Summary of the invention
It is an object of the invention to solve at least the above, and the advantage that at least will be described later is provided.
It is a still further object of the present invention to provide one and realize track plates detection method convenient, quick and high-precision.
In order to realize these purposes according to the present invention and further advantage, it is provided that a kind of method of track plates apparent size deviation detecting CRTS III type, described track plates at least includes track and service sleeve, comprises the following steps:
S1, utilize laser tracker in conjunction with handheld laser scanner scanning high-speed railway track plate to be detected, obtain the cloud data on described track plates surface;
S2, set up track plates local coordinate system, described cloud data is corrected so far coordinate system, obtains the cloud data under track plates local coordinate system;
S3, the cloud data under described coordinate system is classified, obtain the cloud data of track inner surface and service sleeve;
S4, employing plane fitting method extract the model parameter of track inner surface from the cloud data of described track inner surface, adopt spherical model fitting process to extract the parameter of service sleeve from the cloud data of described service sleeve simultaneously;
The parameter of S5, the track inner surface that utilization is extracted and service sleeve, contrasts track plates design document, calculates track plates dimensional discrepancy.
Preferably, the parameter of described track inner surface includes the support rail face parameter of described track soffit plane and the vice jaw surface parameter of described track two side plane.
Preferably, the central three-dimensional coordinate of described service sleeve inserts obtaining from spherical model surface, GUIXIN ball-type frock top in described service sleeve by scanning;
Wherein, the described bottom from GUIXIN frock is can be inserted into the taper cork in service sleeve, and the base plane of described taper cork is fitted with described support rail face.
Preferably, in described step 3, the method for the cloud data classification in support rail face is:
S3-1, defining border, support rail face envelope polygon according to the boundary coordinate of described track base plane, described envelope polygon is the two dimensional surface polygon ignoring support rail face elevation information;
The monoblock track plates point cloud that S3-2, traverse scanning obtain, it is judged that each point, whether in described envelope polygon, completes the preliminary classification in support rail face in XOY projection plane;
S3-3, basis hold maximum and the minima of height above rail surface, the method adopting elevation filtering, set certain elevation threshold value, the cloud data of traversal previous step rectangle segmentation, judge that whether height value that this cloud data is corresponding is in this elevation scope, point within the scope of this elevation, is defined as support rail face cloud data.
Preferably, the model of described laser tracker is LeicaAT960, and described laser scanner model is LeicaT-Scan5.
Preferably, described laser scanner to described laser tracker distance is 1-10 rice.
The present invention at least includes following beneficial effect:
1, detection efficiency: total powerstation+frock mode, one piece of plate the whole series about 40 minutes time of detection, has a strong impact on normal production process;Laser is followed the tracks of and hand held scanner combination technique only needs 3~5 minutes, does not affect normal production process, and odds for effectiveness is obvious.
2, personnel put into: total powerstation+frock mode, it is necessary to two technical staff have worked in coordination with;Laser is followed the tracks of and hand held scanner combination technique has only to a people, if adopting mechanical arm assist in scanning, it is possible to achieve Aulomatizeted Detect;
3, Result Precision: total powerstation range error is about 0.3mm, is difficulty with 0.5mm and detects the required precision of error, and scanner precision substantially meets;Laser is followed the tracks of and the overall precision of hand held scanner combination technique can realize 0.06mm, track plates inspection criterion requirement.
4, Detection results: total powerstation+frock mode can only be fixed detection a little, laser is followed the tracks of and hand held scanner combination technique can realize comprehensive and systematic detection, just as doing a whole body health inspection to track plates, does not lose the machining deviation of optional position.
5, operating cost: save 40 minutes according to every 100 kilometers of 30,000 6 thousand blocks of plates, every block of plate, save 20,000 4 thousand hours, according to 8 hours every days of duty, it is possible to save 3,000 working days, according to for each person every day 200 yuan, per 100 km just can save the labour cost of 1,200,000 yuan.
Part is embodied by the further advantage of the present invention, target and feature by description below, and part is also by by being understood by those skilled in the art the research of the present invention and practice.
Detailed description of the invention
Below in conjunction with accompanying drawing, the present invention is described in further detail, to make those skilled in the art can implement according to this with reference to description word.
