Online automatic detection equipment and detection method for key parts of alloy steel frog

Abstract

The present application relates to a kind of alloy steel frog key part processing online automatic detection equipment and automatic detection method, including line laser, rack, screw, purging device, servo motor etc., line laser is installed on rack, to measure alloy steel rail, the profile of insert block, obtains profile measurement data, servo motor drives the movement of Y, Z direction screw, encoder records the displacement of overall operation, ensure that line laser is located in appropriate detection position, so that detection result is more accurate, purging module is set on rack, for the purging processing of switch rail piece.Occupation: it is convenient to realize alloy steel frog key part processing online automatic detection demand, meet the measurement demand of the geometric dimension of alloy steel rail and insert block milling section profile of different structures;It also has the functions of detection data processing, storage, transmission and real-time display, and can interact with user information system.

Description

Technical Field

[0001] This invention relates to an online automatic inspection method for key components of alloy steel turnouts, capable of online automatic inspection of the machining of alloy steel core rails, inserts, and wing rails, belonging to the field of railway turnout manufacturing technology. Background Technology

[0002] Currently, the inspection of the milling accuracy of key components of alloy steel frogs largely relies on traditional manual inspection equipment for offline testing and manual statistics. This method suffers from drawbacks such as low efficiency, high labor intensity, and cumbersome data entry, hindering online evaluation, data management, and maintenance of the milling accuracy of alloy steel frogs. With the continuous development of computer and sensor technologies, laser camera sensors are increasingly widely used in the field of rail component inspection. This paper proposes an online inspection scheme for the milling accuracy of alloy steel frog sections, employing high-precision inspection and digital processing technologies to achieve automated online inspection and refined management of frog section dimensions. Furthermore, the continuous integration of next-generation information technology, with intelligent manufacturing at its core, and the manufacturing industry has become a prominent trend in the development of advanced manufacturing globally. Currently, my country has explored and formed a number of relatively mature, replicable, and scalable new intelligent manufacturing models, and the intelligent manufacturing promotion system has been basically established. In the future, further technological innovation on the supply side is needed. Intelligent manufacturing is the deep integration and innovative fusion of manufacturing technology and information technology, representing a transformation in production organization methods and business models. The company is also gradually moving towards intelligent manufacturing and automation. Summary of the Invention

[0003] Design objective: To overcome the shortcomings of the prior art, this design proposes an online automatic inspection device and method for key components of alloy steel frogs, such as the center rail, inserts, and rail parts, which can achieve online automatic inspection during the processing of these components. This method aims to reduce the labor intensity of workers, improve processing efficiency, and ensure processing accuracy.

[0004] Design Scheme: With the continuous increase in the operating speed and density of high-speed railways, the wheel-rail impact load will also increase accordingly. Due to differences in structure and load-bearing method, alloy steel frogs are particularly susceptible to wear on their alloy steel core rails, which directly affects the safety of train operation, passenger comfort, and the service life of the alloy steel core rails. Therefore, during the milling process of alloy steel frog core rails and inserts, while strengthening the processing technology, scientific testing techniques should be adopted, and the cross-sectional dimensions of the parts should be strictly controlled and managed in accordance with relevant standards to ensure that the processing dimensions of the parts meet the process requirements and gradually improve the quality of products in the workshop.

[0005] Therefore, based on the existing milling machine, the present invention firstly sets up a frame for mounting the line laser, thereby realizing the overall movement of the laser. A line laser, mounted on the frame, is used to measure the contours of the alloy steel core rail and inserts, obtaining contour measurement data. A data receiving and storage module, connected to the contour measurement module and the distance measurement module respectively, is used to receive and store the contour measurement data and the distance measurement data, and simultaneously retrieve and store standard data of the turnout rail components. A data processing module, connected to the data receiving and storage module, is used to retrieve the contour measurement data, obtain the three-dimensional contour data of the alloy steel core rail and inserts, and compare the standard data of the alloy steel core rail and inserts with the three-dimensional contour data to generate an inspection report. A purging module, located at the front end of the machine tool slide, is used to purge residual iron filings during the processing of the alloy steel core rail and inserts. Secondly, a height adjustment unit, using a separate industrial control computer, controls a servo motor to drive a lead screw to rotate, adjusting the height of the frame. Thirdly, a horizontal position adjustment unit, using a separate industrial control computer, controls a servo motor to drive a lead screw to rotate, adjusting the horizontal position of the frame.

[0006] Therefore, in the design of the online automatic inspection method for key components of alloy steel forks, the data receiving and storage module of this invention includes a data receiving unit and a data storage unit. The data receiving unit is connected to the data storage unit and also to the contour measurement module. The data receiving unit is used to receive the contour measurement data and the distance measurement data. The data storage unit is used to store the contour measurement data and retrieve and store the standard data of the alloy steel core rail and inserts.

