CN114264491B - Rail Vehicle Wheelset Parameter Detection System - Google Patents
Rail Vehicle Wheelset Parameter Detection System Download PDFInfo
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Abstract
Description
技术领域technical field
本发明涉及轨道车辆技术领域，具体涉及一种轨道车辆轮对参数检测系统。The invention relates to the technical field of rail vehicles, in particular to a wheel set parameter detection system for rail vehicles.
背景技术Background technique
目前轮对动态检测系统主要由三套检测模块组成，分别是轮对尺寸检测模 块、轮对踏面缺陷动态图像检测模块、轮对不圆度擦伤检测模块，同时还包含 车号识别模块以及控制采集模块等通用模块。At present, the wheel set dynamic detection system is mainly composed of three sets of detection modules, namely the wheel set size detection module, the wheel set tread defect dynamic image detection module, the wheel set out-of-roundness scratch detection module, and also includes the car number recognition module and the control acquisition module and other general modules.
现有技术中，上述三套检测模块基于三组独立的检测机构实现。In the prior art, the above three sets of detection modules are realized based on three sets of independent detection mechanisms.
轮对尺寸检测模块主要采用8个CCD采集箱，每个CCD采集箱内通过安装 支架安装固定有1个CCD相机，用于车轮踏面曲线采集。8个LD激光线光源箱， 每个LD激光线光源箱内通过安装支架安装固定有1组激光线光源，用于截取车 轮外形曲线，以便CCD完成采集。其主要原理为利用“光截图像测量技术”， 激光线光源沿一定角度投射到车轮踏面，形成包含车轮外形尺寸信息的光截曲 线，高分辨率面阵CCD摄像机拍摄车轮外形光截曲线，经图像采集、处理获得 车轮外形轮廓及关键外形几何尺寸。The wheel set size detection module mainly adopts 8 CCD collection boxes, and a CCD camera is installed and fixed in each CCD collection box through a mounting bracket for wheel tread curve collection. 8 LD laser line light source boxes, each LD laser line light source box is installed with a set of laser line light source through the installation bracket, which is used to intercept the wheel profile curve, so that the CCD can complete the collection. The main principle is to use the "light section image measurement technology". The laser line light source is projected onto the wheel tread at a certain angle to form a light section curve containing the information of the wheel shape and size. The high-resolution area array CCD camera captures the light section curve of the wheel shape, and the wheel shape and key shape geometric dimensions are obtained through image acquisition and processing.
轮对踏面缺陷动态图像检测模块主要采用16个面阵相机、16个补光灯构 成，其主要原理为采用高清工业相机多角度拍摄及高精度控制技术实现对轮对 踏面一周360度无死角的图像拍摄，系统采用图像处理算法，将曲面图像转换 为平面图像。The wheel-tread defect dynamic image detection module is mainly composed of 16 area array cameras and 16 supplementary lights. Its main principle is to use high-definition industrial cameras for multi-angle shooting and high-precision control technology to realize 360-degree image shooting of the wheel-tread surface without dead angles. The system uses image processing algorithms to convert curved surface images into flat images.
轮对不圆度擦伤检测模块采用单边轨道接触式擦伤杆数量不少于4根，通 过合理布局，保证车轮的全周覆盖。擦伤检测机构采用平行四边形平动方式， 位于钢轨内侧。The wheel set out-of-roundness scratch detection module adopts no less than 4 unilateral track contact type scratch rods, and through a reasonable layout, the full circumference coverage of the wheels is guaranteed. The scratch detection mechanism adopts a parallelogram translation method and is located inside the rail.
上述三套模块各自独立的执行各自的检测功能，三组模块的组合才能实现 轮对尺寸关键参数(轮缘高度、踏面磨耗、轮缘厚度、QR值、轮对直径、轮对 内侧距、踏面擦伤图像、不圆度擦伤、擦伤深度等)的测量。The above three sets of modules perform their own detection functions independently, and the combination of the three modules can realize the measurement of the key parameters of the wheel set size (rim height, tread wear, rim thickness, QR value, wheel set diameter, wheel set inner distance, tread scratch image, out-of-roundness scratch, scratch depth, etc.).
现有技术中轮对检测系统的缺点如下：需要的检测设备多，设备施工安装 复杂；安装场地面积大；安装场地需建设检测棚或者挡光墙；设备采用面阵相 机，对于环境光的干扰无法完全避免；轮对尺寸检测模块需要定期标定；检测 精度不高，实际应用效果不显著；不圆度检测采用接触式方式，存在精度损失 及安全隐患等。The disadvantages of the wheel set detection system in the prior art are as follows: a lot of detection equipment is required, and the construction and installation of the equipment is complicated; the installation site has a large area; the installation site needs to build a detection shed or light blocking wall; the equipment uses an area array camera, which cannot completely avoid the interference of ambient light;
发明内容Contents of the invention
本发明目的在于解决以上技术问题之一，提供一种综合性的轨道车辆轮对 检测系统，该检测系统集成性高、所用设备少、占地面积小。The purpose of the present invention is to solve one of the above technical problems and provide a comprehensive rail vehicle wheel set detection system, which has high integration, less equipment and a small footprint.
