JP2007121004A - Method and device for measuring rail size - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method and device for measuring highly accurately various sizes of rails for railroad. <P>SOLUTION: A sectional shape of the rail for the railroad is determined from distance data and a tilt angle of a laser range finder arranged in the tilted state vertically and sidewards and position data during scanning, and each part dimension of the rail for the railroad is operated based on the sectional shape. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method and apparatus for measuring a dimension of a section steel, and more particularly to a rail dimension measuring method and apparatus for measuring a cross-sectional shape and dimensions of a rail for rail (hereinafter also abbreviated as rail or Rail) with high accuracy. .

  For railroad rails used for railways as a means of transporting passengers and cargo, shape inspection in the manufacturing process or maintenance during use is regarded as important. However, until now, the main measurement of rail shape has been manual measurement using a dedicated measuring jig such as a width gauge or micrometer. For this reason, it takes time to measure, causing pitch down, variation in measurement values by the measurer, and a difference between experienced and inexperienced people.

  On the other hand, various techniques have been proposed. For example, Patent Literature 1 discloses a technique called a railroad rail shape measuring method. This technology arranges two scanning laser distance meters in the transport direction, measures the distance to the rail upper surface with respect to the running rail, and extracts the longitudinal extreme values of individual irregularities present on the rail upper surface By doing this, the amount of unevenness is calculated, and the amount of bending at the end is calculated, so that the rail shape is judged online.

  Patent Document 2 discloses a technique referred to as a rail rail column thickness determination method. In this technology, two rails with a laser distance meter are placed on the rail (thickness part), the distance to the rail during the run is measured, and the thickness is measured from the distance between the distance meters and the distance data. Judgment is performed.

Furthermore, Patent Literature 3 discloses a technique called a rail cross-sectional shape measuring device. In this technique, two laser displacement meters are arranged on the upper surface and side surface of the rail, and the upper surface scans the laser displacement meter in the material left-right direction and the side surface in the material up-down direction.
JP-A-8-261742 JP 10-260035 A JP 2003-207319 A

  However, the techniques described in Patent Document 1 and Patent Document 2 are measured during rail transportation, and the measurement items are also determined by measuring the unevenness of the rail upper surface of the entire length in the longitudinal direction of the material. Moreover, the column thickness of the rail is the main one, and there is a problem that the complicated shape of the rail is not measured in detail and with high accuracy.

  Further, in the technique described in Patent Document 2, it is assumed that the rail cross-sectional shape is measured by scanning laser displacement meters installed on the upper surface and the side surface, but there is no description about the measurement of the specific cross-sectional shape.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a rail dimension measuring method and apparatus that can solve the above problems and measure various dimensions of railroad rails with high accuracy.

  The invention according to claim 1 of the present invention is the rail distance measuring method for measuring the cross-sectional shape and dimensions of railroad rails by scanning a laser distance meter disposed in a state where it is tilted vertically and horizontally. A rail dimension measuring method characterized in that a cross-sectional shape of the rail for railroad is obtained from the distance data, inclination angle, and position data during scanning, and the dimensions of each part of the rail for railroad are calculated based on the cross-sectional shape. .

  Further, the invention according to claim 2 of the present invention is the rail dimension measuring method according to claim 1, wherein the dimensions of each part are the head width, bottom width, height, thickness, one foot width, sole flatness of the rail, And a method of measuring a rail size, characterized in that any one of them and a combination thereof is used.

  Further, the invention according to claim 3 of the present invention is the rail distance measuring apparatus that measures the cross-sectional shape and dimensions of the rail for rail by scanning a laser distance meter arranged in an inclined state vertically and horizontally. A rail comprising: an arithmetic unit that obtains a cross-sectional shape of the railroad rail from the distance data of the meter, an inclination angle, and position data during scanning, and calculates the dimensions of each part of the railroad rail based on the cross-sectional shape It is a dimension measuring device.

  In the present invention, the cross-sectional shape of the railroad rail is obtained from the distance data of the laser rangefinder, the inclination angle, and the position data during scanning, and the dimensions of each part of the railroad rail are calculated based on this cross-sectional shape. The dimensions of each part of the rail for rail can be obtained accurately and at high speed.