[0007] The data processing unit includes a mobile terminal and a terminal; the mobile terminal is used to display the contour measurement data in real time and monitor it online; the terminal is used to obtain the three-dimensional contour data based on the contour measurement data, and call the standard data to compare with the three-dimensional contour data to generate the detection report.

[0008] The alloy steel core rail and insert are placed on a CNC milling machine for the first cut.

[0009] The contour measurement module is used to measure the alloy steel core rail and insert after the first cut, thereby obtaining contour measurement data;

[0010] The contour measurement data is received and stored using the data receiving and storage module, and the standard data of the alloy steel core rail and the insert are retrieved and stored at the same time.

[0011] The data processing module processes the contour measurement data to obtain the three-dimensional contour data of the alloy steel core rail and insert after the first cut. Simultaneously, the standard data of the alloy steel core rail and insert are compared with the three-dimensional contour data to calculate the tool feed rate for the second cut of the alloy steel core rail. This feed rate is then fed back to the CNC system for online automatic machining. The above steps are repeated until the three-dimensional contour of the alloy steel core rail and insert meets preset conditions.

[0012] The data processing module is used to process the final contour measurement data of the alloy steel core rail after processing to obtain an inspection report.

[0013] Compared with the prior art, this invention has the following advantages: First, it meets the measurement requirements for the geometric dimensions of milled cross-sectional contours of rail components, core rails, and inserts with different rail types, and the detection accuracy meets industry standard requirements. It also has functions such as data processing, storage, transmission, and real-time display, and can interact with user information systems. Second, based on distance measurement and contour scanning technology, the automatic detection device completes the online automatic detection of the dimensions of alloy steel core rails, inserts, and rail components, improving detection accuracy. Third, it replaces manual inspection with automatic measurement, reducing labor intensity. Combined with information technology, it quickly, efficiently, and accurately completes the detection of key components of alloy steel frogs, reducing worker labor intensity. Fourth, it effectively integrates the detection of various rail types, improving processing efficiency and achieving automated, continuous, and efficient detection. Furthermore, it completes the scanning and comparison of workpiece contour dimensions in a short time, reducing auxiliary time and improving machining efficiency. Fifth, it establishes a database and performs timely data analysis. This is used to establish a standard database, realize comparative analysis of test data, and store the test data in the database to achieve traceability of product quality throughout the entire process and life cycle. This facilitates analysis and verification by technical personnel, provides strong support for product tracking, and promotes the application of the final online testing technology. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of an online automatic inspection device for alloy steel core rail and insert processing.

[0015] Figure 2 This is a structural diagram of an online automatic inspection device used for processing alloy steel core rails and inserts.

[0016] Figure 3 This is a structural diagram of an online automatic inspection device used for processing alloy steel core rails and inserts.

[0017] Figure 4 This is a physical diagram of an online automatic inspection device used for processing alloy steel core rails and inserts.

[0018] Figure 5This is a physical diagram of an online automatic inspection device used for processing alloy steel core rails and inserts.

[0019] Figure 6 This is a schematic diagram of the principle of online automatic testing equipment for testing alloy steel core rails.

[0020] Figure 7 This is a schematic diagram of the least squares method principle.

[0021] Figure 8 This is a schematic diagram of the least squares method principle.

[0022] Figure 9 This is a flowchart of the online automatic detection process. Detailed Implementation

[0023] Example 1: Please refer to Figure 1-9 The frame is fixedly mounted on the milling machine gantry and mainly connects to or is positioned relative to other measurement modules, providing support for the entire online inspection. Simultaneously, a separate track and power system are installed on the frame. The vertical and horizontal displacement is adjusted by rotating the lead screw driven by a servo motor, ensuring the contour measurement module is in the optimal inspection position. After machining to the final depth, chip removal is performed simultaneously to improve efficiency. Once machining is complete, chip removal also ends, and the measurement function is activated. The host computer controls the CNC system and the inspection motors. The CNC system controls the machine tool's X-axis and the host computer's Y and Z axes, positioning the probe to the measurement start position. Then, only the machine tool's X-axis moves, and the cross-sectional contour data is sampled in real time using a line laser. The sampled X-axis coordinates are sampled and uploaded to the host computer. The host computer reconstructs the 3D model and calculates the corresponding contour dimension error, feeding this error value back to the CNC system. The CNC system modifies the machining contour compensation amount by adjusting system variables. This process is repeated until the required accuracy is met.

[0024] Please see Figure 5 It should be noted that a suitable scanning position is crucial for the contour measurement module to perform a complete scan of the entire rail component's contour, while simultaneously meeting the height, width, and cross-sectional shape requirements of the alloy steel core rail. Different shapes of alloy steel core rails have different requirements, and the position of the contour measurement module can be set according to specific circumstances. Furthermore, the contour measurement module is mounted on the frame and used to measure the contour of the alloy steel core rail. The highest points P1 and P2 of two image data points are overlapped to completely stitch the two image data points together, forming a complete contour of the calibration rail component, thus obtaining the contour measurement data. The data receiving and storage modules are connected to the contour measurement module to receive and store the contour measurement data, and simultaneously retrieve and store the standard data of the alloy steel core rail.

