CN112880586B - Dynamic detection method and system for rail profile - Google Patents
Dynamic detection method and system for rail profile Download PDFInfo
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- CN112880586B CN112880586B CN202110024179.4A CN202110024179A CN112880586B CN 112880586 B CN112880586 B CN 112880586B CN 202110024179 A CN202110024179 A CN 202110024179A CN 112880586 B CN112880586 B CN 112880586B
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- 238000001514 detection method Methods 0.000 title claims abstract description 92
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 90
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- 238000012545 processing Methods 0.000 claims abstract description 38
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- 238000003384 imaging method Methods 0.000 claims description 19
- 230000005540 biological transmission Effects 0.000 claims description 12
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- 238000007599 discharging Methods 0.000 claims description 8
- 230000007547 defect Effects 0.000 claims description 5
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- 230000007723 transport mechanism Effects 0.000 claims description 3
- 230000003068 static effect Effects 0.000 claims 1
- 230000033001 locomotion Effects 0.000 description 5
- 238000003466 welding Methods 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
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Abstract
The invention belongs to the technical field of steel detection equipment, and discloses a steel rail profile dynamic detection method.A picture acquisition unit acquires information of the end part of a steel rail to generate end part data; the image acquisition unit acquires information of the body part between two ends of the steel rail to generate body part data; transmitting the end data and the body data to a data processing unit, wherein the data processing unit analyzes and calculates the end data and the body data to obtain actual data; the data processing unit is provided with standard data of steel, and compares the actual data with the standard data to obtain result data. The invention overcomes the result contingency brought by the prior manual detection; and moreover, the detection is prevented from being easily influenced by external jitter, and the detection precision is ensured. The invention also discloses a rail profile dynamic detection system.
Description
Technical Field
The invention belongs to the technical field of steel detection equipment, and particularly relates to a method and a system for dynamically detecting a steel rail profile.
Background
With the continuous development of high-speed and heavy-duty railways, seamless lines are widely accepted due to their high stability and reliability. The rail welding technology, one of the key technologies of the seamless line, has an important influence on the development of the seamless line.
The pre-welding inspection of the steel rail is a necessary premise for welding the steel rail, and comprises the inspection of the steel rail pattern size, the steel rail end flatness, the distortion and the end face inclination of the front end and the rear end of the steel rail and the surface quality of the full-length steel rail. At present, the detection of the external dimensions of the steel rail on the welding production line of each welding rail base in China mainly depends on the detection of key parameters by manually adopting some portable detection instruments, and the detection of the surface mainly depends on human eyes to finish the detection. The operation mode is easy to be influenced by human, the detection result has certain contingency, meanwhile, the detection result is input into the system manually by virtue of the portable instrument, and the detection efficiency is low.
At present, a rail high-precision measuring instrument developed abroad is mainly used for cold treatment and/or detection after heat treatment in the rail production process, integrates a high-precision 2D camera and a high-precision 3D camera, is high in price and is not suitable for rail type in China; in order to adapt to national conditions, china develops a steel rail online detection prototype based on a linear structure optical sensor or a point laser sensor, the prototype has strict requirements on the vibration of the steel rail, the detection accuracy cannot be ensured, and meanwhile, the inclination of the end face cannot be effectively detected.
Disclosure of Invention
In order to solve the problems, the invention discloses a dynamic detection method for the profile of a steel rail, which overcomes the accident of the result caused by the current manual detection; compared with the detection of a prototype, the method avoids the detection being easily influenced by external jitter, and ensures the detection precision. The invention also discloses a detection system using the method, so that the rail profile dynamic detection method can realize detection more conveniently. The specific technical scheme of the invention is as follows:
the rail profile dynamic detection method comprises the following steps:
feeding the steel rail to be detected into a detection area of a detection system;
the image acquisition unit acquires information of the end part of the steel rail to be detected and generates end part data;
the image acquisition unit acquires information of the body part between two ends of the steel rail to be detected, and generates body part data;
transmitting the end data and the body data to a data processing unit, wherein the data processing unit analyzes and calculates the end data and the body data to obtain actual data;
the data processing unit is provided with standard data of steel, and compares the actual data with the standard data to obtain result data.
