Track wear detection device and detection method

Abstract

The invention belongs to the technical field of metal mines, and particularly relates to a track wear detection device and method, and the device is characterized in that the device comprises an electric drive motion measurement platform and a hybrid measurement system, the electric drive motion measurement platform comprises a frame, a brushless motor, a gear, a crown-shaped gear, a driving shaft, a driven shaft, a first driving wheel and a second driving wheel; the first driven wheel, the second driven wheel and the two lug plates are arranged on the two sides of the front end of the frame, and the hybrid measurement system comprises a first micron-order multi-line laser sensor, a second micron-order multi-line laser sensor, a displacement sensor, a first three-axis vibration sensor and a second three-axis vibration sensor. According to the invention, data such as holes, scratches, flatness, cracks and crack depth on the surface of the track can be obtained, and the closed-loop motion platform is combined to realize full-track three-dimensional data synthesis, eliminate or reduce the influence of mechanical vibration on measurement, calibrate the measurement result, identify the abnormal loss of the track, and improve the accuracy, stability and continuity of track detection.

Description

Technical Field

[0001] The invention belongs to the technical field of metal mines, and in particular relates to a track wear detection device and a detection method. Background Art

[0002] In the rail transit system, during the track operation, the locomotive will be affected by vibrations from various factors. These vibrations not only come from the mechanical movement of the track and the locomotive itself, but may also be affected by auxiliary equipment such as motor vibration and computer fan vibration. There are many factors that cause locomotive vibrations during track operation. Therefore, how to use an effective filtering algorithm to quickly and accurately detect the vibrations caused by rail surface wear and damage, eliminate other vibrations, and screen out locomotive vibrations caused by rail wear, and then calculate, determine, set thresholds, alarm, and analyze processing results.

[0003] Due to the natural environment, the quality of the rails themselves, and the dynamic effects of the train, there will be damage, wear, and wave wear (referred to as "wave wear") on the rail surface. The wave wear and damage on the rail surface have a significant impact on the operation of the railway track line. It is the source of vibration and noise generated during locomotive operation, which seriously affects the service life of the locomotive and increases the cost of railway maintenance. In severe cases, it may also cause train derailment, resulting in huge losses of life and property. Practice has shown that rail wave wear and damage must be repaired in the early stages of formation, otherwise it will gradually accelerate over time. Therefore, how to quickly and accurately detect rail surface wave wear and damage has become a key issue in the prevention and control of rail diseases.

[0004] In the prior art, the inertial displacement of the rail tread is often directly measured by using an acceleration sensor as an inertial reference: an acceleration sensor is fixedly connected to the axle box of the train wheelset or a special floating measuring probe that is in direct contact with the measured rail tread and moves relatively along the rail tread. The acceleration sensor can obtain the inertial displacement perpendicular to the direction of the rail tread when the measuring probe moves through secondary integration, and the continuously changing inertial displacement is used as the measurement value of the wave wear and damage state of the rail tread. This measurement method has the following disadvantages: it is difficult to always keep close contact with the measured rail tread due to the limitations of the dynamic characteristics of the mechanism; when in contact with the measured rail tread, there is a large or small contact arc, which will cause unnecessary signal distortion, which is not very conducive to the use of complex railway engineering.

[0005] Another more common detection method in the prior art is the relative displacement fixed-point measurement with a linear guide ruler as the chord reference. The basic principle is: a contact or non-contact sensor that can move along the guide ruler and directly measure the distance between the guide ruler and the tread of the rail being measured is installed on the chord reference guide ruler that is placed on the tread of the rail being measured and relatively static. The continuously changing distance value is used as the measurement value of the wave wear and damage state of the rail tread, such as the HYGP-3 rail straightness measuring instrument. This type of detection method has the following disadvantages: low measurement efficiency and high labor intensity due to the fixed-point measurement method; large overlap error due to the need for data overlap; and inability to handle continuous measurement of wave wear and damage in a larger range.

[0006] Chinese patent CN103115581 discloses a multifunctional rail measurement system, which uses a laser three-dimensional profile scanning device installed on a rail vehicle to scan and measure the rail surface profile, and then processes the measurement data to obtain data such as rail surface profile measurement values. However, the device does not consider the impact of mechanical vibration on the measurement system and does not correct the calibration results.

