CN112937633A - Portable wheel set parameter detector - Google Patents
Portable wheel set parameter detector Download PDFInfo
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- CN112937633A CN112937633A CN202110144619.XA CN202110144619A CN112937633A CN 112937633 A CN112937633 A CN 112937633A CN 202110144619 A CN202110144619 A CN 202110144619A CN 112937633 A CN112937633 A CN 112937633A
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- 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
- B61K9/12—Measuring or surveying wheel-rims
Abstract
The invention relates to the technical field of rail vehicle detection, and discloses a portable wheel set parameter detector for measuring the geometric dimension of a wheel set. The invention provides a non-contact static detection device for measuring the geometric dimension of a wheel set, namely, a positioning block, a linear stepping motor, a laser displacement sensor, a proximity sensor and a control module aiming at the inner/outer side area of a wheel rim are arranged on a handheld carrier, so that the purposes of portability and low cost can be realized, the measurement data of the profile surface of a scanning wheel set can be obtained in an energy-saving mode, the wheel set parameters are calculated based on the measurement data, the purpose of non-contact static measurement of the geometric dimension of the wheel set is realized, further, errors caused by manual measurement can be avoided, the measurement precision is ensured, and the measurement efficiency is improved. In addition, compare with wheel pair parameter dynamic detection device on the existing market, need not direct contact during having the measurement, cost low, maintain the advantage that operation work is simple and detection precision is close.
Description
Technical Field
The invention belongs to the technical field of rail vehicle detection, and particularly relates to a portable wheel set parameter detector for measuring the geometric dimension of a wheel set.
Background
In the field of rail transit, China, as one of the major high-speed rail industry countries in the world, opens a high-speed rail since 2008, and the development of the high-speed rail is very rapid, but many technologies are not mature yet and still are in the starting stage. The wheel set is used as an important part for supporting the train to run, is directly contacted with the steel rail and provides power and braking force for the train during running. When a train is frequently accelerated and emergently braked in operation, the wheel set is acted by the wheel rail force to cause the change and scratch of the geometric parameters of the tread, so that abnormal impact between the wheel set and the rail is caused, impact is brought to the rail and a rail subgrade, and the running safety of the train and the comfort of passengers are influenced. With the rapid development of high-speed railways and urban rail transit, the number of wheel sets to be detected is continuously increased, the detection period is continuously shortened, the detection parameters are continuously increased, and the intelligent requirements on detection instruments are increasingly urgent.
At present, in the aspect of measuring the geometric dimension of wheel pairs of railway vehicles, domestic high-speed motor train units do not have complete devices for measuring the geometric dimension of the wheel pairs. The reason is mainly that the current wheel set parameter detection methods are divided into two types: (1) the dynamic online detection does not occupy the turnover time of the vehicle, has the characteristics of high precision and high efficiency, adopts the ground fixed non-contact measurement mostly, has higher cost, relatively complex maintenance and very complex working environment, is easy to be interfered by electromagnetism, electric fields, harmonic waves and the like on a working site, and can be interfered by other equipment on a train; (2) static detection mainly adopts mechanical measuring tools and contact measurement, but the measurement process depends on manual work, is easily interfered by human factors and has low efficiency, and the MINIProf portable profile curve detector of Denmark and the WP-C type portable wheel profile measuring instrument of a five-link mechanism of Zhang Yingchun and Wenxiangxiang of southwest traffic university belong to the same type. In recent years, although non-contact measurement is adopted to measure geometric parameters, the portable wheel set measuring instrument of ELAG corporation, south kyo university of nursing staff, and the portable vehicle profile measuring instrument of liujie, beijing university of transportation (which performs non-contact measurement based on a laser displacement sensor), the measurement is not popularized due to reasons such as cost and precision. At present, the fourth generation of inspectors and wheel diameter rulers are still widely used by the domestic railway maintenance department, and the instruments are low in measurement precision and easy to be influenced by human factors. Therefore, the research and development of the wheel set parameter detector which is high in precision, reliable and convenient to carry has important practical significance.
Disclosure of Invention
In order to solve the limitation problems of the existing wheel set parameter static detection device in the aspects of precision, reliability and portability, the invention aims to provide a portable wheel set parameter detector for measuring the geometric dimension of a wheel set, which has the advantages of no need of direct contact during measurement, low cost, simple maintenance operation and similar detection precision compared with the wheel set parameter dynamic detection device in the current market, can meet the requirements of maintenance departments such as subways, light rails, motor cars and high-speed rails, and ensures the safety and reliability of the on-the-way operation of high-speed trains.
In a first aspect, the invention provides a portable wheel set parameter detector, which comprises a handheld carrier, and a first positioning block, a second positioning block, a contour acquisition module and a control module which are arranged on the handheld carrier, wherein the first positioning block and the second positioning block are arranged at intervals and are respectively used for positioning a rim inner side area and a rim outer side area;
the contour acquisition module comprises a linear stepping motor, a laser displacement sensor and a proximity sensor, wherein the linear reciprocating direction of the linear stepping motor is parallel to the straight line of the first positioning block and the second positioning block, and the laser displacement sensor and the proximity sensor are respectively bound and arranged on the linear reciprocating part of the linear stepping motor;
the control module is respectively in communication connection with the controlled end of the linear stepping motor, the output end of the laser displacement sensor and the output end of the proximity sensor, and is used for controlling the linear stepping motor to drive the laser displacement sensor and the proximity sensor to do unidirectional uniform motion after receiving a detection starting instruction, then triggering the laser displacement sensor to start measuring the real-time distance from the sensor to the contour surface of the wheel set after receiving a trigger signal fed back by the proximity sensor when the proximity sensor detects the first positioning block until stopping measuring after receiving a trigger signal fed back by the proximity sensor when the proximity sensor detects the second positioning block, and finally calculating to obtain wheel set parameters according to measurement data fed back by the laser displacement sensor, wherein the wheel set parameters comprise the diameter of the wheel, the height of the wheel rim, the height of the wheel set, and the wheel set parameters, Rim thickness and/or rim composite value.
