CN103759695A - Detecting device and method for automatically measuring outline of steel rail - Google Patents

Abstract

The invention provides a detection device and a detection method for automatically measuring the rail profile. The detection device includes a power supply module, a mechanical transmission module, a data acquisition storage module and a display alarm module. The mechanical transmission module includes a frame, a guide rail, a timing belt and a photoelectric switch for controlling the movement of the rail. The rail is set on the frame during detection. superior. The detection device also includes a plurality of movable laser profile sensors and displacement sensors. A plurality of movable laser profile sensors are arranged around the rail to measure the two-dimensional coordinate data of the rail section. The displacement sensors are arranged on the machine along a direction parallel to the length direction of the rail. Mounted to measure displacement data from a movable laser profile sensor. The detection device and detection method according to the present invention can realize the comprehensive measurement of the section size, straightness and twist of the rail by combining the movable laser profile sensor and the displacement sensor.

Description

Detection device and detection method for automatically measuring rail profile

technical field

The invention relates to the field of automatic detection, in particular to a detection device and a detection method for automatically measuring rail profiles.

Background technique

With the development of railway technology and the popularization of seamless rails, the quality of long rails has been paid more and more attention. Whether the dimensions, straightness and twist of the rail meet the standards will affect the safety, stability and speed of railway operation. The rail welding base needs to inspect the shape of the rails before welding the rails to avoid unqualified rails from being put into production, which will cause unnecessary losses.

At present, the rail welding production line mainly uses a sample ruler to measure the rail height, rail head width, rail bottom width, cross-section asymmetry, rail waist thickness, rail foot height and other indicators, and uses feeler gauges, twist gauges, etc. to measure the rails. The straightness and twist of the end are tested, and the rails that do not meet the standards are excluded. This kind of mechanical manual measurement has the following problems: 1. Due to the manual operation, the operating level of the operator has a great influence on the measurement accuracy, which makes it difficult to grasp the accuracy of the measurement results; 2. The rail shape detection is long rail welding. In the first process, the mechanical measurement efficiency is low and the labor intensity is high, which directly affects the overall efficiency of rail welding production; 3. The rail shape inspection data is entered manually, and the data reliability and integrity are poor. Therefore, in order to meet the production requirements of the rail welding base, it is necessary to develop an automatic, accurate, efficient and reliable rail shape detection device.

With the development of rail detection technology, the method of using laser ranging sensor, image processing and other technologies to detect rail has emerged. Since the laser ranging sensor cannot restore the entire rail section, image processing is susceptible to environmental interference such as light and rust spots. These measurement systems need to be improved in terms of data reliability and measurement accuracy. In order to meet the increasing high requirements of production efficiency and automation, a device and method that can automatically detect the rail profile and simultaneously calculate the section size, straightness and twist are needed.

Contents of the invention

In order to solve the above problems, the present invention provides a detection device and a detection method for automatically measuring the rail profile. The detection device and detection method can realize the comprehensive measurement of the section size, straightness and twist of the rail by combining the movable laser profile sensor and the displacement sensor.

According to one aspect of the present invention, a detection device for automatically measuring rail profile includes a power supply module, a mechanical transmission module, a data acquisition and storage module, and a display and alarm module. The photoelectric switch, the rail is set on the frame during the detection. The detection device also includes a plurality of movable laser profile sensors and displacement sensors. A plurality of movable laser profile sensors are arranged around the rail to measure the two-dimensional coordinate data of the rail section. The displacement sensors are arranged on the machine along a direction parallel to the length direction of the rail. Mounted on a stand to measure displacement data from a movable laser profile sensor. A plurality of movable laser profile sensors and displacement sensors are connected to the data acquisition storage module in a communication manner, so that the data acquisition storage module combines the two-dimensional coordinate data and displacement data of the section to detect the profile of the rail.

Optionally, the detection device according to the present invention further includes a sensor mounting plate, the sensor mounting plate is connected to the guide rail and has a central through hole, the central through hole is set so that the steel rail passes through the central through hole, wherein a plurality of movable laser beams The profile sensor is disposed on the periphery of the sensor mounting plate.

