CN115326812A - Vehicle-mounted wheel pair measuring sensor and measuring method - Google Patents
Vehicle-mounted wheel pair measuring sensor and measuring method Download PDFInfo
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- CN115326812A CN115326812A CN202211040182.6A CN202211040182A CN115326812A CN 115326812 A CN115326812 A CN 115326812A CN 202211040182 A CN202211040182 A CN 202211040182A CN 115326812 A CN115326812 A CN 115326812A
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B61K9/02—Profile gauges, e.g. loading gauges
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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
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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
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
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- G—PHYSICS
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- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/22—Measuring arrangements characterised by the use of optical techniques for measuring depth
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
- G01N2021/8887—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges based on image processing techniques
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Abstract
The invention provides a vehicle-mounted wheel pair measuring sensor, which is arranged on the inner side of a wheel and comprises a camera, a laser and a controller, wherein the camera is arranged on the inner side of the wheel; the controller comprises a laser control module, an acquisition module, a tread defect detection module, a tread information storage module and a communication module; collecting laser bar images by a camera; the tread defect detection module acquires point cloud information, searches points with coordinate values exceeding a normal coordinate interval in a tread area of the laser bar and marks the points as defect points, and transmits the coordinates of the defect points to the tread information storage module; the tread information storage module counts the number of defect points and gives a prompt when the number is abnormal; the wheel rim size measuring module is connected with the acquisition module and the wheel rim information storage module; the rim dimension measuring module acquires point cloud information and calculates the geometric dimension of the rim by using the point cloud information; monitoring the state of the wheel rim; the sensor of the scheme of the invention can dynamically monitor the conditions of the wheel set tread and the wheel rim in real time by adopting a vehicle-mounted mode, can find the abnormality of the wheel set in time, and has high safety.
Description
Technical Field
The invention relates to the field of rail transit automatic detection, in particular to a vehicle-mounted wheel pair measuring sensor and a measuring method.
Background
In recent years, with the rapid development of railways in China, railway lines are continuously increased, the speed of trains is gradually increased, the carrying capacity is increased more and more, and vehicles are in explosive growth, wherein the geometric dimension parameter of wheels is out of limit and the surface defect of treads is an important fault in the use process of railway vehicles. At present, the mainstream detection mode is manual detection or automatic detection is realized by arranging a detection sensor beside a track, wherein the manual detection efficiency is low, the false detection rate is high, and the working intensity is high; the automatic detection beside the rail needs the train to finish the detection only through a detection sensor, and the current wheel detection scheme is as follows: the detection method of installing a detection shed near a train parking lot or a station and installing a detection sensor on one side of a track has the following problems:
1. the train is detected only twice in the running process, the detection real-time performance is poor, the problem cannot be found at the first time, and potential safety hazards exist;
2. the existing detection sensor collects the surface image of the wheel set, only two-dimensional image analysis is used for defects, when dirt and other attachments exist on the tread, the method can also mistake the tread as the tread defects, and in the actual rail traffic industry maintenance specification, the defects are pits, scratches and the like which exceed a certain threshold (usually 1 cm);
3. in order to shoot the circumference of the whole wheel, a plurality of detection sensors are required to be arranged, each sensor only collects a local area of the wheel, and the detection areas are spliced by the plurality of detection sensors to obtain the condition of the whole circumference; the splicing process inevitably causes precision loss.
Disclosure of Invention
Traditional rail transit detects the needs that can not satisfy train safety operation, in order to solve above-mentioned technical problem, this paper has proposed a vehicle-mounted train wheel set measuring transducer, installs the sensor in bogie, wheel oblique top, adopts the on-vehicle mode can dynamic real time monitoring wheel set surface condition, in time discovers the wheel set unusual, and the security is high.
