A rail weld identification system and normalizing equipment

Abstract

The present invention provides a rail weld identification system and normalizing equipment, wherein the system includes a controller; a slide, which is arranged above the rail positioning platform; the slide includes a sliding track arranged along the length direction of the rail; a driving component; the driving component can slide along the sliding track under the control of the controller; a camera assembly, which is arranged at the bottom end of the driving component, and the camera assembly takes pictures of the identified rail as the driving component slides along the length direction of the rail, and sends the photographed image to be identified containing the weld to the controller; the controller determines the position of the weld relative to the sliding track according to the position of the weld in the image to be identified. The above scheme of the present invention can determine the exact position of the weld in the sliding track, and then determine the precise position of the heating coil in the sliding track, thereby ensuring that the heating step of the normalizing operation is performed facing the weld, ensuring the effect of normalizing.

Description

Technical Field

[0001] The invention relates to the technical field of post-weld heat treatment of rail welded joints, and in particular to a rail weld seam identification system and normalizing equipment. Background Art

[0002] With the development of railway technology and the continuous increase in train operating speed, the mechanical properties of rail welded joints are increasingly required to ensure the safety of train operation. In order to improve the performance of rail joints, the welds need to be normalized. Normalizing refers to the process of heating the welded workpiece to above the critical temperature and then cooling it in the air. The purpose of normalizing is to eliminate the thermal stress generated inside the material at the weld and eliminate the possibility of cracks in the welded material.

[0003] At present, the normalizing process mainly relies on the operator to manually observe the position of the weld, and then the operator manually controls the working head to the weld position to perform heating. However, manual identification of the weld position is prone to deviation, and manual control of the working head to move to the weld position requires very strict professional and experience requirements of the operator. Obviously, the existing normalizing solution that relies on manual operation will not only generate huge manpower costs, but also easily lead to poor normalizing operation results due to the lack of professional and experience of the operator. Summary of the invention

[0004] The present invention aims to provide a rail weld identification system and normalizing equipment, which are used to solve the technical problem that manual identification of weld positions leads to identification deviations that affect normalizing accuracy.

[0005] To achieve the above object, the present invention adopts the following technical solutions:

[0006] Some embodiments of the present invention provide a rail weld identification system, comprising:

[0007] Controller;

[0008] A slide table is arranged above the rail positioning table, and the rail positioning table is used to place the identified rail; the slide table includes a sliding track arranged along the length direction of the rail;

[0009] A driving component, the top end of which is arranged in the sliding track, and the controlled end of which is connected to the output end of the controller; the driving component can slide along the sliding track under the control of the controller;

[0010] A camera assembly is arranged at the bottom end of the driving component, and the camera assembly takes a picture of the identified rail when the driving component slides along the length direction of the rail, and sends the photographed image to be identified including the weld to the controller;

[0011] The controller determines the position of the weld relative to the sliding track according to the position of the weld in the image to be identified.

[0012] In some embodiments of the present application, the rail weld identification system provided by the camera assembly includes a first camera and a second camera;

[0013] The shooting surface of the first camera faces the identified rail; the shooting surface of the second camera is at a certain angle to the shooting surface of the first camera;

[0014] The controller controls the driving component to slide, and the second camera captures the identified rail during the sliding of the camera assembly, and sends the captured image to the controller as a positioning image; when the controller determines that the positioning image contains the weld, the controller controls the driving component to stop sliding; the controller controls the first camera to perform a shooting action and uses the image captured by the first camera as the image to be identified.

[0015] In some embodiments of the present application, the rail weld recognition system is provided, wherein after receiving the image to be recognized, the controller determines the position of the weld relative to the sliding track in the following manner:

[0016] The controller has a weld identification coordinate system pre-stored therein, wherein the coordinate system has the rail length direction as the X-axis, the rail width direction as the Y-axis, and the rail height direction as the Z-axis;

[0017] The X-axis position X1 of the center line of the first camera in the image to be recognized is X Q , the X-axis position of the weld in the image to be identified is X F ; According to the resolution A of the image to be identified, the distance L between the center line of the first camera and the weld in the X-axis direction of the coordinate system is obtained = (X Q -X F )×A; the corresponding position of the weld on the sliding track is X0=X1+L.

