CN210155545U - Be used for automatic on-line measuring equipment of switch manufacturing process - Google Patents
Be used for automatic on-line measuring equipment of switch manufacturing process Download PDFInfo
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- CN210155545U CN210155545U CN201920726708.3U CN201920726708U CN210155545U CN 210155545 U CN210155545 U CN 210155545U CN 201920726708 U CN201920726708 U CN 201920726708U CN 210155545 U CN210155545 U CN 210155545U
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/19—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/401—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes
Abstract
The utility model discloses a be used for switch manufacturing process automation on-line measuring equipment, this check out test set includes: a frame; the contour measuring module is arranged on the rack and used for measuring the contour of the turnout rail piece to obtain contour measuring data; the distance measuring module is arranged opposite to the rack and used for measuring the distance between the distance measuring module and the rack to obtain distance measuring data; the data receiving and storing module receives and stores the profile measurement data and the distance measurement data, and simultaneously calls and stores turnout rail pieces; the data processing module calls and processes the profile measurement data and the distance measurement data to obtain three-dimensional profile data of the turnout rail piece, and calls and compares standard data of the turnout rail piece with the three-dimensional profile data to form a detection report; and the purging module is arranged on the rack and used for purging the turnout rail piece. The detection equipment realizes automatic detection of the geometric dimension of the numerical control milling contour and improves the measurement precision.
Description
Technical Field
The utility model belongs to railway engineering equipment field, concretely relates to be used for switch to make process automation on-line measuring equipment.
Background
Railway transportation is an important component of economic development and infrastructure construction in China, and plays an extremely important role in promoting social progress in China and improving the quality of life of people; the turnout rail piece is a connection and crossing structure of a railway line for a locomotive vehicle to enter or cross another line, and is a key and weak link for railway transportation. The turnout has various types and complex structural forms, and the production and manufacturing precision of the turnout directly influences the safety, the efficiency and the comfort.
At present, the machining process control and detection mode of the turnout rail member mainly adopts manual detection as a main mode, and single characteristics such as the length position, the height, the rail head width and the like of a limited key section of the rail member are detected by using tools such as a measuring tape, a thickness caliper, a vernier caliper, a sample plate and the like, but the contour and the outer machining surface of the key section cannot be detected; in addition, in the processing process of the turnout rail piece, the section size detection and the manual calculation of the feeding amount are required to be carried out during each feed, the time and the labor are wasted, the efficiency is low, and the detection result is easily influenced by the subjective factors of the detection environment and the detection personnel.
Chinese patent CN106840033A specifically relates to a device and method for measuring steel rail profile parameters based on image processing. The steel rail profile detection device based on image processing is characterized by comprising four line laser sensors, a sensor support, a base, a rail conveying roller and a steel rail, the non-contact laser imaging principle is utilized, four three-dimensional laser profile sensors are adopted to collect steel rail section profile data, the image data collected by the sensors are subjected to coordinate transformation, rotation and translation, graph splicing is carried out, a steel rail section profile is obtained, and the geometric dimension of the calculated section profile is compared with an iron standard for judgment. The utility model provides a detection apparatus and method of standard rail profile has certain suitability, nevertheless can't satisfy the rail spare based on different rail types in the switch rail spare production process under the operating condition, different profiles detect, can't guide the process processing, and do not possess the informationization characteristic.
SUMMERY OF THE UTILITY MODEL
In order to solve the above-mentioned problem that exists among the prior art, the utility model provides a be used for switch manufacturing process automation on-line measuring equipment. The to-be-solved technical problem of the utility model is realized through following technical scheme:
an automatic on-line detection device for a turnout manufacturing process comprises the following steps:
a frame;
the contour measuring module is arranged on the rack and used for measuring the contour of the turnout rail piece to obtain contour measuring data;
the distance measuring module is arranged opposite to the rack and used for measuring the distance between the distance measuring module and the rack to obtain distance measuring data;
the data receiving and storing module is respectively connected with the contour measuring module and the distance measuring module and is used for receiving and storing the contour measuring data and the distance measuring data and calling and storing standard data of turnout rail parts;
and the data processing module is connected with the data receiving and storing module and used for calling and processing the profile measurement data and the distance measurement data to obtain three-dimensional profile data of the turnout rail piece, calling standard data of the turnout rail piece and comparing the standard data with the three-dimensional profile data to form a detection report.
And the purging module is arranged on the rack and used for purging the turnout rail piece.
In an embodiment of the present invention, the present invention further includes:
the height adjusting unit is connected with the milling machine and used for adjusting the height of the rack;
the height measuring unit is connected with the height adjusting unit and is used for measuring the relative height of the rack;
the horizontal angle adjusting unit is connected with the height adjusting unit and the rack and is used for rotatably adjusting the horizontal position of the rack;
and the rotation adjusting unit is connected with the profile measuring module and the rack and is used for adjusting the scanning direction of the profile measuring module.
In an embodiment of the present invention, the profile measuring module may be any one of a laser line scanning sensor, a binocular vision camera, or a laser radar.
In an embodiment of the present invention, the data receiving and storing module includes a data receiving unit and a data storing unit, the data receiving unit is connected to the data storing unit, and the data receiving unit is connected to the contour measuring module and the distance measuring module respectively;
the data receiving unit is used for receiving the profile measurement data and the distance measurement data;
the data storage unit is used for storing the profile measurement data and the distance measurement data and calling and storing the standard data of the turnout rail piece.