  FIG. 1 is a diagram showing an outline of an example of an apparatus for carrying out the present invention. In the figure, 1 is a calibration piece, 2a to f are laser distance meters, 3 is a C frame, 4 is a C frame running mechanism, 5 is a C frame height setting mechanism, 6 is a distance meter height setting mechanism, and 7 is Each rail is shown.

  The laser rangefinders 2a to 2f are arranged so as to sandwich the calibration piece 1 and the rail 7 in an inclined state from the top, bottom, left and right. Specifically, the top and bottom, left and right are 45 ° (X type), and the inclination angle is If the angle is less than 30 °, irregularly reflected light from the laser beam cannot be received or an error may occur. Therefore, the angle is set to 30 ° or more, and preferably 45 ° ± Δθ1) and 90 ° vertically.

  It has a distance meter height setting mechanism 6 that changes the measurement range of the laser distance meter according to the size of the material (hereinafter, the measurement target rail is abbreviated as material). The laser rangefinders 2e and 2f installed 90 degrees above and below are intended to increase the measurement accuracy. If the distance measurement of 45 degrees above and below and left and right is enough to measure the distance of the material, 4 units are available. It doesn't matter. The C frame 3 is equipped with laser distance meters 2a to 2f, and can be moved and moved by a C frame traveling mechanism 4 such as a servo motor, and the frame height can be changed by a C frame height setting mechanism 5. Yes. Further, the C frame 3 on which the laser distance meter is mounted may be a left-right separation type. In that case, the calibration pieces 1 are necessary for each of the left and right sides.

  FIG. 2 is a diagram showing an outline of measurement using the apparatus shown in FIG. While the material is stopped, the laser distance meter is scanned over the material, and the calibration piece and the material are simultaneously measured for each measurement. Using the triangulation principle, the cross-sectional profile of the calibration piece and the material is obtained from the distance data (L), the inclination angle of the distance meter (θ), and the position data during scanning of the distance meter (M). By restoring the cross-sectional profile of the calibration piece, the cross-sectional profile of the fragmented material obtained from each laser distance meter is synthesized.

  FIG. 8 is a diagram showing a processing flow example of the present invention. Details of the processing will be described below with reference to FIG. The following processing / calculation is performed by an arithmetic device (not shown) constituted by an existing process computer or personal computer.

1) A laser distance meter is run in parallel with the material, and distance data to the calibration piece and the rail are sampled (Step 01). The calibration piece restores the cross-sectional profile that is the measurement data of the laser rangefinders in the vertical and horizontal directions.

2) Two-dimensional plane coordinates (x, y) are obtained from the distance data by the following formula (Step 02).
(1) Upper left laser rangefinder
x1 = M + L1 ・ cosθ1 (1)
y1 = H-L1 · sinθ1 (2)
(2) Laser distance meter in the lower left
x2 = M + L2 ・ cosθ2 (3)
y2 = L2 · sinθ2 (4)
(3) Upper right laser distance meter
x3 = M + D-L3 · cosθ3 (5)
y3 = H-L3 · sinθ3 (6)
(4) Lower right laser rangefinder
x4 = M + D-L4 · cosθ4 (7)
y4 = L4 · sinθ4 (8)
Ln (n = 1 to 4): Measurement data θn (n = 1 to 4): Inclination angle
D: Distance between left and right distance meters (setting value)
H: Vertical distance meter interval

3) The cross-sectional profile of the rail is obtained by restoring the 2D plane coordinates of the rail of each distance meter and the 2D plane coordinates of the calibration piece (Step 03). Furthermore, it is also effective to perform a moving average process at several points before and after in order to reduce variation in the data of the cross-sectional profile. Next, the calculation method of each dimension of a rail is shown. For the sake of explanation, feature points are expressed in alphabetic characters with parentheses, and xy coordinates of feature points are expressed in subscript characters. As an example, the xy coordinates of the feature point A are represented as (Ax) and (Ay), respectively. In the following description, the material is conveyed in a posture in which the material has fallen, but the material may be conveyed in a standing posture.

