CN113074655B - Dynamic image wheel out-of-roundness monitoring method - Google Patents
Dynamic image wheel out-of-roundness monitoring method Download PDFInfo
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- CN113074655B CN113074655B CN202010007944.7A CN202010007944A CN113074655B CN 113074655 B CN113074655 B CN 113074655B CN 202010007944 A CN202010007944 A CN 202010007944A CN 113074655 B CN113074655 B CN 113074655B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/2408—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures for measuring roundness
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/002—Measuring arrangements characterised by the use of optical techniques for measuring two or more coordinates
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Abstract
The invention relates to a dynamic image wheel out-of-roundness monitoring method which comprises a main machine part and a dynamic measuring device part. The main machine part comprises an image processing system, and the dynamic measuring device part comprises an image acquisition system and a target following system. The image acquisition system comprises two linear laser light sources and two high-speed cameras. The target following system comprises a linear laser light source, a high-speed camera and a motor control system. The invention can set the image processing system to be in a data acquisition mode and can carry out unmanned operation; through automatic measurement, the measurement time is short, and the data is stable; the final measurement error of the out-of-roundness of the wheel pair is within 0.3 mm.
Description
Technical Field
The invention relates to a method for measuring the out-of-roundness of a wheel by an image monitoring method; the basic principle of the method is that linear laser light sources are used for irradiating treads of wheels on two sides of a train, a group of laser light sources are arranged on an axle in the middle of the wheels on the two sides, the train wheels are continuously shot through a high-speed camera, finally, shot images are processed to obtain the appearance condition of the train wheels, the coordinates of the top points of wheel rims are identified according to the appearance condition of the train wheels, and the out-of-roundness of the treads is calculated.
Background
The monitoring method of the wheel roundness mainly comprises static monitoring and dynamic monitoring. The static monitoring needs to be carried out under the condition that the train stops or wheels are disassembled, so that the turnover time of the train is occupied, the speed is low, the inaccuracy is realized, and the labor intensity is high; the dynamic monitoring not only can realize the on-line monitoring of the wheel set, but also has high degree of automation, does not occupy the turnover time of the vehicle, is convenient for storing information data, most of the current domestic monitoring methods for the roundness of the vehicle are static monitoring, and the dynamic monitoring methods are widely applied in Germany, england, the Netherlands and other countries.
The monitoring system for dynamic monitoring can adopt a ground-borne type and a ground-borne type. The vehicle-mounted monitoring system indirectly obtains the tread shape parameters by monitoring the acceleration of the vibration of the axle. Sensors need to be installed on each axle, which is inconvenient and economical and is not generally adopted; the ground type monitoring system is suitable for monitoring locomotive vehicles in operation and is widely applied abroad.
According to the monitoring principle, the current major dynamic monitoring methods can be divided into: the vibration acceleration monitoring method for monitoring the vibration generated by the action of the wheel track and the contact monitoring method for monitoring the tread eccentricity are adopted. Each of these methods has its advantages and disadvantages as well as the applicable environment.
Vibration acceleration monitoring method: when a train runs on a track, the track can vibrate due to the interaction between the wheel rails, and the vibration can also increase when the wheels are out of round. The vibration acceleration method utilizes the characteristic to collect the vibration condition of the track when the whole train passes through the monitoring point, and extracts the wheel information with defects through analysis. The method has the advantages of convenient installation, stable performance, more accurate monitoring and capability of monitoring medium and high speed trains. The method has the following defects: during monitoring, because rotational vibration caused by the roughness of a tread and the concave-convex of a track exists between wheel tracks, an appropriate method needs to be selected to eliminate the influence of the rotational vibration during data processing; because the magnitude of the vibration acceleration is related to the magnitude of the speed, a perfect speed change curve needs to be established; the sensors are fixed in installation distance, so that the device is not suitable for monitoring wheels with different radiuses, and has higher requirements on the speed of a train.
Contact measurement method: when the train wheel is out of round, the radius of the wheel changes, so that the radius of the wheel in the whole circumference is different, but the wheel flange is always kept unchanged because the out-of-round wheel is only the tread part. Therefore, the defect condition of the wheel tread can be judged by monitoring the change of the height of the wheel flange. When the height of the wheel flange is almost unchanged, the wheel is a perfect wheel; when the height of the wheel rim fluctuates in the whole circumferential direction, the wheel has out-of-roundness; when the rim height changes within a small range, the wheel is scratched. The contact measurement method is based on this principle. The contact measurement method has the advantages of simple principle, convenient installation, capability of directly monitoring the change of the tread radius of the wheel, no need of complex data processing process, accurate measurement and difficult omission of detection. However, due to the structural characteristics of the monitoring system device, the defect information of the wheels can be correctly monitored only by the train slowly passing through the monitoring point, which is difficult to realize for the online monitoring of the wheels; and the structural particularity of the device has certain probability to easily cause accidents.
