CN114088021B - Rail straightness detection method for combined positioning of non-contact sensors - Google Patents
Rail straightness detection method for combined positioning of non-contact sensors Download PDFInfo
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- CN114088021B CN114088021B CN202111294762.3A CN202111294762A CN114088021B CN 114088021 B CN114088021 B CN 114088021B CN 202111294762 A CN202111294762 A CN 202111294762A CN 114088021 B CN114088021 B CN 114088021B
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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
- G01B11/26—Measuring arrangements characterised by the use of optical techniques for measuring angles or tapers; for testing the alignment of axes
- G01B11/27—Measuring arrangements characterised by the use of optical techniques for measuring angles or tapers; for testing the alignment of axes for testing the alignment of axes
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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 discloses a steel rail straightness detection method based on non-contact sensor combined positioning, which comprises the following steps: the laser sensor moves along the length direction of the guide rail, and scans and collects the profile information of the steel rail; identifying and positioning the characteristic arc surface of the steel rail through the profile information of the steel rail, the position information and the parameter information of the laser sensor; determining the position of a steel rail straightness detection area through the positions of the circle centers of the two arc surfaces of the steel rail; and calculating the straightness of the steel rail. The invention reduces human error in manual measurement of straightness, improves accuracy of steel rail straightness detection, reduces cost, improves measurement accuracy, and has good practicability.
Description
Technical Field
The invention particularly relates to a steel rail straightness detection method based on combined positioning of non-contact sensors.
Background
At present, the straightness detection of the steel rail mainly depends on manual detection, the main method is to rely on a plug gauge for detection, but the manual detection has large human error and poor repeatability, the plug gauge cannot detect small errors, then the straightness detection of the steel rail needs to detect the straightness of three surfaces, the traditional measuring method generally adopts three sensors to respectively measure the straightness of the three surfaces, but no standard positioning point exists, the data acquired by one sensor can only be used for the straightness of one surface, and the price of the precision sensor is very high. Aiming at the problems, a novel steel rail straightness measuring method is provided.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides the rail straightness detection method for the combined positioning of the non-contact sensor, which reduces human errors in manual straightness measurement, improves the accuracy of rail straightness detection, reduces the cost, improves the measurement accuracy and has good practicability.
The technical scheme adopted by the invention for solving the technical problems is as follows:
a steel rail straightness detection method for combined positioning of non-contact sensors comprises the following steps:
s1, a laser sensor moves along the length direction of a guide rail, and the laser sensor scans and collects rail profile information;
s2, identifying and positioning the characteristic arc surface of the steel rail through the profile information of the steel rail, the position information and the parameter information of the laser sensor;
s3, determining the position of a steel rail straightness detection area through the positions of circle centers of two arc surfaces of the steel rail;
s4, calculating the straightness of the steel rail.
According to the technical scheme, the number of the laser sensors is two, and the two laser sensors are respectively arranged on two sides above the steel rail.
According to the technical scheme, in the steps S1 and S2, the steel rail profile information is steel rail shape and point location coordinate information in the sector scanning range of the laser sensor;
in the step S2, the position information and parameter information of the laser sensor include the spatial coordinates of the laser sensor and the position information of the effective scanning area of the laser sensor.
According to the above technical scheme, in the step S2, positioning identification of the arc surface of the rail feature is performed according to the obtained rail profile information, and specifically includes the following steps:
s2.1, acquiring image information of the profile surface of the steel rail in real time through a laser sensor;
s2.2, after smooth fitting operation is carried out on the image information, identifying the region of the characteristic arc of the steel rail;
s2.3, identifying a characteristic arc section, and deducing and calculating fitting circle center coordinates of the characteristic arc surface of the steel rail according to the radius of the designed arc.
According to the above technical scheme, in the step S3, the position of the rail straightness detection area is calculated according to the obtained coordinates of the circle center positions of the arc surfaces on both sides of the rail, and specifically includes the following steps:
s3.1, calculating horizontal distances L0 and L1 between the circle centers of the circular arcs on the two sides of the upper surface of the cross section of the steel rail and the sensors on the same side respectively;
s3.2, obtaining the horizontal distance L2 between the two sensors;
s3.3, calculating a straightness detection area of the upper surface of the steel rail;
s3.4, calculating the straightness detection areas of the two sides of the steel rail through the detection areas of the upper surface of the steel rail and the circle center coordinates of the arc surface.
