CN117966529A - Virtual-real combination-based steel rail polishing control method and equipment - Google Patents
Virtual-real combination-based steel rail polishing control method and equipment Download PDFInfo
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Abstract
The invention provides a virtual-real combination-based steel rail polishing control method and equipment, which are technically characterized in that: the method comprises the following steps: step S1, establishing a virtual steel rail model before polishing in a computer, wherein the steel rail model can reflect the health state of a current steel rail; s2, comparing the profile of the established virtual steel rail model with that of the standard steel rail model, and determining the polishing amount according to the difference; and S3, establishing a relation between the polishing amount and polishing parameters of the polishing equipment, simulating a polishing process, calculating a polishing mode of the rail polishing equipment and the rail model according to the polishing amount, generating the polishing parameters, and guiding the polishing equipment to polish. According to the invention, the three-dimensional scanning technology is used for carrying out virtual modeling analysis on the state of the steel rail before polishing, and polishing operation is simulated, so that the optimal polishing mode is matched, polishing equipment is guided to carry out field polishing, the polishing quality of the steel rail is detected, the polishing quality of the steel rail is ensured, and the polishing stability of the steel rail is improved.
Description
Technical Field
The invention relates to the technical field of railway maintenance, in particular to a rail polishing control method and device based on virtual-real combination.
Background
The rail plays an important role in the running process of the train, along with the trend of speeding up the train and reloading goods, the pressure born by the rail during the service period is larger and larger, and after the rail is longer, the rail inevitably generates certain degree of abrasion and deformation, and the abrasion can bring adverse influence on the stability of the train and the riding comfort, and even can influence the driving safety when serious. Compared with the large cost caused by directly replacing the steel rail, the regular polishing of the steel rail becomes the main rail maintenance means at present.
Before the steel rail is polished, the steel rail is detected, and polishing equipment determines a polishing plan according to the detection result. At present, the mainstream rail detection technology comprises an ultrasonic detection technology, a magnetic flux leakage detection technology and a visual detection technology, but the technologies have respective limitations, for example, defects on the surface of the rail can influence the propagation and reflection of ultrasonic waves, so that the flaw detection accuracy is reduced; the magnetic leakage detection is difficult to identify narrower defects, and even if the length and depth of the defects of the steel rail meet disease standards, the detected signals are difficult to identify; the visual detection scheme can be influenced by factors such as illumination, weather and the like to influence the image quality, so that the detection accuracy is influenced.
The three-dimensional detection technology is a measurement technology based on machine vision, which has the characteristics of high precision, strong real-time performance, high precision and the like, is developed faster in recent years, can accurately capture the three-dimensional shape and structure of an object, describe a target more accurately, can acquire the state information of the steel rail in an omnibearing manner by scanning the steel rail through laser to acquire the three-dimensional point cloud, and can not cause secondary damage to the steel rail due to non-contact measurement.
Therefore, the three-dimensional detection technology is applied to the aspect of steel rail polishing control, and polishing operation is simulated, so that the optimal polishing mode is matched, polishing equipment is guided to polish in the field, and development of steel rail polishing equipment and related technologies in China is promoted.
Disclosure of Invention
Aiming at the technical problems in the prior art, the invention provides a virtual-real combination-based steel rail polishing control method and equipment, which are used for carrying out virtual modeling analysis on the state of a steel rail before polishing by applying a three-dimensional scanning technology when polishing the steel rail in a certain section of selected area, so as to simulate polishing operation, thereby matching with an optimal polishing mode and guiding polishing equipment to carry out field polishing. The steel rail polishing quality can be detected, the steel rail polishing quality is guaranteed, and the steel rail polishing stability, safety and high efficiency are improved.
According to a first aspect of the invention, a rail grinding control method based on virtual-real combination is provided, which comprises the following steps:
Establishing a virtual steel rail model before polishing in a computer; comprising the following steps: firstly, scanning a steel rail through three-dimensional scanning equipment to obtain a three-dimensional point cloud of the steel rail, and determining coordinates (x, y, z) of the point cloud in a space coordinate system O-XYZ, so as to obtain a high-precision three-dimensional point cloud model;
Comparing the profile of the established virtual steel rail model with that of the standard steel rail model, and determining the polishing amount according to the difference;
And establishing a relation between the polishing amount and the polishing parameters of the polishing equipment, simulating the polishing process, calculating the most matched polishing mode of the steel rail polishing equipment and the steel rail model according to the polishing amount, generating the polishing parameters, and guiding the polishing equipment to polish.
On the basis of the technical scheme, the invention can also make the following improvements.
