CN113534740B - Detection data analysis and repair method for rim tread of train wheel - Google Patents
Detection data analysis and repair method for rim tread of train wheel Download PDFInfo
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Abstract
The invention belongs to the technical field of numerical control machine tools without wheel dropping, and relates to a method for analyzing and repairing detection data of a rim tread of a train wheel, which comprises the following steps: drawing a standard mould data model and a worn wheel rim tread data model; the horizontal coordinates of the starting points of the two models are the same; translating the standard mould data model, and stopping moving when the absolute value of the difference value of the vertical coordinates of the two models is smaller than the minimum removal value in the range from the peak point of the rim tread data model to the end point of the model by the horizontal coordinate; calculating the sum of the difference values of the longitudinal coordinates of the two models; taking a processing program of the standard die when the difference value of the longitudinal coordinates is accumulated and the sum is minimum as a repairing program; taking a point which is increased by 70mm on the abscissa of the initial position of the standard die data model as the processing end point of the repairing program; a point which is increased by 70mm on the abscissa of the initial position of the wheel rim tread data model is taken as a tool setting point; and calling a repairing program, and inputting the coordinates of the tool setting point and the coordinates of the machining end point of the repairing program into the numerical control machine system without dropping the wheel, so as to realize intelligent automatic machining.
Description
Technical Field
The invention belongs to the technical field of numerical control machine tools without wheel dropping, and relates to a method for analyzing and repairing detection data of a rim tread of a train wheel.
Background
In recent years, due to rapid development of rail transit in China, the requirement for correcting abrasion of wheels of railway locomotives increasingly becomes an attention point of research in the field of metal processing. The wheels of the railway locomotive are rolling mechanisms for supporting a locomotive body to run on a track, and the wheels need to have high wear resistance and running stability. In the contact operation process of the wheels and the rails, under the influence of conditions such as operation mileage, road conditions, vehicle speed and the like, different wear conditions can occur on the wheel rim treads of different wheels, and in order to ensure the operation stability of the locomotive, the shape of the wheel rim treads needs to be regularly corrected according to the national relevant standards so as to ensure that the wheel rim treads have larger shape matching degree with the rail contact surfaces. To ensure that the profile can be corrected, the rim tread is typically left with some margin at the beginning of the design for wear correction. The correction is carried out within a certain margin.
In the conventional correction means, the wear state is manually measured, and after a simple judgment, correction processing is performed using a fixed program. As a result, a large error of manual measurement is often introduced, it is difficult to ensure the pertinence of correction processing and the consistency of batch correction, and the resulting transitional correction and uncertainty of correction also affect the service life of the wheel. In order to improve the correction effect and prolong the service life of the wheel, sampling data of the rim tread of the worn wheel needs to be obtained by a digital detection means, an intelligent data analysis algorithm is adopted to realize data processing, analysis, calculation and optimization, and finally an analysis result is output to guide a numerical control system to output a control instruction by using an optimal program so as to finish the wear correction processing of the rim tread of the locomotive wheel. In the process, the processing, analysis, operation and optimization of the detection data become the technical core of the whole wear correction, and the research on the core analysis algorithm of the detection data is a key for realizing the independent research and development of the core technology in the field. The automatic detection of the abrasion of the wheel rim tread profile of the railway rolling stock selects an optimal correction scheme, autonomously selects a correction program to finish the correction, and has become the requirement of the industry.
Disclosure of Invention
The invention aims to provide a method for analyzing and repairing detection data of a rim tread of a train wheel, which can realize intelligent data analysis aiming at target data acquired by a machine tool and a numerical control system thereof, and realize screening of a rim tread modification program and determination of key points, so that a wheel-dropping-free machine tool can autonomously finish intelligent repair machining of the rim tread.
