CN110979388A - Three-dimensional image through type detection system for train wheel tread defects and out-of-roundness - Google Patents
Three-dimensional image through type detection system for train wheel tread defects and out-of-roundness Download PDFInfo
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- CN110979388A CN110979388A CN201911306465.9A CN201911306465A CN110979388A CN 110979388 A CN110979388 A CN 110979388A CN 201911306465 A CN201911306465 A CN 201911306465A CN 110979388 A CN110979388 A CN 110979388A
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- B61K9/00—Railway vehicle profile gauges; Detecting or indicating overheating of components; Apparatus on locomotives or cars to indicate bad track sections; General design of track recording vehicles
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Abstract
The invention discloses a three-dimensional image through type detection system for train wheel tread defects and out-of-roundness, which comprises an acquisition module, a speed measurement control module, a motor moving module and a data processing module, wherein the motor moving module is fixed on a track bed on two sides of a track, and the acquisition module and the speed measurement control module are installed on the motor moving module. The acquisition module acquires wheel tread contours in the synchronous movement process of the wheels, acquires one contour at an interval of 1mm at the minimum by speed measurement detection control, compresses images by the preprocessing module in the acquisition process, and transmits the compressed images to the image processing module in time; the speed measurement control module measures the speed of the wheels and provides the speed to the motor moving module; the motor moving module drives the motor to work in time according to the signal of the speed measurement control module, so that the acquisition module moves in time and keeps consistent with the advancing speed of the wheels; the data processing module processes the image data compressed by the acquisition module, synthesizes a three-dimensional image of the wheel tread, and calculates out-of-roundness and tread defects.
Description
Technical Field
The invention relates to the field of online detection of rail transit wheels, in particular to a system capable of accurately detecting out-of-roundness and tread defects of wheels.
Background
Wheel out-of-roundness and tread defects are main causes of wheel rail vibration, and currently, no good application detection means is available. The existing wheel online detection system cannot detect out-of-roundness and tread defects when a railway train, particularly a high-speed motor train unit train enters a warehouse. During manual maintenance, the out-of-roundness cannot be checked, and the tread defects in one third of the area of the wheel can be checked only because most of the wheel is shielded, so that the train is not only occupied when the train stops, but also the whole wheel cannot be checked.
The existing direct shooting scheme of the non-linear light source image cannot accurately detect depth information, increases the difficulty of image analysis due to image deformation, has low detection accuracy, can only be manually checked and used by maintainers, and cannot automatically alarm or has very high false alarm rate.
Disclosure of Invention
In view of the above problems, the object of the present invention is: the three-dimensional image through-type detection system for the defects and the out-of-roundness of the train wheel tread is provided, and can detect various defects of the tread, including scratches, peeling, hurting and the like; the out-of-roundness of the wheel can be quantitatively detected; the automatic alarming device can automatically alarm various defects, out-of-roundness and the like, can perform early warning and alarm gate setting, and has high accuracy.
In order to achieve the purpose, the invention adopts the technical scheme that: a three-dimensional image through type detection system for train wheel tread defects and out-of-roundness comprises an acquisition module, a speed measurement control module, a motor moving module and a data processing module; the motor moving module is fixed on the track beds on the two sides of the track, and the acquisition module and the speed measurement control module are installed on the motor moving module;
the acquisition module acquires the tread profile of the wheel according to the speed provided by the speed measurement control module, compresses the acquired profile and transmits the compressed profile to the data processing module, and the multiple groups of acquisition units work simultaneously to respectively detect different wheels on the same bogie;
the speed measurement control module measures the speed of the wheels and provides the speed to the acquisition module and the motor moving module;
the motor moving module drives the motor to work in time according to the signal of the speed measurement control module, so that the acquisition module moves in time and keeps consistent with the traveling speed of the wheels;
and the data processing module synthesizes the data preprocessed by the acquisition module to form a three-dimensional image of the wheel tread, and then calculates out-of-roundness and tread defect size.
Compared with the prior art, the invention has the beneficial effects that:
(1) the installation is convenient;
(2) the detection efficiency is high, the graphic display effect is good, and various defects of the tread, including scratches, peeling, hurting and the like, can be detected;
(3) the informatization degree is high, data cloud storage can be conveniently realized, and data sharing and analysis are facilitated; the non-roundness of the wheel can be quantitatively detected, and automatic alarm can be given to various defects, non-roundness and the like;
(4) the system integration degree is higher, and the intelligent degree is higher to artifical degree of dependence has been reduced.