[0007] Chinese patent CN 105783836 B proposes an automatic track wear detection vehicle that can complete full-automatic track gap inspection, has high detection accuracy, can determine the workload in advance, and reduces the labor intensity of workers. The above detection vehicle uses a high-resolution displacement sensor to detect the gap at any position of the track. The supporting facilities require large investment, the data output by the detection vehicle needs to be converted twice to correspond to the on-site position, detection and marking cannot be performed at the same time, and the operating cost is high.

[0008] Chinese patent CN 212432997 U, a track wear detection device for railways, compared with the existing detection devices, this patent is designed with a mobile component, which can automatically run on the rails without human control, and is suitable for the detection of tracks in remote areas, and can also complete track detection in relatively harsh environments. The detection component uses a laser measurement method to measure the rails from multiple sides, and can store real data to facilitate the analysis of staff. Compared with the existing detection devices, the data collected by this utility model is more accurate and reliable. The above device does not consider the impact of mechanical vibration on the measurement system, and cannot process the measurement data in real time.

[0009] Chinese patent CN 110992345 A, a rail wear detection method and device, the present application provides a rail wear detection method and device, including: obtaining a rail image with laser irradiation; inputting the rail image into a pre-trained rail recognition model, determining the feature vector of the first target pixel point of the rail image, wherein the first target pixel point is a pixel point of the rail surface area with laser irradiation; based on the feature vector of the first target pixel point, determining the second target pixel point in the first target pixel point, the second target pixel point constitutes the horizontal rail surface area of ​​the rail image; based on the coordinates of the second target pixel point in the rail image, determining the rail wear coefficient, the rail wear coefficient is used to indicate the degree of rail wear. The above device can improve the efficiency and accuracy of wear detection, but cannot process the detection results in real time. Summary of the invention

[0010] The purpose of the present invention is to provide a track wear detection device and method, which utilizes micron-level multi-line laser sensors, three-axis vibration sensors and developed filtering algorithms to obtain accurate, stable and continuous data on track surface cavities, scratches, flatness, cracks and crack depths. Combined with a closed-loop motion platform, full track three-dimensional data synthesis can be achieved, and the position of unqualified tracks can be recorded and analyzed in real time through a data processor to provide sound and light alarm prompts.

[0011] The objective of the present invention is achieved through the following technical solutions: The track wear detection device of the present invention is characterized by comprising an electric drive motion measurement platform and a hybrid measurement system. The electric-driven motion measurement platform includes a frame, a motor placed at the middle position of the front end of the upper part of the frame bottom plate, a gear connected to the motor, a crown gear meshing with the gear, a driving shaft and a driven shaft arranged on the frame, a first driving wheel and a second driving wheel respectively arranged on both sides of the driving shaft, a first driven wheel and a second driven wheel respectively arranged on both sides of the driven shaft, two ear plates respectively arranged on both sides of the front end of the frame, and two micron-level multi-line laser sensor connecting rods respectively connected to the two ear plates. The crown gear is arranged on the driving shaft. The hybrid measurement system comprises a first micron-level multi-line laser sensor and a second micron-level multi-line laser sensor respectively arranged on the two micron-level multi-line laser sensor connecting rods, a displacement sensor arranged at the tail end of the upper part of the frame bottom plate, and a first three-axis vibration sensor and a second three-axis vibration sensor respectively arranged at the bottom of the frame bottom plate. The first three-axis vibration sensor and the second three-axis vibration sensor are fixedly connected to the bottom of the frame bottom plate through a fixing seat.

[0012] A storage battery is arranged on the upper part of the frame bottom plate.

[0013] A development board and Bluetooth are arranged in parallel on the upper part of the frame bottom plate.

[0014] The motor is a brushless motor.