The invention provides a method for analyzing and repairing detection data of a rim tread of a train wheel, which comprises the following steps:
step 1: selecting a standard die from the alternative die library, and drawing a standard die data model according to a plurality of contour two-dimensional coordinate data of the standard die;
step 2: acquiring a plurality of two-dimensional coordinate data of a worn rim tread contour line through a machine tool detection system, and drawing a rim tread data model according to the plurality of two-dimensional coordinate data of the contour line;
and step 3: translating the standard mould data model and the rim tread data model, and adjusting the initial positions of the two data models to ensure that the starting point horizontal coordinates of the two data models are the same;
and 4, step 4: the standard mould data model is translated upwards, and when the absolute value of the difference value of the vertical coordinates of the two data models is smaller than the minimum removal value in the range from the peak point of the rim tread data model to the corresponding end point of the right side of the model, the standard mould data model stops moving;
and 5: calculating the accumulated sum of the vertical coordinate difference values of the two data models when the horizontal coordinate of the standard mould data model is within the interval range of the step 4, wherein the smaller the accumulated sum is, the smaller the fitting loss is under the condition that the minimum removal value is not changed;
step 6: repeating the steps 1-5, and taking a machining program of the standard die adopted when the sum of the calculated vertical coordinate difference values is minimum as a repairing program;
and 7: taking a point which is increased by 70mm on the abscissa of the initial position of the standard die data model as the processing end point of the repairing program; taking a point which is obtained by adding 70mm to the abscissa of the initial position of the rim tread data model as a tool setting point;
and 8: and calling a repairing program, and inputting the coordinates of the tool setting point and the coordinates of the machining end point of the repairing program into the numerical control machine system without dropping the wheel, so as to realize intelligent automatic machining.
In the method for analyzing and repairing the detection data of the rim tread of the train wheel, the step 2 comprises the following steps:
step 2.1: collecting a plurality of two-dimensional coordinate data of the wear rim tread contour line, and ensuring that the ordinate of the initial position is greater than that of the initial position of the standard mould data model during collection;
step 2.2: a plurality of two-dimensional coordinate data of the contour line form a discrete data set;
step 2.3: and drawing a point line graph in a two-dimensional coordinate system according to the sequence of horizontal coordinates from small to large from two-dimensional coordinate data in the discrete data set to serve as a wheel rim tread data model.
In the method for analyzing and repairing the detection data of the wheel rim tread of the train wheel, 10000 pieces of two-dimensional coordinate data of a wear wheel rim tread contour line are collected by a machine tool detection system in the step 2, and the abscissa range of a sampling region under a machine tool coordinate system is [630,800 ].
In the method for analyzing and repairing the detection data of the rim tread of the train wheel, the step 7 specifically comprises the following steps:
step 7.1: when a point with the abscissa of the initial position of the standard die data model increased by 70mm is positioned in the standard die data model, taking the point as the processing end point of the correction program;
step 7.2: when a point with the abscissa of the initial position of the rim tread surface data model increased by 70mm is positioned in the worn rim tread surface data model, taking the point as a tool setting point;
step 7.3: and if the step 7.1 and/or the step 7.2 are not met, determining the coordinates of the end point of the processing of the correction program and/or the coordinates of the tool setting point by using a spatial interpolation method.
In the method for analyzing and repairing the detection data of the wheel rim tread of the train wheel, the vertical coordinate of the end point processed by the correction program is determined by using a spatial interpolation method, and specifically comprises the following steps:
(1) finding a point which is 70mm added to the abscissa of the initial position of the standard die data model, and taking a first vertical line which passes through the point and is vertical to the abscissa axis;
(2) searching two sampling points at two sides of the first vertical line and closest to the vertical distance of the first vertical line;
(3) and connecting the two sampling points, wherein the intersection point of the connecting line and the first vertical line is the processing end point of the correction program.
In the method for analyzing and repairing the detection data of the rim tread of the train wheel, the vertical coordinate of the tool setting point is determined by using a spatial interpolation method, and the method specifically comprises the following steps:
(1) finding a point which is 70mm greater than the abscissa of the initial position of the worn rim tread surface data model, and taking a second vertical line which passes through the point and is vertical to the abscissa axis;
(2) searching two sampling points at two sides of the second vertical line and closest to the vertical distance of the second vertical line;
(3) and connecting the two sampling points, wherein the intersection point of the connecting line and the second vertical line is the tool setting point.
The invention discloses a method for analyzing and repairing detection data of a rim tread of a train wheel, which is used for analyzing the detection data of a non-wheel-falling numerical control machine tool for processing the appearance of the rim tread of the train wheel. The purpose is to enable the special numerical control machine tool to realize intelligent data analysis and repair program screening and key point determination aiming at target data acquired by the machine tool and a numerical control system thereof in actual processing. Therefore, the wheel-falling-free machine tool can automatically finish the intelligent repair and processing of the wheel rim tread.
Compared with the prior art, 10000-point data acquisition is carried out, the detail resolution precision of the outline is higher, the recognition effect of local abrasion loss is improved, and the accuracy of the whole algorithm is improved. According to the same-plane and same-reference translation comparison designed according to the characteristics of the model, the recognition efficiency and accuracy are improved. The determined optimal feed path and program tool setting point realize autonomous intelligent identification and program calling, and are particularly suitable for autonomous intelligent processing.
