Turnout rail top adjustment automatic detection device and method

Abstract

The invention discloses an automatic detection device and method for top adjustment of turnout rails, and belongs to the technical field of turnout processing. The method comprises: after each top adjustment, three coordinate values ​​at the top adjustment position are detected by three first laser rangefinders, and the actual vector value is calculated according to the three coordinate values; after all top adjustments are completed, the rail is manually moved toward the straight segment, the starting point of the milling process is located near the initial position of the straight segment detection structure, the starting position is manually marked, the floating lifting structure lifts the rail, the straight segment detection structure moves toward the end point of the straight segment, the first contact displacement sensor detects the starting position and the end point of the straight segment, and obtains the coordinate values ​​of the starting position and the end point of the straight segment; at the same time, the curve segment detection structure moves toward the end point of the curve segment, the second contact displacement sensor detects the predetermined position and the end point, and obtains the coordinate values ​​of the predetermined position and the end point of the curve segment; the support deviation value of the corresponding position is obtained according to the detection result.

Description

Technical Field

[0001] The invention belongs to the technical field of turnout processing, and in particular relates to a device and method for automatically detecting top adjustment of a turnout rail. Background Art

[0002] Turnouts are an important part of railway tracks, and the top adjustment quality of turnout rail parts is an important part of turnout product quality. The top adjustment accuracy during the production process directly affects the subsequent processing accuracy, and the top adjustment accuracy of the finished product is directly related to the key items such as the close fit, gauge, and direction of the entire set of turnout products, and is directly related to driving stability and safety. However, looking back at the current situation, today when almost all other processes in turnout production have achieved precise control and precise detection, since the working edge line type of the rail parts is composed of straight lines and large-radius circular curves that are tangent to or intersecting the straight lines, the top adjustment process can only rely on the primitive detection method of string pulling. The manual wire pulling measurement process is very inefficient and requires multiple personnel to cooperate in the detection. When unqualified values ​​appear, how to make top adjustment corrections still needs to rely on human experience and judgment. It is often necessary to make repeated top adjustment corrections and repeated inspections, and the entire process of top adjustment and inspection is time-consuming.

[0003] Of course, the prior art also provides automatic detection equipment, such as the patent with application number CN201910509023.8, which discloses an automatic detection method for the top adjustment size of a turnout rail member, the method comprising: using a laser scanner and a sensor to search for the starting position of the rail member to be detected; driving the laser scanner and the sensor to scan along the guide rail from the starting position to the linear direction of the rail member to be detected, and after completing the scanning of the rail member, transmitting the scanned information to the control system; comparing the linear information processed by the control system with the pre-input rail linear information; and displaying the comparison results on the display screen. Correspondingly, the automated detection system comprises: a walking rail; a support frame, the support frame is connected to the walking rail through a servo motor; a linear module, the linear module is connected to the support frame; a sensor module, the sensor module is connected to the linear module; the servo motor is used to drive the support frame to move along the walking rail, and the linear module is used to drive the sensor module to move in a direction perpendicular to the axial direction of the walking rail.

[0004] For example, the patent with application number CN202010232946.6 discloses an automatic detection device for turnout top bend, including a guide rail, a first slider, a cantilever bracket, an automatic module mounting plate, an automatic module, a second slider, a manual module mounting plate, a manual module, a third slider, a detection mounting plate and a detection tool, wherein the guide rail is fixed on a horizontal plane, the first slider is mounted on the guide rail, the cantilever bracket is fixed at the upper end of the first slider, the automatic module mounting plate is fixed to the lower surface of the cantilever bracket away from the guide rail, the automatic module is fixed to the lower surface of the automatic module mounting plate, the second slider is mounted at the lower end of the automatic module, the manual module mounting plate is fixed to the lower surface of the second slider, the manual module is fixed to the side of the manual module mounting plate, the manual module is provided with a handwheel at the uppermost end, the third slider is mounted on the side of the manual module away from the manual module mounting plate, the detection mounting plate is fixed to the side of the third slider, and the detection tool is fixed to the side of the detection mounting plate.

[0005] When the applicant used the aforementioned automatic detection device, he found the following problems:

[0006] (1) In the prior art, the test is performed after the top adjustment is completed. There is a high possibility that the test result does not meet the requirements, and the top adjustment needs to be repeated, which is time-consuming and labor-intensive.

[0007] (2) The existing technology is to perform the inspection on special equipment. After the top adjustment is completed, the rail needs to be transferred from the top adjustment machine to the inspection equipment. If the rail does not meet the requirements after the inspection, it needs to be transferred from the inspection equipment to the top adjustment machine. Sometimes the transfer needs to be made three times.

[0008] (3) If the rail is transferred from the top adjustment machine to the testing equipment through the guide roller conveyor structure, the rail has an elastic force to one side after the top adjustment. On the guide roller conveyor structure, the elastic force is not easy to release (for example, after being suspended in the air, the rail may be further bent slightly to release the elastic force). As a result, the rail is not in a natural state during the test, which leads to inaccurate detection.

[0009] (4) The detection results are inaccurate, mainly because the detection of the starting position of the straight line segment, the end point position of the straight line segment and the end point position of the curve segment is inaccurate. Summary of the invention

[0010] In order to solve the above problems, the embodiment of the present invention provides a device and method for automatically detecting the top adjustment of the turnout rail. The detection is performed every time the top adjustment is performed. After the processing is completed, the detection results of the straight segment detection structure and the curve segment detection structure usually meet the requirements. Even if they do not meet the standards, the number of reworks is very small, which saves time and effort. In addition, the detection accuracy of this patent is high. The technical solution is as follows:

[0011] On the one hand, an embodiment of the present invention provides an automatic detection device for top adjustment of a turnout rail, the device comprising an online detection structure 5, a straight segment detection structure 6, a curved segment detection structure 7, a control module and a floating lifting structure 3, the top adjustment machine 1 is arranged along the X-axis direction, the straight segment detection structure 6 and the curved segment detection structure 7 are both located on the same side of the rail 4 and are respectively located on the feeding side and the discharging side of the top adjustment machine 1; the floating lifting structure 3 comprises a plurality of lifting units, and at least one lifting unit is provided on the feeding side and the discharging side of the top adjustment machine 1; the lifting unit is located below the guide roller conveying structure 2 of the top adjustment machine 1, and can move the rail 4 on the guide roller conveying structure 2 The top adjustment machine 1 is lifted upward, and its support member 34 can float elastically in the Y-axis direction; the online detection structure 5 includes three first laser rangefinders 51, which are respectively located at the two ends and the middle of the top adjustment machine 1 and are all located on the same side of the rail 4. The first laser rangefinder 51 in the middle is arranged close to the pickaxe head 11 in the middle of the top adjustment machine 1, and the two first laser rangefinders 51 at both ends can move in the Y-axis direction to be retracted during top adjustment; the straight segment detection structure 6 includes a first detection head 61 that can move in the X-axis, Y-axis and Z-axis directions, and the first detection head 61 can pass over the rail 4 upward to detect the milling non-working edge of the straight segment and is provided with The curved segment detection structure 7 includes two first contact displacement sensors 62 and a second laser rangefinder 63; the curved segment detection structure 7 includes a second detection head 71 that can move in the X-axis and Y-axis directions, and a second contact displacement sensor 72 and a third laser rangefinder 73 are arranged on the second detection head 71. The first contact displacement sensor 62, the second contact displacement sensor 72, the second laser rangefinder 63 and the third laser rangefinder 73 are all arranged along the Y-axis direction, and the two first contact displacement sensors 62 are arranged back to back to select a pair of milling non-working edges of the straight segment for detection; the second laser rangefinder 63 is used to determine the end point position of the straight segment. The first contact displacement sensor 62 is arranged and guided to detect the endpoint, the third laser rangefinder 73 is used to determine the endpoint position of the curved segment and guide the second contact displacement sensor 72 to detect the endpoint, the first contact displacement sensor 62 is used to detect the Y-axis coordinate of the starting position and the endpoint of the straight segment, and the second contact displacement sensor 72 is used to detect the Y-axis coordinate of the predetermined position and the endpoint of the curved segment; the control module calculates the actual vector value according to the detection result of the online detection structure and the corresponding X-axis coordinate, and the control module calculates the offset deviation value according to the detection results of the straight segment detection structure and the curved segment detection structure and the corresponding X-axis coordinate.

[0012] Specifically, the three first laser rangefinders 51 in the embodiment of the present invention are located on the opposite side of the pick head 11 in the middle and are linked with the cylinder of the pick head 11; the two first laser rangefinders 51 at both ends are symmetrically arranged with the pick head 11 in the middle and are both driven by the cylinder to move in the Y-axis direction; during top adjustment, the first laser rangefinders 51 at both ends move away from the rail 4 to be retracted; after the top adjustment is completed, the cylinder contracts and triggers the two first laser rangefinders 51 at both ends to move synchronously toward the rail 4, and the three first laser rangefinders 51 detect the rail 4.

[0013] Specifically, the floating lifting structure 3 in the embodiment of the present invention includes four lifting units, and two lifting units are arranged side by side on the feeding side and the discharging side of the top adjustment machine 1 in the X-axis direction; the lifting unit includes two screw lifting mechanisms 31 arranged side by side in the Y-axis direction and driven synchronously, a slide 32 on the top of the screw lifting mechanism 31, a sliding assembly 33 on the slide 32 and a support member 34 arranged horizontally along the Y-axis direction, and the screw lifting mechanism 31 is arranged vertically; the support member 34 is an I-shaped steel, the top of which is smooth, and the two ends thereof slide respectively. A sliding assembly 33 is arranged on two slide seats 32, and a spring is arranged between its outer side and the corresponding slide seat 32; the spring is arranged along the Y-axis direction; the sliding assembly 33 includes an X-axis bearing on the lower side of the support member 34, two groups of Z-axis bearings on both sides of the bottom plate of the support member 34 and two groups of limit bearings at both ends of the upper side of the bottom plate of the support member 34, the X-axis bearing and the limit bearing are both arranged along the X-axis direction, and the Z-axis bearing is arranged along the Z-axis direction; when the rail 4 is lifted up, the support member 34 is located at the lower side of the rail 4 and its top is higher than the guide roller conveying structure 2.

[0014] Among them, the first laser rangefinder 51 in the embodiment of the present invention is located 16 mm below the top of the rail 4 on the guide roller conveying structure 2, the first contact displacement sensor 62 and the second contact displacement sensor 72 are located on the same horizontal plane and have the same coordinate origin, and the floating lifting structure 3 can make the rail 4 horizontal and naturally stretched; when the rail 4 is lifted by the floating lifting structure 3, the first contact displacement sensor 62 and the second contact displacement sensor 72 are both located 16 mm below the top of the rail 4.

[0015] Specifically, the detection accuracy of the first laser rangefinder 51 in the embodiment of the present invention is 10-50μm; the detection accuracy of the first contact displacement sensor 62 and the second contact displacement sensor 72 is 0.005-0.02mm; the detection accuracy of the second laser rangefinder 63 and the third laser rangefinder 73 is 0.5-1.5mm; the stroke of the first detection head 61 on the X-axis is 1.5-3.0m, driven by a synchronous belt; the stroke of the first detection head 61 on the Y-axis is 1.0-1.5m, the positioning accuracy is 0.005-0.02mm, driven by a lead screw; the stroke of the first detection head 61 on the Z-axis is greater than 180mm; the stroke of the second detection head 71 on the X-axis is 3.5-6.0m, driven by a synchronous belt; the stroke of the second detection head 71 on the Y-axis is 1.0-1.5m, the positioning accuracy is 0.005-0.02mm, driven by a lead screw.

