A rail waist drilling detection device

Abstract

The present invention discloses a rail waist drilling detection device, comprising a main frame, an air source triplet, and a control cabinet. A high-precision detection module, a state detection module, and a high-precision pedometer encoder module are mounted on the main frame. The air source triplet is connected to the high-precision detection module and the state detection module, respectively. The high-precision detection module, the state detection module, and the high-precision pedometer encoder module are each electrically connected to the control cabinet. The rail waist drilling detection device provided by the present invention has a simple structure, is easy to operate, and has low manufacturing cost. It also integrates scanning and calculation to ensure accurate detection results.

Description

Technical Field

[0001] The invention belongs to the technical field of rail detection equipment, and in particular relates to a rail waist drilling detection device. Background Art

[0002] With the rapid development of rail transit, rails, as a fundamental part of rail transportation, are becoming increasingly important. Rails require regular maintenance over extended periods of use to eliminate potential hazards and ensure the safety and stability of rail transit operations. Inspection of the rail waist holes is particularly crucial. Because rails are exposed to the elements for extended periods, the location of the holes on the waist is often obscured by environmental influences, making the location of the holes unclear. Traditional methods of determining location through manual observation are inefficient and offer limited accuracy. Existing equipment often suffers from low camera accuracy and measurement inaccuracies due to the inherent nature of the rails, compromising rail quality. Therefore, the need for higher-precision and more efficient inspection equipment has become a pressing technical challenge for the industry. Furthermore, existing inspection equipment cannot calculate test results in real time, leading to errors in the final results. Furthermore, this inability to perform timely calculations prevents timely re-measurements during data processing, increasing time and wasting manpower and resources. Summary of the Invention

[0003] The purpose of the present invention is to solve the above problems and provide a rail waist drilling detection device with simple structure, easy use, high detection efficiency, high measurement accuracy and low manufacturing cost.

[0004] In order to solve the above technical problems, the technical solution of the present invention is: a rail waist drilling detection equipment, including a main bracket, an air source triplet and a control cabinet, a high-precision detection module, a status detection module and a high-precision pedometer encoder module are installed on the main bracket, the air source triplet is connected to the high-precision detection module and the status detection module respectively, and the high-precision detection module, the status detection module and the high-precision pedometer encoder module are electrically connected to the control cabinet respectively.

[0005] When the rail waist drilling detection device is used, the following steps are included:

[0006] S1. Check whether all parts of the equipment are complete and can work normally, and check whether the laser is normal;

[0007] S2. Start the device, open the cabinet and computer panel, and turn on the computer. Open the CharDetection software. If the status bar in the lower right corner of the software interface displays "System error, cannot be used!", you need to check the device line connection and restart the software. If the problem is still not solved, contact after-sales technical support until the display shows "Ready to start detection!".

[0008] S3. Detection. Click "Start." The status bar will display "Waiting for the rail to enter the system." When the rail enters the detection channel, the status bar will display "Detection in Progress." During the detection process, no operation is required, and the system will wait for the entire rail to pass through the detection channel. As the rail moves forward, if drilling features are detected, the system will automatically collect and analyze drilling data without any operation. After the detection is completed, the system returns to the waiting state and waits for the next rail to enter the detection channel.

[0009] S4. After the test is completed, the system automatically outputs the data file.

[0010] Preferably, the main bracket is in an "X"-shaped structure and is made of aluminum alloy.

[0011] Preferably, the high-precision detection module includes a high-precision first camera and a high-precision second camera. The high-precision first camera and the high-precision second camera have the same structure. The high-precision first camera can stably acquire images at a speed of 200FPS. The high-precision first camera includes a camera housing and a camera body. The camera body is located in the camera housing. The camera housing is a hollow rectangular structure. A camera housing hole is provided at the end of the camera housing. The camera end of the camera body is aligned with the camera housing hole to facilitate shooting of the camera body.

[0012] Preferably, the status detection module includes a left-side status detection unit and a right-side status detection unit. The left-side status detection unit includes a left-side protective cover, a dust removal air blowing nozzle and an infrared fill light. The left-side protective cover is provided with a left-side linear laser emitter, a detection camera, a first laser pair tube emitting end and a second laser pair tube emitting end. The left-side linear laser emitter is used to emit laser, the detection camera is used to capture images, the first laser pair tube emitting end, the second laser pair tube emitting end and the left-side linear laser emitter can all emit laser, the dust removal air blowing nozzle is connected to the air source triplet through a pipe, and the infrared fill light is used for fill light.