[0015] A detection method using a rail wear detection device is characterized by comprising the following steps: Step 1: Place the track wear detection device on the track to be detected, confirm the distance between the first three-axis vibration sensor and the second three-axis vibration sensor and the track to prevent the first three-axis vibration sensor and the second three-axis vibration sensor from being damaged by collision, adjust the distance between the first micron-level multi-line laser sensor and the second micron-level multi-line laser sensor and the track, and confirm the detection area; Step 2: After the device is adjusted, turn on the control device to automatically connect to Bluetooth and adjust the vehicle position, and the displacement sensor confirms the starting position; Step 3: Press the start button, and the track wear detection device moves forward at a constant speed driven by the brushless motor. The first micron-level multi-line laser sensor and the second micron-level multi-line laser sensor scan the surface profile of the track to obtain data on track surface cavities, scratches, flatness, cracks, and crack depth. Combined with the closed-loop motion platform, full track 3D data synthesis can be achieved. Step 4: Due to the interference of the mechanical vibration of the motor itself, the mine car will vibrate during operation, causing the distance between the first micron-level multi-line laser sensor and the second micron-level multi-line laser sensor and the track to change, affecting the accuracy of the sensor measurement data. Therefore, the first three-axis vibration sensor and the second three-axis vibration sensor are used to detect the motor vibration value. The filter algorithm is developed to eliminate the influence of the mechanical vibration of the motor itself on the measurement, calibrate the measurement results, identify the abnormal loss of the track, and improve the accuracy, stability and continuity of the track detection. Step 5: The displacement sensor records the displacement of the track wear detection device in real time, so as to determine the position where the track to be tested is severely worn; Step 6: The data processor compares the corrected data of the vibration sensor with the standard value of wear in the database. When the wear threshold is exceeded, the data processor records the position of the unqualified track in real time, and then sounds an audible and visual alarm to alert the surrounding operators. Step 7: After the measurement is completed, the rail wear detection device is driven to return, and the rail wear data is output to the control end and saved; Step 8: Remove the device and clean the dust and gravel on the surface of the tire and housing.

[0016] Advantages of the present invention: The track wear detection device and detection method of the present invention are characterized by installing a micron-level multi-line laser sensor at the front end of the track wear detection device, which can obtain data such as track surface cavities, scratches, flatness, cracks and crack depth, and can realize full track three-dimensional data synthesis in combination with a closed-loop motion platform; using a three-axis vibration sensor and developing a filtering algorithm, the influence of mechanical vibration on measurement can be eliminated or reduced, the measurement results can be calibrated, abnormal track loss can be identified, and the accuracy, stability and continuity of track detection can be improved; the data processor compares the corrected data with the wear condition standard value in the database, and when the wear condition threshold is exceeded, the data processor records the position of the unqualified track in real time, and then sounds an audible and visual alarm to prompt surrounding workers. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic structural diagram of the track wear detection device of the present invention.

[0018] Figure 2 It is a position diagram of the first three-axis vibration sensor and the second three-axis vibration sensor of the present invention.

[0019] Figure 3 Flow chart of the detection method of the present invention. DETAILED DESCRIPTION

[0020] The specific implementation of the present invention is further described below in conjunction with the accompanying drawings.

[0021] like Figure 1 , 2 As shown in Figure 3, the rail wear detection device of the present invention is characterized by comprising an electric drive motion measurement platform and a hybrid measurement system, The electric drive motion measurement platform includes a frame 1, a brushless motor 2 placed in the middle of the front end of the upper part of the bottom plate of the frame 1, the brushless drive motor provides power for the track wear detection device, and can realize motion control, a gear 3 connected to the brushless motor 2, a crown gear 4 meshing with the gear 3, a driving shaft 5 and a driven shaft 8 arranged on the frame 1, a first driving wheel 6 and a second driving wheel 7 respectively arranged on both sides of the driving shaft 5, a first driven wheel 9 and a second driven wheel 10 respectively arranged on both sides of the driven shaft 8, two ear plates 11 respectively arranged on both sides of the front end of the frame 1, and two micron-level multi-line laser sensor connecting rods 12 respectively connected to the two ear plates 11, The crown gear 4 is arranged on the driving shaft 5. The hybrid measurement system comprises a first micron-level multi-line laser sensor 13 and a second micron-level multi-line laser sensor 14 respectively arranged on the two micron-level multi-line laser sensor connecting rods 12, and high-speed measurement is achieved by using high-precision micron-level multi-line laser sensors. The surface profile of the track is scanned by the first micron-level multi-line laser sensor 13 and the second micron-level multi-line laser sensor 14, and data such as cavities, scratches, flatness, cracks and crack depth on the track surface can be obtained. Combined with a closed-loop motion platform, full track three-dimensional data synthesis can be achieved. The displacement sensor 18 is arranged at the tail end of the upper part of the bottom plate of the frame 1. During the detection process, the location of severe wear is located by the displacement sensor. The first three-axis vibration sensor 19 and the second three-axis vibration sensor 20 are respectively arranged at the bottom of the bottom plate of the frame 1. The first three-axis vibration sensor 19 and the second three-axis vibration sensor 20 are fixedly connected to the bottom of the bottom plate of the frame 1 through a fixing seat 21. The running vibration in the rail will strongly affect the measurement data of the first micron-level multi-line laser sensor 13 and the second micron-level multi-line laser sensor 14. Since the mine car is affected by various factors during track operation, the mine car will vibrate during operation, resulting in changes in the distance between the micron-level multi-line laser sensor and the track, affecting the accuracy of the sensor measurement data. In order to eliminate or reduce the influence of locomotive vibration on precision sensors during track operation, a three-axis vibration sensor, namely the first three-axis vibration sensor 19 and the second three-axis vibration sensor 20, is used to detect the vibration value caused by various factors, and a filtering algorithm is developed to eliminate the influence of other vibrations on the measurement, screen out the locomotive vibration caused by rail wear, identify abnormal track loss, and improve the accuracy, stability and continuity of track detection.

