Rail water jet continuous adjustable grinding method and system based on visual positioning

Abstract

The application discloses a steel rail water jet continuous adjustable polishing method and system based on visual positioning, and the method comprises the following steps: starting a polishing vehicle, collecting a steel rail surface image through an industrial camera, and sending the steel rail surface image to a polishing vehicle control center through a signal emission device; collecting a steel rail surface image through an industrial camera, and sending the steel rail surface image to a polishing vehicle control center through a signal emission device; marking the position of a steel rail disease according to a steel rail disease characteristic data signal, and simultaneously identifying polishing vehicle driving parameters and polishing positioning parameters; and controlling each row of water knives of a water jet polishing device to automatically open and close a continuous adjustable nozzle to sequentially complete the entire polishing and repair task of the position of the disease after reaching the position of the disease according to the polishing vehicle driving parameters and the polishing positioning parameters, so that targeted repair polishing of the steel rail disease is realized, and repeated polishing and excessive polishing are avoided.

Description

Technical Field

[0001] This invention belongs to the field of waterjet polishing technology, and more specifically, relates to a method and system for continuous and adjustable waterjet polishing of rails based on vision positioning. Background Technology

[0002] High-pressure water jet technology boasts advantages such as low energy loss, no sparks during operation, no pollution, and strong adaptability to cutting objects, making it particularly suitable for precision rail repair. Furthermore, the water flow can remove the heat generated during rail grinding, preventing thermal deformation of the steel surface and resulting in excellent grinding effects. However, current water jet grinding processes cannot achieve precise positioning of the grinding location. Typically, grinding is performed from the initial section to the final section according to the desired rail contour. However, in reality, rail damage is not continuous, and the above grinding method can cause the water jet to grind undamaged areas, leading to over-grinding and wasted resources. Additionally, during the operation of the rail repair vehicle, the degree of damage and surface condition of different rails vary, and the cleaning positions and areas required for different components on the rail also differ. Existing water jet nozzles cannot be adjusted in diameter, making it impossible to achieve continuous adjustment of the nozzle flow area and precisely control the location and area of ​​rail damage grinding, resulting in low adaptability.

[0003] Therefore, there is an urgent need for a rail waterjet polishing system that can accurately locate the position of rail defects, avoid repeated and excessive waterjet polishing, and precisely control the polishing position and area by adjusting different nozzle orifice diameters. Summary of the Invention

[0004] To address the aforementioned deficiencies or improvement needs of existing technologies, this invention provides a visual positioning-based continuously adjustable waterjet polishing method and system for rails. This invention rapidly locates rail damage by installing an intelligent positioning module at the bottom front of the polishing vehicle and a polishing vehicle control center in the driver's cab. Whenever the intelligent positioning module and the polishing vehicle control center detect defects in the rail ahead, the control center marks the defects and plans the continuously adjustable nozzle opening and closing time of each waterjet based on the installation parameters of the intelligent positioning module, the arrangement of the water jets in the waterjet polishing module, and the speed of the polishing vehicle. This completes the polishing task of each water jet and achieves precise control over rail polishing. This invention enables accurate positioning of the polishing location, avoiding repeated polishing and over-polishing, and allows for precise control of the polishing position and area by adjusting different nozzle orifice diameters.

[0005] To achieve the above objectives, one aspect of the present invention provides a continuously adjustable waterjet grinding method for steel rails based on vision positioning, comprising the following steps:

[0006] S1: Start the grinding machine, collect images of the rail surface through an industrial camera, and send the images of the rail surface to the grinding machine control center through a signal transmitting device;

[0007] S2: The grinding machine control center uses image processing algorithms to identify the defects in the received rail surface images and obtain rail defect feature data signals.

[0008] S3: The grinding car control center marks the location of rail defects and determines the extent of rail damage based on rail defect characteristic data signals, while also identifying the grinding car's driving parameters and grinding positioning parameters;

[0009] S4: The grinding vehicle control center controls the automatic opening and closing of the continuously adjustable nozzles of each water jet grinding device after reaching the location of the rail defect, based on the location of the rail defect, the grinding vehicle's driving parameters, and the grinding positioning parameters. Simultaneously, while the continuously adjustable nozzles are working, the grinding vehicle control center controls the field generator on the continuously adjustable nozzles to generate a continuously adjustable solidified magnetic field based on the rail damage condition. This alters the orifice diameter and shape of the continuously adjustable nozzles to adapt to a working mode compatible with the rail damage, thereby achieving the complete targeted grinding and repair of the rail damage at the defect location.

[0010] Furthermore, the continuously adjustable nozzle includes a nozzle body, a field generator, and a magnetic fluid; the nozzle body has an inlet section and an outlet section; a water flow channel is formed between the inlet section and the outlet section, and a magnetic fluid cavity is provided on the outlet section, the magnetic fluid cavity being deformable;

[0011] The field generator is located in the water outlet section of the nozzle body. The field generator includes an electromagnetic coil, which can generate a continuously adjustable magnetic field according to the current density flowing through it. The field generator can generate a continuously adjustable magnetic field.

[0012] The magnetic fluid is disposed within the magnetic fluid cavity of the nozzle body. The hardness of the magnetic fluid can change with the magnetic field strength generated by the field generator, thereby changing the cross-sectional area of ​​the magnetic fluid cavity. By changing the continuously adjustable magnetic field generated by the field generator, the hardness of the magnetic fluid is changed, thereby forming a high-hardness magnetic fluid in the water outlet section to block the passage of high-pressure water flow, thus realizing the continuous adjustment of the water outlet diameter of the continuously adjustable nozzle, and thus realizing the continuous adjustment of the nozzle diameter.