[0016] On the other hand, an embodiment of the present invention further provides a method for automatically detecting turnout rail top adjustment, the method comprising:

[0017] During the top adjustment process, after each top adjustment, the three first laser rangefinders 51 on the top adjustment machine 1 detect the three coordinate values ​​at the top adjustment point, calculate the actual vector value based on the three coordinate values, and compare it with the theoretical value. If it meets the requirements, the top adjustment of the next section is carried out, and if it does not meet the requirements, the top adjustment of the current section is carried out again;

[0018] After all the top adjustments are completed, the guide roller conveying structure 2 is manually controlled to move the rail 4 toward the straight segment, so that the starting point of the milling process is located near the initial position of the straight segment detection structure 6, and the starting position is manually marked on the rail 4. The guide roller conveying structure 2 and / or the straight segment detection structure 6 are manually controlled and the floating lifting structure 3 is used to lift the rail 4, and the first contact displacement sensor 62 is used to detect the starting position to obtain the coordinate value of the starting position; the straight segment detection structure 6 is then moved toward the endpoint of the straight segment, and the endpoint is determined by the second laser rangefinder 63 and the first contact displacement sensor is guided. The displacement sensor 62 detects the endpoint to obtain the coordinate value of the endpoint of the straight segment; at the same time, the curve segment detection structure 7 is moved toward the endpoint of the curve segment, the endpoint is judged by the third laser rangefinder 73 and the second contact displacement sensor 72 is guided to detect the endpoint to obtain the coordinate value of the predetermined position and the endpoint of the curve segment; the support deviation value of the corresponding position is obtained according to the coordinate value of the starting position, the endpoint of the straight segment and the predetermined position or the endpoint of the curve segment; wherein the starting position is the horizontal offset X from the starting point of the milling process to the endpoint of the straight segment, and the X is greater than or equal to 150mm.

[0019] Furthermore, the method of the present patent also includes: after all top adjustments are completed, manually judging the bending direction of the rail 4 to determine the milling non-working edge of the straight segment; the first detection head 61 crosses or does not cross the rail 4 according to the judgment result and uses a first contact displacement sensor 62 on the corresponding side to detect the milling non-working edge of the straight segment.

[0020] The two first laser rangefinders 51 at both ends are symmetrically arranged with respect to the pickaxe head 11 in the middle of the top adjustment machine 1, and the actual vector value H is calculated according to formulas Ⅰ and Ⅱ:

[0021] H = [L2-(L1+L3) / 2]*K(Ⅰ);

[0022] K=X 2 / (2X*X1-X1 2 )(Ⅱ);

[0023] Among them, L1 is the Y-axis coordinate of the first laser rangefinder 51 at one end, L2 is the Y-axis coordinate of the first laser rangefinder 51 in the middle, and L3 is the Y-axis coordinate of the first laser rangefinder 51 at the other end; X1 is the difference between the X-axis coordinate of the first laser rangefinder 51 in the middle and the X-axis coordinate of the first laser rangefinder 51 at one end, and X is the difference between the X-axis coordinate of the pick head 11 in the middle and the X-axis coordinate of the first laser rangefinder 51 at one end; K is the trimming coefficient.

[0024] Among them, the support deviation value H is calculated by formula III:

[0025] H=(Y2-Y0)-(Y1-Y0)*X2 / X3(Ⅲ);

[0026] Among them, Y0 is the Y-axis coordinate of the endpoint of the straight line segment, Y1 is the Y-axis coordinate of the starting position, Y2 is the Y-axis coordinate of the predetermined position or endpoint of the curved segment, X2 is the difference between the X-axis coordinate of the predetermined position or endpoint of the curved segment and the X-axis coordinate of the endpoint of the straight line segment, X3 is the difference between the X-axis coordinate of the starting position and the X-axis coordinate of the endpoint of the straight line segment, the predetermined position is a detection point with a distance of N meters from the starting position, and N is a positive integer; when detecting the endpoint of the straight line segment, the detection position of the first contact displacement sensor 62 is 4-8 mm horizontally offset inward from the judgment endpoint of the second laser rangefinder 63; when detecting the endpoint of the curved segment, the detection position of the second contact displacement sensor 72 is 4-8 mm horizontally offset inward from the judgment endpoint of the third laser rangefinder 73.

[0027] Furthermore, the method of the present patent also includes: after each top adjustment, if it does not meet the requirements, the control module gives a first top adjustment suggestion according to a predetermined algorithm or controls the top adjustment machine 1 to perform automatic top adjustment; after all top adjustments are completed, if it does not meet the requirements, the control module gives a second top adjustment suggestion according to a predetermined algorithm or controls the top adjustment machine 1 to perform automatic top adjustment.

[0028] The technical solution provided by the embodiment of the present invention has the following beneficial effects:

[0029] (1) Inspection is carried out at each top adjustment, and the requirements are basically met after processing. Usually, the inspection results of the straight segment inspection structure and the curved segment inspection structure meet the requirements. Even if they do not meet the requirements, the number of reworks is very small (usually only one rework is required), saving time and effort.

[0030] (2) The straight segment detection structure and the curved segment detection structure are respectively arranged on the feeding side and the discharging side of the top adjustment machine. After the top adjustment is completed, it only needs to be slightly moved horizontally; if rework is required, the rail only needs to be slightly moved horizontally (less than 0.8m). This saves time and effort, and the rail is very heavy, which is of practical significance.

[0031] (3) The floating lifting structure lifts the rails, which not only ensures that the rails are level (the guide roller conveyor structure cannot ensure levelness because it is difficult to adjust), but also allows the rails to stretch freely to ensure accuracy.

[0032] (4) The detection of the starting position and the endpoint position has been optimized. Based on a large amount of usage experience, the detection position has been appropriately offset to ensure the detection accuracy.

[0033] (5) The milling non-working edge of the straight line segment is inspected to ensure the inspection accuracy.

