Method for detecting flatness of rail welded joint and method for calculating flatness curve

Abstract

The present application provides a rail welded joint flatness detection method and a flatness curve calculation method, relates to the quality detection field, and particularly relates to a rail welded joint flatness detection method. A sensor walks along the length direction of a rail downward; during walking, the sensor keeps measuring in a detection range L according to a set sampling data amount n; the collected data is transmitted to a calculator for calculation to obtain a rail welded joint flatness detection result. The detection method and the joint flatness curve drawing method greatly improve the precision and efficiency of rail joint flatness detection and flatness curve drawing. Meanwhile, the whole process automation from rail joint flatness detection to flatness curve drawing is realized.

Description

TECHNICAL FIELD

[0001] The present application relates to quality detection, more particularly to a method for detecting the flatness of a rail welded joint. BACKGROUND

[0002] The rail welded joint (hereinafter referred to as "joint") is an important part of the seamless line, and the control of the flatness of the joint is a key prerequisite for ensuring the smooth running of high-speed trains. During the rail welding process, the flatness of each joint needs to be detected to ensure the smoothness of the joint.

[0003] According to the current railway industry standard TB / T1632 in China: "(1) The measurement positions of the flatness of the welded joint are respectively on the longitudinal center line of the rail top surface and the longitudinal line 16 mm away from the rail top surface on the working edge of the rail head side surface; the measurement should take the rail surface at the positions 500 mm on both sides of the center line of the weld as the reference point, the measurement length is 1 m, and the weld is centered. (2) A non-contact sensor automatic detection ruler should be used to measure the flatness of the welded joint, and the display window directly displays the flatness deviation."

[0004] In the production of rail welding, the smoothness of the welded joint is the key to ensuring the safety of the railway. One of the methods to judge the smoothness of the joint is to detect the flatness of the joint. Only the joints that meet the standard requirements after flatness detection can be put into use.

[0005] According to the current railway industry standard TB / T1632 in China: "(1) The measurement positions of the flatness of the welded joint are respectively on the longitudinal center line of the rail top surface and the longitudinal line 16 mm away from the rail top surface on the working edge of the rail head side surface; the measurement should take the rail surface at the positions 500 mm on both sides of the center line of the weld as the reference point, the measurement length is 1 m, and the weld is centered. (2) A non-contact sensor automatic detection ruler should be used to measure the flatness of the welded joint, and the display window directly displays the flatness deviation. When there is a dispute over the measurement results of the automatic detection ruler, the joint can be measured and confirmed by using a detection ruler and a plug gauge.

[0006] The most common detection method at present is a portable device for measuring the flatness of a rail welded joint. It is placed manually at the corresponding detection position, and the flatness curve is obtained after manually clicking the measurement button. The portable detector has a distance measuring sensor installed inside. The operator places the detector on the top surface of the joint to detect the running surface, or on the side surface of the joint to detect the guide surface. The working principle is that the internal sensor of the detector automatically scans the rail surface to obtain distance data, and then calculates the data to draw a curve displayed on the computer software in communication with it.

[0007] However, in a large number of production practices, the obvious defect of the portable flatness measuring device is that the amount of data obtained is obviously less for each measurement of 200 data. In addition, the detection range of the portable flatness measuring device is limited to 1m, which cannot meet the needs of measuring a detection range L of more than 1m. SUMMARY

[0008] The purpose of the present application is to provide a steel rail welded joint flatness detection method, which uses a distance sensor parallel to the guide rail. In the set detection range, the required detection data is continuously obtained according to the set detection data amount.

[0009] The second purpose of the present application is to provide a steel rail welded joint flatness detection method, which can set the detection range according to the detection needs.

[0010] The third purpose of the present application is to provide a steel rail welded joint flatness detection method, which can automatically complete the detection of the flatness within the detection range by setting the detection range.

[0011] The fourth purpose of the present application is to provide a method for processing the series of data obtained by the sensor, which calculates the detection data obtained according to the set detection data and detection range, and draws the steel rail welded joint flatness curve.

[0012] The purpose of the present application is achieved as follows:

[0013] To achieve the above purpose, the present application provides a method for drawing a steel rail welded joint flatness curve. The sensor walks along the length direction of the rail downward; during the walking, the sensor keeps measuring in the detection range L according to the set sampling data amount n; the collected data is transmitted to the calculator for calculation to obtain the steel rail welded joint flatness detection result.