[0013] Preferably, the right side status detection unit includes a right side protective cover, in which a right side line laser emitter, a first laser pair tube receiving end and a second laser pair tube receiving end are provided. The right side line laser emitter is used to emit laser, and the first laser pair tube receiving end and the second laser pair tube receiving end are used to receive lasers emitted by the first laser pair tube emitting end and the second laser pair tube emitting end respectively.

[0014] Preferably, the high-precision pedometer encoder module includes a high-precision pedometer encoder module bracket, a resin roller, a high-precision pedometer encoder and a shock-absorbing spring. The high-precision pedometer encoder is located at the end of the resin roller, and the resin roller is mounted on the high-precision pedometer encoder module bracket. The shock-absorbing spring is located at the bottom of the resin roller to act as a buffer.

[0015] Preferably, the air source triplex includes an air filter, a pressure reducing valve and an oil mist collector, the air filter is used to filter the air, and the pressure reducing valve is used to reduce the pressure of the compressed gas.

[0016] Preferably, the control cabinet includes a cabinet on which an industrial host, a power cabinet and a display are provided, and the industrial host is electrically connected to the power cabinet and the display respectively.

[0017] The present invention provides a rail waist drilling inspection device with a simple structure, easy operation, and low manufacturing cost. It also integrates scanning and calculation to ensure accurate inspection results. It also offers high measurement efficiency and accuracy, and can process measurement results for calculations at any time. Measurement data can be corrected promptly, ensuring accurate final measurement parameters. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a diagram showing the steps of using a rail waist drilling detection device according to the present invention;

[0019] Figure 2 This is a schematic structural diagram of a rail waist drilling detection device according to the present invention;

[0020] Figure 3 This is a schematic diagram of the structure of the main support of the present invention;

[0021] Figure 4 2 is a schematic diagram comparing the structures of the high-precision first camera and the high-precision second camera of the present invention;

[0022] Figure 5 2 is a schematic diagram comparing the structures of the left state detection unit and the right state detection unit of the present invention;

[0023] Figure 6 It is a structural diagram of the left side state detection unit of the present invention;

[0024] Figure 7 Schematic diagram of the structure of the high-precision pedometer encoder module of the present invention;

[0025] Figure 8 It is a structural diagram of the gas source triplex of the present invention;

[0026] Figure 9 It is a structural diagram of the control cabinet of the present invention;

[0027] Figure 10 It is a circuit diagram of the present invention.

[0028] Explanation of Reference Numerals: 1. Main bracket; 2. High-precision detection module; 3. Status detection module; 4. High-precision pedometer encoder module; 5. Air source triplex; 6. Control cabinet; 21. High-precision first camera; 22. High-precision second camera; 31. Left-side status detection unit; 32. Right-side status detection unit; 41. Resin roller; 42. High-precision pedometer encoder; 51. Air filter; 52. Pressure reducing valve; 53. Oil mist collector; 61. Cabinet; 62. Industrial host computer; 63. Power supply cabinet; 64. Display; 210. Camera housing; 211. Camera body; 311. Left protective cover; 312. Left linear laser emitter; 313. Detection camera; 314. First laser pair tube emitting end; 315. Second laser pair tube emitting end; 316. Dust removal air nozzle; 317. Infrared fill light; 321. Right protective cover; 322. Right linear laser emitter; 323. First laser pair tube receiving end; 324. Second laser pair tube receiving end. DETAILED DESCRIPTION

[0029] The present invention will be further described below with reference to the accompanying drawings and specific embodiments:

[0030] like Figures 1 to 10 As shown, the present invention provides a rail waist drilling detection device, which includes a main bracket 1, an air source triplet 5 and a control cabinet 6. A high-precision detection module 2, a status detection module 3 and a high-precision pedometer encoder module 4 are installed on the main bracket 1. The air source triplet 5 is connected to the high-precision detection module 2 and the status detection module 3 respectively. The high-precision detection module 2, the status detection module 3 and the high-precision pedometer encoder module 4 are electrically connected to the control cabinet 6 respectively.

