CN117262787A - Automatic quality inspection method for materials in inner and outer areas of freight train carriage - Google Patents

Abstract

The application discloses an automatic quality testing method for materials in an inner area and an outer area of a freight train carriage, when the train carriage enters a unloading area, the carriage number is identified and matched and butted with peripheral target system information through the carriage number, the train carriage arrangement is virtually displayed according to the carriage number identification result, the unloading equipment is used for unloading layer by layer, in the process, the condition of the materials in the train carriage is monitored in real time through quality testing auxiliary equipment such as a camera, and meanwhile, an unloading video is stored in real time to hardware equipment so as to be beneficial to later searching and tracing; if an early warning signal is sent in the quality testing process, staff intervenes in the process, and after the abnormal processing is finished, unloading and quality testing are continued until the vehicle bottom is detected and no materials or foreign matters exist in the carriage, and quality testing result information of the carriage is sent to a target system and/or a display device; the automatic quality inspection method provided by the application aims at the material inspection flow provided by the freight train, realizes full-flow quality inspection tracking and control, and improves the working efficiency of freight train material quality inspection.

Description

Automatic quality inspection method for materials in inner and outer areas of freight train carriage

Technical Field

The application relates to the technical field of freight quality detection, in particular to an efficient and reliable automatic quality inspection method capable of automatically inspecting materials in the inner and outer areas of a freight train carriage.

Background

The material is the material source of enterprise's production, and the demand is extremely big, and the quality of material etc. is related to the manufacturing cost and the product profit of enterprise. In the modern logistics industry, due to the requirements of monitoring the safety of goods and alarming abnormal events in the transportation process, the volume of goods in a freight car in transportation and the change rate of the volume are monitored in real time, and in addition, special quality inspection personnel can be dispatched and controlled during the transportation process or during the unloading process.

Quality control of freight train car material by quality inspectors generally includes the following: 1. manually detecting and judging the climbing of the train by eyes; 2. entering the carriage for checking; 3. detecting and checking the surface of the material by a camera; 4. and detecting the quality of the object in the movement process of the freight train.

The above-mentioned mode of carrying out quality control to freight train carriage material has following defect:

1. the personnel frequently get on or off the bus for inspection, potential safety hazards exist, and the labor intensity of the personnel is high;

2. the safety risk of falling objects at high altitude or falling at high altitude exists;

3. aiming at the condition that the train transport substances only see the surface, the condition below the object cannot be detected;

4. the discharging progress is influenced, and the production process is influenced;

5. special personnel quality inspection is set, and the labor cost is high;

6. the quality objection is not well-known;

7. the existing scheme is only a dispersion system, and a unified and effective detection closed loop is not formed, so that popularization and application are not facilitated.

Therefore, a new technical solution is needed to solve the problems existing in the prior art.

Disclosure of Invention

The application provides an automatic quality inspection method for materials in inner and outer areas of a freight train carriage, which is used for solving the problems that the materials in the freight train carriage are not detected in place, the detection efficiency is low, the unloading progress is influenced, the manual detection cost is high and potential safety hazards exist in the prior art.

In order to achieve the above object, the present application provides the following technical solutions:

the application provides an automatic quality testing method for materials in an inner area and an outer area of a freight train carriage, which is realized by adopting an automatic quality testing system configured in a unloading area, wherein the automatic quality testing system comprises a quality testing control device, a carriage number identification device, a display device, quality testing auxiliary equipment and a storage device, wherein the carriage number identification device, the display device, the quality testing auxiliary equipment and the storage device are respectively connected with the quality testing control device, and the automatic quality testing method comprises the following steps of:

s1: after the train enters the unloading area, the train carriage number is acquired through a carriage number identification device, the carriage number is stored as a data set, a quality testing control device virtually arranges a plurality of carriages according to the data set to obtain carriage arrangement images, and the virtual carriage arrangement images are displayed on a display device;

s2: the quality testing control device acquires detailed information of each carriage from the target user system and correspondingly displays the carriage detailed information on the display device;

s3: the method comprises the steps of discharging a target carriage layer by layer, acquiring material information in the carriage in real time through quality testing auxiliary equipment in the process, automatically testing the quality of the material in the target carriage according to the acquired information by a quality testing control device, and storing the acquired image and/or video information in a storage device in real time;

s4: the quality inspection control device acquires material information from the quality inspection auxiliary equipment in real time, processes the material information in real time, and controls the early warning device to send out an early warning signal when an abnormal signal is obtained through processing, so that operators intervene and process the abnormality;

s5: when the quality inspection control device detects that the bottom surface of the carriage is free of foreign matters and materials in the carriage, the quality inspection system finishes quality inspection of the target carriage and sends quality inspection result information to the target user system and/or the display device.