[0025] It should be noted that the standard data for the alloy steel core rail refers to the standard data of the end face geometric dimensions of the preset alloy steel core rail, including the standard values, tolerances, key section location information, linear functions between sections, and core rail information. The core rail information includes the drawing number, construction number, and material information of the preset alloy steel core rail. This standard data serves as a benchmark to assist the online testing equipment in its operation, thereby completing the inspection and judgment of the alloy steel core rail's quality. Simultaneously, the data storage unit also pre-stores the alloy steel core rail standard data from the enterprise information system. This data storage unit mainly consists of a storage server, responsible for storing the data received by the data receiving unit. Based on the enterprise information system, this data storage unit communicates with the enterprise information system via a wireless channel, enabling product information interaction and association. By calling the alloy steel core rail standard information in the enterprise information system, the testing parameters of the testing device can be adjusted online for on-site processing guidance, product analysis, and subsequent traceability, thus achieving human-machine interaction.

[0026] Furthermore, the purging module is located on the side of the milling machine ram, and the mechanical cleaning device is fixed to the milling machine with screws. Please refer to [link to relevant documentation]. Figure 3 It is used to purge alloy steel core rails. The purging and cleaning method is a combination of compressed air purging and mechanical cleaning. The compressed air purging uses the pneumatic equipment built into the milling machine.

[0027] After all the accessories are installed, some of them need to be fine-tuned in order to achieve the required measurement accuracy. The line laser can be rotated and adjusted in the vertical and horizontal directions, which can adjust the measurement range of the laser line scanning sensor to achieve a precise position, thereby accurately measuring the contour of the alloy steel core rail being measured.

[0028] The working principle of this automated online inspection equipment for the processing of alloy steel core rails is as follows:

[0029] This automated online inspection equipment for alloy steel mandrel machining uses a follow-along mode to detect the geometric dimensions of the mandrel's machining contour. With each feed, the contour measurement module acquires contour data in real time. Correspondingly, the data receiving and storage module receives and stores the contour measurement data, and retrieves standard data from the enterprise information system for storage. The data processing module processes the contour measurement data and standard data to generate a data inspection report to guide machining. Furthermore, it wirelessly transmits the report to the enterprise information system, storing the final inspection data therein.

[0030] Example 2: Based on Example 1, the present invention also provides an automated online inspection method for the processing of alloy steel core rails. This inspection method is implemented using online inspection equipment and specifically includes the following steps:

[0031] Step (1): Place the alloy steel core rail to be tested on the milling machine worktable for the first cut.

[0032] An automated online inspection device is installed on the crossbeam of a milling machine. The milling cutter is located on the spindle at the front of the milling machine crossbeam to mill the mandrel. The alloy steel mandrel moves with the movement of the machine tool table. At this time, the inspection device is stationary. According to the process requirements, the alloy steel mandrel to be machined is processed with the first cut. The feed rate of the first cut is determined by the specific process.

[0033] Step (2): Use the contour measurement module to measure the alloy steel core rail after the first cut to obtain contour measurement data.

[0034] After the milling machine completes the first cut, it needs to return to the initial position before the second cut can be performed. During the process of the milling machine returning to the initial position, the detection equipment is started, and the cross-section of the alloy steel core rail being processed is scanned by a laser line scanning sensor to obtain the cross-sectional contour information of the alloy steel core rail.

[0035] Step (3): Receive and store the contour measurement data using the data receiving and storage module, and simultaneously retrieve and store the standard data of the alloy steel core rail from the enterprise information system. Receive contour data of different positions of the alloy steel core rail using the industrial control host and send it to the storage server for further storage.

[0036] Step (4): Use the data processing module to process the contour measurement data to obtain the three-dimensional contour data after the first cut of the alloy steel core rail. At the same time, call the standard data of the alloy steel core rail and compare it with the three-dimensional contour data to calculate the tool feed amount for the second cut of the alloy steel core rail.

[0037] Step (5): After adjusting the machining trajectory of the milling machine according to the tool feed rate, perform the second cut on the alloy steel core rail.

[0038] The contour measurement data obtained from the second machining operation is received by the industrial control host and stored on the storage server.

[0039] Step (6): Repeat steps (1) to (5) until the three-dimensional contour shape matches the preset standard data of the alloy steel core rail.

[0040] Step (7): Use the data processing module to process the final contour measurement data of the alloy steel core rail after processing, so as to obtain the inspection report.