Compared with the common method for establishing a function formula based on the contour dimension of the tread profile of the standard wheel rim, the method provided by the invention better conforms to the characteristics of actual data acquisition and analysis, can better embody the characteristics of modern detection technology, and is more favorable for the intelligent development requirement of machine tool equipment under the background of the information era. The method is not limited by the fact that the worn standard rim tread is irregular in appearance and cannot be fitted by a body function, has strong robustness and good generalization characteristics, is based on actual data, is applied to actual direct algorithm research, and has wide practical application value.
Drawings
FIG. 1A is a front view of a railway wheel;
FIG. 1B is a cross-sectional view A-A of FIG. 1;
FIG. 2 is a diagram of a standard mold data model and a rim tread data model of the present invention;
FIG. 3 is a schematic representation of two models translated to the same abscissa;
FIG. 4 is a schematic diagram of calculating the cumulative sum of vertical coordinate differences for a standard mold data model and a rim tread data model;
FIG. 5 is an enlarged view of a standard mold data model and a rim tread data model.
Detailed Description
The invention discloses a method for analyzing and repairing detection data of a rim tread of a train wheel, which mainly comprises the following links of data acquisition, model establishment, model comparison and result output, and specifically comprises the following steps:
step 1: and selecting a standard die from the alternative die library, and drawing a standard die data model according to a plurality of contour two-dimensional coordinate data of the standard die.
Step 2: acquiring a plurality of two-dimensional coordinate data of a worn rim tread contour line through a machine tool detection system, drawing a rim tread data model according to the plurality of two-dimensional coordinate data of the contour line, wherein the step 2 comprises the following steps of:
step 2.1: collecting a plurality of two-dimensional coordinate data of the wear rim tread contour line, and ensuring that the ordinate of the initial position is greater than that of the initial position of the standard mould data model during collection;
step 2.2: a plurality of two-dimensional coordinate data of the contour line form a discrete data set;
step 2.3: and drawing a point line graph in a two-dimensional coordinate system according to the sequence of horizontal coordinates from small to large from two-dimensional coordinate data in the discrete data set to serve as a wheel rim tread data model.
In specific implementation, as shown in fig. 1A and 1B, as shown in fig. 1A, a front view of a train wheel is shown, a wheel rim tread is a part which is in contact with a rail when the train wheel runs, as shown in fig. 1B, the wheel is cut along the diameter direction of the wheel, it can be seen that the wheel rim tread is composed of a plurality of contour lines, and as the wheel rim tread of the train runs for a long distance, the wheel rim tread is uniformly worn, the invention is researched for one contour line S. Based on the data acquisition function of a detection mechanism and a numerical control system of a numerical control machine tool without wheel drop, a machine tool detection system is used for acquiring two-dimensional coordinate data of discrete points of a worn wheel rim tread contour line of a railway rolling stock, the number of sampling points is 10000, and the abscissa range of a sampling region under a machine tool coordinate system is [630,800], and the unit is mm. The near point resolution precision of 17 mu m is realized. The method has the function of improving the data point comparison precision between the wheel rim tread data model and the standard mould data model, thereby improving the calculation precision and the result output precision. During sampling, the vertical coordinate of the initial position is larger than that of the standard mould data model, and therefore the rim tread data model is located above the standard mould data model. And drawing a point line graph on the two-dimensional coordinate data in the discrete data set in sequence. As shown in fig. 2, the upper point diagram in the drawing is a rim tread surface data model formed by a plurality of two-dimensional coordinate data of a worn rim tread surface contour line which are actually collected, the lower point diagram is a standard mold data model drawn according to contour two-dimensional coordinate data sampled by a standard mold, and the number of sampling points and the sampling interval are the same as those of the rim tread surface data model.
And step 3: translating the standard mould data model and the rim tread data model, and adjusting the initial positions of the two data models to ensure that the starting point horizontal coordinates of the two data models are the same;
in specific implementation, as shown in fig. 3, the sampling analysis interval is: abscissa [620, 820 ]; ordinate [420, 490 ]. Translating the initial position of the wheel rim tread surface data model to a fixed position in the drawing, keeping the ordinate unchanged, such as a point with coordinates (630, 450) in the drawing, translating the initial position of the standard mould data model, and keeping the ordinate unchanged (630, 440); the ordinate of the starting position of the standard mould data model is lower than the ordinate of the starting position of the rim tread surface data model.