The technical scheme is as follows:
a vehicle wheel pair measuring sensor is arranged on a bogie on the inner side of a wheel and comprises a camera, a laser and a controller; the camera and the laser are both positioned above the wheels in an inclined manner, the laser is used for projecting laser stripes to the surfaces of the wheels, the camera is used for collecting laser stripe images, and the camera and the laser stripe images are both controlled by the controller;
the controller comprises a laser control module, an acquisition module, a tread defect detection module, a tread information storage module and a communication module;
the communication module is respectively connected with the acquisition module, the laser control module and the tread information storage module, and the tread defect detection module is respectively connected with the acquisition module and the tread information storage module;
the communication module can communicate with an upper computer, and when a train is started, starting signals are respectively sent to the laser control module and the acquisition module; when the train stops, a closing signal is respectively sent to the laser control module and the acquisition module;
the laser control module is used for controlling the laser to continuously project laser stripes to the surface of the wheel;
the acquisition module controls the camera to continuously acquire laser bar images according to a preset frame rate and sequentially transmits the images to the tread defect detection module;
the tread defect detection module acquires point cloud information on each laser bar, searches points with coordinate values exceeding a normal coordinate interval in a tread area of the laser bar as defect points, and transmits the coordinates of the defect points to the tread information storage module for storage;
the tread information storage module counts the number of defect points with continuous coordinates, and when the number exceeds a threshold value A, an alarm signal is sent to the communication module, and the communication module sends the alarm signal to the upper computer to prompt that the wheel tread of a worker is abnormal.
Further, the controller also comprises a rim size measuring module and a rim information storage module;
the rim size measuring module is respectively connected with the acquisition module and the rim information storage module;
the rim information storage module is connected to the communication module;
the acquisition module sequentially transmits the laser bar images acquired by the camera to the rim size measurement module at regular time or real time according to a preset time interval;
the rim dimension measuring module respectively acquires point cloud information on each laser bar and calculates the geometric dimension of the rim by using the point cloud information; the rim geometry comprises one or more of a rim height, a rim thickness, a rim vertical wear, a QR value;
the wheel rim geometrical size is transmitted to a wheel rim information storage module to be stored, the wheel rim information storage module judges whether the wheel rim geometrical size is in a corresponding preset interval, if yes, the wheel rim is normal, if not, the wheel rim is abnormal, an alarm signal is sent to a communication module, and the communication module sends the alarm signal to an upper computer to prompt that the wheel rim of a wheel of a worker is abnormal.
Further, the preset time interval is 1 minute to 10 hours;
the height value of the wheel rim is calculated in the following way:
calculating the vertical distance between each point in the rim area on the laser strip and the reference point, and recording the maximum vertical distance as the height value of the rim;
the rim region is the region to the left of the demarcation point; the demarcation points are: pixel points which are at the left side of the reference point and have a distance of 30-50 mm from the reference point;
the reference points are as follows: pixel points at the position from the inner side surface of the wheel rim to the 70mm position of the tread, wherein the inner side surface of the wheel rim is a plane obtained by utilizing 30-80 pixel points close to the left edge of the image on the laser strip in a fitting mode;
the vertical distance is a coordinate difference value in a vertical direction, and the vertical direction is as follows: the direction vertical to the tangent plane of the tread where the laser strip is located;
the thickness value of the wheel rim is calculated by the following method:
drawing a straight line vertical to the inner side surface of the wheel rim through the reference point, translating the straight line upwards by 10mm or 12mm, intersecting the straight line with the laser strip, and recording the horizontal distance between two intersection points as the thickness value of the wheel rim;
the horizontal distance is the distance along the direction of the train wheel axle;
the abrasion value of the wheel rim is calculated in the following way:
making a straight line perpendicular to the inner side face of the wheel rim through the reference point, translating the straight line upwards by 15mm, intersecting the straight line with the laser bar, and recording the horizontal distance between the two points as a comparison value;
recording the difference between the rim thickness value and the comparison value as a rim abrasion value;
the QR value calculation mode is as follows: and recording a point corresponding to the height value of the wheel rim as a highest point, descending the highest point by 2mm to obtain a point B, drawing a straight line perpendicular to the inner side surface of the wheel rim by using the passing point B, intersecting the straight line with the laser bar, recording a right intersection point as a point C, and recording a horizontal distance between the point A and the point C as a QR value.
Further, the tread defect detection module acquires point cloud information on each laser bar, and searches for a point mark with a coordinate value exceeding a normal coordinate interval in a tread area of the laser bar as a defect point, wherein the mode is as follows:
converting the point cloud on each laser bar into a laser plane coordinate system, sequentially calculating the slope of a tangent line between two adjacent points in the tread area of each laser bar, and marking the two points as defect points if the absolute value of the slope is higher than a threshold B;
the threshold B takes a value of 0.4 to 06;
the tread area is an area on the right side of the demarcation point; the demarcation point is a pixel point which is on the left side of the datum point and is 30-50 mm away from the datum point.