实现上述目的，在本发明一些实施例中，本发明采用的技术方案是：Realize above-mentioned object, in some embodiments of the present invention, the technical scheme that the present invention adopts is:
一种轨道车辆轮对参数检测系统，包括轨旁检测单元、控制单元、轨旁通 信设备及远程终端，所述轨旁通信设备获取轨旁检测单元的检测数据并传递至 远程终端，所述控制单元用于控制轨旁检测单元工作；所述轨旁检测单元包括：A rail vehicle wheel pair parameter detection system includes a trackside detection unit, a control unit, a trackside communication device and a remote terminal, the trackside communication device obtains the detection data of the trackside detection unit and transmits it to the remote terminal, and the control unit is used to control the trackside detection unit to work; the trackside detection unit includes:
三维面阵单元：包括两组，对称设置在两侧轨道的内侧，每组三维面阵单 元包括多个面阵模块，每个面阵模块包括激光器和面阵相机，当车辆驶过时， 所述激光器和所述面阵相机均不与车轮接触；Three-dimensional area array unit: including two groups, symmetrically arranged on the inner side of the rails on both sides, each group of three-dimensional area array unit includes a plurality of area array modules, each area array module includes a laser and an area array camera, when the vehicle passes by, neither the laser nor the area array camera contacts the wheel;
线扫单元：沿车辆行进的方向设置在三维面阵单元的前侧，包括两组，对 称设置在两侧轨道外侧，用于采集车轮点云数据；每组线扫单元包括多个三维 线扫模块，每组中的三维线扫模块呈等间距设置，每组中第一个三维线扫模块 与最后一个三维线扫模块之间的间距不小于单个车轮的外周长，以使线扫单元 可获得轮对踏面全覆盖三维成像；当车辆驶过时，三维线扫模块均不与车轮接 触；Line-scanning unit: set in front of the three-dimensional area array unit along the direction of vehicle travel, including two groups, which are symmetrically arranged outside the tracks on both sides, and are used to collect wheel point cloud data; each group of line-scanning units includes multiple three-dimensional line-scanning modules, and the three-dimensional line-scanning modules in each group are arranged at equal intervals. not in contact with the wheels;
面阵定位单元：靠近三维面阵单元设置，包括面阵定位装置，当检测到所 述面阵定位装置产生感应信号后，控制所述面阵模块启动工作；Area array positioning unit: set close to the three-dimensional area array unit, including an area array positioning device, after detecting that the area array positioning device generates an induction signal, control the area array module to start work;
线扫定位单元：靠近线扫单元设置，包括与单组线扫模块数量相同的线扫 定位装置，多个线扫定位装置设置在同一侧，每个顺次对应一个三维线扫模块； 沿车辆行驶方向，当顺次检测到线扫定位装置产生感应信号，控制三维线扫模 块顺次启动工作；Line-scanning positioning unit: set close to the line-scanning unit, including the same number of line-scanning positioning devices as a single group of line-scanning modules. Multiple line-scanning positioning devices are set on the same side, each corresponding to a three-dimensional line-scanning module in sequence; along the vehicle driving direction, when the line-scanning positioning devices are detected in sequence to generate induction signals, the three-dimensional line-scanning modules are controlled to start working in sequence;
控制单元被配置为：获取线扫单元采集的三维成像数据，进行轮对全圆周 三维数据重建，基于重建后的数据分析车轮踏面擦伤及外轮廓曲线信息；基于 三维面阵单元采集的数据，分析轮对尺寸。The control unit is configured to: obtain the 3D imaging data collected by the line scanning unit, reconstruct the 3D data of the entire circumference of the wheel set, analyze the wheel tread abrasion and outer contour curve information based on the reconstructed data; analyze the wheel set size based on the data collected by the 3D area array unit.
本发明一些实施例中，每组三维面阵单元包括两个面阵模块，两个面阵模 块的图像采集方向呈相对设置。In some embodiments of the present invention, each group of three-dimensional area array units includes two area array modules, and the image acquisition directions of the two area array modules are oppositely arranged.
本发明一些实施例中，所述面阵定位传感器的数量为一，设置在一侧两个 面阵传感器之间。In some embodiments of the present invention, the number of the area array positioning sensor is one, and it is arranged between two area array sensors on one side.
本发明一些实施例中，相邻线扫定位装置之间的间距与三维线扫模块之间 的间距相等；靠近车辆驶来方向的第一个线扫定位装置相对第一个三维线扫模 块，更靠近驶来车辆。In some embodiments of the present invention, the spacing between adjacent line scanning positioning devices is equal to the spacing between three-dimensional line scanning modules; the first line scanning positioning device close to the vehicle's approaching direction is closer to the approaching vehicle than the first three-dimensional line scanning module.
本发明一些实施例中，所述线扫定位装置和所述面阵定位装置均包括：In some embodiments of the present invention, both the line scan positioning device and the area array positioning device include:
车轮传感器：包括两根信号输出线，当车轮经过车轮传感器时，信号输出 线输出正弦信号波；Wheel sensor: including two signal output lines, when the wheel passes the wheel sensor, the signal output line outputs a sine signal wave;
信号处理装置：与信号输出线连接，将信号传递至控制单元。Signal processing device: connected with the signal output line to transmit the signal to the control unit.
本发明一些实施例中，每个三维线扫模块均包括：支架，及间隔安装在支 架上的激光光源和图像采集器；激光光源的出光端与图像采集器的采集端朝向 一致，高度均位于枕木之上。In some embodiments of the present invention, each three-dimensional line scanning module includes: a bracket, and a laser light source and an image collector installed on the bracket at intervals; the light output end of the laser light source is in the same direction as the collection end of the image collector, and the height is above the sleeper.
本发明一些实施例中，每个支架相对轨边线及枕木呈倾斜设置；同组定位 单元中的多个支架平行设置。In some embodiments of the present invention, each support is arranged obliquely relative to the rail edge and the crossties; multiple supports in the same group of positioning units are arranged in parallel.
本发明一些实施例中，图像采集器相对激光光源位于更靠近轨道的一端， 激光光源的出光点位于图像采集器镜头的上方。In some embodiments of the present invention, the image collector is located at one end of the track closer to the laser light source, and the light exit point of the laser light source is located above the lens of the image collector.
