Turnout rail hot forging forming on-line automatic detection device and detection method

Abstract

The present application relates to a kind of both realizes the three-dimensional automatic scanning of switch rail hot forging forming part in blanking position immediately, output the three-dimensional point cloud model of the part, and can utilize processing software to detect all sizes of the part, and generate detection report switch rail hot forging forming online automatic detection device and detection method, including high-precision three-dimensional automatic scanner, six joint industrial robot, robot fixed gantry and corresponding control system and software.Gantry is fixed on the basis of the periphery of press machine, industrial robot is installed on the crossbeam of gantry, scanner and industrial robot end joint connection.Detection, industrial robot drives scanner to take photograph scanning according to pre-set path, the data of each photograph scanning is spliced by processing software, finally forms workpiece three-dimensional point cloud model, utilizes processing software to detect all sizes of the part, and generates detection report.

Description

Technical Field

[0001] This invention relates to an online automatic inspection device and method for hot forging of turnout rail parts, which can immediately perform three-dimensional automatic scanning of the hot forging parts at the blanking position, output the three-dimensional point cloud model of the parts, and use processing software to inspect all dimensions of the parts and generate an inspection report. Background Technology

[0002] Turnouts are an important component of railway transportation equipment. The rails in turnouts undergo hot forging during factory manufacturing. Due to the unique nature of the forging process, the temperature of the rail components after processing reaches over 850℃ (approximately 1000℃ during inspection). Current inspection methods can only measure a few dimensions of a specific cross-section at the end, and some critical aspects (such as cross-sectional symmetry, dimensions in the middle of the formed section, rail straightness, fishtail space, etc.) cannot be detected in a timely manner. Generally, these issues only become apparent after the workpiece cools to room temperature, or even after it has been processed into machining. Problems can lead to batch quality incidents, causing significant waste and hindering workshop production. Furthermore, the heat radiation during inspection is extremely harmful to human health, making product quality control very difficult. Summary of the Invention

[0003] Design Objective: To overcome the shortcomings of the prior art, and considering the actual conditions of hot forging forming of turnout rails on-site, this design proposes an automatic scanner using structured light 3D measurement and a six-joint robot, which interacts with the existing automatic hot forging forming line transfer system. Simultaneously, a corresponding gantry frame for fixing the six-joint robot is designed (an improvement on existing technology, see appendix). Figure 4 This invention relates to an online automatic inspection device and method for hot forging of turnout rail parts, which enables immediate three-dimensional automatic scanning of the hot forging parts at the blanking position, outputs a three-dimensional point cloud model of the part, uses processing software to inspect all dimensions of the part, and generates an inspection report.

[0004] Design Scheme: To achieve the above design objectives, this system includes a high-precision 3D automatic scanner, a six-joint industrial robot, a robot mounting gantry, and corresponding control systems and software. For example... Figure 1 As shown, the gantry frame is fixed to the perimeter of the press, and the industrial robot is mounted on the gantry frame beam. The scanner and the end effector of the industrial robot are connected. During inspection, the industrial robot drives the scanner to take pictures and scan along a pre-set path. The data from each picture scan is stitched together by the processing software to finally form a 3D point cloud model of the workpiece.

[0005] The present invention addresses the issue of high-precision scanners requiring vibration damping. Since presses vibrate significantly during operation, hindering accurate and accurate positioning, industrial robots cannot be mounted on press columns. Furthermore, the inspection location is a pedestrian walkway, requiring frequent passage by operators. Additionally, considering the diverse range of products hot-forged by the press, manual inspection of certain specialized workpieces may be necessary, further limiting the possibility of ground-mounted industrial robots. To resolve the scanner vibration damping issue and minimize the inconvenience for operators, an online automatic inspection device for hot-forged turnouts was designed based on the specific site conditions. Figure 1 As shown.

[0006] The workpiece inspection position corresponds to the foundation pit of the press. To ensure the scanner can scan all parts of the workpiece while minimizing the industrial robot's arm reach, the ideal position is directly opposite the guide rail unloading position, which is the foundation pit of the press. Therefore, the following design was implemented... Figure 2 The fixed base is shown. It is secured to the side of the foundation pit using expansion bolts, with a horizontal plate installed on top and pre-installed connecting screws.

[0007] The side column is connected to the horizontal plate of the fixed base at the bottom and to the horizontal beam at the top. The side column is separate from the press column, forming two independent force-bearing systems to avoid the impact of press vibration on the accuracy of the testing device. The side wall is fixed to the press foundation at the bottom and connected to the horizontal beam at the top. A monitor is installed in front of the side wall to display the scanner's scanning status in real time. The flat plate under the horizontal beam is 1.9m above the ground, facilitating operator movement and measurement. The industrial robot base is installed on the side of the horizontal beam, facing the measuring track, such as... Figure 3 As shown.