Further, recording the direction along the axle of the train as an X axis, recording the direction vertical to the tangent plane of the tread where the laser strip is positioned as a Y axis, recording the direction vertical to the XOY plane as a Z axis, and establishing a sensor coordinate system;
converting the point cloud on each laser bar into a laser plane coordinate system by the following two methods:
the first method is as follows: when the laser bar and the train axle are coplanar, recording the coordinates of the point cloud on an XOY plane as plane coordinates in a laser plane coordinate system;
the second method comprises the following steps: when the laser strip is not in the same plane with the train axle, firstly calibrating to obtain: the equation of a space straight line l of the wheel shaft under a sensor coordinate system and the space plane equation of the inner side face of the wheel rim under the sensor coordinate system;
and then, recording the distance from any point Q on the laser bar to the space straight line l as a Y-axis coordinate in a laser plane coordinate system, and recording the distance from the point Q to the inner side surface of the wheel rim as a Z-axis coordinate in the laser plane coordinate system.
Further, the tread information storage module is further configured to count coordinate intervals of defect points with continuous coordinates in the horizontal direction and coordinate intervals of defect points in the vertical direction, and respectively mark the coordinate intervals as a width distribution interval and a depth distribution interval of the defect;
the horizontal direction is as follows: along the direction of the train wheel axle, the vertical direction is: and the direction is vertical to the tangent plane of the tread on which the laser strip is positioned.
Further, the acquisition module sorts the laser bar images according to time sequence and transmits the images to the tread defect detection module in sequence;
the tread information storage module is also used for recording laser bar serial numbers corresponding to the defect points, counting the number n of laser bars with continuous serial numbers, calculating the length value of the defect = nxxv × t, wherein v is the current speed of the train, and t is the total time required for collecting the laser bars with continuous serial numbers.
Preferably, when the laser is a single-line laser, the camera is a line camera; when the laser is a multi-line laser, the camera is an area-array camera;
the preset frame rate of the camera is 5-30 kHz;
the threshold value A takes a value of 20-100;
the number of the sensors corresponds to the number of the wheels, and a measuring sensor is arranged on the inner side of each wheel;
the sensor is installed on a bogie on the inner side of a wheel through a support frame, one end of the support frame is fixedly connected with the sensor, the other end of the support frame is in threaded connection with the bogie, and after a train runs, the support frame is detached from the current train bogie and installed on other vehicle bogies to be dispatched.
The invention also relates to a method for measuring by using the vehicle-mounted wheel pair measuring sensor, which comprises the following steps: when a controller in the sensor receives a train starting signal, controlling a laser to continuously project a laser bar to the surface of the wheel, wherein the laser bar is vertical to the traveling direction of the wheel;
meanwhile, the camera continuously collects laser bar images according to a preset frame rate and sequentially transmits the images to the controller;
the controller acquires point cloud information on each laser bar, marks points of the tread area, the coordinate values of which exceed a normal coordinate interval, as defect points, stores the coordinates of the defect points, counts the number of the defect points with continuous coordinates, and sends an alarm signal to the upper computer when the number of the defect points exceeds a threshold value A to prompt a worker that the tread of the wheel is abnormal;
when the train stops, the controller sends a shutdown signal to the camera and the laser.
Further, the controller also processes the laser bar images according to a preset time interval; respectively acquiring point cloud information on each laser bar, and calculating the geometric dimension of the wheel rim by using the point cloud information; the rim geometry includes one or more of rim height, rim thickness, rim vertical wear; and judging whether the geometric dimensions of the wheel rims are in respective corresponding preset intervals, if so, judging that the wheel rims are normal, and if not, judging that the wheel rims are abnormal and sending alarm signals to an upper computer to prompt a worker that the wheel rims are abnormal.
The method has the following advantages:
(1) and the state of the wheel set is monitored in real time by adopting a vehicle-mounted mode, so that the safety is improved. The measuring sensor can meet the precision requirement (10 mm) of the tread defect length in the rail transit field, when the train speed is 100km/h, the preset frame rate of the camera is more than or equal to 10kHz, the measuring precision of the sensor can reach 0.5mm, namely the distance between laser bars measured twice is 0.5mm, therefore, the method can effectively identify the defect with the defect length more than 0.5mm, and meet the detection precision requirement of tread defect measurement.
(2) By adopting a structured light measuring mode, the three-dimensional contour of the wheel surface can be obtained, the sunken defect area can be accurately obtained by analyzing the point cloud mutation condition, and the interference of stains on the defect detection is eliminated; the full detection of the width, the length and the depth of the defect can be realized, and the detection precision is high.