Based on the content of the invention, the invention provides the non-contact static detection device for measuring the geometric dimension of the wheel set, namely, the positioning block, the linear stepping motor, the laser displacement sensor, the proximity sensor and the control module aiming at the inner/outer side area of the wheel rim are arranged on the handheld carrier, so that the purposes of portability and low cost can be realized, the measurement data of the profile surface of the wheel set can be obtained in an energy-saving mode, the wheel set parameters are calculated based on the measurement data, the purpose of measuring the geometric dimension of the wheel set in a non-contact static mode is realized, further, errors caused by manual measurement can be avoided, the measurement precision is ensured, and the measurement efficiency is improved. Through using the test, can realize the short-term test, make the single measurement scan time only need 10s, single check-out time is less than 1 minute, and it is exquisite convenient, be fit for the bogie wheel (wheel pair) narrow and small space measurement down, and make the average power consumption of detector be 2.96W, check-out time is sustainable 6 hours, therefore it compares with the wheel pair parameter dynamic detection device on the existing market, need not direct contact when having the measurement, and cost is low, maintain the advantage that operation simple work and detection precision are close, can satisfy the subway, the light rail, the demand of maintenance departments such as motor car and high-speed railway, guarantee the fail safe nature of high-speed train operation in transit.
In one possible design, the wheel set parameters are calculated according to the measurement data fed back by the laser displacement sensor, and the method comprises the following steps:
s101, converting the measurement data into two-dimensional point cloud data which is under an actual measurement rectangular coordinate system XOY and used for representing an actual measurement contour line, wherein the actual measurement rectangular coordinate system XOY takes the first positioning block as a coordinate origin, the moving direction of the laser displacement sensor as a transverse axis direction, and the emitting direction of the laser displacement sensor as a longitudinal axis direction;
s102, calculating a slope kappa of an outer rim inclined section in the actually measured contour line under an XOY (orthogonal coordinate system) by adopting a least square curve fitting method according to the two-dimensional point cloud data, and calculating to obtain a rotation parameter delta theta, namely arctan kappa ' -arctan kappa according to a geometric relation between the slope kappa and an ideal slope kappa ', wherein the ideal slope kappa ' refers to a known slope of the outer rim inclined section in a standard contour line under the XOY;
s103, according to the two-dimensional point cloud data, calculating coordinates (x) of the wheel rim vertex in the actually measured contour line under the actually measured rectangular coordinate system XOY by adopting a radius constraint-based arc fitting methodA,yA) And according to said rotation parameter Δ θ, said coordinate (x)A,yA) And known coordinates (x ') of rim vertices in a standard contour line under the measured rectangular coordinate system XOY'A,y′A) Calculating to obtain translation parameter (delta x ═ x'A-xA cos(Δθ)+yA sin(Δθ),Δy＝y′A-xA sin(Δθ)+yAcos(Δθ))；
S104, according to the rotation parameter delta theta and the translation parameters (delta x, delta y), performing rotation translation operation on all data points in the two-dimensional point cloud data to complete profile matching of the actual measurement contour line and the standard contour line, and according to the new coordinates of the actual measurement contour line and key feature points of the standard contour line, which are used for calculating wheel set parameters, calculating the wheel set parameters which are actually measured.
Based on the possible design, the rotation and translation operation can be carried out on the actually measured contour line according to the rotation parameter and the translation parameter obtained based on the measurement data, the contour matching of the actually measured contour line and the standard contour line is completed, the wheel set parameters are finally calculated through a contour matching method, and the purpose of automatic measurement of the wheel set parameters is achieved.
In a possible design, after step S101 and before step S102, the following steps are further included:
and smoothing the two-dimensional point cloud data by adopting a smoothing algorithm based on a median error term and a spatial continuity adjustment weight.
In a possible design, after the step S104, the following steps are further included:
s201, smoothing the two-dimensional point cloud data by adopting a smoothing algorithm based on a median error term and a spatial continuity adjustment weight to obtain new two-dimensional point cloud data;
s202, aiming at the new two-dimensional point cloud data, sequentially executing the steps S102-S104 to obtain wheel set parameters obtained this time;
s203, comparing the wheel set parameters obtained this time with wheel set parameters obtained in the previous time to obtain wheel set parameter deviation;
s204, judging whether the parameter deviation of the wheel set is smaller than a preset deviation threshold value or not;
s205, if yes, outputting the wheel pair parameters obtained this time, otherwise, after adjusting the median error term and the spatial continuity, returning to execute the step S201.
Based on the possible design, the parameters of the wheel set can be optimized and calculated step by adjusting the median error term and the smoothing processing mode of the spatial continuity for multiple times, and the calculation result reaching the expected optimization target is output, so that the precision of the measurement result is ensured.
In one possible design, smoothing the two-dimensional point cloud data by using a smoothing algorithm based on a median error term and a spatial continuity adjustment weight, includes:
for the m-th data point p sequentially numbered along the horizontal axis direction in the two-dimensional point cloud datam＝(xm,ym) M is 1,2,3 …, M, and the new coordinates after smoothing are calculated according to the following formula
Wherein M represents a number in the two-dimensional point cloud dataAccording to the total number of points, M represents a positive integer not greater than M, N represents a preset positive integer reflecting the range width of the upper limit and the lower limit of the neighborhood, i represents a positive integer, xm+iAbscissa, y, representing the m + i-th data pointm+iOrdinate, y, representing the m + i-th data pointm+i-1Denotes the ordinate, y, of the m + i-1 th data pointm+i+1Denotes the ordinate, ω, of the m + i +1 th data point(m+i)Represents the weight factor, omega, corresponding to the m + i-th data point1,(m+i)Represents the median error term, ω, corresponding to the m + i-th data point2,(m+i)Representing the spatial continuity, σ, corresponding to the m + i-th data point1Representing a first predetermined coefficient, σ2Represents a second predetermined coefficient, | pm+i-pm| | represents the distance from the m + i-th data point to the m-th data point before the smoothing process.
In one possible design, when the wheelset parameter includes a plurality of parameters, comparing the wheelset parameter obtained this time with the wheelset parameter obtained last time to obtain a wheelset parameter deviation, including:
and taking the sum of the deviations of all the parameters obtained by comparison as the deviation of the parameters of the wheel set.