Optionally, the steel rail model can reflect the health status of the current steel rail, including: whether there is wave mill, dent, crack, fat edge disease feature.
Optionally, after the original three-dimensional point cloud of the steel rail is obtained by scanning, the point cloud is required to be simplified, and the method comprises the following steps:
step 1.1, taking an average value of distances between a single point cloud and m point clouds closest to the single point cloud as a point cloud distance of a current point cloud, calculating the point cloud distance of the whole point cloud, and taking the average value as an average point distance of the whole point cloud;
Step 1.2, adjusting the position of the point cloud of the steel rail;
and 1.3, simplifying the point cloud to obtain a point cloud model after steel rail simplification.
Optionally, in step 1.2, the adjusting the position of the rail point cloud includes:
1.2.1. removing discrete noise points by adopting density cluster analysis;
1.2.2. estimating the plane with the largest number of plane point clouds from irregular point clouds, and inputting adjustment parameters to divide the plane point clouds;
1.2.3. calculating the normal direction of a rail top plane centroid point, moving a coordinate origin to a rail top point cloud plane centroid, calculating the normal of a plane point cloud, and finally obtaining the normal of the rail top plane centroid point;
1.2.4. Moving the origin of coordinates to the mass center of the cloud segmentation plane of each point, and adjusting the orientation of the point cloud;
1.2.5. And identifying the rail head point cloud, extracting a Z=0 section, and evaluating similarity with the standard rail head section, wherein the maximum similarity is the rail head point cloud.
Optionally, the comparing the profile of the established virtual rail model with the profile of the standard rail model, and determining the polishing amount according to the difference includes:
the actual measurement steel rail model and the standard steel rail model are led into three-dimensional modeling software, the actual measurement steel rail model and the standard steel rail model are aligned, the axes or other characteristic lines of the actual measurement steel rail model and the standard steel rail model are aligned, the difference is determined through Boolean operation, the actual measurement steel rail model is subtracted from the standard steel rail model, if the Boolean operation is true, the steel rail is required to be polished, the next step can be continued, and otherwise, the steel rail is not required to be polished.
Optionally, the establishing a relationship between the polishing amount and the polishing parameters of the polishing device includes:
According to the polishing parameters of the polishing equipment under different working conditions, the polishing area of the cross section of the steel rail is calculated in a simulation mode, the shape of the polished steel rail is displayed in a kinematic visual simulation mode in three-dimensional software, and the optimal polishing working condition is screened out through calculation and comparison of the profile of the polished steel rail.
Optionally, the polishing parameters comprise polishing angle, polishing speed and polishing power; the generating polishing parameters, guiding polishing equipment to polish, comprises:
Analyzing the profile of the polished steel rail, and screening the optimal polishing working condition;
Outputting the optimal polishing working condition of the screened polishing equipment to a control unit of the polishing equipment, so that the polishing equipment adjusts proper polishing parameters, and polishing the steel rail.
Optionally, the polishing control method further includes a rechecking after polishing, including the following steps:
and (3) establishing a repeated rail virtual model, secondarily modeling the polished rail, extracting the difference between the actual measured profile of the polished rail and the standard profile, evaluating the actual polishing effect, and secondarily polishing the rail if the actual profile of the polished rail does not meet the use requirement, so as to ensure the polishing quality of the rail.
According to a second aspect of the present invention, there is provided a rail grinding control apparatus based on virtual-real combination, comprising:
The acquisition module comprises a three-dimensional scanner and a control unit, wherein the three-dimensional scanner is used for carrying out three-dimensional scanning on the steel rail to acquire steel rail point cloud data; comprising the following steps: scanning the steel rail to obtain a three-dimensional point cloud of the steel rail, and determining coordinates (x, y, z) of the point cloud in a space coordinate system O-XYZ, so as to obtain a high-precision three-dimensional point cloud model; the control unit is used for adjusting the scanning parameters of the three-dimensional scanner;
the simulation analysis module comprises a standard steel rail model library and is used for receiving the point cloud data preprocessed by the preprocessing module, establishing a virtual steel rail model before polishing, and the steel rail model can reflect the health state of the current steel rail; establishing a relation between the polishing amount of the steel rail model and polishing parameters of polishing equipment, and simulating a polishing process;
The polishing control module is used for adjusting scanning parameters of the three-dimensional scanner, determining the required polishing amount of the steel rail by comparing the profile of the steel rail, and selecting the most matched polishing mode according to a set algorithm; and calculating a polishing mode of the steel rail polishing equipment and the steel rail model, which is most matched, according to the polishing amount, generating polishing parameters, and guiding the polishing equipment to polish.