In the step S1 of the technical scheme, a train unloading area is provided with a train inlet and a train outlet, and a carriage number identification device is arranged at the train inlet; or alternatively, the first and second heat exchangers may be,

a carriage number identification device is arranged at a fixed position of a preset stop road section of each carriage; or alternatively, the first and second heat exchangers may be,

a fixed area is selected in the unloading area and used for stopping a section of carriages to be unloaded, a carriage number recognition device is arranged in the fixed area, and a plurality of carriages are sequentially stopped in the fixed area for quality inspection.

In step S2 of the above technical solution, the quality testing control device obtains, from the target user system, car detailed information corresponding to the car number according to the car number in the data set, where the car detailed information includes at least one of vendor information, car origin information, car destination information, cargo receiving information, and material information in the car; the material information in the carriage at least comprises one of material name, type, danger, radiation and inflammability; the car details are correspondingly associated with the target car in the car arrangement image by the car number and displayed by the display device.

In step S3 of the above technical solution, when quality inspection is performed on each carriage simultaneously by the quality inspection control device, each carriage is provided with a corresponding unloading device and quality inspection auxiliary devices, each carriage is unloaded layer by layer, material information in the carriage is collected in real time by the corresponding quality inspection auxiliary devices in the process, and the quality inspection control device performs one-to-one correspondence on the information sent by each quality inspection auxiliary device and the corresponding carriage according to the carriage number.

In the above technical scheme, the quality inspection auxiliary equipment at least comprises a 2D camera, a light supplementing lamp, a 3D camera, a distance sensor and an early warning device; the 3D camera comprises a TOF camera and/or a point cloud camera, the distance sensor comprises a laser distance measuring sensor and/or a radar distance measuring sensor, and the early warning device comprises an audible alarm, a light alarm and an audible and light alarm.

In step S3 of the above technical solution, when each carriage is tested for quality one by one according to the sequence, the first carriage is unloaded layer by layer, in-process material information in the carriage is collected in real time through quality testing auxiliary equipment, and the quality testing control device tests quality of the material in the first carriage according to the information received from the quality testing auxiliary equipment, and tests quality of the second carriage after the quality testing of the first carriage is completed.

In the above technical scheme, when quality inspection is performed on each carriage one by one according to the sequence, the quality inspection auxiliary equipment and the unloading equipment are moved to perform quality inspection on each carriage stopped in the unloading area one by one; or, the first carriage of the train is parked in the working ranges of the quality testing auxiliary equipment and the unloading equipment at the fixed positions, the quality testing of the first carriage is realized through the cooperation of the quality testing control device and the quality testing auxiliary equipment, after the quality testing is finished, the quality testing control device sends out a car moving prompt signal, an operator removes the first carriage, and the second carriage is moved and parked in the working ranges of the quality testing auxiliary equipment and the unloading equipment at the fixed positions.

In the above technical solution, the quality testing control device includes a storage module and a processing module, the storage module stores quality standard judgment information of the target material, the quality standard judgment information at least includes material appearance pictures and material characteristic parameter information, and the processing module compares the signal obtained from the quality testing auxiliary equipment with the quality standard judgment information in the storage module to obtain quality testing result information; the processing module stores 3D vision algorithms.

The auxiliary equipment for inspecting quality comprises radiation detection equipment, wherein the radiation detection equipment is close to a train inlet of a unloading area, is used for detecting whether the material has radiation or not, and sends a monitoring result to the quality inspection control device.

In step S4 in the above technical solution, the material information received by the quality testing control device from the quality testing auxiliary device at least includes volume information, shape information and size information of the material.

In step S5 of the above technical solution, the quality inspection control device determines whether the bottom surface of the car is detected, whether no foreign matter exists in the car or no material exists in the car according to the material information acquired from the quality inspection auxiliary device, and if the bottom surface of the car is detected and no foreign matter exists in the car or no material exists in the car, sends a prompt signal for indicating the end of quality inspection, and sends quality inspection result information to the target user system and/or the display device.

Compared with the prior art, the application has the following beneficial effects:

the utility model provides an inside and outside regional material automatic quality testing method of freight train carriage realizes through automatic quality testing system, obtain train carriage number through carriage number recognition device after the train gets into the area of unloading, the virtual carriage arrangement image of data set that constitutes according to the carriage number, the material information that quality testing in-process gathered is related through carriage number and corresponding carriage, quality testing auxiliary device can gather and unload image and/or unload the video, look for when later stage product objection behind the save it, when quality testing in-process is unusual, accessible early warning device suggestion staff intervenes the processing, the flexibility to abnormal situation processing is higher, carry out real-time supervision and information acquisition to the material in the carriage through quality testing auxiliary device, confirm that the carriage is unloaded and is accomplished, send the quality testing result information to target user system and/or display device to the carriage, the user can long-range quality testing. Therefore, the automatic quality inspection method replaces manual automatic intelligent quality inspection, avoids errors existing in quality inspection by manual naked eyes, avoids safety risks existing in climbing of staff, improves quality inspection efficiency, reduces labor cost and guarantees unloading efficiency; in addition, the automatic quality inspection method provided by the application is a perfect material inspection flow provided for the freight train, a unified quality inspection scheme is formed, the quality inspection flow and quality inspection data effectively close loop, the full-flow quality inspection tracking and control are realized, and the working efficiency of the freight train material quality inspection is improved.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present application, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art. It should be understood that the specific shape and configuration shown in the drawings should not be considered in general as limiting upon the practice of the present application; for example, based on the technical concepts and exemplary drawings disclosed herein, those skilled in the art have the ability to easily make conventional adjustments or further optimizations for the add/subtract/assign division, specific shapes, positional relationships, connection modes, dimensional scaling relationships, etc. of certain units (components).

FIG. 1 is a flow chart of an automated quality inspection method provided herein in one embodiment;

FIG. 2 is a schematic diagram of an arrangement of railcars in an unloading area in the present application showing a 2D camera mounting relationship to a train in one embodiment;

fig. 3 is a schematic diagram of an arrangement of train cars in the present application in a dump zone in another embodiment, the diagram showing a mounting relationship of a camera, a car number recognition device and a train, the car number recognition device in the diagram being fixed in position, all cars being checked one by one, all cars being moved sequentially past the car number recognition device.

Reference numerals illustrate:

1. a train car; 2. a 2D camera; 3. a slide rail; 4. a driving mechanism; 5. a camera; 6. a carriage number recognition device;

A. and (5) unloading the vehicle.

Detailed Description

The present application is further described in detail below with reference to the attached drawings.

In the description of the present application: unless otherwise indicated, the meaning of "a plurality" is two or more. The terms "first," "second," and the like in this application are intended to distinguish between the referenced objects without a special meaning in terms of technical connotation (e.g., should not be construed as emphasis on degree or order of importance, etc.). The expressions "comprising", "including", "having", etc. also mean "not limited to" (certain units, components, materials, steps, etc.).

The terms such as "front", "rear", "middle", and the like, as used in this application, are generally used for the purpose of facilitating visual understanding with reference to the drawings and are not intended to be an absolute limitation of the positional relationship of the actual product. Such changes in relative positional relationship are considered to be within the scope of the present description without departing from the technical concepts disclosed herein.

The existing train cargo quality inspection mode is low in efficiency, quality inspection is not in place, unloading progress is affected, and a certain safety risk exists due to high labor intensity of personnel. In order to solve the problems in the prior art, the application provides an automatic quality testing method for materials in inner and outer areas of a freight train carriage, the automatic quality testing method is realized based on an automatic quality testing system, the quality testing system and the quality testing method are convenient to popularize and apply, a testing closed loop is formed, and the method can be suitable for all materials in the train carriage and is wide in application range.

The automatic quality testing system for realizing the automatic quality testing method for the materials in the inner and outer areas of the freight train carriage is configured on the unloading site when the freight train is used for transporting and loading and unloading materials, intelligent identification is carried out on the materials in the carriage, manual quality testing is replaced, the existing quality testing mode is improved, quality testing efficiency is greatly improved, quality testing in place is guaranteed, personnel participation is reduced, manual intervention is reduced, manual errors are reduced, personnel cost is reduced, and potential safety hazards are greatly reduced.

The quality testing method and the quality testing system are an integrated scheme aiming at intelligent quality testing of freight train materials, optimize and improve the quality testing implementation mode, mainly realize the positioning and identification of materials in the carriages aiming at the carriages by identifying carriage information for later virtual out of the arrangement condition of the whole carriages of the train and using the automatic quality testing system of the materials, and bind the materials with the carriages one by one to realize the closed loop of the whole quality testing, and all the systems in the train quality testing process are directly connected in series and cooperate to improve the production rhythm and efficiency of the site; in addition, the post quality objection of the data of the quality testing process stored by the system can be checked. The automatic quality testing system and the automatic quality testing method for the materials in the inner and outer areas of the freight train carriage provided by the application are described in detail below.

Example 1

The automatic quality testing method for the materials in the inner and outer areas of the freight train carriage is a quality testing flow method for the materials in the inner and outer areas of the freight train carriage, combines hardware and comprehensive machine vision technology in the aspects of existing artificial intelligence and automation, and is applied to quality testing of the materials transported by the freight train, logic realization of the whole quality testing flow from identification of the number of the train carriage is achieved, quality testing flow optimization is completed, working intensity of operators is reduced, manual participation is reduced, safety is improved, and labor cost is reduced.