In one possible design, according to the two-dimensional point cloud data, calculating the coordinate (x) of the rim vertex in the actually measured contour line under the actually measured rectangular coordinate system XOY by adopting a circular arc fitting method based on radius constraintA,yA) The method comprises the following steps:
let the equation of the circle where the arc is located be: (x-D)2+(y-E)2-R2The circular arc is a circular arc where a rim vertex is located, (D, E) represents a circle center to be solved of a circle where the circular arc is located, and R represents a preset radius of the circle where the circular arc is located;
the objective function is set as:
wherein z represents a binary unknown quantity about the center of the circle to be found, and z is (z)x,zy) N represents a positive integer, j represents a positive integer not greater than n;
the objective function f (z) is approximately converted into a quadratic function q (z) using a taylor series as follows:
in the formula, gkDenotes the target function f (z) when z ═ zkFirst derivative of (A), GkDenotes the target function f (z) when z ═ zkThe second derivative of (a), T denotes the transposed sign;
obtaining a minimum value point of the quadratic function Q (x) by adopting a Newton iteration method, and taking the minimum value point as an optimal solution coordinate of the circle center to be solved;
and determining the coordinates of the top point of the wheel rim in the actually measured contour line according to the geometric relation between the optimal solution coordinates of the circle center to be solved and the arc.
In a possible design, the control module is further configured to trigger and control the linear stepper motor to drive the laser displacement sensor and the proximity sensor to perform unidirectional deceleration motion after receiving a trigger signal fed back by the proximity sensor when the proximity sensor detects the second positioning block, so as to stop moving when the sensor reaches the mechanical limit.
In one possible design, the handheld vehicle further comprises a data interaction module, a data storage module and a power supply module which are arranged on the handheld vehicle, wherein the data interaction module comprises a bluetooth communication circuit and/or a USB interface circuit;
the data interaction module and the data storage module are respectively in communication connection with the control module, and the power supply module is respectively and electrically connected with the contour acquisition module, the control module, the data interaction module and the data storage module.
In one possible design, the control module employs a processor chip of model number STM32F407 and its peripheral circuits.
The invention has the beneficial effects that:
(1) the invention provides a non-contact static detection device for measuring the geometric dimension of a wheel set, namely, a positioning block, a linear stepping motor, a laser displacement sensor, a proximity sensor and a control module aiming at the inner/outer side area of a rim are arranged on a handheld carrier, so that the purposes of portability and low cost can be realized, the measurement data of the profile surface of a scanning wheel set can be obtained in the most energy-saving mode, the wheel set parameters are calculated based on the measurement data, the purpose of measuring the geometric dimension of the wheel set in a non-contact static manner is realized, further, errors caused by artificial measurement can be avoided, the measurement precision is ensured, and the measurement efficiency is improved;
(2) through the use and the test, the rapid measurement can be realized, the single measurement scanning time is only 10s, the single detection time is less than 1 minute, the device is exquisite and convenient, the device is suitable for the measurement of a narrow space of a wheel (wheel set) of a bogie, the average power consumption of a detector is 2.96W, and the detection time can last for 6 hours, so that the device has the advantages of no need of direct contact during measurement, low cost, simple maintenance and operation and similar detection precision compared with a dynamic wheel set parameter detection device in the current market, can meet the requirements of maintenance departments such as subways, light rails, motor cars, high-speed rails and the like, and ensures the safety and reliability of the in-transit operation of a high-speed train;
(3) the measured contour line can be subjected to rotation translation operation according to rotation parameters and translation parameters obtained based on the measurement data, the profile matching of the measured contour line and the standard contour line is completed, wheel set parameters are finally calculated through a profile matching method, and the purpose of automatic measurement of the wheel set parameters is achieved;
(4) the wheel set parameters can be optimized and calculated step by adjusting the smoothing processing mode of the median error term and the spatial continuity for multiple times, the calculation result reaching the expected optimization target is output, the precision of the measurement result is ensured, and through experimental tests, compared with a manual measurement scheme, the errors of the height and the thickness of the wheel rim can be both smaller than 0.12 mm.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
Fig. 1 is a schematic circuit structure diagram of the portable wheel set parameter detector provided by the invention.
FIG. 2 is a schematic view of the portable wheel set parameter detector provided by the invention in use.
FIG. 3 is a schematic diagram of the internal algorithm flow of the portable wheel set parameter detector provided by the invention.
Fig. 4 is a schematic diagram of wheel section and wheelset parameters provided by the present invention.
FIG. 5 is an exemplary illustration of coordinate rotational translation provided by the present invention.
FIG. 6 is a comparative example diagram of the actual measurement contour line before and after smoothing processing according to the present invention.
In the above drawings: 1-a handheld carrier; 21-a first positioning block; 22-a second locating block; 31-linear stepper motor; 32-laser displacement sensors; 33-a proximity sensor; 34-mechanical limiting; 100-wheel section.
Detailed Description
The invention is further described with reference to the following figures and specific embodiments. It should be noted that the description of the embodiments is provided to help understanding of the present invention, but the present invention is not limited thereto. Specific structural and functional details disclosed herein are merely illustrative of example embodiments of the invention. This invention may, however, be embodied in many alternate forms and should not be construed as limited to the embodiments set forth herein.
It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments of the present invention.
It should be understood that, for the term "and/or" as may appear herein, it is merely an associative relationship that describes an associated object, meaning that three relationships may exist, e.g., a and/or B may mean: a exists alone, B exists alone, and A and B exist at the same time; for the term "/and" as may appear herein, which describes another associative object relationship, it means that two relationships may exist, e.g., a/and B, may mean: a exists independently, and A and B exist independently; in addition, for the character "/" that may appear herein, it generally means that the former and latter associated objects are in an "or" relationship.
It will be understood that when an element is referred to herein as being "connected," "connected," or "coupled" to another element, it can be directly connected or coupled to the other element or intervening elements may be present. Conversely, if a unit is referred to herein as being "directly connected" or "directly coupled" to another unit, it is intended that no intervening units are present. In addition, other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between … …" versus "directly between … …", "adjacent" versus "directly adjacent", etc.).
