Milling device for guiding the milling of a rail weld based on visual recognition and milling method

Abstract

The application discloses a kind of based on visual identification guide rail weld milling equipment and milling method, it is related to rail processing technical field.Based on visual identification guide rail weld milling equipment includes rack, conveying device, clamp, detection device, milling device and milling control device, clamp is used to clamp the weld of rail in the first direction relative two sides;Detection device is used to non-contact acquisition rail weld in the first direction relative two sides section profile, and generates weld milling reference based on the section profile;Milling device is used to mill rail weld processing.In the technical scheme of the application, detection device adopts non-contact mode to acquire the section profile of the opposite two sides of rail weld, non-contact compared with contact, can save the time of contact and leave with rail section, and can acquire rail section profile at a time, compared with changing position to take point multiple times, can further save detection time.

Description

Technical Field

[0001] This invention relates to the field of rail processing technology, and in particular to a milling device and milling method for rail weld seams guided by visual recognition. Background Technology

[0002] In rail transit systems such as subways, light rails, railways, and high-speed rail, steel rails are used as running guides. The manufacturing process of steel rails includes the following steps: short steel rails are butt-welded together; after welding, the weld seam is removed, rough milled, heat-treated, and then finish-milled to produce longer steel rails for use.

[0003] For rough milling, before rough milling, a testing device is needed to inspect the cross-sections at both ends of the weld to establish a benchmark for the rough milling process. Currently, the commonly used testing device is a contact-type measuring probe. During inspection, the probe is sequentially brought into contact with the cross-sections at both ends of the weld to obtain multiple inspection points. Data from these multiple inspection points is then processed to establish the benchmark for the rough milling process. However, existing contact-type measuring probes require contact with the cross-section of the rail, and the probe's position needs to be changed to detect multiple points on a single cross-section. This results in a long inspection cycle, affecting the overall processing cycle of the rough milling process and making it difficult to meet actual requirements for the rough milling cycle time. Summary of the Invention

[0004] The main objective of this invention is to propose a milling device and method for guiding rail welds based on visual recognition, aiming to solve the problem of long cycle time in the rough milling of existing rail welds.

[0005] To achieve the above objectives, the present invention proposes a milling device for rail weld seams guided by visual recognition, comprising: The frame has a feeding station, a positioning station, an inspection station, and a milling station; A conveying device is provided corresponding to the feeding station for conveying steel rails with welded seams; A clamp is provided corresponding to the positioning station to clamp the weld seam of the rail on both sides opposite each other in a first direction, wherein the first direction corresponds to the length direction of the rail; The detection device, set up corresponding to the detection station, is used to non-contactly collect the cross-sectional profiles of the weld seam on both sides opposite to each other in the first direction, and generate a weld seam milling reference based on the cross-sectional profiles. A milling device, configured and movable corresponding to the milling station, is used to mill the weld seams of the rail; and, A milling control device, which is communicatively connected to the detection device and electrically connected to the milling device, is used to control the activity of the milling device according to the weld milling reference generated by the detection device.

[0006] In one embodiment, the detection device includes: A 2D vision recognition camera is used to acquire the cross-sectional profile of the rail weld on both sides opposite each other in the first direction; and, The data processing unit is communicatively connected to the 2D vision recognition camera and the milling control device, respectively, and is used to sequentially generate point cloud data, curves, and surfaces from the cross-sectional contours acquired by the 2D vision recognition camera, and to form the weld milling reference from the surface. Wherein, on either side of the first direction, the cross-sectional profile is at least two.

[0007] In one embodiment, the clamp includes: The bottom support structure is located on the side of the rail weld in the third direction to support the rail; A top clamping structure, located on the opposite side of the rail weld in a third direction and movable in that direction, clamps the top of the rail; and, The lateral clamping structure is located on both sides of the rail weld in the second direction and can move in the second direction to clamp both sides of the rail. Wherein, the second direction corresponds to the lateral direction of the rail, and the third direction corresponds to the height direction of the rail.

[0008] In one embodiment, the top clamping structure includes a first support rod movable in a third direction, a mounting base disposed on the first support rod, and a clamping head movably disposed on the mounting base, wherein a first elastic element is disposed between the clamping head and the mounting base; and / or, The lateral clamping structure includes a first lateral clamping structure and a second lateral clamping structure. The first lateral clamping structure includes a second support rod that can move in a second direction, and a clamping head disposed on the second support rod. The second lateral clamping structure includes a third support rod movable in a second direction, and a clamping member movably disposed on the third support rod, the clamping member being disposed opposite to the clamping head.

[0009] In one embodiment, the first elastic element includes a disc spring; and / or, The clamping head is mounted on the mounting base via a guide assembly, the guide assembly comprising: A guide portion is disposed on the clamping head and faces the mounting base; A mating part is provided on the mounting base and is provided corresponding to the guide part; One of the guide part and the mating part is a guide rod, and the other is a guide hole.