Optionally, the method further comprises:
the preprocessing module consists of a processor with a calculation function and is used for preprocessing the three-dimensional point cloud model acquired by the acquisition module to remove noise points and point clouds irrelevant to the steel rail;
the communication module is used for realizing data transmission and communication among the modules;
and the rechecking module is used for repeating the establishment of the virtual model of the steel rail, carrying out secondary modeling on the polished steel rail, extracting the difference between the actual measured profile of the polished steel rail and the standard profile, evaluating the actual polishing effect, and if the actual profile of the polished steel rail does not meet the use requirement, carrying out secondary polishing on the steel rail, so as to ensure the polishing quality of the steel rail.
The invention has the technical effects and advantages that:
The invention provides a virtual-real combination-based steel rail polishing control method and equipment, which perform virtual modeling analysis on the state of a steel rail before polishing by using a three-dimensional scanning technology and simulate polishing operation, so that the optimal polishing mode is matched, the polishing equipment is guided to polish in the field, the polishing quality of the steel rail is detected, the polishing quality of the steel rail is ensured, the stability, the safety and the high efficiency of steel rail polishing are improved, and a scheme support is provided for manufacturing complete technical equipment in the field of steel rail maintenance.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
Drawings
Fig. 1 is a schematic flow chart of a rail polishing control method based on virtual-real combination according to an embodiment of the present invention;
Fig. 2 is a diagram of binocular vision equipment provided by an embodiment of the present invention;
Fig. 3 is a plan division flow chart provided in an embodiment of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The virtual-real combination-based steel rail polishing control method and equipment provided by the embodiment of the invention are mainly applied to the field of railway maintenance and repair, are used for polishing a section of steel rail in a selected area, and perform virtual modeling analysis on the state of the steel rail before polishing by applying a three-dimensional scanning technology to simulate polishing operation, so that the optimal polishing mode is matched, the polishing equipment is guided to perform field polishing, the polishing quality of the steel rail can be detected, the polishing quality of the steel rail is ensured, the stability, safety and high efficiency of steel rail polishing are improved, and a scheme support is provided for manufacturing complete technical equipment in the field of steel rail maintenance and repair.
It can be appreciated that based on the defects in the background technology, the embodiment of the invention provides a rail polishing control method based on virtual-real combination, specifically as shown in fig. 1, the polishing control method comprises the following steps:
Firstly, establishing a virtual steel rail model before polishing in a computer; comprising the following steps: firstly, scanning a steel rail through three-dimensional scanning equipment to obtain a three-dimensional point cloud of the steel rail, and determining coordinates (x, y, z) of the point cloud in a space coordinate system O-XYZ, so as to obtain a high-precision three-dimensional point cloud model;
The steel rail model can reflect the health state of the current steel rail and comprises the following steps: whether the wave mill, the dent, the crack, the fat edge and other disease characteristics exist or not;
in the embodiment, the steel rail is scanned by a binocular vision scanner in three-dimensional scanning, and the equipment is convenient to operate, high in scanning speed and wide in scanning breadth, and can efficiently acquire profile data of the steel rail. As shown in fig. 2 in particular, the binocular vision apparatus consists of two cameras, Is the left camera coordinate system, and the focal length is/>，/>Is the right camera coordinate system, focal length is/>To/>Is the principal coordinate system/>Any measuring point P on the steel rail and the imaging centers of the two cameras form a triangular relationship, as shown in the figure, P, P, P2 and P3 are arranged on the imaging surface/>, of the left cameraThe upper image points are allOn the imaging plane/>, of the right cameraImage point on/>Thus, the main coordinate system of P can be obtainedIs defined by the coordinates of (a). /(I)And/>The conversion relation between the two coordinate systems is as follows:
Wherein the method comprises the steps of Respectively express/>To/>Is a rotation matrix and a translation matrix of the same. From the geometrical perspective, it is possible to:
Then P is at The coordinates in the main coordinate system are:
the rotation matrix R and the translation matrix T can be obtained by calibration of the camera, by means of the image plane points 、/>The coordinates of the measuring point P can be measured.
After the original point cloud is obtained by scanning, the scanned point cloud contains a plurality of points which are irrelevant to the current rail simulation establishment because of the large scanning range of the scanner, and the subsequent processing efficiency is affected, so that the point cloud needs to be simplified, and the efficiency and the accuracy of the subsequent extraction of the rail profile are improved.