4) A bottom edge at both ends of the bottom surface is detected (Step 04). A virtual line having a certain inclination (θk) is brought close to the bottom surface, and coordinates in contact with the virtual line are defined as both bottom bottom edges (A and B). (See Figure 4)

5) Obtain the inclination of the material (Step 05). Approximate the coordinates between the bottom bottom edges (A and B) by the following formula and obtain the inclination (a, θr) of the material.
y = ax + b (9)
θr = tan-1 (a) (10)

6) The coordinates are rotated (Step 06). The profile is rotated counterclockwise by the tilt of the material. In other words, the rail is in a standing state. For all points in the xy coordinates, the radius and angle are obtained, and the coordinates are rotated according to the inclination (θr) of the material, so that the cross section is erected as shown in FIG. The coordinates after rotation are (X, Y).
r = √x2 + y2 (11)
θ = tan-1 (x /-y) (12)
X = -r ・ sin (θ ± θr) (13)
Y = r ・ cos (θ ± θr) (14)

7) The upper edge at both ends of the bottom surface is detected (Step 07). The coordinates in contact with the imaginary line are defined as both edges (C / D) on the bottom surface.

8) The bottom end is detected (Step 08). Moving average (A ・ C) ・ (B ・ D) between both edges on the bottom surface, and the peak is the bottom edge (E ・ F).

9) The width is calculated (Step 09). The distance (X coordinate) between the bottom left and right protrusions (E, F) is the width.
B = Ex-Fx (15)

10) Find the width center (Step 10). From the bottom left and right protrusions (E, F), find the width center position using the following formula.
bHx = (Ex-Fx) / 2 + Fx (16)
Ey> Fy bHy = Ey-(Ey-Fy) / 2 (17)
Ey <Fy bHy = Fy-(Fy-Ey) / 2 (18)
Ey = Fy bHy = Ey (19)

11) A bottom end is detected (Step 11). The moving average between the bottom bottom edges (A and B) is taken, and the peak is defined as the bottom tip (G). The peak is signed, and as shown in FIG. 6, the peak is convex if it is smaller than the Y coordinate between the bottom bottom edges (A and B), and the sign is +, if it is larger, it is concave.

12) The flatness of the sole is calculated (Step 12). Flatness is defined as the difference between the Y coordinate between the bottom bottom edges (A and B) and the Y coordinate of the peak (G).
H = By-Gy (20)

13) Calculate both ends of the head width (Step 13). Coordinates that contact the virtual line with respect to the head width are the head width left and right edges (HI). Try to average over a range.

14) The head width is calculated (Step 14). The head width is the distance (X coordinate) between the left and right edges of the head width (HI).
c = Hx-Ix (21)

15) The center of the head width is obtained (Step 15). From the head width left and right edges (H · I), the width center position is obtained from the following expression.
cHx = (Hx + Ix) / 2 + Ix (22)
Hy> Iy cHy = Hy-(Hy-Iy) / 2 (23)
Hy <Iy cHy = Iy-(Iy-Hy) / 2 (24)
Hy = Iy cHy = Hy (25)

16) Find misalignment (Step 16). From the head width center and the xy coordinates of the width center, the misalignment is calculated by the following formula. FIG. 7 is a diagram showing an outline of misalignment calculation.
± θrT = tan-1 ((bHx-cHx) / (cHy-bHy)) (26)

17) The head width after the misalignment correction is obtained (Step 17). For head width C, misalignment correction is performed as follows.
C = c ・ cosθrT (27)

18) A head width tip is detected (Step 18). The head width left and right edges (H / I) are moving averaged, and the upper limit peak (maximum Y coordinate) is the head width peak (J).

19) Find the height (Step 19). The height (Y coordinate) between the head width protrusion (J) and the bottom protrusion (G) is the height.
A = Jy-Gy (28)
However, if the bottom tip (G) is concave, the moving average between the bottom bottom edges (A and B) is calculated, the minimum Y coordinate is calculated, and the difference between the head width tip (J) and the Y coordinate is the height To do.