In an embodiment of the present invention, the data processing module includes: a mobile terminal and a terminal;
the mobile terminal is used for displaying the profile measurement data and the distance measurement data in real time and monitoring on line;
the terminal is used for obtaining the three-dimensional profile data according to the profile measurement data and the distance measurement data, calling the standard data to be compared with the three-dimensional profile data, and generating the detection report.
The utility model has the advantages that:
1. the utility model provides an online detection equipment for switch rail spare manufacturing process simple structure, convenient to use, carry out continuous detection to switch rail spare through laser line scanning sensor, laser range finding sensor, can not only accomplish traditional product quality and judge, can also carry out the data feedback of intermediate link in the course of working, provide processing guidance suggestion for operating personnel, solved in traditional manual detection system, the testing process is non-automatic, the detection error has human factor, can't carry out continuous detection scheduling problem to switch rail spare;
2. the utility model realizes the automatic detection of the geometric dimension of the numerical control milling contour, improves the measurement precision, reduces the labor intensity of workers, improves the production efficiency, and can calculate and optimize the feed amount of the turnout rail piece processing feed based on the detected data, guide the optimization, the improvement and the product processing quality of the forming cutter;
3. the utility model can adjust three deflection directions of the profile measuring instrument by utilizing the height adjusting module, the height measuring module, the horizontal angle adjusting module and the rotation adjusting module so as to adapt to the detection of turnout rail pieces with various rail types and different gauge baselines;
4. the utility model discloses an automatic online check out test set of this kind can form alternately with enterprise information system, realizes detecting data real-time transmission, storage to traceing back with product information.
The present invention will be described in further detail with reference to the accompanying drawings and examples.
Drawings
Fig. 1 is a schematic structural diagram of an automatic online detection device for a turnout manufacturing process according to an embodiment of the present invention;
fig. 2 is a schematic structural diagram of another automatic online detection device for a turnout manufacturing process according to an embodiment of the present invention;
fig. 3 is a schematic structural diagram of an apparatus for automatic online detection of a switch manufacturing process according to an embodiment of the present invention;
FIG. 4 is a schematic structural view of portion A of FIG. 3;
fig. 5 is a schematic view of an operating state of a profile measuring module for an automatic online detection device in a turnout manufacturing process according to an embodiment of the present invention;
fig. 6(a) is a schematic diagram of an image structure of a standard rail member scanned by a profile measurement module for an automatic online detection device in a switch manufacturing process according to an embodiment of the present invention;
FIG. 6(b) is a schematic diagram of the image structure obtained by rotating the image in FIG. 6 (a);
FIG. 6(c) is a schematic diagram of the image structure obtained after the highest points of the images in FIG. 6(b) are overlapped;
fig. 7 is an electrical connection schematic diagram of an automatic on-line detection device for a switch manufacturing process according to an embodiment of the present invention;
fig. 8 is a schematic view of a work flow of the automatic on-line detection device for the switch manufacturing process provided by the embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to specific examples, but the present invention is not limited thereto.
Referring to fig. 1-4, the embodiment of the present invention provides an automatic on-line detection device for a turnout manufacturing process, which includes: a frame 2, a profile measuring module 3, a distance measuring module 4, a data receiving and storing module 1, a data processing module 5 and a purging module 7.
In one embodiment, the frame 2 is fixedly disposed on a beam of the milling machine 8, and is mainly connected to or disposed opposite to other measurement modules, so as to provide support for the whole online detection.
It should be noted that, the frame 2 may also be provided with a track and a power system separately, and is not connected to the milling machine 8, and specifically may be provided according to actual requirements, and the embodiment of the present invention is not specifically limited herein.
Further, the on-line detection apparatus is also provided with a height adjustment unit 21, a height measurement unit 22, a horizontal angle adjustment unit 23, a rotation adjustment unit 24; the height adjusting unit 21 is fixed on the milling machine 8 and used for adjusting the height of the frame 2; a height measuring unit 22 is fixed to the height adjusting unit 21 for measuring a relative height of the housing 2, which is a height of the housing 2 with respect to the milling machine 8; the rack 2 and the height adjusting unit 21 are connected through a horizontal angle adjusting unit 23, and the horizontal rotation position of the rack 2 can be adjusted through the horizontal angle adjusting unit 23; the rotation adjusting unit 24 connects the profile measuring module 3 with the frame 2 for fixing the profile measuring module 3 on the frame 2, and the rotation adjusting unit 24 can rotate the profile measuring module 3 to adjust its scanning orientation, wherein the profile measuring module 3 is a laser line scanning sensor 31.
Further, the height adjusting unit 21 mainly consists of a lead screw guide rail 211 and a servo motor; the servo motor is controlled to drive the lead screw guide rail 211 to move, so that the rack 2 reaches a proper height; wherein the type of the lead screw guide rail 211 is KR 100; the servo motor is a 57S closed-loop servo motor; the height measuring unit 22 mainly comprises a short-distance laser ranging sensor 221, and the height of the rack 2 is measured by the short-distance laser ranging sensor 221, so that the relative height of the rack 2 is obtained; wherein the short-distance laser ranging sensor 221 is IL100 in model number; the horizontal angle adjusting unit 23 is mainly composed of a main rotating table 231, and the frame 2 is brought to a proper horizontal position by manually rotating the main rotating table 231; this rotation regulation unit 24 mainly comprises sensor revolving stage 241, thereby adjusts laser line scanning sensor 31's scanning position through manual rotation sensor revolving stage 241, and in addition, horizontal angle regulating unit 23 and rotation regulation unit 24 all can adopt servo motor as power device, the embodiment of the utility model discloses do not do specifically to limit here.