Preferably, the end data includes header data; the step of acquiring the header data includes:
the image acquisition unit acquires data to obtain header data.
Preferably, the step of acquiring the body data includes:
the data processing unit obtains header data;
the image acquisition unit acquires data again to obtain body data.
Preferably, the end data further includes tail data; the step of acquiring the tail data comprises the following steps:
the data processing unit obtains body data;
and finally, the image acquisition unit acquires data to obtain tail data.
A rail profile dynamic detection system comprising:
the conveying mechanism is used for conveying the steel rail to be tested;
the first scanning mechanism is fixedly arranged and used for panoramic scanning;
the row frame is provided with a second scanning mechanism which moves along the length direction of the steel rail to be tested and is used for linear scanning; and
the data processing equipment is electrically connected with the first scanning mechanism and the second scanning mechanism respectively.
The invention realizes the image scanning of the steel to be detected through the first scanning mechanism and the second scanning mechanism, and the detection system performs segmented data acquisition according to actual conditions at different stages through the transmission mechanism, thereby meeting the detection requirement.
Preferably, the first scanning mechanism includes:
a fixedly arranged housing; and
and the 3D imaging equipment is provided with 4 pieces of 3D imaging equipment which are respectively positioned at four corners of the housing.
In the invention, 3D imaging equipment can realize the determination of the depth of the surface defect of the steel rail to be detected; the housing has certain strength and protection capability, and can provide safety protection and dust prevention for the imaging equipment.
Preferably, the transmission mechanism includes:
a fixedly arranged frame body;
the carrier roller is used for conveying the steel rail to be tested;
the guide mechanism is used for righting the deviated steel rail to be tested; and
the calibration plate moves up and down in the height direction of the frame body and is used for moving the calibration plate to the view field range of the image acquisition unit.
In the invention, the guide mechanism can effectively correct the deviation phenomenon after the rail to be detected moves and deviates; the calibration plate can enable the steel rail to be tested to obtain an accurate position when the image scanning is carried out, so that the auxiliary image acquisition of the steel rail to be tested is realized.
Preferably, the calibration plate is provided with a locking mechanism, and the locking mechanism locks the calibration plate after downward movement with the frame body.
The locking mechanism can enable the calibration plate and the steel rail to be tested to be stably connected, so that the steel rail to be tested is guaranteed to have more accurate position precision in calibration.
Preferably, two ends of the transmission mechanism are respectively provided with a feeding encoder and a discharging encoder; the feeding encoder and the discharging encoder are respectively and electrically connected with the data processing equipment.
According to the invention, the absolute positioning of the steel rail to be detected is realized through the feeding encoder and the discharging encoder, so that the position of the steel rail to be detected is determined by matching with the calibration plate.
Preferably, the device also comprises a safety protection device; the safety shield apparatus includes at least one set of safety light curtains; the safety protection device is electrically connected with the data processing equipment.
In the invention, when the detection system performs normal detection work, whether staff or other foreign matters invade is sensed through the safety light curtain, and under the condition, the emergency stop of the detection system is realized, thereby ensuring the detection safety, stability and accuracy of detection.
Compared with the prior art, the detection method disclosed by the invention can overcome the accidental and uncertainty caused by measuring the torsion resistance and the geometric dimension error of the steel rail to be detected in the current manual detection; meanwhile, the flatness, the end face inclination and the surface defect detection accuracy of the steel rail to be detected can be guaranteed through the first scanning mechanism and the second scanning mechanism, and on the basis, a large amount of errors are eliminated, so that the accuracy is guaranteed. The invention also discloses a detection system based on the method, through the detection system, the detection of the steel rail to be detected can be more convenient, and the detection system has good position positioning precision, so that the detection error is further eliminated.