It should be noted that experimental technique described in following embodiment, if no special instructions, it is conventional method, described reagent and material, if no special instructions, all commercially obtains;In describing the invention, term " transverse direction ", " longitudinal direction ", " on ", D score, "front", "rear", "left", "right", " vertically ", " level ", " top ", " end ", " interior ", the orientation of the instruction such as " outward " or position relationship be based on orientation shown in the drawings or position relationship, it is for only for ease of the description present invention and simplifies description, be not instruction or hint indication device or element must have specific orientation, with specific azimuth configuration and operation, be therefore not considered as limiting the invention.
As it is shown in figure 1, the present invention provides a kind of method detecting high-speed railway CRTS III type fragment-free track slab apparent size deviation, described track plates at least includes track and service sleeve, comprises the following steps:
S1, utilize laser tracker in conjunction with handheld laser scanner scanning high-speed railway track plate to be detected, obtain the cloud data on described track plates surface;
S2, set up track plates local coordinate system, described cloud data is corrected so far coordinate system, obtains the cloud data under track plates local coordinate system;
S3, the cloud data under described coordinate system is classified, obtain the cloud data of track inner surface and service sleeve;
S4, employing plane fitting method extract the model parameter of track inner surface from the cloud data of described track inner surface, adopt spherical model fitting process to extract the parameter of service sleeve from described service sleeve cloud data simultaneously;
The parameter of S5, the track inner surface that utilization is extracted and service sleeve, contrasts track plates design document, calculates track plates scale error.
This method is laser tracker and hand held scanner combination technique, and laser tracker provides real time position and attitude to hand held scanner, and scanning element cloud is in the same coordinate system, it is not necessary to carry out model splicing.Respectively the support rail face (soffit plane) of track, vice jaw surface (two side planes) are carried out plane fitting by the method for models fitting, service sleeve is carried out ball-type matching.
nullDue to service sleeve diameter only 25.5mm,The degree of depth reaches 141mm,Such dimension scale,It is unfavorable for that scanner directly obtains cloud data inside service sleeve,Therefore to the service sleeve central three-dimensional coordinate embedded bottom acquisition track,The i.e. intersecting point coordinate in service sleeve axis and support rail face,The applicant devises from GUIXIN ball-type frock,Described from GUIXIN Fixture Design it is: taper cork for can be inserted in service sleeve bottom it,Insert the plane bottom GUIXIN frock after service sleeve tightly to fit with support rail face,The height of bottom surface to the top ball from GUIXIN ball-type frock after laminating is fixed value,And can be measured accurately by slide gauge,In this method from GUIXIN ball-type frock height H be 120mm,From the ball center at GUIXIN ball-type frock top, the subpoint on support rail face is service sleeve central point,And the radius of ball can be accurately measured by slide gauge,The radius of a ball that this method adopts is 45mm.By scanning from GUIXIN ball-type frock mode, indirectly obtain service sleeve central three-dimensional coordinate.In described step S1, during scanning track, inserting in corresponding service sleeve from GUIXIN ball-type frock, scanning is from spherical model surface, GUIXIN ball-type frock top.Adopting the mode from GUIXIN frock, indirectly obtain service sleeve center, scan efficiency significantly improves.
In order to realize from the monoblock track plates surface cloud data that scanning obtains, sort out the laser point cloud of the vice jaw surface of the support rail face bottom track and both sides, described step S3 comprises the following steps, when being designed due to high-speed railway, each piece of track plates can design all fronts and uniquely number, the track plates of this numbering can provide design parameter, design parameter comprises size and the relative position of track plates parts, therefore border, support rail face envelope polygon is defined according to the boundary coordinate of this track plates track base plane, this envelope polygon is the two dimensional surface polygon ignoring support rail face elevation information, the monoblock track plates point cloud that traverse scanning obtains again, judge that each point (ignoring height value a little equally) is whether in this polygon, adopt in this way, the preliminary classification in support rail face is completed in XOY projection plane;Secondly, owing to the design document of track plates can define the minimum point in support rail face, peak and plane value of slope, therefore, as shown in Equation 1, according to maximum and the minima of holding height above rail surface, the method adopting elevation filtering, set certain elevation threshold value, the cloud data of traversal previous step rectangle segmentation, it is judged that whether height value corresponding to this cloud data be in this elevation scope, point within the scope of this elevation, is defined as support rail cake cloud.In like manner can obtain the vice jaw surface point cloud classifications of track both sides.