The step of simplifying the point cloud acquired by the binocular scanner is as follows:
1.1. Homogenizing the point cloud distance to make the single point cloud closest to the single point cloud The average value of the distances among the point clouds is used as the point cloud distance of the current point cloud, the point cloud distance of the whole point cloud is calculated, the average value is taken as the average point distance of the whole point cloud, and the formula is as follows:
wherein P is any point in the point cloud, qi (i=1, 2, 3, 4, …, m) is P is The point closest to the P single distance is calculated, and the average point distance of the whole point cloud is as follows:
Wherein, Get/>, as the total number of point clouds=4。
1.2. And the position of the point cloud is adjusted, and the uncertainty of the installation position and the angle of the scanner in the actual scanning process is considered, so that the position of the point cloud of the steel rail is required to be adjusted, and the difficulty of subsequent data processing is reduced.
Rail adjustment requires specific implementation goals, including:
(1) Coinciding the origin of coordinates with the cloud center point of the rail top Ping Miandian;
(2) The positive direction of the Z axis is consistent with the direction of the maximum main component of the point cloud of the plane of the rail top, namely the running direction of the polishing equipment;
(3) The positive direction of the Y axis is consistent with the normal direction of the cloud center point of the rail top Ping Miandian;
(4) The X-axis is directed forward to the inside of the track.
The flow for adjusting the position relationship of the point cloud is specifically shown in fig. 3, and comprises the following steps:
1.2.1. Firstly, removing discrete noise points by adopting density cluster analysis; the judgment method comprises the following steps that when the number of samples of the sample points in the neighborhood threshold r is greater than or equal to the minimum set number The point is added to the nearest cluster. According to the above, let/>、/>=10000, The point cloud can be divided into different parts such as a head point cloud, a web point cloud, and a ground point cloud.
1.2.2. Plane extraction, estimating a plane AX+BY+CZ+D=0 with the largest number of plane point clouds from irregular point clouds, and inputting adjustment parameters of the plane AX+BY+CZ+D=0, wherein the input adjustment parameters are respectively [ (a)、/>)，/>Representing a deviation value that determines whether a certain point cloud is an in-plane point,Representing the maximum number of algorithm iterations. The method comprises the following specific steps: firstly, setting the minimum plane point cloud quantity n, initializing a plane parameter ABCD based on the value, and then calculating the distance d between each point and the plane if d is smaller than/>And determining the point as an in-plane point, after all the point clouds are divided, adjusting the model parameters to start the next iteration, stopping the iteration when the set iteration times are reached, finding out the round with the largest number of the plane point clouds, and taking the corresponding model parameters as a final plane model. Specifically, according to the point distance, set/>、/>=100, Split the point cloud plane.
1.2.3. And calculating the normal direction of the centroid point of the rail top plane, moving the origin of coordinates to the centroid of the plane of the rail top point cloud, calculating the normal of the plane point cloud, and finally obtaining the normal of the centroid point of the rail top plane.
1.2.4. And (3) adjusting the point cloud orientation, and moving the origin of coordinates to the centroid of the point cloud segmentation plane. Firstly, calculating a rotation matrix R1 of a plane centroid normal direction and a Y-axis positive direction, so that a point cloud plane normal coincides with the Y-axis positive direction; secondly, calculating the direction of the main component with the largest plane, calculating a rotation matrix R2 in the positive direction of the Z axis, enabling the direction of the main component and the rotation matrix R2 to coincide, finding a group of mutually orthogonal coordinate axes according to the distribution characteristics of data by using a main component dividing method, wherein the first coordinate axis is the direction with the largest variance in the original data, namely the rail direction corresponding to the rail top plane, and the second coordinate axis is the positive direction of the X axis; and finally, calculating the mass center of the whole point cloud, and rotating 180 degrees around the Y axis if the X coordinate of the mass center is negative at the moment, so as to ensure that the positive direction of the X axis points to one side of the mass center.
1.2.5. The rail head point cloud is identified, the point cloud after position adjustment has different states such as a rail head point cloud plane, a rail web point cloud plane and the like due to different plane generation, so that the rail head point cloud needs to be identified, and the rail head point cloud is obtained by extracting a Z=0 section and evaluating similarity with a standard rail head section, wherein the maximum similarity is the rail head point cloud due to the fact that the pose of the point cloud after position adjustment in space is clear.
The formula for calculating the similarity is as follows:
Wherein, Is a distance paradigm between A, B points,/> The maximum value of the unidirectional distance between the two point sets is represented, the smaller the value is, the closer the two point sets are, and the rail head interface can be screened out by virtue of the different rail head, rail web and ground sections, so that the rail point cloud is adjusted to the target position.