The sensor mounting plate is arranged on the connecting bracket, the two ends of the connecting bracket are respectively arranged on the guide rail, and the connecting bracket is connected to the timing belt.

Optionally, the plurality of movable laser profile sensors comprises four movable laser profile sensors.

Preferably, two of the four movable laser profile sensors are arranged symmetrically on one side of the sensor mounting plate with respect to the rail, and are positioned to form an angle of 30° with respect to the rail respectively, while the four movable laser profile sensors The remaining two of them are symmetrically arranged on the other side of the sensor mounting plate with respect to the rail, and are positioned to form an angle of 50° with respect to the rail, respectively.

The data acquisition storage module may include multiple data acquisition cards and a computer, the data acquisition cards are respectively arranged on multiple movable laser profile sensors and displacement sensors, and the multiple data acquisition cards are connected to the computer in a communication manner.

According to another aspect of the present invention, a detection method for automatically measuring rail profile includes the following steps: Step A01: Transmit the rail to be detected to the rail end detection range through the mechanical transmission module and stop to wait for measurement; Step A02: A plurality of movable laser profile sensors arranged on the rail measure the cross-sectional two-dimensional coordinate data of the rail, and measure the displacement data of the plurality of movable laser profile sensors through a displacement sensor arranged along a direction parallel to the length direction of the rail; Step A03: Transmit the two-dimensional coordinate data and displacement data of the section to the data acquisition storage module by means of communication; Step A04: the data acquisition storage module performs data processing on the two-dimensional coordinate data and displacement data of the section to obtain a complete section of the rail, and display the section of the rail image; step A05: the data acquisition and storage module calculates the section size, straightness and twist of the rail according to the two-dimensional coordinate data and displacement data of the section; and step A06: displays the detection result of the rail through the display alarm module and gives an alarm to the unqualified rail remind.

The data processing in step A04 includes the following steps: converting the two-dimensional coordinate data of the section between the camera coordinate system and the world coordinate system to splice the scattered rail curves into a complete section profile; and performing angle correction on the section profile.

The calculation of the straightness in step A05 includes: obtaining the highest point of the rail head or the side point of the rail head through the plurality of movable laser profile sensors; collecting the measured length of the rail required for the straightness calculation; Flatness calculations; forming and displaying flatness curves; calculating vertical straightness and horizontal flatness of rails; and displaying flatness calculation results.

The calculation of the degree of twist in step A05 includes: obtaining four points on the bottom surface of the rail according to the cross-sectional profile of the rail; calculating the degree of twist of the rail by using the coplanar method; and displaying the calculation result of the degree of twist. The step of calculating the degree of distortion by using the co-planar method includes: obtaining the plane where any three points of the four points are located; and calculating the distance from the remaining one of the four points to the plane to obtain the degree of distortion.

The step of obtaining four points on the bottom surface of the rail includes: taking two points on the lower surface of the rail end section; and taking another two points on the lower surface of the rail bottom within 1m from the rail end section.

Further, the distance between the center of each of the four points and the edge of the rail bottom is 10mm, and the surface area of each of the four points is in the range of 150mm ² -250mm ² .

Optionally, in step A03, a plurality of movable laser profile sensors and displacement sensors transmit the two-dimensional coordinate data and displacement data of the section to the computer of the data acquisition storage module through their respective data acquisition cards.

Description of drawings

The above and other aspects and features of the present invention will be clearly presented from the following description of the embodiments in conjunction with the accompanying drawings, wherein:

Fig. 1 is a schematic diagram showing the constituent modules of the detection device for automatically measuring rail profile according to the present invention;

Fig. 2 is a perspective view showing a detection device according to a first embodiment of the present invention, wherein part C of a box shows a sensor mounting plate on which a movable laser profile sensor is installed in an enlarged form;

Figure 3 is a view schematically showing the positions of the movable laser profile sensor and the displacement sensor relative to the rail;

Fig. 4 is the front view of the sensor mounting plate of part C in Fig. 2, and four movable laser profile sensors are installed on the sensor mounting plate;

Fig. 5 is the flow chart of the detection method of automatic measurement rail profile according to the present invention;

6 is a flow chart schematically showing a detection method for automatically measuring rail profile according to a second embodiment of the present invention;

Fig. 7 is the image view before rail curve splicing;

Figure 8 is an image view after rail curve splicing, showing the complete profile of the rail section;

Fig. 9 is a graph of straightness calculated by the chord method; and

Fig. 10 is a graph of calculating the degree of torsion using the coplanar method.