[0022] The various factors of locomotive vibration during track operation include: 1. Uneven track: The uneven track surface will cause vertical and lateral vibrations when the locomotive is running.

[0023] 2. Interaction between wheels and tracks: The gap, friction and collision between wheels and tracks will produce vibrations.

[0024] 3. The locomotive's own vibration: including motor vibration, suspension system vibration, and vibration of auxiliary equipment such as computer fans.

[0025] 4. External environmental factors: factors such as wind force and temperature changes will also have a certain impact on locomotive operation.

[0026] The developed filtering algorithm uses an adaptive Kalman filter to accurately filter out locomotive vibration caused by rail wear from complex vibration signals. The Kalman filter is a recursive algorithm that uses a series of measurements (including noise and other inaccuracies) to estimate the state of a dynamic system. The adaptive Kalman filter can automatically adjust its parameters based on real-time data to more accurately track and predict vibration signals.

[0027] The core formula of the adaptive Kalman filter includes the state prediction equation and the observation update equation: State prediction equation The state prediction equation is used to predict the state at the next moment based on the dynamic model of the system using the previous state estimate and to estimate the uncertainty of the state. The formula is as follows: x(k∣k−1)=F(k−1)x(k−1∣k−1)+B(k−1)u(k−1) in: x(k|k−1) represents the state prediction value at time k.

[0028] F(k−1) is the state transition matrix.

[0029] x(k−1|k−1) is the estimated value of the state at time k−1.

[0030] B(k−1) is the control input matrix.

[0031] u(k−1) is the moment k A control input of −1.

[0032] Observation update equation The observation update equation is used to compare the new measured values ​​with the predicted values ​​and update the estimated value and uncertainty of the state according to their uncertainty. The formula is as follows: x(k∣k)=x(k∣k−1)+K(k)(z(k)−H(k)x(k∣k−1)) in: x(k|k) represents the state estimate at time k.

[0033] x(k|k−1) is the predicted value of the state at time k.

[0034] K(k) is the Kalman gain.

[0035] z(k) is the measured value at time k.

[0036] H(k) is the measurement matrix.

[0037] A battery 15 is arranged on the upper part of the bottom plate of the frame 1 to provide electric energy for the driving system and the detection system.

[0038] The upper part of the bottom plate of the frame 1 is provided with a development board 16 and a Bluetooth 17 in parallel. A brushless motor 2 is provided on one side of the battery 15, and a development board 16 is provided on the other side. The development board 16 and the Bluetooth 17 are provided in parallel on the upper part of the bottom plate of the frame 1. The track wear detection device uses the development board 16 and the Bluetooth 17 to control the overall action of the device, and realizes the automatic operation, detection, and position adjustment of the robot by using the program installed on the development board.

[0039] A detection method using a rail wear detection device is characterized by comprising the following steps: Step 1: Signal acquisition: Use sensors to collect vibration signals during locomotive operation.