According to the above technical scheme, in the step S3.3, the specific process of calculating the detection area of the upper surface of the steel rail is as follows: and (3) carrying out rapid characteristic recognition and capture on profile information data of each group of section steel rail transmitted back by the two laser sensors, positioning theoretical circle center positions of circular arcs on two sides of the upper surface of the steel rail, and carrying out average calculated values of abscissa on the theoretical circle centers of the circular arcs on two sides according to approximate symmetry of a steel rail interface to serve as central abscissa values for positioning a detection area on the upper surface of the steel rail.
According to the above technical solution, in the step S3.3, the central abscissa of the area where the detection area of the upper surface of the rail is located is calculated by the formula 0.5×l0-0.5×l1+0.5×l2.
According to the technical scheme, in the step S3.4, the relative distance between the straightness detection area on the upper surface of the steel rail and the straightness detection areas on the two sides of the steel rail is obtained according to the related standard specification of the railway track, and the central abscissa of the area where the straightness detection areas on the two sides of the steel rail are located is obtained through calculation.
According to the above technical solution, in the step S4, the specific process of calculating the straightness of the steel rail includes: all the obtained data of the 3 straightness detection areas are grouped, moving average noise reduction treatment of the length L is carried out, 3 groups of data of the same section are averaged to be used as center point coordinates, a fitting curve equation is obtained according to a least square method, a center line is fitted, the distance Zn between a point and the fitting straight line is calculated, and the straightness of three planes is calculated according to the following formula;
the 3 straightness detection areas are respectively a steel rail upper surface straightness detection area and two steel rail side straightness detection areas.
According to the technical scheme, the length L is 3-8 mm.
The invention has the following beneficial effects:
the invention reduces the human error when the straightness is measured manually, improves the accuracy of the straightness detection of the steel rail, reduces the cost compared with other straightness measuring systems of sensors, improves the straightness measuring method, improves the measuring precision, has good practicability, and can be mentioned as follows: the detection principle of the invention is different from that of the traditional plug gauge detection, the traditional plug gauge detection can only detect continuous straightness defects with the length exceeding 3 to 5mm (the detection threshold depends on the size of the plug gauge), and the laser infrared detection sensor can detect the finer discontinuous straightness defects.
Drawings
FIG. 1 is a workflow diagram of a rail straightness detection method with non-contact sensor joint positioning in an embodiment of the invention;
FIG. 2 is a schematic diagram of the operation of a laser sensor scanning a rail in an embodiment of the invention;
FIG. 3 is a schematic diagram of the center positions of arc surfaces on two sides of a steel rail in an embodiment of the invention;
FIG. 4 is a schematic view of a rail upper surface straightness detection area in an embodiment of the present invention;
FIG. 5 is a schematic view of a rail side surface straightness detection area in an embodiment of the present invention;
FIG. 6 is an elevation view of a rail in an embodiment of the invention;
in the figure, a 1-laser sensor, a 2-steel rail, a 3-circular arc center, a 4-steel rail upper surface straightness detection area and a 5-steel rail side straightness detection area.
Detailed Description
The invention will now be described in detail with reference to the drawings and examples.
Referring to fig. 1 to 6, the rail straightness detection method for combined positioning of non-contact sensors in one embodiment provided by the invention comprises the following steps:
s1, moving a laser sensor along the length direction of a guide rail, and scanning the laser sensor at an angle to acquire local profile information of the steel rail;
s2, identifying the characteristic arc surface of the steel rail through the local profile information of the steel rail, the position information and the parameter information of the laser sensor;
s3, determining the position of a steel rail straightness detection area through position coordinates of circle centers of two arc surfaces of the steel rail;
s4, calculating the straightness of the steel rail.
Further, before step S1, the laser sensor returns to the starting point after scanning is finished; if the information is not acquired, the measurement system self-checking is restarted until the information is ready to be completed.
Before step S2, filtering invalid points according to the collected local profile information of the steel rail.
Further, the number of the laser sensors is two, the two laser sensors are respectively arranged on two sides above the steel rail, and a single laser sensor scans the same side of the steel rail and the surface of the steel rail, and the specific range is shown in fig. 2, and the range from K1 to K2 is shown.