It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments of the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises," "comprising," "includes" and/or "including," when used herein, specify the presence of stated features, quantities, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, quantities, steps, operations, elements, components, and/or groups thereof.
It should also be noted that, in some alternative designs, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed substantially concurrently, or the figures may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
It should be understood that specific details are provided in the following description to facilitate a thorough understanding of example embodiments. However, it will be understood by those of ordinary skill in the art that the example embodiments may be practiced without these specific details. For example, systems may be shown in block diagrams in order not to obscure the examples in unnecessary detail. In other instances, well-known processes, structures and techniques may be shown without unnecessary detail in order to avoid obscuring example embodiments.
As shown in fig. 1 to 6, the portable wheel set parameter detector provided in the first aspect of the present embodiment includes a handheld carrier 1, and a first positioning block 21, a second positioning block 22, a contour acquisition module and a control module which are arranged on the handheld carrier 1, where the first positioning block 21 and the second positioning block 22 are arranged at intervals and are respectively used for positioning a rim inner area and a rim outer area; the contour acquisition module comprises a linear stepping motor 31, a laser displacement sensor 32 and a proximity sensor 33, wherein the linear reciprocating direction of the linear stepping motor 31 is parallel to the straight line of the first positioning block 21 and the second positioning block 22, and the laser displacement sensor 32 and the proximity sensor 33 are respectively bound and arranged on the linear reciprocating part of the linear stepping motor 31; the control module is respectively in communication connection with the controlled end of the linear stepping motor 31, the output end of the laser displacement sensor 32 and the output end of the proximity sensor 33, and is used for controlling the linear stepping motor 31 to drive the laser displacement sensor 32 and the proximity sensor 33 to move at a uniform speed in a single direction after receiving a detection starting instruction, then triggering the laser displacement sensor 32 to start measuring the real-time distance from the sensor to the wheel set profile surface after receiving a trigger signal fed back by the proximity sensor 33 when the first positioning block 21 is detected, stopping measuring after receiving a trigger signal fed back by the proximity sensor 33 when the second positioning block 22 is detected, and finally calculating wheel set parameters according to the measurement data fed back by the laser displacement sensor 32, wherein the wheel set parameters include but are not limited to wheel diameters, Rim height, rim thickness, and/or rim composite values, etc.
As shown in fig. 1-2, in the specific structure of the portable wheelset parameter measuring device, the handheld carrier 1 is used for carrying all components of the whole measuring device, so that a measurer can hold the measuring device to measure wheelset parameters, and the purpose of convenient operation and portability can be achieved by adopting a conventional handheld structure. Because the first positioning block 21 and the second positioning block 22 are respectively used for positioning the inner side area and the outer side area of the rim, the distance from the first positioning block 21 to the second positioning block 22 is inevitably greater than the distance from the inner side edge of the rim to the outer side edge of the rim, and the measurement data corresponding to the contour surface of the complete wheel set can be acquired. The profile collection module is configured to collect a real-time distance from the sensor to the wheel set profile surface and a real-time displacement of the sensor through the laser displacement sensor 32, and transmit the real-time distance and the real-time displacement to the control module as feedback measurement data, so that the control module converts the measurement data into two-dimensional point cloud data representing an actually measured contour line, where the linear stepper motor 31 is configured to drive the laser displacement sensor 32 and the proximity sensor 33 to perform a linear reciprocating motion under the control of the control module (specifically, but not limited to, control through a pulse width modulation PWM signal generated by a basic timer TIM in the control module), and specifically, may be implemented by using a conventional existing motor structure; the laser displacement sensor 32 is used for acquiring the distance from the sensor to the surface of the wheel set profile based on a laser ranging principle while generating linear displacement, and can be realized by adopting a conventional existing sensor structure, and can realize data transmission through an RS485 bus without limitation; the proximity sensor 33 is configured to detect proximity to a positioning block by using an eddy current generated in a metal body of a detection object (i.e., the first positioning block 21 or the second positioning block 22) by electromagnetic induction, a capacity change of an electrical signal by proximity of a capturing body (i.e., the first positioning block 21 or the second positioning block 22), or a guidance switch, and transmit a corresponding trigger signal to the control module when the proximity to the positioning block is found.
The detection starting instruction received by the control module is generated by a measurer operating on a human-computer interaction interface (such as a mobile phone APP interface and the like) and is transmitted to the control module through a conventional communication link. Since the laser displacement sensor 32 is triggered to start measuring the real-time distance from the sensor to the wheel set contour surface after receiving the trigger signal fed back by the proximity sensor 33 when the first positioning block 21 is detected, and the measurement is stopped after receiving the trigger signal fed back by the proximity sensor 33 when the second positioning block 22 is detected, the measurement data corresponding to the complete wheel set contour surface can be acquired, the laser displacement sensor 32 can be started in the shortest time, the required electric energy is reduced, and the endurance time of the detector is prolonged. Finally, as the wheel set parameters are calculated according to the measurement data fed back by the laser displacement sensor 32, errors caused by artificial measurement can be avoided, the measurement precision is ensured, the measurement efficiency is improved, and the problems that the contact type measurement process is easily interfered by artificial factors and the efficiency is low in the traditional manual detection state at present can be solved. Preferably, the control module is further configured to trigger and control the linear stepping motor 31 to drive the laser displacement sensor 32 and the proximity sensor 33 to perform a unidirectional deceleration motion after receiving a trigger signal fed back by the proximity sensor 33 when detecting the second positioning block 22, so as to stop moving when the sensor reaches a mechanical limit (i.e., a position indicated by reference numeral 34 in fig. 2). In addition, the control module can be implemented by, but is not limited to, a processor chip of the model STM32F407 and peripheral circuits thereof.