Formula 1:Zmin-δ≤Zpi≤Zmax+δ;
Cloud data is carried out the computing formula of elevation filtering
Wherein, Zmin: track plates design document defines the minimum height value of support rail face or vice jaw surface;
Zmax: track plates design document defines the highest elevation value of support rail face or vice jaw surface;
δ: the threshold value in the filtering of laser point cloud elevation, can be set according to scanner precision;
Zpi: the height value that cloud data to be sorted is corresponding.
Further, due to high-speed railway design time, the parameter of each piece of fragment-free track slab can be designed, this parameter contains the relative position coordinates of service sleeve, following steps are that the design three-dimensional coordinate under the local coordinate system of service sleeve center calculates process: illustrate with the track plates of P5600 model, as in figure 2 it is shown, the service sleeve of this model is rearranged (picture overturns 90 ° of observations counterclockwise) by 9*4 matrix form.Design standard flat figure can read from track plates: unilateral track service sleeve central plane distance W1For 233.3mm, both sides track service sleeve ymmetry center plane distance W2For 1515.6mm, the plan range L of unilateral adjacent support rails platform service sleeve symmetrical centre is 630mm, and support rail face, both sides is both designed as inside circuit to tilt, and gradient S is 1:40.On the left of line direction, the first left service sleeve center of track is defined as track plates local coordinate system initial point, and period is defined as T11, coordinate figure is (0,0,0), and other any service sleeve periods are defined as Tij(wherein i is the line number of service sleeve, and j is the row number of service sleeve), the design coordinate figure of the local coordinate system at any service sleeve center of P5600 model track plates is:
Yij={ YT11+L* (i-1)=630* (i-1) mm
Wherein, i: track line number, j: track row number, W1: unilateral track service sleeve central plane distance, W2: both sides track service sleeve ymmetry center plane distance, L: the plan range of unilateral adjacent support rails platform service sleeve symmetrical centre, S: both sides support rail is towards gradient inside circuit.
The module extender board (P4925, P4856) of other two kinds of models, it is also possible to according to above-named formula, calculates service sleeve design centre D coordinates value under track plates local coordinate system.Curve ruler is relative to module extender board, and corresponding track moves adjustment in circuit transverse horizontal, moves longitudinally up and down adjustment at circuit, and concrete adjusted value is clear and definite in design document.If the D coordinates value under the engineering coordinate system at given each piece of each service sleeve center of plate in design document, assume that along service sleeve center, first, the line direction lower left corner be track plates local coordinate system initial point, other service sleeve centers design coordinate figure under track plates local coordinate system, it is possible to obtained by ordinate transform.
Service sleeve place will be placed in from GUIXIN ball-type frock, recycling handheld laser scanner obtains described from GUIXIN ball-type frock surface laser point cloud, owing to can measure in advance to the height bottom frock from ball-type center, GUIXIN ball-type frock top, can calculate from the center theory three-dimensional coordinate of GUIXIN ball-type frock top ball.
Owing to mismachining tolerance is typically small, the position of each service sleeve is substantially stationary, through the track plates cloud data that coordinate system is corrected, can set that certain distance threshold, utilize the algorithm of half path search shown in formula 2, carry out half path search, it may be achieved automatically classify from GUIXIN ball-type frock laser point cloud.This method is by scanning precision machined ball-type surface, it is thus achieved that a large amount of laser spots data in ball surface (about 50 laser spots/balls), again through the method for models fitting, it is possible to improving certainty of measurement, precision is about the positional accuracy of 0.03mm.
Formula 2:(R+ δ)2≤(Xi-X0)*(Xi-X0)+(Yi-Y0)*(Yi-Y0)+(Zi-Z0)*(Zi-Z0)
Cloud data is carried out the computing formula of half path search
Wherein, Xi\Yi\Zi: the three-dimensional coordinate of track plates laser point cloud data;
X0\Y0\Z0: in track plates design document define service sleeve top from the spherical frock sphere centre coordinate of GUIXIN;
R: from the spherical frock spherical radius value of GUIXIN;
δ: the distance threshold of laser point cloud half path search, can be set according to scanner precision.