Further, when the horizontal angle adjusting unit 23 and the rotation adjusting unit 24 both use servo motors as power devices, the height adjusting unit 21, the height measuring unit 22, the horizontal angle adjusting unit 23, and the rotation adjusting unit 24 are respectively connected to the data receiving and storing module 1, and are controlled by the data receiving and storing module 1 to perform various actions, so that the profile measuring module 3 is in a proper scanning position.
It should be noted that the adjustment of the gantry 2 by the height adjustment unit 21, the height measurement unit 22, and the horizontal angle adjustment unit 23 is finally performed to make the profile measurement module 3 in a proper scanning position.
Please refer to fig. 5, it should be noted that, the suitable scanning position is a position that enables the profile measuring module 3 to completely scan the profile of the whole rail member, and simultaneously meets the requirements of the height, width and cross-sectional shape of the turnout rail member 6, the turnout rail members with different shapes have different requirements, and the position of the profile measuring module 3 can be set according to specific situations, which is not specifically described herein in the embodiments of the present invention.
Further, the profile measuring module 3 is disposed on the frame 2, and is configured to measure the profile of the switch rail member 6 to obtain profile measurement data.
Furthermore, the profile measuring module 3 comprises a pair of non-contact laser devices which are oppositely arranged at two ends of the outer side wall of the frame 2 and used for scanning the geometric profile of the turnout rail member 6 and acquiring data of the profile point of the turnout rail member 6; the non-contact laser device can be any one of a laser line scanning sensor, a binocular vision camera or a laser radar.
Preferably, the non-contact laser device is a laser line scanning sensor 31, and the model of the laser line scanning sensor 31 is LJV 7300; the embodiment of the utility model provides an use laser line scanning sensor 31 as the example, explain whole automatic on-line measuring equipment.
Specifically, after the two laser line scanning sensors 31 are adjusted to appropriate scanning positions by the height adjusting unit 21, the height measuring unit 22, the horizontal angle adjusting unit 23 and the rotation adjusting unit 24, the turnout rail member 6 is scanned, image data obtained by the two laser line scanning sensors 31 are subjected to rotation transformation according to a preset angle, after transformation is completed, the highest points of the two image data are overlapped, so that the two image data are completely spliced, and finally, a complete profile of the turnout rail member 6 is formed.
Further, the preset angle is obtained by measuring the sampling of the calibration rail according to the laser line scanning sensor 31 during installation, specifically, please refer to fig. 6(a) -6 (c) simultaneously, the two scanned image data are rotated until the two image data are located in the horizontal direction, and the rotation angles are respectively recorded as θ1And theta2Namely the angle is the preset angle; and then finding the highest points P1 and P2 of the two image data, and superposing the P1 and the P2, so that the two image data are completely spliced to form the outline of the complete calibration rail.
It should be noted that the embodiment of the present invention only describes a mode of splicing two image data obtained by scanning the laser line scanning sensor 31 to form a complete profile, and can also adopt other reasonable modes to splice, and the embodiment of the present invention is not specifically limited herein.
Further, in order to avoid the interference of the laser line scanning sensor 31 to the scanning result when scanning the rail member, the two laser line scanning sensors 31 are respectively covered with the first light-shielding covers, and the first light-shielding covers are fixed on two sides of the frame 2 to wrap the laser line scanning sensor 31 and only expose one side of the laser to be emitted.
Further, the distance measuring module 4 is disposed opposite to the rack 2, and is configured to measure a distance between the distance measuring module 4 and the rack 2, so as to obtain distance measurement data.
It should be noted that the relative arrangement here means that the distance measuring module 4 can ensure that the emitted laser light just hits on the reflector 411 on the rack 2, so as to measure accurate distance measurement data.
Further, the distance measuring module 4 adopts a laser distance measuring sensor, and the laser distance measuring sensor emits laser to the rack 2, so that the distance between the distance measuring module 4 and the rack 2 is obtained; the type of the laser ranging sensor is IL 100; the distance measuring module 4 is matched with the data of the rail member contour points acquired by the contour measuring module 3 to realize the three-dimensional data positioning of the turnout rail member 6. The three-dimensional data of the turnout rail member 6 specifically refers to two-dimensional data of a certain section of the turnout rail member and position data of the section in the length direction of the turnout rail member.
In a specific embodiment, in order to ensure the laser measurement accuracy of the laser distance measuring sensor during distance measurement, an auxiliary device is further provided, and the auxiliary device comprises a second light shield and a light reflecting plate 411, wherein the second light shield is covered on the whole milling machine 8 and is used for filtering an interference light source of the laser distance measuring sensor; the reflector 411 is fixed on the frame 2 for enhancing the detection light source of the laser distance measuring sensor, thereby ensuring the measurement accuracy of the laser distance measuring sensor.
Further, the reflector 411 is a diamond reflector.
Further, the data receiving and storing module 1 is respectively connected with the contour measuring module 3 and the distance measuring module 4, and is used for receiving and storing contour measuring data and distance measuring data, and calling and storing standard data of the turnout rail member.