[0018] In some embodiments of the present application, the rail weld recognition system is provided, wherein after receiving the image to be recognized, the controller determines the position of the weld relative to the sliding track in the following manner:

[0019] The Z-axis center position Z0 of the weld in the coordinate system is determined according to the distribution of the weld in the Z-axis direction in the image to be identified.

[0020] In some embodiments of the present application, the rail weld identification system provided by the camera assembly further includes a third camera:

[0021] The third camera is arranged opposite to the second camera; the third camera photographs the other side of the identified rail during the sliding process of the camera assembly, and sends the photographed image to the controller as an auxiliary positioning image; when the controller determines that the positioning image contains the weld, the controller controls the driving component to stop sliding.

[0022] In some embodiments of the present application, the rail weld recognition system is provided, wherein after receiving the image to be recognized, the controller determines the position of the weld relative to the sliding track in the following manner:

[0023] The controller determines the Y-axis center position Y0 of the identified rail in the coordinate system based on the positioning image captured by the second camera, the auxiliary positioning image captured by the third camera, the installation position and shooting angle of the second camera, and the installation position and angle of the third camera.

[0024] In some embodiments of the present application, the rail weld identification system provided by the camera assembly further includes:

[0025] A fill light is used to emit a light beam of set light intensity to the identified rail.

[0026] Some embodiments of the present application further provide a normalizing device, including any of the rail weld identification systems described above, and also including a heating coil and a coil driving component:

[0027] The top end of the coil driving component is arranged in the sliding track of the slide table, and the controlled end thereof is connected to the output end of the controller; the heating coil is fixed to the bottom end of the coil driving component;

[0028] After determining the position of the weld relative to the sliding track, the controller controls the coil driving component to move the heating coil to a position directly facing the weld.

[0029] In the normalizing equipment provided in some embodiments of the present application, the coil driving component includes a vertical slide, which is arranged perpendicular to the horizontal plane. The controller is also used to control the coil driving component to move the heating coil up and down along the vertical slide after determining the center position of the weld in the Z-axis direction of the coordinate system, so that the weld is in the central area of ​​the heating coil in the Z-axis direction.

[0030] In the normalizing equipment provided in some embodiments of the present application, the coil driving component includes a vertical slide, which is parallel to the horizontal plane and perpendicular to the sliding track. The controller is also used to control the coil driving component to move the heating coil along the vertical slide after determining the center position of the weld in the Y-axis direction of the coordinate system, so that the weld is in the center area of ​​the Y-axis direction of the heating coil.

[0031] Compared with the prior art, the above technical solution of the present invention has at least the following beneficial effects:

[0032] In the solution provided by the present invention, the camera assembly is arranged on the slide table through a driving component, and the driving component can slide along the slide track of the slide table under the control of the controller, which is equivalent to the camera assembly being able to slide along the length direction of the identified rail. When sliding, the camera assembly takes real-time photos of the identified rail and sends the captured images to the controller. If there is a weld in the captured image, the controller can determine the relative position of the weld in the slide track according to the position of the weld in the image. Because the slide track is the track for the subsequent movement of the heating coil, determining the relative position of the weld in the slide track can determine the precise position of the subsequent heating coil in the slide track, thereby ensuring that the heating step of the normalizing operation is performed facing the weld, ensuring the effect of normalizing. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a schematic diagram of the structure of a rail weld identification system according to an embodiment of the present application;

[0034] Figure 2 This is a schematic structural diagram of the rail weld identification system from another perspective according to an embodiment of the present application;