Aiming at the current situation that the roundness of the wheel is monitored frequently and the polygon problem of the wheel is increased day by day, the lowest monitoring speed and the highest monitoring speed of a vibration acceleration monitoring method are respectively 30km/h and 100km/h, various trains in China cannot be monitored completely, although a contact measurement method can well meet the data requirement of the classification standard of the out-of-roundness of the wheel in China, the monitoring speed is too low, and the potential safety hazard caused by the particularity of a monitoring device is not in line with the purpose of monitoring the wheel.
Disclosure of Invention
The problems to be solved by the invention are as follows: aiming at the existing measuring method and measuring precision, a scheme for monitoring the out-of-roundness of the wheel set tread based on the cooperation of image processing and a motor control system is provided. Through the scheme, the purposes of high precision requirement and convenient use can be achieved.
In order to solve the technical problems, the invention adopts the following technical scheme:
a dynamic image wheel out-of-roundness monitoring method is characterized by comprising the following steps: the dynamic measuring device comprises a host part and a dynamic measuring device part; wherein, the host computer part comprises an image processing system; the dynamic measuring device part comprises an image acquisition system and an object following system. The image acquisition system comprises two linear laser light sources and two high-speed cameras. The target following system comprises a linear laser light source, a high-speed camera and a motor control system. The main machine part and the dynamic measuring device part are respectively arranged at different places. The image processing system of the host part is deployed in the equipment cabinet, and the image processing system can be operated and set directly through remote connection or equipment. The dynamic measuring device is partially arranged on the inner sides of two rails of the wheel set out-of-roundness measuring area. The main machine part and the dynamic measuring device part are in communication connection and data transmission by means of a plurality of data lines and network cables. And a motor control system of a target following system of the dynamic measuring device part is arranged on the inner side surfaces of the two rails and can walk along the direction of the steel rails. The image acquisition system of the dynamic measuring device part is arranged on the motor control system and can move along with the movement of the motor control system. When a train passes through the dynamic monitoring device for the out-of-roundness of the wheel set, a linear light source and a high-speed camera in the target following system start to recognize until the wheel axle of the wheel set passes through, the linear light source feeds back data of the camera to recognize the wheel axle and judge the position of the circle center, and the motor control system is guided to move along with the movement of the wheel set by judging the position of the circle center. Meanwhile, two linear laser light sources of the image acquisition system are respectively arranged at two sides (inner sides of two rails) of the motor control system and simultaneously irradiate wheels at two sides of the wheel pair, and the linear laser light sources pass through the circle center; two high-speed cameras of the image acquisition system respectively acquire laser light source data which are arranged on two sides and hit wheels on two sides of the wheel pair, and transmit the laser light source data to the image processing system. When the image acquisition system follows up the acquired data with one wheel pair, after the data acquisition of one circle of the wheel pair is judged to be finished, the information is fed back to the motor control system, the motor control system controls the motor to start to butt joint with the wheel shaft of the next wheel pair, the related data of the out-of-roundness of the wheels of the next wheel pair is acquired, and the like. When the out-of-roundness data of the wheels on the two sides of the wheel pair is monitored, the image processing system of the host machine part identifies the positions of the vertexes of the rims of the left wheel and the right wheel of the wheel pair through data fed back by the image acquisition system of the dynamic measurement device part through a data line and a network cable, and calculates the relation between the coordinates of the vertexes of the rims of the left wheel and the right wheel and the sensor so as to obtain the out-of-roundness of the wheels on the two sides of the wheel pair.
Has the advantages that: the invention has the characteristics of simple working principle and simple operation, and can carry out unmanned operation when the image processing system is set to be in a data acquisition mode; automatic measurement, stable data and short measurement time; the out-of-roundness measurement error of the wheel set is within 0.3 mm.
Drawings
For better clarity of the apparatus and method of the embodiments of the present invention, the drawings that will be used in the description of the embodiments of the present invention are briefly introduced below, and it is obvious that the drawings in the following description are only one embodiment of the present invention, and it is obvious to those skilled in the art that other design schemes can be obtained according to the principles of these drawings without inventive effort.
