CN112254696A - Track slab and detection system and method for flatness of preparation mold of track slab - Google Patents
Track slab and detection system and method for flatness of preparation mold of track slab Download PDFInfo
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Abstract
The invention relates to the field of track slab production and manufacturing, in particular to a track slab and a system and a method for detecting the planeness of a preparation mold of the track slab. The device comprises a truss, a placing plate of a to-be-measured part, a rectangular coordinate robot, a reference calibration flat plate and a sensor assembly, wherein the placing plate of the to-be-measured part, the rectangular coordinate robot, the reference calibration flat plate and the sensor assembly are arranged on the truss; the cartesian robot includes: the robot comprises a robot body, a right-angle triangular block, an X-axis guide rail and a Y-axis guide rail; the robot body is connected with the Y-axis guide rails in a sliding manner, and two X-axis guide rails are arranged on the truss in parallel; two ends of the Y-axis guide rail are connected with the X-axis guide rail in a sliding manner through sliding blocks; the right-angle surface A of the right-angle triangular block is hinged with the bottom of the robot body, and the right-angle surface B of the right-angle triangular block is arranged in parallel with the ground; the reference calibration flat plate is parallel to the right-angle surface B of the right-angle triangular block and is arranged on the truss; the placing plate of the to-be-detected piece is parallel to the reference calibration flat plate; the right-angle triangular block is provided with a sensor assembly. The invention can separate the reference errors of the guide rail operation and the like in the detection process and has high detection precision.
Description
Technical Field
The invention relates to the field of track slab production and manufacturing, in particular to a track slab and a system and a method for detecting the planeness of a preparation mold of the track slab.
Background
In recent years, with the large-scale construction of high-speed railways and intercity railways in China, the production and detection standards of track slabs are greatly developed, wherein the technical indexes of the flatness of the track slabs are directly related to the running safety of railway trains and the riding comfort of passengers, and the flatness of the track slab preparation molds after being pre-tensioned is a main factor for ensuring the flatness of the track slabs, so that the high-precision measurement of the flatness of the track slabs and the preparation molds after being tensioned is important capability guarantee for ensuring the railway construction quality. At present, the requirement of the planeness of the track slab is less than or equal to 1mm, and the requirement of the planeness of the track slab mould is less than or equal to 0.5 mm.
The measurement method for large planes includes direct methods such as a gap method, an optical axis method, and a liquid level method, and indirect methods such as an autocollimator method, but all have a problem of high requirements for a measurement reference plane. The detection system is a typical detection, adjustment and track slab detection system for a CRTS III type track slab mold, which is proposed in southern surveying and mapping, and is used for collecting measurement data by using a high-precision total station with an automatic servo system, a digital level gauge and other tools and calculating deviation by using software. The theoretical measurement precision of the P5600 track plate is about 0.6mm, the repeated precision of test measurement is about 0.2mm, the measurement process is complicated, the detection efficiency is low, and the requirement on the site is high, so that the method cannot well meet the actual measurement requirement.
In recent years, an error separation technology is widely applied to measurement of shape errors, and the principle is that a plurality of sensor measuring heads are adopted, a workpiece is measured on line according to certain arrangement and routing, sampling point data of the sensors are correspondingly processed, a measurement reference error and other errors are separated, and a real shape error of a measured plane is obtained. Based on an error separation technology, a set of simple and efficient plane shape error detection system and a detection method are designed to be the key for solving the problem of high-precision measurement of the plane precision of the track slab and the preparation mold thereof.
Disclosure of Invention
In view of the above problems, the present invention provides a system and a method for detecting the flatness of a track slab and a mold for manufacturing the track slab, so as to realize online detection of flatness errors of the track slab and the mold for manufacturing the track slab.