[0031] When a rail waist drilling detection device is used, the following steps are included:

[0032] S1. Check whether all parts of the equipment are complete and can work normally, and check whether the laser is normal;

[0033] S2. Start the device, open the cabinet and computer panel, and turn on the computer. Open the CharDetection software. If the status bar in the lower right corner of the software interface displays "System error, cannot be used!", you need to check the device line connection and restart the software. If the problem is still not solved, contact after-sales technical support until the display shows "Ready to start detection!".

[0034] S3. Detection. Click "Start" and the status bar will display "Waiting for the rail to enter the system." When the rail enters the detection channel, the status bar will display "Detection in progress." During the detection process, no operation is required, and the system will wait for the entire rail to pass through the detection channel. When drilling features are detected during the rail's movement, the system will automatically collect and analyze drilling data without any operation. After the detection is completed, the system returns to the waiting state and waits for the next rail to enter the detection channel.

[0035] S4. After the test is completed, the system automatically outputs the data file.

[0036] The main support 1 is an "X" shaped structure made of aluminum alloy. In this embodiment, the height of the main support 1 can be adjusted during installation to ensure that the rail waist is completely within the detection range when the rail enters the detection area from the roller conveyor.

[0037] Depending on the actual use environment, the main bracket 1 can take on a variety of shapes and structures to better meet the measurement needs. The rail is located above the main bracket 1. External equipment moves the high-precision rail detection module 2, the status detection module 3, and the high-precision pedometer encoder module 4 to complete the rail measurement. The measured data is fed back to the control cabinet 6 for data processing.

[0038] Main support 1 is equipped with a high-precision camera, laser alignment tube, and spray head, ensuring the secure and stable installation of the main inspection equipment on the saw drill. This ensures the equipment can inspect rail holes and spray-paint detected characters in a normal and stable manner without affecting rail movement. The spray head is primarily used to clean the window on the protective cover, removing iron filings and dust. Controlled by the host computer, the spray head automatically sprays paint near qualified characters as the rail passes.

[0039] A high-precision camera is used to photograph the rails, and a laser alignment tube is used to measure the rails with a laser. In this embodiment, the spray head is connected to the air source triplex 5 via a pipeline. Externally available compressed air passes through the air source triplex 5 and supplies compressed air to the spray head, completing the painting operation.

[0040] The high-precision detection module 2 includes a high-precision first camera 21 and a high-precision second camera 22. The high-precision first camera 21 and the high-precision second camera 22 have the same structure. The high-precision first camera 21 can capture images at a stable speed of 200FPS. The high-precision first camera 21 includes a camera housing 210 and a camera body 211. The camera body 211 is located in the camera housing 210. The camera housing 210 is a hollow rectangular structure. A camera housing hole is opened at the end of the camera housing 210. The camera end of the camera body 211 is aligned with the camera housing hole to facilitate shooting of the camera body 211.

[0041] Cameras on both sides of the high-precision inspection module 2 sample the laser line incident on the rail waist at a specific angle at high speed, accurately capturing the characters and drill holes on the rail waist. This data is then transmitted to the host computer in the control cabinet 6, which calculates the hole diameter and height. Even when the rail is not being sawn and drilled, the rail waist can still be inspected for characters and the diameter, height, and spacing of the drill holes can be calculated.

[0042] In actual use, the positions of the high-precision first camera 21 and the high-precision second camera 22 and the camera models used can be changed according to measurement requirements, so as to meet the measurement requirements while saving costs.

[0043] The status detection module 3 includes a left-side status detection unit 31 and a right-side status detection unit 32. The left-side status detection unit 31 includes a left-side protective cover 311, a dust removal air blowing nozzle 316 and an infrared fill light 317. The left-side protective cover 311 is provided with a left-side line laser emitter 312, a detection camera 313, a first laser pair tube emitting end 314 and a second laser pair tube emitting end 315. The left-side line laser emitter 312 is used to emit laser, the detection camera 313 is used to capture images, the first laser pair tube emitting end 314, the second laser pair tube emitting end 315 and the left-side line laser emitter 312 can all emit laser, the dust removal air blowing nozzle 316 is connected to the air source triplet 5 through a pipe, and the infrared fill light 317 is used for fill light.

[0044] The left-side line laser emitter 312 in the state detection module 3 can emit a high-precision line laser, which is coplanar with the line laser on the other side, to determine the cross-sectional position for detection by the high-precision detection module.

[0045] A single chip microcomputer is also installed on the status detection module 3 , and the single chip microcomputer is electrically connected to the computer host in the control cabinet 6 .