It should be noted that the standard data of the turnout rail member refers to standard data of the end face geometric dimension of a preset turnout rail member, and includes standard values of the external dimensions of the preset turnout rail member, tolerance, position information of key sections, linear functions between sections and rail member information; the rail piece information comprises information such as a figure number, a construction number and materials of a preset turnout rail piece; the standard data of the turnout rail piece is used as a reference to assist the online detection equipment to work, so that the detection and judgment of the quality of the turnout rail piece 6 are completed.
Further, the data receiving and storing module 1 comprises a data receiving unit 11 and a data storing unit 12, the data receiving unit 11 is connected with the data storing unit 12, and the data receiving unit 11 is respectively connected with the contour measuring module 3 and the distance measuring module 4.
The data receiving unit 11 is used for receiving the profile measurement data and the distance measurement data; the data receiving unit 11 is mainly composed of an industrial control host and is responsible for controlling the profile measuring module 3, the distance measuring module 4 and running communication software, and specifically, the data receiving unit 11 is connected with the profile measuring module 3 through gigabit Ethernet and adopts a TCP/IP communication protocol; the distance measuring module 4 is connected with a data transmission radio station and adopts a ModBus bus protocol; similarly, the transmission objective can be achieved in a limited manner and with an equivalent protocol, and the embodiments of the present invention are not limited in this respect.
In addition, when the horizontal angle adjusting unit 23 and the rotation adjusting unit 24 use servo motors as power devices, the data receiving unit 11 controls the height adjusting unit 21, the height measuring unit 22, the horizontal angle adjusting unit 23 and the rotation adjusting unit 24 to perform corresponding actions, so that the profile measuring module 3 is in a proper scanning position.
Further, this industrial control host computer can satisfy for any kind such as high performance computer, singlechip, PLC, motion control card the utility model discloses the product of embodiment, the model of this industrial control host computer can be TB-BPC.
The data storage unit 12 is used for storing profile measurement data and distance measurement data, when the automatic online detection equipment works, the milling machine 8 can obtain different profile measurement data and distance measurement data after each time of cutting of the turnout rail 6, the profile measurement module 3 and the distance measurement module 4 can acquire data of the turnout rail 6 once every 200Hz or higher, data storage is carried out for every 2mm of sampling point, the data are sent to the data storage unit 12 through the data receiving unit 11, the data in the data storage unit 12 are called by the data processing module 5 and displayed in real time and simultaneously detected online, the data detected by each time of cutting are stored in the data storage unit 12 until the turnout rail 6 is processed, all the measurement data are stored in the data storage unit 12, the data processing module 5 calls the data in the data storage unit for processing, so as to form a detection report, and meanwhile, the data storage unit 12 calls standard data of turnout rail members from an enterprise information system in advance for storage; the data storage unit 12 is mainly composed of a storage server and is responsible for storing data received by the data receiving unit 11, the data storage unit 12 is based on an information system of an enterprise and is in mutual communication with the information system of the enterprise through a 5.8GHZ wireless channel, product information interaction and association can be achieved, and standard information of turnout rail members in the information system of the enterprise is called, so that detection parameters of the detection device are adjusted on line.
Further, the storage server may be of a model R230, and the storage server uses enterprise-level secure disks and sets up a raid1 redundant array, which effectively guarantees data security.
Further, the data processing module 5 is connected with the data receiving and storing module 1 and used for calling and processing the profile measurement data and the distance measurement data to obtain three-dimensional profile data of the turnout rail member 6, calling standard data of the turnout rail member and comparing the standard data with the three-dimensional profile data to form a detection report for field processing guidance, product analysis and later-stage tracing, and therefore human-computer interaction is achieved.
Further, the data processing module 5 includes a mobile terminal 51 and a terminal 52.
The mobile terminal 51 is used for displaying the profile measurement data and the distance measurement data in real time and monitoring on line; the mobile terminal 51 may be any mobile device meeting the requirements, such as a tablet computer, a mobile phone, a PC, a dedicated server, and the like, and the mobile terminal 51 is loaded with corresponding data processing software.
In addition, the mobile terminal 51 is wirelessly connected with the data storage unit 12, so that information in the data storage unit 12 can be directly read and modified; the mobile terminal 51 sends the data collected on site to the data storage unit 12 for storage, so that the data can be conveniently checked later.
In one embodiment, the mobile end 51 may further be provided with a code scanning gun, and each switch rail member 6 is provided with a corresponding bar code corresponding to the standard data of the switch rail member; the bar codes on the turnout rail pieces 6 can be scanned through the code scanning gun, the acquired bar code data are sent to the data receiving unit 11, the data receiving unit 11 calls turnout rail piece standard data from an enterprise information system as required and stores the turnout rail piece standard data into the data storage unit 12, and the mobile terminal 51 calls relevant information from the data storage unit 12 and generates a field detection table, so that field processing is guided.
In one embodiment, the mobile terminal 51 may also read data directly from the enterprise information system, and the mobile terminal 51 is connected to the enterprise information system through wireless communication.
The mobile terminal 51 can process the data of the turnout rail member 6 acquired on site, display the width and height of the specific section of the turnout rail member 6 in real time according to the distance measurement data to form a three-dimensional profile shape, and compare the three-dimensional profile shape with standard data of the turnout rail member, so as to guide the processing of the turnout rail member on site.