[0013] Furthermore, the image processing algorithm in step S2 includes "grayscale processing - noise reduction processing - adaptive threshold change - morphological operation" or the YOLO object detection algorithm.

[0014] Furthermore, the grinding vehicle driving parameters in step S3 include the speed of the grinding vehicle.

[0015] The grinding positioning parameters include the distance between the industrial camera and the center of the first drainage blade of the foremost water jet grinding device, and the distance between two adjacent drainage blades of the water jet grinding device.

[0016] Furthermore, the completion of all grinding and repair tasks at the location of the defect described in step S4 also includes the following steps:

[0017] S41: The grinding vehicle control center calculates the time required for the first drainage blade of the water jet grinding device to reach the location of the defect based on the grinding vehicle's speed and the distance between the industrial camera and the center of the first drainage blade of the foremost water jet grinding device. It then controls the first drainage blade to automatically open and close the continuously adjustable nozzle after reaching the location of the defect to complete the grinding task.

[0018] S42: The grinding machine control center calculates the time required for the second drainage knife to reach the defect after the first drainage knife finishes its grinding task based on the grinding machine's speed and the distance between two adjacent drainage knives, and controls the second drainage knife to automatically open and close the continuously adjustable nozzle to complete the grinding task after reaching the location of the defect.

[0019] S43: Similarly, the grinding control module in the grinding machine control center calculates the time required for each subsequent drainage blade to reach the defect, and controls each subsequent drainage blade to automatically open and close the continuously adjustable nozzle after reaching the location of the defect to complete the grinding task, until all grinding and repair tasks at the location of the defect are completed.

[0020] Another aspect of the present invention provides a vision-based, continuously adjustable waterjet grinding system for rails, comprising a grinding vehicle travel guidance module, a grinding vehicle power module, a waterjet grinding module, and an intelligent positioning module mounted on a waterjet grinding vehicle; wherein,

[0021] The grinding vehicle driving guidance module includes a grinding vehicle control center, a driver's seat, and a driver's cab electrical control cabinet located in the cab of the water jet grinding vehicle.

[0022] The grinding vehicle control center includes a signal receiving module, an image processing algorithm module, a rail defect marking module, a parameter setting and recognition module, and a grinding control module.

[0023] The signal receiving module is used to receive the rail surface image data collected and sent by the intelligent positioning module;

[0024] The image processing algorithm module is used to identify the defects in the rail surface image data received by the signal receiving module and obtain rail defect feature data signals.

[0025] The rail defect marking module is used to mark the location of rail defects.

[0026] The parameter setting and recognition module is used to set and recognize the grinding vehicle's driving parameters and grinding positioning parameters;

[0027] The grinding control module is used to control the water jet grinding module to perform grinding tasks, including controlling the automatic opening and closing of the grinding water jet and controlling the continuously adjustable nozzle to adjust to different diameters.

[0028] The intelligent positioning module is located at the front end of the waterjet grinding module, with a gap between them, for pre-collecting images of the rail surface and transmitting these images to the grinding vehicle control center. The grinding vehicle control center plans the continuously adjustable nozzle opening and closing time of each waterjet on the waterjet grinding module based on the installation position parameters of the intelligent positioning module, the arrangement position of the waterjet in the waterjet grinding module, and the travel speed of the grinding vehicle, thereby completing the grinding task of each waterjet and achieving precise control of rail grinding.

[0029] Furthermore, the intelligent positioning module includes an industrial camera located at the bottom of the front end of the vehicle frame and a signal transmitting device connected to the industrial camera;

[0030] The industrial camera is used to capture images of the rail surface;

[0031] The signal transmitting device is communicatively connected to the signal receiving module and is used to send the rail surface image data collected by the industrial camera to the grinding vehicle control center.

[0032] Furthermore, the driving parameters of the grinding vehicle include the speed of the grinding vehicle.

[0033] The grinding positioning parameters include the distance between the industrial camera and the center of the first drainage blade of the foremost water jet grinding device, and the distance between two adjacent drainage blades of the water jet grinding device.

[0034] Furthermore, the water jet polishing device includes multiple water jet blades arranged side by side; each water jet blade has a different cutting angle and is used to polish different positions of the rail; the rail is repaired in all directions through the sequential polishing of the multiple water jet blades.

[0035] Furthermore, each water jet in the water jet polishing device is equipped with a continuously adjustable nozzle; the continuously adjustable nozzle includes a nozzle body, a field generator, and a magnetic fluid; the nozzle body has an inlet section and an outlet section; a water flow channel is formed between the inlet section and the outlet section, and a magnetic fluid cavity is provided on the outlet section, which can be deformed;

[0036] The field generator is located in the water outlet section of the nozzle body. The field generator includes an electromagnetic coil, which can generate a continuously adjustable magnetic field according to the current density flowing through it. The field generator can generate a continuously adjustable magnetic field.

[0037] The magnetic fluid is disposed within the magnetic fluid cavity of the nozzle body. The hardness of the magnetic fluid can change with the magnetic field strength generated by the field generator, thereby changing the cross-sectional area of ​​the magnetic fluid cavity. By changing the continuously adjustable magnetic field generated by the field generator, the hardness of the magnetic fluid is changed, thereby forming a high-hardness magnetic fluid in the water outlet section to block the passage of high-pressure water flow, thus realizing the continuous adjustment of the water outlet diameter of the continuously adjustable nozzle, and thus realizing the continuous adjustment of the nozzle diameter.