[0040] 1. Place the track wear detection device on the track to be detected, confirm the distance between the three-axis vibration sensor and the track to prevent the three-axis vibration sensor from being damaged by collision, adjust the distance between the micron-level multi-line laser sensor and the track, and confirm the detection area; 2. After the device is adjusted, turn on the control device, connect Bluetooth, adjust the vehicle position, and confirm the starting position of the displacement sensor; 3. Press the start button, and the track wear detection device moves forward at a constant speed driven by the brushless motor. The micron-level multi-line laser sensor scans the surface profile of the track to obtain data on track surface cavities, scratches, flatness, cracks, and crack depth. Combined with the closed-loop motion platform, the three-dimensional data synthesis of the entire track can be achieved; 4. Use a three-axis vibration sensor to detect vibration values ​​caused by various factors, and use the developed filtering algorithm to eliminate the influence of other vibrations on the measurement, screen out locomotive vibration caused by rail wear, and identify abnormal rail loss; 5. The displacement sensor records the displacement of the track wear detection device in real time to determine the location where the track to be tested is severely worn; Step 2: Preprocessing: Preprocess the collected vibration signal, including denoising and removing DC components, to improve signal quality.

[0041] Step 3: Adaptive filtering: Use the adaptive Kalman filter to filter the preprocessed signal to remove the vibration components generated by auxiliary equipment such as motor vibration and computer fan vibration.

[0042] Step 4: Feature extraction: Perform feature extraction on the filtered signal, including spectrum analysis, time domain analysis, etc., to identify the characteristics of locomotive vibration caused by rail wear.

[0043] Step 5: Determination and threshold setting: Based on the result of feature extraction, a threshold is set to distinguish between vibration caused by rail wear and other types of vibration. When the vibration signal exceeds the threshold, it is determined to be vibration caused by rail wear.

[0044] Vertical wear standard 1) Rails weighing 50kg / m or less: On the main line, when vertical wear exceeds 6mm, replacement or repair should be considered.

[0045] When the vertical wear exceeds 8mm on the starting line, corresponding treatment is required.

[0046] On other station lines, the limit of vertical wear may be higher, but generally does not exceed 10mm.

[0047] 2) Rails weighing 60kg / m and above: On the main line with an allowable speed greater than 120km / h, replacement or repair is required when vertical wear exceeds 6mm.

[0048] On other main lines, treatment is required when vertical wear exceeds 8mm.

[0049] On the arrival and departure lines and other station lines, the limit values ​​for vertical wear may be 10mm and 11mm respectively (or higher, depending on the regulations).

[0050] 2. Side wear standard 1). Lines with a curve radius of less than 500m: When the standard rail steel strength is 700N / mm² and the line traffic volume is 5Mt, the rail side wear is 1mm.

[0051] When the rail steel strength is 900N / mm² and the line traffic volume is 6-10Mt, the side wear is also 1mm.

[0052] 2). Other lines: For lines with a curve radius greater than 500m or straight lines, the limit values ​​of side wear may vary depending on the specific circumstances.

[0053] Generally speaking, the limit value of side wear is lower than that of vertical wear because side wear has a greater impact on track stability.

[0054] 3. Comprehensive wear standard When calculating the total wear, the value is equal to the vertical wear plus half of the side wear (or calculated according to specific regulations). When the wear degree of the rail approaches or reaches the allowable wear of the corresponding line, it must be replaced or repaired.

[0055] Step 6: Correction and alarm: When vibration caused by rail wear is detected, correction processing is performed according to the characteristics of the vibration signal, such as adjusting the filter parameters, optimizing the filtering algorithm, etc. The data processor compares the corrected data of the vibration sensor with the standard value of wear in the database. When the wear threshold is exceeded, the data processor records the position of the unqualified track in real time, and then sounds an audible and visual alarm to alert the surrounding workers; Step 7: Elimination and recording: Eliminate the selected rail wear vibration and record relevant information for subsequent analysis and maintenance. After the measurement is completed, the rail wear detection device is driven back and the rail wear data is output to the control end and saved; Step 8. Save and clean: After the measurement is completed, drive the track wear detection device back, and output the track wear data to the control end and save it; remove the device and clean the dust and gravel on the surface of the tire and shell.

