CN112880586A - Dynamic detection method and system for steel rail profile - Google Patents
Dynamic detection method and system for steel rail profile Download PDFInfo
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- CN112880586A CN112880586A CN202110024179.4A CN202110024179A CN112880586A CN 112880586 A CN112880586 A CN 112880586A CN 202110024179 A CN202110024179 A CN 202110024179A CN 112880586 A CN112880586 A CN 112880586A
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- 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 belongs to the technical field of steel detection equipment, and discloses a dynamic detection method for a steel rail profile, wherein an image acquisition unit acquires information of the end part of a steel rail to generate end part data; the image acquisition unit acquires body information between two ends of the steel rail to generate body data; transmitting the end data and the body data to a data processing unit, and analyzing and calculating the end data and the body data by the data processing unit to obtain actual data; the data processing unit is provided with standard data of steel, and the data processing unit compares the actual data with the standard data to obtain result data. The invention overcomes the result contingency brought by the current manual detection; and the detection is prevented from being easily influenced by external shaking, and the detection precision is guaranteed. The invention also discloses a dynamic detection system for the profile of the steel rail.
Description
Technical Field
The invention belongs to the technical field of steel detection equipment, and particularly relates to a dynamic detection method and system for a steel rail profile.
Background
With the continuous development of high-speed and heavy-duty railways, jointless tracks are widely accepted due to high stability and reliability. The rail welding technology, which is one of the key technologies of the seamless track, has an important influence on the development of the seamless track.
The pre-welding inspection of the steel rail is a necessary prerequisite for steel rail welding, and comprises the inspection of the steel rail pattern size, the steel rail end flatness, the distortion and the end face inclination of the front end and the rear end of the steel rail, and the surface quality of the full-length steel rail. At present, the detection of the outline dimension of the steel rail on each welding rail foundation welding production line in China mainly depends on manual detection of key parameters by adopting some portable detection instruments, and the detection of the surface mainly depends on human eyes to finish the detection. The operation mode is easy to be influenced by people, the detection result has certain contingency, and meanwhile, the detection is carried out by a portable instrument, the detection result needs to be input into a system manually, so that the detection efficiency is not high.
At present, a steel rail high-precision measuring instrument developed abroad is mainly used for cold treatment and/or detection after heat treatment in the steel rail production process, integrates a high-precision 2D camera and a high-precision 3D camera, and is expensive and not suitable for rail types in China; in order to adapt to the national conditions, the steel rail online detection prototype based on the line structured light sensor or the point laser sensor is developed in China, and the prototype has strict requirements on the vibration of the steel rail, the detection accuracy cannot be guaranteed, and meanwhile, the end face inclination cannot be effectively detected.
Disclosure of Invention
In order to solve the problems, the invention discloses a dynamic detection method for the profile of a steel rail, which overcomes the result contingency brought by the current manual detection; compared with the prototype detection, the method avoids the detection being easily affected by external shaking and ensures the detection precision. The invention also discloses a detection system using the method, so that the dynamic detection method of the steel rail profile can realize detection more conveniently. The specific technical scheme of the invention is as follows:
the dynamic detection method for the steel rail profile comprises the following steps:
conveying the steel rail to be detected into a detection area of a detection system;
the image acquisition unit acquires information of the end part of the steel rail and generates end part data;
the image acquisition unit acquires information of a body part between two ends of the steel rail to generate body part data;
transmitting the end data and the body data to a data processing unit, and analyzing and calculating the end data and the body data by the data processing unit to obtain actual data;
the data processing unit is provided with standard data of steel, and the data processing unit compares the actual data with the standard data to obtain result data.
Preferably, the end data includes header data; the step of acquiring the header data comprises:
the image acquisition unit acquires data to obtain header data.
Preferably, the acquiring of the body data includes:
the data processing unit obtains header data;
and the image acquisition unit acquires data to obtain body data.
