | Online contour outline measuring set |
| CN106441091A (en) * | 2016-08-31 | 2017-02-22 | 武汉汉宁轨道交通技术有限公司 | Steel rail automatic detection device and method |
| CN106840033A (en) * | 2017-03-13 | 2017-06-13 | 武汉理工大学 | A kind of profile of steel rail detection means and method based on image procossing |
| CN107632022A (en) * | 2017-08-30 | 2018-01-26 | 武汉理工大学 | A kind of detection method of surface flaw of steel rail and device based on data processing |
| CN108248634A (en) * | 2018-01-24 | 2018-07-06 | 西南交通大学 | Track switch and track full-sized abrasion vision measurer and its measuring method |
| CN110954026A (en) * | 2019-11-19 | 2020-04-03 | 上海理工大学 | On-line detection device for measuring geometric profile of steel rail |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN106370106A (en) | Industrial robot and linear guide rail-combined linear laser scanning measurement system and method | |
| CN107421445A (en) | A kind of device and method for detecting the elastic state of rail fastener | |
| CN109708615A (en) | A kind of subway tunnel limit dynamic testing method based on laser scanning | |
| WO2023045299A1 (en) | Road surface technical condition detection method and device based on three-dimensional contour | |
| CN105588514A (en) | T-shaped elevator guide rail mortise and tenon automatic detection system | |
| CN111014605B (en) | Online real-time measurement system and calculation method for width and length of casting blank | |
| CN112033299A (en) | Intelligent profile on-line detection system for steel rail | |
| CN211504076U (en) | Detection system for ovality of roller belt of centrifugal nodular cast iron pipe | |
| CN113320924A (en) | Belt longitudinal tearing detection device based on single line laser radar | |
| CN102980536B (en) | Brake block steel back flatness detection system and method | |
| CN103699089A (en) | Process control system and method | |
| CN115503788B (en) | Ballast track bed section scanning detection system | |
| CN112974753B (en) | Online measurement and adjustment method for casting blank scalping amount of flame cleaning machine | |
| CN102398006A (en) | Device and method for detecting speed of continuous casting blank | |
| CN213517195U (en) | High-precision calibrating system for full-automatic multifunctional flow velocity meter water depth meter | |
| CN209623637U (en) | A kind of contactless conductor rail track geometry detection device | |
| CN112763006A (en) | Rail-mounted movable multifunctional integrated detection device and method | |
| CN113776440A (en) | Machine vision-based billet width online detection method and system | |
| Li et al. | Research and application of online quality detection system based on 3D vision in rectangular steel production line | |
| CN202814356U (en) | Quartz crucible profile dimension detection apparatus | |
| CN204159809U (en) | A kind of on-line monitoring system be shaped for steel ball cold heading | |
| CN104308060B (en) | A kind of method for supervising of the on-line monitoring system for steel ball cold heading shaping | |
| CN107966994B (en) | A kind of large-scale hydraulic door machine automatic station-keeping system and method based on machine vision | |
| CN115430814A (en) | Method for judging and early warning of continuous casting machine state | |
| CN214039890U (en) | Automatic detection device for wind power blade forming die |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| RJ01 | Rejection of invention patent application after publication |
Application publication date: 20201204 |
|
| RJ01 | Rejection of invention patent application after publication |