Further, in the steps S1 and S2, the rail local profile information is rail shape and point location coordinate information within the sector scanning range of the laser sensor;
in the step S2, the position information and parameter information of the laser sensor include the spatial coordinates of the laser sensor and the position information of the effective scanning area of the laser sensor that need to be manually input.
Further, in the step S2, positioning and identifying of the arc surface of the rail feature is performed according to the obtained local profile image information of the rail, and specifically includes the following steps:
s2.1, acquiring image information of a local profile surface of the steel rail in real time through a laser sensor;
s2.2, after the smooth fitting operation is carried out on the image information, the area of the characteristic arc surface of the steel rail is identified;
s2.3, identifying a characteristic arc section, and deducing and calculating fitting circle center coordinates of the characteristic arc surface of the steel rail according to the radius of the designed arc.
Further, in the step S3, the position of the rail straightness detection area is calculated according to the obtained coordinates of the circle center positions of the arc surfaces on both sides of the rail, and specifically includes the following steps:
s3.1, calculating horizontal distances L0 and L1 between the circle centers of the circular arcs on the two sides of the upper surface of the cross section of the steel rail and the sensors on the same side respectively;
s3.2, obtaining the horizontal distance L2 between the two sensors;
s3.3, calculating a straightness detection area of the upper surface of the steel rail;
s3.4, calculating the straightness detection areas of the two sides of the steel rail through the detection areas of the upper surface of the steel rail and the circle center coordinates of the arc surface.
Further, in the step S3.3, the specific process of calculating the detection area of the upper surface of the steel rail is as follows: and (3) carrying out rapid characteristic recognition and capture on profile information data of each group of section steel rail transmitted back by the two laser sensors, positioning theoretical circle center positions of circular arcs on two sides of the upper surface of the steel rail, and carrying out average calculation on abscissa coordinates of the theoretical circle centers of the circular arcs on two sides according to the approximate symmetry of a steel rail interface to serve as a central abscissa value for positioning a detection area on the upper surface of the steel rail.
Further, in the step S3.2, the horizontal distance between the circle centers of the arcs on both sides and the sensors on both sides is calculated and obtained by using a horizontal projection method; the horizontal distance L2 between the two sensors is determined by the sensor field installation process guidance, and the manual input system is measured after the sensors are installed.
Further, in the step S3.3, the central abscissa of the area of the decored neighborhood of the upper surface detection area of the rail is calculated by the formula 0.5×l0-0.5×l1+0.5×l2.
Further, in the step S3.4, the relative distance between the upper surface straightness detection area of the steel rail and the straightness detection areas of the two sides of the steel rail is obtained according to the related standard specification of the railway track, and the central abscissa of the coring neighborhood area where the straightness detection areas of the two sides of the steel rail are located is calculated.
And taking two side areas of the section of the steel rail, which are vertically separated by H=19.4mm below the upper surface of the steel rail, as the centers of detection areas of the side surfaces of the steel rail according to the standard, and extracting data from the detection areas with the width B (B is optionally 6-8 mm and the optimal choice of B is 7 mm).
Further, straightness calculation processing is carried out on the collected data, and straightness indexes are obtained.
Further, in the step S4, the specific process of calculating the straightness of the steel rail includes: all the obtained data of the 3 straightness detection areas are grouped, moving average noise reduction treatment of the length L is carried out, 3 groups of data of the same section are averaged to be used as center point coordinates, a fitting curve equation is obtained according to a least square method, a center line is fitted, the distance Zn between a point and the fitting straight line is calculated, and the straightness of three planes is calculated according to the following formula; the 3 straightness detection areas are respectively a steel rail upper surface straightness detection area and two steel rail side straightness detection areas.
Further, the difference between the maximum value of the single-point theoretical residual error and the minimum value of the theoretical residual error of the fitting curve and the actual data is calculated as a final output straightness result.
Further, the length L is 3 to 8mm.
Further, the optimal choice of the length L is 5mm.