本发明一些实施例中，进一步包括车号识别模块，设置在轨旁，包括立柱 和设置在立柱上的车号采集相机；所述控制单元获取车号识别模块采集的车号 信息，并将对三维面阵单元和线扫单元的分析信息与车号匹配。In some embodiments of the present invention, it further includes a car number identification module, which is arranged on the side of the track, including a column and a car number acquisition camera arranged on the column; the control unit acquires the car number information collected by the car number identification module, and matches the analysis information of the three-dimensional area array unit and the line scanning unit with the car number.
本发明一些实施例中，进一步包括测速雷达模块，设置在轨旁，用于测量 车辆的瞬时速度和加速度。In some embodiments of the present invention, it further includes a speed measuring radar module, which is arranged on the side of the track, and is used to measure the instantaneous speed and acceleration of the vehicle.
与现有技术相比，本发明提供的轮对参数检测系统的有益效果在于：Compared with the prior art, the beneficial effects of the wheel set parameter detection system provided by the present invention are:
1、为一套集成化轨道车辆轮对参数检测系统，系统兼容既有轮对尺寸检测 模块、轮对踏面缺陷动态图像检测模块、轮对不圆度擦伤检测模块监测等功能。 减少了所需相机数量，同时降低安装场地面积要求、直线段距离要求。1. It is an integrated rail vehicle wheel set parameter detection system. The system is compatible with the existing wheel set size detection module, wheel set tread defect dynamic image detection module, and wheel set out-of-roundness scratch detection module monitoring and other functions. The number of cameras required is reduced, and at the same time, the requirements for the area of the installation site and the distance of the straight line are reduced.
2、采用超高速三维检测技术实现轨道车辆轮对关键参数检测装置，采用高 光谱高速非接触式激光三角法三维成像技术，利用高光谱激光光源检测实现地 铁车辆轮对高密度横截面三维成像，通过图像处理技术自动判别通过车辆的轮 对踏面尺寸超差故障、自动计算轮对内侧距、轮径、不圆度等重要信息。2. Use ultra-high-speed 3D detection technology to realize the detection device for key parameters of rail vehicle wheelsets, use hyperspectral high-speed non-contact laser triangulation 3D imaging technology, and use hyperspectral laser light source detection to realize high-density cross-sectional 3D imaging of subway vehicle wheelsets, use image processing technology to automatically identify faults that pass the vehicle’s wheelset tread size out of tolerance, and automatically calculate important information such as the inner distance of the wheelset, wheel diameter, and out-of-roundness.
3、采用三维成像技术，可以做到每毫米一线全轮面的360°全覆盖，数据 可靠性增加明显。实现踏面图像三维重建，解决轮面镜面反射问题。3. Using three-dimensional imaging technology, it can achieve 360° full coverage of the entire wheel surface per millimeter line, and the data reliability is significantly increased. Realize the three-dimensional reconstruction of the tread image and solve the problem of the specular reflection of the wheel surface.
4、整个系统数据采集过程中，采用非接触式采集，可靠性高。4. During the data collection process of the whole system, non-contact collection is adopted, which has high reliability.
附图说明Description of drawings
为了更清楚地说明本发明实施例中的技术方案，下面将对实施例或现有技 术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅 仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳 动性的前提下，还可以根据这些附图获得其他的附图。In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following will briefly introduce the accompanying drawings used in the embodiments or prior art descriptions. Obviously, the accompanying drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can also be obtained according to these drawings without paying creative labor.
图1为本发明轮对参数检测系统整体架构示意图；Fig. 1 is a schematic diagram of the overall architecture of the wheel set parameter detection system of the present invention;
图2a为轨旁基本检测单元第一视角结构示意图；Fig. 2a is a structural schematic diagram of the first viewing angle of the basic detection unit at the trackside;
图2b为轨旁基本检测单元第二视角结构示意图；Fig. 2b is a schematic structural diagram of the second viewing angle of the basic detection unit at the trackside;
图3为定位单元触发信号原理图；Fig. 3 is a schematic diagram of a positioning unit trigger signal;
图4a为三维线扫模块结构示意图；Fig. 4a is a schematic structural diagram of a three-dimensional line scanning module;
图4b为三维线扫模块结构示意图；Fig. 4b is a schematic structural diagram of a three-dimensional line scanning module;
图5为三维检测相机畸变图像示意图；Fig. 5 is a schematic diagram of a distorted image of a three-dimensional detection camera;
图6为轮对参数检测方法流程图。Fig. 6 is a flow chart of a wheel set parameter detection method.
其中，图中各附图标记：Wherein, each reference sign in the figure:
1～5：第一组线扫单元结构示意图；1~5: Schematic diagram of the structure of the first group of line scanning units;
6～10：第二组线扫单元结构示意图；6~10: Schematic diagram of the structure of the second group of line scanning units;
11～15：线扫定位单元结构示意图；11~15: Schematic diagram of the structure of the line scanning positioning unit;
16、18：第一组三维面阵单元结构示意图；16, 18: Schematic diagram of the structure of the first group of three-dimensional array elements;
17：面阵定位单元结构示意图；17: Schematic diagram of the structure of the area array positioning unit;
19、20：第二组三维面阵单元结构示意图。19, 20: Schematic diagram of the structure of the second group of three-dimensional array elements.
21-支架；21 - bracket;
22-激光光源；22-laser light source;
23-图像采集器；23 - image collector;
24-枕木；24 - sleepers;
25-轨边线。25-rail edge.
具体实施方式Detailed ways
为了使本发明所要解决的技术问题、技术方案及有益效果更加清楚明白， 以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描 述的具体实施例仅仅用以解释本发明，并不用于限定本发明。In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention clearer, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the present invention, not to limit the present invention.