(3) Not only can monitor tread defect, can also regularly, regularly or real-time supervision rim's geometric dimensions (rim height, thickness), monitoring content is more comprehensive.
(4) A single wheel only needs a camera and a laser to run along with the wheel, so that the running condition of the whole circumference can be monitored, splicing processing is not needed, precision loss is reduced, and the processing speed is high.
Drawings
FIG. 1 is a block diagram of a measurement sensor system in accordance with an embodiment;
FIG. 2 is a schematic view of the installation position of a measurement sensor in an embodiment;
FIG. 3 is a schematic view of a wheel pair according to an embodiment;
FIG. 4 is a schematic view of a single laser stripe projected onto a wheel surface according to one embodiment;
FIG. 5 is a schematic view of laser bar projection and single laser bar calculated rim dimensions in accordance with an exemplary embodiment;
FIG. 6 is a schematic diagram of a single laser bar finding a defect point;
FIG. 7a is a schematic illustration of a plurality of laser bars stitched together in a global image;
FIG. 7b is a schematic diagram of the tread area of multiple laser bars.
Detailed Description
The technical solution of the present invention is described in detail below with reference to the accompanying drawings and the detailed description.
A vehicle-mounted wheel pair measuring sensor is arranged on a bogie on the inner side of a wheel and comprises a camera, a laser and a controller; as shown in fig. 2, the camera and the laser are both located obliquely above the wheel, the laser is used for projecting the laser stripe to the surface of the wheel, the camera is used for collecting the laser stripe image, and both are controlled by the controller; the preset frame rate of the camera is 5-30 kHz;
when the laser is a single-line laser, the camera is a linear array camera; when the laser is a multi-line laser, the camera is an area-array camera;
in the embodiment, a single-line laser is adopted, and a camera is a linear array camera; the frame rate is 15kHz;
as shown in fig. 1, the controller comprises a laser control module, an acquisition module, a tread defect detection module, a tread information storage module and a communication module;
the communication module is respectively connected with the acquisition module, the laser control module and the tread information storage module, and the tread defect detection module is respectively connected with the acquisition module and the tread information storage module;
the communication module can communicate with an upper computer, and when the train is started, starting signals are respectively sent to the laser control module and the acquisition module; when the train stops, a closing signal is respectively sent to the laser control module and the acquisition module;
the laser control module is used for controlling the laser to continuously project laser stripes to the surface of the wheel; as shown in fig. 4 and 5, the laser bar penetrates through the wheel tread;
the acquisition module controls the camera to continuously acquire laser bar images according to a preset frame rate and sequentially transmits the images to the tread defect detection module;
the tread defect detection module acquires point cloud information on each laser bar, searches points with coordinate values exceeding a normal coordinate interval in a tread area of each laser bar as defect points, and transmits the coordinates of the defect points to the tread information storage module for storage;
the tread information storage module counts the number of defect points with continuous coordinates, and when the number exceeds a threshold value A (the value of the threshold value A is 20-100), an alarm signal is sent to the communication module, and the communication module sends the alarm signal to the upper computer to prompt a worker that the tread of the wheel is abnormal.
In order to quickly find the defect point, in this embodiment, the defect point is marked in the following manner:
converting the point cloud on each laser bar into a laser plane coordinate system, sequentially obtaining the slope of a tangent line between two adjacent points in the tread area of each laser bar as shown in fig. 6, and marking the two points as defect points if the absolute value of the slope is higher than a threshold value B;
the value of the threshold B is 0.4-06; in the present embodiment, the threshold B =0.58 (tan 30 °);
the tread area is the area on the right side of the demarcation point; the demarcation point is a pixel point which is at the left side of the reference point and is 30-50 mm away from the reference point.
As shown in fig. 3 and 5, the reference points are: pixel points at the position from the inner side surface of the wheel rim to the 70mm position of the tread, wherein the inner side surface of the wheel rim is a plane obtained by utilizing 30-80 pixel points on the laser bar close to the left edge of the image in a fitting mode; the demarcation points are: pixel points which are at the left side of the datum point and have a distance of 30-50 mm from the datum point;
the rim region is the region to the left of the dividing point, and the tread region is the region to the right of the dividing point.