[0046] Status Detection Module 3 detects whether a rail has entered the detection zone. This is done by first and second laser pair emitting terminals 314 and 315, communicating with the host computer via a single-chip microcomputer. Status Detection Module 3 also detects the presence of drill holes in the rail's waist. A camera captures images in real time, directly determining the presence of holes through the program and coordinating with the high-precision detection module for detection.

[0047] The right side status detection unit 32 includes a right side protective cover 321, in which a right side line laser emitter 322, a first laser pair tube receiving end 323 and a second laser pair tube receiving end 324 are provided. The right side line laser emitter 322 is used to emit laser, and the first laser pair tube receiving end 323 and the second laser pair tube receiving end 324 are used to receive lasers emitted by the first laser pair tube emitting end 314 and the second laser pair tube emitting end 315 respectively.

[0048] The right state detection unit 32 does not need to detect drilling, and the rest of its functions are the same as those of the left state detection unit 31 , and it acts as the receiving end of the laser pair tube and cooperates with the left side to perform detection.

[0049] The high-precision pedometer encoder module 4 includes a high-precision pedometer encoder module bracket, a resin roller 41, a high-precision pedometer encoder 42, and a shock-absorbing spring. The high-precision pedometer encoder 42 is located at the end of the resin roller 41, which is mounted on the high-precision pedometer encoder module bracket. The shock-absorbing spring is located at the bottom of the resin roller 41 to act as a buffer. The high-precision pedometer encoder 42 is electrically connected to the control cabinet 6 and transmits the corresponding data to the control cabinet 6 for data processing.

[0050] The high-precision pedometer encoder 42 is used to record the position information of each drill hole or character after the rail enters the detection area, communicate with the microcontroller, and then the microcontroller sends the data to the host and cooperates with the status detection module to complete the pedometer work.

[0051] A high-precision pedometer encoder 42 is connected to the roller. When the rail contacts the roller, the angle of rotation of the high-precision pedometer encoder 42 is converted into the length of the rail. The resin roller 41 in contact with the rail is made of a non-slip and wear-resistant resin material. A shock absorber is installed at the connection between the main bracket 1 and the base. When the detector is not working, the highest horizontal surface of the roller is slightly higher than the highest horizontal surface of the roller. This can reduce vibration when the rail passes by, avoiding errors caused by vibration in the encoder. At the same time, it can keep the roller close to the bottom of the rail, ensuring that the rail will not slide across the roller surface and cause pedometer errors.

[0052] The air source triplex 5 includes an air filter 51, a pressure reducing valve 52, and an oil mist collector 53. The air filter 51 is used to filter air, and the pressure reducing valve 52 is used to reduce the pressure of compressed air. The pressure reducing valve 52 is connected to the dust removal air nozzle 316 through a pipeline to provide compressed air to the dust removal air nozzle 316.

[0053] The pressure reducing valve 52 is connected to the oil mist device 53 through a pipeline. During the rail inspection process, there are parts that need lubrication. After the compressed gas passes through the oil mist device 53, it is sprayed to the parts that need lubrication for lubrication, thereby ensuring the accuracy of the measurement.

[0054] The control cabinet 6 includes a cabinet 61, which contains an industrial host 62, a power cabinet 63, and a display 64. The industrial host 62 is electrically connected to the power cabinet 63 and the display 64. The industrial host 62 is an existing industrial computer used to process data collected by the corresponding equipment.

[0055] This system is used for high-precision automatic detection (hole height, hole diameter, and hole spacing), automatic positioning of drill holes, automatic rail length measurement, and automatic rail waist character detection. This product is detachable and can be installed on the rail pull roller line behind the existing drilling machine operation area, independent of the drilling machine system. It provides automatic and continuous measurement and features simple operation, high accuracy and efficiency, high automation, and stable operation. It utilizes state-of-the-art laser imaging technology, a patented deformation locking algorithm, and real-time data analysis and judgment to create a comprehensive analysis system for rail waist drilling measurement. This system has been used in the field with significant results. It analyzes and collects information based on the actual situation of rail waist drilling, enabling automated management and monitoring of rail waist drilling detection, providing an effective measurement device for transportation safety and production.

[0056] Those skilled in the art will appreciate that the embodiments described herein are intended to help readers understand the principles of the present invention, and it should be understood that the scope of protection of the present invention is not limited to such specific descriptions and embodiments. Those skilled in the art can make various other specific variations and combinations based on the technical teachings disclosed in the present invention without departing from the essence of the present invention, and such variations and combinations are still within the scope of protection of the present invention.