Detailed ways

The illustrative and non-limiting embodiments of the present invention will be described in detail below with reference to the accompanying drawings, and the rail detection device and detection method according to the present invention will be further described.

Specifically, the detection device for automatically measuring the rail profile according to the present invention is described with reference to Figs. 1-3. The detection device is an automatic detection device capable of comprehensively measuring the section size, straightness and twist of the rail. The detection device according to the present invention includes a power supply module 1 , a mechanical transmission module 2 , a data collection and storage module 3 and a display and alarm module 4 . The power module provides stable and reliable power for the detection device for measurement, control and recording operations. The mechanical transmission module 2 includes a frame 10, a guide rail 11, a synchronous belt 12 and a photoelectric switch, and the rail 5 to be detected is set on the frame 10 during detection. The detection device also includes a plurality of movable laser profile sensors 6 and displacement sensors 7 . Referring to FIG. 3 , the movable laser profile sensor 6 is arranged around the rail 5 to measure the two-dimensional coordinate data of the rail section, and can move in a direction parallel to the length direction of the rail through the mechanical transmission module 1 . The displacement sensor 7 is arranged on the frame along a direction parallel to the length direction of the rail 5 to measure the displacement data of the movable laser profile sensor. The movable laser profile sensor 6 and the displacement sensor 7 are connected with the data acquisition storage module 3 in a communication manner, so as to transmit the two-dimensional coordinate data of the section detected by the movable laser profile sensor and the displacement data detected by the displacement sensor to the data acquisition storage module . The data acquisition and storage module 3 further combines the two-dimensional coordinate data and the displacement data of the section to detect the profile of the rail. The movable laser profile sensor and the displacement sensor can be connected with the data acquisition storage module in any wireless or limited communication mode known in the art.

Figure 3 schematically shows the position of the movable laser profile sensor and the displacement sensor relative to the rail. A plurality of movable laser profile sensors 6 are arranged around the rail 5 to be tested. For example, the detection device may include four movable laser profile sensors, two of which are located on one side of the rail, and the remaining two sensors are located on the other side of the rail. . The displacement sensor 7 is arranged along the direction parallel to the rail length direction to detect the displacement data of the movable laser profile sensor. It should be noted that although the detection device with four movable laser profile sensors is only exemplarily described here, those skilled in the art can imagine that the movable laser profile sensors are not limited to four, and any number can be used. The laser profile sensor only needs to be able to detect the two-dimensional coordinate data of the rail section. In the mechanical transmission module, the frame supports, protects and fixes the movable laser profile sensor and displacement sensor, and the guide rail and synchronous belt are used to transport the rail and the movable laser profile sensor smoothly and at a constant speed. The photoelectric switch is used to control the movement of the rail, so that the rail stops when it moves to the measurement range of the rail end and waits for measurement. The rail end measurement range means that the section of the rail falls within the measurement range of multiple movable laser profile sensors.

According to a first embodiment of the invention, a plurality of movable laser profile sensors are mounted on a sensor mounting plate. Specifically, referring to FIGS. 3 and 4 , the sensor mounting plate 20 is connected to the guide rail 11 and has a central through hole 21 . The central through hole 21 is arranged such that the rail to be tested passes through the central through hole. The movable laser profile sensor 6 is disposed on the periphery of the sensor mounting plate 20 . According to an example of the present invention, the sensor mounting plate is arranged on the connection bracket 22 . Both ends of the connection bracket 22 are respectively disposed on the guide rail 11 , and the connection bracket 22 is connected to the timing belt 12 . During detection, the connecting bracket 22 can move along the guide rail 11 driven by the synchronous belt 12, thereby driving the movable laser profile sensor to move along the length direction of the rail.