More specifically, as shown in fig. 4, in this embodiment, a direction along a train wheel axle is taken as an X-axis, a direction perpendicular to a tangent plane of a tread where a laser bar is located is taken as a Y-axis, and a direction perpendicular to an XOY plane is taken as a Z-axis, so as to establish a sensor coordinate system;
the point cloud on each laser stripe is converted into a laser plane coordinate system by the following two methods:
the first method is as follows: when the laser bar and the train axle are coplanar, recording the coordinates of the point cloud on an XOY plane as plane coordinates in a laser plane coordinate system;
the second method comprises the following steps: when the laser strip is not in the same plane with the train axle, firstly calibrating to obtain: the equation of a space straight line l of the wheel shaft under the sensor coordinate system and the space plane equation of the inner side face of the wheel rim under the sensor coordinate system;
and then, recording the distance from any point Q on the laser strip to the space straight line l as a Y-axis coordinate in a laser plane coordinate system, and recording the distance from the point Q to the inner side surface of the wheel rim as a Z-axis coordinate in the laser plane coordinate system.
The calibration process in the second mode is as follows:
the method comprises the steps of collecting three-dimensional information of the surface of a wheel by using a photogrammetric system or a three-coordinate machine, fitting by using three-dimensional points on the inner side surface of a wheel rim to obtain a space plane equation of the inner side surface of the wheel rim, fitting a circle by using points on the circumference of the wheel rim to obtain the circle center, and recording a straight line passing through the circle center and perpendicular to the inner side surface of the wheel rim as a space straight line l.
For ease of resolution, the preferred implementation is: when the sensor is installed, the laser plane is made to pass through the wheel shaft, namely: the laser bar is coplanar with the train axle. And converting the three-dimensional points into two-dimensional points by adopting a first mode.
For convenience of understanding, as shown in fig. 7a, a plurality of laser bars are spliced according to an acquisition time sequence to obtain a global image; for ease of resolution, in implementation, the tread region may be truncated in the global image (see FIG. 7 b). The tread information storage module is also used for counting the coordinate intervals of the defect points with continuous coordinates in the horizontal direction and the vertical direction and respectively recording the coordinate intervals as the width distribution interval and the depth distribution interval of the defect;
the horizontal direction is as follows: along the direction of train shaft (X axle direction), the vertical direction is: the direction (Y-axis direction) perpendicular to the tangent plane (see fig. 4) of the tread on which the laser bar is located.
The acquisition module sorts the laser bar images according to time sequence and sequentially transmits the images to the tread defect detection module; the tread information storage module is further used for recording laser bar sequence numbers corresponding to the defect points, counting the number n of laser bars with continuous sequence numbers, calculating the length value of the defect = n × v × t, wherein v is the current speed of the train, and t is the total time required for collecting the n laser bars with continuous sequence numbers.
In this embodiment, the measuring sensor further has a rim size measuring function, and specifically, in order to obtain rim size information, as shown in fig. 1, the controller further includes a rim size measuring module and a rim information storage module;
the rim size measuring module is respectively connected with the acquisition module and the rim information storage module;
the wheel rim information storage module is connected to the communication module;
specifically, the acquisition module transmits the laser bar images acquired by the camera to the rim size measurement module in sequence at regular time or real time according to a preset time interval; wherein the preset time interval value is 1 minute to 10 hours; in this embodiment, the preset time interval is set to 1 hour;
the rim dimension measuring module respectively acquires point cloud information on each laser bar and calculates the geometric dimension of the rim by using the point cloud information; the rim geometry comprises one or more of rim height, rim thickness, rim vertical wear, QR value;
the wheel rim information storage module judges whether the wheel rim geometric dimensions are all in respective corresponding preset intervals, if yes, the wheel rim is normal, if not, the wheel rim is abnormal, an alarm signal is sent to the communication module, and the communication module sends the alarm signal to an upper computer to prompt a worker that the wheel rim is abnormal.
The preset interval corresponding to the geometric dimension of the wheel rim is configured according to the detection precision requirement, and the following is an exemplary description: the preset interval of the rim height is 25-38 m; the preset interval of the rim thickness is 20-40 mm; the preset interval of the vertical abrasion of the wheel rim is 1-5 mm.