[0041] The embodiments of this invention, through this automated inspection equipment, achieve the following beneficial effects: First, the online inspection equipment for the alloy steel core rail manufacturing process provided by this invention has a simple structure and is easy to use. It continuously inspects the alloy steel core rail using a line laser vision sensor, not only completing traditional product quality judgments but also providing data feedback during intermediate stages of processing, offering processing guidance to operators. This solves the problems of non-automation in the inspection process, human error in inspection, and the inability to continuously inspect alloy steel core rails in traditional manual inspection systems. Second, this invention, through this online inspection equipment, achieves automatic inspection of the geometric dimensions of CNC milling contours, improving measurement accuracy, reducing worker labor intensity, and increasing production efficiency. Furthermore, based on the detected data, the feed rate of the core rail machining tool can be calculated and optimized, guiding the optimization and improvement of forming tools and ensuring product processing quality. Third, this invention can utilize height adjustment modules and horizontal position adjustment modules to adjust the three deflection directions of the contour measuring instrument to adapt to the inspection of various core rails and inserts. Fourth, this automated online inspection equipment of this invention can interact with enterprise information systems to achieve real-time transmission and storage of inspection data for product information traceability.

[0042] The measurement method of the present invention: as follows Figure 6 As shown, the cross-sectional contour coordinate data measured by line laser 1 and line laser 2 respectively are transformed to the coordinate system {YOZ}, and then... Figure 7 The least squares method shown is used to obtain the base plane contour line, and then the distance between the two side contours is obtained.

[0043] 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. An online automatic inspection device for key components of alloy steel forks, characterized in that... In the industrial control computer, COM1 interface is connected to the signal input terminal of the Y-axis motor driver, and the signal output terminal of the Y-axis motor driver is connected to the signal input terminal of the Y-axis motor. COM2 interface is connected to the signal input terminal of the Z-axis motor driver, and the signal output terminal of the Z-axis motor driver is connected to the signal input terminal of the Z-axis motor. COM3 interface is connected to the signal input terminal of the left-side jet device. COM4 interface is connected to the signal input terminal of the right-side jet device. Network port 2 is connected to the machine tool's communication port. Network port 1 is connected to the switch's communication interface, and the switch's communication interface is connected to the signal input terminals of line laser I and line laser II, respectively. USB I interface is connected to the switch's communication interface, and USB II interface is connected to the display's signal input terminal. HDM I interface is connected to the display's signal input terminal.

2. The online automatic inspection equipment for key components of alloy steel forks according to claim 1, characterized in that: Includes a rack, line laser, data receiving and storage module, data processing module, and purge module; The line laser is mounted on the frame and moves as a whole on the frame to measure the contours of the alloy steel core rail and the insert, and obtain contour measurement data. In the industrial control computer, the data receiving and storage module is connected to the contour measurement module and the distance measurement module respectively. The data receiving and storage module is used to receive contour measurement data and distance measurement data and store them using the storage module. The data receiving and storage module also retrieves and stores the standard data of the alloy steel core rail. The data processing module and the data receiving and storage module in the industrial control computer are connected to call the contour measurement data and obtain the three-dimensional contour data of the alloy steel core rail and the insert. The data processing module calls the standard data of the alloy steel core rail and the insert and compares it with the three-dimensional contour data to form an inspection report. The purging module is located at the front end of the machine tool slide and is used to purge iron filings remaining during the machining of the alloy steel core rail and inserts.

3. The online automatic inspection equipment for key components of alloy steel forks according to claim 1, characterized in that: In the industrial control computer, the COM2 interface is connected to the Z-axis motor driver signal input terminal, and the Z-axis motor driver signal output terminal is connected to the Z-axis motor signal input terminal; the height adjustment unit uses a separate industrial control computer to control the servo motor to drive the lead screw to rotate, thereby adjusting the height of the frame; The COM1 interface of the industrial control computer is connected to the signal input terminal of the Y-axis motor driver, and the signal output terminal of the Y-axis motor driver is connected to the signal input terminal of the Y-axis motor. The horizontal position adjustment unit uses a separate industrial control computer to control the servo motor to drive the lead screw to rotate, thereby adjusting the horizontal position of the frame.

4. The online automatic inspection equipment for key components of alloy steel forks according to claim 2, characterized in that: The data receiving and storage module includes a data receiving unit and a data storage unit. The data receiving unit is connected to the data storage unit and is also connected to the contour measurement module. The data receiving unit is used to receive the contour measurement data. The data storage unit is used to store the contour measurement data and retrieve and store the standard data of the alloy steel core rail and the insert.

5. The online automatic inspection equipment for key components of alloy steel forks according to claim 2, characterized in that: Repeat the above steps until the three-dimensional contours of the alloy steel core rail and the insert meet the preset conditions; The data processing module is used to process the final contour measurement data of the alloy steel core rail after processing to obtain an inspection report.

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