[0010] In one embodiment, the first support rod includes the piston rod of a first hydraulic cylinder; and / or, The second support rod includes the piston rod of the second hydraulic cylinder, and the third support rod includes the piston rod of the third hydraulic cylinder; and / or, The lateral clamping structure also includes a position sensor, which is mounted on the second support rod with its detection end facing the clamping member, to detect whether the clamping head is in contact with the side of the rail.

[0011] In one embodiment, the clamping member includes: A connecting plate is hinged to the third support rod, and the connecting plate has a connecting end away from the third support rod; A clamping plate is hinged to the connecting end, the clamping plate having a clamping surface facing the clamping head; The second elastic element is disposed between the connecting plate and the clamping plate.

[0012] In one embodiment, the clamping surface is inclined away from the clamping head.

[0013] In one embodiment, the milling equipment for guiding rail welds based on visual recognition further includes: A tool holder, mounted on the frame and rotatable, has a tool pick-up and drop-off station; Multiple milling cutters are mounted circumferentially on the tool holder. The projections of the multiple milling cutters onto the horizontal plane formed by the first and second directions are annular, and the angle between the axis of each milling cutter and the horizontal plane formed by the first and second directions does not exceed 20°; and, A milling cutter transfer device is mounted on the frame and is movable. The range of motion of the milling cutter transfer device covers the tool pick-and-place station and the milling station, for transferring the milling cutter on the tool holder located at the tool pick-and-place station to the milling device located at the milling station, and / or transferring the milling cutter on the milling device located at the milling station to the tool holder located at the tool pick-and-place station.

[0014] This invention also proposes a method for milling rail welds, including a milling device for guiding rail welds based on visual recognition, wherein the milling device for guiding rail welds based on visual recognition includes: The frame has a feeding station, a positioning station, an inspection station, and a milling station; A conveying device is provided corresponding to the feeding station for conveying steel rails with welded seams; A clamp is provided corresponding to the positioning station to clamp the weld seam of the rail on both sides opposite each other in a first direction, wherein the first direction corresponds to the rail conveying direction; The detection device, set up corresponding to the detection station, is used to non-contactly collect the cross-sectional profiles of the weld seam on both sides opposite to each other in the first direction, and generate a weld seam milling reference based on the cross-sectional profiles. A milling device, configured and movable corresponding to the milling station, is used to mill the weld seams of the rail; and, A milling control device, which is communicatively connected to the detection device and electrically connected to the milling device, is used to control the activity of the milling device according to the weld milling reference generated by the detection device.

[0015] In the technical solution of this invention, a conveying device is used to transport the rail to be processed so that the rail weld corresponds to the milling station. A clamping fixture clamps and positions the rail weld on both opposite sides in a first direction. The detection device uses a non-contact method to collect the cross-sectional profile of the rail weld on both opposite sides. Compared to the contact method, the non-contact method saves time in contacting and separating from the rail cross-section, and can collect the rail cross-sectional profile in one go. Compared to taking multiple points by changing positions, it further saves detection time, effectively reduces the milling cycle time, and improves processing efficiency to better meet practical needs. Furthermore, based on the cross-sectional profile, 600-1600 feature points can be extracted. Compared to the existing detection method of approximately 20 points, the generated weld milling datum has higher accuracy. The milling control device controls the milling device's activity according to the weld milling datum to perform milling processing on the rail weld, effectively improving the quality of the milling process.

[0016] The technical solution of this invention uses visual recognition to guide the milling of rail welds, which reduces the milling cycle time and improves the milling accuracy, enabling high-precision milling. The technical solution of this invention is also applicable to the precision milling process of rails after heat treatment in rail production lines. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0018] Figure 1 A three-dimensional structural schematic diagram of an embodiment of a milling equipment for guiding rail welds based on visual recognition provided by the present invention; Figure 2 for Figure 1 A top view of a milling machine for guiding rail welds based on visual recognition. Figure 3 for Figure 1A structural schematic diagram of the weld seams and cross-sectional profile on the steel rail; Figure 4 This is a schematic diagram of a structure of an embodiment of the clamp provided by the present invention; Figure 5 for Figure 4 Enlarged structural diagram of section A in the middle; Figure 6 for Figure 4 Schematic diagram of the structure in the middle BB direction; Figure 7 A schematic diagram of another embodiment of the clamp provided by the present invention; Figure 8 for Figure 7 A schematic diagram of the structure in which the clamps hold the rails together; Figure 9 for Figure 8 Schematic diagram of the CC-axis structure; Figure 10 for Figure 7 A schematic diagram of the structure in which the clamping device pre-clamps the other side of the rail; Figure 11 This is a schematic diagram of the structure in which the first milling cutter mills the top of the guide rail and one side of the top of the guide rail; Figure 12 This is a schematic diagram of the structure for the second milling cutter to mill the lower jaw of the rail head and the upper part of the rail web; Figure 13 A schematic diagram of the structure for the third milling cutter to mill the lower part of the rail web and the upper jaw of the rail bottom; Figure 14 This is a schematic diagram of the structure for the fourth milling cutter to mill the bottom of the guide rail and one side of the bottom of the guide rail; Figure 15 A schematic diagram of the structure for milling the lower chamfer on the top side of the rail using the fifth milling cutter; Figure 16 A schematic diagram of the structure for milling the chamfer on the bottom side of the rail using the fifth milling cutter; Figure 17 A schematic diagram of the structure for the sixth milling cutter to perform finish milling on the upper jaw of the guide rail; Figure 18 This is a schematic diagram of the structure for the seventh milling cutter to perform precision milling on the bottom of the guide rail.