[0034] (6) High degree of automation, capable of automatically determining endpoints and performing calculations. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 is a schematic structural diagram of a turnout rail top adjustment automatic detection device in an embodiment of the present invention;

[0036] Figure 2 is a top view of a turnout rail top adjustment automatic detection device in an embodiment of the present invention;

[0037] Figure 3 is a front view of a turnout rail top adjustment automatic detection device in an embodiment of the invention;

[0038] Figure 4 is a side view of a turnout rail top adjustment automatic detection device in an embodiment of the invention;

[0039] Figure 5 is a schematic structural diagram of a straight line segment detection structure in an embodiment of the present invention;

[0040] Figure 6 It is a structural schematic diagram of the curve section detection structure and the top adjustment machine combination;

[0041] Figure 7 It is a structural schematic diagram of a floating lifting structure;

[0042] Figure 8 It is a schematic diagram of actual vector value calculation;

[0043] Fig. 9 This is a schematic diagram of the calculation of the offset deviation value.

[0044] In the figure: 1 top adjustment machine, 2 guide roller conveying structure, 3 floating top lifting structure, 4 rail, 5 online detection structure, 6 straight segment detection structure, 7 curve segment detection structure;

[0045] 11 pickaxe;

[0046] 31 screw rod lifting mechanism, 32 slide seat, 33 sliding assembly, 34 support member;

[0047] 51 The first laser rangefinder;

[0048] 61 first detection head, 62 first contact displacement sensor, 63 second laser rangefinder;

[0049] 71 is a second detection head, 72 is a second contact displacement sensor, and 73 is a third laser rangefinder. DETAILED DESCRIPTION

[0050] In order to make the objectives, technical solutions and advantages of the present invention more clear, the present invention will be further described in detail below with reference to the accompanying drawings.

[0051] Example 1

[0052] See also Figure 1-7 Embodiment 1 provides an automatic detection device for top adjustment of turnout rails, which includes an online detection structure 5, a straight segment detection structure 6, a curved segment detection structure 7, a control module, and a floating lifting structure 3. The top adjustment machine 1 is arranged along the X-axis direction (left-right arrangement), and the guide roller conveying structure 2 thereon can convey the rail 4 left-right. The straight segment detection structure 6 and the curved segment detection structure 7 are both located on the same side of the rail 4 and are respectively located on the feeding side and the discharging side of the top adjustment machine 1. Among them, the positions of the online detection structure 5, the straight segment detection structure 6, and the curved segment detection structure 7 cannot affect the normal top adjustment process.

[0053] The floating lifting structure 3 includes a plurality of lifting units, and at least one lifting unit is provided on the feeding side and the discharging side of the top adjusting machine 1. The lifting unit is located below the guide roller conveying structure 2 of the top adjusting machine 1, and can lift the rail 4 on the guide roller conveying structure 2 upward, and its support member 34 can float elastically in the Y-axis direction.

[0054] Among them, the online detection structure 5 includes three first laser rangefinders 51, which are respectively located at the two ends and the middle of the top adjustment machine 1 and are all located on the same side of the rail 4. The first laser rangefinder 51 in the middle is arranged close to the pick head 11 in the middle of the top adjustment machine 1 (adjacent to the left or right side), and the two first laser rangefinders 51 at the two ends can move in the Y-axis direction to be retracted during top adjustment.

[0055] Among them, the straight segment detection structure 6 includes a first detection head 61 that can move in the X-axis, Y-axis and Z-axis directions. The first detection head 61 can pass upward over the rail 4 to detect the milling non-working edge of the straight segment and is provided with two first contact displacement sensors 62 and a second laser rangefinder 63.

[0056] The curve segment detection structure 7 includes a second detection head 71 that can move in the X-axis and Y-axis directions. A second contact displacement sensor 72 and a third laser rangefinder 73 are provided on the second detection head 71 .

[0057] Among them, the first contact displacement sensor 62, the second contact displacement sensor 72, the second laser rangefinder 63 and the third laser rangefinder 73 are all arranged along the Y-axis direction, and the two first contact displacement sensors 62 are arranged back to back to select a pair of milling non-working edges of the straight line segment for detection. The first contact displacement sensor 62 and the second laser rangefinder 63 can be arranged side by side up and down, and the second contact displacement sensor 72 and the third laser rangefinder 73 can be arranged side by side up and down. The second laser rangefinder 63 is used to determine the endpoint position of the straight line segment and guide the first contact displacement sensor 62 to detect the endpoint, the third laser rangefinder 73 is used to determine the endpoint position of the curved segment and guide the second contact displacement sensor 72 to detect the endpoint, the first contact displacement sensor 62 is used to detect the Y-axis coordinates of the starting position and the endpoint of the straight line segment, and the second contact displacement sensor 72 is used to detect the Y-axis coordinates of the predetermined position and the endpoint of the curved segment.

[0058] The control module calculates the actual vector value according to the detection results of the online detection structure and the corresponding X-axis coordinates, and calculates the support deviation value according to the detection results of the straight segment detection structure and the curve segment detection structure and the corresponding X-axis coordinates. The control module can also output the top adjustment suggestion or directly control the top adjustment machine 1 to realize automatic top adjustment as needed.

[0059] Specifically, the three first laser rangefinders 51 in the embodiment of the present invention are located on the opposite side of the pickaxe head 11 in the middle and are linked to the oil cylinder of the pickaxe head 11. The two first laser rangefinders 51 at both ends are symmetrically arranged with the pickaxe head 11 in the middle and are both driven by the cylinder to move in the Y-axis direction. During the top adjustment, the first laser rangefinders 51 at both ends move away from the rail 4 to be retracted. After the top adjustment is completed, the oil cylinder contracts and triggers the two first laser rangefinders 51 at both ends to move synchronously toward the rail 4, and the three first laser rangefinders 51 detect the rail 4. Preferably, the three first laser rangefinders 51 are provided with a protective cover for protection.