[0014] The steel rail welded joint flatness detection method as described above, wherein the sensor walks parallel to the length direction of the rail by the driving of the transmission mechanism; the transmission mechanism at least includes a power source, a transmission mechanism and a precision guide rail, which are used to control the movement of the sensor.

[0015] The steel rail welded joint flatness detection method as described above, wherein the amount of collected data is set by adjusting the sampling frequency r of the sensor.

[0016] The steel rail welded joint flatness detection method as described above, wherein the detection range L is controlled by at least one signal switch respectively arranged at the starting point and the end point of the rail detection.

[0017] In the above-described method for detecting the straightness of rail welded joints, the travel range of the sensor is greater than the detection range L; the sensor is controlled to start collecting data when it reaches the starting point of the detection range L, and is controlled to stop collecting data when it reaches the ending point of the detection range L.

[0018] In the above-described method for detecting the straightness of rail welded joints, the sensor remains connected to the data acquisition device during measurement.

[0019] In the above-described method for detecting the straightness of rail welded joints, the detection range L extends to both sides along the length of the rail, with the weld as the center.

[0020] In the above-described method for detecting the straightness of rail welded joints, the sensor is a distance measuring sensor; the sampling data is the data on the relative distance between the upper surface of the rail and the sensor.

[0021] To achieve the above objectives, the present invention also proposes a method for drawing the straightness curve of a rail welded joint, which includes at least the following steps:

[0022] S1 Data Acquisition: Acquire the 1st, 2nd, ..., xth, ..., nth sampled data d1, d2, ... dn within the detection range L. n ;

[0023] S2: Create an array: Reverse the order of the 1st, 2nd, ..., xth, ..., nth sampled data d in the detection range L to create a one-dimensional array A[n] containing n elements;

[0024] S3 Data Storage: Store the one-dimensional array A[n] as the raw data of flatness measurement;

[0025] S4 Data Reversal: Reading the first data d of a one-dimensional array A[n]. n Subtract all the data in the array from this data in sequence, and use the difference as the array B[n].

[0026] S5 coordinate system transformation: Perform the following operations on all elements of array B[n] to obtain a set of data constituting array C[n]:

[0027] b x - [ b n [×(x-1)] / n

[0028] Where: b x The data with index x in array B[n];

[0029] n is the amount of sampled data; x is the sequence number of the data. ;

[0030] S6 data storage: C[n] array as the ordinate of the rail straightness curve, the number as the straightness detection data.

[0031] S7 curve drawing: establish the XY coordinate system of the straightness curve; set the abscissa value of each detection point on the horizontal axis X with the detection range L; set the ordinate value of each data of C[n] array as the corresponding ordinate value of each detection point on the vertical axis Y; connect each coordinate point to form the rail straightness curve within the detection range L.

[0032] The drawing method of the rail welded joint straightness curve as described above, wherein the number of sampling data is: n = (L x r) / v;

[0033] Wherein: n is the number of sampling data; L is the detection range length, unit: mm;

[0034] r is the sampling frequency, unit: Hz; v is the sensor walking speed, unit: mm / s.

[0035] The drawing method of the rail welded joint straightness curve as described above, wherein the establishment of one-dimensional array A[n] including n elements is:

[0036] A[n] = [a1, a2, a3…, a x …, a n ] = [d n , d （n-1） , d （n-2） …, d x …, d3, d2, d1];

[0037] Wherein: d n is the nth sampling data; x is the serial number of data, 1 .

[0038] The drawing method of the rail welded joint straightness curve as described above, wherein the array B[n] is:

[0039] B[n] = [b1, b2, b3…, b x …, b n ] = [0, d （n-1） -d n , d （n-2） -d n …, d x -d n …, d1-d n ];

[0040] Wherein: d n is the nth sampling data;

[0041] x is the serial number of data, 1 .

[0042] The method for drawing the flatness curve of the rail welded joint as described above, wherein the array C[n]:

[0043] C[n]=[c1, c2, c3…, c x …, c n ]=[b1, b2-b n / n, b3-2 b n / n, …b x - [ b n ×(x-1)] / n…, b n ×1 / n];

[0044] Wherein: d n is the nth sampling data.

[0045] x is the serial number of the data, 1 .

[0046] The method for drawing the flatness curve of the rail welded joint as described above, wherein the intersection o of the longitudinal axis Y and the horizontal axis X of the flatness curve is the center of the joint weld.

