CN111469882A - Use method of portable modular self-correcting rail three-dimensional detection system - Google Patents
Use method of portable modular self-correcting rail three-dimensional detection system Download PDFInfo
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Abstract
The invention belongs to the technical field of railway safe transportation, and relates to a use method of a portable modular self-correcting rail three-dimensional detection system. When the device is used, the device is quickly assembled on site, and the manual operator is wirelessly connected with the two detection units to complete the integral initialization of the device; scanning the marker of the calibration rod to obtain a 3D image, comparing the left and right outgoing calibration reference 3D images to judge whether the error range exists, further reading the reading of the horizontal detection sensor if no fault is detected, and respectively correcting the three-dimensional space coordinate system of the unit; correcting the whole coordinate system according to the calibration rod, establishing a coordinate system taking the ground level as a reference through factory calibration information of the horizontal detection sensor, and starting to integrally scan the 3D image of the railway track; identifying characteristic information including a rail, a rail top surface and a rail edge, and calculating characteristic information including a rail gauge, a rail height, a rail extension angle and a rail profile; the detection unit acquires GPS positioning information and walking information of a walking encoder.
Description
The technical field is as follows:
the invention belongs to the technical field of railway safe transportation, relates to a system and a method for automatically correcting a rail, in particular to a using method of a portable modular self-correcting rail three-dimensional detection system, and can realize quick assembly and detection.
Background art:
railway transportation is one of the main transportation modes in China. The rail performance state directly affects the railway driving safety. The measurement of the geometric parameters of the rail is one of important bases for verifying the performance parameters of the rail. At present, the most common detection means on the railway is detection of a manual measuring tool, different measuring tools are required to be operated manually, and a detection result is directly influenced by the level of an operator, so that manual interference is easily introduced. The automatic detection equipment is relatively large in size, inconvenient to transport manually, complex in assembly and calibration processes and high in maintenance difficulty. The precision of the equipment which is easy to assemble on site quickly is affected by assembly errors and is difficult to guarantee. The problem is not solved, chinese patent with application number CN209605771U discloses a track profile detector convenient for disassembly and assembly, a clamping component is connected to the bottom of a detection box, an operating rod and a display screen are detachably connected and fixed through a locking piece, a handheld rod is connected to the operating rod, the operating rod can rotate along a vertical plane relative to a conversion head and is detachably connected between the operating rod and the conversion head, the conversion head and a connector base are fixed by the locking piece, the connector base and a folding base are respectively fixed on a connecting rod through the locking piece, and the connecting plate is respectively detachable between the connecting rod and the detection box; although this contourgraph can be dismantled through self structure, the equipment is simple, installs the detector at the rail when the railway detects fast, and the dismantlement of device of can being convenient for improves detection effect and efficiency to the rail damage. But the simultaneous detection of multi-dimensional data such as track height, track gauge, track profile and the like cannot be realized. The Chinese patent with the application number of CN201610813938.4 discloses a method for detecting the geometric outline of a high-precision rail, which adopts a plurality of lasers and a plurality of cameras to construct a combined measurement system, and obtains the geometric outline characteristic points of the rail in two non-overlapped dynamic three-dimensional coordinate systems with high precision by the combined calibration of the measurement system and the comprehensive processing of collected data. The detection equipment is simple and flexible to install and high in detection precision, can calibrate world coordinates of the bilateral rail at the same time, and effectively completes three-dimensional detection of the geometric profile of the rail. The invention has the characteristics of simple and flexible installation, high detection precision, capability of calibrating world coordinates of bilateral rails and the like. However, the detection workload is heavy, and errors are easily introduced by manual operation. Chinese patent application No. CN106114553A discloses a photoelectric dynamic measurement method for the platform shake of a railway detection vehicle, which utilizes the joint work of multiple sets of rail displacement precise photoelectric measurement systems installed on a detection vehicle equipment platform to obtain the relative displacement at multiple points on a rail, thereby realizing the dynamic measurement of the relative position and attitude information of a rail surface and a measurement platform. The rail displacement precise photoelectric measurement system consists of a line laser, a point laser and a camera, and adopts a precise photoelectric displacement measurement method combining a point laser displacement measurement technology and a line laser displacement profile triangulation technology to measure the precise displacement of a laser point, and utilizes line laser triangulation to obtain a rail section profile, and determines the position of the laser point on the rail surface profile according to the image relationship of the point laser and the line laser. However, when the device is installed, fit clearance is easily left between installation parts, errors are introduced during assembly, measuring results are affected, and meanwhile, the testing device is large, inconvenient to move and complex to install and debug. Therefore, the present invention seeks to provide a method for using a portable modular self-correcting rail three-dimensional detection system, which can effectively solve the above problems.
The invention content is as follows:
the invention aims to overcome the defects mentioned above, and seeks to design a method for using a portable modular self-correcting rail three-dimensional detection system, which can complete rail geometric feature detection simultaneously by one-time detection, and comprises the following steps: the invention synchronously records the geographic coordinates of the detection points for tracing and searching the detection records.