The automatic quality testing method for the materials in the inner and outer areas of the freight train carriage provided by the application can be summarized as follows: the information of the freight train carriage is recognized in advance, information matching and butt joint are carried out on the information of the freight train carriage and a peripheral target system, detailed data information of the carriage is obtained, a recognition device for recognizing the carriage number is arranged at a gate or an entrance of a train carriage entering a unloading area (or a stock yard, a batching room and the like) (of course, a fixed image acquisition device can be arranged at a fixed position of a preset stop section of each carriage to acquire the carriage number; and then, the quality testing system is used for arranging information for all carriages according to the data set, arranging the virtual display train carriages, and displaying detailed information in the train carriages which are in butt joint with the target system on a PC or a screen casting center, so that the quality testing system is convenient for operators to check and check. Then, when the train is stopped and stabilized, the quality inspection system starts to automatically inspect the quality of the train, the camera (along the sliding rail) is automatically moved to a designated position (of course, according to actual conditions, the camera can be fixed, and the working linkage of quality inspection auxiliary equipment such as a carriage and the camera can be realized by sequentially moving the carriage); when the train is unloaded, the quality inspection system monitors the material condition in the train carriage in real time, and simultaneously stores the unloading video in hardware equipment in real time for subsequent inspection. The final quality testing result obtained by the quality testing system can be displayed in real time in a quality testing hall or end-use equipment, a terminal can be set on site, and the quality testing result can be displayed or not.

In the quality inspection process, the system can send an early warning signal (such as detecting special conditions of unqualified materials, large impurities, dangerous articles and the like) according to conditions encountered in the quality inspection process, and related operators intervene in corresponding follow-up operations after receiving the early warning signal. When the whole carriage is completely unloaded, the system detects the bottom surface of the carriage and no foreign matters or materials exist in the carriage, automatically finishes quality testing, sends data to a target system (such as an ERP system and other external systems) and prompts through field devices (including but not limited to acousto-optic devices, voice devices, video devices and other hardware devices).

The quality inspection system and the quality inspection method can inspect quality of all carriages simultaneously, and can inspect quality of all carriages one by one according to the sequence.

The automatic quality testing system for realizing the automatic quality testing method for the materials in the inner and outer areas of the freight train carriage provided by the application comprises a quality testing control device, and a storage device, a display device, quality testing auxiliary equipment and a carriage number identification device which are respectively connected with the quality testing control device.

The train carriage number recognition device is used for recognizing train carriage numbers, recognition results are received by the quality testing control device and stored as a data set, the quality testing control device is used for carrying out arrangement information on all carriages according to the data set, virtually displaying train carriage arrangement and virtually outputting train carriage arrangement images. If a target system exists, the quality inspection control device is used for butting the detailed information of the corresponding train carriage with the target system through the carriage number, and displaying the virtual carriage arrangement image and the carriage detailed information on a display device (such as a PC end or a screen on a display screen of a centralized control center and the like), so that inspection and check of operators are facilitated.

Quality testing aids include, but are not limited to: camera (2D camera), light filling lamp, 3D camera, distance sensor and audible and visual alarm.

The camera can be movable or fixed, and is used for shooting car unloading pictures and/or shooting car unloading videos, and the shot car unloading pictures and/or car unloading videos can be stored in the storage device. The installation number and the installation position of the cameras can be determined independently according to the field requirements.

The 3D camera can be used for capturing three-dimensional form information of materials, and can also be used for capturing unloading motion information and the like through the 3D camera according to the use requirement, and in a specific installation application process, data which can be used for further analysis can be acquired through the 3D camera according to the function adaptation of the 3D camera.

The 3D camera may include a TOF camera and/or a point cloud camera, where the point cloud camera is a special 3D camera, and may be used to capture surface geometry information of a material, etc. to further obtain point cloud data, and in a specific installation application process, other point cloud data that may be used for further analysis may be obtained by the point cloud camera according to a function of the point cloud camera.

The distance sensor comprises a laser distance sensor and/or a radar distance sensor, the volume information of the materials in the carriage can be obtained through the distance sensor, meanwhile, the residual volume of the materials in the carriage can be continuously monitored in the unloading process, and the volume information can be used as point cloud data to be further analyzed and processed through a point cloud technology. Of course, the setting positions, the installation number and the specific use modes of the distance sensors in the application can be adaptively set according to specific installation application conditions.

The audible and visual alarm can be controlled to send out early warning information to prompt workers to intervene some special conditions in the quality inspection process. Of course, the audible and visual alarm may be replaced by an audible alarm (buzzer) or a visual alarm (warning lamp).