[0047] The method for drawing the flatness curve of the rail welded joint as described above, wherein the coordinate value of each detection point on the horizontal axis X is:

[0048] -L / 2, -L / 2+L / n, …, -L / 2+xL / n, …, L / 2;

[0049] Wherein: L is the detection range length; n is the sampling data quantity;

[0050] x is the serial number of the sampling data, 1 .

[0051] -L / 2, L / 2 are respectively the coordinate points of the two ends of the detection range L with the intersection o of the XY axis as the center.

[0052] The technical effect of the present application is remarkable,

[0053] Firstly, the present application uses a distance sensor parallel to the guide rail, and according to the set detection data quantity, realizes the technical effect of continuously obtaining the required detection data within the set detection range L.

[0054] Secondly, the present application realizes the technical effect of setting the detection range L according to the detection requirement through the setting method of the rail detection starting point 21 and the ending point 22. Thus, the defect that the detection range of the detection device in the prior art is limited to 1m and cannot meet the need of measuring the detection range L of more than 1m is overcome.

[0055] Thirdly, in the present application, the signal switch for setting the detection range L can also realize the automatic detection of the flatness in the detection range L by the sensor.

[0056] Fourthly, by providing a method for processing the series data obtained by the sensor 2, the detection data obtained according to the set detection data and detection range L can be calculated, and the flatness curve of the rail joint can be directly and automatically drawn.

[0057] A large number of tests prove that the detection method and the joint flatness curve drawing method of the present application greatly improve the precision and efficiency of the rail joint flatness detection and the flatness curve drawing. The whole process of the rail joint flatness detection to the flatness curve drawing is realized automatically. BRIEF DESCRIPTION OF DRAWINGS

[0058] Figure 1 The rail flatness detection method of the present application is shown in the figure.

[0059] Figure 2 The sampling data of the distance measuring sensor of the present application is shown in the figure.

[0060] Figure 3 The specific embodiment of the flatness curve drawing method of the present application is shown in the figure.

[0061] Figure 4 The flatness curve of the above-mentioned embodiment of the present application is shown in the figure.

[0062] In the figure: 1 rail; 11 rail surface; 13 rail joint weld;

[0063] 2 sensor; 21 measurement starting point; 22 measurement ending point;

[0064] 3 data acquisition area; 4 distance trajectory;

[0065] The drawings described herein are only for illustrative purposes, and are not intended to limit the scope of the present application in any way. In addition, the shapes and proportions of the components in the figures are only illustrative, and are used to help understand the present application, and are not specific limitations on the shapes and proportions of the components of the present application. Those skilled in the art can select various possible shapes and proportions according to specific circumstances to implement the present application under the guidance of the present application. DETAILED DESCRIPTION

[0066] As Figure 1As shown, the present application provides a kind of steel rail welded joint flatness detection method, by sensor 2 to the detected steel rail 1 is measured, and the relative distance data of steel rail 1 surface and sensor 2 are collected;It is characterized in that, the sensor 2 is walked along the length direction of steel rail 1 downwards;During walking, sensor 2 keeps measuring state in the detection range L according to the set sampling data amount n;The acquisition data is transmitted to calculator for calculation, and the flatness detection result of steel rail welded joint is obtained.Due to the distance sensor that can be walked parallel to guide rail is used in the present application, according to the set detection data amount, in the set detection range L, the technical effect of continuously obtaining the required detection data is realized.

[0067] In one embodiment of the present application, the sensor 2 is driven by a transmission mechanism to walk parallel to the length direction of the steel rail;The transmission mechanism at least includes a power source, a transmission mechanism and a precision guide rail for controlling the movement of the sensor, and the transmission mechanism in the embodiment can adopt a conventional technical solution.

[0068] In one embodiment of the present application, the acquisition data amount is set by adjusting the sampling frequency r of the sensor 2.

[0069] In one embodiment of the present application, the detection range L is controlled by at least one signal switch arranged at the starting point 21 and the ending point 22 of the steel rail detection to determine the detection range L of the present application.In this embodiment, the conventional signal switch technology can be used, Figure 1 As shown in the figure.

[0070] Obviously, by the setting method of the starting point 21 and the ending point 22 of the steel rail detection, the technical effect of setting the detection range L according to the detection requirement can be realized, so that the defect that the detection range of the detection device in the prior art is limited to 1m and cannot meet the need of measuring the detection range L of more than 1m is overcome.