FIG. 1 is a schematic diagram of a host portion and a dynamic measurement device portion according to an embodiment of the present invention;
FIG. 2 is a schematic view of a portion of a dynamic measuring device and a pair of measuring wheels according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a host portion according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a portion of a dynamic measurement apparatus according to an embodiment of the present invention;
FIG. 5 is a schematic view of a measuring wheel pair according to an embodiment of the present invention;
FIG. 6 is a schematic diagram illustrating a principle of circle center recognition of a target following system according to an embodiment of the present invention;
FIG. 7 is a schematic flow chart illustrating a measurement principle according to an embodiment of the present invention;
FIG. 8 is a schematic diagram of data coordinate system transformation according to an embodiment of the present invention;
FIG. 9 is a schematic diagram of measured data according to an embodiment of the present invention;
fig. 10 is an overall schematic diagram of an embodiment of the present invention.
Description of the drawings
1. Dynamic measuring device part 2, host part 3 and target following system
4. Image acquisition system 5, image processing system 6, motor control system
7. Linear light source and high-speed camera for target following system
8. Linear light source and high-speed camera 9 of image acquisition system, wheel pair wheel axle
10. Wheel set rim vertex 11, wheel shaft bottommost data point 12 and wheel shaft topmost data point
13. Axle center
Detailed Description
The technical solutions in the embodiments of the present invention will be described below with reference to the drawings of the present invention, and it is obvious that the described embodiments are only a part of specific embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, the present invention mainly comprises two parts: a main machine part (2) and a dynamic measuring device part (1). Two linear laser light sources on a motor control system (6) of an image acquisition system (4) of the dynamic measuring device part (1) respectively irradiate wheel treads on two sides of a wheel pair, and two corresponding high-speed cameras acquire tread image information and transmit the tread image information to an image processing system (5) of the host part (2) through a data line and a network cable. A motor control system (6) of a target tracking system (3) of the dynamic measuring device part (1) identifies wheel set wheel shafts through a linear light source and a high-speed camera (7) so as to control the motor system and the wheel sets to move simultaneously. The image processing system (5) of the host part (2) is positioned in the cabinet, and corresponding data processing is synchronously carried out when the image data is received.
Referring to fig. 2, fig. 2 depicts a dynamic measurement device portion (1) of an embodiment of the present invention. A total of three high-speed cameras are mounted on a motor control system (6) of the target following system (3). The lateral rotation angle and the elevation angle of the left high-speed camera and the right high-speed camera are respectively 33 degrees and 45 degrees, the installation height is 50mm from the sinking distance of the rail surface, and the purpose is to collect more complete and comprehensive linear laser data. The three parameters of the middle high-speed camera are different from the two because the three parameters are used for identifying the wheel set wheel shaft (9) and controlling the motor to track the simultaneous movement of the wheel set. Therefore, the lateral rotation angle of the middle high-speed camera is 0, the elevation angle is 60 degrees, and the installation height is 70mm away from the sinking distance of the rail surface.
Referring to fig. 3, fig. 3 depicts a cabinet for the main part (2) of an embodiment of the invention. An image processing system (5) is mounted in the cabinet. The linear laser light source data collected by the image collecting system (4) are transmitted to the image processing and analyzing system for data processing and analysis.
Referring to fig. 4, fig. 4 depicts an image acquisition system (4) and motor control system (6) of an embodiment of the present invention.
Referring to fig. 5, fig. 5 depicts a wheel-set model measured by an embodiment of the present invention.
Referring to fig. 6, fig. 6 illustrates the principle of the object following system (3) for identifying the center (13) of the wheel axle according to the embodiment of the invention. When a linear light source and a high-speed camera (7) of the target following system (3) receive data information fed back by a wheel set wheel shaft (9), a bottommost data point (11) and an uppermost data point (12) in the data are identified, a wheel set circle center (13) is fitted through the two data points, and the wheel set position information is accurately judged. Therefore, the dynamic measuring device controls the motor control system (6) to enable the image acquisition system (4) to move forward along with the advancing of the wheel pair.
Referring to fig. 7, fig. 7 describes the image data processing flow of the image processing system (5). Firstly, whether the incoming data are abnormal is judged, and then the data are analyzed and transformed into a coordinate point set under a coordinate system. And then carrying out corresponding coordinate transformation on the data coordinate point set according to the coordinates and the installation positions of the three high-speed cameras. And then, carrying out abnormal data elimination processing on the data after the coordinate transformation so as to shield the interference of the miscellaneous points on the data processing and the influence on the data result. And then, the position and the coordinate of the rim vertex (10) are preliminarily extracted through an algorithm, the point interpolation operation within a certain range is carried out on the existing data according to the position and the coordinate of the rim vertex (10) preliminarily, and the position and the coordinate of the rim vertex (10) are accurately searched again. And finally, the whole dynamic measuring device part (1) moves along with the movement of the wheel set wheel shaft (9), and after one circle of data of the wheel is acquired, the coordinates and the positions of the wheel rim vertexes (10) calculated according to the data acquired in one circle are calculated, and finally the out-of-roundness information of the wheel is obtained.