Therefore, based on the detailed description of the portable wheel set parameter detector, the non-contact static detection device for measuring the geometric dimension of the wheel set is provided, namely, the positioning block, the linear stepping motor, the laser displacement sensor, the proximity sensor and the control module aiming at the inner/outer side area of the wheel rim are arranged on the handheld carrier, so that the purposes of portability and low cost can be realized, the measurement data of the profile surface of the scanned wheel set can be obtained in the most energy-saving mode, the wheel set parameter is calculated based on the measurement data, the purpose of measuring the geometric dimension of the wheel set in a non-contact static mode is realized, further, errors caused by artificial measurement can be avoided, the measurement precision is ensured, and the measurement efficiency is improved. Through using the test, can realize the short-term test, make the single measurement scan time only need 10s, single check-out time is less than 1 minute, and it is exquisite convenient, be fit for the bogie wheel (wheel pair) narrow and small space measurement down, and make the average power consumption of detector be 2.96W, check-out time is sustainable 6 hours, therefore it compares with the wheel pair parameter dynamic detection device on the existing market, need not direct contact when having the measurement, and cost is low, maintain the advantage that operation simple work and detection precision are close, can satisfy the subway, the light rail, the demand of maintenance departments such as motor car and high-speed railway, guarantee the fail safe nature of high-speed train operation in transit.
On the basis of the technical solution of the first aspect, the present embodiment further provides a first possible design for specifically obtaining the parameters of the wheel set according to the measurement data calculation, that is, as shown in fig. 3, the parameters of the wheel set are obtained according to the measurement data fed back by the laser displacement sensor 32 through calculation, including but not limited to the following steps S101 to S104.
And S101, converting the measurement data into two-dimensional point cloud data which is under an actual measurement rectangular coordinate system XOY and is used for representing an actual measurement contour line, wherein the actual measurement rectangular coordinate system XOY takes the first positioning block 21 as an origin of coordinates, the moving direction of the laser displacement sensor 32 as a transverse axis direction, and the emitting direction of the laser displacement sensor 32 as a longitudinal axis direction.
In step S101, specifically, the measured contour line composed of all data points in the two-dimensional point cloud data and shown in fig. 5 may be obtained by using the displacement value in the measurement data as a horizontal axis coordinate value and the distance value in the measurement data as a vertical axis coordinate value.
S102, calculating a slope kappa of the outer rim inclined section in the actually measured contour line under the actually measured rectangular coordinate system XOY by adopting a least square curve fitting method according to the two-dimensional point cloud data, and calculating to obtain a rotation parameter delta theta, namely arctan kappa ' -arctan kappa according to a geometric relation between the slope kappa and an ideal slope kappa ', wherein the ideal slope kappa ' refers to a known slope of the outer rim inclined section in the standard contour line under the actually measured rectangular coordinate system XOY.
In the step S102, since the wheel set parameter calculation is performed by using a conventional profile matching method (that is, the wheel set parameter calculation is realized by using the feature points at the same positions on the actually measured contour line and the standard contour line), and it is known from the working principle of the profile acquisition module, since the laser displacement sensor moves in the axial direction of the wheel set in each measurement process, the two-dimensional point cloud data of the actually measured contour line and the two-dimensional point cloud data of the standard contour line are in the same plane, and thus, for the profile matching of the two contour lines in the same plane, the rotation parameter and the translation parameter are provided, and the rotation parameter Δ θ can be calculated by using the geometric relationship between the slope κ of the outer inclined segment of the rim in the actually measured contour line and the ideal slope κ'. Specifically, the least square curve fitting method is an existing fitting method, and the rim outer side inclined section in the actually measured contour line can be identified based on a conventional technical means. In addition, the ideal slope k' can be manually determined in the actual measurement rectangular coordinate system XOY after two-dimensional point cloud data representing a standard contour line is acquired by the detector in advance.
S103, according to the two-dimensional point cloud data, calculating coordinates (x) of the wheel rim vertex in the actually measured contour line under the actually measured rectangular coordinate system XOY by adopting a radius constraint-based arc fitting methodA,yA) And according to said rotation parameter Δ θ, said coordinate (x)A,yA) And known coordinates (x ') of rim vertices in a standard contour line under the measured rectangular coordinate system XOY'A,y′A) Calculating to obtain translation parameter (delta x ═ x'A-xA cos(Δθ)+yA sin(Δθ),Δy＝y′A-xA sin(Δθ)+yAcos(Δθ))。
In said step S103, the same can be saidAnd (3) solving the translation parameters (delta x, delta y) based on the coordinates of the corresponding characteristic points (namely, the wheel rim vertexes A and A' shown in the figure 5) of the actually-measured contour line and the standard contour line by using a space coordinate transformation relation. Furthermore, the known coordinates (x'A,y′A) And the two-dimensional point cloud data representing the standard contour line can be acquired and obtained by the detector in advance and then manually determined in the actually measured rectangular coordinate system XOY.
In step S103, specifically, according to the two-dimensional point cloud data, a circular arc fitting method based on radius constraint is used to calculate coordinates (x) of the rim vertex in the actually measured contour line under the actually measured rectangular coordinate system XOYA,yA) The method includes, but is not limited to, the following steps S1031 to S1035.
S1031, setting an equation of a circle where the arc is located as follows: (x-D)2+(y-E)2-R2The circular arc is the circular arc where the rim vertex is located, (D, E) represents the center of the circle where the circular arc is located, and R represents the preset radius of the circle where the circular arc is located.
S1032, setting the objective function as:
wherein z represents a binary unknown quantity about the center of the circle to be found, and z is (z)x,zy) N represents a positive integer, and j represents a positive integer not greater than n.
S1033, approximately converting the objective function f (z) into a quadratic function Q (z) by using Taylor series:
in the formula, gkDenotes the target function f (z) when z ═ zkFirst derivative of (A), GkDenotes the target function f (z) when z ═ zkThe second derivative of (a), T denotes the transposed sign.
S1034, obtaining a minimum value point of the quadratic function Q (x) by adopting a Newton iteration method, and taking the minimum value point as the optimal solution coordinate of the circle center to be solved.
In the step S1034, when G is positivekAt positive timing, the quadratic function Q (z) has a minimum point
Therefore, the minimum value point can be used as the optimal solution coordinate of the circle center to be solved.
And S1035, determining the coordinates of the top point of the wheel rim in the actually measured contour line according to the geometric relation between the optimal solution coordinates of the circle center to be solved and the arc.