Here, the three-dimensional contour represents the contour of the switch rail element 6 at a fixed cross-sectional position.
The terminal 52 is used for obtaining the three-dimensional profile data of the turnout rail member 6 according to the profile measurement data and the distance measurement data, calling preset turnout rail member standard data to compare with the three-dimensional profile data, and generating a detection report for product analysis and later-stage tracing; meanwhile, the detection report generated by the terminal 52 is sent to the data storage unit 12 and the enterprise information system for storage.
After the processing of the turnout rail member 6 is finished, all real-time data are stored in the data storage unit 12, the terminal 52 calls the profile measurement data and the distance measurement data which are processed for the last time from the data storage unit 12 to form complete three-dimensional profile data, establishes a three-dimensional model, calls turnout rail member standard data to compare with the three-dimensional profile data, generates a detection report, performs data table analysis, generates a dimension diagram with a section as an abscissa and the width and the height of the turnout rail member 6 as an ordinate, performs line drawing analysis, and analyzes and traces the product in a later period according to the established three-dimensional model, the data table analysis result and the line drawing analysis result.
Further, the terminal 52 can be any mobile device meeting the requirement, such as a tablet computer, a mobile phone, a PC, a dedicated server, and the like, and the terminal 52 is also loaded with corresponding data processing software.
Further, the purging module 7 is arranged on the frame 2 and used for purging the turnout rail member 6.
In a specific embodiment, the sweeping module 7 is an intelligent sweeping module, a machine vision system is adopted, a top view of a turnout rail piece can be collected for a camera through a vision sensor, whether scrap iron influencing scanning exists at the top of the turnout rail piece 6 to be scanned or not is identified through processes of binarization, filtering, XY axis gray change rate statistics and the like, then the pollution degree of the turnout rail piece 6 is automatically judged through a data receiving unit 11, and sweeping is carried out; the method for automatically judging the pollution degree of the track is visual detection, namely, the track is operated by a machine vision system, and the blowing and cleaning method is a combination of compressed air source blowing and mechanical cleaning; wherein, the compressed air source purging adopts a milling machine 8 with an air pressure device.
It should be noted that, the machine vision system uses machine to replace human eyes to make various measurements and judgments, the vision system converts the object to be shot into image signal through machine vision product (i.e. image shooting device, which is divided into CMOS and CCD), and transmits it to special image processing system, and converts it into digital signal according to the information of pixel distribution, brightness and color; the image system performs various calculations on these signals to extract the features of the target, and then controls the operation of the on-site equipment, which is referred to herein as the purge module 7, according to the result of the determination.
Further, please refer to fig. 4 again, in an embodiment of the present invention, the intelligent purging module 7 includes a camera 71, a connecting frame 72, an air blowing device 73, and a mechanical cleaning device 74; the camera 71, the connecting frame 72, the air blowing device 73 and the mechanical cleaning device 74 are all arranged on the frame 2; the mechanical cleaning device 74 is fixed on the connecting frame 72 through screws, and the mechanical cleaning device 74 drives the steel wire cleaning head to complete the purpose of mechanical cleaning through the cleaning RV speed reducing motor; in addition, the mechanical cleaning device 74 may be a high-temperature-resistant material cleaning head, a servo motor, or the like.
The image of the turnout rail member 6 is shot by the camera 71, the image is transmitted to the image processing system on the data receiving unit 12, then the image processing system judges and sends the judgment result to the data receiving unit 12, the data receiving unit 12 controls the action of the purging module 7 according to the judgment result, and the turnout rail member 6 is cleaned by the air blowing device and the mechanical cleaning device.
Further, please refer to fig. 7, 211 is a lead screw guide rail, which belongs to a main bearing component, and is connected with the milling machine 8 through a steel adapter plate and fixed by screws; 25 is a screw adapter plate; 26 is a laser ranging sensor connection plate; 221 is a short-range laser ranging sensor; 231 is a main rotating table; 71 is a video camera; 2 is a frame; 241 is a sensor rotary table; 31 is a laser line scanning sensor; 4 is a distance measuring module; wherein, the screw rod adapter plate 25 and the screw rod guide rail 211 are fixed by screws along the direction of the dotted line; the main rotating platform 231 is fixed on the bottom surface of the screw rod adapter plate 25 by screws; the laser ranging sensor connecting plate 26 is fixed on the vertical surface of the screw rod adapter plate 25 through screws; the short-distance laser ranging sensor 221 and the laser ranging sensor connecting plate 26 are fixed by screws; the camera 71 is fixed to the back surface of the sensor mounting plate 27 by screws; the sensor rotating platform 241 is fixed on the sensor mounting plate 27 through screws; the laser line scanning sensor 31 and the sensor rotating platform 241 are fixed by a connecting piece, and are respectively fixed with two sides of the connecting piece through screws.
After all the components are installed, some of the components need to be finely adjusted in order to achieve the required measurement accuracy, as shown by the arrow in fig. 7, the main rotating platform 231 can rotate in the horizontal direction to adjust the angle, so that the frame 2, the sensor rotating platform 241 and the laser line scanning sensor 31 rotate along with the main rotating platform; in addition, the sensor rotating platform 241 can be adjusted to rotate vertically, as shown by the arrow in fig. 7, so that the measuring range of the laser line scanning sensor 31 can be adjusted to reach an accurate position, and the profile of the switch rail member 6 to be measured can be accurately measured.