Preferably, the tip data further includes tail data; the acquiring step of the tail data comprises the following steps:
the data processing unit obtains body data;
and finally, the image acquisition unit acquires data to obtain tail data.
Dynamic detection system of rail profile shape includes:
the transmission mechanism is used for transmitting the steel rail to be detected;
the first scanning mechanism is fixedly arranged and used for panoramic scanning;
the travelling frame is provided with a second scanning mechanism which moves along the length direction of the track and is used for linear scanning; and
and the data processing equipment is respectively and electrically connected with the first scanning mechanism and the second scanning mechanism.
The invention realizes the image scanning of the steel to be detected through the first scanning mechanism and the second scanning mechanism, and enables the detection system to carry out segmented data acquisition according to actual conditions at different stages through the transmission mechanism, thereby meeting the detection requirements.
Preferably, the first scanning mechanism includes:
a housing fixedly arranged; and
and the 3D imaging devices are provided with 4 imaging devices which are respectively positioned at four corners of the housing.
In the invention, the 3D imaging equipment can realize the depth judgment of the surface defect of the steel rail; and the housing has certain intensity and protective capability, and can provide safety protection and dust prevention for the imaging equipment.
Preferably, the transfer mechanism comprises:
a frame body fixedly arranged;
a carrier roller for transporting the steel rail to be detected;
the guide mechanism is used for righting the deviated steel rail to be detected; and
and the calibration plate moves up and down in the height direction of the frame body and is used for moving the calibration plate to the field range of the image acquisition unit.
In the invention, the guide mechanism can effectively correct the deviation phenomenon after the movement deviation of the steel rail to be detected; the arrangement of the calibration plate can enable the steel rail to be detected to obtain an accurate position when image scanning is carried out, so that the auxiliary image acquisition of the steel rail to be detected is realized.
Preferably, the calibration plate is provided with a locking mechanism, and the calibration plate and the frame body after downward movement are locked by the locking mechanism.
The locking mechanism can enable the calibration plate to be stably connected with the steel rail to be tested, so that the steel rail to be tested has more accurate position precision in calibration.
Preferably, a feeding encoder and a discharging encoder are respectively arranged at two ends of the transmission mechanism; and the feeding encoder and the discharging encoder are respectively electrically connected with the data processing equipment.
The absolute positioning of the steel rail to be measured is realized through the feeding encoder and the discharging encoder, so that the position of the steel rail to be measured is determined by matching with the calibration plate.
Preferably, the safety protection device is further included; the safety protection device comprises at least one group of safety light curtains; the safety protection device is electrically connected with the data processing equipment.
In the invention, when the detection system performs normal detection work, whether workers or other foreign matters invade is sensed through the safety light curtain, and under the condition, the detection system is stopped suddenly, so that the detection safety, stability and accuracy are ensured.
Compared with the prior art, the detection method disclosed by the invention can overcome the contingency and uncertainty caused by the measurement of the torsion and the geometric dimension error of the steel rail to be detected in the conventional manual detection; meanwhile, the flatness, the end face inclination and the surface defect detection accuracy of the steel rail to be detected can be guaranteed through the first scanning mechanism and the second scanning mechanism, and on the basis, a large number of errors are eliminated, so that the accuracy is guaranteed. The invention also discloses a detection system based on the method, and the detection system can enable the detection of the steel rail to be detected to be more convenient and faster and has good position positioning precision, thereby further eliminating detection errors.
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FIG. 1 is a schematic diagram of an embodiment of the present invention;
FIG. 2 is a schematic diagram of a first scanning mechanism according to an embodiment of the present invention;
FIG. 3 is a schematic view of a transport mechanism in an embodiment of the present invention;
FIG. 4 is a schematic diagram of a chord survey method in accordance with an embodiment of the present invention;
FIG. 5 is a schematic diagram illustrating a coplanar alignment method according to an embodiment of the present invention;
FIG. 6 is a schematic diagram illustrating the principle of the coplanar method in the embodiment of the present invention.