The quality inspection auxiliary equipment is mainly used for collecting various signals in the quality inspection process, such as unloading photos and/or unloading videos, three-dimensional form information, surface geometric information, dynamic volume information and the like of materials; the quality inspection control device analyzes and processes the signals acquired by the quality inspection auxiliary equipment to realize quality inspection of materials in the unloading process.

Therefore, the quality inspection control device is a main control part for controlling the realization of the quality inspection method, and comprises an information receiving module, an information sending module, a processing module, an output control module and a storage module.

The information receiving module of the quality testing control device is connected with the quality testing auxiliary equipment and receives various signals output by the quality testing auxiliary equipment, and the signals are processed and analyzed by the processing module to obtain quality testing result information which can be stored in the storage module and can be sent to the storage device for storage; and the quality inspection result information can be sent to a display device for display. If abnormal information appears in the processing and analyzing process, a control signal is sent to the audible and visual alarm through the output control module, and the audible and visual alarm sends an early warning signal.

The quality inspection method mainly judges the quality of the materials through appearance or information of related characteristics of the materials, so that quality standard judgment information of target materials is stored in a storage module of the quality inspection control device, and the quality standard judgment information comprises but is not limited to material appearance pictures and material characteristic parameter information. The processing module is used for adaptively comparing the signal acquired from the quality testing auxiliary equipment with the quality standard judging information in the storage module, and scientifically judging a quality testing result; the processing module in the application carries an artificial intelligence vision algorithm, including but not limited to a point cloud algorithm, a 3D vision algorithm and the like.

According to actual needs and field device conditions, the quality testing auxiliary device can also comprise a radiation detection device, and detection information obtained by the radiation detection device is provided to the quality testing control device for analysis and processing so as to be used as a decision basis for subsequent material judgment.

Therefore, the automatic quality testing system provided by the application is characterized in that a detailed configuration scheme is made for carrying out high-efficiency intelligent quality testing on materials carried by a freight train, quality testing auxiliary equipment is erected above a train carriage or in a region near the carriage (the region in the carriage can be completely seen), the materials in the train carriage are subjected to real-time quality testing identification through the quality testing auxiliary equipment, and the real-time quality testing identification process is used for judging quality testing information in a mode of not distinguishing photographed pictures or extracting frames through video streams. The quality inspection control device is used as an intelligent control system to analyze and infer the data read by the quality inspection auxiliary equipment by an artificial intelligent visual algorithm, and the materials are classified, graded, classified and segmented to form a large data set. Through the flow, the data binding is carried out with the previously identified carriage information, the final quality inspection system makes a decision, the result is deduced, and then the result is pushed to a hall, a terminal or other third party systems. If there is data objection or other abnormal conditions, the early warning information can be sent in real time. Timely notifying relevant hardware devices and systems.

Therefore, the application configures the fixed hardware equipment, and recognizes the carriage information through the carriage number recognition device (including the visual recognition device of the camera), not only the mode existing in fig. 3, but also includes that each carriage fixed position installs the fixed equipment to collect the carriage number. (either an image acquisition device is set up for each railway carriage stopping position or a fixed area is set up, after each railway carriage is unloaded, the unloaded carriage is pulled away, and the second full carriage is pulled).

The system is configured in a freight train unloading area, hardware equipment is installed on site, then quality testing related information is acquired through the installed hardware equipment, automatic, intelligent and efficient quality testing is performed through a quality testing control device with an artificial intelligent visual algorithm, a human-computer interaction mode is configured in the automatic quality testing system, and a user can perform information interaction with the automatic quality testing system through intelligent terminal modes such as a mobile terminal App, a PC end application, a webpage or other intelligent centralized control centers.

According to the automatic quality inspection system and the automatic quality inspection method for the materials in the inner and outer areas of the freight train carriage, which are provided by the application, the automatic intelligent quality inspection is replaced by manual operation, the safety risk of staff climbing is avoided, the quality inspection efficiency is improved, the labor cost is reduced, and the unloading efficiency is ensured; in addition, the method and the system provide a perfect inspection flow, a unified quality inspection scheme and a system are formed, the flow and quality inspection data effectively close loop, the full-flow quality inspection tracking and management and control are realized, and the working efficiency of freight train material quality detection is improved; further, through the quality inspection system, a user can realize remote quality inspection through the terminal.

Example two

The present embodiment provides an automatic quality inspection method (hereinafter abbreviated as quality inspection method) for materials in freight train cars, which can be adapted to all materials loaded on freight trains, including but not limited to: coal, steel, ore, alloy and other materials. The quality inspection method provided by the application is mainly used for judging the quality of the material through appearance or information of related characteristics of the material and judging whether the material is qualified or not.