More specifically, the height value of the rim is calculated by:
calculating the vertical distance between each point in the rim area on the laser strip and the reference point, and recording the maximum vertical distance as the height value of the rim;
the vertical distance is a coordinate difference in the vertical direction, and the vertical direction is: the direction (Y-axis direction) perpendicular to the tangent plane (as shown in FIG. 4) of the tread on which the laser bar is located;
the thickness value of the rim is calculated by:
drawing a straight line vertical to the inner side surface of the wheel rim through the reference point, translating the straight line upwards by 10mm or 12mm, intersecting the straight line with the laser strip, and recording the horizontal distance between two intersection points as the thickness value of the wheel rim;
the horizontal distance is the distance along the direction of the train axle;
the wheel rim wear value is calculated by:
drawing a straight line perpendicular to the inner side face of the wheel rim through the reference point, translating the straight line upwards by 15mm, intersecting the straight line with the laser bar, and recording the horizontal distance between the two points as a comparison value;
recording the difference between the rim thickness value and the comparison value as a rim abrasion value;
the QR value calculation mode is as follows: and recording a point corresponding to the height value of the wheel rim as a highest point, descending the highest point by 2mm to obtain a point B, drawing a straight line perpendicular to the inner side surface of the wheel rim by using the passing point B, intersecting the straight line with the laser bar, recording a right side intersection point (an intersection point far away from the wheel rim area) as a point C, and recording a horizontal distance between the point A and the point C as a QR value.
Correspondingly, the method for measuring the measurement sensor by using the vehicle-mounted wheel comprises the following steps: when a controller in the sensor receives a train starting signal, the controller controls the laser to continuously project a laser bar to the surface of the wheel, and the laser bar is vertical to the advancing direction of the wheel;
meanwhile, the camera continuously collects laser bar images according to a preset frame rate and sequentially transmits the images to the controller;
the controller acquires point cloud information on each laser bar, marks points of the tread area, the coordinate values of which exceed a normal coordinate interval, as defect points, stores the coordinates of the defect points, counts the number of the defect points with continuous coordinates, and sends an alarm signal to the upper computer when the number of the defect points exceeds a threshold value A to prompt a worker that the wheel tread is abnormal;
when the train stops, the controller sends a shutdown signal to the camera and the laser.
In order to obtain the wheel rim size information, the controller also processes the laser bar images according to a preset time interval; respectively acquiring point cloud information on each laser bar, and calculating the geometric dimension of the wheel rim by using the point cloud information; the rim geometry includes one or more of rim height, rim thickness, rim vertical wear; and judging whether the geometric dimensions of the wheel rims are in respective corresponding preset intervals, if so, judging that the wheel rims are normal, and if not, judging that the wheel rims are abnormal and sending alarm signals to an upper computer to prompt a worker that the wheel rims are abnormal.
As an application of the measuring sensor of the present invention:
the number of the sensors corresponds to the number of the wheels, and a measuring sensor is arranged on the inner side of each wheel; the whole train wheel pair is fully monitored;
in order to save equipment cost, in the design of a mounting structure, a sensor is mounted on a bogie on the inner side of a wheel through a support frame, one end of the support frame is fixedly connected with the sensor, the other end of the support frame is in threaded connection with the bogie, and after a train runs, the support frame is detached from the current train bogie and mounted on other vehicle bogies to be dispatched.
The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. The foregoing description is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiments were chosen and described in order to explain certain principles of the present invention and its practical application to enable others skilled in the art to make and utilize various exemplary embodiments of the present invention and various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the following claims and their equivalents.
Claims (10)
1. The vehicle-mounted wheel pair measuring sensor is characterized in that the sensor is mounted on a bogie on the inner side of a wheel and comprises a camera, a laser and a controller; the camera and the laser are both positioned above the wheels in an inclined manner, the laser is used for projecting laser stripes to the surfaces of the wheels, the camera is used for collecting laser stripe images, and the camera and the laser stripe images are both controlled by the controller;
the controller comprises a laser control module, an acquisition module, a tread defect detection module, a tread information storage module and a communication module;
the communication module is respectively connected with the acquisition module, the laser control module and the tread information storage module, and the tread defect detection module is respectively connected with the acquisition module and the tread information storage module;
the communication module can communicate with an upper computer, and when a train is started, starting signals are respectively sent to the laser control module and the acquisition module; when the train stops, a closing signal is respectively sent to the laser control module and the acquisition module;
the laser control module is used for controlling the laser to continuously project laser stripes to the surface of the wheel;
the acquisition module controls the camera to continuously acquire laser bar images according to a preset frame rate and sequentially transmits the images to the tread defect detection module;
the tread defect detection module acquires point cloud information on each laser bar, searches points with coordinate values exceeding a normal coordinate interval in a tread area of the laser bar and marks the points as defect points, and transmits the coordinates of the defect points to the tread information storage module for storage;
the tread information storage module counts the number of defect points with continuous coordinates, and when the number exceeds a threshold value A, an alarm signal is sent to the communication module, and the communication module sends the alarm signal to the upper computer to prompt that the wheel tread of a worker is abnormal.