[0035] Figure 3 This is a structural schematic diagram of another perspective of the rail weld identification system described in the embodiment of the present application;

[0036] Figure 4 This is a schematic diagram of an image to be identified captured by the first camera in one embodiment of the present application;

[0037] Figure 5 This is a structural schematic diagram of a normalizing device according to an embodiment of the present application;

[0038] Figure 6 This is a logical diagram of the heating execution of the normalizing equipment described in one embodiment of the present application. DETAILED DESCRIPTION

[0039] The embodiments of the present invention will be further described below in conjunction with the accompanying drawings. In the description of the present invention, it should be noted that the orientations or positional relationships indicated by the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc. are based on the orientations or positional relationships shown in the accompanying drawings, and are only simplified descriptions for the convenience of describing the present invention, rather than indicating or implying that the device or component referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", and "third" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance. Among them, the terms "first position" and "second position" are two different positions.

[0040] This embodiment provides a rail weld identification system, including a controller such as Figure 1 and Figure 2 As shown, the rail weld identification system also includes a slide 100, which is arranged above the rail positioning platform 200, and the rail positioning platform 200 is used to place the identified rail 203; the slide 100 includes a sliding track 102 arranged along the length direction of the rail; a driving component, which can be a driving motor, a cylinder, etc. Its top end is arranged in the sliding track, and its controlled end is connected to the output end of the controller; the driving component can slide along the sliding track 102 under the control of the controller; a camera component is arranged at the bottom of the driving component through a frame 101, and the camera component shoots the identified rail 203 as the driving component slides along the length direction of the rail, and sends the image to be identified containing the weld 204 to the controller; the controller determines the position of the weld 204 relative to the sliding track 102 according to the position of the weld 204 in the image to be identified. The controller can be a PLC controller, a conventional PC, a desktop computer, etc., and it can be implemented in a combination of multiple hardware modules according to actual needs.

[0041] In the above scheme, the camera assembly is arranged on the slide 100 through the driving component. The driving component can slide along the slide track 102 of the slide 100 under the control of the controller, which is equivalent to the camera assembly being able to slide along the length direction of the identified rail. The camera assembly takes real-time photos of the identified rail 203 while sliding and sends the captured image to the controller. If there is a weld 204 in the captured image, the controller can determine the relative position of the weld 204 in the slide track 102 according to the position of the weld 204 in the image. Because the slide track 102 is the track for the subsequent movement of the heating coil, by determining the relative position of the weld 204 in the slide track 102, the precise position of the subsequent heating coil in the slide track 102 can be determined, thereby ensuring that the heating step of the normalizing operation is performed facing the weld 204, ensuring the effect of normalizing.

[0042] like Figure 1 and Figure 2 As shown, preferably, the camera assembly includes a first camera 104 and a second camera 103; the shooting surface of the first camera 104 faces the identified rail 203, wherein the position of the first camera 104 can be located on one side of the identified rail 203 and faces the identified rail 203 as shown in the figure, or can be located directly above the identified rail 203 and faces the identified rail 203; the shooting surface of the second camera 103 is at a certain angle to the shooting surface of the first camera 104; as shown in the figure, preferably, the shooting surface of the second camera 103 and the shooting surface of the first camera 104 are set at a 45° angle. The controller controls the driving component to slide, and the second camera 103 shoots the identified rail 203 during the sliding process of the camera assembly, and sends the shot image to the controller as a positioning image; when the controller determines that the positioning image contains the weld 204, it controls the driving component to stop sliding; the controller controls the first camera 104 to perform the shooting action and uses the image shot by the first camera 104 as the image to be identified.