[0038] In summary, compared with the prior art, the above-described technical solutions conceived by this invention can achieve the following beneficial effects:

[0039] (1) The visual positioning-based continuous adjustable water jet polishing method and system for rails of the present invention, by installing an intelligent positioning module at the bottom of the front end of the polishing vehicle and installing a polishing vehicle control center in the cab, the polishing vehicle control center includes a signal receiving module, an image processing algorithm module, a rail defect marking module, a parameter setting and recognition module, and a polishing control module; the signal receiving module is used to receive rail surface image data collected and sent by the intelligent positioning module; the image processing algorithm module is used to perform defect feature recognition on the rail surface image data received by the signal receiving module and obtain rail defect feature data signals; the rail defect marking module is used to mark the location of rail defects; the parameter setting and recognition module is used to set and recognize the polishing vehicle driving parameters and polishing positioning parameters; the polishing control module is used to control the water jet polishing module to perform polishing tasks; the intelligent positioning module includes a signal receiving module, an image processing algorithm module, a rail defect marking module, a parameter setting and recognition ... An industrial camera and a signal transmitting device connected to the industrial camera are located at the bottom front of the vehicle frame. The signal transmitting device is communicatively connected to a signal receiving module and is used to send the rail surface image data collected by the industrial camera to the grinding vehicle control center. The intelligent positioning module and the grinding vehicle control center quickly locate the damaged location of the rail. Whenever the intelligent positioning module and the grinding vehicle control center detect defects in the rail ahead, the grinding vehicle control center marks the defects and plans the continuously adjustable nozzle opening and closing time of each water jet according to the installation position parameters of the intelligent positioning module, the arrangement position of the water jet grinding module, and the traveling speed of the grinding vehicle. This completes the grinding task of each water jet, achieves precise control of rail grinding, avoids repeated grinding and over-grinding, and saves resources. At the same time, the grinding position and area can be precisely controlled by adjusting different nozzle orifice diameters.

[0040] (2) The visual positioning-based rail water jet continuously adjustable grinding method and system of the present invention adopts a continuously adjustable nozzle, and generates a continuously adjustable magnetic field by changing the field generator to change the hardness of the magnetic fluid, thereby forming a high hardness magnetic fluid in the water outlet section to block the passage of high pressure water flow, thereby realizing the continuous adjustment of the outlet section diameter of the continuously adjustable nozzle for high pressure water jet rail grinding, realizing the continuous adjustment of the nozzle diameter, which can accurately control the position and area of ​​rail damage grinding, and has high adaptability. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the overall structure of a visual positioning-based continuously adjustable water jet polishing system for rails, according to an embodiment of the present invention.

[0042] Figure 2 This is a schematic diagram of the assembly structure of the continuously adjustable nozzle of a vision-based, water-jet continuously adjustable grinding system for rails, according to an embodiment of the present invention.

[0043] Figure 3 This is a cross-sectional schematic diagram of the continuously adjustable nozzle of a vision-based, continuously adjustable water jet polishing system for rails, according to an embodiment of the present invention.

[0044] Figure 4 This is a schematic flowchart of a vision-based, continuously adjustable water jet polishing method for rails according to an embodiment of the present invention.

[0045] In all the accompanying drawings, the same reference numerals denote the same technical features, specifically: 1-water jet grinding vehicle, 11-bogie, 12-frame, 13-body, 2-grinding vehicle driving guidance module, 21-grinding vehicle control center, 22-driver's seat, 23-cab electrical control cabinet, 3-grinding vehicle power module, 31-diesel engine, 32-generator set, 33-gearbox, 34-cooling unit, 35-power system control cabinet, 36-battery, 37-diesel tank, 4-water jet grinding module, 41-air compressor. 42-Filter, 43-Abrasive tank, 44-Vacuum pump, 45-Booster pump, 46-Water tank, 47-Water jet grinding device, 470-Continuously adjustable nozzle, 4701-Magnetic fluid inlet and outlet, 4702-Magnetic fluid channel, 4703-Abrasive inlet, 47031-Abrasive inlet sealing ring, 4704-Filter screen, 471-Nozzle body, 4711-Water inlet section, 4712-Water outlet section, 4714-Magnetic fluid cavity, 4721-Electromagnetic coil, 4722-Coil connector, 5-Intelligent positioning module, 6-Rail. Detailed Implementation