需要说明的是，当元件被称为“设置在”、“安装在”另一个元件，它可以 直接在另一个元件上或者间接在该另一个元件上。当一个元件被称为是“连接 于”另一个元件，它可以是直接连接到另一个元件或间接连接至该另一个元件 上。It should be noted that when an element is referred to as being "disposed on" or "mounted on" another element, it may be directly on the other element or indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element.
需要理解的是，术语“上”、“下”、“顶”、“底”“内”、“外”等 指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述 本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、 以特定的方位构造和操作，因此不能理解为对本发明的限制。It should be understood that the orientation or positional relationship indicated by the terms "upper", "lower", "top", "bottom", "inner", "outer", etc. are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be construed as limiting the present invention.
需要说明的是，术语“第一”、“第二”、“第三”、“第四”等，仅用 于描述目的，不用于暗指相对重要性。It should be noted that the terms "first", "second", "third", "fourth", etc. are used for descriptive purposes only, and are not used to imply relative importance.
本发明提供一种轨道车辆轮对参数检测系统，结构参考图1。包括轨旁检 测单元、控制单元、轨旁通信设备及远程终端，用于轨道车辆轮对数据的检测， 包括但不限于：轮对尺寸、踏面尺寸、轮对内侧距、轮径、不圆度等。轨旁通 信设备获取轨旁检测单元的检测数据并传递至远程终端，控制单元用于控制轨 旁检测单元工作，控制单元可设置在远程终端。The present invention provides a rail vehicle wheel set parameter detection system, the structure of which refers to FIG. 1 . Including wayside detection unit, control unit, wayside communication equipment and remote terminal, used for detection of rail vehicle wheel set data, including but not limited to: wheel set size, tread size, wheel set inner distance, wheel diameter, out-of-roundness, etc. The wayside communication equipment obtains the detection data of the wayside detection unit and transmits it to the remote terminal, and the control unit is used to control the work of the wayside detection unit, and the control unit can be set in the remote terminal.
轨旁检测单元为执行检测功能的核心功能结构，包括三维面阵单元、线扫 单元、定位单元等，其中定位单元又可分为面阵定位单元和线扫定位单元。The trackside detection unit is the core functional structure for performing detection functions, including three-dimensional area array unit, line scanning unit, positioning unit, etc., and the positioning unit can be divided into area array positioning unit and line scanning positioning unit.
三维面阵单元：包括两组，对称设置在两侧轨道的内侧，每组三维面阵单 元包括多个面阵模块，每个面阵模块包括激光器和面阵相机，当车辆驶过时， 所述激光器和所述面阵相机均不与车轮接触。Three-dimensional area array unit: includes two groups, symmetrically arranged on the inner side of the rails on both sides, each group of three-dimensional area array unit includes a plurality of area array modules, each area array module includes a laser and an area array camera, when the vehicle passes by, neither the laser nor the area array camera contacts the wheel.
更进一步的，为了适时启动三维面阵单元的工作，系统还包括面阵定位单 元，靠近三维面阵单元设置，包括面阵定位装置，当检测到所述面阵定位装置 产生感应信号后，控制所述面阵模块启动工作。Furthermore, in order to start the work of the three-dimensional area array unit in a timely manner, the system also includes an area array positioning unit, which is arranged close to the three-dimensional area array unit, and includes an area array positioning device. When it detects that the area array positioning device generates an induction signal, it controls the area array module to start working.
参考图3所示，面阵定位单元的启动原理图。每个面阵定位单元包括：车 轮传感器和信号处理装置。车轮传感器包括两根信号输出线，当车轮经过车轮 传感器时，信号输出线输出正弦信号波；信号处理装置与信号输出线连接，将 信号传递至控制单元。Referring to Figure 3, the schematic diagram of the start-up of the area array positioning unit. Each area array positioning unit includes: wheel sensor and signal processing device. The wheel sensor includes two signal output lines. When the wheel passes the wheel sensor, the signal output line outputs a sinusoidal signal wave; the signal processing device is connected with the signal output line to transmit the signal to the control unit.
具体的说，车轮传感器的信号通过AB两根线发出，当车轮压过接车传感器， 会在两线之间产生一种类似正弦波的信号，车辆经过的速度越快，其峰值越高， 反之则越低，在没有车轮压过时，接车传感器也会产生一些干扰信号，但是干 扰信号的幅值一般都很低，或者就是幅值较高但是周期很短，所以这就给我们 滤除干扰提供了可能。控制单元中的磁钢板便是对接车传感器信号进行处理后， 将实际的轮子压过时的信号传输至控制机。Specifically, the signal of the wheel sensor is sent out through the two wires A and B. When the wheel passes over the pick-up sensor, a signal similar to a sine wave will be generated between the two lines. The faster the vehicle passes, the higher the peak value, and vice versa. When no wheels pass by, the pick-up sensor will also generate some interference signals, but the amplitude of the interference signal is generally very low, or the amplitude is high but the cycle is very short, so it is possible for us to filter out the interference. The magnetic steel plate in the control unit processes the sensor signal of the docking car, and then transmits the actual wheel overrun signal to the control machine.
控制单元配置车轮传感器参数调整软件，其工作原理为：The control unit is equipped with wheel sensor parameter adjustment software, and its working principle is as follows:
软件提供了3个参数供修改，分别是“幅值”、“脉宽1”、“脉宽2”。 这三者共同在制约，达到滤除干扰但又不会丢轴的效果。滤波的原则是：滤除 幅值较低的，滤除尖峰。所以，我们在调整参数时，根据实际情况，适当调整 这三个参数。The software provides 3 parameters for modification, namely "Amplitude", "Pulse Width 1" and "Pulse Width 2". These three are jointly constrained to achieve the effect of filtering out interference without losing the axis. The principle of filtering is: filter out the low amplitude and filter out the peak. Therefore, when we adjust the parameters, we should adjust these three parameters appropriately according to the actual situation.