Claims

1. A rail waist drilling detection device, characterized by: The invention comprises a main support (1), an air source triplex (5) and a control cabinet (6); a high-precision detection module (2), a state detection module (3) and a high-precision pedometer encoder module (4) are installed on the main support (1); the air source triplex (5) is connected to the high-precision detection module (2) and the state detection module (3) respectively; the high-precision detection module (2), the state detection module (3) and the high-precision pedometer encoder module (4) are electrically connected to the control cabinet (6) respectively; The high-precision detection module (2) includes a high-precision first camera (21) and a high-precision second camera (22). The high-precision first camera (21) and the high-precision second camera (22) have the same structure. The high-precision first camera (21) can stably acquire images at a speed of 200 FPS. The high-precision first camera (21) includes a camera housing (210) and a camera body (211). The camera body (211) is located in the camera housing (210). The camera housing (210) is a hollow rectangular parallelepiped structure. A camera housing hole is provided at the end of the camera housing (210). The camera end of the camera body (211) is aligned with the camera housing hole, so as to facilitate shooting of the camera body (211). The state detection module (3) includes a left state detection unit (31) and a right state detection unit (32). The left state detection unit (31) includes a left protective cover (311), a dust removal air blowing nozzle (316) and an infrared fill light (317). The left protective cover (311) is provided with a left line laser emitter (312), a detection camera (313), a first laser pair tube emitting end (314) and a second laser pair tube emitting end (315). The left line laser emitter (312) is used to emit laser light, the detection camera (313) is used to capture images, the first laser pair tube emitting end (314), the second laser pair tube emitting end (315) and the left line laser emitter (312) can all emit laser light, the dust removal air blowing nozzle (316) is connected to the air source triplet (5) through a pipeline, and the infrared fill light (317) is used to fill light. The right state detection unit (32) includes a right protective cover (321), wherein a right line laser emitter (322), a first laser pair tube receiving end (323), and a second laser pair tube receiving end (324) are provided in the right protective cover (321), wherein the right line laser emitter (322) is used to emit laser light, and the first laser pair tube receiving end (323) and the second laser pair tube receiving end (324) are used to receive laser light emitted by the first laser pair tube emitting end (314) and the second laser pair tube emitting end (315), respectively. The high-precision pedometer encoder module (4) comprises a high-precision pedometer encoder module bracket, a resin roller (41), a high-precision pedometer encoder (42) and a shock-absorbing spring, wherein the high-precision pedometer encoder (42) is located at the end of the resin roller (41), the resin roller (41) is mounted on the high-precision pedometer encoder module bracket, and the shock-absorbing spring is located at the bottom of the resin roller (41) to play a buffering role; When the rail waist drilling detection device is used, the following steps are included: S1. Check whether all parts of the equipment are complete and can work normally, and check whether the laser is normal; S2. Start the device, open the cabinet and computer panel, and turn on the computer. Open the CharDetection software. If the status bar in the lower right corner of the software interface displays "System error, cannot be used!", you need to check the device line connection and restart the software. If the problem is still not solved, contact after-sales technical support until the display shows "Ready to start detection!". S3. Detection. Click "Start". The status bar will display "Waiting for the rail to enter the system". When the rail enters the detection channel, the status bar will display "Detection in progress". During the detection process, no operation is required, and the system will wait for the entire rail to pass through the detection channel. When drilling features are detected during the rail's movement, the system will automatically collect and analyze drilling data without any operation. After the detection is completed, the system returns to the waiting state and waits for the next rail to enter the detection channel. S4. After the test is completed, the system automatically outputs the data file.

2. The rail waist drilling detection device according to claim 1, characterized in that: The main bracket (1) has an "X"-shaped structure and is made of aluminum alloy.

3. The rail waist drilling detection device according to claim 1, characterized in that: The air source triplex (5) comprises an air filter (51), a pressure reducing valve (52) and an oil mist collector (53). The air filter (51) is used to filter air, and the pressure reducing valve (52) is used to reduce the pressure of compressed gas.

4. The rail waist drilling detection device according to claim 1, characterized in that: The control cabinet (6) includes a cabinet (61), on which an industrial host (62), a power cabinet (63) and a display (64) are provided. The industrial host (62) is electrically connected to the power cabinet (63) and the display (64), respectively.

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