20) Both ends of the column thickness are detected (Step 20). Both ends of the column thickness portion at an arbitrary height position are defined as column thickness ends (K · L) with reference to the bottom protrusion (G). Averaging is performed in a certain range, and an arbitrary height position is, for example, 60 mm. However, if the bottom tip (G) is concave, the moving average between the bottom bottom edges (A and B) is taken, and the minimum Y coordinate is the bottom tip (G).

21) One leg width is calculated (Step 21). The displacement (X coordinate) between the bottom end (E, F) and both ends of the column thickness (K, L) is the width of one foot.
K1 = L-F (29)
K2 = E-K (30)

22) The thickness is calculated (Step 22). The thickness is obtained in the height direction with respect to the column thickness portion, and the thinnest thickness is detected and set as the thickness g. Although averaging is performed within a certain range, the column thickness portion may be based on a position 60 mm in height from the bottom end.

23) The thickness after the misalignment correction is calculated (Step 23). The misalignment correction is performed on the thickness g as follows.
G = g ・ cosθrT ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ (31)

24) Head width shake is calculated (Step 24). The displacement of the bottom left and right protrusions (E and F) and the head width left and right edges (H and I) is the head width shake.
The head width left and right edges (H · I) are averaged over a certain range.
TF1 = Ex-Hx (32)
TF2 = Lx-Fx (33)
As described above, by calculating the dimensions of each part of the rail shown in FIG. 5, highly accurate rail dimension measurement can be performed.

  Examples of the present invention are shown below. Targeting a rail piece with a height of 122.7 mm, a bottom surface of 122.8 mm, and a thickness of 13.6 mm, a skilled person manually measures it with a micrometer or the like to obtain a true value, and “the dimension obtained by the present invention−true value = error” Tidy. The number of measurements was 10, and the measurement error was height + 0.11mm, thickness -0.09mm, head width -0.06mm (2σ 0.06mm), and good results were obtained.

  By feeding back this measurement result to a rolling mill or a straightening machine, quality control is also possible. In addition, the measurement time which conventionally took 2 to 3 minutes can be obtained within 10 seconds in the present invention, and it has been confirmed that the pitch down due to the measurement is greatly reduced.

It is a figure which shows the outline | summary of the example of an apparatus for implementing this invention. It is a figure which shows the measurement outline | summary using the apparatus shown in FIG. It is a figure which shows the outline | summary of a cross-sectional profile measurement. It is a figure which shows the cross-sectional profile after cross-sectional profile synthesis | combination. It is a figure which shows the outline | summary of the dimension calculation of a rail. It is a figure which shows the outline | summary of sole flatness calculation. It is a figure which shows the outline | summary of misalignment calculation. It is a figure which shows the example of a processing flow of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Calibration piece 2a-f Laser rangefinder 3 C frame 4 C frame travel mechanism 5 C frame height setting mechanism 6 Distance meter height setting mechanism 7 Rail

Claims (3)

In the rail dimension measurement method of measuring the cross-sectional shape and dimensions of railroad rails by scanning a laser rangefinder arranged in a state tilted up and down, left and right,
Rail dimensions, wherein a cross-sectional shape of the railroad rail is obtained from distance data of the laser rangefinder, an inclination angle, and position data during scanning, and dimensions of each part of the railroad rail are calculated based on the cross-sectional shape. Measuring method. In the rail dimension measuring method according to claim 1,
The dimensions of each part are as follows:
A rail dimension measuring method, characterized in that the head width, bottom surface width, height, thickness, one foot width, sole flatness, and head width touch of the rail, or a combination thereof. In a rail dimension measuring device that measures the cross-sectional shape and dimensions of railroad rails by scanning a laser distance meter arranged in a state tilted vertically and horizontally,
A calculation device is provided that obtains a cross-sectional shape of the railroad rail from distance data of the laser rangefinder, an inclination angle, and position data during scanning, and calculates the dimensions of each part of the railroad rail based on the cross-sectional shape. Rail dimension measuring device.

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