And 4, step 4: the standard mould data model is translated upwards, and when the absolute value of the difference value of the vertical coordinates of the two data models is smaller than the minimum removal value in the range from the peak point of the rim tread data model to the corresponding end point of the right side of the model, the standard mould data model stops moving;
in specific implementation, as shown in fig. 4, the standard mold data model is translated upwards, and the abscissa of the standard mold data model is [646, 800] during the ascending process]Within the interval, the longitudinal coordinate of the wheel rim tread data model is set asy 1The ordinate of the standard mould data model is y2When the vertical coordinates of the two data models meet the following formula, stopping moving the standard die data model;
wherein,tfor the desired minimum removal value, taket=1。
And 5: calculating the accumulated sum of the difference values of the longitudinal coordinates of the two data models when the abscissa of the standard mould data model is in the range corresponding to the interval from the peak point of the rim tread data model to the right end point of the model, wherein the smaller the accumulated sum is, the smaller the fitting loss is under the condition that the minimum removal value is not changed;
in particular, calculate [646, 800]]Ordinate amplitude of tread data model in intervalf(x) Amplitude of ordinate of data model of standard mouldg(x) The cumulative sum S of distance differences is, as shown in the shaded area in fig. 4, the cumulative sum of vertical coordinate differences of the portion is the amount of material removed when the standard mold data model is used for repairing the edge tread surface data model. In thattThe smaller the sum of the parts is under the same condition, which shows that the smaller the fitting loss of the selected standard mould data model to the edge tread surface data model is, namely the selected standard mould is considered to be most reasonable in all the alternative mould libraries.
Step 6: and (5) repeating the steps 1-5, and taking the machining program of the standard die adopted when the calculated sum of the vertical coordinate difference values is minimum as a repairing program.
And 7: taking a point which is increased by 70mm on the abscissa of the initial position of the standard die data model as the processing end point of the repairing program; taking a point of which the abscissa of the initial position of the rim tread data model is increased by 70mm as a tool setting point, specifically:
step 7.1: when a point with the abscissa of the initial position of the standard die data model increased by 70mm is positioned in the standard die data model, taking the point as the processing end point of the correction program;
step 7.2: when a point with the abscissa of the initial position of the rim tread surface data model increased by 70mm is positioned in the worn rim tread surface data model, taking the point as a tool setting point;
step 7.3: and if the step 7.1 and/or the step 7.2 are not met, determining the coordinates of the end point of the processing of the correction program and/or the coordinates of the tool setting point by using a spatial interpolation method.
In specific implementation, the method for determining the vertical coordinate of the endpoint of the correction program processing by using the spatial interpolation method specifically comprises the following steps:
(1) finding a point which is 70mm added to the abscissa of the initial position of the standard die data model, and taking a first vertical line which passes through the point and is vertical to the abscissa axis;
(2) searching two sampling points at two sides of the first vertical line and closest to the vertical distance of the first vertical line;
(3) and connecting the two sampling points, wherein the intersection point of the connecting line and the first vertical line is the processing end point of the correction program.
The method for determining the vertical coordinate of the tool setting point by using the spatial interpolation method specifically comprises the following steps:
(1) finding a point which is 70mm greater than the abscissa of the initial position of the worn rim tread surface data model, and taking a second vertical line which passes through the point and is vertical to the abscissa axis;
(2) searching two sampling points at two sides of the second vertical line and closest to the vertical distance of the second vertical line;
(3) and connecting the two sampling points, wherein the intersection point of the connecting line and the second vertical line is the tool setting point.
In specific implementation, a spatial interpolation method is used for determining the coordinates of the end point of the processing of the correction program and the coordinates of the tool setting point.
As shown in FIG. 5, the first vertical line from the standard mold data model is searchedxClosest sampling point D (X) of =630+70=700D,YD). Determining the corresponding sampling point serial number n of the D point, if XD >700, sample point C (X) of n-1C,YC) Otherwise, getSample point n + 1E (X)E,YE). Line C, D or D, E is connected to the straight linexThe intersection point of =630+70=700 is the end point O of the correction program machining. Accordingly, the ordinate of the O point can be obtained.
Similarly, the tool setting point A can be determined, and the vertical coordinate of the tool setting point A is obtained.
And 8: and calling a repairing program, and inputting the coordinates of the tool setting point and the coordinates of the machining end point of the repairing program into the numerical control machine system without dropping the wheel, so as to realize intelligent automatic machining.
Compared with the common repairing and processing method, the method for analyzing and repairing the detection data of the rim tread of the train wheel has the advantages that the advantages are very obvious, and the specific expression is as follows: see Table 1-1
Tables 1 to 1:
the above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the scope of the present invention, which is defined by the appended claims.