The operating principle of the automatic online detection equipment for the turnout rail member manufacturing process is as follows:
the automatic online detection equipment for the turnout rail piece manufacturing process realizes the detection of the geometric dimension of the rail piece processing profile in a following mode, the profile measuring module 3 carries out real-time profile data acquisition while feeding every time, and the positioning of three-dimensional data is realized by combining with the distance measuring module 4; correspondingly, the data receiving and storing module 1 is used for receiving and storing the profile measurement data and the distance measurement data, and calling the standard data from the enterprise information system for storage; the data processing module 5 processes the profile measurement data, the distance measurement data and the standard data to form a data detection report for guiding processing, associates the data detection report with the enterprise information system through wireless transmission, and stores the finally obtained detection data in the enterprise information system.
Further, please refer to fig. 8, an embodiment of the present invention further provides a workflow diagram for the automatic on-line detection device in the turnout manufacturing process, wherein the workflow is implemented according to the on-line detection device, and specifically includes the following steps:
step (1): and (3) placing the turnout rail piece 6 to be tested on a milling machine 8 for first processing.
The automatic online detection equipment is arranged on a cross beam of a milling machine 8, wherein a distance measurement module 4 is arranged at one end of the milling machine 8 in the moving direction and is arranged opposite to a reflector 411 on a rack, a milling cutter 9 is positioned on a main shaft at the front side of the cross beam of the milling machine 8 so as to mill a rail part, and a turnout rail part 6 is fixed; according to the process requirements, carrying out first processing on the turnout rail piece 6 to be processed; the feed of the first pass is determined by the particular process.
It should be noted that the front side herein is based on the orientation or positional relationship illustrated in the drawings.
Step (2): and measuring the turnout rail member 6 after the first processing by using the contour measuring module 3 and the distance measuring module 4 to respectively obtain contour measuring data and distance measuring data.
After the milling machine 8 finishes the first processing, the milling machine needs to return to the initial position to perform the second processing, in the process that the milling machine 8 returns to the initial position, the laser ranging sensor is used for recording the position information of the milling machine 8 to obtain the position information of the turnout rail piece 6 every 2mm, and the laser line scanning sensor 31 is used for scanning the section of the processed turnout rail piece to obtain the section profile information of the turnout rail piece 6.
It should be noted that, since the detection device is installed on the milling machine 8, the distance between the distance measurement module 4 and the machine frame 2 measured by the distance measurement module 4 is the distance between the distance measurement module 4 and the milling machine 8, the milling machine 8 and the switch rail member 6 move relatively, and the start position and the end position of the switch rail member 6 are determined by detecting, so that the position information of any section of the switch rail member 6 can be determined.
And (3): and the data receiving and storing module 1 is used for receiving and storing the profile measurement data and the distance measurement data, and meanwhile, standard data of the turnout rail member is called from the enterprise information system and stored.
And receiving profile data of different positions of the turnout rail piece by using the industrial control host, and sending the profile data to the storage server for continuous storage.
It should be noted that the profile measurement data and the distance measurement data of the switch rail member 6 obtained by each cutting of the milling machine 8 are sent to the storage server for storage.
And (4): and processing the profile measurement data and the distance measurement data by using the data processing module 5 to obtain three-dimensional profile data of the turnout rail member 6 after the first processing, and calling standard data of the turnout rail member to compare with the three-dimensional profile data, thereby calculating the cutter feeding amount of the turnout rail member 6 for the second processing.
The mobile terminal 51 in the data processing module 5 calls distance measurement data and profile measurement data from the storage server, and forms a three-dimensional profile shape of the turnout rail member 6 in real time according to the distance measurement data and the profile measurement data, and compares the three-dimensional profile shape with standard data of the turnout rail member to obtain information such as feed amount, residual amount, deviation amount and the like generated in the processing process of the turnout rail member 6, and obtain cutter feed amount for second processing, and displays the acquired data on the mobile terminal 51 in real time to facilitate observation.
It should be noted that, calculating the tool feeding amount is an existing method, and the embodiment of the present invention is not described herein again.
And (5): and adjusting the processing track of the milling machine 8 according to the cutter feeding amount, and then performing second processing on the turnout rail piece.
And the profile measurement data and the distance measurement data obtained by the second processing are received by the industrial control host and stored in the storage server.
And (6): and (5) repeating the steps (1) to (5) until the comparison between the three-dimensional outline and the preset outline standard data of the turnout rail member 6 meets the preset condition.
And (7): and processing the final profile measurement data and the distance measurement data of the processed turnout rail piece by using the data processing module so as to obtain a detection report.
After the turnout rail piece 6 to be processed is processed, in the process that the milling machine 8 returns to the initial position, the laser ranging sensor is used for recording the position information of the milling machine 8 so as to obtain the position information of the turnout rail piece 6, the laser line scanning sensor 31 is used for scanning the surface of the processed rail piece so as to obtain the section profile information of the turnout rail piece 6, the position information and the section profile information of the turnout rail piece 6 are sent to the data receiving and storing module 1 for storage, the data receiving and storing module 1 receives and stores the data and sends the data to the mobile terminal 51 for processing and displaying, then, the terminal 52 calls the profile measurement data and the distance measurement data which are processed at the last time from the data storage unit 12 so as to form complete three-dimensional profile data, establishes a three-dimensional model, calls standard data of the turnout rail piece to compare with the three-dimensional profile data so as to generate a, performing number table analysis, generating a turnout rail member size chart with the section as an abscissa and the width and the height of the turnout rail member 6 as ordinates, performing line graph analysis, and performing product analysis and later-stage tracing according to the three-dimensional model, the number table analysis result and the line graph analysis result; after the detection is completed, the terminal 52 sends the finally obtained detection report to the data storage unit 12 for storage, and at the same time, the data storage unit 12 uploads the detection report to the enterprise information system for storage and backup.