According to an optional embodiment of the present invention, the detection device may include four movable laser profile sensors. Preferably, two of the four movable laser profile sensors are symmetrically arranged on one side of the sensor mounting plate 20 with respect to the rail, and are positioned at an angle of 30° with respect to the rail, respectively. The remaining two laser profile sensors are arranged symmetrically on the other side of the sensor mounting plate 20 with respect to the rail, and are positioned at an angle of 50° with respect to the rail, as shown in FIG. 4 . The movable laser profile sensor arranged as above can form a complete measurement section by detecting the profile of the rail.

Next, a detection method for automatically measuring the profile of a rail using the detection device described above will be described with reference to FIGS. 5-8.

Fig. 5 is a flow chart of the detection method for automatically measuring rail profile according to the present invention. Detection method according to the present invention comprises:

Step A01: Transmit the rail 5 to be detected to the detection range of the rail end through the mechanical transmission module 2 and stop to wait for measurement;

Step A02: Measure the cross-sectional two-dimensional coordinate data of the rail with a plurality of movable laser profile sensors 6 arranged around the rail 5, and measure the movable laser profile sensor 6 with a displacement sensor 7 arranged along a direction parallel to the length direction of the rail displacement data;

Step A03: Transmit the two-dimensional coordinate data and displacement data of the section to the data acquisition storage module 3 by means of communication;

Step A04: The data acquisition and storage module 3 performs data processing on the two-dimensional coordinate data and displacement data of the section to obtain a complete section of the rail, and displays the section image of the rail;

Step A05: The data collection and storage module 3 calculates the cross-sectional size, straightness and twist of the rail according to the two-dimensional coordinate data and displacement data of the cross-section; and

Step A06: displaying the detection result of the rail through the display alarm module 4 and giving an alarm reminder to the unqualified rail.

According to the detection method of the present invention, the steel rail to be detected is automatically transferred to the detection range of the rail end through the mechanical transmission module and stopped to wait for detection. The movable laser profile sensor scans the rail, and the projected laser forms a complete rail section. The rail profile is converted into two-dimensional coordinate data by using the optical triangulation method commonly used in this field, and the accuracy can reach 0.019mm. Thus, the movable laser profile sensor can directly obtain the two-dimensional coordinate data of the complete cross-section of the rail, so as to calculate the cross-sectional size according to the two-dimensional coordinate data. The displacement sensor records the movement displacement data of the laser profile sensor in real time, so as to obtain the coordinate data in the direction of the rail length. The two-dimensional coordinate data detected by the laser profile sensor and the displacement data detected by the displacement sensor are combined to calculate the flatness and twist. Therefore, compared with the existing detection methods, the rail profile detection method according to the present invention can simultaneously realize comprehensive measurement of cross-sectional size, straightness and twist, thereby significantly improving the detection efficiency of rail quality.

Next, the rail profile detection method according to the second embodiment of the present invention will be further described in detail with reference to FIG. 6 .

Furthermore, after the data acquisition and storage module is started, the rail profile data collected by the laser profile sensor are spliced into a complete section, and the image is displayed on the interface. After the angle correction of the rail section is completed, the size calculation, straightness calculation and twist calculation of the rail section can be carried out. At the same time, the calculation results are displayed on the interface, the flatness curve is drawn and the measurement results are automatically stored in the database for operators to query and manage historical data. For example, the data acquisition and storage module may include a data acquisition card respectively arranged on the laser profile sensor and the displacement sensor, and a computer communicated with the data acquisition card. The laser profile sensor and the displacement sensor transmit the two-dimensional coordinate data and displacement data of the section to the computer through their respective data acquisition cards. For example, the entire control can be performed by two computers, one as a client, connected to some laser profile sensors; the other computer is connected to the rest of the laser profile sensors and displacement sensors, and acts as a server for calculation and storage of results.

Specifically, the data processing in step A04 includes: converting the two-dimensional coordinate data of the section between the camera coordinate system and the world coordinate system, so as to splice the scattered rail curves into a complete section profile; and then, performing angle correction on the section profile. Figures 7 and 8 show the images of rail curves before and after splicing, respectively, where Figure 8 shows the complete profile of the detected rail section. After the data acquisition and storage module obtains the complete section profile, it can calculate the section size of the rail.