In order to achieve the purpose, the invention adopts the following technical scheme: a track slab and a detection system for the flatness of a preparation mold thereof comprise a truss, a placing plate of a to-be-detected piece, a rectangular coordinate robot, a reference calibration flat plate and a sensor assembly, wherein the placing plate of the to-be-detected piece, the rectangular coordinate robot, the reference calibration flat plate and the sensor assembly are arranged on the truss;
wherein the cartesian robot comprises: the robot comprises a robot body, a right-angle triangular block, an X-axis guide rail and a Y-axis guide rail; the robot body is connected with the Y-axis guide rails in a sliding mode, and the two X-axis guide rails are arranged on the truss in parallel; two ends of the Y-axis guide rail are connected with the X-axis guide rail in a sliding manner through sliding blocks; the right-angle surface A of the right-angle triangular block is hinged with the bottom of the robot body, the right-angle surface B of the right-angle triangular block is arranged in parallel with the ground, and the robot body can drive the right-angle triangular block to move in an active area formed by the X guide rail and the Y guide rail;
the reference calibration flat plate is parallel to the right-angle surface B of the right-angle triangular block and is arranged on the truss through a support; the placing plate of the to-be-tested piece is parallel to the reference calibration flat plate and is hinged with the bottom surface of the bracket; and a sensor assembly is arranged on the right-angle triangular block.
The sensor assembly comprises a plurality of sensors, and the sensors are distance sensors for detecting height values between the sensors and the track slabs.
The distance sensors are arranged on the side faces of the right-angle triangular blocks, and the distance between the distance measuring heads of any two adjacent distance sensors is the same, so that the scanning step length of each distance sensor is the same as the installation distance.
A track slab and a detection system and a method for flatness of a preparation mold thereof comprise the following steps:
(1) the robot body drives the sensor assembly (4) to move right above the reference calibration plane (3), and the measured heights of all the sensors are adjusted to be the same;
(2) conveying the track board to be tested to a placing board of a piece to be tested;
(3) the robot body drives the sensor assembly (4) to move along a set track, and the initial position X is set for sampling point data measured by the sensor assembly in real time0＝0，Y0Taking the position 0 as a reference point, and performing error separation through an industrial personal computer to obtain an actual sampling value Z of a Z-direction sampling point of the sensor ranging head;
(4) setting the measured plane as a grid-shaped plane with m rows and n columns, setting coordinates (i, j) as measured points on the grid, and then separating errors on the measured plane by the sensor to obtain a sampling value Z, namely Zij(ii) a Establishing a mathematical function between a sampling value of the sensor distance measuring head in the Z direction and an X axis and a Y axis, and converting the mathematical function into a matrix of the sampling value of the distance measuring head in the Z direction;
(5) according to the least square method, estimating the parameter alpha in the matrix to obtain the measured value Z of the measured planeijThe regression value of (a) is corresponding to the evaluation benchmark model; sampling value Z according to sampling point in Z direction of sensor ranging headijCombining the coordinate values of the x axis and the y axis and uploading the coordinate values to an industrial personal computer to obtain a least square plane equation;
(6) fitting the evaluation reference model through a least square plane equation to obtain the positive direction of the data of each sampling point from the least square plane and the distance of the negative direction from the least square plane;
(7) and obtaining the flatness error of the measured plane according to the distance between the positive direction and the negative direction and the least square plane.
In step (3), error separation is performed through an industrial personal computer to obtain a sampling value Z of a Z-direction sampling point of the sensor ranging head, and the method specifically comprises the following steps:
error separation analysis was as follows: setting the values of four sensors A, B, C and D at position i as SAi，SBi，SCi，SDiSetting an initial position X during measurement0＝0，Y0＝0，(X0，Y0) As a reference point in the grid points, byThe position of the movable guide rail scans a workpiece once and simultaneously separates out the linear error of the measured plane and the linear motion error of the guide rail, and the specific errors are separated as follows:
measured plane error XiThe error separation expression of (1) is:
Error of linear motion of guide rail YiThe error separation expression of (1) is:
Wherein, XiIs the difference between the guide rail moving to position i and the initial point; y isiThe difference value of the measured workpiece at the position i and the initial position is obtained; k is the total number of movements of the measuring assembly.