According to the rim parameters of the section of the standard wheel set, the top of the rim is an arc with the radius of 12mm, but because the detector designed by the embodiment is difficult to directly detect the vertex of the arc at the top of the rim, if the general equation x of the circle is directly adopted2+y2And the +2Dx +2Ey + F is 0 to perform fitting to obtain the vertex of the rim, which easily causes poor stability of the fitting circle center and the radius. In order to realize accurate calculation of the rim vertex, the radius of the circle is used as a known condition, and the arc fitting method based on the radius constraint is performed as described in the previous steps S1031 to S1035, so as to obtain the coordinate (x) of the rim vertex in the measured rectangular coordinate system XOYA,yA)。
S104, according to the rotation parameter delta theta and the translation parameters (delta x, delta y), performing rotation translation operation on all data points in the two-dimensional point cloud data to complete profile matching of the actual measurement contour line and the standard contour line, and according to the new coordinates of the actual measurement contour line and key feature points of the standard contour line, which are used for calculating wheel set parameters, calculating the wheel set parameters which are actually measured.
In step S104, specifically, as shown in fig. 4, a complete profile is formed by the rim and the tread on the radial section of the wheel, wherein the arc portion of the protrusion is referred to as the rim, and the inclined surface directly contacting the rail is the tread. And a point on the tread, which is 70mm away from the inner side edge of the rim, is defined as a tread base point, a circle formed by the tread base point around the wheel in a circle is called a rolling circle of the wheel pair, and the diameter of the rolling circle is the diameter of the wheel. And the vertical distance from the tread base point to the top point of the wheel rim is the height of the wheel rim. The horizontal distance between the inner side of the rim and a point on the rim, which is 10mm from the base point of the tread, is the thickness of the rim, and the vertical distance for calculating the thickness of the rim is different for different wheel models, and 10mm is generally used for calculation. A vertical line drawn by 10mm upwards from a datum line of the rolling round tread and the inner side of the wheel rim form an intersection point, a vertical line drawn by 2mm downwards from the top of the wheel rim and the inner side of the wheel rim form an intersection point, and the horizontal distance between the two intersection points is defined as a comprehensive qR value of the wheel rim; at present, the maintenance department mainly detects wheel set parameters, namely wheel diameter, wheel rim height, wheel rim thickness, qR value and the like. Therefore, after the profile matching between the actual measurement contour line and the standard contour line is completed, the key feature points of the standard contour line and used for calculating the wheel set parameters, such as the intersection point of the tread base point, the rim vertex and the vertical line drawn by the rolling circular tread datum line upwards by 10mm and the inner side of the rim, the other intersection point of the vertical line drawn by the rim top downwards by 2mm and the inner side of the rim, and the like, can be found, and the actual measurement wheel set parameters can be calculated according to the new coordinates of the actual measurement contour line.
Based on the possible design one described in the foregoing steps S101 to S104, the rotation and translation operation may be performed on the actually measured contour line according to the rotation parameter and the translation parameter obtained based on the measurement data, so as to complete the contour matching between the actually measured contour line and the standard contour line, and the wheel set parameter is finally calculated by the contour matching method, thereby achieving the purpose of automatically measuring the wheel set parameter.
On the basis of the technical solution of the first possible design, the second possible design for improving the measurement accuracy is provided in this embodiment, that is, after the step S101 and before the step S102, the method further includes the following steps: and smoothing the two-dimensional point cloud data by adopting a smoothing algorithm based on a median error term and a spatial continuity adjustment weight. Because the laser displacement sensor 32 is influenced by slight mechanical vibration when moving linearly, the acquired corresponding distance data locally presents a 'wave' shape aiming at the originally flat wheel pair contour surface; meanwhile, because the distance data interfered by sunlight can form noise points, and the actually-measured contour line is not smooth, the accuracy of contour feature extraction can be influenced by considering the existence of errors and noise points, and the matching precision can be influenced.
Specifically, a smoothing algorithm based on a median error term and a spatial continuity adjustment weight is adopted to smooth the two-dimensional point cloud data, and the smoothing algorithm includes but is not limited to: for the m-th data point p sequentially numbered along the horizontal axis direction in the two-dimensional point cloud datam＝(xm,ym) M is 1,2,3 …, M, and the new coordinates after smoothing are calculated according to the following formula
Wherein M represents the total number of data points in the two-dimensional point cloud data, M represents a positive integer not greater than M, N represents a preset positive integer reflecting the width of the upper and lower limits of the neighborhood, i represents a positive integer, and x represents a maximum number of data points in the two-dimensional point cloud datam+iAbscissa, y, representing the m + i-th data pointm+iOrdinate, y, representing the m + i-th data pointm+i-1Denotes the ordinate, y, of the m + i-1 th data pointm+i+1Denotes the ordinate, ω, of the m + i +1 th data point(m+i)Represents the weight factor, omega, corresponding to the m + i-th data point1,(m+i)Represents the median error term, ω, corresponding to the m + i-th data point2,(m+i)Representing the spatial continuity, σ, corresponding to the m + i-th data point1Representing a first predetermined coefficient, σ2Represents a second predetermined coefficient, | pm+i-pm| | represents the distance from the m + i-th data point to the m-th data point before the smoothing process.
In detail, the first preset coefficient σ1And the second predetermined coefficient sigma2The selection of (A) can vary depending on the complexity and noise interference of the two-dimensional point cloud data, among othersEffectively selecting the first predetermined coefficient sigma1Different smoothing effects can be achieved and the second predetermined coefficient sigma is selected appropriately2The interference in the two-dimensional point cloud data can be effectively removed. As shown in fig. 6, a better smoothing effect can be obtained.
On the basis of the technical solution of the first possible design, the present embodiment further provides another possible design three for improving the measurement accuracy, that is, after the step S104, the following steps S201 to S205 are included, but not limited thereto.
S201, smoothing the two-dimensional point cloud data by adopting a smoothing algorithm based on a median error term and a spatial continuity adjustment weight to obtain new two-dimensional point cloud data.
In step S201, the details of the smoothing algorithm are described in the second possible design, and are not described herein again. Furthermore, the first preset coefficient σ that is initially set may be specifically based on when the smoothing algorithm is first adopted1And the second predetermined coefficient sigma2The median error term and the spatial continuity are determined.