[0046] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0047] like Figure 1 As shown, one aspect of the present invention provides a visual positioning-based continuously adjustable waterjet grinding system for rails, including a grinding vehicle driving guidance module 2, a grinding vehicle power module 3, a waterjet grinding module 4, and an intelligent positioning module 5 mounted on a waterjet grinding vehicle 1; the grinding vehicle driving guidance module 2 includes a grinding vehicle control center 21, a driver's seat 22, and a cab electrical control cabinet 23; the grinding vehicle control center 21 includes a signal receiving module, an image processing algorithm module, a rail defect marking module, a parameter setting and recognition module, and a grinding control module; the signal receiving module is used to receive rail surface image data collected and transmitted by the intelligent positioning module 5; the image processing algorithm module is used to perform defect feature recognition on the rail surface image data received by the signal receiving module and obtain rail defect feature data signals; the rail defect marking module is used to mark the location of rail defects; the parameter setting and recognition module is used to set and recognize grinding vehicle driving parameters and grinding positioning parameters; the grinding control module... The control module is used to control the waterjet grinding module 4 to perform grinding tasks, including controlling the automatic opening and closing of the grinding water jets and controlling the continuously adjustable nozzles to adjust to different diameters; the grinding vehicle travel parameters include the speed of the grinding vehicle; the grinding positioning parameters include the distance between the industrial camera and the center position of the first water jet grinding blade of the foremost waterjet grinding device and the distance between two adjacent water jet grinding blades of the waterjet grinding device; the intelligent positioning module 5 is located at the front end of the waterjet grinding module 4 and is spaced apart from each other; the intelligent positioning module 5 is used to collect images of the rail surface in advance and transmit the images of the rail surface to the grinding vehicle control center 21; the grinding vehicle control center 21 controls the opening and closing time of the continuously adjustable nozzles of each water jet grinding blade on the waterjet grinding module 4 and adjusts the continuously adjustable nozzles to different diameters according to the installation position parameters of the intelligent positioning module 5, the arrangement position of the water jet grinding blades of the waterjet grinding module, and the travel speed of the grinding vehicle, thereby completing the grinding task of each water jet and achieving precise control of rail grinding.

[0048] Furthermore, such as Figure 1As shown, the waterjet grinding vehicle 1 includes a bogie 11 that travels on the rails to be ground, a frame 12 mounted on the bogie 11, and a body 13 mounted on the frame 12; the body 13 includes a cab, a first machine room, and a second machine room arranged sequentially from front to back; the cab electrical control cabinet 23 is used to control the power supply of the grinding vehicle; the grinding vehicle control center 21, the driver's seat 22, and the cab electrical control cabinet 23 are all located in the cab.

[0049] Furthermore, such as Figure 1 As shown, the power module 3 of the grinding vehicle includes a diesel engine 31, a generator set 32, a gearbox 33, a cooling unit 34, a power system control cabinet 35, a battery 36, and a diesel tank 37. The diesel engine 31 provides power for the grinding vehicle to move forward; the generator set 32 ​​provides continuous power to the grinding vehicle; the gearbox 33 provides different power outputs to the generator set 32; the cooling unit 34 prevents the power system from overheating; the power system control cabinet 35 controls the power system; the battery 36 stores electrical energy; and the diesel tank 37 stores fuel. The diesel engine 31, the generator set 32, the gearbox 33, the cooling unit 34, and the power system control cabinet 35 are all located in the first machine room; the battery 36 and the diesel tank 37 are mounted on the frame 12.

[0050] Furthermore, such as Figure 1As shown, the waterjet polishing module 4 includes an air compressor 41, a filter 42, an abrasive tank 43, a vacuum pump 44, a booster pump 45, a water tank 46, and a waterjet polishing device 47. The abrasive tank 43 is used to store the abrasive required for waterjet polishing. The filter 42 is connected to the abrasive tank 43 and is used to filter out abrasives that do not meet the requirements. Abrasive pipelines are provided between the air compressor 41 and the abrasive tank 43, and between the abrasive tank 43 and the waterjet polishing device 47. The air compressor 41 is used to provide high-pressure air to the abrasive pipelines, providing power for the air brake of the polishing vehicle and providing power for the abrasive transport of the waterjet polishing device 47. The water tank 46 is used to store water. 46. ​​A water pipeline 64 is sequentially connected between the booster pump 45 and the water jet polishing device 47; the vacuum pump 44 is connected to the booster pump 45, the booster pump 45 is connected to the water tank 46, and the water tank 46 is connected to the water jet polishing device 47. The vacuum pump 44 provides vacuum in the water pipeline, and the booster pump 45 pressurizes the water in the water tank 46. After the booster pump, the water pressure can reach a maximum of over 420 MPa and is mixed with the abrasive output from the abrasive tank 43 to polish the rail; the air compressor 41, the filter 42, the abrasive tank 43, the vacuum pump 44, the booster pump 45, and the water tank 46 are all located in the second machine room.

[0051] Furthermore, such as Figures 1-3As shown, the water jet polishing device 47 includes multiple water jet blades arranged side by side; each water jet blade has a different cutting angle and is used to polish different positions of the rail; the rail is repaired in all directions by the sequential polishing of the multiple water jet blades; each water jet blade of the water jet polishing device 47 is equipped with a continuously adjustable nozzle 470; the continuously adjustable nozzle includes a nozzle body 471, a field generator, and a magnetic fluid; the nozzle body 471 has an inlet section 4711 and an outlet section 4712, the inlet section is used for the inflow of high-pressure water, the outlet section is used for the outflow of high-pressure water, a water flow channel is formed between the inlet section and the outlet section, and a magnetic fluid cavity 4714 is provided on the outlet section, the magnetic fluid cavity 4714 can be deformed; the field generator is located on the nozzle body. The water outlet section includes a field generator comprising an electromagnetic coil 4721. The electromagnetic coil 4721 generates a continuously adjustable magnetic field based on the current density flowing through it. The field generator is capable of generating a continuously adjustable magnetic field. A magnetic fluid is disposed within the magnetic fluid cavity 4714 of the nozzle body. The hardness of the magnetic fluid can change with the magnetic field strength generated by the field generator, thereby altering the cross-sectional area of ​​the magnetic fluid cavity. The magnetic fluid consists of solid magnetic particles. By changing the continuously adjustable magnetic field generated by the field generator, the hardness of the magnetic fluid is altered, thus forming a high-hardness magnetic fluid in the water outlet section to block the passage of high-pressure water flow. This achieves continuously adjustable nozzle diameter for the continuously adjustable nozzle section used for high-pressure water jet rail grinding.

