CN100449264C - On-line detection method and device for thread defect of vehicle wheel set - Google Patents
On-line detection method and device for thread defect of vehicle wheel set Download PDFInfo
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Abstract
The present invention discloses a method for online detecting railway car wheel set tread defect and its on-line detecting equipment. It is characterized by that the light sent out by light source of structure light can be irradiated on the wheel set tread, on the tread a projection image is formed. When the wheel set is run to the set position, the third position sensor can give out a triggering signal to start image sensor to shoot a series of tread projection images. By utilizing analysis and calculation a deviation image of actual shot image and defectless image can be obtained, it can further judge that in the deviation image the defect is existed or not, and can calculate tread defect parameter.
Description
Technical field
The present invention relates to a kind of detection method and pick-up unit, particularly a kind of track traffic department vehicle wheel is to the online test method and the pick-up unit of thread defect, be specifically related to the vehicle wheel tread in the structured light light source irradiation slow running, obtain view data, thereby and the real-time analysis view data obtain the detection method and the device of thread defect parameter.
Background technology
Vehicle wheel comprises flat sliding and shelled tread to thread defect.Defective is in operation to train and brings extra impact shock, influences the safety and the serviceable life of train and orbital facilities, is a measuring technique difficult problem of being badly in need of solution in the development of bullet train and heavy haul train.The wheel that falls that causes because of flat sliding and peeling off accounts for the significant proportion that year falls to taking turns total quantity.Wheel mainly contains online detection under the running status, online detection under the shed repair state and the manual detection under the shed repair state to the detection method of parameter and technology.
Online detection under the running status is meant the detection of carrying out when rolling stock travels along the railway track.Measure the automaticity height, do not take the rolling stock turnaround time and be convenient to store characteristics such as wheel information material owing to have, be subjected to the attention of countries in the world day by day.Have at present with two kinds on car measurement type and ground survey type.With car measurement type is exactly that the measuring system of wheel to parameter is installed on rolling stock, only has Central Japan Railway that the exploitation of electric motor car group in the Shinkansen has been tried out vehicle mounted type wheel wear pick-up unit at present, and can not detect the thread defect parameter.The ground survey type is exactly in the measuring system of fixed installation wheel in rail limit to parameter.20th century the mid-80, Germany takes the lead in utilizing the electromagnetic acoustic technology to succeed in developing ground type vehicle wheel tread failure detector.This failure detector has been realized the dynamic flaw detection of taking turns defective in service, the package unit technical sophistication, costs an arm and a leg.Online detection under the shed repair state is meant the detection of carrying out in the shed repair workshop, and wheel is separated from vehicle needs.Online test method and technology under the at present existing multiple this state.Manual detection under the shed repair state is meant in the shed repair workshop detection of being undertaken by the special measurement utensil by manually, and wheel is separated from vehicle also needing.
At present, the China railways vehicle wheel also rests on manual detection stage under the shed repair state to the detection great majority of parameter, and workman's working condition is poor, labour intensity is big, efficiency is low, is difficult to avoid gauger's human factor, has influenced precision and reliability.Online test method and technology under a small amount of maintenance department employing shed repair state are also arranged, overcome the shortcoming of manual detection to a certain extent, but wheel is separated and could be detected to needs from vehicle.
Along with the increase of continuous speed-raising of China railways and heavy haul train, take turns right wearing and tearing and also constantly accelerate, have higher requirement to taking turns right detection and maintenance.Therefore develop wheel tread defect online detection method and technology under the running status, become a difficult problem that presses for solution in China's track traffic development.Wheel tread defect online detection method under the running status and technology are developing direction of China's digitizing railway.The realization of digitizing railway has great importance to the development of China railways cause.For car inspection and repair department, digitized realization has positive meaning to the transition that state is repaiied from present preventive maintenance to future.Owing to lack more accurate, the quick and economic automatic detection means of wheel tread defective at present, so be difficult to accomplish long-term tracing record train wheel tread parameter.If each inspection can both obtain measurement data, then according to the accumulation and the trend analysis of data, just can be to of the prediction of every wheel to abrading and peeling off, thus carry out maintenance targetedly, significantly reduce maintenance cost.
Summary of the invention
Purpose of the present invention is exactly at the deficiencies in the prior art, provides a kind of vehicle wheel to the thread defect online test method and the relevant detection device is provided.
Detection method of the present invention is to utilize the projection information of structured light light source on thread defect to detect flat sliding and two defect parameters of shelled tread, specifically may further comprise the steps:
(1) tests the speed.Train operation detects train speed between detection zone the time, when speed V start detection unit when setting range (0＜V＜10 kms/hour).