本实施例中，每组三维面阵单元包括两个面阵模块，两个面阵模块的图像 采集方向呈相对设置；面阵定位传感器的数量为一，设置在一侧两个面阵传感 器之间。参考图2a和图2b所示，每个面阵模块安装在两个枕木的间隙内，每 组三维面阵单元中的两个面阵模块间隔两个枕木设置，面阵定位单元设置在一 侧三维面阵单元的两个面阵模块之间。In this embodiment, each group of three-dimensional area array units includes two area array modules, and the image acquisition directions of the two area array modules are set oppositely; the number of area array positioning sensors is one, and is arranged between two area array sensors on one side. Referring to Figures 2a and 2b, each area array module is installed in the gap between two sleepers, the two area array modules in each group of three-dimensional area array units are arranged at intervals of two sleepers, and the area array positioning unit is arranged between the two area array modules of the three-dimensional area array unit on one side.
线扫单元：沿车辆行进的方向设置在三维面阵单元的前侧，以图2a所示的 方向，从左至右的方向为车辆行进的方向，前侧是指相对位于车辆向前行驶的 方向上。线扫单元包括两组，对称设置在两侧轨道外侧，用于采集车轮点云数 据；每组线扫单元包括多个三维线扫模块，每组中的三维线扫模块呈等间距设 置，每组中第一个三维线扫模块与最后一个三维线扫模块之间的间距不小于单 个车轮的外周长，以使线扫单元可获得轮对踏面全覆盖三维成像；当车辆驶过 时，三维线扫模块均不与车轮接触。Line scanning unit: set on the front side of the three-dimensional area array unit along the direction of vehicle travel, with the direction shown in Figure 2a, the direction from left to right is the direction of vehicle travel, and the front side refers to the direction in which the vehicle travels forward. The line-scanning unit consists of two groups, which are arranged symmetrically on the outside of the tracks on both sides to collect wheel point cloud data; each group of line-scanning units includes multiple 3D line-scanning modules, and the 3D line-scanning modules in each group are arranged at equal intervals, and the distance between the first 3D line-scanning module and the last 3D line-scanning module in each group is not less than the outer circumference of a single wheel, so that the line-scanning unit can obtain a full-coverage 3D image of the wheel-to-tread surface; when a vehicle passes by, the 3D line-scanning module does not touch the wheel.
更进一步的，为了适时启动线扫单元的工作，系统还包括线扫定位单元： 靠近线扫单元设置，包括与单组线扫模块数量相同的线扫定位装置，多个线扫 定位装置设置在同一侧，每个顺次对应一个三维线扫模块；沿车辆行驶方向， 当顺次检测到线扫定位装置产生感应信号，控制三维线扫模块顺次启动工作。Furthermore, in order to start the work of the line scanning unit in good time, the system also includes a line scanning positioning unit: set close to the line scanning unit, including the same number of line scanning positioning devices as a single group of line scanning modules, multiple line scanning positioning devices are set on the same side, each corresponding to a three-dimensional line scanning module in sequence; along the direction of vehicle travel, when the line scanning positioning devices are detected in sequence to generate induction signals, the three-dimensional line scanning modules are controlled to start working in sequence.
线扫定位装置的工作原理和面阵定位装置的工作原理相同，此处不再赘述。The working principle of the line scan positioning device is the same as that of the area array positioning device, and will not be repeated here.
本实施例中，每组线扫单元包括5个三维线扫模块，相应的包括5各线扫 定位装置。相邻线扫定位装置之间的间距与三维线扫模块之间的间距相等；靠 近车辆驶来方向的第一个线扫定位装置相对第一个三维线扫模块，更靠近驶来 车辆。当第一个线扫定位装置检测到车辆信号后，控制单元启动第一个三维线 扫模块启动工作；随着车辆向前运动，每个线扫定位模块逐一检测到车辆信号， 每个三维线扫模块逐一被启动。由于每个三维线扫模块的图像采集范围有限， 单个三维线扫模块不能采集完整的车轮图像数据。当车辆运行出三维线扫模块 图像采集区域后，线扫单元可以采集完整的车轮数据。In this embodiment, each group of line scanning units includes 5 three-dimensional line scanning modules, and correspondingly includes 5 line scanning positioning devices. The spacing between adjacent line scanning positioning devices is equal to the spacing between the three-dimensional line scanning modules; the first line scanning positioning device close to the vehicle's approaching direction is closer to the oncoming vehicle than the first three-dimensional line scanning module. When the first line scanning positioning device detects the vehicle signal, the control unit starts the first three-dimensional line scanning module to start working; as the vehicle moves forward, each line scanning positioning module detects the vehicle signal one by one, and each three-dimensional line scanning module is activated one by one. Due to the limited image acquisition range of each 3D line scan module, a single 3D line scan module cannot collect complete wheel image data. When the vehicle runs out of the image acquisition area of the 3D line scan module, the line scan unit can collect complete wheel data.
参考图4a和图4b所示，为单个三维线扫模块的结构示意图。Referring to Fig. 4a and Fig. 4b, it is a schematic structural diagram of a single three-dimensional line scanning module.
本发明一些实施例中，每个三维线扫模块均包括：支架21，及间隔安装在 支架21上的激光光源22和图像采集器23；激光光源22的出光端与图像采集 器23的采集端朝向一致，高度均位于枕木24之上。In some embodiments of the present invention, each three-dimensional line scanning module includes: a bracket 21, and a laser light source 22 and an image collector 23 installed at intervals on the bracket 21; the light output end of the laser light source 22 is in the same direction as the collection end of the image collector 23, and the height is all located on the crossties 24.