(5) The accuracy is high, and early warning and alarm gate setting can be performed.
The invention improves the integration level of the data acquisition module, improves the efficiency and the accuracy of real-time detection, allows the moving speed of the train to reach 7.2km/h, has C scanning and 3D display, has a cloud data transmission function, and is beneficial to sharing and recycling of data.
The mapping from the flaw detection data to the pixel space adopts a one-to-one mode, namely each effective data corresponds to one pixel point, and the corresponding mode can reduce the complexity of the algorithm and is beneficial to improving the efficiency. The data processing of the software system adopts a multi-core parallel processing architecture, but the quantity of the parallel processing of the software at the same time is not more than that of the core processors in the industrial control machine. The architecture mode can solve the contradiction between large data volume and real-time processing.
Drawings
FIG. 1 is a field layout of the detection system of the present invention.
FIG. 2 is a schematic diagram of the collection module of the detection system of the present invention.
FIG. 3 is a flow chart of the operation of the detection system of the present invention.
The system comprises a motor moving module 1, a motor collecting module 2, a speed measuring control module 3, a sleeper 4, a steel rail 5 and a wheel pair to be detected 6, wherein the motor moving module, the speed measuring control module, the sleeper, the steel rail and the wheel pair are arranged in sequence; 21 is a workbench, 22 is a linear laser source, 23 is a data compression preprocessing circuit board, 24 is a high-performance camera, and 25 is an outer cover; in fig. 1, the train passes from left to right.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
As shown in fig. 1, the field layout of the detection system of the present invention includes an acquisition module, a speed measurement control module, a motor moving module and a data processing module, wherein the motor moving module is fixed on the track beds at the two sides of the track, and the acquisition module and the speed measurement control module are installed on the motor moving module; the detection system of the embodiment is arranged on a throat key way of a warehousing train, and the train can detect out-of-roundness of wheels and tread defects through one-time detection.
The acquisition module acquires the tread profile of the wheel according to the speed provided by the speed measurement control module, compresses the acquired profile and transmits the compressed profile to the data processing module, and the multiple groups of acquisition units work simultaneously to respectively detect different wheels on the same bogie;
the speed measurement control module measures the speed of the wheels and provides the speed to the acquisition module and the motor moving module;
the motor moving module drives the motor to work in time according to the signal of the speed measurement control module, so that the acquisition module moves in time and keeps consistent with the traveling speed of the wheels;
and the data processing module synthesizes the data preprocessed by the acquisition module to form a three-dimensional image of the wheel tread, and then calculates out-of-roundness and tread defect size.
As shown in fig. 2, the schematic diagram of the acquisition module of the detection system of the present invention is shown, the acquisition module is a laser triangle acquisition and preprocessing module, and comprises a workbench, a high performance camera, a linear laser source, a housing, a data compression preprocessing circuit board and a structural member fixed on a driving rod, when a train wheel advances to be matched with a laser beam of the acquisition module, that is, the laser beam passes through the center of a circle of the wheel, the acquisition module starts to acquire the profile from the top of a wheel rim of the laser wheel to the outer side of the wheel rim, an outline image is acquired at an interval of 1mm at minimum according to a signal of a speed measurement control unit, and a large number of acquired outline images are preprocessed and compressed and then transmitted to.
The line laser source includes all line light sources capable of forming an image contour on the wheel and recognizing contrast by the camera, such as a red light laser source, a blue light laser source, and the like; the outer cover is provided with a transparent window matched with the line laser source.
The speed measurement control module comprises a speed measurement sensor and a speed measurement control circuit board, and the speed measurement control circuit board transmits wheel speed information to the acquisition module and the motor moving module.
The motor moving module comprises a motor and a 4m long driving rod, the motor is driven to work in time according to signals of the speed measurement control module, the acquisition module is moved, the contour acquired by the acquisition module is consistent with the movement of the wheels, and the acquisition module is ensured to acquire images accurately.
The data processing module comprises a data processing circuit board, an industrial computer and a software system, the compressed images transmitted by the acquisition module are synthesized to reproduce a wheel tread three-dimensional image, the out-of-roundness and the depth and the size of tread defects are calculated, and the out-of-roundness and the tread defects which are out of limit are alarmed according to a set gate.