[0008] The fixed base is lowered into the press pit and secured to the side foundation of the pit using expansion bolts. The level plate is then adjusted to be parallel to the ground by adjusting the bottom screws. The side columns are installed on the level plate and connected with screws. The side walls are installed on the level ground and fixed to the foundation at the bottom using expansion bolts. A horizontal beam is installed on the side columns and side walls, with the side with the mounting plate facing the workpiece. The horizontal beam, side walls, and side columns are bolted together. The industrial robot is mounted on the horizontal beam mounting plate and bolted together. Finally, the scanner is installed on the tail joint of the industrial robot. The robot's movement drives the scanner to complete the workpiece photographing and measurement. During the initial measurement, the industrial robot teach pendant is used to determine the required photographing points and path for the scanner to measure the workpiece, and an automatic control program is generated to achieve automated measurement.

[0009] Specifically, the rail components are transferred from the hot forging production line to the unloading position on the unloading rack via the transfer mechanism. When a photoelectric switch at the unloading position detects the incoming material, it sends a signal to the automatic detection system. Upon receiving the rail arrival signal, the detection system activates an industrial robot to scan and photograph the rail along a pre-set path. The images are then stitched together using processing software to create a 3D point cloud model. After measurement, the industrial robot sends a measurement completion signal to the control system of the transfer mechanism on the hot forging production line. Upon receiving the signal, the control system pushes the rail to the unloading storage area. The process is repeated when the next hot forged rail is transferred to the unloading position on the unloading rack, thus achieving online automatic detection.

[0010] Compared with the prior art, this invention has the following advantages: First, it is applicable to three-dimensional online automatic measurement of rails after hot forging at high temperatures (900-1050℃), generating a three-dimensional point cloud model that meets all quality inspection requirements for hot-forged rails. It achieves online automatic inspection of hot workpieces, with high inspection efficiency, comprehensive inspection items, high accuracy, and wide applicability. It can quickly identify product appearance and dimensional quality problems, avoiding waste in production. Second, it solves the problem in existing technologies that cannot detect some key dimensions of turnout rails after hot forging (such as cross-sectional symmetry, dimensions at the middle of the formed section, rail straightness, fishtail space, etc.). Third, it is practical... The invention features several key improvements. First, it allows for direct measurement at the material unloading location to determine quality, preventing issues from arising only after hot-forged rails have entered the next process, thus avoiding batch quality problems. Second, it incorporates an industrial robot gantry fixing device, designed to accommodate the actual foundation conditions of the press, securing the robot 1.9m above the ground for easy operator access and manual retesting. Third, it employs an independent force-bearing system to prevent press vibrations from affecting the accuracy of repeated measurements by the industrial robot. Fourth, it utilizes an industrial robot-controlled scanner for image scanning, significantly expanding the device's applicability and enabling measurement of all hot-forged turnout rail products. Attached Figure Description

[0011] Figure 1 This is a 3D schematic diagram of an online automatic inspection device for hot forging of turnout rails.

[0012] Figure 2 yes Figure 1 Front view diagram.

[0013] Figure 3 yes Figure 1 Side view diagram.

[0014] Figure 4 This is a schematic diagram of the main view of the gantry crane.

[0015] Figure 5 This is a top-view diagram of the gantry crane.

[0016] Figure 6 This is a 3D schematic diagram of a gantry crane. Detailed Implementation

[0017] Example 1: Refer to Appendix Figure 1-6 An online automatic inspection device for hot forging of turnout rails includes a control cabinet 13, a gantry frame fixed on a foundation 2 around a press 1, a foundation pit 3 on the foundation, and the rail component unloading position directly opposite the foundation pit. An industrial robot 4 (ABBIRB2600) is mounted on the gantry beam 5, facing the rail component being measured. A scanner 6 is connected to the end joint of the industrial robot 4. The workpiece inspection position corresponds to the foundation pit 3 of the press. Multiple unloading supports 7 are provided in the foundation pit 3, and the upper support surface of the multiple unloading supports 7 is the workpiece inspection position. The ideal position for workpiece inspection is directly opposite the rail component unloading position. A fixed base 8 is fixed to the side of the foundation pit with expansion bolts, and a horizontal plate 12 is installed on it with pre-installed connecting screws. The bottom of the gantry side column 9 is connected to the horizontal plate of the fixed base, and the top of the gantry side column 9 is connected to the gantry beam 5. The side column 9 is separate from the press column 10. The bottom of the gantry side wall 10 is fixed to the press foundation 2, and the top of the gantry side wall 10 is connected to the gantry beam 5. A display 11 is installed in front of the side wall to show the scanner scanning status in real time. A photoelectric switch is installed at the unloading position.

