CN202974887U - Steel rail surface defect detection device - Google Patents
Steel rail surface defect detection device Download PDFInfo
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- CN202974887U CN202974887U CN 201220725111 CN201220725111U CN202974887U CN 202974887 U CN202974887 U CN 202974887U CN 201220725111 CN201220725111 CN 201220725111 CN 201220725111 U CN201220725111 U CN 201220725111U CN 202974887 U CN202974887 U CN 202974887U
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Abstract
The utility model relates to a steel rail surface defect detection device which comprises an IPC (Industrial Personal Computer), a PLC (Programmable Logic Controller), and a bracket and an alarm device arranged on a steel rail transporting line, wherein an LED (Light Emitting Diode) lamp, an industrial camera and a marking machine are mounted on the bracket; the PLC comprises an output interface and a communication module; and the switches of the industrial camera, the LED lamp and the alarm device are connected with the output interface of the PLC through a control line. The IPC comprises a video acquisition module and the communication module, wherein the communication module of the IPC is respectively connected with the communication module of the PLC and a communication module of the marker; and the video acquisition module of the IPC is connected with a video output interface of the industrial camera through a video line. The steel rail surface defect detection device is reliable in measuring result, can perform a fully-automatic rapid detection on the surface of a steel rail and is free of influencing the production, and can meet the requirement on online detection.
Description
Technical field
The utility model provides a kind of rail surface defects pick-up unit, is specially a kind of device that on the Rail Production pipeline, rail surface defects is detected and reports to the police that is applied in.
Technical background
along with transportation by railroad at a high speed, the heavy duty future development has proposed more and more higher requirement to the Rail Surface quality, and some rail surface defects cause the situation of rail fracture more and more common, but in the steel rail rolling process, due to steel billet, rolling equipment, the reasons such as rolling mill practice may cause the surface crackle to occur, scab, roll marks, scratch, the defectives such as skin lamination, these defectives have not only affected the rail outward appearance, and what more want is the corrosion resistivity that has reduced rail, resistance to abrasion, fatigue limit so rail surface defects detects the part as the rail testing, plays vital effect to the safety of railway operation, and detection in the past is by detection person, Rail Surface to be carried out the artificial visually examine, and manual detection exists labour intensity large, loss is high, accuracy of detection is low, the problem of rail foot detection difficult, simultaneously along with the swift and violent development of domestic railway high speed, produce the renewal of rail equipment and introduce, the manufacturing speed of rail is also progressively accelerated, and the work of in the past manually rail being carried out surface imperfection can not be satisfied the actual production requirement.
Summary of the invention
The purpose of this utility model is to provide a kind of rail surface defects pick-up unit, can be online to rail surface defects detect, without undetected, precision is high, measurement result is reliable.
the technical solution of the utility model is: the rail surface defects pick-up unit, comprise industrial computer, programmable logic controller (PLC), be arranged on support and warning device on the rail pipeline, it is characterized in that: the LED lamp is housed on support, industrial camera and marking machine, described programmable logic controller (PLC) comprises output interface and communication module, industrial camera, the LED lamp is connected switch and is connected with the output interface of programmable logic controller (PLC) by control line with warning device, described industrial computer comprises video acquisition module, communication module, the communication module of industrial computer is connected communication module with the communication module of programmable logic controller (PLC) respectively by signal wire and is connected with marking machine, the video acquisition module of industrial computer is connected with the video output interface of industrial camera by video line.
the support of rail surface defects pick-up unit of the present utility model is contained on the pipeline of Rail Production line end, by industrial camera and the LED lamp of installing on support, image input industrial computer with Rail Surface, industrial computer carries out analyzing and processing to image, with result feedback to display module, as Rail Surface exist defective industrial computer by order wire, the programmable logic controller (PLC) controls warning device is reported to the police, the utility model has the advantages that several industrial cameras of rack-mount different angles can be simultaneously fast to the end face of survey rail, central plane, instep, capture is carried out on the surface of bottom surface, can not produce undetected phenomenon, and with obtained image transmitting processing to industrial computer, the precision of industrial computer Treatment Analysis image is high, the measurement result that produces is reliable, can full automatic Rail Surface be detected fast, do not affect production, can satisfy the requirement of online detection.
Description of drawings
Accompanying drawing is the principle schematic of the utility model rail surface defects pick-up unit.