[0060] Specifically, see Figure 1-3 The floating lifting structure 3 in the embodiment of the present invention includes four lifting units, and two lifting units are arranged side by side on the feeding side and the discharging side of the top adjustment machine 1 in the X-axis direction. Figure 7 The lifting unit includes two screw lifting mechanisms 31 arranged side by side and synchronously driven in the Y-axis direction, a slide 32 on the top of the screw lifting mechanism 31, a sliding assembly 33 on the slide 32, and a support member 34 arranged horizontally along the Y-axis direction, etc. The screw lifting mechanism 31 is arranged vertically. The support member 34 is an I-shaped steel with a smooth top. Its two ends are respectively slidably arranged on the sliding assemblies 33 of the two slides 32, and a spring (not shown) is arranged between its outer side and the corresponding slide 32. The spring is arranged along the Y-axis direction. The sliding assembly 33 includes an X-axis bearing on the lower side of the support member 34 (two X-axis bearings are arranged side by side front and back), two groups of Z-axis bearings on both sides of the bottom plate of the support member 34 (in each group, two Z-axis bearings are arranged side by side front and back), and two groups of limit bearings on both ends of the upper side of the bottom plate of the support member 34 (located between the two Z-axis bearings on the same side). The X-axis bearing and the limit bearing are both arranged along the X-axis direction, and the Z-axis bearing is arranged along the Z-axis direction. When the rail 4 is lifted up, the support member 34 is located at the lower side of the rail 4 and the top of the support member 34 is higher than the guide roller conveying structure 2 .

[0061] Among them, the first laser rangefinder 51 in the embodiment of the present invention is located 16 mm below the top of the rail 4 on the guide roller conveying structure 2 (of course, if the model of the rail 4 is different or the detection position in the industry is adjusted, the adaptability is adjusted, and the manual detection position in the industry shall prevail), the first contact displacement sensor 62 and the second contact displacement sensor 72 are located on the same horizontal plane and have the same coordinate origin, and the floating lifting structure 3 (multiple lifting units are controlled separately) can make the rail 4 horizontal and naturally stretched. When the rail 4 is lifted by the floating lifting structure 3, the first contact displacement sensor 62 and the second contact displacement sensor 72 are both located 16 mm below the top of the rail 4.

[0062] Specifically, the detection accuracy of the first laser rangefinder 51 in the embodiment of the present invention is 10-50μm; the detection accuracy of the first contact displacement sensor 62 and the second contact displacement sensor 72 is 0.005-0.02mm; the detection accuracy of the second laser rangefinder 63 and the third laser rangefinder 73 is 0.5-1.5mm; the stroke of the first detection head 61 on the X-axis is 1.5-3.0m, driven by a synchronous belt; the stroke of the first detection head 61 on the Y-axis is 1.0-1.5m, the positioning accuracy is 0.005-0.02mm, driven by a lead screw; the stroke of the first detection head 61 on the Z-axis is greater than 180mm; the stroke of the second detection head 71 on the X-axis is 3.5-6.0m, driven by a synchronous belt; the stroke of the second detection head 71 on the Y-axis is 1.0-1.5m, the positioning accuracy is 0.005-0.02mm, driven by a lead screw.

[0063] Example 2

[0064] See also Figure 1-4 Embodiment 2 provides an automatic detection device for top adjustment of turnout rails, and its structure is basically the same as that of Embodiment 1, except that: the straight segment detection structure 6 and the curved segment detection structure 7 in this embodiment are both located behind the rail 4, the straight segment detection structure 6 is located on the left side of the top adjustment machine 1, and the curved segment detection structure 7 is located on the right side of the top adjustment machine 1. The three first laser rangefinders 51 are all located on the front side of the top adjustment machine 1, and the two first laser rangefinders 51 at both ends are respectively located on the left and right ends of the top adjustment machine 1. The two first contact displacement sensors 62 are respectively located on the front and rear sides of the first detection head 61. When the milling non-working edge of the straight segment is located on the rear side, the first detection head 61 does not cross the rail 4, and the first detection head 61 on the front side is used to detect the milling non-working edge; when the milling non-working edge of the straight segment is located on the front side, the first detection head 61 crosses the rail 4, and the first detection head 61 on the rear side is used to detect the milling non-working edge.

[0065] Example 3

[0066] Embodiment 3 provides an automatic detection device for the top adjustment of a turnout rail, and its structure is basically the same as that of Embodiment 1, except that: the detection accuracy of the first laser rangefinder 51 in the embodiment of the present invention is 30 μm, and the specific model may be HG-C1050. The detection accuracy of the first contact displacement sensor 62 and the second contact displacement sensor 72 is 0.01 mm. The detection accuracy of the second laser rangefinder 63 and the third laser rangefinder 73 is 0.8 mm, and the specific model may be HG-C1400. The stroke of the first detection head 61 on the X-axis is 2.0 m, and it is driven by a synchronous belt. The stroke of the first detection head 61 on the Y-axis is 1.2 m, and the positioning accuracy is 0.01 mm, and it is driven by a lead screw. The stroke of the first detection head 61 on the Z-axis is 200 mm. The stroke of the second detection head 71 on the X-axis is 4 m, and it is driven by a synchronous belt. The stroke of the second detection head 71 on the Y-axis is 1.2 m, and the positioning accuracy is 0.01 mm, and it is driven by a lead screw.

[0067] Example 4

[0068] Embodiment 4 provides a method for automatically detecting the top adjustment of a turnout rail, using the automatic detection device for the top adjustment of a turnout rail disclosed in Embodiments 1-3. The method comprises:

[0069] During the top adjustment process, after each top adjustment, the three first laser rangefinders 51 on the top adjustment machine 1 detect the three coordinate values ​​at the top adjustment point, and the actual vector value is calculated based on the three coordinate values. Compared with the theoretical value, if it meets the requirements, the next section of top adjustment is carried out, and if it does not meet the requirements, the current section is top adjusted again.