In the figure: 100-a transport mechanism; 101-a frame body; 102-carrier rollers; 103-calibration plate; 104-a guide plate; 105-a guide roller; 106-a scissor mechanism; 107-an electromagnet; 108-a feed encoder; 109-discharge encoder; 200-a first scanning mechanism; 201-a housing; 202-a 3D imaging device; 300-a truss; 400-a data processing device; 500-a second scanning mechanism; 600-safety protection device.
Detailed Description
In order that those skilled in the art will better understand the technical solutions of the present invention, the present invention will be further described in detail with reference to the following embodiments.
As shown in fig. 1 to 3, the present embodiment provides a rail profile shape detecting system, which includes a transmission mechanism 100, a first scanning mechanism 200, a line frame 300 and a data processing apparatus 400; the transmission mechanism 100 is used for conveying a steel rail to be detected; the first scanning mechanism 200 is used for panoramic scanning; the traveling frame 300 is provided with a second scanning mechanism 500 which moves along the length direction thereof and is used for linear scanning; the data processing apparatus 400 is electrically connected to the first scanning mechanism 200 and the second scanning mechanism 500, respectively.
In this embodiment, the traveling frame 300 has four upright posts, and the main body of the traveling frame is supported by the upright posts, so that the positions of the four upright posts provide a detection area, and the transmission mechanism 100 for conveying the steel rail to be detected in the detection area is arranged in the detection area; the first scanning mechanism 200 is disposed at one end of the conveying mechanism 100; the second scanning mechanism 500 moves in the length direction of the traveling frame 300 to realize fast movement and positioning to different detection points; the data processing device 400 is a computer, and performs corresponding data operation and display through a calculator.
For better use of the present embodiment, the first scanning mechanism 200 includes a fixedly disposed housing 201 and a 3D imaging device 202; the 3D imaging device 202 is connected to the housing 201.
In the present embodiment, the casing 201 is disposed at one end of the transmission mechanism 100, and is used for disposing the 3D imaging device 202; it should be noted that, in the present embodiment, the 3D imaging device 202 has four, which are respectively located at four corners of the housing; furthermore, the 3D camera is a three-dimensional camera based on laser triangulation technology. It is also possible for the second scanning mechanism 500 to perform three-dimensional measurement, but the component that performs image scanning is a scanner based on binocular vision technology.
In this embodiment, the scanner is moved rapidly by a five-axis robot, which is slidably coupled to the gantry 300 robot. Specifically, the five-axis robot realizes the requirements of the working posture of the scanner by three linear movement axes X, Y, Z and two rotation axes A, B.
For better use of the embodiment, the conveying mechanism 100 comprises a fixedly arranged frame body 101, a carrier roller 102, a guide mechanism and a calibration plate 103; the carrier roller 102 is used for transporting a steel rail to be detected; the guide mechanism is used for righting the deviated steel rail to be detected; the calibration plate 103 moves up and down in the height direction of the frame body 101 and is used for lifting the steel rail to be measured for positioning and scanning.
In the embodiment, the steel material to be measured moves in the detection area by the rotation of the carrier roller 102; before the steel to be detected enters the detection area and is pushed out of the detection area, the movement correction is realized by utilizing a guide mechanism; wherein the guiding mechanism comprises a set of guiding plates 104 and a set of guiding rollers 105.
In this embodiment, the frame body 101 is provided with a scissors mechanism 106, the scissors mechanism 106 is opened and closed by an electric push rod, so that the calibration plate 103 is connected with the scissors mechanism 106, and when the scissors mechanism 106 is opened, the calibration plate 103 descends; when the scissor mechanism 106 is closed, the calibration plate 103 rises, so that the steel to be measured is positioned better.
For better use of the present embodiment, the calibration plate 103 is provided with an electromagnet 107; the electromagnet 107 is electrified to attract the calibration plate 103 and the frame body 101.