Drawings
FIG. 1 is a schematic diagram of an embodiment of the present invention;
FIG. 2 is a schematic diagram of a first scanning mechanism according to an embodiment of the invention;
FIG. 3 is a schematic diagram of a transmission mechanism according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of the principle of chord measurement in an embodiment of the invention;
FIG. 5 is a schematic view of a co-planar approach to point in an embodiment of the present invention;
FIG. 6 is a schematic illustration of the principle of the coplanar method in the embodiment of the present invention.
In the figure: 100-a transmission mechanism; 101-a frame body; 102-carrier rollers; 103-calibrating a plate; 104-a guide plate; 105-guide rollers; 106-a fork shearing mechanism; 107-an electromagnet; 108-a feed encoder; 109-discharge encoder; 200-a first scanning mechanism; 201-a housing; 202-3D imaging devices; 300-row rack; 400-a data processing device; 500-a second scanning mechanism; 600-safety shield apparatus.
Detailed Description
In order to make the technical scheme of the present invention better understood by those skilled in the art, the present invention will be further described in detail with reference to the following specific embodiments.
As shown in fig. 1 to 3, the present embodiment provides a rail profile shape detection system including a conveying mechanism 100, a first scanning mechanism 200, a row rack 300, and a data processing apparatus 400; the conveying mechanism 100 is used for conveying the steel rail to be tested; the first scanning mechanism 200 is used for panoramic scanning; the row frame 300 is provided with a second scanning mechanism 500 which moves along the length direction thereof and is used for linear scanning; the data processing apparatus 400 is electrically connected to the first scanning mechanism 200 and the second scanning mechanism 500, respectively.
In this embodiment, the row frame 300 has four columns, and the main body portion of the column is supported by the columns, so that the four columns are located at positions to provide a detection area, and the conveying mechanism 100 for conveying the steel rail to be detected in the detection area is disposed in the detection area; the first scanning mechanism 200 is disposed at one end of the transmission mechanism 100; the second scanning mechanism 500 is movable in the length direction of the row frame 300 to realize rapid movement and positioning to different detection points; the data processing device 400 is a computer, and performs corresponding data operation and display through the computer.
For better use of the present embodiment, the first scanning mechanism 200 includes a housing 201 and a 3D imaging device 202 that are fixedly disposed; the 3D imaging device 202 is connected to the housing 201.
In the present embodiment, the cover 201 is disposed at one end of the transmission mechanism 100, for disposing the 3D imaging device 202; note that, in the present embodiment, the 3D imaging device 202 has four pieces, which are located at four corners of the housing, respectively; further, the 3D imaging device 202 is a three-dimensional camera based on laser triangulation techniques. The second scanning mechanism 500 is also capable of three-dimensional measurement, but the means for performing image scanning is a scanner based on binocular vision technology.
In this embodiment, the scanner is moved quickly by a five-axis robot, which is slidingly coupled to the gantry 300 robot. Specifically, the five-axis robot is configured to meet the requirements of the working posture of the scanner by three linear movement axes X, Y, Z and two rotation axes A, B.
For better use of the present embodiment, the transmission mechanism 100 includes a frame 101, a carrier roller 102, a guiding mechanism, and a calibration plate 103 that are fixedly disposed; the carrier roller 102 is used for transporting the steel rail to be tested; the guide mechanism is used for righting the deviated steel rail to be tested; the calibration plate 103 moves up and down in the height direction of the frame 101 and is used for lifting the steel rail to be tested in positioning scanning.
In this embodiment, the steel to be measured is moved in the detection area by the rotation of the carrier roller 102; before the steel to be measured enters the detection area and before the steel to be measured is pushed out of the detection area, the guide mechanism is used for realizing motion correction; wherein the guiding mechanism comprises a set of guiding plates 104 and a set of guiding rollers 105.
In this embodiment, the frame 101 is provided with a fork mechanism 106, and the fork mechanism 106 is opened and closed by an electric push rod, so that the calibration plate 103 is connected with the fork mechanism 106, and when the fork mechanism 106 is opened, the calibration plate 103 descends; when the shearing fork mechanism 106 is closed, the calibration plate 103 rises, so that the steel to be measured is better positioned.