(2) start light source.The structured light of being made up of the light of a series of regular arrangements shines on the right tread of vehicle wheel, and the projection of structured light on tread forms the projected image of tread by the line array video camera imaging.
(3) start image acquisition.When vehicle wheel when running to desired location, the speed measuring position sensor produces trigger pip, detects this trigger pip in real time, the control image collecting device is gathered the projected image of a series of structured lights on tread.The time interval between adjacent two width of cloth images is determined according to the actual measurement speed of a motor vehicle.The video camera of each side of wheel by more than 3 makes the week that the scope of shooting can complete covering wheel tread.
Projected image when (4) asking zero defect.The collection of corresponding every width of cloth image is t constantly
x, at first (x, y z), obtain not having under the defect situation at t according to known tread dimensional parameters T
xThe intersection C of moment light source and tread (x, y, z), and the projected image P of this intersection (α, β).α wherein, β is the coordinate of video camera imaging face, x, y, z are the object space coordinate.
(5) ask offset images.t
xConstantly corresponding actual photographed image be P ' (α, β), this image has comprised the defect information on the tread, then the offset images Δ P of real image and zero defect image is: Δ P=P ' (α, β)-P (α, β).
(6) judge whether there is defective in the offset images.If e is a critical value of judging whether defective exists, e≤0.1mm.If the deviate of each pixel is all less than e among the Δ P, then judging does not have defective to exist on this image.Otherwise then judge to have defective in the offset images, and deviate corresponds to point on the thread defect greater than the pixel of e.
(7) degree of depth of calculating defect point.According to image acquisition moment t
x, and imaging relations, can obtain the defective locations that each defect point corresponds to object space.Simultaneously, the departure Δ P of certain point among the offset images Δ P
iPut the depth d of corresponding defect point with this
i, and the section at corresponding defect point place be directly proportional with respect to the angle ω of optical plane.After the position relation of image collecting device was determined, angle ω was a known quantity.By Δ P
iValue can calculate the depth d of corresponding defect point
iValue: d
i=Δ P
i* tan ω.
(8) generate defect image.A series of linear array images are spliced into a width of cloth two dimensional image, and will have the gray-scale value of the image pixel of defective to be changed to 0, the gray-scale value of defective image pixel is changed to the depth of defect d of the corresponding thread defect point of this pixel
i, then this width of cloth two dimensional image is the image of thread defect.
Described optical plane is the plane that all light of structured light light source emission constitute; Described section be utilize in the drop shadow curve of optical plane on wheel tread more arbitrarily, with this point is that benchmark is done two tangent lines, wherein one parallel with wheel rolling circle, another is tangent with tread axial profile line, the plane that two tangent lines constitute is flat for cutting of this point.
(9) calculating of defect parameters.For the flat sliding parameter, obtain the degree of depth of defect point maximum in the scratch defect image, be the value of flat sliding parameter.For the shelled tread parameter, obtain peel off in the defect image initial with stop the corresponding rolling circle length of defect point, be the value of shelled tread parameter.
The relevant detection device comprises along the outside of one section straight track near the position of a track wherein and is arranged in order two speed measuring position sensors and a trigger position sensor.Two speed measuring position sensors are used to detect the speed of vehicle, and spacing between the two is less than the girth of a wheel.The trigger position sensor is used to trigger the collection of image.The output of two speed measuring position sensors and a trigger position sensor is connected in the signal processing apparatus, and signal of sensor is transformed into the digital signal that computing machine can be discerned.
In the track outside two cover image collecting devices are set respectively in trigger position sensor the place ahead, install, be respectively applied for the thread defect image of gathering left and right wheels along two track symmetries.
Every cover image collecting device comprises at least three line array video cameras and a structured light light source.The oblique setting of structured light light source and track, the laser beam irradiation of generation is to the right tread of the wheel that passes through from pick-up unit.Video camera is arranged between structured light light source and the track, and is fixed on the position near track, and direction along ng a path is arranged in order.Wheel to by the time, start successively in order, finish wheel to the scanning in a week, go out the defect image of whole tread by the image mosaic of multiple cameras collection.The image of every video camera output is input in digital signal processor (DSP) and the computing machine by image collecting device and carries out analyzing and processing, the thread defect information that every of being passed through successively wheel is right.
The present invention is by the structured light light source online real time collecting and handle the tread image that structural light stripes is arranged, and obtains the information of wheel tread defective, by multiple digital image processing techniques the image that collects is carried out analyzing and processing, finally calculates the thread defect parameter.In whole testing process pick-up unit with the wheel to not contacting, pick-up unit can not produce wear phenomenon, pick-up unit be easy to the maintenance; Pick-up unit can the real-time online collection, Treatment Analysis.