[0043] The first camera 104 and the second camera 103 in the above scheme can be implemented by industrial cameras, and the lens is distortion-free or minimally distorted, and the focal length is reasonably selected according to the actual size of the target object. The first camera 104 is installed and fixed perpendicular to the inner side of the identified rail 203, and the second camera 103 is installed at an angle of 45 degrees. As shown in the figure, the frame 101 is used to fix the first camera 104 and the second camera 103. Preferably, a fill light 400 is also fixedly provided on the frame 101, and the fill light 400 is used to emit a light beam of a set light intensity to the identified rail 203, and the light beam is the light intensity of natural light, which can ensure that the first camera and the second camera can capture a clear picture.

[0044] More preferably, if Figure 3 As shown, the camera assembly further includes a third camera 105, which is arranged opposite to the second camera 103; the third camera 105 photographs the other side of the identified rail 203 during the sliding process of the camera assembly, and sends the photographed image to the controller as an auxiliary positioning image; when the controller determines that the positioning image contains the weld 204, it controls the driving component to stop sliding. Figure 2 As shown, the third camera 105 and the second camera 103 can be fixed on the frame 101 symmetrically, and the third camera 105 can also be equipped with a fill light 400. Moreover, in order to ensure that the second camera 103 and the third camera 105 can capture clear images, a fill light 400 can also be set at the upper position of the frame 101. In this solution, the fill light 400 is installed vertically to the inner side of the identified rail 203 and vertically above, and the light intensity is guaranteed to ensure that all three cameras can capture clear images for the controller to identify the weld 204.

[0045] In some embodiments, the controller receives Figure 4 After the image to be identified is obtained, the position of the weld 204 relative to the sliding track 102 is determined in the following manner:

[0046] The controller has a weld identification coordinate system pre-stored in it, wherein the coordinate system takes the rail length direction as the X-axis, the rail width direction as the Y-axis, and the rail height direction as the Z-axis. As shown in the figure, the X-axis position X1 of the center line of the first camera 104 in the image to be identified is X Q The X-axis position of the weld 204 in the image to be identified is X F According to the resolution A of the image to be identified, the distance L between the center line of the first camera 104 and the weld in the X-axis direction of the coordinate system is obtained = (X Q -X F )×A; the corresponding position of the weld on the sliding track is X0=X1+L. Specifically, Figure 4 As shown in FIG. 1 , the total distance occupied by the image to be identified in the X-axis direction can be obtained in advance, and the resolution of the image to be identified can be determined at the same time, so that the corresponding parameters of the position and distance occupied by each column of pixels in the X-axis direction can be obtained. Q The number of pixel columns occupied and X F The number of pixel columns occupied and the difference between the two can be used to calculate the L value based on the corresponding parameters of pixels and distance.

[0047] Similarly, the Z-axis center position Z0 of the weld in the coordinate system is determined according to the distribution of the weld in the Z-axis direction in the image to be identified. In this embodiment, assuming that the weld 204 is a straight line distributed along the height of the rail, the Z-axis center position of the weld in the coordinate system can be obtained in the following manner: Figure 4 As shown, the controller determines the Z-axis center position of the weld in the coordinate system as Z0=(Z1+Z2) / 2 according to the Z-axis position Z1 of the first edge of the identified rail in the image to be identified and the Z-axis position Z2 of the second edge of the identified rail in the image to be identified. And, according to the positioning image captured by the second camera, the auxiliary positioning image captured by the third camera, the installation position and shooting angle of the second camera, and the installation position and angle of the third camera, the Y-axis center position Y0 of the identified rail in the coordinate system is determined. In actual application, the shape of the weld 204 may be irregular in various ways. The controller can determine the center position of the weld in the Z-axis and Y-axis according to the relative position relationship between the camera that captures the image and the weld, as well as image processing and calculation models.

[0048] The above scheme can combine the images taken by multiple cameras to determine the spatial position information of the weld 204 in the three directions of the X-axis, Y-axis and Z-axis. When the weld is subsequently heated by the coil, the position of the coil can be adjusted according to the spatial position information of the weld, so that the weld is located in the middle position of the coil in the three directions of the X-axis, Y-axis and Z-axis.