In this embodiment, when the calibration plate 103 descends, the electromagnet 107 is energized, so that the calibration plate 103 is attracted to the frame body 101; when the calibration plate 103 is raised, the electromagnet 107 is de-energized, whereby the calibration plate 103 is well disengaged from the housing 101. The specific number of calibration plates 103 provided is determined by the specific length of the transfer mechanism 100, and in general, each calibration plate 103 has two electromagnets.
In some embodiments, the electromagnet 107 can float telescopically on the calibration plate 103, thereby providing the electromagnet 107 with a latching function.
For better use of the present embodiment, the two ends of the conveying mechanism 100 are respectively provided with a feeding encoder 108 and a discharging encoder 109; the feed encoder 108 and the discharge encoder 109 are electrically connected to the data processing apparatus 400, respectively.
The feeding encoder 108 and the discharging encoder 109 can timely acquire the motion information of the steel material to be detected by the data processing device 400, so as to judge the stopping and the continuing of the steel material to be detected at the corresponding stage. In this embodiment, the feed encoder 108 and the discharge encoder 109 are both photoelectric encoders.
For better use of the present embodiment, safety shield apparatus 600 is also included; the safety device 600 comprises at least one set of safety light curtains; the safety guard 600 is electrically connected to the data processing apparatus 400.
In this embodiment, the number of safety guards 600 is two; the safety light curtain is arranged on the side surface of the upright post. In this embodiment, the safety light curtain is a correlation type safety light curtain.
On the basis of the embodiment, the rail profile detection is carried out by using a rail profile dynamic detection method, and the method comprises the following steps:
conveying the steel rail to be detected into a detection area of a detection system;
the image acquisition unit acquires information of the end part of the steel rail and generates end part data;
the image acquisition unit acquires information of a body part between two ends of the steel rail to generate body part data;
transmitting the end data and the body data to a data processing unit, and analyzing and calculating the end data and the body data by the data processing unit to obtain actual data;
the data processing unit is provided with standard data of steel, and the data processing unit compares the actual data with the standard data to obtain result data.
The method comprises the steps of acquiring end data and body data in a segmented mode, wherein the end data comprise head data and tail data. Specifically, the data processing unit sequentially acquires head data, body data, and tail data, and therefore, the method for detecting the profile shape of the steel rail includes:
s101, conveying a steel rail to be detected into a detection area of a detection system;
s201, after the rail head of the steel rail to be detected enters a detection area for a first distance, stopping the steel rail to be detected from moving forwards;
s202, an image acquisition unit acquires data to obtain header data;
s301, the data processing unit obtains header data;
s302, the steel rail to be detected continues to move forwards for a second distance in the detection area, and the steel rail to be detected stops moving forwards;
s303, acquiring data by an image acquisition unit to obtain body data;
s401, the data processing unit obtains body data;
s402, continuing to move the steel rail to be detected in the detection area;
s403, when the rail tail distance of the steel rail to be detected leaves the detection area for the residual third distance, stopping the steel rail to be detected from moving forwards;
s404, acquiring data by an image acquisition unit to obtain tail data;
s501, the data processing unit has standard data of steel, and the data processing unit compares the actual data with the standard data to obtain result data.
And S601, the data processing unit exports result data for visual judgment of workers.
Specifically, when the detection system is used, the length of the steel to be detected is 100 meters. A worker opens the detection system and inputs the serial number and the adaptive speed of the steel rail to be detected; when the steel rail to be detected enters the detection area, the rail head moves into the detection area by 3 meters, the transmission mechanism 100 stops, the scanner scans the whole surface of the steel rail to be detected, and meanwhile, the 3D imaging equipment 202 also scans synchronously; after scanning is finished, the steel rail to be detected continuously moves along the length direction of the steel rail to be detected at a certain speed, at the moment, the 3D imaging equipment 202 stops working, the scanner collects the profile of the steel rail in real time, and the surface quality of the steel rail to be detected is judged in real time; when the steel rail to be detected moves to a position 3 meters away from the tail rail end, the transmission mechanism 100 stops, and the detection method is the same as that of the rail head for 3 meters; in the detection process, the data processing device 400 processes data in real time, gives an alarm for the overrun data, and can generate a report and provide printing after the detection of the whole steel rail to be detected is completed.