Description of drawings
Fig. 1: pick-up unit totally constitutes synoptic diagram;
Fig. 2: speed detects principle schematic;
Fig. 3: light source is arranged synoptic diagram;
Fig. 4: light source irradiation tread synoptic diagram;
Fig. 5-1: some P
xPlace's tangent line synoptic diagram;
Fig. 5-2: some P
xPlace's another synoptic diagram of tangent line;
Fig. 6: formula (7) is described synoptic diagram;
Fig. 7: defect image synoptic diagram.
Embodiment
Before the thread defect detection system, must obtain the size profile parameters of wheel tread by the online in advance detection of other pick-up unit, the known conditions of the dimensional parameters of each wheel tread during as defects detection.
Wheel tread is the contact portion of left and right wheels and rail.Thread defect comprises flat sliding and two parameters of shelled tread, measures with the scratch degree of depth with along the strip length of wheel rolling circular direction respectively.
Fig. 1 totally constitutes synoptic diagram for pick-up unit.Be arranged in order two speed measuring position sensors 1 and 2, one trigger position sensors 4 along a side of track near the position of track.Structured light light source 5 and line array video camera 6,7 and 8 are formed a cover image collecting device, are distributed in the outside of straight track 9.Structured light light source 11 and line array video camera 12,13 and 14 are formed another set of image collecting device, are distributed in the outside of track 10.Two cover image collecting devices are symmetrical expression to be arranged in the track both sides, is respectively applied for the defects detection of the left and right wheel of wheel centering.Structured light light source 5 and 11 laser beam irradiations that produce are to taking turns on 3 the tread.
Utilize in the train travelling process right self the rolling of wheel to finish scanning to tread, by multiple cameras 6,7 and 8 and 12,13 and 14 successively at wheel to through out-of-date collection a series of images, the video camera of every side more than 3 splices the defect image of whole tread.The collection sequential of image is according to the train speeds of front end speed measuring position sensor 1 and 2 monitoring, and comprehensive reckoning of overall size obtain, and the zero hour of being gathered by the trigger pip control of trigger position sensor 4.The collection of image and processing are finished in real time by computer control DSP, every thread defect information that wheel is right finally being passed through successively.
(1) tests the speed
Among Fig. 1, wheel to 3 with less than 10 kms/hour speed through between detection zone, be one section straight rectilinear orbit between detection zone.Wheel is to passing through speed measuring position sensor 1 and 2 at first successively, and the speed measuring position sensor can send trigger pip when taking turns the arrival correspondence position, and postpone is connected to computing machine to trigger pip through signal processing device.
As shown in Figure 2, utilize same the wheel, obtain train process speed measuring position sensor 2 velocity amplitude constantly the mistiming Δ t of process speed measuring position sensor 1 and 2 and the fixed range S between speed measuring position sensor 1 and 2:
Can obtain n the velocity amplitude that wheel is right of process successively thus, form a velocity amplitude sequence v
1, v
2, v
3... v
nBy the velocity amplitude sequence, can calculate t
xThe speed of train constantly, and then obtain the position X of its working direction.The speed that only detects just starts the subsequent detection unit when setting range (0＜v＜10 kms/hour), otherwise vehicle is only by between detection zone and do not detect.The existing multiple proven technique that tests the speed that vehicle wheel is right can realize.
(2) start light source
When speed during at setting range light source start.After light source started, the structured light of being made up of the light of a series of regular arrangements shone on the right tread of vehicle wheel, and the projection of structured light on tread forms the projected image of tread by the line array video camera imaging.
(3) start image acquisition
Projected image when (4) asking zero defect and offset images
As shown in Figure 3, structured light light source 5 is made up of three groups of light sources, and every group of light source is arranged in parallel by a series of single line bar laser beams again and constitutes.The coverage of respectively corresponding three video cameras in the zone of three groups of light source irradiation.Video camera 6,7 and 8 is being taken turns in-position X
1, X
2, X
3(corresponding time point is respectively t
X1, t
X2, t
X3) after begin to gather a series of images respectively, the zone of every camera acquisition image is three segment limits of corresponding three groups of light source irradiation respectively, make the week that the image of three camera acquisitions can complete covering wheel tread.