[0071] In a preferred embodiment of the present application, the walking range of the sensor is greater than the detection range L;The sensor starts to collect data under control when walking to the starting point of the detection range L, and stops collecting data under control when walking to the ending point of the detection range L.Further, the sensor 2 in the present application is kept coupled with the data acquisition device in the measuring state.

[0072] In the present application, the signal switch for setting the detection range L also controls the sensor 2 to start collecting data when walking to the starting point 21 of the detection range L, and stops collecting data when walking to the ending point 22 of the detection range L, so that the sensor 2 can automatically complete the continuous detection of the flatness in the detection range.

[0073] In another embodiment of the present application, the detection range L extends to both sides along the length direction of the steel rail with the steel rail joint weld 13 as the center. Figure 1As shown, the rail joint weld 13 extends 1 / 2L along the length direction of the rail. In this embodiment, the flatness of the rail joint is affected by the rail joint weld 13. Therefore, setting the rail joint weld 13 as the center of the detection range L can be beneficial to increase the accuracy of the flatness detection of the rail joint.

[0074] The sensor 2 is a distance measuring sensor, and the sampling data is the data of the relative distance between the upper surface of the rail and the sensor. Figure 1 As shown in FIG. 4, the sensor 2 scans the upper surface of the rail along the track 4 to obtain the sampling data.

[0075] As shown in FIG. 4, the sensor 2 scans the upper surface of the rail along the track 4 to obtain the sampling data. Figure 2 As shown in FIG. 4, the sensor 2 scans the upper surface of the rail along the track 4 to obtain the sampling data.

[0076] S1 Obtain data: obtain the first, second, …, xth, …, nth sampling data d in the detection range L from the data acquisition device. Figure 2 As shown in FIG. 4, the sensor 2 scans the upper surface of the rail along the track 4 to obtain the sampling data. n-1 , d n ;

[0077] S2 Establish array: sequentially invert the first, second, …, xth, …, nth sampling data d in the detection range L to establish a one-dimensional array A[n] including n elements.

[0078] S3 Data storage: store the one-dimensional array A[n] as the original data of the flatness measurement.

[0079] S4 Data inversion: subtract d n from all data in the one-dimensional array A[n] respectively, and the difference is taken as an array B[n];

[0080] S5 Coordinate system conversion: all elements in the array B[n] are respectively operated as follows to obtain a group of data constituting the array C[n]:

[0081] b x - [b n ×(x-1)] / n

[0082] Wherein: b x is the data with the xth sequence number in the array B[n];

[0083] n is the sampling data amount; x is the sequence number of the data, ;

[0084] S6 Data storage: store the array C[n] as the ordinate of the rail flatness curve, and store the number as the flatness detection data.

[0085] S7 Curve Plotting: Establish an XY coordinate system for the straightness curve; set the horizontal coordinate value of each detection point on the horizontal axis X with the detection range L; set each data point of the C[n] array on the vertical axis Y with the vertical coordinate value corresponding to each detection point; connect each coordinate point to form the rail straightness curve within the detection range L.

[0086] In one possible embodiment of the present invention, the number of sampled data is: n = (L×r) / v;

[0087] Where: n is the number of sampled data; L is the detection range, in mm;

[0088] r is the sampling frequency in Hz; v is the sensor travel speed in mm / s.

[0089] In step S2, the establishment of a one-dimensional array A[n] comprising n elements is as follows:

[0090] A[n]=[a1, a2, a3, ..., a x …、a n ]=[d n d （n-1） d （n-2） …、d x …、d3、d2、d1];

[0091] Where: d n This represents the nth sampled data; x is the data index, 1 .

[0092] In step S4, the array B[n]:

[0093] B[n] = [b1, b2, b3, ..., bn] x …、b n ]=[0、d （n-1） -d n d （n-2） -d n …、d x -d n …、d1-d n ]; where: d n This is the nth sampled data;

[0094] x is the data index, 1 .

[0095] In step S5, the array C[n]:

[0096] C[n] = [c1, c2, c3, ..., c x …、c n ]=[b1, b2-b n / n、b3-2 bn / n, … b x - [ b n ×(x-1)] / n, …, b n ×1 / n].

[0097] wherein: d n is the nth sampling data.

[0098] x is the serial number of the data, 1 .

[0099] Referring to Figure 2 , in the present application, the intersection o of the longitudinal axis Y and the horizontal axis X of the flatness curve is the center of the welded joint.