The following describes a specific flow of the quality inspection method provided in the present application:

the quality inspection process 1 mainly occurs in a train unloading area, wherein the train unloading area is provided with a train inlet and a train outlet, when a train passes through the train inlet, the incoming carriage number is identified in real time, and the identification result is stored in a data set for subsequent use; the car number is usually used to represent information of the car, such as the number of tons and the type of the car (caravan, scattered car), and the like, and the detailed information of the car can be further obtained from the target system according to the car number.

And 2, the quality testing system acquires detailed information of each carriage from a target system (such as a user ERP system or other systems) through the carriage number, for example: vendor information, carriage origin and destination information, whether dangerous objects, whether cooling is needed, a person abutting the goods, goods receiving information (comprising a place, a contact mode, a discharging mode, an entering time and the like), carriage material information (comprising a material name, a type, dangerously, whether water afraid, flammability, whether personnel can approach, radiation detection) and the like;

the quality inspection system virtually emits a carriage arrangement image through the data set, wherein the carriage arrangement image is an image representing the arrangement information of each carriage of the train, and comprises a 3D effect image and a two-dimensional schematic image, and the carriage arrangement image can also display carriage detailed information acquired from the target system corresponding to each carriage; the situation of train carriage arrangement is virtually displayed, so that carriage information can be quickly positioned during whole train transferring and unloading at a later stage.

And 3, after each carriage sequentially enters the unloading area and is stopped, the quality inspection system starts to automatically inspect the quality of the materials in each carriage, so that the quality inspection can be performed on each carriage simultaneously, the quality inspection can be performed on each carriage one by one according to the sequence, and the two conditions are respectively described as follows:

(1) When the quality of each carriage is checked at the same time, each carriage is respectively provided with a corresponding unloading device (including but not limited to a crown block) and a quality checking auxiliary device, each carriage is unloaded layer by layer, the material condition in the carriage is acquired in real time through the corresponding quality checking auxiliary device in the process, including but not limited to image information and video information acquisition, and the acquired image and video information (unloading video) are stored in a hardware storage device in real time for later checking; when the quality inspection system detects that the bottom surface of the carriage is completely unloaded and no foreign matters or materials exist in the carriage, the quality inspection system stops the quality inspection process of the carriage, and when the quality inspection system detects that all the carriages are completely unloaded, the quality inspection system automatically ends; the quality testing system displays the quality testing result information of each carriage in the corresponding carriage information in the virtual carriage arrangement image, and sends the quality testing result of each carriage to the target system for further storage (wherein, the display or the sending of the quality testing result information of each carriage can be independent, for example, the carriage with the quality tested is displayed and sent in advance, and of course, the whole quality testing can be displayed and sent after the quality testing is completed).

(2) When quality inspection is performed on each carriage in sequence, two conditions are divided: after the train is stopped, moving quality testing auxiliary equipment and unloading equipment to test quality of each carriage one by one; secondly, the first carriage of the train is stopped in the working range of the quality testing auxiliary equipment and the unloading equipment at the fixed positions, the quality testing system prompts on-site personnel to move the carriage after the quality testing is finished, and the second carriage is stopped in the working range of the quality testing auxiliary equipment and the unloading equipment at the fixed positions, and the like until the quality testing of all carriages is finished.

In summary, when each carriage is tested for quality one by one according to the sequence, each carriage is unloaded layer by layer, in the process, the material conditions in the carriage are collected in real time through corresponding quality testing auxiliary equipment, including but not limited to collecting image information and video information, and the collected image and video information (unloading video) are stored in hardware storage equipment in real time for subsequent checking; when the quality inspection system detects that the bottom surface of the carriage and no foreign matters or materials exist in the carriage, the carriage is characterized in that the unloading is completed, the quality inspection system stops the quality inspection process of the carriage, prompts on-site personnel to move the carriage or quality inspection auxiliary equipment to inspect the quality of the next carriage, displays quality inspection result information of the carriage with the quality inspected completion in corresponding carriage information in a virtual carriage arrangement image, and sends the quality inspection result of the carriage into a target system for further storage; when the quality inspection system detects that all carriages are completely unloaded, the quality inspection system is automatically ended.

And 4, if the quality inspection system sends out an early warning signal in the quality inspection process, the related operators intervene and carry out corresponding processing operation, and after the processing is finished, the automatic quality inspection is continued. In the quality inspection process, some unqualified materials have larger impurities or are disputed to be larger and are not well determined, or dangerous materials, dangerous materials and the like can send out early warning.

And 5, a display terminal can be arranged, the virtual carriage arrangement image is displayed on the display terminal, and the display terminal can be arranged in the quality testing hall, and of course, the display terminal can also be used for displaying no image information.