The step (4) specifically comprises the following steps:
1) dividing a measured plane into m rows and n columns of grids with equal sides, and enabling points on the grids to be measured points (i, j), wherein i is 1, 2, …, m; j is 1, 2, …, n; (i, j) represents the current row and column of the measurement;
2) neglecting the initial position deviation of the distance sensor after error separation of the distance sensor, and recording the sampling value of the ith row and the jth column of the sensor on the rectangular grid of the measured surface as Zij；
Neglecting the initial position deviation of the distance sensor after error separation to obtain a sampling value ZijI.e. Y in the linear dimensioniIn the expression in m rows and n columns of two-dimensional space, for two sensors on the same side of a right-angle triangular block, a distance sensor A, a distance sensor B and a sampling value ZijThe relationship of (a) to (b) is as follows:
wherein m and n are respectively the number of rows and columns of the grid, SAijMeasured values for the distance sensor A in the ith row and jth column, SBijThe measured value of the distance sensor B in the ith row and the jth column;
3) taking the height value of the sensor distance measuring head in the Z direction as a dependent variable of a function, and x and y are two independent variables of the function, establishing a mathematical function as follows:
Zij＝AXij+BYij+C (4)
wherein: i is 1, 2, …, m; j is 1, 2, …, n, ZijHeight of each sample point in Z direction from the reference point, XijAnd YijThe X axis and the Y axis respectively correspond to the coordinates of the relative reference points of each sampling point, and A, B and C are constants;
4) converted to a matrix form according to equation (4) as follows:
Z＝Xα(5)
α＝[A,B,C]T；
and (5) estimating a parameter alpha in the matrix according to a least square method to obtain a measured plane value ZijThe evaluation benchmark model corresponding to the regression value is specifically as follows:
estimate the parameter α with least squares: let b0，b1，b2Least squares estimates for parameters a, B, C respectively,
as measured value z of the measured planeijRegression ofThe corresponding assessment benchmark model is then:
the step (5) is that the sampling value Z of the sampling point in the Z direction of the distance measuring head of the sensor is usedijAnd combining the coordinate values of the x axis and the y axis to upload to an industrial personal computer to obtain a least square plane equation, which specifically comprises the following steps:
obtaining Z of each sampling point in the grid according to the error separation formula of the formula (3)ijThe value is uploaded to an industrial personal computer in combination with x and y axis grid coordinate information, and the expression mode of the matrix b is obtained through calculation according to a formula (7) as follows:
the least squares plane equation is then:
in the step (6), the method specifically comprises the following steps:
each sampling point (x)ij,yij,zij) If X, Y, Z in equation (9), the distance from each sample point of the measured plane to the least-squares plane is:
taking the maximum distance d from the least-square plane in the positive directionmax+Minimum distance d of negative direction from least square planemax-。
In the step (7), the flatness error d of the measured plane obtained according to the distance between the positive direction and the negative direction and the least square plane is as follows:
d＝|dmax+|+|dmax-|。
the invention has the following beneficial effects and advantages:
1. the detection equipment and the detection method can separate the reference errors such as guide rail operation and the like in the detection process, and have high detection precision.
2. The detection equipment and the detection method have the advantages of reliable measurement principle, simple equipment structure, low preparation cost and good application prospect.
Drawings
FIG. 1 is a schematic structural diagram of a detecting apparatus according to the present invention;
FIG. 2 is a schematic diagram of data sampling for the detection method of the present invention;
FIG. 3 is a schematic view of the arrangement of the sensor assembly of the present invention;
FIG. 4 is a schematic view of the path of movement of the sensor assembly of the present invention;
in the figure: 1 is the cartesian robot, 2 is the distance sensor subassembly, and 3 are the benchmark and mark the plane, and 4 are distance sensor.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in detail with reference to the accompanying drawings and specific embodiments.
As shown in fig. 1, the embodiment of the detection equipment for the track slab and the mold for manufacturing the track slab provided by the invention comprises a cartesian robot 1, a sensor assembly 4 and a reference calibration flat plate 3, wherein the cartesian robot 1 is installed on the ground, the reference calibration flat plate 3 is fixed after being adjusted, and the distance sensor assembly 4 is composed of at least three distance sensors 5.
The detection method comprises the following steps:
firstly, the distance sensor assembly 4 moves to the reference calibration plane 3 under the driving of the rectangular coordinate robot 1, and single distance sensors are adjusted one by one on the basis of the high-precision reference, so that all sensors in the distance sensor assembly reach the consistent calibration height.