In one embodiment of the invention, the specific workflow of the invention is:
the first step: firstly, a measuring system is started, a sensor moves to a fixed area, a sensor A scans and is started, whether the scanning data of the sensor A is empty or not is detected, if so, the sensor B is started for scanning, whether the scanning data of the sensor B is empty or not is detected, if so, the sensor A returns to the previous step, and if not, the data at the moment is numbered and stored. Moving to the next area for scanning, judging whether the data with the preset length is obtained or not, and if not, returning to the first scanning again;
and a second step of: and taking out the first group of data of the storage queue, identifying an arc curve of the central area of the sensor A, and calculating to obtain the theoretical circle center of the arc surface. Judging whether the data are effective coordinates, if so, identifying an arc curve of the central area of the sensor B, calculating to obtain a theoretical circle center of the arc surface, and if not, deleting the group of data, and further adding the latter data. The step of this step is performed again;
and a third step of: taking two center coordinates calculated in the previous step, finding out center points of the two center coordinates, calculating an average value of a region to be detected with the width B (B is optionally 6-8 mm, and the optimal choice of B is 7 mm) taking the center points as midpoints, detecting and collecting the center points of the center coordinates of a plurality of pairs of two sides on the same section of a steel rail for multiple times by a laser sensor, storing the values, selecting the center points belonging to the region to be detected, judging whether the center points are effective values, judging whether the center points are successfully stored, and if all the center points are successful, entering the next step;
fourth step: according to the average value of the center points calculated in the third step, the coordinates to be measured of the two sides are calculated according to a formula, the average value of the 7mm region to be measured taking the point as the midpoint is found out, whether the average value is an effective value is judged, if so, the next step is carried out, and if not, the step is repeated;
( Description: taking a 2m long rail as an example, the method measures 4000 cross sections, that is, in the second to fourth steps, 4000 times of calculation of each characteristic point is performed, and the number of the cross sections is related to the frequency of the sensor and the speed of the sensor movement. )
Fifth step: according to the average value of the midpoints on the three surfaces obtained by calculation in the previous steps, a fitting curve formula is obtained through a least square method, all recorded data are traversed, the distance between the points and the fitting straight line is calculated, and finally the straightness of the three surfaces of the steel rail is calculated according to the straightness calculation formula.
As shown in fig. 2, the laser sensor is a Gocator 2340 sensor of LMI company, the area of the sensor for scanning the steel rail at a certain moment is marked by red area in the figure, each sensor can scan the data of the corresponding side surface and upper surface, and the data is stored and processed for the next step;
1. the arcs in the graph are identified according to the following method:
when a certain point i meets the following conditions, we consider i as the tangent point of the arc tangent to a certain horizontal line, and as the locating feature point of the arc (b is constant)
Z is the Z-axis coordinate value of each point of the steel rail scanning data, n is the total group number of the scanning data, b is the step length, and the Z is the noise reduction parameter.
After the circular arc is found, the circle center of the circle where the circular arc is positioned inside the steel rail according to the process standard that the radius of the circular arc is 13 mm.
2. According to the design standard of the railway steel rail, the midpoint of the two circle centers is on the central axis of the section of the steel rail, the equation of the central axis is determined according to the coordinate formula and the coordinates of the two circle centers, and the central axis and the focal point of the upper surface are straightness detection center points. Because the error of the coordinates of a single point is large, in order to remove the error, the data of the points of the region to be measured, which are 3.5mm on both sides of the center point and 7mm in total, are taken and averaged to form the coordinates of a new center point.
3. And taking the intersection point of the horizontal line at the position of 19.4mm vertically downwards of the center point and the two sides of the steel rail as the center point of the two sides of the steel rail according to the coordinates of the center point of the upper surface calculated in the last step and the railway steel rail design standard, and taking the data of points of the areas to be measured, which are 3.5mm on the two sides of the center point and are 7mm in total, as the center point of the two sides of the steel rail, and averaging the data to form the coordinates of a new center point.
Fitting a central line by using the coordinates of the three groups of average central points according to a least square method, traversing all recorded data, calculating the distance Zn between the points and the fitting straight line, and respectively calculating the straightness of three surfaces according to the following formula:
straightness o=max { zi|i=1, 2..n } -min { zi|i=1, 2..n } (where Z is the Z-axis height value of each point of the rail scan data, and i is the number of the scan data).
The foregoing is merely illustrative of the present invention and is not intended to limit the scope of the invention, which is defined by the claims and their equivalents.