[0052] Furthermore, such as Figures 1-3 As shown, the hardening ability of the magnetohydrodynamic fluid is positively correlated with the magnetic induction intensity of the magnetic field generated by the field generator. The function of the hardening ability of the magnetohydrodynamic fluid with the magnetic field induction intensity is: ， in ， The magnetic viscosity of the magnetofluid is such that the greater the magnetic viscosity, the greater the hardness. This is the proportionality coefficient. Let be the relative permeability of the magnetic fluid. The magnetic field strength is shown above. As can be seen from the above function, the continuously adjustable nozzle 470 for high-pressure water jet rail grinding of the present invention increases the magnetic induction intensity of the magnetic field to improve the hardening degree of the magnetic fluid, thereby achieving the formation of a barrier in the water outlet section.

[0053] Furthermore, such as Figures 1-3As shown, the electromagnetic coil 4721 has multiple coils, which are located in the water outlet section 4712. Different currents can flow through the coil of each electromagnetic coil 4721 to form a continuous magnetic fluid of varying hardness in the water outlet section. The continuously adjustable nozzle for high-pressure water jet steel rail grinding of this invention controls the flow of different currents through multiple electromagnetic coils to excite magnetic fields of varying magnetic induction intensities, and forms magnetic fluids of varying hardening degrees near each electromagnetic coil. This allows for the variation of different nozzle types in the continuously adjustable nozzle for high-pressure water jet steel rail grinding, improving its practicality. It enables switching between different nozzle types according to different application environments, meeting diverse usage needs and enriching user choices.

[0054] Furthermore, such as Figures 1-3 As shown, the nozzle is provided with a magnetic fluid inlet / outlet 4701 and a magnetic fluid channel 4702. The magnetic fluid inlet / outlet 4701 is located on the outer periphery of the nozzle body 471. The magnetic fluid inlet / outlet 4701 communicates with the magnetic fluid cavity 4714 through the magnetic fluid channel 4702. The magnetic fluid can enter or leave the magnetic fluid cavity 4714 through the magnetic fluid inlet / outlet 4701. The electromagnetic coil 4721 has a coil connector 4722, which extends out through the magnetic fluid inlet / outlet 4701. It can be understood that the electromagnetic coil 4721 can be connected to an external power source through the coil connector 4722 to achieve adjustable current within the electromagnetic coil 4721. By extending the coil connector 4722 from the magnetic fluid inlet / outlet 4701, an external electromagnetic coil outlet is not required.

[0055] Furthermore, such as Figures 1-3 As shown, 470 also includes an abrasive inlet 4703, which is located on the outer periphery of the nozzle body 111. The abrasive inlet 4703 is positioned away from the magnetic fluid inlet / outlet 4701 and is also connected to the water flow channel. It can be understood that the function of the abrasive inlet 4703 is to inject abrasive into the high-pressure water jet rail grinding process 470. The addition of abrasive increases the kinetic energy of the high-pressure water flow, thereby improving the cutting ability. Simultaneously, due to the siphon effect, the abrasive automatically fills the water flow channel. Positioning the abrasive inlet 4703 away from the magnetic fluid inlet / outlet 4701 avoids interference between the abrasive addition process and the filling and removal of the magnetic fluid. The high-pressure water jet rail grinding device 10 of the present invention also includes an abrasive inlet sealing ring 47031, which prevents high-pressure water from spraying out from the abrasive inlet 4703.

[0056] Furthermore, such as Figures 1-3As shown, the cross-section of the inlet section 4711 is larger than that of the outlet section 4712. The nozzle has a stepped structure. The high-pressure water jet rail grinding 470 of this invention also includes a filter screen 4704. The cross-section of the filter screen 4704 is larger than that of the stepped structure, and the filter screen 4704 can be fixed to the stepped structure under water pressure. It can be understood that because the cross-section of the inlet section 4711 is larger than that of the outlet section 4712, the flow velocity of the outlet section 4712 is increased, further enhancing the kinetic energy of the high-pressure water flow to improve cutting ability. The filter screen 4704 prevents external impurities in the water flow from affecting the use of the high-pressure water jet rail grinding 470. The sealing ring of the abrasive inlet 4703 prevents high-pressure water from being ejected from the filter screen 4704.

[0057] Furthermore, such as Figures 1-3 As shown, the abrasive tank 43 is connected to the abrasive inlet 4703 of the continuously adjustable nozzle via an external circuit. The upper surface of the nozzle body 471 is connected to the high-pressure water tank 46 via a pipeline to provide a high-pressure source. The magnetofluid inlet and outlet 4701 are connected to the magnetofluid tank in sequence, and the coil connector 4722 is connected to the power supply in sequence.