According to the actual needs and the situation of the field device, in the process 1, the train can pass through the radiation detection device after passing through the train inlet of the unloading area, and the detection information obtained by the radiation detection device can be provided to the quality inspection system to be used as the basis for the decision of the subsequent materials. That is, the radiation detecting device is disposed in the unloading area near the train entrance, so that each car is detected by the radiation detecting device, and the detection result corresponds to the car number.

The quality testing aids mentioned in procedure 3 above include, but are not limited to: camera, light filling lamp, audible and visual alarm, 3D camera for 3D detects, point cloud camera for the point cloud technique, laser range sensor, radar range sensor, other detecting instrument etc.. The camera is arranged in a plurality of modes, and can be fixedly arranged according to the use requirement, and also can be movably arranged, for example: the camera is arranged on the sliding rail, the setting position of the sliding rail is determined according to the shooting angle and the position, the sliding rail is generally arranged on one side or two sides of the length direction of the train (can be arranged on one unloading side according to the requirement), the camera and the driving mechanism for driving the camera to move along the sliding rail are arranged on the sliding rail, so that the movable camera is formed, and other quality testing auxiliary equipment can be arranged on the sliding rail according to the condition. For another example: the fixed monitoring rod is arranged at the selected position of the unloading area in advance, the camera is fixed on the monitoring rod, the camera can be fixed on a lamp stand or a portal frame meeting the installation requirement, and other quality testing auxiliary equipment is arranged at a proper position according to the requirement.

If the materials in the carriage are scrap steel, the quality inspection system provided by the application can judge, grade, identify, grade and other judging conditions for the scrap steel through the system storage, and finish the operations of judging, grade, identify, grade and the like for the scrap steel in the quality inspection process. Of course, if other materials are, the corresponding quality testing and grading operation can be completed by changing the quality testing and grading conditions of the materials set by the system. The final quality testing result obtained by the quality testing system can be displayed in real time in a quality testing hall or equipment which is used finally, a terminal can be set up on a quality testing site, and the quality testing result can be displayed on the terminal or not. When a car is finished in quality testing, the quality testing system sends the quality testing result of the car to a target system (such as an ERP system) and prompts through field devices (without limiting any other hardware devices such as sound and light, voice, video and the like).

The automatic quality inspection method for the materials in the freight train carriage is a quality inspection flow method for the materials in the inner and outer areas of the freight train carriage, combines hardware and comprehensive machine vision technology in the aspects of existing artificial intelligence and automation, is applied to quality inspection of the materials transported by the freight train, and achieves logic realization from recognition of the carriage number of the train carriage to the overall quality inspection flow, thereby completing quality inspection flow optimization, reducing the working intensity of operators, reducing the manual participation degree, improving the safety and reducing the labor cost.

Any combination of the technical features of the above embodiments may be performed (as long as there is no contradiction between the combination of the technical features), and for brevity of description, all of the possible combinations of the technical features of the above embodiments are not described; these examples, which are not explicitly written, should also be considered as being within the scope of the present description.

The foregoing has outlined and detailed description of the present application in terms of the general description and embodiments. It should be appreciated that numerous conventional modifications and further innovations may be made to these specific embodiments, based on the technical concepts of the present application; but such conventional modifications and further innovations may be made without departing from the technical spirit of the present application, and such conventional modifications and further innovations are also intended to fall within the scope of the claims of the present application.

Claims (10)

1. The automatic quality inspection method for the materials in the inner and outer areas of the freight train carriage is characterized by being realized by adopting an automatic quality inspection system arranged in a unloading area, wherein the automatic quality inspection system comprises a quality inspection control device, a carriage number identification device, a display device, quality inspection auxiliary equipment and a storage device, wherein the carriage number identification device, the display device, the quality inspection auxiliary equipment and the storage device are respectively connected with the quality inspection control device, and the automatic quality inspection method comprises the following steps of:

s1: after the train enters the unloading area, the train carriage number is acquired through the carriage number identification device, the carriage number is stored as a data set, the quality inspection control device virtually arranges the plurality of carriages according to the data set to obtain carriage arrangement images, and the virtual carriage arrangement images are displayed on the display device;

s2: the quality inspection control device acquires detailed information of each carriage from the target user system and correspondingly displays the carriage detailed information on the display device;

s3: the material information in the carriage is acquired in real time through the quality inspection auxiliary equipment in the process of unloading the target carriage layer by layer, the quality inspection control device automatically inspects the quality of the material in the target carriage according to the acquired information, and the acquired image and/or video information is stored in the storage device in real time;

s4: the quality inspection control device acquires material information from the quality inspection auxiliary equipment in real time, processes the material information in real time, and controls the early warning device to send out an early warning signal when an abnormal signal is obtained through processing, so that operators intervene and process the abnormality;

s5: when the quality inspection control device detects the bottom surface of the carriage and no foreign matters or materials exist in the carriage, the quality inspection system finishes quality inspection on the target carriage and sends quality inspection result information to the target user system and/or the display device.