Claims (7)
1. A rail straightness detection method for combined positioning of non-contact sensors is characterized by comprising the following steps:
s1, a laser sensor moves along the length direction of a guide rail, and the laser sensor scans and collects rail profile information;
s2, identifying and positioning the characteristic arc surface of the steel rail through the profile information of the steel rail, the position information and the parameter information of the laser sensor;
s3, determining the position of a steel rail straightness detection area through the positions of circle centers of two arc surfaces of the steel rail;
s4, calculating the straightness of the steel rail;
in the step S3, the position of the rail straightness detection area is calculated according to the obtained coordinates of the circle center positions of the arc surfaces on both sides of the rail, and the method specifically comprises the following steps:
s3.1, calculating horizontal distances L0 and L1 between the circle centers of the circular arcs on the two sides of the upper surface of the cross section of the steel rail and the sensors on the same side respectively;
s3.2, obtaining the horizontal distance L2 between the two sensors;
s3.3, calculating a straightness detection area of the upper surface of the steel rail;
s3.4, calculating straightness detection areas of two sides of the steel rail through the detection areas of the upper surface of the steel rail and circle center coordinates of the arc surface;
in the step S3.3, the specific process of calculating the detection area of the upper surface of the steel rail is as follows: carrying out rapid characteristic recognition and capture on profile information data of each group of section steel rails transmitted back by the two laser sensors, positioning theoretical circle center positions of circular arcs on two sides of the upper surface of the steel rail, and carrying out average calculated values of abscissa on the theoretical circle centers of the circular arcs on two sides according to approximate symmetry of a steel rail interface to serve as central abscissa values for positioning a detection area on the upper surface of the steel rail;
in the step S3.3, the central abscissa of the area where the detection area of the upper surface of the rail is located is calculated by the formula 0.5×l0-0.5×l1+0.5×l2.
2. The method for detecting the straightness of the steel rail by combining and positioning non-contact sensors according to claim 1, wherein the number of the laser sensors is two, and the two laser sensors are respectively arranged on two sides above the steel rail.
3. The method for detecting the straightness of the steel rail by combining and positioning the non-contact sensor according to claim 1, wherein in the steps S1 and S2, the steel rail profile information is steel rail shape and point location coordinate information in a sector scanning range of the laser sensor;
in the step S2, the position information and parameter information of the laser sensor include the spatial coordinates of the laser sensor and the position information of the effective scanning area of the laser sensor.
4. The method for detecting the straightness of the steel rail by combining and positioning the non-contact sensor according to claim 1, wherein in the step S2, positioning and identifying of the characteristic arc surface of the steel rail are performed according to the obtained profile information of the steel rail, and specifically comprises the following steps:
s2.1, acquiring image information of the profile surface of the steel rail in real time through a laser sensor;
s2.2, after smooth fitting operation is carried out on the image information, identifying the region of the characteristic arc of the steel rail;
s2.3, identifying a characteristic arc section, and deducing and calculating fitting circle center coordinates of the characteristic arc surface of the steel rail according to the radius of the designed arc.
5. The method for detecting the straightness of the steel rail by combining and positioning the non-contact sensor according to claim 1, wherein in the step S3.4, the relative distance between the straightness detection area on the upper surface of the steel rail and the straightness detection areas on the two sides of the steel rail is obtained according to the related standard specification of the railway track, and the central abscissa of the area where the straightness detection areas on the two sides of the steel rail are located is calculated.
6. The method for detecting the straightness of the steel rail by combining and positioning the non-contact sensor according to claim 1, wherein in the step S4, the specific process of calculating the straightness of the steel rail comprises the following steps: all the obtained data of the 3 straightness detection areas are grouped, moving average noise reduction treatment of the length L is carried out, 3 groups of data of the same section are averaged to be used as center point coordinates, a fitting curve equation is obtained according to a least square method, a center line is fitted, the distance Zn between a point and the fitting straight line is calculated, and the straightness of three planes is calculated according to the following formula;
the 3 straightness detection areas are respectively a steel rail upper surface straightness detection area and two steel rail side straightness detection areas.
7. The method for detecting the straightness of the steel rail by combining and positioning the non-contact sensors according to claim 6, wherein the length L is 3-8 mm.
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2021
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