[0049] like Figure 3 , 5 and Figure 6As shown, the embodiment of the present application also provides a normalizing device, including the rail weld identification system described in any one of the above items, and also including a heating coil 301 and a coil driving component, the coil driving component can be a motor, an electric cylinder, etc.: the top end of the coil driving component is arranged in the sliding track 102 of the slide, and its controlled end is connected to the output end of the controller; the heating coil 301 is fixed to the bottom end of the coil driving component; after determining the position of the weld 204 relative to the sliding track 102, the controller controls the coil driving component to move the heating coil 301 to a position directly opposite to the weld 204. Preferably, the movement process of the heating coil and the weld identification system on the sliding track may not interfere with each other, and the relative position of the heating coil and the frame in the weld identification system remains fixed. The fill light 400, three cameras and the heating coil are all fixed on the same rigid object (slide) to avoid offset. The positions of the three cameras and the heating coil cannot be offset to avoid affecting the accuracy of coordinate conversion. The setting positions of the three cameras will not change to ensure that the three cameras can capture the gap between the left and right sides of the identified rail and the top of the heating coil.

[0050] Furthermore, the coil driving component includes a vertical slide, which is arranged perpendicular to the horizontal plane, and the controller is also used to control the coil driving component to move the heating coil up and down along the vertical slide after determining the center position of the weld in the Z-axis direction of the coordinate system, so that the weld is in the center area of ​​the Z-axis direction of the heating coil. And, the coil driving component includes a vertical slide, which is arranged parallel to the horizontal plane and perpendicular to the sliding track, and the controller is also used to control the coil driving component to move the heating coil along the vertical slide after determining the center position of the weld in the Y-axis direction of the coordinate system, so that the weld is in the center area of ​​the Y-axis direction of the heating coil.

[0051] from Figure 3It can be seen from the structure shown that when the heating operation is performed, the heating coil moves to a position directly opposite to the weld. At this time, the corresponding relationship between the heating coil and the weld can also be determined through the images captured by the three cameras respectively, and the position of the heating coil is accurately adjusted according to the gap distance between the heating coil and the weld in all directions captured by the three cameras. In addition, at least one additional light source can be added to the coil, the light source and the coil are on the same straight line, and this straight line is perpendicular to the rail. The additional light source can be located on the side or directly above the rail. The light beam emitted by the light source can pass through the heating coil and irradiate the identified rail. The part blocked by the heating coil will form a shadow. The image captured by the camera can determine whether the shadow part coincides with the weld. If the shadow part coincides with the weld, it means that the coil is facing the weld at this time. Since the thickness and width of the rail are known quantities, the Y-axis and Z-axis positions of the heating coil in the coordinate system can be adjusted according to the inner diameter of the heating coil and the thickness and width of the identified rail. In the present application, in order to improve the accuracy of the position adjustment of the heating coil, the position of the weld in the coordinate system is accurately located through the images captured by the three cameras, and the position of the heating coil in three directions in the coordinate system is adjusted based on the precise positioning, so that the heating effect of the heating coil on the weld can be optimized.

[0052] Although the above describes the specific implementation of the present invention in conjunction with the accompanying drawings, it is not intended to limit the scope of protection of the present invention. For those skilled in the art, other different forms of modifications or deformations can be made on the basis of the above description. It is not necessary and impossible to list all the implementation methods here. On the basis of the technical solution of the present invention, various modifications or deformations that can be made by those skilled in the art without creative work are still within the scope of protection of the present invention.