In order to achieve the purpose, the use method of the portable modular self-correcting rail three-dimensional detection system is realized by the following technical scheme:
the invention relates to a using method of a portable modularized self-correcting rail three-dimensional detection system, wherein the main structure of the portable modularized self-correcting rail three-dimensional detection system comprises two detection units for detection, a mounting bracket for supporting and connecting and a manual operator, wherein the main structure of the detection units comprises a walking mechanism, a scanning mechanism, a control unit, a horizontal detection sensor, a power supply unit and a temperature and humidity sensor; the horizontal detection sensor is arranged at the rear side of the scanning mechanism; the control unit is communicated with the walking mechanism, the scanning mechanism and the horizontal detection sensor to collect and process the information of the components; the power supply unit supplies power to the walking mechanism, the scanning mechanism, the control unit and the horizontal detection sensor;
the main structure of the walking mechanism comprises a power wheel, a bracket, an auxiliary wheel and an encoder; the power wheel is a servo wheel, the running distance can be accurately controlled, the encoder is arranged in the power wheel, the auxiliary wheel is horizontally arranged on the front side of the power wheel, the bracket is of a double-frame side-mounted plate structure, and the power wheel and the auxiliary wheel are positioned at the lower middle part of the bracket and are connected with double supporting plates of the bracket; the power supply and the servo controller are both arranged in the middle of the side mounting plate of the framework, wherein the servo controller is connected with the power wheel for control;
the main structure of the scanning mechanism comprises three groups of sliding tables and laser 2D/3D sensors, wherein the three groups of laser 2D/3D sensors are arranged at the front part of the upper part between the two double-framework side mounting plates and are positioned at the upper part of the sliding tables, and the sliding tables can drive the laser 2D/3D sensors to move longitudinally so as to adjust the angles of the sensors;
the main structure of the control unit comprises an industrial personal computer, a GPS positioning module, a 4G module and a wireless communication module which form integrated package, and the control unit can be communicated with a computer through the GPS positioning module, the 4G module and the wireless communication module;
the main structure of the mounting bracket comprises a bearing frame, a locking mechanism and a reference rod piece, wherein the plug-in type bearing frame is of a triangular arrangement structure, two ends of the plug-in type bearing frame are respectively in plug-in connection with the side mounting plate of the framework, the reference rod piece is positioned at the lower side of the bearing frame and is connected with the unit bracket through the locking mechanism, the main structure of the locking mechanism comprises a magnetic concave plate, a top spring and a base, the magnetic concave plate is connected with the base through the top spring to form the integral locking mechanism, the base of the locking mechanism is connected with the unit bracket, and the base is connected with the side plate of; the magnetic concave plate and the top spring structure can realize quick installation, and meanwhile, the accuracy and stability of installation are ensured;
wherein the manual operator is a commercial tablet personal computer, and a related program is arranged in the computer;
furthermore, the main structure of the bracket comprises two vertically arranged bracket side mounting plates, a bracket stabilizing link rod used for connecting the two bracket side mounting plates, and bracket assembling members, wherein the number of the bracket assembling members is three, and the bracket stabilizing link rod and the bracket assembling members are arranged between and connected with the two bracket side mounting plates on the two sides in a triangular manner, so that the integral mounting precision and stability of the system are ensured, and the quick assembly and disassembly are realized; the bracket assembly component is matched with the mounting bracket, so that the introduced error of the system equipment is reduced;
furthermore, the control unit and the power supply unit are arranged in the detection unit and close to the upper part, wherein the control unit is positioned at the front side of the power supply unit, and the temperature and humidity sensor is positioned at the front side of the control unit so as not to be shielded and interfered by other parts during measurement;
the specific operation method of the invention is carried out according to the following steps:
step one, self calibration is carried out
S1, the sliding table, the mobile laser 2D/3D sensor and the horizontal detection sensor are in rigid connection, the laser 2D/3D sensor calibration component is moved, the obtained contour can be compared with a reference contour, and if the contour is matched with the reference contour, the mobile laser 2D/3D sensor is free of faults;
s2, the calibration components are located on the reference rod piece and are rigidly connected, so that the relative spatial position relationship between the calibration components is fixed, the detection unit can obtain the contour space coordinates of the reference calibration components through detection, calculate the relative spatial attitude position of the detection unit relative to the calibration components, and detect the contour space coordinates of the rail to use the contour space coordinates as a reference object, thereby eliminating and correcting the installation error caused by the rapid installation fit clearance;
s3, mutually verifying the detection results of the horizontal detection sensors according to the correction calibration, and correcting the whole system according to the reading of the horizontal detection sensors;
step two, a specific operation method:
the left side and the right side of the reference rod piece are provided with reference calibration components which are triangular prisms, straight lines of convex edges of the prisms are coplanar, the straight lines of the convex edges of the prisms on the left side and the right side are parallel, and the straight lines of the convex edges of the prisms on the left side and the right side are parallel to the straight lines of the convex edges of the prisms on the left side and the right side on the; wherein the distance between the line 2 and the line 3 is D, the distance between the calibrated parallel line 1 and the line 4 at the two ends is equal to the distance between the calibrated parallel line 5 and the line 8 at the two ends is D1;
s1, forming a matrix array by scanning coordinates of the left 3D image
S2, acquiring the inclination angle of α 1 around the X axis and the inclination angle of β 1 around the Y axis by the horizontal coordinate sensor according to α 1 and β 1 rotating coordinate systems
S3, dividing A2[ n ] into three area coordinate matrix arrays according to x coordinates
A21 i value A2 n (P2 ≤ x1 n)
A22[ j ] value A2[ n ] (x1[ n ] is not more than P1)
A23[ k ] takes the value A2[ n ] (P1< x1[ n ] < P2)
S4, at A21[ i ]]Step by delta Y, the resolution of delta Y is 2 times of the resolution of Y-axis direction, and search for n delta Y<y1[i]Less than or equal to delta y (n +1) within z21[ i]The point with the maximum value is obtained, and the high points in the plane form a new matrix arrayThe matrix array point is a point through which a straight line 1 where the convex side of the prism passes;
s5, calculating the projection straight line of matrix array B1[ r ] on the plane where z is 0
Obtaining a projection equation of a straight line 1, wherein the projection equation of the straight line is y, b1x + a1, and the projection equation is 0;
s6, determining a projection line y of B1[ r ] on the plane x being 0 as B11z + a11 according to the method of step S5;