[0058] Furthermore, such as Figure 1 As shown, the intelligent positioning module 5 includes an industrial camera 51 located at the bottom of the front end of the vehicle frame and a signal transmitting device connected to the industrial camera 51; the industrial camera 51 is used to collect images of the rail surface; the signal transmitting device is communicatively connected to the signal receiving module and is used to send the rail surface image data collected by the industrial camera 51 to the grinding vehicle control center 21; the distance between the industrial camera 51 and the grinding center of the first drainage blade of the water jet grinding device 47 in the water jet grinding module is S, and the interval between two adjacent drainage blades of the water jet grinding device 47 is L; The invention utilizes an intelligent positioning module installed at the bottom of the front end of the grinding vehicle and a grinding vehicle control center installed in the cab to quickly locate the damaged position of the rail. Whenever the intelligent positioning module and the grinding vehicle control center detect defects in the rail ahead, the grinding vehicle control center marks the defects and plans the continuously adjustable nozzle opening and closing time of each water jet based on the position parameters of the intelligent positioning module, the arrangement of the water jets of the water jet grinding module, and the speed of the grinding vehicle. This completes the grinding task of each water jet, achieving precise control of rail grinding, avoiding repeated grinding and over-grinding, and saving resources.

[0059] like Figure 4 As shown, another aspect of the present invention provides a visual positioning-based method for continuously adjustable water jet polishing of rails, specifically including the following steps.

[0060] S1: Start the grinding car, collect images of the rail surface through the industrial camera of the intelligent positioning module, and send the images of the rail surface to the grinding car control center through the signal transmitter of the intelligent positioning module; specifically, the direction of the grinding car is controlled by the grinding car driving guidance module 2, and the power module 3 provides the power for the grinding car to move forward; the industrial camera 51 of the intelligent positioning module 5 at the bottom of the front of the grinding car collects images of the rail surface.

[0061] S2: The grinding vehicle control center uses image processing algorithms to identify rail defect features from the received rail surface images to obtain rail defect feature data signals. Specifically, the signal receiving module of the grinding vehicle control center uses image processing algorithms to identify rail defect features from the received rail surface images to obtain rail defect feature data signals. The image processing algorithms include identifying rail surface defects through "grayscale processing - noise reduction processing - adaptive threshold change - morphological operation" or through the YOLO target detection algorithm. When using the YOLO algorithm to identify rail surface defects, the YOLO algorithm needs to be trained in advance. The YOLO algorithm is trained with a large number of images of rail surface defect features to increase the accuracy of the algorithm in identifying defect features. This ensures that during operation, the intelligent positioning module 5 can accurately identify the rail defect features at the current position through its onboard industrial camera and transmit the grinding information to the water jet grinding device 47 located behind it, thus making sufficient preparations for rail defect grinding and repair.

[0062] S3: The grinding car control center marks the location of rail defects and determines the extent of rail damage based on rail defect characteristic data signals, while simultaneously identifying the grinding car's driving parameters and grinding positioning parameters. Specifically, the rail defect marking module in the grinding car control center marks the location of rail defects based on rail defect characteristic data signals, and the parameter setting and identification module in the grinding car control center identifies the grinding car's driving parameters and grinding positioning parameters. The grinding car's driving parameters include the speed of the grinding car; the grinding positioning parameters include the distance between the industrial camera and the center of the first drainage blade of the water jet grinding device, and the distance between two adjacent drainage blades of the water jet grinding device. For example, if the grinding car's driving speed is v (m / s), the distance between the industrial camera and the center of the first drainage blade of the foremost water jet grinding device 47 is S (m), and the distance between two adjacent drainage blades of the water jet grinding device 47 is L (m).

[0063] S4: The grinding trolley control center controls the automatic opening and closing of the continuously adjustable nozzles of each water jet grinding device after reaching the location of the rail defect, based on the location of the rail defect, the grinding trolley travel parameters, and the grinding positioning parameters. Simultaneously, while the continuously adjustable nozzles are operating, the grinding trolley control center controls the field generator on the continuously adjustable nozzles to generate a continuously adjustable solidified magnetic field based on the rail damage condition. This alters the orifice diameter and shape of the continuously adjustable nozzles to adapt to a working mode suitable for the rail damage, thereby achieving the complete targeted grinding and repair of the rail damage at the defect location. Specifically, this includes the following steps:

[0064] S41: The grinding control module of the grinding vehicle control center calculates the time required for the first water jet polishing blade of the water jet polishing device to reach the location of the defect based on the speed of the grinding vehicle and the distance between the industrial camera and the center position of the first water jet polishing blade of the foremost water jet polishing device. It then controls the first water jet polishing blade to automatically open and close the continuously adjustable nozzle after reaching the defect location to complete the grinding task. Specifically, the time t1 required for the first water jet polishing blade of the water jet polishing device 47 to reach the defect location is t1 = S / v, in seconds (s). That is, after S / v (s), the first water jet polishing blade of the water jet polishing device 47 will travel to the defect location. When the first water jet polishing blade of the water jet polishing device 47 reaches the defect location, the grinding vehicle control center automatically controls the first water jet polishing blade nozzle to open and polish the rail at the defect location. When the first water jet polishing blade leaves the defect location, the water jet nozzle is automatically closed, completing the grinding and repair task of the first water jet polishing blade at the defect location.

[0065] S42: The grinding control module of the grinding car control center calculates the time required for the second water jet to reach the defect after the first water jet has completed its grinding task based on the grinding car's speed and the distance between two adjacent water jets. It then controls the second water jet to automatically open and close the continuously adjustable nozzle after reaching the defect location to complete the grinding task. Specifically, after the first water jet of the water jet grinding device 47 reaches the defect location, the time required for the second water jet to reach the defect is t2, where t2 = L / v, in seconds (s). That is, after the first water jet of the water jet grinding device 47 completes its grinding task, it takes L / v (s) for the second water jet of the water jet grinding device 47 to reach the defect location. When the second water jet of the water jet grinding device 47 reaches the defect location, the grinding car control center automatically controls the second water jet nozzle to open and grind the rail at the defect location. When the second water jet leaves the defect location, the nozzle automatically closes, completing the grinding and repair task of the second water jet at the defect location.