Embodiment
the rail surface defects pick-up unit, comprise industrial computer, programmable logic controller (PLC), be arranged on support and warning device on the rail pipeline, the LED lamp is housed on support, industrial camera and marking machine, described programmable logic controller (PLC) comprises output interface and communication module, industrial camera, the LED lamp is connected switch and is connected with the output interface of programmable logic controller (PLC) by control line with warning device, described industrial computer comprises video acquisition module, communication module, the communication module of industrial computer is connected communication module with the communication module of programmable logic controller (PLC) respectively by signal wire and is connected with marking machine, the video acquisition module of industrial computer is connected with the video output interface of industrial camera by video line.
described warning device adopts sound and light alarm, point out warning by alarm lamp and alarm sound to the reviewer, described support can be soldered on pipeline, also can be independent rack, but it is stable that support should be installed, the LED lamp is housed on support, the LED lamp is the LED lamp of bar shaped, advantage is that illumination is stable, life-span is long, power consumption is low, industrial camera also is housed on support, present embodiment adopts six industrial cameras, from different angles respectively to the end face of rail, central plane, instep, capture is carried out on the surface of bottom surface, camera is started or stoped by programmable logic controller (PLC) controls, described programmable logic controller (PLC) refers to adopt a class programmable memory, be used for its internally stored program, the actuating logic computing, sequential control, regularly, the user oriented instructions such as counting and arithmetical operation, and by numeral or analog pattern input, various types of machineries or production run are controlled in output, it comprises output interface, wherein input interface module is that on-the-spot input interface circuit is by the input interface circuit of optically coupled circuit and microcomputer, effect is the input channel of the connection interface of programmable logic controller (PLC) and field control, output interface module is by the output data register, gating circuit and interrupt request circuit are integrated, the effect programmable logic controller (PLC) is by the execution unit output corresponding control signal of on-the-spot output interface module to the scene, programmable logic controller (PLC) also comprises memory module, power module, display module, functional module, CPU (central processing unit) module and communication module, industrial camera, the LED lamp is connected switch and is connected with the output interface of programmable logic controller (PLC) by control line with warning device, by the programmable logic controller (PLC) controls industrial camera, the startup of LED lamp and warning device or close, in fact in order better to reach its result of use, also sensor can be housed on support, when rail passes through the support shooting area from production line, sensor sensing is given signal of programmable logic controller (PLC) immediately to rail, at this moment programmable logic controller (PLC) controls industrial camera, LED lamp and warning device work or standby.
described industrial computer comprises video acquisition module and communication module, also comprise power module, display module, human-machine interface module, CPU (central processing unit) module and memory module, it is mainly that result with industrial computer analyzes is transferred to industrial computer by signal wire that the communication module of industrial computer is connected with marking machine with the communication module of programmable logic controller (PLC) (hereinafter to be referred as PLC) that communication module is connected respectively by signal wire, when checking that Rail Surface is indefectible, industrial computer is transferred to one of PLC and passes through signal, this moment, PLC controlled the light warning demonstration green of alarm module, when checking that Rail Surface has defective flaw, industrial computer by communication module to signal of marking machine, marking machine is a kind of spray-painting plant with controller, when marking machine receives the signal that sends from the industrial computer communication module, the marking machine mark that sprays paint at defective position, industrial computer is transferred to alerting signal of PLC simultaneously, this moment, PLC controlled the light warning demonstration danger signal of alarm module, carry out simultaneously audible alarm, the video acquisition module of described industrial computer is connected with the video output interface of industrial camera by video line, the image of industrial camera collection is stored into carry out analyzing and processing on memory module and be shown on display module, the reviewer can inquire about and process the result of industrial computer by human-machine interface module and display module.
Rail surface defects pick-up unit of the present utility model belongs to the embedded vision device, is mounted on the rail pipeline, automatically measures the surface imperfection of rail; And with automatic control PLC output alarm, stop signal, guarantee that the rail that comes into operation is all the second best in quality, this device can Improving The Quality of Products, reduce labor workload, promotes the added value of production line.
Rail surface defects pick-up unit of the present utility model uses industrial computer in conjunction with industrial camera, triggers camera by PLC and completes image acquisition, and detection, result output are all completed in industrial computer software.