s7, obtaining A22[ j ] according to the method of steps S4 and S6]High-point matrix array in planeThe matrix array point is a point through which a straight line 4 where the convex edge of the prism passes; obtaining a projection equation of the matrix array, namely a projection equation of a straight line y ═ b2x + a2 on a plane where z is 0, and a projection equation of a straight line y ═ b22z + a22 on a plane where x is 0, namely a straight line 4;
s8, obtaining A23[ k ] according to the method of step S4 and step S6]High-point matrix array in planeThe matrix array point is a point through which a straight line 3 where the convex side of the prism passes; obtaining a projection equation of the matrix array, namely a projection equation of a straight line y, b3x + a3, projected on a plane z, 0, and a projection equation of a straight line y, b33z + a33, namely a straight line 3;
s9, if y is not parallel to b1x + a1 and y is not parallel to b2x + a2, the system fails self-checking, if parallel, the system determines the rotation angle γ 1 around the Z-axis
γ1=arccot(b1);
S10, straight line with distance y equal to b1x + a1 and y equal to b2x + a2The projection equation of the straight line 2 in z is 0;
s11, straight line equal to distance y-b 11x + a11 and y-b 22x + a22The projection equation of the straight line 2 in the plane x is 0;
S13, substituting the value of X1 in step S10 into y ═ b33z + a 33;
s14, summarizing the results, the left coordinate system correction parameters are α 1, β 1 and gamma 1 around XYZ rotation angle, the translation amounts are X1, Y1 and Z1,
s15, according to the method from step S1 to step S14, the processing of forming a matrix array of the right 3D image scanning coordinates can derive three projection equations, i.e. a projection equation of a straight line 5, where the projection straight line equation on the plane where z is 0 is c1x + D1 and the projection straight line equation on the plane where x is 0 is c11z + D11;
a projection equation of a straight line y, c2x + d2, projected on a plane z, 0, and a projection equation of a straight line y, c22z + d22, namely a straight line 8; c3x + d3 on the plane of 0, c33z + d33 on the plane of 0, that is, the projection equation of line 7; the self-checking is carried out through the parallelism of y-b 11x + a11 and y-b 22x + a22, and if the parallelism is not parallel, the self-checking cannot be carried out through the unit;
by self-checking, the projection straight line on the plane where z is 0 can be deducedProjecting straight lines on a plane where x is 0
The right coordinate system correction parameters can be obtained by deducing, wherein the rotation angles around X, Y and Z are α 11, β 11 and gamma 11, and the translation amounts are X11, Y11 and Z11;
If D1 is not equal to e1, it indicates that the deformation of the standard rod or the deformation inclination angle deflection of the mechanical mechanism of the scanning unit, the whole system cannot pass the self-check, and if the D1 is equal to the e1, the offset parallel to the X of the center of the left 3D image coordinate system and the center of the right 3D image coordinate system is deduced to be
If D11 is not equal to e11, it indicates that the deformation of the standard rod or the deformation of the mechanical mechanism of the scanning unit is deflected at the inclined angle, the whole system can not pass the self-check, if the D11 is equal to the e11, the offset parallel to the Z between the center of the left 3D image coordinate system and the center of the right 3D image coordinate system is deduced to be
In conclusion, system self-checking and mutual verification are completed, and the left 3D image self-calibration parameters X Y Z are obtained to have rotation angles of α 1, β 1 and gamma 1, translation amounts X1, Y1 and Z1, the right 3D image self-calibration parameters X Y Z are obtained to have rotation angles of α 11, β 11 and gamma 11, translation amounts X11, Y11 and Z11, and the right 3D image is corrected by the obtained parameters relative to the translation amounts X12 and Z12 of the left 3D image due to the quick installation fit clearance;
step three, detecting the rail profile:
after the self-calibration is completed, the scanning mechanism scans the 3D contour of the rail, and the test results of all the units are registered according to the calibration results to form an integral detection contour;
s1, track gauge: one side of the rail outline edge is taken as a datum line and vertically extends to the other side of the rail edge, the length is taken as a gauge, multi-point detection is carried out, errors caused by the fact that a measuring tool cannot be vertically measured with the rail by manpower are avoided, the accuracy of multi-point position detection is improved, and the parallelism of two rail detection sections can be verified simultaneously;
s2, rail height: calculating the rail height by taking the multipoint gauge and the rail outline edge in the S1 as reference lines and vertically extending towards the included angle between the rail edge on the other side and the ground level;
s3, track extension included angle: obtaining an included angle between the track extending direction and the ground level;
s4, rail profile: after coordinate correction, the rail profile can be obtained by taking the rail vertical plane as a tangent plane, and meanwhile, the horizontal position relation of the rail relative to the ground can be obtained, so that horizontal information is provided for further analysis of rail abrasion;
s5, others: the contour space 3D information of the two steel rail detection sections and the ground level relation can further extract data according to the needs;
step four, measurement is carried out:
s1, field rapid assembly and detection, the invention relates to a portable modular self-correcting rail three-dimensional detection system, wherein a manual operator 3 is connected with two detection units in a wireless way to complete the integral initialization of the equipment;
s2, the left unit detection unit and the right unit detection unit respectively control the sliding table and the movable laser 2D/3D sensor to scan the marker of the calibration rod, and a 3D image is obtained;
s3, comparing the obtained data with factory calibration reference 3D images on the left side and the right side to judge whether the data are in an error range, mutually verifying the data of the three laser 2D/3D sensors to deduce which sensor is possible to have a fault, and if the fault is reported, exiting;
s4, further reading the reading of the horizontal detection sensor in case of no fault detection, and correcting the three-dimensional space coordinate system of the unit respectively;
s5, comparing the data of the left and right detection units with the data of the calibration rod before delivery, judging whether the calibration rod is deformed, and if the deformation fault alarm exits;
s6, correcting the whole coordinate system according to the calibration rod, establishing a coordinate system taking the ground level as a reference through factory calibration information of the horizontal detection sensor, and starting to integrally scan the 3D image of the railway track;
s7, detecting the current temperature and humidity by a temperature and humidity sensor;
s8, identifying characteristic information including a rail, a rail top surface and a rail edge, and further calculating characteristic information including a rail gauge, a rail height, a rail extension angle and a rail outline according to temperature and humidity correction;
s9, the detection unit acquires GPS positioning information and walking information of a walking encoder, and the control unit uploads the information through the 4G module;
and S10, automatically walking and moving to the next detection point for detection.
Compared with the prior art, the invention has the following beneficial effects:
1. the invention can complete the detection of the geometrical characteristics of the rail at the same time by one-time detection, which comprises the following steps: the invention synchronously records the geographic coordinates of the detection points for tracing and searching the detection records.