The embodiment of the utility model provides a through this kind of automatic check out test set, can reach following beneficial effect:
1. the utility model provides an online detection equipment for switch rail spare manufacturing process simple structure, convenient to use, through line laser vision sensor, laser ranging system carry out continuous detection to switch rail spare, can not only accomplish traditional product quality and judge, can also carry out the data feedback of intermediate link in the course of working, provide processing guidance suggestion for operating personnel, solved in traditional manual detection system, the testing process is non-automatic, the detection error has human factor, can't carry out continuous detection scheduling problem to switch rail spare;
2. the utility model realizes the automatic detection of the geometric dimension of the numerical control milling contour, improves the measurement precision, reduces the labor intensity of workers, improves the production efficiency, can calculate and optimize the feeding amount of the rail piece processing feed based on the detected data, and guides the optimization, the improvement and the product processing quality of the forming cutter;
3. the utility model can adjust three deflection directions of the profile measuring instrument by utilizing the height adjusting module, the height measuring module, the horizontal angle adjusting module and the rotation adjusting module so as to adapt to the detection of turnout rail pieces with various rail types and different gauge baselines;
4. the utility model discloses an automatic online check out test set of this kind can form alternately with enterprise information system, realizes detecting data real-time transmission, storage to traceing back with product information. The foregoing is a more detailed description of the present invention, taken in conjunction with the specific preferred embodiments thereof, and it is not intended that the invention be limited to the specific embodiments shown and described. To the utility model belongs to the technical field of ordinary technical personnel, do not deviate from the utility model discloses under the prerequisite of design, can also make a plurality of simple deductions or replacement, all should regard as belonging to the utility model discloses a protection scope.
Claims (5)
1. An automatic on-line detection device for a turnout manufacturing process is characterized by comprising:
a frame;
the contour measuring module is arranged on the rack and used for measuring the contour of the turnout rail piece to obtain contour measuring data;
the distance measuring module is arranged opposite to the rack and used for measuring the distance between the distance measuring module and the rack to obtain distance measuring data;
the data receiving and storing module is respectively connected with the contour measuring module and the distance measuring module and is used for receiving and storing the contour measuring data and the distance measuring data and calling and storing standard data of turnout rail parts;
the data processing module is connected with the data receiving and storing module and used for calling and processing the profile measurement data and the distance measurement data to obtain three-dimensional profile data of the turnout rail piece, calling standard data of the turnout rail piece and comparing the standard data with the three-dimensional profile data to form a detection report;
and the purging module is arranged on the rack and used for purging the turnout rail piece.
2. The automatic on-line detection device for the switch manufacturing process according to claim 1, characterized by further comprising:
the height adjusting unit is connected with the milling machine and used for adjusting the height of the rack;
the height measuring unit is connected with the height adjusting unit and is used for measuring the relative height of the rack;
the horizontal angle adjusting unit is connected with the height adjusting unit and the rack and is used for rotatably adjusting the horizontal position of the rack;
and the rotation adjusting unit is connected with the profile measuring module and the rack and is used for adjusting the scanning direction of the profile measuring module.
3. The automatic on-line detection equipment for the turnout manufacturing process according to claim 1, wherein the profile measurement module can be any one of a laser line scanning sensor, a binocular vision camera or a laser radar.
4. The automatic on-line detection equipment for the turnout manufacturing process according to claim 1, wherein the data receiving and storing module comprises a data receiving unit and a data storing unit, the data receiving unit is connected with the data storing unit, and meanwhile, the data receiving unit is respectively connected with the profile measuring module and the distance measuring module;
the data receiving unit is used for receiving the profile measurement data and the distance measurement data;
the data storage unit is used for storing the profile measurement data and the distance measurement data and calling and storing the standard data of the turnout rail piece.