Then the track plate or the preparation mould thereof moves to the working range of the detection system along with the circulation system and keeps a stable body.
Finally, the cartesian robot 1 drives the distance sensor 5 to move along a set track, and the coverage measurement of the plane to be measured is completed; and processing the real-time sampling point data in real time through an industrial personal computer and calculating the error value of the measured point to obtain the flatness error of the workpiece.
As shown in fig. 2 to 3, the layout diagram and the measurement sampling schematic diagram of the sensors in the sensor assembly 5 of the present invention are obtained by installing four sensors with a distance d at the vertex of a square, adjusting the four sensor probes on the same plane, and moving forward by a distance d each time, so that the scanning step length is the same as the installation distance, and at this time, the repeated reading of the two sensors in the motion direction of the guide rail is obtained, and the error of the repeated reading is the reference error of the distance sensor 4 in the motion process, that is, the reference error of the guide rail and the like in the operation process of the cartesian robot 1. And the measurement is performed by analogy, and the shape error of the moving straight line of the measured plane and the linear motion error of the guide rail can be obtained through processing. The specific error separation analysis is as follows: setting the values of four sensors A, B, C and D at position i as SAi，SBi，SCi，SDiThen, the measured plane error and the guide rail linear motion error are separated as follows:
in the formula: xiIs the difference between the guide rail moving to position i and the initial point; y isiThe difference value of the measured workpiece at the position i and the initial point is obtained; k is the total number of movements of the measuring assembly.
Neglecting the initial position deviation of the distance sensor after error separation to obtain a sampling value ZijI.e. Y in the linear dimensioniIn the expression in m rows and n columns of two-dimensional space, for two sensors on the same side of a right-angle triangular block, a distance sensor A, a distance sensor B and a sampling value ZijThe relationship of (a) to (b) is as follows:
during measurement, an initial position X is set0＝0，Y00, i.e. (X)0，Y0) Is a reference point. Therefore, the linear error of the measured plane and the linear motion error of the guide rail can be simultaneously separated by moving the position of the guide rail to scan the workpiece once.
Fig. 4 is a schematic diagram of a trajectory movement path of the present invention, a plane to be measured is divided into m rows and n columns of grids, points on the grids are points to be measured, and (i, j) (i ═ 1, 2, …, m; j ═ 1, 2, …, n) represents a current row and column of measurement. After the distance sensor is calibrated, the initial position deviation of the distance sensor can be ignored, and the sampling value of the ith row and the j column of the sensor on the rectangular grid of the measured surface is recorded as Zij. And (3) evaluating the flatness error by using a least square method to obtain a least square plane as an evaluation reference, taking the height value of the sensor measuring head in the Z direction as a dependent variable of a function, and establishing a mathematical function as follows when x and y are two independent variables of the function:
Zij＝AXij+BYij+C (4)
in the formula: i is 1, 2, …, m; j is 1, 2, …, n, ZijHeight of each sample point in Z direction from the reference point, XijAnd YijThe relative coordinates of the X and Y axes to the sampling points are shown. A, B and C are parameters.
Writing equation (3) in matrix form:
Z＝Xα(5)
α＝[A,B,C]T
estimating the parameter α, b by least squares0，b1，b2Least squares estimation of parameters a, B, C respectively,
as measured value z of the measured planeijThe corresponding evaluation reference plane is:
measuring Z at each node of grid by using formula (2)ijAnd (3) uploading the values combined with the x-axis and y-axis grid coordinate information to an industrial personal computer to calculate to obtain a matrix b, wherein a least square plane equation corresponding to the matrix b is as follows:
the distance from each sampling point of the measured plane to the least square plane is as follows:
each sampling point (x)ij,yij,zij) Taking the maximum distance d from the positive direction to the ideal planemax+Maximum distance d from the ideal plane in the negative directionmax-And finally, calculating the flatness error of the measured plane as follows:
d＝|dmax+|+|dmax-|
the above description is only an embodiment of the present invention, and is not intended to limit the scope of the present invention. Any modification, equivalent replacement, improvement, extension, etc. made within the spirit and principle of the present invention are included in the protection scope of the present invention.