Experiment and analysis
In order to evaluate the reliability and precision introducing method herein, it is scanned experiment in certain visitor specially certain plate factory.This line adopts CRTS III type track plates, and current detection method mainly adopts automatic motor type total powerstation+special frock to realize.Selecting Switzerland to come the laser tracker of card measurement system herein, the model of absolute laser tracker is LeicaAT960, and positional precision is: U_ (x, y, z)=0.015mm+0.006mm/m.Handheld laser scanners model is LeicaT-Scan5, and precision is: 0.060mm, and maximum measuring rate is: 210000 points/second.Laser tracker sets and stands in track plates near zone to be detected, hand held scanner to laser tracker distance controlling within the scope of 10 meters.
The track plates surface laser cloud data that scanner is obtained, lead in track guidance tape Point Cloud Processing software, through simple interactive operation, the track plates apparent size detection content required in specification can be generated.Fig. 3 a shows track service sleeve centre distance on the left of track plates, and Fig. 3 b shows track service sleeve centre distance on the right side of track plates.A content in this distance simply achievement, other each detections also generate similar form and corresponding curve chart.Due to laser characteristics and employing from GUIXIN frock, the service sleeve required in specification is crooked and height of projection, and 3 indexs of protective layer thickness cannot be measured, can by other frock subsidiaries.
In order to verify detection method reliability in this paper, accuracy assessment will be carried out from two aspects.First the precision of analytical model matching, the standard deviation of ball-type matching is 0.13mm, and the standard deviation of plane fitting is 0.06mm.Secondly, adopting tradition total powerstation detection method, measure service sleeve distance, result is table 1 such as.Owing to adopting different equipment, so total powerstation and scanner precision are not quite identical, but deviation value is basically identical.
The adjacent cannula center of same track two of table 1 total station survey is from table
The industrial applicibility of the present invention
Adopt laser tracker+hand held scanner technology, it is possible to achieve the quick high accuracy of track plates surface point cloud obtains.For the detection project that track plates inspection criterion requires, write laser point cloud data and process software, by point cloud classifications and sampling consistency algorithm, extract track plates partial model, then compare with design document, it is possible to be automatically obtained the detection of track plates apparent size.In the later stage, scanner can be disposed on the robotic arm, it is achieved on-line automaticization scanning and data analysis.
1, detection efficiency: total powerstation+frock mode, one piece of plate the whole series about 40 minutes time of detection, has a strong impact on normal production process;Laser is followed the tracks of and hand held scanner combination technique only needs 3~5 minutes, does not affect normal production process, and odds for effectiveness is obvious.
2, personnel put into: total powerstation+frock mode, it is necessary to two technical staff have worked in coordination with;Laser is followed the tracks of and hand held scanner combination technique has only to a people, if adopting mechanical arm assist in scanning, it is possible to achieve Aulomatizeted Detect;
3, Result Precision: total powerstation range error is about 0.3mm, is difficulty with 0.5mm and detects the required precision of error, and scanner precision substantially meets;Laser is followed the tracks of and the overall precision of hand held scanner combination technique can realize 0.06mm, track plates inspection criterion requirement.
4, Detection results: total powerstation+frock mode can only be fixed detection a little, laser is followed the tracks of and hand held scanner combination technique can realize comprehensive and systematic detection, just as doing a whole body health inspection to track plates, does not lose the machining deviation of optional position.
5, operating cost: save 40 minutes according to every 100 kilometers of 30,000 6 thousand blocks of plates, every block of plate, save 20,000 4 thousand hours, according to 8 hours every days of duty, it is possible to save 3,000 working days, according to for each person every day 200 yuan, per 100 km just can save the labour cost of 1,200,000 yuan.
Although embodiment of the present invention are disclosed as above, but listed utilization that it is not restricted in description and embodiment, it can be applied to various applicable the field of the invention completely, for those skilled in the art, it is easily achieved other amendment, therefore, under the general concept limited without departing substantially from claim and equivalency range, the present invention is not limited to specific details and shown here as the legend with description.