2. The vehicle-mounted wheelset measuring sensor of claim 1, wherein: the controller also comprises a rim size measuring module and a rim information storage module;
the rim size measuring module is respectively connected with the acquisition module and the rim information storage module;
the rim information storage module is connected to the communication module;
the acquisition module sequentially transmits the laser bar images acquired by the camera to the rim size measurement module at regular time or real time according to a preset time interval;
the rim dimension measuring module respectively acquires point cloud information on each laser bar and calculates the geometric dimension of the rim by using the point cloud information; the rim geometry comprises one or more of a rim height, a rim thickness, a rim vertical wear, a QR value;
the wheel rim geometrical size is transmitted to a wheel rim information storage module to be stored, the wheel rim information storage module judges whether the wheel rim geometrical size is in a corresponding preset interval, if yes, the wheel rim is normal, if not, the wheel rim is abnormal, an alarm signal is sent to a communication module, and the communication module sends the alarm signal to an upper computer to prompt that the wheel rim of a wheel of a worker is abnormal.
3. The vehicle-mounted wheelset measuring sensor of claim 2, wherein: the preset time interval is 1 minute to 10 hours;
the height value of the wheel rim is calculated in the following way:
calculating the vertical distance between each point in the rim area on the laser strip and the reference point, and recording the maximum vertical distance as the height value of the rim;
the rim region is a region to the left of the demarcation point; the demarcation points are as follows: pixel points which are at the left side of the reference point and have a distance of 30-50 mm from the reference point;
the reference points are as follows: pixel points from the inner side surface of the wheel rim to the position of 70mm of the tread, wherein the inner side surface of the wheel rim is a plane obtained by utilizing 30-80 pixel points on the laser bar close to the left edge of the image for fitting;
the vertical distance is a coordinate difference value in a vertical direction, and the vertical direction is as follows: the direction vertical to the tangent plane of the tread where the laser strip is located;
the thickness value of the wheel rim is calculated by the following method:
drawing a straight line vertical to the inner side surface of the wheel rim after passing through the reference point, translating the straight line upwards by 10mm or 12mm, intersecting the straight line with the laser bar, recording a right intersection point as a point A, and recording a horizontal distance between the two intersection points as a wheel rim thickness value;
the horizontal distance is the distance along the direction of the train wheel axle;
the abrasion value of the wheel rim is calculated in the following way:
making a straight line perpendicular to the inner side face of the wheel rim through the reference point, translating the straight line upwards by 15mm, intersecting the straight line with the laser bar, and recording the horizontal distance between the two points as a comparison value;
recording the difference between the rim thickness value and the comparison value as a rim abrasion value;
the QR value calculation mode is as follows: and recording a point corresponding to the height value of the wheel rim as a highest point, descending the highest point by 2mm to obtain a point B, drawing a straight line perpendicular to the inner side surface of the wheel rim by using the passing point B, intersecting the straight line with the laser bar, recording a right intersection point as a point C, and recording a horizontal distance between the point A and the point C as a QR value.
4. The vehicle-mounted wheelset measuring sensor of claim 1, wherein: the tread defect detection module acquires point cloud information on each laser bar, and a point mark with a coordinate value exceeding a normal coordinate interval is searched in a tread area of each laser bar and is a defect point, and the mode is as follows:
converting the point cloud on each laser bar into a laser plane coordinate system, sequentially solving the slope of a tangent line between two adjacent points in the tread area of each laser bar, and marking the two points as defect points if the absolute value of the slope is higher than a threshold value B;
the value of the threshold B is 0.4-06;
the tread area is the area on the right side of the demarcation point; the demarcation point is a pixel point which is on the left side of the datum point and is 30-50 mm away from the datum point.