For better use of the present embodiment, the calibration plate 103 is provided with an electromagnet 107; after the electromagnet 107 is electrified, the calibration plate 103 and the frame 101 are attracted.
In the present embodiment, when the calibration plate 103 descends, the electromagnet 107 is energized, thereby attracting the calibration plate 103 to the frame 101; when the calibration plate 103 is lifted, the electromagnet 107 is deenergized, so that the calibration plate 103 is well separated from the frame 101. The specific number of calibration plates 103 provided is dependent on the specific length of the transport mechanism 100, and in general, each calibration plate 103 has two electromagnets.
In some embodiments, the electromagnet 107 is capable of telescoping on the calibration plate 103, thereby providing the electromagnet 107 with a latch function.
For better use of the present embodiment, two ends of the conveying mechanism 100 are respectively provided with a feeding encoder 108 and a discharging encoder 109; the feed encoder 108 and the discharge encoder 109 are electrically connected to the data processing apparatus 400, respectively.
The feeding encoder 108 and the discharging encoder 109 can timely acquire the motion information of the steel to be measured by the data processing device 400, so as to judge the stop and the continuous advancing of the steel to be measured in the corresponding stages. In this embodiment, the feeding encoder 108 and the discharging encoder 109 are both photoelectric encoders.
For better use of the present embodiment, safety shield apparatus 600 is also included; the safety shield apparatus 600 includes at least one set of safety light curtains; the safety device 600 is electrically connected to the data processing apparatus 400.
In this embodiment, the number of the safety devices 600 is two; the safety light curtain is arranged on the side face of the upright post. In this embodiment, the safety light curtain is a correlation safety light curtain.
On the basis of the embodiment, the rail profile detection is performed by using a rail profile dynamic detection method, which comprises the following steps:
feeding the steel rail to be detected into a detection area of a detection system;
the image acquisition unit acquires information of the end part of the steel rail to be detected and generates end part data;
the image acquisition unit acquires information of the body part between two ends of the steel rail to be detected, and generates body part data;
transmitting the end data and the body data to a data processing unit, wherein the data processing unit analyzes and calculates the end data and the body data to obtain actual data;
the data processing unit is provided with standard data of steel, and compares the actual data with the standard data to obtain result data.
The end data and the body data are obtained by sectional data, and the end data comprise head data and tail data. Specifically, the data processing unit sequentially acquires the head data, the body data and the tail data, so that the rail profile form detection method comprises the following steps:
s101, conveying a rail to be detected into a detection area of a detection system;
s201, stopping the steel rail to be tested from advancing after the rail head of the steel rail to be tested enters a first distance of a detection area;
s202, an image acquisition unit acquires data to obtain header data;
s301, the data processing unit obtains header data;
s302, the steel rail to be tested continues to move forward for a second distance in the detection area, and the steel rail to be tested stops moving forward;
s303, the image acquisition unit acquires data to obtain body data;
s401, a data processing unit obtains body data;
s402, the steel rail to be tested continues to move forward in the detection area;
s403, when the tail distance of the steel rail to be tested exits the detection area by a third distance, the steel rail to be tested stops moving forwards;
s404, the image acquisition unit acquires data to obtain tail data;
s501, the data processing unit is provided with standard data of steel materials, and compares the actual data with the standard data to obtain result data.
S601, the data processing unit exports result data for visual judgment of staff.
In particular, when the detection system is used, the length of the steel to be detected is 100 meters. A worker opens the detection system and inputs the number and the adaptation speed of the steel rail to be detected; when the steel rail to be detected enters the detection area, the rail head moves into the detection area by 3 meters, the transmission mechanism 100 stops, the scanner scans the whole surface of the steel rail to be detected, and meanwhile, the 3D imaging equipment 202 also scans synchronously; after the scanning is finished, the steel rail to be detected continuously moves along the length direction of the steel rail to be detected at a certain speed, at this time, the 3D imaging equipment 202 stops working, the scanner acquires the profile of the steel rail in real time, and the surface quality of the steel rail to be detected is judged in real time; when the rail to be detected moves to 3 meters from the tail rail end, the transmission mechanism 100 stops, and the detection method is the same as that of 3 meters of rail head detection; in the detection process, the data processing device 400 processes data in real time, alarms and prompts the overrun data, and after the detection of the whole steel rail to be detected is completed, a report can be generated and printing is provided.