2. By adopting the module design, the field assembly is simple, convenient and quick, the assembly has the automatic correction and calibration functions after the assembly to eliminate the assembly error, and the detection error caused by manual assembly or assembly looseness of the similar portable products is overcome.
3. Compared with the existing detection method, the invention can more comprehensively display the geometric dimension relation of the rails, the relative position relation between the rails and the ground in the detection range through the three-dimensional image, thereby eliminating the error introduced by manually operating the equipment.
4. The detection can be automatically moved on the rail, and the moving distance is recorded.
5. The modular structure is convenient to carry and assemble, the modular structure is provided with the reference rod piece, and the system can realize self-correction verification and eliminate introduced errors by matching the 3D profile imaging of the reference rod piece with the inclination angle sensor.
6. The method has a complete self-correction verification method, can realize self-detection by calibrating the result obtained by detecting the reference component by each unit with a standard result, and realizes integral correction by matching the reference component.
7. The method realizes detection of each characteristic relation of the rail by means of 3D detection, and can effectively eliminate error introduction which is difficult to avoid manual operation in the traditional method.
8. The invention can more specifically provide complete spatial 3D geometrical information of the steel rail, and can more comprehensively provide the spatial relationship of the steel rail, and the spatial relationship comprises the following steps: the spatial horizontal vertical relation, the transverse longitudinal inclined relation of the rail, the parallelism relation of the rail and the like correspond to the abrasion of the steel rail, so that the abrasion degree of the steel rail can be detected, and basic data can be provided for the analysis of abrasion factors.
In conclusion, the main body of the device has the advantages of ingenious conception, scientific and reasonable structural design, convenient, rapid and accurate use and measurement, environment-friendly application and wide market prospect.
Description of the drawings:
fig. 1 is a schematic view of the present invention in relation to a rail.
Fig. 2 is a schematic diagram of the main structure of the present invention.
FIG. 3 is a schematic diagram of the main structure of the detecting unit according to the present invention.
FIG. 4 is a schematic diagram of the position relationship of the laser 2D/3D sensor according to the present invention.
FIG. 5 is a schematic view of the principal structure of the running gear according to the present invention.
Fig. 6 is a schematic diagram of the main structure of the locking mechanism according to the present invention.
Fig. 7 is a schematic diagram of the internal structure of the detection unit according to the present invention.
Fig. 8 is a schematic workflow diagram of a method for using the portable modular self-correcting rail three-dimensional detection system according to the present invention.
Fig. 9 is a schematic diagram of the self-calibration principle involved in the present invention.
The specific implementation mode is as follows:
in order to clearly illustrate the technical features of the present solution, the present invention is further described below with reference to the following embodiments.
Example 1
The main structure of the portable modular self-correcting rail three-dimensional detection system comprises two detection units 1 for detection, a mounting bracket 2 for supporting and connecting and a manual operator 3, wherein the main structure of the detection unit 1 comprises a walking mechanism 1.1, a scanning mechanism 1.2, a control unit 1.3, a horizontal detection sensor 1.4, a power supply unit 1.5 and a temperature and humidity sensor 1.6, and the walking mechanism 1.1 is connected with the scanning mechanism 1.2 to realize scanning while advancing; the horizontal detection sensor 1.4 is arranged at the rear side of the scanning mechanism 1.2; the control unit 1.3 is communicated with the walking mechanism 1.1, the scanning mechanism 1.2 and the horizontal detection sensor 1.4 to collect and process the information of the components; the power supply unit 1.5 supplies power to the walking mechanism 1.1, the scanning mechanism 1.2, the control unit 1.3 and the horizontal detection sensor 1.4;
the main structure of the running mechanism 1.1 in the embodiment comprises a power wheel 1.1.1, a bracket 1.1.2, an auxiliary wheel 1.1.3 and an encoder 1.1.4; the power wheel 1.1.1 is a servo wheel, the running distance can be accurately controlled, the encoder 1.1.4 is arranged in the power wheel 1.1.1, the auxiliary wheel 1.1.3 is horizontally arranged on the front side of the power wheel 1.1.1, the bracket 1.1.2 is of a double-frame side mounting plate 1.1.2.1 structure, and the power wheel 1.1.1 and the auxiliary wheel 1.1.3 are positioned at the lower part of the middle of the bracket 1.1.2 and are connected with double supporting plates of the bracket; the power supply 1.7 and the servo controller 1.8 are both arranged in the middle of the frame side mounting plate 1.1.2.1, wherein the servo controller 1.8 is connected with the power wheel 1.1.1 for control;
the main body structure of the scanning mechanism 1.2 comprises three groups of sliding tables 1.2.1 and laser 2D/3D sensors 1.2.2, wherein the three groups of laser 2D/3D sensors 1.2.2 are arranged at the front part of the upper part between the two double-framework side installation plates 1.1.2.1 and are positioned at the upper part of the sliding tables 1.2.1, and the sliding tables 1.2.1 can drive the laser 2D/3D sensors 1.2.2 to move longitudinally so as to adjust the angle of the sensors;
the main structure of the control unit 1.3 comprises an industrial personal computer, a GPS positioning module, a 4G module and a wireless communication module which form an integrated package, and the control unit can be communicated with a computer through the GPS positioning module, the 4G module and the wireless communication module;