Therefore, in the present embodiment, the header data is data acquired by the scanner and data acquired by the 3D imaging device 202; the body data is data of the 3D imaging device 202; the tail data is data acquired by the scanner and data acquired by the 3D imaging device 202. After the data processing device 400 obtains the data in segments, the transportation process is performed respectively, including the rail dimension detection to be detected, the straightness detection, the distortion detection, the end face inclination detection and the surface defect detection.
The size of the rail to be detected is detected by the complete steel rail profile data collected by the scanner. Firstly, the collected steel rail profile and the standard steel rail profile are overlapped through shifting the gravity center with the standard steel rail profile, the coordinate position of a detection point is searched on the shifted steel rail profile, if the rail height is the height difference between the horizontal center of a rail head and the horizontal center of a rail bottom and is recorded as a measurement value, the measurement value of the position corresponding to the standard steel rail profile is standard data, the measurement value is compared with the standard data, and if the deviation exceeds the required deviation, the alarm processing is carried out.
As shown in FIG. 4, the straightness test is performed by a chord measuring method, taking a measuring range of 3 meters at the head as an example.
Two endpoints, P, are selected from the header data1And P2Straight line P1P2Perpendicular to the end face of the rail to be measured, then line P1P2Referred to as a reference line;
selecting a straight line P1P2A plurality of points M at equal intervals1、M2、……、Mn(n is positive)Integer), calculating the depth information corresponding to the points, and recording the distances from the points to the datum line as the deviation value of straightness, wherein positive numbers are positive deviations, and negative numbers are negative deviations;
obtaining the maximum value of flatness deviation for all deviation values, M in the figurenWhere the deviation value reaches the maximum, i.e. MnIs the flatness sought.
As shown in fig. 5, the twist detection uses a coplanar method. For example, two calculation points P are taken on the lower surface of the rail to be measured3、P4Taking two calculation points P on the lower surface of the section rail bottom 1 m away from the end5、P6Setting the distance between the point and the edge of the rail bottom to be 10mm, and calculating P6To P3、P4And P5And comparing the distance of the formed surface with the distance value of the standard data, and if the deviation exceeds the required deviation, performing alarm processing.
And the end face inclination detection adopts a mode of calculating a plane included angle to acquire parameters. For example, when the end face inclination of the end face of the rail to be detected is detected, the coordinates N of 3 points on each face of the rail are obtained1(X1，Y1，Z1)、N2(X2，Y2，Z2)、N3(X3，Y3，Z3) And constructing a plane equation of the steel rail by the following steps:
end face: a. the1·X+B1·Y+C1·Z＝0；
Bottom surface: a. the2·X+B2·Y+C2·Z＝0；
Side surface: a. the3·X+B3·Y+C3·Z＝0；
A is obtained by the above three equations1、A2、B1、B2、C1、C2；
The cosine value of the included angle between the surfaces is obtained:
end-bottom surface:
end-side:
and obtaining the end face inclination, then comparing the inclination with the standard data, and if the deviation exceeds the required deviation, performing alarm processing.