As can be seen from this, in the present embodiment, the header data is data acquired by the scanner and data acquired by the 3D imaging device 202; the body data is data of the 3D imaging device 202; the tail data is data acquired by the scanner and data acquired by the 3D imaging device 202. After the data processing apparatus 400 acquires the above data in sections, transport processes are performed, including rail size detection, flatness detection, twist detection, end face inclination detection, and surface defect detection, respectively.
The size of the rail to be measured detects the complete rail profile data acquired by the scanner. Firstly, the acquired rail profile and the standard rail profile are overlapped through the translational gravity center, on the translated rail profile, the coordinate position of a detection point is searched, if the rail height is the height difference between the horizontal center of the rail head and the horizontal center of the rail bottom, the height difference is recorded as a measured value, the measured value of the position corresponding to the standard rail profile is standard data, the measured value is compared with the standard data, and if the required deviation is exceeded, alarm processing is carried out.
As shown in FIG. 4, flatness detection is performed by chord measurement, and is described by taking the measurement range of 3 meters in the head as an example.
Selecting two endpoints from the header data, P 1 And P 2 Straight line P 1 P 2 Perpendicular to the end face of the rail to be measured, straight line P 1 P 2 Called a reference line;
selecting a straight line P 1 P 2 A plurality of points M at equal intervals 1 、M 2 、……、M n Calculating depth information corresponding to the points, recording distances from the points to the datum line as deviation values of flatness, wherein positive numbers are positive deviations, and negative numbers are negative deviations;
obtaining the maximum value of flatness deviation for all deviation values, M in the figure n The deviation value at the point reaches the maximum, namely M n Is the flatness required.
As shown in fig. 5, the distortion detection adopts a coplanar method. The example is as follows, two calculation points P are taken from the lower surface of the steel rail to be measured 3 、P 4 Taking two calculation points P on the lower surface of the section rail bottom 1 m from the end 5 、P 6 Let the distance between the point and the rail bottom edge be 10mm, calculate P 6 To P 3 、P 4 And P 5 Distance of formed face, then go throughAnd comparing the distance value with the standard data, and if the deviation exceeds the required deviation, carrying out alarm processing.
The end face inclination detection adopts a mode of calculating a plane included angle to acquire parameters. The example is as follows, when detecting the end face inclination of the end face of the rail to be measured, the coordinates N of 3 points on each face of the rail to be measured are obtained 1 (X 1 ，Y 1 ，Z 1 )、N 2 (X 2 ，Y 2 ，Z 2 )、N 3 (X 3 ，Y 3 ，Z 3 ) The plane equation of the steel rail is constructed by the following steps:
end face: a is that 1 ·X+B 1 ·Y+C 1 ·Z＝0；
And (2) bottom surface: a is that 2 ·X+B 2 ·Y+C 2 ·Z＝0；
Side face: a is that 3 ·X+B 3 ·Y+C 3 …Z＝0；
A is obtained by the three equations 1 、A 2 、B 1 、B 2 、C 1 、C 2 ；
Thereby obtaining the cosine value of the included angle between the surfaces:
end face-bottom face:
end-side:
the end face inclination is obtained, inclination comparison is then carried out with standard data, and if the deviation exceeds the required deviation, alarm processing is carried out.
The surface defect detection is carried out by adopting a depth value comparison mode. An example is as follows, taking the coordinates (D 2 ，E 2 ，F 2 ) Wherein D is 2 And E is 2 At the section of the rail to be measured, F 2 In the transport direction of the transport mechanism 100;
at this time, the combined shape of the four 3D imaging devices 202 is a complete rail section;
in the detection process, the center of the steel rail to be detected shakes up and down integrally near the center of the steel rail to be detected; let t be 0 At the moment, the center point of the rail to be detected is scanned as (D t ，E t ) The stationary state assumes that the center point of the section of the standard rail is (D 0 ，E 0 ) Then t 0 The moment translation vector is:
and then the section of the steel rail to be detected acquired by the 3D imaging equipment 202 is measured according to vectorsTranslating integrally;
after translation, calculating the difference Deltal between the target points on the scanning rail surface and the vertical direction of the standard data one by one;
assuming that the crack depth standard data is L, when Deltal > L, it is judged that the crack is here.