According to the present invention, the data acquisition and storage module can also calculate the straightness and twist of the rail in addition to the section size of the rail. The calculation of rail straightness includes: obtaining the highest point of the rail head or the side point of the rail head through a movable laser profile sensor; collecting the measured length of the rail required for straightness calculation; using the chord method for straightness calculation; forming and Displays the straightness curve; calculates the vertical straightness and horizontal straightness of the rail; and displays the straightness calculation results. When calculating the straightness, the measured length of the rail is different according to different rail types, and the straightness calculation is carried out by using the chord measurement method commonly used in this field. Fig. 9 is a graph of straightness calculated by the chord method. Curve P ₁ P ₂ is the surface profile in the length direction of the measured rail. The first and last measurement points are connected by a straight line as the reference plane, and the maximum distance between the remaining measurement points and the curve is the obtained straightness.

The calculation of the twist of the rail includes: obtaining four points on the bottom surface of the rail according to the section profile of the rail; calculating the twist of the rail by using the coplanar method; and displaying the calculation result of the twist.

Next, calculation of the degree of twist by the coplanar method will be described with reference to FIG. 10 . Rail twist refers to the degree of twist in the longitudinal direction of the rail. First, obtain the plane on which any three of the four points on the bottom surface of the rail lie. Then, calculate the distance from the remaining one of the four points to the plane, and this distance is the twist of the rail. According to one embodiment, as shown in Figure 10, two points Q ₁ Q ₂ are taken on the lower surface of the rail end section, and two other points are taken on the lower surface of the rail bottom within 1m from the rail end section Q ₃ Q ₄ . When using the coplanar method to calculate the torsion of the rail, first find the plane M where Q ₁ Q ₂ Q ₃ is located, and the distance from Q ₄ to the plane M is the torsion of the rail. The distance between the center of each of the four points on the rail bottom surface and the edge of the rail bottom is 10 mm, and the surface area of each point is in the range of 150 mm ² to 250 mm ² . If the calculated twist does not exceed 0.45mm, it means that the twist of the rail to be tested meets the requirements.

From the above, it can be known that the detection device and detection method for automatically measuring the rail profile according to the present invention can realize the comprehensive measurement of the cross-sectional size, straightness and twist of the entire rail through the combination of two sensors, and the unqualified rail Alarm prompt, convenient operation and high degree of automation. In the detection process of the present invention, the profile of the rail is automatically collected, measured and stored without manual intervention, thus improving work efficiency. In addition, the measurement process is easy to operate, and the unqualified rails are alarmed, which effectively reduces the labor intensity, and the rail profile data can be automatically recorded to provide managers with real, reliable and highly traceable data records. At the same time, the detection device and detection method according to the present invention adopt a laser wheel sensor for measurement, which has high measurement accuracy and solves the problem that manual measurement accuracy is difficult to grasp.

While exemplary embodiments of the invention have been described, it will be apparent to those skilled in the art that changes may be made without departing from the spirit and principles of the invention, the scope of which is defined in the claims and their equivalents .

Claims (14)

1. automatically measure the pick-up unit of rail profile for one kind, comprise power module, mechanical drive module, data acquisition memory module and display alarm module, described mechanical drive module comprises frame, guide rail, Timing Belt and the optoelectronic switch moving for controlling rail, rail is being arranged between detection period in described frame, wherein:

Described pick-up unit also comprises multiple movable laser profile sensors and displacement transducer, described multiple movable laser profile sensor ring is measured the section two-dimensional coordinate data of described rail around described rail setting, described displacement transducer is arranged in described frame to measure the displacement data of described movable laser profile sensor along the direction of the length direction that is parallel to described rail; And

Described multiple movable laser profile sensor is connected with described data acquisition memory module by correspondence with described displacement transducer, thereby described data acquisition memory module combines described section two-dimensional coordinate data and described displacement data to detect the profile of described rail.