[0018] The gantry has a П-shaped structure in the front view and an L-shaped structure in the top view. The three-dimensional view consists of the П-shaped structure and the side wall 10. The horizontal beam at the top of the П-shaped structure is equipped with an industrial robot mounting base plate. One side of the П-shaped structure is a side wall.

[0019] Example 2: Based on Example 1, an online automatic detection method for hot forging of turnout rails is provided. The rail components are transferred to the unloading position of the unloading rack by the transfer mechanism of the hot forging production line. When the photoelectric switch at the unloading position detects the incoming material, it sends a signal to the automatic detection device system in the control cabinet. After receiving the rail arrival signal, the detection system starts the industrial robot to take pictures and scan the rails according to the preset path. The images are then stitched together by the processing software (existing software, VisionScanV6.1 and Geomagic) to form a three-dimensional point cloud model. After the industrial robot completes the measurement, it sends the measurement completion signal to the control system of the transfer mechanism of the hot forging production line (existing mechanism, i.e., the automatic feeding system of the press). After receiving the signal, the control system pushes the rails to the unloading storage area. When the next hot forged rail is transferred to the unloading position of the unloading rack, the above actions are repeated to achieve online automatic detection (the overall three-dimensional dimensions and shape of the workpiece being measured, including the rail base width, rail height, rail web thickness, rail head width, fishtail space, etc.).

[0020] It should be understood that although the above embodiments provide a relatively detailed textual description of the design concept of the present invention, these textual descriptions are merely simple textual descriptions of the design concept of the present invention, and not limitations on the design concept of the present invention. Any combination, addition, or modification that does not exceed the design concept of the present invention falls within the protection scope of the present invention.

Claims

1. A method for on-line automatic detection of hot-forging forming of a turnout rail, the detection method being used in an on-line automatic detection device for hot-forging forming of a turnout rail, the device comprising a control cabinet (13), characterized in that: The gantry is fixed on the foundation (2) of the press (1), the foundation is provided with a foundation pit (3), the opposite side of the foundation pit is the rail unloading position, the industrial robot (4) is installed on the gantry beam (5) and faces the measuring rail, the scanner (6) is connected with the end joint of the industrial robot (4); the method comprises the following steps: the rail is transferred to the unloading position of the unloading frame by the transfer mechanism of the rail hot forging forming production line, when the incoming material is detected by the photoelectric switch at the unloading position, the signal is sent to the automatic detection device system in the control cabinet, after the rail positioning signal is received by the detection system, the industrial robot starts to take pictures and scan the rail according to the preset path, the pictures are spliced by the processing software, finally the three-dimensional point cloud model is formed, after the industrial robot is measured, the measurement completion signal is sent to the control system of the transfer mechanism of the rail hot forging forming production line, after the signal is received by the control system, the rail is pushed to the unloading storage area, when the next hot forging forming rail is transferred to the unloading position of the unloading frame, the above-mentioned action is repeated, and then the overall three-dimensional size and shape of the measured workpiece are realized, including the rail bottom width, the rail height, the rail waist thickness, the rail head width and the fish tail space.

2. The online automatic detection method for hot forging of turnout rails according to claim 1, characterized in that: the workpiece The detection position corresponds to the foundation pit (3) of the press, and the foundation pit (3) is provided with a plurality of unloading supports (7), and the upper end supporting surface of the unloading supports (7) is the workpiece detection position.

3. The method according to claim 2, wherein the workpiece is a switch rail. The most ideal position of the detection position is the opposite side of the rail unloading position. ​ 4. The method for on-line automatic detection of hot swage forming of switch rail according to claim 1, characterized in that: The fixed base (8) is fixed with the foundation pit side by expansion nails, and a horizontal plate (12) is arranged on the fixed base, and a connecting screw is reserved.

5. The method for on-line automatic detection of hot swage forming of switch rail according to claim 1, characterized in that: The bottom of the gantry side column (9) is connected with the fixed base horizontal plate, the top of the gantry side column (9) is connected with the gantry beam (5), and the side column (9) is separated from the gantry side wall.

6. The method of claim 1, wherein the method further comprises: determining the position of the rail head; and determining the position of the rail foot. The bottom of the gantry side wall (10) is fixed with the press foundation (2), the top of the gantry side wall (10) is connected with the gantry beam (5), and the display (11) is installed on the front of the side wall to display the scanning condition of the scanner in real time.

7. The method according to claim 3, wherein the method is characterized by: The unloading position is provided with a photoelectric switch.

8. The method of claim 1, wherein the method is characterized by: The three-dimensional online automatic measurement is carried out at a high temperature of 900-1050℃.

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