The foregoing is merely a preferred embodiment of the present invention, and it should be noted that the above-mentioned preferred embodiment should not be construed as limiting the invention, and the scope of the invention should be defined by the appended claims. It will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the spirit and scope of the invention, and such modifications and adaptations are intended to be comprehended within the scope of the invention.
Claims (5)
1. The rail profile dynamic detection method is characterized by comprising the following steps of:
the image acquisition unit acquires information of the end part of the steel rail to be detected and generates end part data;
the image acquisition unit acquires information of the body part between two ends of the steel rail to be detected, and generates body part data;
transmitting the end data and the body data to a data processing unit, wherein the data processing unit analyzes and calculates the end data and the body data to obtain actual data;
the data processing unit is provided with standard data of steel, and compares the actual data with the standard data to obtain result data;
the data processing unit sequentially acquires head data, body data and tail data;
acquiring end data by a first scanning mechanism which is fixedly arranged and a second scanning mechanism which is moved along the length direction of the steel rail to be tested, and acquiring body data by the second scanning mechanism;
the result data includes surface defect detection comprising the steps of:
taking coordinates (D2, E2 and F2) of section points of the steel rail to be detected, wherein D2 and E2 are positioned on the section of the steel rail to be detected, and F2 is positioned in the transmission direction of the transmission mechanism;
at this time, the combined shape of the four first scanning mechanisms is a complete steel rail section;
the conveying mechanism comprises a frame body and a calibration plate which are fixedly arranged, the calibration plate moves up and down in the height direction of the frame body and is used for lifting a steel rail to be tested for positioning scanning, the calibration plate is provided with an electromagnet, and the calibration plate and the frame body are attracted after the electromagnet is electrified;
in the detection process, the center of the steel rail to be detected shakes up and down integrally near the center of the steel rail to be detected; assuming that the center point of the steel rail to be detected is (Dt, et) at the time t0, and assuming that the center point of the section of the standard steel rail is (D0, E0) in the static state, the translation vector at the time t0 is:
then translating the section of the steel rail to be tested acquired by the first scanning mechanism integrally according to vectors;
after translation, calculating the difference Deltal between the target points on the scanning rail surface and the vertical direction of the standard data one by one;
assuming that the crack depth standard data is L, when Deltal > L, it is judged that the crack is here.
2. A rail profile dynamic detection system, characterized in that it comprises, based on the rail profile dynamic detection method according to claim 1:
the conveying mechanism is used for conveying the steel rail to be tested;
the first scanning mechanism is fixedly arranged and used for panoramic scanning;
the row frame is provided with a second scanning mechanism which moves along the length direction of the steel rail to be tested and is used for linear scanning; and
the data processing equipment is electrically connected with the first scanning mechanism and the second scanning mechanism respectively;
the first scanning mechanism includes:
a fixedly arranged housing; and
and the 3D imaging equipment is provided with 4 pieces of 3D imaging equipment which are respectively positioned at four corners of the housing.
3. The rail profile dynamic detection system of claim 2, wherein the transport mechanism further comprises:
the carrier roller is used for conveying the steel rail to be tested; and
and the guide mechanism is used for righting the deviated steel rail to be tested.
4. The dynamic rail profile detecting system as claimed in claim 2, wherein both ends of the conveying mechanism are respectively provided with a feeding encoder and a discharging encoder; the feeding encoder and the discharging encoder are respectively and electrically connected with the data processing equipment.
5. The rail profile dynamic detection system of claim 2, further comprising a safety guard; the safety shield apparatus includes at least one set of safety light curtains; the safety protection device is electrically connected with the data processing equipment.
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