The surface defect detection is carried out by comparing depth values. An example is as follows, taking the coordinates (D) of the section point of the track to be measured2，E2，F2) Wherein D is2And E2In the section of the rail to be measured, F2In the transport direction of the transport mechanism 100;
at this time, the shape of the combined four 3D imaging devices 202 is a complete rail cross section;
in the detection process, the center of the track to be detected integrally shakes up and down near the central line of the track to be detected; let t0At the moment, the central point of the track to be measured is scanned as (D)t，Et) The central point of the cross section of the standard steel rail is assumed to be (D) in the static state0，E0) Then t is0The time shift vector is:
then the section of the track to be measured acquired by the 3D camera is expressed according to the vector
Integral translation;
after translation, calculating difference delta l between target points on the scanning rail surface and standard data in the vertical direction one by one;
assuming that the standard data of crack depth is L, when Deltal > L, the crack is judged here.
The above is only a preferred embodiment of the present invention, and it should be noted that the above preferred embodiment should not be considered as limiting the present invention, and the protection scope of the present invention should be subject to the scope defined by the claims. It will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the spirit and scope of the invention, and these modifications and adaptations should be considered within the scope of the invention.
Claims (10)
1. The dynamic detection method for the steel rail profile is characterized by comprising the following steps of:
the image acquisition unit acquires information of the end part of the steel rail and generates end part data;
the image acquisition unit acquires information of a body part between two ends of the steel rail to generate body part data;
transmitting the end data and the body data to a data processing unit, and analyzing and calculating the end data and the body data by the data processing unit to obtain actual data;
the data processing unit is provided with standard data of steel, and the data processing unit compares the actual data with the standard data to obtain result data.
2. The dynamic rail profile detection method according to claim 1, wherein the end data includes header data; the step of acquiring the header data comprises:
the image acquisition unit acquires data to obtain header data.
3. The dynamic rail profile detection method according to claim 2, wherein the acquiring step of the body data includes:
the data processing unit obtains header data;
and the image acquisition unit acquires data to obtain body data.
4. The dynamic rail profile detection method according to claim 3, wherein the end data further includes tail data; the acquiring step of the tail data comprises the following steps:
the data processing unit obtains body data;
and finally, the image acquisition unit acquires data to obtain tail data.
5. Dynamic detection system of rail profile shape, its characterized in that includes:
the transmission mechanism is used for transmitting the steel rail to be detected;
the first scanning mechanism is fixedly arranged and used for panoramic scanning;
the travelling frame is provided with a second scanning mechanism which moves along the length direction of the track and is used for linear scanning; and
and the data processing equipment is respectively and electrically connected with the first scanning mechanism and the second scanning mechanism.
6. The dynamic rail profile detection system of claim 5, wherein said first scanning mechanism comprises:
a housing fixedly arranged; and
and the 3D imaging devices are provided with 4 imaging devices which are respectively positioned at four corners of the housing.
7. The dynamic rail profile detection system of claim 5, wherein said transmission means comprises:
a frame body fixedly arranged;
a carrier roller for transporting the steel rail to be detected;
the guide mechanism is used for righting the deviated steel rail to be detected; and
and the calibration plate moves up and down in the height direction of the frame body and is used for moving the calibration plate to the field range of the image acquisition unit.
8. The dynamic rail profile detection system according to claim 7, wherein said calibration plate is provided with a locking mechanism for locking said calibration plate after downward movement with said housing.
9. The dynamic rail profile detection system according to claim 5, wherein a feeding encoder and a discharging encoder are respectively arranged at two ends of the transmission mechanism; and the feeding encoder and the discharging encoder are respectively electrically connected with the data processing equipment.
10. The dynamic rail profile detection system of claim 5, further comprising a safety guard; the safety protection device comprises at least one group of safety light curtains; the safety protection device is electrically connected with the data processing equipment.
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|---|---|---|---|---|
| CN115235385A (en) * | 2022-08-03 | 2022-10-25 | 江苏精益智控科技有限公司 | Steel pipe flatness full-length detection device and method |
| CN115235385B (en) * | 2022-08-03 | 2024-01-05 | 江苏精益智控科技有限公司 | Equipment and method for detecting flatness and overall length of steel pipe |
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| CN112880586B (en) | 2024-01-30 |
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