1.3. Point cloud simplification operations
1.3.1. The rail head, the rail web and the discrete point cloud are segmented through the point cloud adjustment operation, the maximum Y coordinate value of the non-target point cloud after the rail point cloud position adjustment is smaller than the maximum Y coordinate value of the rail head and the rail web point cloud, so that the point clouds after the position adjustment are ordered from large to small according to the Y coordinate value, the first two pieces of clustered point clouds are reserved, and the outlier removal can be completed.
1.3.2. After the rail point cloud is aligned, the distribution on the XYZ coordinate axis is clear, a straight-pass filter can be adopted to filter noise points, the size of a section of 60 rails is taken as an example, the distance from the rail bottom to the rail waist on the X axis is 66.75mm as a filtering condition, and points with X more than 66.75mm can be directly filtered;
1.3.3. firstly setting the size of voxels in X, Y and Z by adopting a voxel filtering method, then processing the point cloud through voxel filtering, namely dividing the point cloud into discrete three-dimensional cube grids, processing the point cloud data in each grid, and compressing the point cloud data into a single centroid point so as to reduce the magnitude of original point cloud data; the point cloud after position adjustment can be divided into three parts, namely, a horizontal plane point cloud mainly distributed in two dimensions of an X axis and a Z axis, a vertical Ping Miandian cloud mainly distributed in two dimensions of a Y axis and a Z axis and a curved surface point cloud distributed in three dimensions of X, Y, Z;
finally, the point cloud model after the steel rail is simplified can be obtained after the processing.
Comparing the profile of the established virtual steel rail model with that of the standard steel rail model, and determining the polishing amount according to the difference;
Specifically, comparing the profile of the established virtual rail model with the profile of the standard rail model, and determining the polishing amount according to the difference comprises:
And importing the obtained point cloud model after steel rail simplification into CATIA, SOLIDWORKS three-dimensional modeling software, calling a model in a standard steel rail model library, comparing the model with the model, and determining the difference through Boolean operation. The specific flow of the Boolean operation is as follows:
The measured rail model and the standard rail model are imported into three-dimensional modeling software such as CATIA, SOLIDWORKS and the like to ensure that the measured rail model and the standard rail model are both located in the same coordinate system and at the correct positions. And aligning the actual measurement steel rail model with the standard steel rail model, aligning the axes or other characteristic lines of the actual measurement steel rail model and the standard steel rail model, and subtracting the standard steel rail model from the actual measurement steel rail model by using a Boolean operation function in software. This means that the geometry of the standard rail model part is removed from the measured rail model. If the boolean operation is true, the steel rail is indicated to be polished, the next step can be continued, otherwise the steel rail is not polished.
In another possible embodiment, comparing the established virtual rail model with the profile of the standard rail model, determining the amount of grinding based on the difference further comprises: the comparison of the actually measured steel rail point cloud and the standard steel rail profile is directly carried out in the point cloud processing software CloudCompare, autodeskRecap, the difference quantity is determined, and then the difference part is imported into CATIA, SOLIDWORKS three-dimensional modeling software for subsequent kinematic simulation.
In the present embodiment, when the grinding amount is determined, the specific grinding energy is definedThe grinding work efficiency can be evaluated in comparison with the energy consumed for grinding a unit volume of work piece:
In the above formula, W is the energy consumed by grinding the steel rail, V is the volume of the metal on the surface of the steel rail removed by grinding, P is the grinding power, S is the grinding area of the cross section of the steel rail, V is the grinding operation speed, and t is the grinding time.
Parameters of grinding metal workpiece by grinding wheel at a certain working conditionThe grinding area S of the cross section of the steel rail during grinding can be obtained according to the above method, wherein the grinding area S is constant:
the influence of factors such as the performances of different grinding wheels, the materials of the steel rail, the ambient temperature and the like in the grinding process is considered, and the adjustment coefficient k is introduced to correct the above-mentioned factors, so that the steel rail grinding machine is obtained
K is a constant and can be determined by a grinding test. It can be seen from the above that when the grinding conditions are determined, the rail cross-sectional grinding area S is proportional to the grinding power P and inversely proportional to the grinding operation speed v.
And 3, establishing a relation between the polishing amount and polishing parameters of the polishing equipment, simulating a polishing process, calculating a polishing mode of the steel rail polishing equipment and the steel rail model according to the polishing amount, generating the polishing parameters, and guiding the polishing equipment to polish.
The establishing of the relation between the polishing amount and the polishing parameters of the polishing equipment comprises the following steps:
According to the polishing parameters such as polishing angle, polishing speed and polishing power of the polishing equipment under different working conditions, the polishing area of the cross section of the steel rail can be simulated, the shape of the polished steel rail is displayed in a kinematic visual simulation mode in three-dimensional software, and the optimal polishing working condition is screened out by calculating and comparing the profile of the polished steel rail.