S202, aiming at the new two-dimensional point cloud data, the steps S102-S104 are sequentially executed, and the wheel set parameters obtained this time are obtained.
S203, comparing the wheel set parameters obtained this time with the wheel set parameters obtained in the previous time to obtain wheel set parameter deviation.
In step S203, when the wheelset parameter includes a plurality of parameters, the sum of the deviations of all the parameters obtained by comparison is used as the wheelset parameter deviation. For example, when the wheelset parameter includes wheel diameter, rim height, rim thickness, and rim integrated value, the sum of the deviations of the four parameters and obtained by comparison can be used as the wheelset parameter deviation.
And S204, judging whether the wheel set parameter deviation is smaller than a preset deviation threshold value.
S205, if yes, outputting the wheel pair parameters obtained this time, otherwise, after adjusting the median error term and the spatial continuity, returning to execute the step S201.
In the above-mentionedIn step S205, the specific manner of adjusting the median error term and the spatial continuity is also specifically based on the adjusted first preset coefficient σ1And the second predetermined coefficient sigma2To make the adjustment.
Based on the third possible design described in the foregoing steps S201 to S205, the parameters of the wheel set can be optimized and calculated step by adjusting the median error term and the spatial continuity smoothing processing manner multiple times, and the calculation result reaching the expected optimization target is output, so as to ensure the accuracy of the measurement result. By performing a test on four wheels of the same bogie, the calculation results shown in table 1 below can be obtained after 10 seconds of measurement and calculation, and the measurement errors shown in table 2 can be obtained by comparing the calculation results with the manual measurement results.
TABLE 1 wheel-set parameter calculation results for four wheels
TABLE 2 wheel set parameter measurement errors for four wheels
Experimental results show that the third technical scheme possibly designed by the embodiment has higher precision, and compared with a manual measuring scheme, errors of the height of the wheel rim and the thickness of the wheel rim can be smaller than 0.12 mm.
On the basis of the technical solution of the first aspect, the present embodiment further provides a fourth possible design with more practical features, that is, as shown in fig. 1, the fourth possible design further includes a data interaction module, a data storage module and a power supply module, which are arranged on the handheld carrier 1, wherein the data interaction module includes, but is not limited to, a bluetooth communication circuit and/or a USB interface circuit; the data interaction module and the data storage module are respectively in communication connection with the control module, and the power supply module is respectively and electrically connected with the contour acquisition module, the control module, the data interaction module and the data storage module. The data interaction module is used for receiving a detection starting instruction of the external equipment and outputting a calculation result to the detection starting instruction, for example, receiving the detection starting instruction from a mobile phone APP terminal, and outputting the calculation result to the mobile phone APP terminal after calculating wheel pair parameters so as to display the parameters. The data storage module is used for realizing a data storage function, can but not limited to store the calculation result and the raw measurement data of the wheel set parameters, and can but not limited to adopt an SD memory card. The power module is used for supplying power to other modules, and a lithium battery is preferably selected so as to improve cruising ability.
The embodiments described above are merely illustrative, and may or may not be physically separate, if referring to units illustrated as separate components; if reference is made to a component displayed as a unit, it may or may not be a physical unit, and may be located in one place or distributed over a plurality of network units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of the embodiment. One of ordinary skill in the art can understand and implement it without inventive effort.
The above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: modifications may be made to the embodiments described above, or equivalents may be substituted for some of the features described. And such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.
Finally, it should be noted that the present invention is not limited to the above alternative embodiments, and that various other forms of products can be obtained by anyone in light of the present invention. The above detailed description should not be taken as limiting the scope of the invention, which is defined in the claims, and which the description is intended to be interpreted accordingly.
Claims (10)
1. A portable wheel set parameter detector is characterized by comprising a handheld carrier (1), and a first positioning block (21), a second positioning block (22), a contour acquisition module and a control module which are arranged on the handheld carrier (1), wherein the first positioning block (21) and the second positioning block (22) are arranged at intervals and are respectively used for positioning a rim inner side area and a rim outer side area;
the contour acquisition module comprises a linear stepping motor (31), a laser displacement sensor (32) and a proximity sensor (33), wherein the linear reciprocating direction of the linear stepping motor (31) is parallel to the straight line of the first positioning block (21) and the second positioning block (22), and the laser displacement sensor (32) and the proximity sensor (33) are respectively bound and arranged on the linear reciprocating part of the linear stepping motor (31);
the control module is respectively in communication connection with the controlled end of the linear stepping motor (31), the output end of the laser displacement sensor (32) and the output end of the proximity sensor (33), and is used for controlling the linear stepping motor (31) to drive the laser displacement sensor (32) and the proximity sensor (33) to move in a unidirectional uniform speed after receiving a detection starting instruction, triggering the laser displacement sensor (32) to start measuring the real-time distance from the sensor to the wheel set profile surface after receiving a triggering signal fed back by the proximity sensor (33) when detecting the first positioning block (21), stopping measuring after receiving a triggering signal fed back by the proximity sensor (33) when detecting the second positioning block (22), and finally calculating to obtain the wheel set parameter according to the measurement data fed back by the laser displacement sensor (32), wherein the wheel set parameters comprise wheel diameter, rim height, rim thickness and/or rim composite value.