Claims

1. A rail weld identification system, characterized in that: include: Controller; A slide table is arranged above the rail positioning table, and the rail positioning table is used to place the identified rail; the slide table includes a sliding track arranged along the length direction of the rail; A driving component, the top end of which is arranged in the sliding track, and the controlled end of which is connected to the output end of the controller; the driving component can slide along the sliding track under the control of the controller; A camera assembly is arranged at the bottom end of the driving component, and the camera assembly takes a picture of the identified rail when the driving component slides along the length direction of the rail, and sends the photographed image to be identified including the weld to the controller; The controller determines the position of the weld relative to the sliding track according to the position of the weld in the image to be identified; The camera assembly includes a first camera and a second camera; The shooting surface of the first camera faces the identified rail; the shooting surface of the second camera forms a certain angle with the shooting surface of the first camera; the angle is 45 degrees; wherein: the first camera is installed perpendicular to the inner side of the identified rail, and the second camera is installed at an oblique angle of 45 degrees; The controller controls the driving component to slide, and the second camera captures the identified rail during the sliding of the camera assembly, and sends the captured image to the controller as a positioning image; when the controller determines that the positioning image contains the weld, the controller controls the driving component to stop sliding; the controller controls the first camera to perform a shooting action and uses the image captured by the first camera as the image to be identified; After receiving the image to be identified, the controller determines the position of the weld relative to the sliding track in the following manner: The controller has a weld identification coordinate system pre-stored therein, wherein the coordinate system has the rail length direction as the X-axis, the rail width direction as the Y-axis, and the rail height direction as the Z-axis; The X-axis position X1 of the center line of the first camera in the image to be recognized is X Q , the X-axis position of the weld in the image to be identified is X F ; According to the resolution A of the image to be identified, the distance L between the center line of the first camera and the weld in the X-axis direction of the coordinate system is obtained = (X Q -X F )×A; the corresponding position of the weld on the sliding track is X0=X1+L.

2. The rail weld identification system according to claim 1, characterized in that: After receiving the image to be identified, the controller determines the position of the weld relative to the sliding track in the following manner: The Z-axis center position Z0 of the weld in the coordinate system is determined according to the distribution of the weld in the Z-axis direction in the image to be identified.

3. The rail weld identification system according to claim 2, characterized in that: The camera assembly also includes a third camera: the third camera is arranged opposite to the second camera; the third camera photographs the other side of the identified rail during the sliding process of the camera assembly, and sends the photographed image to the controller as an auxiliary positioning image; when the controller determines that the positioning image contains the weld, the controller controls the driving component to stop sliding.

4. The rail weld identification system according to claim 3, characterized in that: After receiving the image to be identified, the controller determines the position of the weld relative to the sliding track in the following manner: The controller determines the Y-axis center position Y0 of the identified rail in the coordinate system based on the positioning image captured by the second camera, the auxiliary positioning image captured by the third camera, the installation position and shooting angle of the second camera, and the installation position and angle of the third camera.

5. The rail weld identification system according to any one of claims 1 to 4, characterized in that: The camera assembly also includes: a fill light, which is used to emit a light beam of set light intensity to the identified rail.

6. A normalizing device, characterized in that: The rail weld identification system comprises the rail weld identification system according to any one of claims 1 to 5, and further comprises a heating coil and a coil driving component: The top end of the coil driving component is arranged in the sliding track of the slide table, and the controlled end thereof is connected to the output end of the controller; the heating coil is fixed to the bottom end of the coil driving component; After determining the position of the weld relative to the sliding track, the controller controls the coil driving component to move the heating coil to a position directly facing the weld.

7. The normalizing equipment according to claim 6, characterized in that: The coil driving component includes a vertical slide, which is arranged perpendicular to the horizontal plane. The controller is also used to control the coil driving component to move the heating coil up and down along the vertical slide after determining the center position of the weld in the Z-axis direction of the coordinate system, so that the weld is in the center area of ​​the heating coil in the Z-axis direction.

8. The normalizing equipment according to claim 7, characterized in that: The coil driving component includes a vertical slide, which is parallel to the horizontal plane and perpendicular to the sliding track. The controller is also used to control the coil driving component to move the heating coil along the vertical slide after determining the center position of the weld in the Y-axis direction of the coordinate system, so that the weld is in the center area of ​​the Y-axis direction of the heating coil.

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