As shown in Figure 4, the three-dimensional function of supposing each bar light in the structured light light source is respectively L
1(x, y, z), L
2(x, y, z), L
3(x, y, z) ... L
k(z), that represent among the figure is the space plane function L of n bar light for x, y
n(z), the plane at ABC place is the shadow surface of this light for x, y.Combination by k bar light can obtain spatially distributed functions so
According to formula (1), obtain speed one time curve after, can further try to achieve at t
xConstantly, take turns right position X, this moment, (z) (this dimensional parameters needs detect in advance before defects detection, when defects detection as known parameters) can be in the hope of at t for x, y according to the dimensional parameters T of tread
xConstantly, the function F of wheel tread in pick-up unit coordinate system OXYZ
x:
F
x＝S(T(x，y，z)，X) (3)
The spatially distributed functions L of known structure radiant (x, y, z) and the tread function S (T (and x, y, z), X), the space curve of every the light that just can send in the hope of structured light light source and the space intersection of tread:
C(x，y，z)＝I(L(x，y，z)，S(T(x，y，z)，X)) (4)
Video camera imaging relation is designated as (α, β)=CCD (x, y, z), and α wherein, β is the imaging surface coordinate, x, y, z are volume coordinate.Then any point α in space on the tread (x, y, z) picture point on the video camera imaging face be α ' (α, β).Therefore, at t
xConstantly, do not have under the defect situation, light source and tread intersection C on the tread (image z) just can be calculated, and is designated as for x, y:
P(α，β)＝CCD(C(x，y，z)) (5)
And t
xConstantly corresponding actual photographed image be P ' (α, β), actual photographed image P ' (α β) has comprised the defect information on the tread, then:
ΔP＝P′(α，β)-P(α，β) (6)
What formula (6) reflected is the deviation of real image and zero defect image.
(5) judge whether there is defective in the offset images
If e is a critical value of judging whether defective exists.If the deviate of each pixel is all less than e among the Δ P, then judging does not have defective to exist on this image.Otherwise then judge to have defective in the offset images, and deviate corresponds to point on the thread defect greater than the pixel of e.
(6) degree of depth of calculating defect point
As shown in Figure 4, establish P
xBe on the intersection of optical plane ABC and tread a bit, cross a some P
xDo one with the tangent line 1 (shown in Fig. 5-1, dotted line is represented rolling circle) of the parallel circumference of rolling circle, after a P
xDo a tread axial profile line tangent line 2 (shown in Fig. 5-2, camber line EF for the some P
xThe axial outline line of place's tread), the plane that tangent line 1, tangent line 2 are constituted is called a P
xThe section.
The departure Δ P of any point in the offset images
iWith corresponding point P on the tread
xThe depth d of place's defective
i, and optical plane ABC with the some P
xSection angulation ω be directly proportional.After the position relation of image collecting device is determined, angle ω is a known quantity, therefore by Δ P
iValue can calculate the depth d of corresponding defect point
iValue:
d
i＝ΔP
i×tanω (7)
The synoptic diagram of formula (7) as shown in Figure 6, camber line EF is the profile of tread, supposes depression to occur at the dotted line place, then the intersection point of optical plane and EF will be from P
xMove on to P
x', Δ P is the degree of 2 skews, and ω is optical plane and puts P
xThe section between angle.Can calculate the thread defect degree of depth of each defect point correspondence in the offset images according to formula (7).
(7) generate defect image
One week of the complete covering wheel tread of a series of linear array images of every line array video camera collection is by the analyzing and processing in above the 4th, the 5th, the 6th step, the degree of depth of defective in the time of can determining whether there is thread defect in these linear array images and have defective.A series of linear array images are spliced into a width of cloth two dimensional image, and will have the gray-scale value of the image pixel of defective to be changed to 0, the gray-scale value of defective image pixel is changed to the depth of defect d of the corresponding thread defect point of this pixel
i, then this width of cloth two dimensional image is the image of thread defect, and the defect image synoptic diagram is seen Fig. 7.
(8) calculating of defect parameters
In Fig. 7, C
1There is the zone of defective on the expression tread, is called defective C
1, C
2Be area free from defect.Defective C
1Form by a series of defect points, at defective C
1Inside if the depth value of each defect point meets gradually the regularity of distribution that increases, reduces gradually along the rolling circle direction, is thought that then this defective belongs to flat sliding, otherwise is thought that this defective belongs to shelled tread.
Because the depth of defect d of each defect point correspondence
iKnown, therefore can obtain defective C
1In the greatest drawback depth d
Max, d
MaxBe defective C
1The degree of depth.If defective C
1Starting point along the rolling circle direction is M, and terminal point is N, and then the corresponding length l along the rolling circle direction is defective C between M, the N
1Length.If the many places defective occurs in the defect image, then can calculate the degree of depth and the length of each defective equally.