Specifically, the working conditions of the polishing equipment are required to be modeled by realizing the operation visual simulation in the three-dimensional software, the working conditions of the polishing equipment can be obtained through a product specification, parameters of polishing heads of the polishing equipment under different working conditions, such as the number of the polishing heads, the angle of the polishing heads, the speed of the polishing equipment, the polishing power and the like, are respectively set in the software according to different working conditions, and the steel rail can be polished after the setting is completed.
Modeling is needed to be carried out on all working conditions of polishing equipment during primary polishing, and an established polishing working condition model can be directly called during secondary polishing;
In addition, after polishing, the profile of the polished steel rail is analyzed, and the optimal polishing working condition is screened.
In this embodiment, the optimal polishing condition is determined, and the screening, calculating and analyzing process is as follows:
Firstly dividing a rail head wheel and rail contact area into different areas, wherein X < -30 > -20 > is an area 1, X < -20 > 0> is an area 2, X <0> -30 > is an area 3, X < -30 > +35 > is an area 4, and the weight coefficient of each area is G1=G4=0.2 and G3=G4=0.3 respectively; secondly, clustering each region with arc length of 0.5mm, wherein the discrete point number of each region is The normal deviation of each discrete point within the nth interval is expressed as/>Normal deviation is defined as the measured profile of the rail being positive when above the standard profile and negative when not. Equivalent deviation index/>The closer to 0, the closer to the standard profile the rail profile is, the greater/>The calculation formula of (2) is as follows:
In addition, in order to ensure the polishing quality, the polished workpiece needs to be ensured />, Before sandingAt the same time, in order to avoid excessive sanding, the method comprisesAllowed value/>Thus, the polishing mode is selected by
The optimal polishing mode of the polishing equipment is matched according to the actual model of the steel rail through the process, so that polishing is performed without manual detection, and the detection and polishing efficiency is improved.
And finally, outputting the optimal polishing working condition of the screened polishing equipment to a control unit of the polishing equipment, so that the polishing equipment adjusts proper polishing parameters, such as polishing speed, polishing power and polishing angle, and polishing the steel rail.
Finally, the polishing control method further comprises the step of rechecking after polishing, including:
By repeating the method for establishing the virtual model of the steel rail provided by the embodiment of the invention, the polished steel rail is subjected to secondary modeling, the difference between the actual measured profile of the polished steel rail and the standard profile is extracted, the actual polishing effect is estimated, and if the actual profile of the polished steel rail does not meet the use requirement, namely the Boolean operation is true, the steel rail is subjected to secondary polishing, so that the polishing quality of the steel rail is ensured.
In summary, the embodiment of the invention provides a virtual-real combination-based steel rail polishing control method, which applies a three-dimensional detection technology to the aspect of steel rail polishing control, obtains a steel rail three-dimensional point cloud model, obtains a simplified point cloud model through operation processing operations such as homogenizing a point cloud distance, adjusting a point cloud position, filtering the point cloud, and the like, extracts a steel rail profile interface, compares the steel rail profile interface with a standard steel rail profile, determines polishing amount, establishes a relation between polishing amount and polishing parameters of polishing equipment, guides the polishing equipment to polish after simulation analysis, ensures the polishing quality of the steel rail, and improves the stability, safety and high efficiency of steel rail polishing.
According to a second aspect of the present invention, there is provided a rail grinding control apparatus based on virtual-real combination, comprising:
The acquisition module comprises a three-dimensional scanner and a control unit, wherein the three-dimensional scanner is used for carrying out three-dimensional scanning on the steel rail to acquire steel rail point cloud data; comprising the following steps: scanning the steel rail to obtain a three-dimensional point cloud of the steel rail, and determining coordinates (x, y, z) of the point cloud in a space coordinate system O-XYZ, so as to obtain a high-precision three-dimensional point cloud model; the control unit is used for adjusting scanning parameters of the three-dimensional scanner, such as scanning angle and scanning precision;
the simulation analysis module comprises a standard steel rail model library and is used for receiving the point cloud data preprocessed by the preprocessing module, establishing a virtual steel rail model before polishing, and the steel rail model can reflect the health state of the current steel rail; establishing a relation between the polishing amount of the steel rail model and polishing parameters of polishing equipment, and simulating a polishing process;
The polishing control module consists of a control unit and polishing equipment, and is used for adjusting the scanning parameters of the three-dimensional scanner, determining the required polishing amount of the steel rail by comparing the profile of the steel rail, and selecting the most matched polishing mode according to a set algorithm; according to the calculated polishing mode of the rail polishing equipment and the rail model, generating polishing parameters and guiding the polishing equipment to polish; the control unit can receive the polishing mode transmitted by the simulation analysis module, adjust polishing parameters such as the angle, the speed and the like of the polishing head, and guide polishing equipment to polish.