[0056] The track wear detection device and detection method of the present invention installs a micron-level multi-line laser sensor at the front end of the track wear detection device, which can obtain data such as track surface cavities, scratches, flatness, cracks and crack depth. Combined with a closed-loop motion platform, it can realize the synthesis of three-dimensional data of the entire track; using a three-axis vibration sensor and developing a filtering algorithm, it can effectively screen out the locomotive vibration caused by rail wear from the complex vibration signals during track operation. This not only helps to timely discover and repair rail wear problems, improve the safety and stability of rail transit systems, but also provides an important basis for track maintenance. The data processor compares the corrected data with the standard value of the wear condition in the database. When the wear condition threshold is exceeded, the data processor records the position of the unqualified track in real time, and then sounds an audible and visual alarm to prompt the surrounding operators.

Claims

1. A rail wear detection device, characterized in that Including electric drive motion measurement platform and hybrid measurement system, The electric-driven motion measurement platform includes a frame, a motor placed at the middle position of the front end of the upper part of the frame bottom plate, a gear connected to the motor, a crown gear meshing with the gear, a driving shaft and a driven shaft arranged on the frame, a first driving wheel and a second driving wheel respectively arranged on both sides of the driving shaft, a first driven wheel and a second driven wheel respectively arranged on both sides of the driven shaft, two ear plates respectively arranged on both sides of the front end of the frame, and two micron-level multi-line laser sensor connecting rods respectively connected to the two ear plates. The crown gear is arranged on the driving shaft. The hybrid measurement system comprises a first micron-level multi-line laser sensor and a second micron-level multi-line laser sensor respectively arranged on the two micron-level multi-line laser sensor connecting rods, a displacement sensor arranged at the tail end of the upper part of the frame bottom plate, and a first three-axis vibration sensor and a second three-axis vibration sensor respectively arranged at the bottom of the frame bottom plate. The first three-axis vibration sensor and the second three-axis vibration sensor are fixedly connected to the bottom of the frame bottom plate through a fixing seat.

2. The rail wear detection device according to claim 1, characterized in that: A storage battery is arranged on the upper part of the frame bottom plate.

3. The rail wear detection device according to claim 1, characterized in that: A development board and Bluetooth are arranged in parallel on the upper part of the frame bottom plate.

4. The rail wear detection device according to claim 1, characterized in that: The motor is a brushless motor.

5. A detection method using a rail wear detection device, characterized in that: The steps include: Step 1: Place the track wear detection device on the track to be detected, confirm the distance between the first three-axis vibration sensor and the second three-axis vibration sensor and the track to prevent the first three-axis vibration sensor and the second three-axis vibration sensor from being damaged by collision, adjust the distance between the first micron-level multi-line laser sensor and the second micron-level multi-line laser sensor and the track, and confirm the detection area; Step 2: After the device is adjusted, turn on the control device to automatically connect to Bluetooth and adjust the vehicle position, and the displacement sensor confirms the starting position; Step 3: Press the start button, and the track wear detection device moves forward at a constant speed driven by the brushless motor. The first micron-level multi-line laser sensor and the second micron-level multi-line laser sensor scan the surface profile of the track to obtain data on track surface cavities, scratches, flatness, cracks, and crack depth. Combined with the closed-loop motion platform, full track 3D data synthesis can be achieved. Step 4: Due to the interference of the mechanical vibration of the motor itself, the mine car will vibrate during operation, causing the distance between the first micron-level multi-line laser sensor and the second micron-level multi-line laser sensor and the track to change, affecting the accuracy of the sensor measurement data. Therefore, the first three-axis vibration sensor and the second three-axis vibration sensor are used to detect the motor vibration value. The filter algorithm is developed to eliminate the influence of the mechanical vibration of the motor itself on the measurement, calibrate the measurement results, identify the abnormal loss of the track, and improve the accuracy, stability and continuity of the track detection. Step 5: The displacement sensor records the displacement of the track wear detection device in real time, so as to determine the position where the track to be tested is severely worn; Step 6: The data processor compares the corrected data of the vibration sensor with the standard value of wear in the database. When the wear threshold is exceeded, the data processor records the position of the unqualified track in real time, and then sounds an audible and visual alarm to alert the surrounding operators. Step 7: After the measurement is completed, the rail wear detection device is driven to return, and the rail wear data is output to the control end and saved; Step 8: Remove the device and clean the dust and gravel on the surface of the tire and housing.

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