As shown in fig. 3, the three-dimensional image passing-type detection method for the train wheel tread defect and the out-of-roundness of the train wheel of the embodiment has the working principle that: the detection system comprises a motor moving module, a collection module and a speed measurement control module, wherein the motor moving module is fixed on the track beds on two sides of a track, and the collection module and the speed measurement control module of the detection system are installed on the motor moving module, and the detection system comprises the following specific steps:
the collection step comprises: the method comprises the following steps that wheel tread profiles are collected according to the speed provided by a speed measurement control module of a detection system, the collected profiles are compressed and transmitted to a data processing module of the detection system, and a plurality of groups of collection units work simultaneously to respectively detect different wheels on the same bogie;
speed measurement control: measuring the wheel speed, and providing the wheel speed to an acquisition module and a motor moving module of the detection system;
a motor moving step: the motor is driven to work in time according to signals of a speed measurement control module of the detection system, so that an acquisition module of the detection system moves in time and keeps consistent with the traveling speed of the wheel;
and (3) data processing: and synthesizing the data preprocessed by the acquisition module of the detection system to form a three-dimensional image of the wheel tread, and then calculating out-of-roundness and the size of tread defects.
The method comprises the steps of collecting and preprocessing a laser triangle, when a train wheel is matched with a laser beam required for collection when the train wheel advances, namely a laser line passes through the circle center of the wheel, collecting the contour from the top of a wheel rim of the laser wheel to the outer side of the wheel rim, collecting a contour image at intervals of 1mm at minimum according to a signal of a speed measurement control unit, and performing data processing after preprocessing and compressing a large number of collected contour images;
and the data processing step synthesizes the compressed images transmitted in the acquisition step into a three-dimensional image of the wheel tread, calculates out the out-of-roundness and the depth and the size of the tread defect, and alarms the out-of-roundness and the tread defect which are out of limit according to a set gate.
The specific process is as follows:
1 when the train arrives, the speed measurement control module detects the speed of the train and the position information of wheels and transmits the speed and the position information to the acquisition module and the mobile motor module in real time.
And 2, the acquisition module acquires the tread profile of the wheel according to the speed provided by the speed module and the sampling rate of every 1mm, and meanwhile, the motor module timely moves the acquisition module to enable the profile acquired by the acquisition module to be consistent with the motion of the wheel.
And 3, the acquisition module compresses the acquired contour in time in the acquisition process and transmits the compressed contour to the processing computer module.
And 4, synthesizing the data preprocessed by the acquisition module by using the processing computer to form a three-dimensional image of the wheel tread, and then calculating out-of-roundness and the size of tread defects.
And 5, the whole system is connected with a user network system, and a user can browse three-dimensional images, tread defects and out-of-roundness data and alarm information formed by the system at each terminal.
The above embodiments are only for illustrating the technical idea of the present invention, and the protection scope of the present invention is not limited thereby, and any modification made on the basis of the technical solution according to the technical idea of the present invention falls within the protection scope of the present invention. The technology according to the present invention can be realized by conventional technologies unless described in detail.
Claims (10)
1. The utility model provides a train wheel tread defect and out of roundness three-dimensional image through type detecting system which characterized in that: the device comprises an acquisition module, a speed measurement control module, a motor moving module and a data processing module; the motor moving module is fixed on the track beds on the two sides of the track, and the acquisition module and the speed measurement control module are installed on the motor moving module;
the acquisition module acquires the tread profile of the wheel according to the speed provided by the speed measurement control module, compresses the acquired profile and transmits the compressed profile to the data processing module, and the multiple groups of acquisition units work simultaneously to respectively detect different wheels on the same bogie;
the speed measurement control module measures the speed of the wheels and provides the speed to the acquisition module and the motor moving module;
the motor moving module drives the motor to work in time according to the signal of the speed measurement control module, so that the acquisition module moves in time and keeps consistent with the traveling speed of the wheels;
and the data processing module synthesizes the data preprocessed by the acquisition module to form a three-dimensional image of the wheel tread, and then calculates out-of-roundness and tread defect size.
2. The train wheel tread defect and out-of-roundness three-dimensional image pass-through detection system of claim 1, wherein: the acquisition module is a laser triangle acquisition and preprocessing module and comprises a workbench, a high-performance camera, a linear laser source, an outer cover, a data compression preprocessing circuit board and a structural part fixed on a driving rod, when a train wheel moves to be matched with a laser beam of the acquisition module, namely the laser beam passes through the circle center of the wheel, the acquisition module starts to acquire the contour from the top of the wheel rim of the laser wheel to the outer side of the wheel rim, a contour image is acquired at an interval of 1mm at minimum according to a signal of a speed measurement control unit, and a large amount of acquired contour images are transmitted to the data processing module after being subjected to preprocessing compression.