[0070] After all the top adjustments are completed, the guide roller conveying structure 2 is manually controlled to move the rail 4 toward the straight segment (movement 500-800mm), the starting point of the milling process is located near the initial position of the straight segment detection structure 6, the starting position is manually marked on the rail 4, the guide roller conveying structure 2 and / or the straight segment detection structure 6 are manually controlled and the floating lifting structure 3 is used to lift the rail 4, and the first contact displacement sensor 62 is used to detect the starting position to obtain the coordinate value of the starting position. Then the straight segment detection structure 6 is moved toward the end point of the straight segment, the end point is determined by the second laser rangefinder 63 and the first contact displacement sensor 62 is guided to detect the end point to obtain the coordinate value of the end point of the straight segment. At the same time, the curve segment detection structure 7 is moved toward the end point of the curve segment, stops at the predetermined position and detects, the end point is determined by the third laser rangefinder 73 and the second contact displacement sensor 72 is guided to detect the end point to obtain the predetermined position and the coordinate value of the curve segment end point. The offset deviation value of the corresponding position is obtained according to the coordinate values ​​of the starting position, the end point of the straight line segment and the predetermined position or the end point of the curve segment; wherein the starting position is the horizontal offset X from the starting point of the milling process to the end point of the straight line segment, X is greater than or equal to 150mm, specifically 200mm.

[0071] Furthermore, the method of the present patent also includes: after all top adjustments are completed, manually judging the bending direction of the rail 4 to determine the milling non-working edge of the straight segment; the first detection head 61 crosses or does not cross the rail 4 according to the judgment result and uses a first contact displacement sensor 62 on the corresponding side to detect the milling non-working edge of the straight segment.

[0072] Among them, see Figure 8 The two first laser rangefinders 51 at both ends are symmetrically arranged with the pickaxe head 11 in the middle of the top adjustment machine 1, and the actual vector value H is calculated according to formulas Ⅰ and Ⅱ:

[0073] H = [L2-(L1+L3) / 2]*K(Ⅰ);

[0074] K=X 2 / (2X*X1-X1 2 )(Ⅱ);

[0075] Wherein, L1 is the Y-axis coordinate of the first laser rangefinder 51 at one end, L2 is the Y-axis coordinate of the first laser rangefinder 51 in the middle, and L3 is the Y-axis coordinate of the first laser rangefinder 51 at the other end; X1 is the difference between the X-axis coordinate of the first laser rangefinder 51 in the middle and the X-axis coordinate of the first laser rangefinder 51 at one end, and X is the difference between the X-axis coordinate of the pickaxe head 11 in the middle and the X-axis coordinate of the first laser rangefinder 51 at one end; K is the trimming coefficient. If: X=650, X1=500, then K=1.063.

[0076] Among them, see Fig. 9 , calculate the offset deviation value H through formula III:

[0077] H=(Y2-Y0)-(Y1-Y0)*X2 / X3(Ⅲ);

[0078] Among them, Y0 is the Y-axis coordinate of the endpoint of the straight segment, Y1 is the Y-axis coordinate of the starting position, Y2 is the Y-axis coordinate of the predetermined position or endpoint of the curve segment, X2 is the difference between the X-axis coordinate of the predetermined position or endpoint of the curve segment and the X-axis coordinate of the endpoint of the straight segment, X3 is the difference between the X-axis coordinate of the starting position and the X-axis coordinate of the endpoint of the straight segment, the predetermined position is a detection point with a distance of N meters from the starting position, and N is a positive integer; when detecting the endpoint of the straight segment, the detection position of the first contact displacement sensor 62 is 4-8 mm horizontally offset inward from the judgment endpoint of the second laser rangefinder 63; when detecting the endpoint of the curve segment, the detection position of the second contact displacement sensor 72 is 4-8 mm horizontally offset inward from the judgment endpoint of the third laser rangefinder 73. Specifically, when X2 is the difference between the X-axis coordinate of the endpoint of the curve segment and the X-axis coordinate of the endpoint of the straight segment, correspondingly, Y2 is the Y-axis coordinate of the endpoint of the curve segment, and H is the calculated offset deviation value at the endpoint. When X2 is the difference between the X-axis coordinate of the predetermined position of the curve segment (such as 2m away from the starting position) and the X-axis coordinate of the endpoint of the straight line segment, correspondingly, Y2 is the Y-axis coordinate of the predetermined position of the curve segment, then H is the calculated offset deviation value at the predetermined position.

[0079] Furthermore, the method of the present patent also includes: after each top adjustment, if it does not meet the requirements, the control module gives a first top adjustment suggestion according to a predetermined algorithm or controls the top adjustment machine 1 to perform automatic top adjustment; after all top adjustments are completed, if it does not meet the requirements, the control module gives a second top adjustment suggestion according to a predetermined algorithm or controls the top adjustment machine 1 to perform automatic top adjustment.

[0080] Example 5

[0081] Embodiment 5 provides a method for automatically detecting turnout rail top adjustment, comprising the following steps:

[0082] Line detection structure 5 performs detection:

[0083] S101: After starting up, first place the ruler on the measuring positions of the three first laser rangefinders 51 to perform zero point calibration, which can be performed once per shift.

[0084] S102: After each top adjustment, when the top adjustment machine oil cylinder returns, the actual angle value is automatically measured, whether it is qualified is judged, and the direction and value of the second top adjustment are given. This information is automatically displayed on the touch screen.

[0085] S103: After the next top adjustment is completed, the new measurement result is automatically displayed again, covering the last measurement value.

[0086] S104: Detection cycle: less than 3 seconds. That is, after the press cylinder retracts, the detection is automatically completed within 3 seconds.

[0087] The straight line segment detection structure 6 and the curve segment detection structure 7 perform detection:

[0088] S201: After starting up, execute the zero point verification procedure and use the verification pile to perform zero point verification once per shift. Use the standard straight rail to verify the zero position once a week to determine whether the verification pile system is reliable.