Claims (10)
1. A track slab and a detection system for the flatness of a preparation mold thereof are characterized by comprising a truss (1), a placing plate of a to-be-detected piece arranged on the truss (1), a rectangular coordinate robot (2), a reference calibration flat plate (3) and a sensor assembly (4);
wherein the cartesian robot (2) comprises: the robot comprises a robot body, a right-angle triangular block, an X-axis guide rail and a Y-axis guide rail; the robot body is connected with the Y-axis guide rails in a sliding mode, and the two X-axis guide rails are arranged on the truss in parallel; two ends of the Y-axis guide rail are connected with the X-axis guide rail in a sliding manner through sliding blocks; the right-angle surface A of the right-angle triangular block is hinged with the bottom of the robot body, the right-angle surface B of the right-angle triangular block is arranged in parallel with the ground, and the robot body can drive the right-angle triangular block to move in an active area formed by the X guide rail and the Y guide rail;
the reference calibration flat plate (3) is parallel to a right-angle surface B of the right-angle triangular block and is arranged on the truss (1) through a support; the placing plate of the to-be-measured piece is parallel to the reference calibration flat plate (3) and is hinged with the bottom surface of the bracket; and a sensor assembly (4) is arranged on the right-angle triangular block.
2. The detecting system for detecting the flatness of the track plate and the preparation mold thereof according to claim 1, wherein the sensor assembly comprises a plurality of sensors, and the sensors are distance sensors for detecting the height value between the sensors and the track plate.
3. The detecting system for detecting the planeness of the track slab and the mold for manufacturing the track slab as claimed in claim 2, wherein the distance sensors are installed on the side of the right-angled triangle block, and the distance between the distance measuring heads of any two adjacent distance sensors is the same, so that the scanning step length of the distance sensors is the same as the installation distance.
4. A track slab and a detection system and a method for flatness of a preparation mold thereof are characterized by comprising the following steps:
(1) the robot body drives the sensor assembly (4) to move right above the reference calibration plane (3), and the measured heights of all the sensors are adjusted to be the same;
(2) conveying the track board to be tested to a placing board of a piece to be tested;
(3) the robot body drives the sensor assembly (4) to move along a set track, and the initial position X is set for sampling point data measured by the sensor assembly in real time0＝0，Y0Taking the position 0 as a reference point, and performing error separation through an industrial personal computer to obtain an actual sampling value Z of a Z-direction sampling point of the sensor ranging head;
(4) setting the measured plane as a grid-shaped plane with m rows and n columns, setting coordinates (i, j) as measured points on the grid, and then separating errors on the measured plane by the sensor to obtain a sampling value Z, namely Zij(ii) a Establishing a mathematical function between a sampling value of the sensor distance measuring head in the Z direction and an X axis and a Y axis, and converting the mathematical function into a matrix of the sampling value of the distance measuring head in the Z direction;
(5) according to the least square method, estimating the parameter alpha in the matrix to obtain the measured value Z of the measured planeijThe regression value of (a) is corresponding to the evaluation benchmark model; sampling value Z according to sampling point in Z direction of sensor ranging headijCombining the coordinate values of the x axis and the y axis and uploading the coordinate values to an industrial personal computer to obtain a least square plane equation;
(6) fitting the evaluation reference model through a least square plane equation to obtain the positive direction of the data of each sampling point from the least square plane and the distance of the negative direction from the least square plane;
(7) and obtaining the flatness error of the measured plane according to the distance between the positive direction and the negative direction and the least square plane.
5. The track slab and the detection method for the flatness of the manufacturing mold thereof according to claim 4, wherein in the step (3), the error separation is performed through an industrial personal computer to obtain a sampling value Z of a Z-direction sampling point of the distance measuring head of the sensor, and the method specifically comprises the following steps:
error separation analysis was as follows: setting the values of four sensors A, B, C and D at position i as SAi，SBi，SCi，SDiWhen measuringSetting an initial position X0＝0，Y0＝0，(X0，Y0) The method is characterized in that a reference point in grid points is used as a reference point, a workpiece is scanned once by moving the position of a guide rail, and a measured plane linear error and a guide rail linear motion error are separated simultaneously, wherein the specific errors are separated as follows:
measured plane error XiThe error separation expression of (1) is:
error of linear motion of guide rail YiThe error separation expression of (1) is:
wherein, XiIs the difference between the guide rail moving to position i and the initial point; y isiThe difference value of the measured workpiece at the position i and the initial position is obtained; k is the total number of movements of the measuring assembly.