2. pick-up unit according to claim 1, also comprises:

Installation of sensors plate, described installation of sensors plate is connected to described guide rail and is provided with center through hole, and described center through hole is configured such that described rail is through described center through hole,

Wherein, described multiple movable laser profile sensor setting is at the periphery of described installation of sensors plate.

3. pick-up unit according to claim 2, wherein, described installation of sensors plate is arranged in connection bracket, and the two ends of described connection bracket are separately positioned on described guide rail, and described connection bracket is connected to described Timing Belt.

4. pick-up unit according to claim 2, wherein, described multiple movable laser profile sensors comprise four movable laser profile sensors.

5. pick-up unit according to claim 4, wherein:

Two in described four movable laser profile sensors are arranged on symmetrically a side of described installation of sensors plate, and are positioned to respect to described rail, become 30 ° of angles respectively with respect to described rail; And

All the other two in described four movable laser profile sensors are arranged on symmetrically the opposite side of described installation of sensors plate, and are positioned to respect to described rail, become 50 ° of angles respectively with respect to described rail.

6. pick-up unit according to claim 1, wherein, described data acquisition memory module comprises multiple data collecting cards and computing machine, described data collecting card is separately positioned on described multiple movable laser profile sensor and described displacement transducer, and described multiple data collecting card is connected with described computing machine by correspondence.

7. a detection method of automatically measuring rail profile, comprises the following steps:

Steps A 01: by mechanical drive module rail to be detected is sent in rail end sensing range and stop with etc. to be measured;

Steps A 02: by the section two-dimensional coordinate data of multiple movable laser profile sensor measurement rail arranging around rail, and by the displacement data of multiple movable laser profile sensors described in the displacement sensor arranging along the direction of length direction that is parallel to described rail;

Steps A 03: by correspondence described section two-dimensional coordinate data and described displacement data are transferred to data acquisition memory module;

Steps A 04: described data acquisition memory module is carried out data processing to obtain the complete section of rail to described section two-dimensional coordinate data and described displacement data, and shows the cross-section image of rail;

Steps A 05: described data acquisition memory module is calculated cross dimensions, flatness and the torsion resistance of rail according to described section two-dimensional coordinate data and described displacement data; With

Steps A 06: show rail testing result and defective rail is carried out to warning reminding by display alarm module.

8. detection method according to claim 7, wherein, the data processing in described steps A 04 comprises the following steps:

To the make a video recording conversion of coordinate system and world coordinate system of described section two-dimensional coordinate data, so that scattered steel rail bending splicing is become to complete profiled outline; With

Described profiled outline is carried out to angle correction.

9. detection method according to claim 7, wherein, the calculating of the flatness in described steps A 05 comprises:

By described multiple movable laser profile sensors, obtain peak or the rail head side point of rail head;

Gather flatness and calculate required rail measurement length;

Adopt string survey method to carry out flatness calculating;

Form and show flatness curve;

Calculate perpendicular straight degree and the horizontal flatness of rail; With

Show flatness result of calculation.

10. detection method according to claim 7, wherein, the calculating of the torsion resistance in described steps A 05 comprises:

According to the profiled outline of rail, obtain four points of flange of rail face;

Adopt coplanar method to calculate the torsion resistance of rail; With

Show torsion resistance result of calculation.

11. detection methods according to claim 10, wherein, the step that described employing coplanar method is calculated torsion resistance comprises:

Obtain any 3 planes that are positioned in described four points; With

Calculate in described four points, remain a point to the distance of described plane to obtain described torsion resistance.

12. detection methods according to claim 11, wherein, described in obtain four points of flange of rail face step comprise:

On the lower surface of end of rail section, get two points; With

In scope in the described end of rail section 1m of distance, on flange of rail lower surface, get two other points.

13. detection methods according to claim 12, wherein:

Distance between each Dian center and flange of rail edge in described four points is 10mm; And

The surface area of each point in described four points is at 150mm ²～250mm ²scope in.

14. detection methods according to claim 7, wherein, in described steps A 03, described multiple movable laser profile sensors and described displacement transducer are transferred to described section two-dimensional coordinate data and described displacement data by the data collecting card being provided with separately the computing machine of described data acquisition memory module.

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