Further comprises: the preprocessing module consists of a processor with a calculation function and is used for preprocessing the three-dimensional point cloud model acquired by the acquisition module to remove noise points and point clouds irrelevant to the steel rail; such as an ambient point cloud, a fastener point cloud; the preprocessing module also has the function of storing the preprocessed point cloud;
The communication module is used for realizing data transmission and communication among the modules, the supported communication protocol comprises TCP/IP or MODBUS, the transmission mode can be wired or wireless, the limited transmission mode comprises Ethernet, and the wireless transmission mode comprises WIFI and Bluetooth;
and the rechecking module is used for repeating the establishment of the virtual model of the steel rail, carrying out secondary modeling on the polished steel rail, extracting the difference between the actual measured profile of the polished steel rail and the standard profile, evaluating the actual polishing effect, and if the actual profile of the polished steel rail does not meet the use requirement, carrying out secondary polishing on the steel rail, so as to ensure the polishing quality of the steel rail.
According to the rail polishing control method and system based on virtual-real combination, firstly, a rail to be polished needs to be established for profile modeling, the rail head profile of the rail to be polished is obtained, and the actual state of the rail head profile is reflected. The method specifically comprises a series of operations of scanning the steel rail and simplifying the point cloud, and finally the simplified steel rail point cloud is obtained. Secondly, extracting the rail head outline of the rail to be polished and comparing with the standard rail head outline, and matching the corresponding polishing modes through calculation and analysis, wherein the specific polishing modes comprise: the number of the polishing heads, the polishing angle, the polishing power, the polishing speed and the like are used for demonstrating the polishing process through a computer, finally matching with the optimal polishing mode, guiding polishing equipment to polish, detecting the polishing quality of the steel rail, guaranteeing the polishing quality of the steel rail and improving the stability, safety and high efficiency of steel rail polishing.
Finally, it should be noted that: the foregoing description is only illustrative of the preferred embodiments of the present invention, and although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that modifications may be made to the embodiments described, or equivalents may be substituted for elements thereof, and any modifications, equivalents, improvements or changes may be made without departing from the spirit and principles of the present invention.
Claims (10)
1. The rail polishing control method based on virtual-real combination is characterized by comprising the following steps of:
Establishing a virtual steel rail model before polishing in a computer; comprising the following steps: firstly, scanning a steel rail through three-dimensional scanning equipment to obtain a three-dimensional point cloud of the steel rail, and determining coordinates (x, y, z) of the point cloud in a space coordinate system O-XYZ, so as to obtain a high-precision three-dimensional point cloud model;
Comparing the profile of the established virtual steel rail model with that of the standard steel rail model, and determining the polishing amount according to the difference;
And establishing a relation between the polishing amount and the polishing parameters of the polishing equipment, simulating the polishing process, calculating the most matched polishing mode of the steel rail polishing equipment and the steel rail model according to the polishing amount, generating the polishing parameters, and guiding the polishing equipment to polish.
2. The virtual-real combination-based steel rail polishing control method as claimed in claim 1, wherein the steel rail model can reflect the health state of the current steel rail, and comprises the following steps: whether there is wave mill, dent, crack, fat edge disease feature.
3. The virtual-real combination-based steel rail polishing control method as claimed in claim 2, wherein after the three-dimensional point cloud of the steel rail is obtained, the point cloud is further required to be simplified, and the method comprises the following steps:
step 1.1, taking an average value of distances between a single point cloud and m point clouds closest to the single point cloud as a point cloud distance of a current point cloud, calculating the point cloud distance of the whole point cloud, and taking the average value as an average point distance of the whole point cloud;
Step 1.2, adjusting the position of the point cloud of the steel rail;
and 1.3, simplifying the point cloud to obtain a point cloud model after steel rail simplification.