6. The method for detecting the flatness of the track plate and the mold for manufacturing the track plate according to claim 4, wherein the step (4) specifically comprises the following steps:
1) dividing a plane to be measured into m rows and n columns of grids with equal sides, and enabling points on the grids to be measured points (i, j), wherein i is 1, 2, the. j is 1, 2,. n; (i, j) represents the current row and column of the measurement;
2) neglecting the initial position deviation of the distance sensor after error separation of the distance sensor, and recording the sampling value of the ith row and the jth column of the sensor on the rectangular grid of the measured surface as Zij；
Neglecting the initial position deviation of the distance sensor after error separation to obtain a sampling value ZijI.e. Y in the linear dimensioniIn the expression of m rows and n columns in two-dimensional space, for two sensors on the same side of a right-angle triangular block, a distance sensor A and a distanceSensor B and sampling value ZijThe relationship of (a) to (b) is as follows:
wherein m and n are respectively the number of rows and columns of the grid, SAijMeasured values for the distance sensor A in the ith row and jth column, SBijThe measured value of the distance sensor B in the ith row and the jth column;
3) taking the height value of the sensor distance measuring head in the Z direction as a dependent variable of a function, and x and y are two independent variables of the function, establishing a mathematical function as follows:
Zij＝AXij+BYij+C (4)
wherein: 1, 2,. m; j is 1, 2, n, ZijHeight of each sample point in Z direction from the reference point, XijAnd YijThe X axis and the Y axis respectively correspond to the coordinates of the relative reference points of each sampling point, and A, B and C are constants;
4) converted to a matrix form according to equation (4) as follows:
Z＝Xα (5)
α＝[A，B，C]T；
7. the method for detecting the flatness of the track slab and the mold for manufacturing the track slab according to claim 4, wherein in the step (5), the parameter α in the matrix is estimated according to the least square method to obtain the measured plane ZijThe evaluation benchmark model corresponding to the regression value is specifically as follows:
estimating the parameter α with least squares: let b0，b1，b2Least squares estimates for parameters a, B, C respectively,
as measured value z of the measured planeijThe corresponding evaluation benchmark model is:
8. the track plate and the method for detecting the flatness of the manufacturing mold thereof according to claim 4, wherein in the step (5), the sampling value Z according to the Z-direction sampling point of the distance measuring head of the sensor is obtainedijAnd combining the coordinate values of the x axis and the y axis to upload to an industrial personal computer to obtain a least square plane equation, which specifically comprises the following steps:
obtaining Z of each sampling point in the grid according to the error separation formula of the formula (3)ijThe value is uploaded to an industrial personal computer in combination with x and y axis grid coordinate information, and the expression mode of the matrix b is obtained through calculation according to a formula (7) as follows:
the least squares plane equation is then:
9. the method for detecting the flatness of the track plate and the mold for manufacturing the track plate according to claim 4, wherein in the step (6), the method specifically comprises the following steps:
each sampling point (x)ij，yij，zij) X, Y, Z in equation (9), the distance between each sampling point of the measured plane and the least square plane is obtainedComprises the following steps:
taking the maximum distance d from the least-square plane in the positive directionmax+Minimum distance d of negative direction from least square planemax-。
10. The method for detecting the flatness of the track plate and the mold for manufacturing the track plate according to claim 4, wherein in the step (7), the flatness error d of the measured plane according to the distance between the positive direction and the negative direction and the least square plane is as follows:
d＝|dmax+|+|dmax-|。
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117053687A (en) * | 2023-08-17 | 2023-11-14 | 广州市西克传感器有限公司 | Cell height level difference detection method based on laser line scanning 3D camera |
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