Referring to fig. 8, fig. 8 illustrates a process of converting the camera coordinate system of the data received by the high-speed video camera from the linear laser to the global reference coordinate system.
Referring to fig. 9, fig. 9 illustrates data values measured by the method for the wheel set at the rim vertex of one circle in a real-world situation.
The invention has the effects of avoiding the traditional contact detection method and avoiding the non-roundness of the connected wheel by manual measurement. The traditional static contact detection mode has low efficiency, large labor capacity, inaccurate measured value and large fluctuation range. The lowest monitoring speed and the highest monitoring speed of a dynamic vibration acceleration monitoring method are respectively 30km/h and 100km/h, and various trains in China cannot be completely monitored; although the contact measurement method can well meet the data requirements of the classification standard of the out-of-roundness of the wheel in China, the monitoring speed is too low, and the potential safety hazard brought by the particularity of the monitoring device is not in line with the purpose of on-line monitoring of the wheel.
The invention belongs to a novel, non-contact, dynamic and high-safety wheel out-of-roundness monitoring method, which is simple to operate, short in measurement time and automatic in measurement, and the measured out-of-roundness value of the wheel is stable, and the precision error is only within 0.3 mm.
The foregoing embodiments are provided to illustrate the technical principles of the present invention, the principle of dynamic wheel out-of-roundness monitoring by image processing, and the advantages thereof, it should be understood that the foregoing embodiments are merely exemplary embodiments of the present invention, and are not intended to limit the scope of the present invention, and any modifications, equivalents, improvements, etc. made within the spirit and scope of the present invention should be included in the scope of the present invention.
Claims (1)
1. A dynamic monitoring method for out-of-roundness of a train wheel set is characterized by comprising the following steps: comprises a dynamic measuring device part (1) and a host part (2); wherein the host part (2) comprises an image processing system (5); the dynamic measuring device part (1) comprises an image acquisition system (4) and a target following system (3); the image acquisition system (4) comprises two first linear laser light sources and two first high-speed cameras (8); the target following system (3) comprises a second linear laser light source, a second high-speed camera (7) and a motor control system (6)；The host part (2) and the dynamic measuring device part (1) are respectively arranged at different places; the image processing system (5) of the host part (2) is hosted in an equipment cabinet, either by remote connection or directly by equipmentThe image processing system (5) performs operation and setting; the dynamic measuring device part (1) is deployed on the inner sides of two rails of a wheel set out-of-roundness measuring area; the host part (2) and the dynamic measuring device part (1) are in communication connection and data transmission by virtue of a plurality of data lines and network cables; a motor control system (6) of a target following system (3) of the dynamic measuring device part (1) is arranged on the inner side surfaces of the two rails and walks along the direction of the steel rails; the image acquisition system (4) of the dynamic measuring device part (1) is arranged on the motor control system (6) and moves along with the movement of the motor control system (6); the measurement steps are as follows:
when the train passes through the dynamic measuring device part (1), a second linear laser light source and a second high-speed camera (7) in the target following system (3) start to identify until the wheel set wheel shaft (9) passes through, the data fed back to the camera by the second linear laser light source identifies the wheel set wheel shaft (9) and judges the position of the center of a circle (13) of the wheel shaft, and the motor control system (6) is guided to move along with the movement of the wheel set by judging the position of the center of the circle (13) of the wheel shaft; meanwhile, two first linear laser light sources of the image acquisition system (4) are respectively arranged at two sides of the motor control system (6) and simultaneously irradiate wheels at two sides of the wheel pair, and a second linear laser light source passes through the circle center of the wheel shaft; two first high-speed cameras of the image acquisition system (4) respectively acquire first linear laser light source data which are arranged on wheels on two sides of the wheel pair and transmit the first linear laser light source data to the image processing system (5); when the image acquisition system (4) follows up with one wheel pair to acquire data, after the data acquisition of one circle of the wheel pair is judged to be finished, the information is fed back to the motor control system (6), the motor control system (6) controls the motor to start to butt joint with a wheel shaft (9) of the next wheel pair, the related data of the out-of-roundness of the wheel of the next wheel pair is acquired, and the like; when the out-of-roundness data of the wheels on the two sides of the wheel pair is monitored, the image processing system (5) of the host part (2) identifies the positions of the wheel rim vertexes (10) of the left wheel and the right wheel of the wheel pair through data fed back by the image acquisition system (4) of the dynamic measuring device part (1) through a data line and a network cable, and calculates the relationship between the coordinates of the wheel rim vertexes of the left wheel and the right wheel and the sensor so as to obtain the out-of-roundness of the wheels on the two sides of the wheel pair.
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