本发明一些实施例中，每个支架21相对轨边线25及枕木24呈倾斜设置； 同组定位单元中的多个支架21平行设置。In some embodiments of the present invention, each bracket 21 is arranged obliquely relative to the rail edge 25 and the crossties 24; multiple brackets 21 in the same group of positioning units are arranged in parallel.
本发明一些实施例中，图像采集器23相对激光光源22位于更靠近轨道的 一端，激光光源22的出光点位于图像采集器23镜头的上方。In some embodiments of the present invention, the image collector 23 is located at one end closer to the track relative to the laser light source 22, and the light exit point of the laser light source 22 is located above the lens of the image collector 23.
轨边设备间由电源、电气设备及设备柜中的1台控制工控机、3台采集识 别工控机、1台数据存储服务器、1个千兆交换机、1个电源箱、1个IO触发箱、 1个KVM、1个UPS不间断电源、2个PDU组成。完成设备的供电、系统自动运 行控制、数据(图像)采集、数据(图像)分析、数据(图像)的存储、数据 存储运用等任务。该部分属于常规功能，不再赘述。The trackside equipment room is composed of 1 control industrial computer, 3 acquisition and identification industrial computers, 1 data storage server, 1 Gigabit switch, 1 power box, 1 IO trigger box, 1 KVM, 1 UPS uninterruptible power supply, and 2 PDUs in the power supply, electrical equipment and equipment cabinet. Complete tasks such as power supply of equipment, automatic operation control of the system, data (image) collection, data (image) analysis, data (image) storage, and data storage application. This part is a general function and will not be repeated here.
在以上具体实施例中，采用轮对外形三维面阵检测模块4个、踏面外形轮 廓高密度三维线扫模块10个，利用三维技术能够实现高密度激光线(激光线间 距1mm)，提高各关键参数检测精度；采用808nm激光光源，能够有效降低环境 光的干扰；相机数量较当前设备方案大幅度减少，减少对安装场地的要求；采 用三维自标定技术，轮对尺寸无需定期标定；采用三维重建技术，输出轮对踏 面(与钢轨接触横截面)三维图像，能够利用非接触方式实现不圆度检测，减 少接触式测量的安全隐患。In the above specific embodiments, four three-dimensional area array detection modules for the shape of the wheel set and ten high-density three-dimensional line-scanning modules for the contour of the tread are used. Using three-dimensional technology, high-density laser lines (laser line spacing of 1mm) can be used to improve the detection accuracy of key parameters; the use of 808nm laser light source can effectively reduce the interference of ambient light; The three-dimensional image of the surface (cross-section in contact with the rail) can be used for non-contact detection of out-of-roundness, reducing the safety hazards of contact measurement.
控制单元被配置为：获取线扫单元采集的三维成像数据，进行轮对全圆周 三维数据重建，基于重建后的数据分析车轮踏面擦伤及外轮廓曲线信息；基于 三维面阵单元采集的数据，分析轮对尺寸。控制单元可设置在远程控制室，由 数据存储服务器、操作终端、交换机等设备组成，为各子系统共用。用于控制 轮对动态检测及车顶监测系统的启停，监控设备的运行状况，管理最终的检测 结果。The control unit is configured to: obtain the 3D imaging data collected by the line scanning unit, reconstruct the 3D data of the entire circumference of the wheel set, analyze the wheel tread abrasion and outer contour curve information based on the reconstructed data; analyze the wheel set size based on the data collected by the 3D area array unit. The control unit can be set in the remote control room, which is composed of data storage server, operation terminal, switch and other equipment, and is shared by all subsystems. It is used to control the start and stop of the dynamic detection of the wheel set and the roof monitoring system, monitor the operation status of the equipment, and manage the final detection results.
本发明一些实施例中，进一步包括车号识别模块，设置在轨旁，包括立柱 和设置在立柱上的车号采集相机；所述控制单元获取车号识别模块采集的车号 信息，并将对三维面阵单元和线扫单元的分析信息与车号匹配。In some embodiments of the present invention, it further includes a car number identification module, which is arranged on the side of the track, including a column and a car number acquisition camera arranged on the column; the control unit acquires the car number information collected by the car number identification module, and matches the analysis information of the three-dimensional area array unit and the line scanning unit with the car number.
车号识别模块用于与识别车号信息，将轮对尺寸与车辆信息绑定。采用图 像车号识别模块拍摄列车车号图像并自行智能识别输出车号及端位信息。检测 机根据车位触发装置采集的信息，控制车号识别相机的采集和补光灯的触发， 当列车经过车号识别相机时，车号识别相机采用图像方式快速拍摄列车车号图 像，其内部集成了车牌定位算法、车牌字符分割算法等算法，在车辆不停车的 情况下，识别每辆车的车号信息，并及时将车号数据、图像、视频信息上传到 服务器，对进出的车辆进行自动统计，并保存数据。各子系统能够根据读取的 车辆车号信息对应记录所测量的数据。The vehicle number recognition module is used to identify the vehicle number information and bind the wheel set size with the vehicle information. The image car number recognition module is used to capture the image of the train number and intelligently recognize and output the car number and end position information. According to the information collected by the parking space trigger device, the detection machine controls the acquisition of the car number recognition camera and the triggering of the supplementary light. When the train passes by the car number recognition camera, the car number recognition camera uses the image mode to quickly capture the image of the train number. Each subsystem can record the measured data correspondingly according to the read vehicle number information.
图像车号基于嵌入式技术利用彩色面阵相机、防晃眼补偿光源对通过的列 车侧墙上车号、端位进行智能识别，提高系统稳定性及车组号识别准确率。The image car number is based on the embedded technology, using the color area array camera and the anti-glare compensation light source to intelligently identify the car number and end position on the side wall of the passing train, improving the system stability and the recognition accuracy of the train group number.