the main structure of the mounting bracket 2 comprises a bearing frame 2.1, a locking mechanism 2.2 and a reference rod piece 2.3, wherein the plug-in type bearing frame 2.1 is of a triangular arrangement structure, two ends of the plug-in type bearing frame 2.1 are respectively in plug-in connection with a frame side mounting plate 1.1.2.1, the reference rod piece 2.3 is positioned at the lower side of the bearing frame 2.1 and is connected with a unit bracket 1.1.2 through the locking mechanism 2.2, wherein the main structure of the locking mechanism 2.2 comprises a magnetic concave plate 2.2.1, a top spring 2.2.2 and a base 2.2.3, the magnetic concave plate 2.2.1 is connected with the base 2.2.3 through the top spring 2.2.2.2 to form an integral locking mechanism, the base 2.3 of the locking mechanism is connected with the unit bracket 1.1.2.2, and the base 2.3 is connected with a 1.1.2.1 side plate; the magnetic concave plate 2.2.1 and the top spring 2.2.2 structure can realize quick installation, and meanwhile, the installation accuracy and stability are ensured;
wherein the manual operator is a commercial tablet personal computer, and a related program is arranged in the computer;
furthermore, the main structure of the rack 1.1.2 in this embodiment includes two vertically disposed rack side mounting plates 1.1.2.1, a rack stabilizing link 1.1.2.2 for connecting the two rack side mounting plates 1.1.2.1, and a rack assembling member 1.1.2.3, wherein the rack stabilizing link 1.1.2.2 and the rack assembling member 1.1.2.3 are both located between and connected to the rack side mounting plates 1.1.2.1 on both sides, and three rack assembling members 1.1.2.3 are installed and arranged in a triangular manner, so as to ensure the overall installation accuracy and stability of the system, and realize quick assembly and disassembly; the bracket mounting member 1.1.2.3 cooperates with the mounting bracket 2 to reduce system equipment introduction errors;
further, in the present embodiment, the control unit 1.3 and the power supply unit 1.5 are disposed in the detection unit 1 and close to the upper portion, wherein the control unit 1.3 is located at the front side of the power supply unit 1.5, and the temperature and humidity sensor 1.6 is located at the front side of the control unit 1.3, so as to be free from shielding and interference of other components during measurement;
the specific operation method of the embodiment is performed according to the following steps:
step one, self calibration is carried out
S1, the sliding table 1.2.1, the mobile laser 2D/3D sensor 1.2.2 and the horizontal detection sensor 1.4 are in rigid connection, the mobile laser 2D/3D sensor 1.2.2 calibrates parts, the obtained contour can be compared with a reference contour, and if the contour is matched with the reference contour, the mobile laser 2D/3D sensor 1.2.2 is free of faults;
s2, the calibration components are located on the reference rod piece and are rigidly connected, so that the relative spatial position relationship between the calibration components is fixed, the detection unit 1 can obtain the contour space coordinates of the reference calibration components through detection, calculate the relative spatial attitude position of the detection unit relative to the calibration components, and detect the contour space coordinates of the rail to use the contour space coordinates as a reference object, thereby eliminating and correcting the installation error caused by the rapid installation fit clearance;
s3, mutually verifying the detection result of the level detection sensor 1.4 according to the correction calibration, and correcting the whole system according to the reading of the level detection sensor 1.4;
step two, a specific operation method:
as shown in fig. 9, the reference calibration components are arranged on the left and right sides of the reference rod member, the calibration components are triangular prisms, the straight lines of the prism convex edges are coplanar, the straight lines of the prism convex edges on the left and right sides are parallel, and are parallel to the straight lines of the prism convex edges on the left and right sides on the right; wherein the distance between the line 2 and the line 3 is D, the distance between the calibrated parallel line 1 and the line 4 at the two ends is equal to the distance between the calibrated parallel line 5 and the line 8 at the two ends is D1;
s1, forming a matrix array by scanning coordinates of the left 3D image
S2, acquiring the inclination angle of α 1 around the X axis and the inclination angle of β 1 around the Y axis by the horizontal coordinate sensor according to α 1 and β 1 rotating coordinate systems
S3, dividing A2[ n ] into three area coordinate matrix arrays according to x coordinates
A21 i value A2 n (P2 ≤ x1 n)
A22[ j ] value A2[ n ] (x1[ n ] is not more than P1)
A23[ k ] takes the value A2[ n ] (P1< x1[ n ] < P2)
S4, at A21[ i ]]Step by delta Y, the resolution of delta Y is 2 times of the resolution of Y-axis direction, and search for n delta Y<y1[i]Less than or equal to delta y (n +1) within z21[ i]The point with the maximum value is obtained, and the high points in the plane form a new matrix arrayThe matrix array point is a point through which a straight line 1 where the convex side of the prism passes;
s5, calculating the projection straight line of matrix array B1[ r ] on the plane where z is 0
Obtaining a projection equation of a straight line 1, wherein the projection equation of the straight line is y, b1x + a1, and the projection equation is 0;
s6, determining a projection line y of B1[ r ] on the plane x being 0 as B11z + a11 according to the method of step S5;
s7, obtaining A22[ j ] according to the method of steps S4 and S6]High-point matrix array in planeThe matrix array point is a point through which a straight line 4 where the convex edge of the prism passes; obtaining a projection equation of the matrix array, namely a projection equation of a straight line y ═ b2x + a2 on a plane where z is 0, and a projection equation of a straight line y ═ b22z + a22 on a plane where x is 0, namely a straight line 4;
s8, obtaining A23[ k ] according to the method of step S4 and step S6]High point matrix in planeArray of elementsThe matrix array point is a point through which a straight line 3 where the convex side of the prism passes; obtaining a projection equation of the matrix array, namely a projection equation of a straight line y, b3x + a3, projected on a plane z, 0, and a projection equation of a straight line y, b33z + a33, namely a straight line 3;
s9, if y is not parallel to b1x + a1 and y is not parallel to b2x + a2, the system fails self-checking, if parallel, the system determines the rotation angle γ 1 around the Z-axis
γ1=arccot(b1);
S10, straight line with distance y equal to b1x + a1 and y equal to b2x + a2The projection equation of the straight line 2 in z is 0;