2. The portable wheelset parameter measuring instrument of claim 1, wherein the wheelset parameter is calculated from the measurement data fed back from the laser displacement sensor (32), comprising the steps of:
s101, converting the measurement data into two-dimensional point cloud data which are under an actual measurement rectangular coordinate system XOY and are used for representing an actual measurement contour line, wherein the actual measurement rectangular coordinate system XOY takes the first positioning block (21) as a coordinate origin, the moving direction of the laser displacement sensor (32) as a transverse axis direction, and the emitting direction of the laser displacement sensor (32) as a longitudinal axis direction;
s102, calculating a slope kappa of an outer rim inclined section in the actually measured contour line under an XOY (orthogonal coordinate system) by adopting a least square curve fitting method according to the two-dimensional point cloud data, and calculating to obtain a rotation parameter delta theta, namely arctan kappa ' -arctan kappa according to a geometric relation between the slope kappa and an ideal slope kappa ', wherein the ideal slope kappa ' refers to a known slope of the outer rim inclined section in a standard contour line under the XOY;
s103, according to the two-dimensional point cloud data, calculating coordinates (x) of the wheel rim vertex in the actually measured contour line under the actually measured rectangular coordinate system XOY by adopting a radius constraint-based arc fitting methodA,yA) And according to said rotation parameter Δ θ, said coordinate (x)A,yA) And known coordinates (x ') of rim vertices in a standard contour line under the measured rectangular coordinate system XOY'A,y′A) Calculating to obtain translation parameter (delta x ═ x'A-xA cos(Δθ)+yA sin(Δθ),Δy＝y′A-xA sin(Δθ)+yA cos(Δθ))；
S104, according to the rotation parameter delta theta and the translation parameters (delta x, delta y), performing rotation translation operation on all data points in the two-dimensional point cloud data to complete profile matching of the actual measurement contour line and the standard contour line, and according to the new coordinates of the actual measurement contour line and key feature points of the standard contour line, which are used for calculating wheel set parameters, calculating the wheel set parameters which are actually measured.
3. The portable wheelset parameter measuring instrument of claim 2, further comprising, after step S101 and before step S102, the steps of:
and smoothing the two-dimensional point cloud data by adopting a smoothing algorithm based on a median error term and a spatial continuity adjustment weight.
4. The portable wheelset parameter measuring instrument of claim 2, further comprising, after the step S104, the steps of:
s201, smoothing the two-dimensional point cloud data by adopting a smoothing algorithm based on a median error term and a spatial continuity adjustment weight to obtain new two-dimensional point cloud data;
s202, aiming at the new two-dimensional point cloud data, sequentially executing the steps S102-S104 to obtain wheel set parameters obtained this time;
s203, comparing the wheel set parameters obtained this time with wheel set parameters obtained in the previous time to obtain wheel set parameter deviation;
s204, judging whether the parameter deviation of the wheel set is smaller than a preset deviation threshold value or not;
s205, if yes, outputting the wheel pair parameters obtained this time, otherwise, after adjusting the median error term and the spatial continuity, returning to execute the step S201.
5. The portable wheel set parameter detector according to claim 3 or 4, wherein smoothing the two-dimensional point cloud data by using a smoothing algorithm based on a median error term and a spatial continuity adjustment weight comprises:
for the m-th data point p sequentially numbered along the horizontal axis direction in the two-dimensional point cloud datam＝(xm,ym) M is 1,2,3 …, M, and the new coordinates after smoothing are calculated according to the following formula
Wherein M represents the two-dimensional pointThe total number of data points in the cloud data, M represents a positive integer not greater than M, N represents a preset positive integer reflecting the width of the upper and lower limits of the neighborhood, i represents a positive integer, and x represents a preset positive integerm+iAbscissa, y, representing the m + i-th data pointm+iOrdinate, y, representing the m + i-th data pointm+i-1Denotes the ordinate, y, of the m + i-1 th data pointm+i+1Denotes the ordinate, ω, of the m + i +1 th data point(m+i)Represents the weight factor, omega, corresponding to the m + i-th data point1,(m+i)Represents the median error term, ω, corresponding to the m + i-th data point2,(m+i)Representing the spatial continuity, σ, corresponding to the m + i-th data point1Representing a first predetermined coefficient, σ2Represents a second predetermined coefficient, | pm+i-pm| | represents the distance from the m + i-th data point to the m-th data point before the smoothing process.
6. The portable wheelset parameter measuring instrument of claim 4, wherein when the wheelset parameter includes a plurality of parameters, comparing the wheelset parameter obtained this time with a wheelset parameter obtained a previous time to obtain a wheelset parameter deviation, comprises:
and taking the sum of the deviations of all the parameters obtained by comparison as the deviation of the parameters of the wheel set.
7. The portable wheelset parameter measuring instrument of claim 2, wherein the coordinates (x) of the wheel rim vertices in the measured contour line in the measured rectangular coordinate system XOY are calculated according to the two-dimensional point cloud data by using a circular arc fitting method based on radius constraintsA,yA) The method comprises the following steps:
let the equation of the circle where the arc is located be: (x-D)2+(y-E)2-R2The circular arc is a circular arc where a rim vertex is located, (D, E) represents a circle center to be solved of a circle where the circular arc is located, and R represents a preset radius of the circle where the circular arc is located;
the objective function is set as:
wherein z represents a binary unknown quantity about the center of the circle to be found, and z is (z)x,zy) N represents a positive integer, j represents a positive integer not greater than n;
the objective function f (z) is approximately converted into a quadratic function q (z) using a taylor series as follows:
in the formula, gkDenotes the target function f (z) when z ═ zkFirst derivative of (A), GkDenotes the target function f (z) when z ═ zkThe second derivative of (a), T denotes the transposed sign;
obtaining a minimum value point of the quadratic function Q (x) by adopting a Newton iteration method, and taking the minimum value point as an optimal solution coordinate of the circle center to be solved;
and determining the coordinates of the top point of the wheel rim in the actually measured contour line according to the geometric relation between the optimal solution coordinates of the circle center to be solved and the arc.
8. The portable wheelset parameter measuring instrument according to claim 1, wherein the control module is further configured to trigger and control the linear stepping motor (31) to drive the laser displacement sensor (32) and the proximity sensor (33) to perform a unidirectional deceleration motion after receiving a trigger signal fed back by the proximity sensor (33) when the second positioning block (22) is detected, so as to stop the motion when the sensor reaches a mechanical limit.
9. The portable wheel set parameter detector according to claim 1, further comprising a data interaction module, a data storage module and a power supply module arranged on the handheld vehicle (1), wherein the data interaction module comprises a bluetooth communication circuit and/or a USB interface circuit;
the data interaction module and the data storage module are respectively in communication connection with the control module, and the power supply module is respectively and electrically connected with the contour acquisition module, the control module, the data interaction module and the data storage module.
10. The portable wheel set parameter detector according to claim 1, wherein the control module employs a processor chip of model number STM32F407 and its peripheral circuitry.
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