[0100] In step S6, the coordinate value of each detection point on the horizontal axis X is set as:

[0101] -L / 2, -L / 2+L / n, …, -L / 2+xL / n, …, L / 2;

[0102] wherein: L is the detection range; n is the number of sampling data;

[0103] x is the serial number of the sampling data, 1 ;

[0104] -L / 2, L / 2 are respectively the coordinate points of the two ends of the detection range L with the intersection o of the XY axis as the center.

[0105] The present application provides a method for processing the series data obtained by the sensor 2, and the detection data obtained according to the set detection data and the detection range L is calculated, that is, the flatness curve technique of the steel rail welded joint can be directly and automatically drawn.

[0106] The detailed explanations of the above-mentioned embodiments are only for the purpose of explaining the present application, so as to better understand the present application, but these descriptions cannot be explained as the limitation of the present application for any reason, especially, the various features described in different embodiments can be arbitrarily combined with each other, so as to form other embodiments, except for the explicit opposite description, these features should be understood as being applicable to any one embodiment, and not limited to the described embodiments.

Claims

1. A method for drawing a rail welded joint flatness curve, by measuring a detected rail with a sensor to collect the relative distance data between the rail surface and the sensor; the sensor walks along the rail length direction downward; during the walking, the sensor keeps measuring in the detection range L according to the set sampling data amount n; the collected data is transmitted to a calculator for calculation to obtain the rail welded joint flatness detection result; The method for drawing the rail welded joint flatness curve at least includes the following steps: S1 acquires data: acquires the 1st, 2nd, …, xth, …, nth sampling data d1, d2, … d n ; S2. Establishing an array: inverting the first, second, xth, nth sampling data in the detection range L in order to establish a one-dimensional array A[n] including n elements; S3. Data storage: storing the one-dimensional array A[n] as the original data of the flatness measurement; S4 Data Reversal: Subtract d from all data in a one-dimensional array A[n]. n The difference obtained is used as an array B[n]. S5. Coordinate system conversion: operating all elements in B[n] array respectively according to the following way to obtain a group of data constituting C[n] array: b x - [ b n ×(x-1)] / n wherein: b x B[n] is the data with serial number x in the B[n] array; n is the sampling data amount; x is the serial number of the data, ; S6. Data storage: storing C[n] array as the longitudinal coordinate of the rail flatness curve and the storage number as the flatness detection data; S7. Curve drawing: establishing the XY coordinate system of the flatness curve; Setting the horizontal coordinate value of each detection point on the horizontal axis X according to the detection range L; Setting the longitudinal coordinate value of each detection point on the longitudinal axis Y according to each data of C[n] array; Connecting each coordinate point to constitute the rail flatness curve in the detection range L.

2. The method of plotting a rail weld flatness curve as defined in claim 1 wherein, The sampling data amount is: n = (L x r) / v; Wherein: n is the sampling data amount; L is the detection range length, unit: mm; r is the sampling frequency, unit: Hz; v is the walking speed of the sensor, unit: mm / s.

3. The method of plotting a rail weld flatness curve of claim 1 wherein, The one-dimensional array A[n] including n elements is: A[n]=[a1, a2, a3…, a x …、a n ]=[d n d （n-1） d （n-2） …、d x …、d3、d2、d1]; Wherein: d n is the nth sampling data; x is the serial number of data, 1 .

4. The method of plotting a rail weld flatness curve of claim 1 wherein, The array B[n] is: B[n]=[b1、b2、b3…、b x …、b n ]=[0、d （n-1） -d n 、d （n-2） -d n …、d x -d n …、d1-d n ]; wherein: d n is the nth sample data; x is the serial number of the data, 1 .

5. The method of plotting a rail weld flatness curve of claim 4 wherein, The array C[n] is: C[n]=[c1、c2、c3…、c x …、c n ]=[b1、b2-b n / n、b3-2 b n / n、…b x - [ b n ×(x-1)] / n…、b n ×1 / n]。 6. The method of plotting a rail weld flatness curve of claim 1 wherein, The intersection o of the longitudinal axis Y and the horizontal axis X of the flatness curve is the center of the joint weld.

7. The method of plotting a rail weld flatness curve as defined in claim 1 or 6 wherein, The coordinate value of each detection point set on the horizontal axis X is: -L / 2, -L / 2+L / n, …, -L / 2+xL / n, …, L / 2; Wherein: L is the detection range length; n is the sampling data amount; x is the serial number of the sampling data, 1 ; -L / 2, L / 2 are the coordinate points of the two end points of the detection range L with the intersection o of the XY axis as the center.

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