本发明一些实施例中，进一步包括测速雷达模块，设置在轨旁，用于测量 车辆的瞬时速度和加速度。In some embodiments of the present invention, it further includes a speed measuring radar module, which is arranged on the side of the track, and is used to measure the instantaneous speed and acceleration of the vehicle.
测速雷达利用多普勒效应原理采集列车经过设备时的列车实时速度信息。 测速雷达采用T·CL-2AⅢ抗干扰型驼峰测速雷达，采用(8mm)Ka波段，利用多 普勒效应测量溜放车组的瞬时速度和加速度，同时，采用新一代微波技术及其 器件，降低了电源能耗；应用了FPGA数字信号处理技术，对于车组在减速器区 段溜放状态进行精确测量和定位跟踪；结构设计采用在轨道中心安装方式，驼 峰溜放车辆的速度范围1km/h～30km/h(可根据现场使用要求提高到1km/h～ 350km/h)。The speed measuring radar uses the Doppler effect principle to collect the real-time speed information of the train when the train passes the equipment. The speed measuring radar adopts T·CL-2AⅢ anti-jamming hump speed measuring radar, adopts (8mm) Ka band, and uses Doppler effect to measure the instantaneous speed and acceleration of the rolling car group. At the same time, it adopts a new generation of microwave technology and its devices to reduce power consumption; it uses FPGA digital signal processing technology to carry out accurate measurement and positioning tracking for the rolling state of the car group in the reducer section; the structural design adopts the installation method in the center of the track, and the speed range of the hump rolling car is 1km/h～30km/h (can be Increase to 1km/h～350km/h according to the requirements of field use).
以下，详述控制单元的控制计算功能。Hereinafter, the control calculation function of the control unit will be described in detail.
三维数据重建的过程如下。The process of 3D data reconstruction is as follows.
在三维重建过程中，需要将世界坐标系中的点pw转换到像素坐标系中。In the process of 3D reconstruction, it is necessary to transform the point p w in the world coordinate system into the pixel coordinate system.
首先，要将世界坐标系中的点pw＝(xw,yw,zw)T利用齐次变换矩阵cHw转换到 相机坐标系中，用pc＝(xc,yc,zc)T表示：First, the point p w =(x w ,y w ,z w ) T in the world coordinate system should be transformed into the camera coordinate system by using the homogeneous transformation matrix c H w , expressed by p c =(x c ,y c ,z c ) T :
pc＝cHw·pw (4-1)p c = c H w p w (4-1)
即：Right now:
式中，齐次变换矩阵cHw是通过六个元素确定的，分别是X、Y、Z轴上的 平移分量tx,ty,tz和旋转角度α,β,γ，也叫做相机的外部参数。In the formula, the homogeneous transformation matrix c H w is determined by six elements, which are the translation components t x , ty , t z on the X, Y, and Z axes and the rotation angles α, β, γ, which are also called the external parameters of the camera.
然后，将相机坐标系中的三维点pc转化为图像平面坐标系中的点pi＝(u,v)T：Then, transform the 3D point p c in the camera coordinate system into a point p i =(u,v) T in the image plane coordinate system:
式中f——相机镜头的焦距。Where f is the focal length of the camera lens.
由于镜头存在畸变，造成了点的偏移，实际坐标应为根据关系 公式：Due to the distortion of the lens, the point is shifted, and the actual coordinates should be According to the relational formula:
式中k——畸变系数，k为负数为鼓形失真，k为正数为枕形失真，如图5 所示。In the formula, k—distortion coefficient, k is a negative number for drum distortion, and k is a positive number for pincushion distortion, as shown in Figure 5.
通过变换，可以得到：By transformation, you can get:
最后，将P′点从图像平面坐标系转换到像素坐标系中：Finally, transform the point P' from the image plane coordinate system to the pixel coordinate system:
式中r——像素坐标系中的横坐标；In the formula, r—the abscissa in the pixel coordinate system;
c——像素坐标系中的纵坐标；c—the vertical coordinate in the pixel coordinate system;
Sx——相机像元的宽度；S x - the width of the camera pixel;
Sy——相机像元的高度；S y ——height of camera pixel;
Cx——图像中心点的横坐标；C x —— the abscissa of the center point of the image;
Cy——图像中心点的纵坐标。C y ——the vertical coordinate of the center point of the image.
从上面得到的参数f、k、Sx、Sy、Cx和Cy组成了相机的内部参数。The parameters f, k, S x , S y , C x and C y obtained from above constitute the internal parameters of the camera.
利用相机的内部参数和外部参数，可以进行对光平面的标定。本方法中采 用三维自标定技术，轮对尺寸无需定期标定；采用三维重建技术，输出轮对踏 面(与钢轨接触横截面)三维图像，能够利用非接触方式实现不圆度检测，减 少接触式测量的安全隐患。Using the internal parameters and external parameters of the camera, the alignment plane can be calibrated. In this method, the three-dimensional self-calibration technology is adopted, and the size of the wheel set does not need to be regularly calibrated; the three-dimensional reconstruction technology is used to output the three-dimensional image of the wheel set tread (cross-section in contact with the rail), and the non-contact method can be used to realize the out-of-roundness detection and reduce the safety hazard of contact measurement.
首先移动标定板，是其与激光线平面分别相交两次，得到两条光条图像。 利用灰度中心法提取出光条中心(ui,vi)，计算方法如下：First, move the calibration plate so that it intersects the laser line plane twice to obtain two light strip images. Use the gray center method to extract the light bar center (u i , v i ), the calculation method is as follows:
式中G(x,y)——(x,y)点的灰度值。In the formula, G(x, y)——the gray value of point (x, y).