5. The vehicle-mounted wheelset measurement sensor of claim 4, wherein: recording the direction along a train wheel axle as an X axis, recording the direction vertical to the tangent plane of the tread where the laser strip is positioned as a Y axis, recording the direction vertical to an XOY plane as a Z axis, and establishing a sensor coordinate system;
the point cloud on each laser stripe is converted into a laser plane coordinate system by the following two methods:
the first method is as follows: when the laser bar and the train axle are coplanar, recording the coordinates of the point cloud on an XOY plane as plane coordinates in a laser plane coordinate system;
the second method comprises the following steps: when the laser strip is not in the same plane with the train axle, firstly calibrating to obtain: the equation of a space straight line l of the wheel shaft under a sensor coordinate system and the space plane equation of the inner side face of the wheel rim under the sensor coordinate system;
and then, recording the distance from any point Q on the laser strip to the space straight line l as a Y-axis coordinate in a laser plane coordinate system, and recording the distance from the point Q to the inner side surface of the wheel rim as a Z-axis coordinate in the laser plane coordinate system.
6. The vehicle-mounted wheel pair measurement sensor according to claim 1 or 4, characterized in that: the tread information storage module is also used for counting a coordinate interval of the defect points with continuous coordinates in the horizontal direction and a coordinate interval of the defect points in the vertical direction, and respectively recording the coordinate intervals as a width distribution interval and a depth distribution interval of the defect;
the horizontal direction is as follows: along the direction of the train wheel axle, the vertical direction is: and the direction is vertical to the tangent plane of the tread on which the laser strip is positioned.
7. The vehicle-mounted wheelset measurement sensor of claim 1, wherein: the acquisition module sequences the laser bar images according to time sequence and sequentially transmits the images to the tread defect detection module;
the tread information storage module is also used for recording laser bar serial numbers corresponding to the defect points, counting the number n of laser bars with continuous serial numbers, calculating the length value of the defect = nxxv × t, wherein v is the current speed of the train, and t is the total time required for collecting the laser bars with continuous serial numbers.
8. The vehicle-mounted wheelset measurement sensor of claim 1, wherein: when the laser is a single-line laser, the camera is a line camera; when the laser is a multi-line laser, the camera is an area-array camera;
the preset frame rate of the camera is 5-30 kHz;
the threshold value A takes a value of 20-100;
the number of the sensors corresponds to the number of the wheels, and a measuring sensor is arranged on the inner side of each wheel;
the sensor is installed on a bogie on the inner side of a wheel through a support frame, one end of the support frame is fixedly connected with the sensor, the other end of the support frame is in threaded connection with the bogie, and after a train runs, the support frame is detached from the current train bogie and installed on other vehicle bogies to be dispatched.
9. A method of measuring with a vehicle-mounted wheel set measuring sensor according to any of claims 1 to 3, characterized in that: when a controller in the sensor receives a train starting signal, controlling a laser to continuously project a laser bar to the surface of the wheel, wherein the laser bar is vertical to the traveling direction of the wheel;
meanwhile, the camera continuously collects laser bar images according to a preset frame rate and sequentially transmits the images to the controller;
the controller acquires point cloud information on each laser bar, marks points of the tread area, the coordinate values of which exceed a normal coordinate interval, as defect points, stores the coordinates of the defect points, counts the number of the defect points with continuous coordinates, and sends an alarm signal to the upper computer when the number of the defect points exceeds a threshold value A to prompt a worker that the tread of the wheel is abnormal;
when the train stops, the controller sends a shutdown signal to the camera and the laser.
10. The method of claim 9, wherein: the controller also processes the laser bar images according to a preset time interval; respectively acquiring point cloud information on each laser bar, and calculating the geometric dimension of the wheel rim by using the point cloud information; the rim geometry includes one or more of rim height, rim thickness, rim vertical wear; and judging whether the geometric dimensions of the wheel rims are in respective corresponding preset intervals, if so, judging that the wheel rims are normal, and if not, judging that the wheel rims are abnormal and sending alarm signals to an upper computer to prompt a worker that the wheel rims are abnormal.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202211040182.6A CN115326812A (en) | 2022-08-29 | 2022-08-29 | Vehicle-mounted wheel pair measuring sensor and measuring method |
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| CN202211040182.6A CN115326812A (en) | 2022-08-29 | 2022-08-29 | Vehicle-mounted wheel pair measuring sensor and measuring method |
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| CN202211040182.6A Pending CN115326812A (en) | 2022-08-29 | 2022-08-29 | Vehicle-mounted wheel pair measuring sensor and measuring method |
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