Rail surface defects pick-up unit of the present utility model is equipped with image processing software in industrial computer, having enabled medium filtering, morphological process and threshold value in image processing software controls, extract the defect area of low pixel in the bright field, extract the defect area of high pixel in dark field, the detection that reaches defective and classification that can be correct, at first, for the structure of central plane, the defective such as adopt the mode of bright field to highlight pit, to peel off; Adopt the imaging mode of dark field for instep, end face, bottom surface, extract crackle, indistinct crackle, and the impact of oxide own is minimized.Rail surface defects pick-up unit of the present utility model mainly detects the surface crack on rail, surperficial scratch, mechanical roll printing and because the abrasion that the severe oxidations such as crackle, scratch form.
For example:
1, damaging of rail head adopted the calculating of border width, extracts the dark field edge feature, and the edge transfinites, and namely inwardly damaging appears in rail head;
2, scratch is peeled off and has been used medium filtering, morphological process and threshold value to control, and extracts the defect area of low pixel in the bright field, extracts the defect area of high pixel in dark field, and the laboratory stage feature is stable;
3, crackle, polishing scratch have used medium filtering, morphological process and threshold value to control, and extract the defect area of low pixel in the bright field, extract the defect area of high pixel in dark field, and the laboratory stage feature is stable.
Can test through the new of laboratory model machine, the fastest detection speed of rail surface defects pick-up unit of the present utility model is 1.5 meter per seconds, and accuracy of detection is 0.1mm; Device can carry out testing in continuous 24 hours, and long run test work 120 hours is without any fault; In the laboratory to randomly draw from the Rail Production line ten groups totally eight ten 25 meters long rail detect, it is 0% that this device is taken false pass rate (bad be a good); Rail surface defects pick-up unit of the present utility model adopts special optical facilities, the GigE camera, and Iimaging Stability is high; And device volume is little, lightweight, mechanism is uncomplicated, little, pollution-free to requirements of installation space, noiselessness, without waste gas, without waste material, meet the requirement of environmental protection; Rail surface defects pick-up unit of the present utility model energy saving detects and need not consumptive material, auxiliary material, saves cost, system maintenance is simple, easy to operate.
Claims (1)
1. rail surface defects pick-up unit, comprise industrial computer, programmable logic controller (PLC), be arranged on support and warning device on the rail pipeline, it is characterized in that: the LED lamp is housed on support, industrial camera and marking machine, described programmable logic controller (PLC) comprises output interface and communication module, industrial camera, the LED lamp is connected switch and is connected with the output interface of programmable logic controller (PLC) by control line with warning device, described industrial computer comprises video acquisition module, communication module, the communication module of industrial computer is connected communication module with the communication module of programmable logic controller (PLC) respectively by signal wire and is connected with marking machine, the video acquisition module of industrial computer is connected with the video output interface of industrial camera by video line.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 201220725111 CN202974887U (en) | 2012-12-25 | 2012-12-25 | Steel rail surface defect detection device |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 201220725111 CN202974887U (en) | 2012-12-25 | 2012-12-25 | Steel rail surface defect detection device |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN202974887U true CN202974887U (en) | 2013-06-05 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN 201220725111 Expired - Fee Related CN202974887U (en) | 2012-12-25 | 2012-12-25 | Steel rail surface defect detection device |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN202974887U (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108226186A (en) * | 2018-03-31 | 2018-06-29 | 苏州梅克兰检测服务有限公司 | A kind of liquid crystal display wear resistence detection device |
| CN108955646A (en) * | 2018-05-15 | 2018-12-07 | 武汉理工大学 | Steel rail welding line center automatic detection device |
| CN109490416A (en) * | 2018-12-10 | 2019-03-19 | 上海市东方海事工程技术有限公司 | A kind of weld joint recognition method applied to double rail type rail examination |
-
2012
- 2012-12-25 CN CN 201220725111 patent/CN202974887U/en not_active Expired - Fee Related
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108226186A (en) * | 2018-03-31 | 2018-06-29 | 苏州梅克兰检测服务有限公司 | A kind of liquid crystal display wear resistence detection device |
| CN108955646A (en) * | 2018-05-15 | 2018-12-07 | 武汉理工大学 | Steel rail welding line center automatic detection device |
| CN109490416A (en) * | 2018-12-10 | 2019-03-19 | 上海市东方海事工程技术有限公司 | A kind of weld joint recognition method applied to double rail type rail examination |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant | ||
| C17 | Cessation of patent right | ||
| CF01 | Termination of patent right due to non-payment of annual fee |
Granted publication date: 20130605 Termination date: 20131225 |