[0066] S43: Similarly, the grinding control module in the grinding machine control center calculates the time required for each subsequent drainage blade to reach the defect, and controls each subsequent drainage blade to automatically open and close the continuously adjustable nozzle after reaching the location of the defect to complete the grinding task, until all grinding and repair tasks at the location of the defect are completed, avoiding repeated grinding and over-grinding.

[0067] The working principle of the visual positioning-based continuously adjustable waterjet grinding method and system for rails proposed in this invention is as follows: When the grinding vehicle control center identifies rail defects based on the rail surface image collected by the intelligent positioning module at a certain position on the rail, the location of the rail defect is marked by the rail defect marking module. The parameter setting and recognition module records the current speed of the grinding vehicle v (m / s), the distance of the industrial camera from the center of the foremost waterjet is S (m), and the interval between two adjacent waterjet blades is L (m). After S / v (s), the first waterjet blade will reach the grinding position. When the first waterjet blade reaches the grinding position, the grinding vehicle control center automatically controls the nozzle to open and begin grinding, completing the grinding task of the first waterjet blade. After the first waterjet blade has finished grinding, after L / v (s), the second waterjet blade reaches the grinding position, and the grinding vehicle control center automatically... The system controls the opening of the second water jet nozzle for grinding, completing the grinding task of the second water jet nozzle, and so on, until all grinding tasks at the current position are completed. This invention uses an intelligent positioning module installed at the bottom of the front end of the grinding vehicle and a grinding vehicle control center installed in the cab to quickly locate the damaged location of the rail. Whenever the intelligent positioning module and the grinding vehicle control center detect defects in the rail ahead, the grinding vehicle control center marks the defects and plans the continuously adjustable nozzle opening and closing time of each water jet nozzle based on the position parameters of the intelligent positioning module, the arrangement position of the water jet grinding module, and the traveling speed of the grinding vehicle. This completes the grinding task of each water jet, achieving precise control of rail grinding, avoiding repeated grinding and over-grinding, and saving resources. At the same time, the grinding position and area can be precisely controlled by adjusting different nozzle orifice diameters.

[0068] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for continuous and adjustable waterjet grinding of steel rails based on vision positioning, characterized in that, Includes the following steps: S1: Start the grinding vehicle and use an industrial camera located at the bottom front of the vehicle frame to capture images of the rail surface. Then, use a signal transmitter to send the images of the rail surface to the grinding vehicle control center. S2: The grinding machine control center uses image processing algorithms to identify the defects in the received rail surface images to obtain rail defect feature data signals; and marks the location of rail defects and determines the extent of rail damage based on the rail defect feature data signals. S3: The grinding car control center identifies the grinding car's driving parameters and grinding positioning parameters; the grinding car's driving parameters are the speed of the grinding car, and the grinding positioning parameters include the distance between the industrial camera and the center position of the first drainage blade of the foremost water jet grinding device and the distance between two adjacent drainage blades of the water jet grinding device. S4: The grinding trolley control center accurately calculates the time it takes for each water jet to reach the defect location based on the location of the rail defect, the grinding trolley's travel parameters, and the grinding positioning parameters. It then controls each water jet of the water jet grinding device to automatically open and close the continuously adjustable nozzle after reaching the defect location, keeping the nozzle closed in non-defect areas. Simultaneously, while the continuously adjustable nozzle is working, the grinding trolley control center controls the current density of the electromagnetic coil in the field generator on the continuously adjustable nozzle according to the rail damage condition, generating a continuously adjustable solidified magnetic field. This continuous change in magnetic field strength alters the hardness of the magnetic fluid, thereby changing the aperture and shape of the continuously adjustable nozzle. This allows for continuous adjustment of the nozzle aperture to adapt to a working mode suitable for the rail damage, thus achieving all targeted grinding and repair tasks for the rail damage at the defect location, avoiding repeated grinding and over-grinding. A vision-based, continuously adjustable waterjet grinding system for rails, used to implement the grinding method, includes a grinding vehicle driving guidance module (2), a grinding vehicle power module (3), a waterjet grinding module (4), and an intelligent positioning module (5) mounted on a waterjet grinding vehicle (1); wherein, The grinding vehicle driving guidance module (2) includes a grinding vehicle control center (21), a driver's seat (22), and a driver's cab electrical control cabinet (23) located in the cab of the water jet grinding vehicle (1). The grinding vehicle control center (21) includes a signal receiving module, an image processing algorithm module, a rail defect marking module, a parameter setting and identification module, and a grinding control module; The signal receiving module is used to receive the rail surface image data collected and sent by the intelligent positioning module (5); The image processing algorithm module is used to identify the defects in the rail surface image data received by the signal receiving module and obtain rail defect feature data signals. The rail defect marking module is used to mark the location of rail defects. The parameter setting and recognition module is used to set and recognize the grinding vehicle's driving parameters and grinding positioning parameters; The grinding control module is used to control the water jet grinding module (4) to perform grinding tasks, including controlling the automatic opening and closing of the grinding water jet and controlling the continuously adjustable nozzle to adjust to different diameters; The intelligent positioning module (5) is located at the front end of the water jet polishing module (4) and is spaced apart from each other. It is used to collect images of the rail surface in advance and transmit the images of the rail surface to the polishing vehicle control center (21). The polishing vehicle control center (21) plans the continuously adjustable nozzle opening and closing time of each water jet polishing module (4) according to the installation position parameters of the intelligent positioning module (5), the arrangement position of the water jet polishing module water jets and the driving speed of the polishing vehicle, so as to complete the polishing task of each water jet and realize the precise control of rail polishing.