[0089] S202: After the last top adjustment, the operator moves the rail back 500-800mm, so that the straight section of the rail is within the travel coverage of the first detection head 61, and presses the final inspection button. The system automatically completes all inspections through the first contact displacement sensor 62 and the second laser rangefinder 63. And the results are displayed on the screen. The display content includes: straight section length, rail straight section slope, straight extension trajectory, end deflection (base rail, point rail heel section support deviation). The display information remains on the screen until it is covered by new information during the next top adjustment. At the same time, the curve section detection structure 7 performs the same inspection.

[0090] S203: Detection cycle: less than 20 seconds. The time from pressing the final inspection button to the completion of automatic inspection shall not exceed 20 seconds.

[0091] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. Automatic detection device for turnout rail top adjustment, characterized in that: It comprises an online detection structure (5), a straight segment detection structure (6), a curved segment detection structure (7), a control module and a floating lifting structure (3); the lifting machine (1) is arranged along the X-axis direction; the straight segment detection structure (6) and the curved segment detection structure (7) are both located on the same side of the rail (4) and are respectively located on the feeding side and the discharging side of the lifting machine (1); The floating lifting structure (3) comprises a plurality of lifting units, and at least one lifting unit is provided on the feeding side and the discharging side of the top adjusting machine (1); the lifting unit is located below the guide roller conveying structure (2) of the top adjusting machine (1), and can lift the steel rail (4) on the guide roller conveying structure (2) upward, and its support member (34) can float elastically in the Y-axis direction; The online detection structure (5) comprises three first laser rangefinders (51), which are respectively located at the two ends and the middle of the top adjustment machine (1) and are all located on the same side of the rail (4), the first laser rangefinder (51) in the middle is arranged close to the pickaxe head (11) in the middle of the top adjustment machine (1), and the two first laser rangefinders (51) at the two ends can move in the Y-axis direction so as to be retracted during top adjustment; The straight segment detection structure (6) comprises a first detection head (61) that can move in the directions of the X-axis, the Y-axis and the Z-axis, the first detection head (61) can pass upward over the rail (4) to detect the milling non-working edge of the straight segment and is provided with two first contact displacement sensors (62) and a second laser distance meter (63); the curved segment detection structure (7) comprises a second detection head (71) that can move in the directions of the X-axis and the Y-axis, the second detection head (71) is provided with a second contact displacement sensor (72) and a third laser distance meter (73), the first contact displacement sensor (62), the second contact displacement sensor (72) and the second laser distance meter (63) 3) and the third laser rangefinder (73) are both arranged along the Y-axis direction, and the two first contact displacement sensors (62) are arranged back to back to select a pair of milling non-working edges of the straight line segment for detection; the second laser rangefinder (63) is used to determine the endpoint position of the straight line segment and guide the first contact displacement sensor (62) to detect the endpoint, the third laser rangefinder (73) is used to determine the endpoint position of the curved segment and guide the second contact displacement sensor (72) to detect the endpoint, the first contact displacement sensor (62) is used to detect the Y-axis coordinates of the starting position and the endpoint of the straight line segment, and the second contact displacement sensor (72) is used to detect the Y-axis coordinates of the predetermined position and the endpoint of the curved segment; The control module calculates the actual vector value according to the detection result of the online detection structure and the corresponding X-axis coordinate, and calculates the offset deviation value according to the detection result of the straight segment detection structure and the curve segment detection structure and the corresponding X-axis coordinate.

2. The automatic detection device for turnout rail top adjustment according to claim 1 is characterized in that: The three first laser rangefinders (51) are located on the opposite side of the pickaxe (11) in the middle and are linked to the oil cylinder of the pickaxe (11); the two first laser rangefinders (51) at both ends are symmetrically arranged with the pickaxe (11) in the middle and are both driven by the cylinder to move in the Y-axis direction; during top adjustment, the first laser rangefinders (51) at both ends move away from the rail (4) to be retracted; after the top adjustment is completed, the oil cylinder contracts and triggers the two first laser rangefinders (51) at both ends to move synchronously toward the rail (4), and the three first laser rangefinders (51) detect the rail (4).

3. The automatic detection device for turnout rail top adjustment according to claim 1 is characterized in that: The floating lifting structure (3) comprises four lifting units, and two lifting units are arranged side by side on the feeding side and the discharging side of the top adjustment machine (1) in the X-axis direction; the lifting units comprise two screw lifting mechanisms (31) arranged side by side in the Y-axis direction and driven synchronously, a slide seat (32) at the top of the screw lifting mechanism (31), a sliding assembly (33) on the slide seat (32), and a support member (34) arranged horizontally along the Y-axis direction, and the screw lifting mechanism (31) is arranged vertically; the support member (34) is an I-shaped steel, the top of which is smooth, and the two ends of which are respectively slidably arranged on the two slide seats. On the sliding assembly (33) of the support member (32), a spring is provided between its outer side and the corresponding sliding seat (32); the spring is arranged along the Y-axis direction; the sliding assembly (33) comprises an X-axis bearing on the lower side of the support member (34), two groups of Z-axis bearings on both sides of the bottom plate of the support member (34) and two groups of limit bearings at both ends of the upper side of the bottom plate of the support member (34), the X-axis bearing and the limit bearing are both arranged along the X-axis direction, and the Z-axis bearing is arranged along the Z-axis direction; when the steel rail (4) is lifted up, the support member (34) is located at the lower side of the steel rail (4) and its top is higher than the guide roller conveying structure (2).

4. The automatic detection device for turnout rail top adjustment according to claim 1, characterized in that: The first laser rangefinder (51) is located 16 mm below the top of the rail (4) on the guide roller conveying structure (2); the first contact displacement sensor (62) and the second contact displacement sensor (72) are located on the same horizontal plane and have the same coordinate origin; the floating lifting structure (3) allows the rail (4) to be horizontal and naturally extended; when the rail (4) is lifted by the floating lifting structure (3), the first contact displacement sensor (62) and the second contact displacement sensor (72) are both located 16 mm below the top of the rail (4).