2. The automatic quality testing method for materials in the inner and outer areas of freight train carriage according to claim 1, wherein in step S1, the unloading area is provided with a train inlet and a train outlet, and the carriage number identification device is arranged at the train inlet; or alternatively, the first and second heat exchangers may be,

the carriage number identification device is arranged at a fixed position of a preset stop road section of each carriage; or alternatively, the first and second heat exchangers may be,

the method comprises the steps that a fixed area is selected in a car unloading area, the fixed area is used for stopping a section of car to be unloaded, a car number identification device is arranged in the fixed area, and a plurality of sections of cars are sequentially stopped in the fixed area for quality inspection.

3. The automatic quality testing method for materials in the inner and outer areas of a freight train compartment according to claim 1, wherein in step S2, the quality testing control device obtains compartment detailed information corresponding to the compartment number from a target user system according to the compartment number in the data set, the compartment detailed information at least comprising one of vendor information, compartment origin information, compartment destination information, cargo receiving information and material information in the compartment; the material information in the carriage at least comprises one of material name, type, danger, radiation and flammability;

the car details are correspondingly associated with the target cars in the car arrangement image through car numbers and displayed through the display device.

4. The automatic quality testing method for materials in the inner and outer areas of freight train carriages according to claim 1, characterized in that in step S3, when quality testing is performed on each carriage by a quality testing control device, each carriage is provided with a corresponding unloading device and quality testing auxiliary devices respectively, each carriage is unloaded layer by layer, material information in the carriage is collected in real time by the corresponding quality testing auxiliary devices in the process, and the quality testing control device performs one-to-one correspondence between the information sent by each quality testing auxiliary device and the corresponding carriage according to carriage numbers;

the quality inspection auxiliary equipment at least comprises a 2D camera, a light supplementing lamp, a 3D camera, a distance sensor and an early warning device; the 3D camera comprises a TOF camera and/or a point cloud camera, the distance sensor comprises a laser distance measuring sensor and/or a radar distance measuring sensor, and the early warning device comprises an audible alarm, a lamplight alarm and an audible and visual alarm.

5. The automatic quality testing method for materials in inner and outer areas of freight train carriages according to claim 1, characterized in that in step S3, when the carriages are tested one by one in sequence, the first carriage is discharged layer by layer, material information in the carriage is collected in real time through quality testing auxiliary equipment in the process, the quality testing control device tests the materials in the first carriage according to the information received from the quality testing auxiliary equipment, and after the quality testing of the first carriage is completed, the quality testing of the second carriage is performed.

6. The automatic quality inspection method for materials in the inner and outer areas of freight train cars according to claim 5, wherein when the quality inspection is performed on the cars one by one in sequence, the quality inspection auxiliary equipment and the unloading equipment are moved to inspect the quality of the cars one by one stopped in the unloading area; or, the first carriage of the train is parked in the working ranges of the quality testing auxiliary equipment and the unloading equipment at the fixed positions, the quality testing of the first carriage is realized through the cooperation of the quality testing control device and the quality testing auxiliary equipment, after the quality testing is finished, the quality testing control device sends out a car moving prompt signal, an operator removes the first carriage, and the second carriage is moved and parked in the working ranges of the quality testing auxiliary equipment and the unloading equipment at the fixed positions.

7. The automatic quality testing method for materials in the inner and outer areas of a freight train carriage according to claim 1, wherein the quality testing control device comprises a storage module and a processing module, wherein quality standard judging information of target materials is stored in the storage module, the quality standard judging information at least comprises material appearance pictures and material characteristic parameter information, and the processing module compares signals acquired from quality testing auxiliary equipment with the quality standard judging information in the storage module to obtain quality testing result information;

and the processing module stores a 3D vision algorithm.

8. The automated mass inspection method of materials in an interior and exterior area of a freight train car according to claim 7, wherein the mass inspection auxiliary device comprises a radiation detection device, the radiation detection device being positioned proximate to a train inlet of the unloading area, the radiation detection device being configured to detect whether the material is irradiated and to send the monitoring result to the mass inspection control device.

9. The method according to claim 1, wherein in step S4, the material information received by the quality inspection control device from the quality inspection auxiliary device includes at least volume information, shape information and size information of the material.

10. The automatic quality testing method for materials in the inner and outer areas of a freight train according to claim 1, wherein in step S5, the quality testing control device determines whether the bottom surface of the train is detected, whether the train is free of foreign matters or materials, and if the bottom surface of the train is detected and the train is free of foreign matters or materials, sends a prompt signal indicating the end of quality testing, and sends quality testing result information to a target user system and/or a display device.