2. The visual positioning-based continuous adjustable waterjet grinding method for rails according to claim 1, characterized in that, The continuously adjustable nozzle includes a nozzle body, a field generator, and a magnetic fluid; the nozzle body has an inlet section and an outlet section; a water flow channel is formed between the inlet section and the outlet section, and a magnetic fluid cavity is provided on the outlet section, which can be deformed. The field generator is located in the water outlet section of the nozzle body. The field generator includes an electromagnetic coil, which can generate a continuously adjustable magnetic field according to the current density flowing through it. The field generator can generate a continuously adjustable magnetic field. The magnetic fluid is disposed within the magnetic fluid cavity of the nozzle body. The hardness of the magnetic fluid can change with the magnetic field strength generated by the field generator, thereby changing the cross-sectional area of ​​the magnetic fluid cavity. By changing the continuously adjustable magnetic field generated by the field generator, the hardness of the magnetic fluid is changed, thereby forming a high-hardness magnetic fluid in the water outlet section to block the passage of high-pressure water flow, thus realizing the continuous adjustment of the water outlet diameter of the continuously adjustable nozzle, and thus realizing the continuous adjustment of the nozzle diameter.

3. The visual positioning-based continuous adjustable waterjet grinding method for rails according to claim 2, characterized in that, The image processing algorithm in step S2 includes "grayscale processing - noise reduction processing - adaptive threshold change - morphological operation" or the YOLO object detection algorithm.

4. The visual positioning-based continuous adjustable waterjet grinding method for rails according to claim 3, characterized in that, The completion of all grinding and repair tasks at the location of the defect mentioned in step S4 also includes the following steps: S41: The grinding vehicle control center calculates the time required for the first drainage blade of the water jet grinding device to reach the location of the defect based on the grinding vehicle's speed and the distance between the industrial camera and the center of the first drainage blade of the foremost water jet grinding device. It then controls the first drainage blade to automatically open and close the continuously adjustable nozzle after reaching the location of the defect to complete the grinding task. S42: The grinding machine control center calculates the time required for the second drainage knife to reach the defect after the first drainage knife finishes its grinding task based on the grinding machine's speed and the distance between two adjacent drainage knives, and controls the second drainage knife to automatically open and close the continuously adjustable nozzle to complete the grinding task after reaching the location of the defect. S43: Similarly, the grinding control module in the grinding machine control center calculates the time required for each subsequent drainage blade to reach the defect, and controls each subsequent drainage blade to automatically open and close the continuously adjustable nozzle after reaching the location of the defect to complete the grinding task, until all grinding and repair tasks at the location of the defect are completed.

5. The visual positioning-based continuously adjustable waterjet grinding method for rails according to any one of claims 1-4, characterized in that: The intelligent positioning module (5) includes an industrial camera (51) located at the bottom of the front end of the vehicle frame and a signal transmitting device connected to the industrial camera (51). The industrial camera (51) is used to capture images of the rail surface; The signal transmitting device is communicatively connected to the signal receiving module and is used to send the rail surface image data collected by the industrial camera (51) to the grinding vehicle control center (21).

6. The visual positioning-based continuous adjustable waterjet grinding method for rails according to claim 5, characterized in that, The driving parameters of the grinding vehicle include the speed of the grinding vehicle. The grinding positioning parameters include the distance between the industrial camera and the center of the first drainage blade of the foremost water jet grinding device, and the distance between two adjacent drainage blades of the water jet grinding device.

7. The visual positioning-based continuous adjustable waterjet grinding method for rails according to claim 6, characterized in that: The water jet polishing device (47) includes multiple water jet blades arranged side by side; each water jet blade has a different cutting angle and is used to polish different positions of the rail; the rail is repaired in all directions by the sequential polishing of the multiple water jet blades.

8. The visual positioning-based continuous adjustable water jet polishing method for rails according to claim 7, characterized in that: Each water jet polishing device (47) is equipped with a continuously adjustable nozzle; the continuously adjustable nozzle includes a nozzle body, a field generator and a magnetic fluid; the nozzle body has an inlet section and an outlet section; a water flow channel is formed between the inlet section and the outlet section, and a magnetic fluid cavity is provided on the outlet section, which can be deformed. The field generator is located in the water outlet section of the nozzle body. The field generator includes an electromagnetic coil, which can generate a continuously adjustable magnetic field according to the current density flowing through it. The field generator can generate a continuously adjustable magnetic field. The magnetic fluid is disposed within the magnetic fluid cavity of the nozzle body. The hardness of the magnetic fluid can change with the magnetic field strength generated by the field generator, thereby changing the cross-sectional area of ​​the magnetic fluid cavity. By changing the continuously adjustable magnetic field generated by the field generator, the hardness of the magnetic fluid is changed, thereby forming a high-hardness magnetic fluid in the water outlet section to block the passage of high-pressure water flow, thus realizing the continuous adjustment of the water outlet diameter of the continuously adjustable nozzle, and thus realizing the continuous adjustment of the nozzle diameter.

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