5. The automatic detection device for turnout rail top adjustment according to claim 1, characterized in that: The detection accuracy of the first laser rangefinder (51) is 10-50 μm; the detection accuracy of the first contact displacement sensor (62) and the second contact displacement sensor (72) is 0.005-0.02 mm; the detection accuracy of the second laser rangefinder (63) and the third laser rangefinder (73) is 0.5-1.5 mm; the stroke of the first detection head (61) on the X axis is 1.5-3.0 m, and is driven by a synchronous belt; the stroke of the first detection head (61) on the Y axis is 1.0-1.5 m, and the positioning accuracy is 0.005-0.02 mm, and is driven by a lead screw; the stroke of the first detection head (61) on the Z axis is greater than 180 mm; the stroke of the second detection head (71) on the X axis is 3.5-6.0 m, and is driven by a synchronous belt; the stroke of the second detection head (71) on the Y axis is 1.0-1.5 m, and the positioning accuracy is 0.005-0.02 mm, and is driven by a lead screw.

6. A detection method using the automatic detection device for top adjustment of turnout rails according to any one of claims 1 to 5, characterized in that: The method comprises: During the top adjustment process, after each top adjustment, three first laser rangefinders (51) on the top adjustment machine (1) detect three coordinate values ​​at the top adjustment location, calculate the actual vector value based on the three coordinate values, and compare it with the theoretical value. If it meets the requirements, the next section of top adjustment is carried out; if it does not meet the requirements, the current section is top adjusted again; After all the top adjustments are completed, the guide roller conveying structure (2) is manually controlled to move the steel rail (4) toward the straight segment, so that the starting point of the milling process is located near the initial position of the straight segment detection structure (6), and the starting position is manually marked on the steel rail (4). The guide roller conveying structure (2) and / or the straight segment detection structure (6) are manually controlled to allow the floating lifting structure (3) to lift the steel rail (4), and the first contact displacement sensor (62) detects the starting position to obtain the coordinate value of the starting position; then the straight segment detection structure (6) is moved toward the end point of the straight segment, and the end point is determined by the second laser rangefinder (63) and guided. The first contact displacement sensor (62) is guided to detect the endpoint to obtain the coordinate value of the endpoint of the straight segment; at the same time, the curved segment detection structure (7) is moved toward the endpoint of the curved segment, the endpoint is determined by the third laser rangefinder (73) and the second contact displacement sensor (72) is guided to detect the endpoint to obtain the coordinate value of the predetermined position and the endpoint of the curved segment; the offset value of the corresponding position is obtained according to the coordinate value of the starting position, the endpoint of the straight segment and the predetermined position or the endpoint of the curved segment; wherein the starting position is the horizontal offset X from the starting point of the milling process to the endpoint of the straight segment, and X is greater than or equal to 150 mm.

7. The detection method according to claim 6, characterized in that: The method further comprises: after all top adjustments are completed, manually judging the bending direction of the steel rail (4) to determine the milling non-working edge of the straight section; the first detection head (61) passes over or does not pass over the steel rail (4) according to the judgment result and uses a first contact displacement sensor (62) on the corresponding side to detect the milling non-working edge of the straight section.

8. The detection method according to claim 6, characterized in that: The two first laser rangefinders (51) at both ends are symmetrically arranged with the pickaxe head (11) in the middle of the top adjustment machine (1), and the actual vector value H is calculated according to formulas Ⅰ and Ⅱ: H = [L2-(L1+L3) / 2]*K(Ⅰ); K=X 2 / (2X*X1-X1 2 )(Ⅱ); Wherein, L1 is the Y-axis coordinate of the first laser rangefinder (51) at one end, L2 is the Y-axis coordinate of the first laser rangefinder (51) in the middle, and L3 is the Y-axis coordinate of the first laser rangefinder (51) at the other end; X1 is the difference between the X-axis coordinate of the first laser rangefinder (51) in the middle and the X-axis coordinate of the first laser rangefinder (51) at one end, and X is the difference between the X-axis coordinate of the pickaxe head (11) in the middle and the X-axis coordinate of the first laser rangefinder (51) at one end; and K is a trimming coefficient.

9. The detection method according to claim 6, characterized in that: The support deviation value H is calculated by formula III: H=(Y2-Y0)-(Y1-Y0)*X2 / X3(Ⅲ); Wherein, Y0 is the Y-axis coordinate of the endpoint of the straight segment, Y1 is the Y-axis coordinate of the starting position, Y2 is the Y-axis coordinate of the predetermined position or endpoint of the curved segment, X2 is the difference between the X-axis coordinate of the predetermined position or endpoint of the curved segment and the X-axis coordinate of the endpoint of the straight segment, and X3 is the difference between the X-axis coordinate of the starting position and the X-axis coordinate of the endpoint of the straight segment. The predetermined position is a detection point with a distance of N meters from the starting position, where N is a positive integer. When detecting the endpoint of the straight segment, the detection position of the first contact displacement sensor (62) is 4-8 mm horizontally offset inward from the judgment endpoint of the second laser rangefinder (63); when detecting the endpoint of the curved segment, the detection position of the second contact displacement sensor (72) is 4-8 mm horizontally offset inward from the judgment endpoint of the third laser rangefinder (73).

10. The detection method according to claim 6, characterized in that: The method further comprises: after each top adjustment, if the requirements are not met, the control module gives a first top adjustment suggestion according to a predetermined algorithm or controls the top adjustment machine (1) to perform automatic top adjustment; after all top adjustments are completed, if the requirements are not met, the control module gives a second top adjustment suggestion according to a predetermined algorithm or controls the top adjustment machine (1) to perform automatic top adjustment.

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