Claims (6)
1. A method for analyzing and repairing detection data of a rim tread of a train wheel is characterized by comprising the following steps:
step 1: selecting a standard die from the alternative die library, and drawing a standard die data model according to a plurality of contour two-dimensional coordinate data of the standard die;
step 2: acquiring a plurality of two-dimensional coordinate data of a worn rim tread contour line through a machine tool detection system, and drawing a rim tread data model according to the plurality of two-dimensional coordinate data of the contour line;
and step 3: translating the standard mould data model and the rim tread data model, and adjusting the initial positions of the two data models to ensure that the starting point horizontal coordinates of the two data models are the same;
and 4, step 4: the standard mould data model is translated upwards, and when the absolute value of the difference value of the vertical coordinates of the two data models is smaller than the minimum removal value in the range from the peak point of the rim tread data model to the corresponding end point of the right side of the model, the standard mould data model stops moving;
and 5: calculating the accumulated sum of the vertical coordinate difference values of the two data models when the horizontal coordinate of the standard mould data model is within the interval range of the step 4, wherein the smaller the accumulated sum is, the smaller the fitting loss is under the condition that the minimum removal value is not changed;
step 6: repeating the steps 1-5, and taking a machining program of the standard die adopted when the sum of the calculated vertical coordinate difference values is minimum as a repairing program;
and 7: taking a point which is increased by 70mm on the abscissa of the initial position of the standard die data model as the processing end point of the repairing program; taking a point which is obtained by adding 70mm to the abscissa of the initial position of the rim tread data model as a tool setting point;
and 8: and calling a repairing program, and inputting the coordinates of the tool setting point and the coordinates of the machining end point of the repairing program into the numerical control machine system without dropping the wheel, so as to realize intelligent automatic machining.
2. The method for analyzing and repairing the detection data of the rim tread of a train wheel according to claim 1, wherein the step 2 comprises:
step 2.1: collecting a plurality of two-dimensional coordinate data of the wear rim tread contour line, and ensuring that the ordinate of the initial position is greater than that of the initial position of the standard mould data model during collection;
step 2.2: a plurality of two-dimensional coordinate data of the contour line form a discrete data set;
step 2.3: and drawing a point line graph in a two-dimensional coordinate system according to the sequence of horizontal coordinates from small to large from two-dimensional coordinate data in the discrete data set to serve as a wheel rim tread data model.
3. The method for analyzing and repairing the detection data of the rim tread of the railway wheel as claimed in claim 1, wherein 10000 pieces of two-dimensional coordinate data of the contour line of the tread of the worn rim are collected by a machine tool detection system in the step 2, and the abscissa range of the sampling region under the machine tool coordinate system is [630,800 ].
4. The method for analyzing and repairing the detection data of the rim tread of the train wheel according to claim 1, wherein the step 7 is specifically as follows:
step 7.1: when a point with the abscissa of the initial position of the standard die data model increased by 70mm is positioned in the standard die data model, taking the point as the processing end point of the correction program;
step 7.2: when a point with the abscissa of the initial position of the rim tread surface data model increased by 70mm is positioned in the worn rim tread surface data model, taking the point as a tool setting point;
step 7.3: and if the step 7.1 and/or the step 7.2 are not met, determining the coordinates of the end point of the processing of the correction program and/or the coordinates of the tool setting point by using a spatial interpolation method.
5. The method for analyzing and repairing the detected data of the rim tread of the train wheel as claimed in claim 4, wherein the step of determining the ordinate of the end point of the correction program processing by using the spatial interpolation method is specifically as follows:
(1) finding a point which is 70mm added to the abscissa of the initial position of the standard die data model, and taking a first vertical line which passes through the point and is vertical to the abscissa axis;
(2) searching two sampling points at two sides of the first vertical line and closest to the vertical distance of the first vertical line;
(3) and connecting the two sampling points, wherein the intersection point of the connecting line and the first vertical line is the processing end point of the correction program.
6. The method for analyzing and repairing the detected data of the rim tread of the train wheel as claimed in claim 4, wherein the method for determining the ordinate of the tool set point by using the spatial interpolation method specifically comprises:
(1) finding a point which is 70mm greater than the abscissa of the initial position of the worn rim tread surface data model, and taking a second vertical line which passes through the point and is vertical to the abscissa axis;
(2) searching two sampling points at two sides of the second vertical line and closest to the vertical distance of the second vertical line;
(3) and connecting the two sampling points, wherein the intersection point of the connecting line and the second vertical line is the tool setting point.
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