3. The train wheel tread defect and out-of-roundness three-dimensional image pass-through detection system of claim 2, wherein: the line laser source comprises all line laser sources which can form an image contour on the wheel and can be identified by the camera, and the outer cover is provided with a transparent window.
4. The train wheel tread defect and out-of-roundness three-dimensional image pass-through detection system of claim 3, wherein: the line laser source comprises line laser sources of all colors such as a red laser source and a blue laser source.
5. The train wheel tread defect and out-of-roundness three-dimensional image pass-through detection system of claim 1, wherein: the speed measurement control module comprises a speed measurement sensor and a speed measurement control circuit board, and the speed measurement control circuit board transmits wheel speed information to the acquisition module and the motor moving module.
6. The train wheel tread defect and out-of-roundness three-dimensional image pass-through detection system of claim 1, wherein: the motor moving module comprises a motor and a driving rod, the motor is driven to work in time according to signals of the speed measurement control module, the acquisition module is moved, the contour acquired by the acquisition module is consistent with the movement of the wheels, and the acquisition module is ensured to acquire images accurately.
7. The train wheel tread defect and out-of-roundness three-dimensional image pass-through detection system of claim 1, wherein: the data processing module comprises a data processing circuit board, an industrial computer and a software system, the compressed images transmitted by the acquisition module are synthesized to reproduce a wheel tread three-dimensional image, the out-of-roundness and the depth and the size of tread defects are calculated, and the out-of-roundness and the tread defects which are out of limit are alarmed according to a set gate.
8. The train wheel tread defect and out-of-roundness three-dimensional image pass-through detection system of claim 1, wherein: the system is connected with a user network system, and a user can browse three-dimensional images and tread defect and out-of-roundness data and alarm information formed by the system at each terminal.
9. A passing type detection method for three-dimensional images of tread defects and out-of-roundness of train wheels uses a passing type detection system for three-dimensional images of tread defects and out-of-roundness of train wheels, a motor moving module of the detection system is fixed on track beds on two sides of a track, and an acquisition module and a speed measurement control module of the detection system are installed on the motor moving module, and the method is characterized by comprising the following specific steps:
the collection step comprises: the method comprises the following steps that wheel tread profiles are collected according to the speed provided by a speed measurement control module of a detection system, the collected profiles are compressed and transmitted to a data processing module of the detection system, and a plurality of groups of collection units work simultaneously to respectively detect different wheels on the same bogie;
speed measurement control: measuring the wheel speed, and providing the wheel speed to an acquisition module and a motor moving module of the detection system;
a motor moving step: the motor is driven to work in time according to signals of a speed measurement control module of the detection system, so that an acquisition module of the detection system moves in time and keeps consistent with the traveling speed of the wheel;
and (3) data processing: and synthesizing the data preprocessed by the acquisition module of the detection system to form a three-dimensional image of the wheel tread, and then calculating out-of-roundness and the size of tread defects.
10. The method for three-dimensional image pass-through detection of train wheel tread defects and out-of-roundness according to claim 9, wherein: the method comprises the steps of collecting and preprocessing a laser triangle, when a train wheel is matched with a laser beam required for collection when the train wheel advances, namely a laser line passes through the circle center of the wheel, collecting the contour from the top of a wheel rim of the laser wheel to the outer side of the wheel rim, collecting a contour image at intervals of 1mm at minimum according to a signal of a speed measurement control unit, and performing data processing after preprocessing and compressing a large number of collected contour images;
and the data processing step synthesizes the compressed images transmitted in the acquisition step into a three-dimensional image of the wheel tread, calculates out the out-of-roundness and the depth and the size of the tread defect, and alarms the out-of-roundness and the tread defect which are out of limit according to a set gate.
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| CN201911306465.9A CN110979388A (en) | 2019-12-18 | 2019-12-18 | Three-dimensional image through type detection system for train wheel tread defects and out-of-roundness |
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| CN201911306465.9A CN110979388A (en) | 2019-12-18 | 2019-12-18 | Three-dimensional image through type detection system for train wheel tread defects and out-of-roundness |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112781524A (en) * | 2021-01-25 | 2021-05-11 | 成都铁安科技有限责任公司 | Falling wheel type wheel detection system |
| CN113432897A (en) * | 2021-06-25 | 2021-09-24 | 中国铁建重工集团股份有限公司 | Detection system and detection method for tire wear of straddle type monorail train |
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