5. The automatic on-line detection device for the switch manufacturing process according to claim 1, characterized in that said data processing module comprises: a mobile terminal and a terminal;
the mobile terminal is used for displaying the profile measurement data and the distance measurement data in real time and monitoring on line;
the terminal is used for obtaining the three-dimensional profile data according to the profile measurement data and the distance measurement data, calling the standard data to be compared with the three-dimensional profile data, and generating the detection report.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201811567596.8A CN109491322A (en) | 2018-12-21 | 2018-12-21 | One kind being used for switch manufacture process automation online detection instrument and method |
| CN2018115675968 | 2018-12-21 |
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| Publication Number | Publication Date |
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| CN210155545U true CN210155545U (en) | 2020-03-17 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN201811567596.8A Withdrawn CN109491322A (en) | 2018-12-21 | 2018-12-21 | One kind being used for switch manufacture process automation online detection instrument and method |
| CN201920726708.3U Active CN210155545U (en) | 2018-12-21 | 2019-05-21 | Be used for automatic on-line measuring equipment of switch manufacturing process |
| CN201910421820.0A Active CN110007643B (en) | 2018-12-21 | 2019-05-21 | Automatic on-line detection equipment and method for turnout manufacturing process |
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| Application Number | Title | Priority Date | Filing Date |
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| CN201811567596.8A Withdrawn CN109491322A (en) | 2018-12-21 | 2018-12-21 | One kind being used for switch manufacture process automation online detection instrument and method |
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| Application Number | Title | Priority Date | Filing Date |
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| CN201910421820.0A Active CN110007643B (en) | 2018-12-21 | 2019-05-21 | Automatic on-line detection equipment and method for turnout manufacturing process |
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| CN (3) | CN109491322A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110007643A (en) * | 2018-12-21 | 2019-07-12 | 中铁宝桥（南京）有限公司 | One kind being used for switch manufacture process automation online detection instrument and method |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110143218B (en) * | 2019-06-27 | 2020-07-31 | 合肥工业大学 | Method and device for detecting straightness and torsion angle of high-speed railway turnout |
| CN112444198A (en) * | 2019-08-28 | 2021-03-05 | 中南大学 | Automatic detection and alarm system integrated equipment for geometric dimension of rail |
| CN110954027A (en) * | 2019-11-22 | 2020-04-03 | 四川深瑞视科技有限公司 | Track slab measuring system and track slab measuring method |
| CN110954028A (en) * | 2019-11-22 | 2020-04-03 | 四川深瑞视科技有限公司 | Track slab measuring system and track slab measuring method |
| CN111397535A (en) * | 2020-04-29 | 2020-07-10 | 苏州龙抬头智能科技有限公司 | Dynamic calibration method based on linear scanning laser and conveyor belt operating platform device |
| CN112147979B (en) * | 2020-09-22 | 2022-04-12 | 北京新风航天装备有限公司 | Machining online detection method based on three-dimensional model integrated application |
| CN112589534A (en) * | 2021-01-07 | 2021-04-02 | 中铁宝桥（南京）有限公司 | On-line detection equipment and detection method for numerical control drilling machining of turnout rail piece |
| CN112902867B (en) * | 2021-01-18 | 2023-06-02 | 北京京城智通机器人科技有限公司 | Track contour measuring method |
| CN113552845B (en) * | 2021-07-29 | 2022-06-21 | 重庆博张机电设备有限公司 | Measurement control method and flaker |
| CN114132358B (en) * | 2021-10-29 | 2023-03-14 | 北京自动化控制设备研究所 | Multi-platform intelligent track comprehensive detection system |
| CN114100876A (en) * | 2021-11-12 | 2022-03-01 | 深圳市奥极因科技有限公司 | Method for positioning and controlling deflection state of centrifuge rotor through intelligent algorithm |
| CN115267407B (en) * | 2022-09-16 | 2023-01-03 | 北京中电飞华通信有限公司 | Equipment state early warning device based on artificial intelligence and early warning method thereof |
| CN117048113B (en) * | 2023-10-13 | 2023-12-22 | 江苏爱箔乐铝箔制品有限公司 | Dynamic precision detection method and system for stamping aluminum foil cutlery box |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AT5911U3 (en) * | 2002-10-29 | 2003-11-25 | Plasser Bahnbaumasch Franz | METHOD FOR CONTACT-FREE MEASUREMENT OF A CROSS-PROFILE OR DISTANCE FROM RAILS OF A TRACK |
| CN102591257B (en) * | 2012-02-27 | 2013-09-18 | 山东理工大学 | Parameter curve cutter path oriented numerical control system contour error control method |
| CN102699359B (en) * | 2012-05-31 | 2014-07-23 | 长春理工大学 | Tool setting device and method for micro lathe |
| CN103115581B (en) * | 2013-01-23 | 2015-11-25 | 爱佩仪中测（成都）精密仪器有限公司 | Multifunction railway measuring system and method |
| JP6445383B2 (en) * | 2015-04-27 | 2018-12-26 | 東日本旅客鉄道株式会社 | Trajectory inspection method and apparatus |
| CN106513689A (en) * | 2016-11-04 | 2017-03-22 | 中国铁道科学研究院铁道建筑研究所 | Method for improving turnout performance by adopting 3D printing technology |
| CN108844497A (en) * | 2018-06-07 | 2018-11-20 | 东北大学 | A kind of numerical control machine slide rail mounting surface linearity testing apparatus and method |
| CN109491322A (en) * | 2018-12-21 | 2019-03-19 | 中铁宝桥（南京）有限公司 | One kind being used for switch manufacture process automation online detection instrument and method |
-
2018
- 2018-12-21 CN CN201811567596.8A patent/CN109491322A/en not_active Withdrawn
-
2019
- 2019-05-21 CN CN201920726708.3U patent/CN210155545U/en active Active
- 2019-05-21 CN CN201910421820.0A patent/CN110007643B/en active Active
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110007643A (en) * | 2018-12-21 | 2019-07-12 | 中铁宝桥（南京）有限公司 | One kind being used for switch manufacture process automation online detection instrument and method |
| CN110007643B (en) * | 2018-12-21 | 2024-01-02 | 中铁宝桥（南京）有限公司 | Automatic on-line detection equipment and method for turnout manufacturing process |
Also Published As
| Publication number | Publication date |
|---|---|
| CN110007643B (en) | 2024-01-02 |
| CN110007643A (en) | 2019-07-12 |
| CN109491322A (en) | 2019-03-19 |
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