s11, straight line equal to distance y-b 11x + a11 and y-b 22x + a22The projection equation of the straight line 2 in the plane x is 0;
S13, substituting the value of X1 in step S10 into y-b 33z + a33
S14, summarizing the results, the left coordinate system correction parameters have rotation angles of α 1, β 1 and gamma 1 around X Y Z, the translation amounts are X1, Y1 and Z1,
s15, according to the method from step S1 to step S14, the processing of forming a matrix array of the right 3D image scanning coordinates can derive three projection equations, i.e. a projection equation of a straight line 5, where the projection straight line equation on the plane where z is 0 is c1x + D1 and the projection straight line equation on the plane where x is 0 is c11z + D11;
a projection equation of a straight line y, c2x + d2, projected on a plane z, 0, and a projection equation of a straight line y, c22z + d22, namely a straight line 8; c3x + d3 on the plane of 0, c33z + d33 on the plane of 0, that is, the projection equation of line 7; the self-checking is carried out through the parallelism of y-b 11x + a11 and y-b 22x + a22, and if the parallelism is not parallel, the self-checking cannot be carried out through the unit;
by self-checking, the projection straight line on the plane where z is 0 can be deducedProjecting straight lines on a plane where x is 0The right coordinate system correction parameters can be obtained by deducing, wherein the rotation angles around X, Y and Z are α 11, β 11 and gamma 11, and the translation amounts are X11, Y11 and Z11;
If D1 is not equal to e1, it indicates that the deformation of the standard rod or the deformation inclination angle deflection of the mechanical mechanism of the scanning unit, the whole system cannot pass the self-check, and if the D1 is equal to the e1, the offset parallel to the X of the center of the left 3D image coordinate system and the center of the right 3D image coordinate system is deduced to be
If D11 is not equal to e11, it indicates that the deformation of the standard rod or the deformation of the mechanical mechanism of the scanning unit is deflected at the inclined angle, the whole system can not pass the self-check, if the D11 is equal to the e11, the offset parallel to the Z between the center of the left 3D image coordinate system and the center of the right 3D image coordinate system is deduced to be
In conclusion, system self-checking and mutual verification are completed, and the left 3D image self-calibration parameters X Y Z are obtained to have rotation angles of α 1, β 1 and gamma 1, translation amounts X1, Y1 and Z1, the right 3D image self-calibration parameters X Y Z are obtained to have rotation angles of α 11, β 11 and gamma 11, translation amounts X11, Y11 and Z11, and the right 3D image is corrected by the obtained parameters relative to the translation amounts X12 and Z12 of the left 3D image due to the quick installation fit clearance;
step three, detecting the rail profile:
after the self-calibration is finished, the scanning mechanism 1.2 scans the 3D contour of the rail, and the test results of all units are registered according to the calibration results to form an integral detection contour;
s1, track gauge: one side of the rail outline edge is taken as a datum line and vertically extends to the other side of the rail edge, the length is taken as a gauge, multi-point detection is carried out, errors caused by the fact that a measuring tool cannot be vertically measured with the rail by manpower are avoided, the accuracy of multi-point position detection is improved, and the parallelism of two rail detection sections can be verified simultaneously;
s2, rail height: calculating the rail height by taking the multipoint gauge and the rail outline edge in the S1 as reference lines and vertically extending towards the included angle between the rail edge on the other side and the ground level;
s3, track extension included angle: obtaining an included angle between the track extending direction and the ground level;
s4, rail profile: after coordinate correction, the rail profile can be obtained by taking the rail vertical plane as a tangent plane, and meanwhile, the horizontal position relation of the rail relative to the ground can be obtained, so that horizontal information is provided for further analysis of rail abrasion;
s5, others: the contour space 3D information of the two steel rail detection sections and the ground level relation can further extract data according to the needs;
step four, measurement is carried out:
s1, rapidly assembling and detecting the portable modular self-correcting rail three-dimensional detection system related to the embodiment on site, wherein the manual operator 3 is connected with the two detection units 1 in a wireless manner to complete the integral initialization of the equipment;
s2, the left unit detection unit and the right unit detection unit 1 respectively control the sliding table 1.2.1 and the movable laser 2D/3D sensor 1.2.2 to scan the marker of the calibration rod at the front section to obtain a 3D image;
s3, comparing the obtained data with factory calibration reference 3D images on the left side and the right side to judge whether the data are in an error range, mutually verifying the 1.2.2 data of the three laser 2D/3D sensors to deduce which sensor is possible to have a fault, and if the fault is reported, exiting;
s4, further reading the reading of the horizontal detection sensor 1.4 without fault detection, and correcting the three-dimensional space coordinate system of the unit respectively;
s5, comparing the data of the left and right detection units 1 with the data of the calibration rod before delivery, judging whether the calibration rod is deformed, and if the deformation fault alarm exits;
s6, correcting the whole coordinate system according to the calibration rod, establishing a coordinate system based on the ground level through factory calibration information of the horizontal detection sensor 1.4, and starting to integrally scan the 3D image of the railway track;
s7, detecting the current temperature and humidity by a temperature and humidity sensor 1.6;
s8, identifying characteristic information including a rail, a rail top surface and a rail edge, and further calculating characteristic information including a rail gauge, a rail height, a rail extension angle and a rail outline according to temperature and humidity correction;
s9, the detection unit 1 acquires GPS positioning information and walking information of a walking encoder, and the control unit 1.3 uploads the information through a 4G module;
and S10, automatically walking and moving to the next detection point for detection.