4. The method for controlling grinding of a rail based on virtual-real combination according to claim 1, wherein in step 1.2, the adjusting the position of the rail point cloud comprises:
1.2.1. removing discrete noise points by adopting density cluster analysis;
1.2.2. estimating the plane with the largest number of plane point clouds from irregular point clouds, and inputting adjustment parameters to divide the plane point clouds;
1.2.3. calculating the normal direction of a rail top plane centroid point, moving a coordinate origin to a rail top point cloud plane centroid, calculating the normal of a plane point cloud, and finally obtaining the normal of the rail top plane centroid point;
1.2.4. Moving the origin of coordinates to the mass center of the cloud segmentation plane of each point, and adjusting the orientation of the point cloud;
1.2.5. And identifying the rail head point cloud, extracting a Z=0 section, and evaluating similarity with the standard rail head section, wherein the maximum similarity is the rail head point cloud.
5. The virtual-real combination-based steel rail grinding control method according to claim 1, wherein the comparing the established virtual steel rail model with the profile of the standard steel rail model, and determining the grinding amount according to the difference comprises:
the actual measurement steel rail model and the standard steel rail model are led into three-dimensional modeling software, the actual measurement steel rail model and the standard steel rail model are aligned, the axes or other characteristic lines of the actual measurement steel rail model and the standard steel rail model are aligned, the difference is determined through Boolean operation, the actual measurement steel rail model is subtracted from the standard steel rail model, if the Boolean operation is true, the steel rail is required to be polished, the next step can be continued, and otherwise, the steel rail is not required to be polished.
6. The method for controlling polishing of steel rail based on virtual-real combination according to claim 1, wherein the establishing a relation between the polishing amount and the polishing parameters of the polishing equipment comprises:
According to the polishing parameters of the polishing equipment under different working conditions, the polishing area of the cross section of the steel rail is calculated in a simulation mode, the shape of the polished steel rail is displayed in a kinematic visual simulation mode in three-dimensional software, and the optimal polishing working condition is screened out through calculation and comparison of the profile of the polished steel rail.
7. The steel rail grinding control method based on virtual-real combination according to claim 1, wherein the grinding parameters comprise the number of grinding heads, the grinding angle, the grinding speed and the grinding power; the generating polishing parameters, guiding polishing equipment to polish, comprises:
Analyzing the profile of the polished steel rail, and screening the optimal polishing working condition;
Outputting the optimal polishing working condition of the screened polishing equipment to a control unit of the polishing equipment, so that the polishing equipment adjusts proper polishing parameters, and polishing the steel rail.
8. The steel rail polishing control method based on virtual-real combination as claimed in claim 1, wherein the polishing control method further comprises post-polishing rechecking, comprising:
and (3) establishing a repeated rail virtual model, secondarily modeling the polished rail, extracting the difference between the actual measured profile of the polished rail and the standard profile, evaluating the actual polishing effect, and secondarily polishing the rail if the actual profile of the polished rail does not meet the use requirement, so as to ensure the polishing quality of the rail.
9. Steel rail polishing control equipment based on virtual-real combination is characterized by comprising:
The acquisition module comprises a three-dimensional scanner and a control unit, wherein the three-dimensional scanner is used for carrying out three-dimensional scanning on the steel rail to acquire steel rail point cloud data; comprising the following steps: scanning the steel rail to obtain a three-dimensional point cloud of the steel rail, and determining coordinates (x, y, z) of the point cloud in a space coordinate system O-XYZ, so as to obtain a high-precision three-dimensional point cloud model; the control unit is used for adjusting the scanning parameters of the three-dimensional scanner;
the simulation analysis module comprises a standard steel rail model library and is used for receiving the point cloud data preprocessed by the preprocessing module, establishing a virtual steel rail model before polishing, and the steel rail model can reflect the health state of the current steel rail; establishing a relation between the polishing amount of the steel rail model and polishing parameters of polishing equipment, and simulating a polishing process;
The polishing control module is used for adjusting scanning parameters of the three-dimensional scanner, determining the required polishing amount of the steel rail by comparing the profile of the steel rail, and selecting the most matched polishing mode according to a set algorithm; and calculating a polishing mode of the steel rail polishing equipment and the steel rail model, which is most matched, according to the polishing amount, generating polishing parameters, and guiding the polishing equipment to polish.
10. The virtual-real combination-based steel rail grinding control device according to claim 9, further comprising:
the preprocessing module consists of a processor with a calculation function and is used for preprocessing the three-dimensional point cloud model acquired by the acquisition module to remove noise points and point clouds irrelevant to the steel rail;
the communication module is used for realizing data transmission and communication among the modules;
and the rechecking module is used for repeating the establishment of the virtual model of the steel rail, carrying out secondary modeling on the polished steel rail, extracting the difference between the actual measured profile of the polished steel rail and the standard profile, evaluating the actual polishing effect, and if the actual profile of the polished steel rail does not meet the use requirement, carrying out secondary polishing on the steel rail, so as to ensure the polishing quality of the steel rail.
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