通过对两个位置的标定板进行标定，可以得到标定板的Z轴坐标Zw1和Zw2， 把低位置的定义为0平面。By calibrating the calibration board at two positions, the Z-axis coordinates Z w1 and Z w2 of the calibration board can be obtained, and the lower position is defined as the 0 plane.
根据上述像素坐标系和世界坐标系之间的关系，可以得到对应关系式：According to the above relationship between the pixel coordinate system and the world coordinate system, the corresponding relationship can be obtained:
式中n——未知参数；In the formula, n——unknown parameter;
M——投影矩阵；M——projection matrix;
R——3×3大小的旋转矩阵；R——rotation matrix of 3×3 size;
t——3×1大小的平移矩阵；t——translation matrix of 3×1 size;
Xwi、Ywi、Zwi——激光平面中的坐标。X wi , Y wi , Z wi - coordinates in the laser plane.
通过展开上面的矩阵方程，可以得到：By expanding the above matrix equation, we get:
消去n，可得Eliminate n to get
通过之前的计算，Zwi是已知的，M中各元素也是已知的，代入光条中心坐 标即可得到(Xwi,Ywi,Zwi)的坐标，不在同一条直线上的三个点即可确定一个平面：Through the previous calculation, Z wi is known, and the elements in M are also known. Substituting the coordinates of the center of the light bar can get the coordinates of (X wi , Y wi , Z wi ), and three points that are not on the same straight line can determine a plane:
式中X、Y、Z——光平面法向量。In the formula, X, Y, Z——light plane normal vector.
参数检测流程参考图5。Refer to Figure 5 for the parameter detection process.
接车前：Before picking up the car:
列车通过最接近车辆的车轮传感器时，传感器产生正弦波微信号并传输至 车轮传感器处理装置，车轮传感器处理装置对正线波信号进行滤波、整形、抬 压等处理后将数据通过485转网口模块传输至24口交换机，控制工控机对该数 据进行分析并判断该轴距特征是否符合所要检测车型，若符合所要检测的车型 数据，则系统进入接车状态。When the train passes the wheel sensor closest to the vehicle, the sensor generates a sine wave micro-signal and transmits it to the wheel sensor processing device. The wheel sensor processing device performs filtering, shaping, boosting and other processing on the sine wave signal and then transmits the data to the 24-port switch through the 485 network port module. The control industrial computer analyzes the data and judges whether the wheelbase characteristics conform to the vehicle type to be detected.
接车中：Picking up the car:
(1)接车(1) pick up the car
控制工控机通过UDP广播协议发送接车指令，三维面阵单元和三维线扫单 元的相机均处于待命状态；Control the industrial computer to send the pick-up command through the UDP broadcast protocol, and the cameras of the 3D area array unit and the 3D line scan unit are in standby state;
(2)开始采集(2) Start collecting
控制工控机通过UDP广播协议给图像车号采集装置、采集识别工控机、数 据存储识别服务器发送开始工作指令，控制工控机结合车轮传感器处理装置处 理数据及雷达测速装置测速数据计算出相机采集频率，并通过UDP广播传输至 控制箱，控制箱输出相应的信号触发各采集模块。同时，图像车号采集装置按 照最高帧率采集并将识别的数据通过网线传输至车辆信息采集计算机内，各通 道采集图片均从采集机实时传输至数据存储服务器。Control the industrial computer to send start work instructions to the image vehicle number acquisition device, acquisition and identification industrial computer, and data storage and identification server through the UDP broadcast protocol. The control industrial computer combines the processing data of the wheel sensor processing device and the speed measurement data of the radar speed measuring device to calculate the camera acquisition frequency, and transmit it to the control box through UDP broadcast. The control box outputs corresponding signals to trigger each acquisition module. At the same time, the image vehicle number collection device collects according to the highest frame rate and transmits the identified data to the vehicle information collection computer through the network cable, and the pictures collected by each channel are transmitted from the collection machine to the data storage server in real time.
接车后：After picking up the car:
(1)停止采集(1) stop collecting
列车每个车轮经过定位单元后，定位单元会进行计数统计。当面阵定位单 元17、线扫定位单元11、12、13(最靠近面阵定位单元的三个线扫定位单元) 的计轴统计数量一致时，系统认为过车已结束，此时车辆信息采集计算机停止 发送指令采集，所有采集模块停止采集。After each wheel of the train passes the positioning unit, the positioning unit will count and count. When the axle counting statistics of the area array positioning unit 17 and the line scanning positioning units 11, 12, 13 (the three line scanning positioning units closest to the area array positioning unit) are consistent, the system thinks that the passing vehicle has ended, and at this time the vehicle information acquisition computer stops sending commands to collect, and all acquisition modules stop collecting.
(2)休眠+吹风除尘(2) Sleep + Blowing and Dust Removal
接着，车辆信息采集计算机通过UDP广播发送结束指令，各采集模块处于 休眠状态，同时，电源箱吹风除尘接口输出DC24V，吹风除尘装置对采集模块 进行吹风除尘处理。Then, the vehicle information collection computer sends an end command through UDP broadcast, and each collection module is in a dormant state. At the same time, the blower and dust removal interface of the power supply box outputs DC24V, and the blower and dust removal device carries out blowing and dust removal processing to the collection modules.
(3)数据处理(3) Data processing
与此同时，数据存储识别服务器通过24口交换机从采集机获取过车的图片 数据并进行处理。At the same time, the data storage and identification server obtains the picture data of passing cars from the acquisition machine through a 24-port switch and processes them.
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发 明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明 的保护范围之内。The above descriptions are only preferred embodiments of the present invention, and are not intended to limit the present invention. Any modifications, equivalent replacements and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
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