Claims (6)
1. A use method of a portable modular self-correcting rail three-dimensional detection system is characterized by comprising the following steps of:
step one, self calibration is carried out
S1, the sliding table, the mobile laser 2D/3D sensor and the horizontal detection sensor are in rigid connection, the laser 2D/3D sensor calibration component is moved, the obtained contour can be compared with a reference contour, and if the contour is matched with the reference contour, the mobile laser 2D/3D sensor is free of faults;
s2, the calibration components are located on the reference rod piece and are rigidly connected, so that the relative spatial position relationship between the calibration components is fixed, the detection unit can obtain the contour space coordinates of the reference calibration components through detection, calculate the relative spatial attitude position of the detection unit relative to the calibration components, and detect the contour space coordinates of the rail to use the contour space coordinates as a reference object, thereby eliminating and correcting the installation error caused by the rapid installation fit clearance;
s3, mutually verifying the detection results of the horizontal detection sensors according to the correction calibration, and correcting the whole system according to the reading of the horizontal detection sensors;
step two, a specific operation method:
the left side and the right side of the reference rod piece are provided with reference calibration components which are triangular prisms, straight lines of convex edges of the prisms are coplanar, the straight lines of the convex edges of the prisms on the left side and the right side are parallel, and the straight lines of the convex edges of the prisms on the left side and the right side are parallel to the straight lines of the convex edges of the prisms on the left side and the right side on the; wherein the distance between the line 2 and the line 3 is D, the distance between the calibrated parallel line 1 and the line 4 at the two ends is equal to the distance between the calibrated parallel line 5 and the line 8 at the two ends is D1;
s1, forming a matrix array by scanning coordinates of the left 3D image
S2, acquiring the inclination angle of α 1 around the X axis and the inclination angle of β 1 around the Y axis by the horizontal coordinate sensor according to α 1 and β 1 rotating coordinate systems
S3, dividing A2[ n ] into three area coordinate matrix arrays according to x coordinates
A21 i value A2 n (P2 ≤ x1 n)
A22[ j ] value A2[ n ] (x1[ n ] is not more than P1)
A23[ k ] value A2[ n ] (P1< x1[ n ] < P2)
S4, at A21[ i ]]Step by delta Y, the resolution of delta Y is 2 times of the resolution of Y-axis direction, and search n delta Y is less than Y1[ i]Less than or equal to delta y (n +1) within z21[ i]The point with the maximum value is obtained, and the high points in the plane form a new matrix arrayThe matrix array point is a point through which a straight line 1 where the convex side of the prism passes;
s5, calculating the projection straight line of matrix array B1[ r ] on the plane where z is 0
Obtaining a projection equation of a straight line 1, wherein the projection equation of the straight line is y, b1x + a1, and the projection equation is 0;
s6, determining a projection line y of B1[ r ] on the plane x being 0 as B11z + a11 according to the method of step S5;
s7, obtaining A22[ j ] according to the method of steps S4 and S6]High-point matrix array in planeThe straight line 4 where the convex edge of the prism of the matrix array point position passes throughA point of (a); obtaining a projection equation of the matrix array, namely a projection equation of a straight line y ═ b2x + a2 on a plane where z is 0, and a projection equation of a straight line y ═ b22z + a22 on a plane where x is 0, namely a straight line 4;
s8, obtaining A23[ k ] according to the method of step S4 and step S6]High-point matrix array in planeThe matrix array point is a point through which a straight line 3 where the convex side of the prism passes; obtaining a projection equation of the matrix array, namely a projection equation of a straight line y, b3x + a3, projected on a plane z, 0, and a projection equation of a straight line y, b33z + a33, namely a straight line 3;
s9, if y is not parallel to b1x + a1 and y is not parallel to b2x + a2, the system fails self-checking, if parallel, the system determines the rotation angle γ 1 around the Z-axis
γ1=arccot(b1);
S10, straight line with distance y equal to b1x + a1 and y equal to b2x + a2The projection equation of the straight line 2 in z is 0;
s11, straight line equal to distance y-b 11x + a11 and y-b 22x + a22The projection equation of the straight line 2 in the plane x is 0;
S13, substituting the value of X1 in step S10 into y ═ b33z + a 33;
s14, summarizing the results, the left coordinate system correction parameters are α 1, β 1 and gamma 1 around XYZ rotation angle, the translation amounts are X1, Y1 and Z1,
s15, according to the method from step S1 to step S14, the processing of forming a matrix array of the right 3D image scanning coordinates can derive three projection equations, i.e. a projection equation of a straight line 5, where the projection straight line equation on the plane where z is 0 is c1x + D1 and the projection straight line equation on the plane where x is 0 is c11z + D11;
a projection equation of a straight line y, c2x + d2, projected on a plane z, 0, and a projection equation of a straight line y, c22z + d22, namely a straight line 8; c3x + d3 on the plane of 0, c33z + d33 on the plane of 0, that is, the projection equation of line 7; the self-checking is carried out through the parallelism of y-b 11x + a11 and y-b 22x + a22, and if the parallelism is not parallel, the self-checking cannot be carried out through the unit;
by self-checking, the projection straight line on the plane where z is 0 can be deducedProjecting straight lines on a plane where x is 0The right coordinate system correction parameters can be obtained by deducing, wherein the rotation angles around XYZ are α 11, β 11 and gamma 11, and the translation amounts are X11, Y11 and Z11;
If D1 is not equal to e1, it indicates that the deformation of the standard rod or the deformation inclination angle deflection of the mechanical mechanism of the scanning unit, the whole system cannot pass the self-check, and if the D1 is equal to the e1, the offset parallel to the X of the center of the left 3D image coordinate system and the center of the right 3D image coordinate system is deduced to be
If D11 is not equal to e11, it indicates that the deformation of the standard rod or the deformation of the mechanical mechanism of the scanning unit is deflected at the inclined angle, the whole system can not pass the self-check, if the D11 is equal to the e11, the offset parallel to the Z between the center of the left 3D image coordinate system and the center of the right 3D image coordinate system is deduced to be
In conclusion, system self-checking and mutual verification are completed, and the left 3D image self-calibration parameters XYZ are obtained to have rotation angles of α 1, β 1 and gamma 1, translation amounts X1, Y1 and Z1, the right 3D image self-calibration parameters XYZ are obtained to have rotation angles of α 11, β 11 and gamma 11, translation amounts X11, Y11 and Z11, and the right 3D image is corrected by the parameters obtained by the translation amounts X12 and Z12 relative to the left 3D image so as to correct the installation error caused by the quick installation fit clearance;
step three, detecting the rail profile:
after the self-calibration is completed, the scanning mechanism scans the 3D contour of the rail, and the test results of all the units are registered according to the calibration results to form an integral detection contour;
s1, track gauge: one side of the rail outline edge is taken as a datum line and vertically extends to the other side of the rail edge, the length is taken as a gauge, multi-point detection is carried out, errors caused by the fact that a measuring tool cannot be vertically measured with the rail by manpower are avoided, the accuracy of multi-point position detection is improved, and the parallelism of two rail detection sections can be verified simultaneously;