If defective C
1Belong to flat sliding, then defective C
1In the greatest drawback depth d
MaxBe the value of flat sliding parameter.If defective C
1Belong to shelled tread, then defective C
1Length l be the value of shelled tread parameter.
Obtain successively after the value of flat sliding and shelled tread, judge further according to relevant maintenance standard whether thread defect crosses limit again, and take corresponding maintenance measures.
Claims (2)
1, vehicle wheel is characterized in that to the thread defect online test method this detection utilizes the projection information of structured light light source on thread defect to detect flat sliding and two defect parameters of shelled tread, specifically may further comprise the steps:
(1) when vehicle operating is between detection zone, detect running velocity, when speed V 0～10 km/hour the time shoulder moving detecting unit;
(2) when speed V 0～10 km/hour the time start light source, the structured light of being made up of the light of a series of regular arrangements shines on the right tread of vehicle wheel, the projection of structured light on tread be by the line array video camera imaging, the projected image of formation tread;
(3) when vehicle wheel when running to the detection position, the speed measuring position sensor produces trigger pip, detects this trigger pip in real time, the control image collecting device is gathered the projected image of a series of structured lights on tread; The video camera of each side of wheel by more than 3 makes the week that the scope of shooting can complete covering wheel tread;
(4) collection of corresponding every width of cloth image moment t
x, at first (x, y z), obtain not having under the defect situation at t according to known tread dimensional parameters T
xConstantly the intersection C of light source and tread (x, y, z), and the projected image P of this intersection (α, β), α wherein, β is the coordinate of video camera imaging face, x, y, z are the object space coordinate;
(5) t
xConstantly corresponding actual photographed image be P ' (α, β), this image has comprised the defect information on the tread, then the offset images Δ P of real image and zero defect image is: Δ P=P ' (α, β)-P (α, β);
(6) establishing e is the critical value of judging whether defective exists, e≤0.1mm, if the deviate of each pixel is all less than e among the Δ P, then judging does not have defective to exist on this image; Otherwise then judge to have defective in the offset images, and deviate corresponds to point on the thread defect greater than the pixel of e;
(7) according to image acquisition moment t
r, and imaging relations, can obtain the defective locations that each defect point corresponds to object space; Simultaneously, the departure Δ P of certain point among the offset images Δ P
iPut the depth d of corresponding defect point with this
i, and the section at corresponding defect point place be directly proportional with respect to the angle ω of optical plane; After the position relation of image collecting device was determined, angle ω was a known quantity, by Δ P
iValue can calculate the depth d of corresponding defect point
iValue: d
i=Δ P
i* tan ω;
Described optical plane is the plane that all light of structured light light source emission constitute; Described section be utilize in the drop shadow curve of optical plane on wheel tread more arbitrarily, with this point is that benchmark is done two tangent lines, wherein one parallel with wheel rolling circle, another is tangent with tread axial profile line, the plane that two tangent lines constitute is the section of this point;
(8) a series of linear array images are spliced into a width of cloth two dimensional image, and will have the gray-scale value of the image pixel of defective to be changed to 0, the gray-scale value of defective image pixel is changed to the depth of defect d of the corresponding thread defect point of this pixel
i, then this width of cloth two dimensional image is the image of thread defect;
(9) for the flat sliding parameter, obtain the degree of depth of defect point maximum in the scratch defect image, be the value of flat sliding parameter; For the shelled tread parameter, obtain peel off in the defect image initial with stop the corresponding rolling circle length of defect point, be the value of shelled tread parameter.
2, adopt the pick-up unit of detection method use according to claim 1, it is characterized in that this pick-up unit is to comprise along the outside of one section straight track near the position of a track wherein being arranged in order two speed measuring position sensors and a trigger position sensor, the spacing between two speed measuring position sensors is less than the girth of a wheel; In the track outside two cover image collecting devices are set respectively in trigger position sensor the place ahead, install along two track symmetries; Every cover image collecting device comprises at least three line array video cameras and a structured light light source; The oblique setting of structured light light source and track, the laser beam irradiation of generation is to the right tread of the wheel that passes through from pick-up unit; Video camera is arranged between structured light light source and the track, and is fixed on the position near track, and direction along ng a path is arranged in order.
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| CNB2006101552813A CN100449264C (en) | 2006-12-18 | 2006-12-18 | On-line detection method and device for thread defect of vehicle wheel set |
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| CNB2006101552813A CN100449264C (en) | 2006-12-18 | 2006-12-18 | On-line detection method and device for thread defect of vehicle wheel set |
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