s2, rail height: calculating the rail height by taking the multipoint gauge and the rail outline edge in the S1 as reference lines and vertically extending towards the included angle between the rail edge on the other side and the ground level;
s3, track extension included angle: obtaining an included angle between the track extending direction and the ground level;
s4, rail profile: after coordinate correction, the rail profile can be obtained by taking the rail vertical plane as a tangent plane, and meanwhile, the horizontal position relation of the rail relative to the ground can be obtained, so that horizontal information is provided for further analysis of rail abrasion;
s5, others: the contour space 3D information of the two steel rail detection sections and the ground level relation can further extract data according to the needs;
step four, measurement is carried out:
s1, field rapid assembly and detection, the invention relates to a portable modular self-correcting rail three-dimensional detection system, wherein a manual operator 3 is connected with two detection units in a wireless way to complete the integral initialization of the equipment;
s2, the left unit detection unit and the right unit detection unit respectively control the sliding table and the movable laser 2D/3D sensor to scan the marker of the calibration rod, and a 3D image is obtained;
s3, comparing the obtained data with factory calibration reference 3D images on the left side and the right side to judge whether the data are in an error range, mutually verifying the data of the three laser 2D/3D sensors to deduce which sensor is possible to have a fault, and if the fault is reported, exiting;
s4, further reading the reading of the horizontal detection sensor in case of no fault detection, and correcting the three-dimensional space coordinate system of the unit respectively;
s5, comparing the data of the left and right detection units with the data of the calibration rod before delivery, judging whether the calibration rod is deformed, and if the deformation fault alarm exits;
s6, correcting the whole coordinate system according to the calibration rod, establishing a coordinate system taking the ground level as a reference through factory calibration information of the horizontal detection sensor, and starting to integrally scan the 3D image of the railway track;
s7, detecting the current temperature and humidity by a temperature and humidity sensor;
s8, identifying characteristic information including a rail, a rail top surface and a rail edge, and further calculating characteristic information including a rail gauge, a rail height, a rail extension angle and a rail outline according to temperature and humidity correction;
s9, the detection unit acquires GPS positioning information and walking information of a walking encoder, and the control unit uploads the information through the 4G module;
and S10, automatically walking and moving to the next detection point for detection.
2. The use method of the portable modular self-correcting rail three-dimensional detection system according to claim 1, wherein the method is implemented according to the portable modular self-correcting rail three-dimensional detection system, the main structure of the system comprises two detection units for detection, a mounting bracket for supporting and connecting, and a hand operator, wherein the main structure of the detection units comprises a walking mechanism, a scanning mechanism, a control unit, a horizontal detection sensor, a power supply unit, and a temperature and humidity sensor, and the walking mechanism is connected with the scanning mechanism to scan while walking; the horizontal detection sensor is arranged on the scanning mechanism; the control unit is communicated with the walking mechanism, the scanning mechanism and the horizontal detection sensor to collect and process the information of the components; the power supply unit supplies power to the walking mechanism, the scanning mechanism, the control unit and the horizontal detection sensor;
the main structure of the walking mechanism comprises a power wheel, a bracket, an auxiliary wheel and an encoder; the power wheel is a servo wheel, the running distance can be accurately controlled, the encoder is arranged in the power wheel, the auxiliary wheel is horizontally arranged on the front side of the power wheel, the bracket is of a double-frame side-mounted plate structure, and the power wheel and the auxiliary wheel are positioned at the lower middle part of the bracket and are connected with double supporting plates of the bracket; the power supply and the servo controller are both arranged in the middle of the side mounting plate of the framework, wherein the servo controller is connected with the power wheel for control;
the main structure of the scanning mechanism comprises three groups of sliding tables and laser 2D/3D sensors, wherein the three groups of laser 2D/3D sensors are arranged at the front part of the upper part between the two double-framework side mounting plates and are positioned at the upper part of the sliding tables, and the sliding tables can drive the laser 2D/3D sensors to move longitudinally so as to adjust the angles of the sensors;
the main structure of the control unit comprises an industrial personal computer, a GPS positioning module, a 4G module and a wireless communication module which form integrated packaging, and the control unit can be communicated with a computer through the GPS positioning module, the 4G module and the wireless communication module.
3. The use method of the portable modular self-correcting rail three-dimensional detection system according to claim 2, wherein the main structure of the mounting bracket comprises a bearing frame, a locking mechanism and a reference rod member, wherein the plug-in type bearing frame is a triangular arrangement structure, two ends of the plug-in type bearing frame are respectively plug-in connected with the frame side mounting plate, the reference rod member is positioned at the lower side of the bearing frame and is connected with the unit bracket through the locking mechanism, wherein the main structure of the locking mechanism comprises a magnetic concave plate, a top spring and a base, the magnetic concave plate is connected with the base through the top spring to form the integral locking mechanism, the base of the locking mechanism is connected with the unit bracket, and the base is connected with the component side plate; wherein magnetic force concave plate, top spring structure can realize quick installation, guarantees the accuracy and the stability of installation simultaneously.
4. The method of claim 2, wherein the hand-held device is a commercially available tablet computer with associated programming.
5. The use method of the portable modular self-correcting rail three-dimensional detection system according to claim 2, wherein the main structure of the bracket comprises two vertically arranged bracket side mounting plates, a bracket stabilizing link for connecting the two bracket side mounting plates, and a bracket assembling member, wherein the bracket stabilizing link and the bracket assembling member are both arranged between and connected with the two bracket side mounting plates, and the number of the mounting bracket assembling members is three, and the mounting bracket assembling members are arranged in a triangular manner, so as to ensure the mounting precision and stability of the whole system and realize quick assembly and disassembly; the bracket assembly component is matched with the mounting bracket, so that the introduced error of the system equipment is reduced.
6. The use method of the portable modular self-correcting rail three-dimensional detection system according to claims 2-5, wherein the control unit and the power supply unit are arranged in the detection unit and on the upper portion, wherein the control unit is arranged on the front side of the power supply unit, and wherein the temperature and humidity sensor is arranged on the front side of the control unit so as not to be shielded and interfered by other components during measurement.
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