[0019] Explanation of icon numbers: 100. Milling equipment for rail welds; 1. Frame; 2. Conveying device; 3. Fixture; 31. Bottom support structure; 32. Top clamping structure; 321. First hydraulic cylinder; 322. First support rod; 323. Mounting seat; 323a. Mating part; 324. Clamping head; 324a. Guide part; 325. First elastic element; 326. Limiting element; 33. Clamping head; 331. Second hydraulic cylinder; 332. Second support rod; 34. Clamping element; 341. Third hydraulic cylinder; 342. Third support rod; 343. Clamping plate; 343a. Clamping surface; 344. Second 345. Elastic component; 35. Connecting plate; 36. Position sensor; 37. Connector; 4. 2D vision recognition camera; 5. Milling device; 58. First mounting slot; 6. Mounting plate; 79. Tool holder; 70. Second mounting slot; 71. First milling cutter; 722. Second milling cutter; 723. Third milling cutter; 724. Fourth milling cutter; 725. Fifth milling cutter; 726. Seventh milling cutter; 727. Seventh milling cutter; 8. Milling control device; 90. Rail; 91. Top of rail; 92. One side of rail; 93. The other side of rail; 94. Bottom of rail; 95. Weld; 96. Cross-sectional profile.

[0020] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0022] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0023] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0024] For the rough milling process of rail welds, a testing device is needed to inspect the cross-sections at both ends of the weld to establish a reference for the rough milling process. Currently, the commonly used testing device is a contact measuring probe. During inspection, the probe is sequentially brought into contact with the cross-sections at both ends of the weld to obtain multiple inspection points. The data from these multiple inspection points are then processed to form the reference for the rough milling process. However, existing contact measuring probes require contact with the rail cross-section, and the probe's position needs to be changed for each cross-section to detect multiple points. This results in a long inspection cycle, affecting the overall processing cycle of the rough milling process. Furthermore, the number of inspection points in each cross-section is often only around 20, which is relatively small, leading to low accuracy of the established rough milling reference and affecting the quality of the milling process.

[0025] In view of this, the present invention proposes a milling equipment for rail welds based on visual recognition to solve the problem of long rough milling cycle of existing rail welds.

[0026] Please see Figures 1 to 3In one embodiment of the present invention, the milling equipment 100 for guiding rail welds based on visual recognition includes a frame 1, a conveying device 2, a clamp 3, a detection device, a milling device 5, and a milling control device 8. The frame 1 has a feeding station, a positioning station, a detection station, and a milling station. The conveying device 2 is arranged corresponding to the feeding station to convey rails 9 with welds 95. The clamp 3 is arranged corresponding to the positioning station to clamp the welds 95 of the rails 9 on opposite sides in a first direction, wherein the first direction corresponds to the rails 9. The length direction of rail 9; the detection device is set up corresponding to the detection station, and is used to non-contactly collect the cross-sectional profile 96 of the weld 95 of rail 9 on both sides opposite in the first direction, and generate a weld milling reference based on the cross-sectional profile 96; the milling device 5 is set up corresponding to the milling station and is movable, and is used to mill the weld 95 of rail 9; the milling control device 8 is communicatively connected to the detection device and electrically connected to the milling device 5, and is used to control the movement of the milling device 5 according to the weld milling reference generated by the detection device.

[0027] In the technical solution of this invention, the conveying device 2 is used to convey the rail 9 to be processed so that the weld 95 of the rail 9 corresponds to the milling station. The clamp 3 clamps and positions the weld of the rail on both sides opposite in the first direction. The detection device uses a non-contact method to collect the cross-sectional profile 96 of the weld on both sides opposite to the rail. Compared with the contact method, the non-contact method can save the time of contacting and leaving the rail cross-section, and can collect the rail cross-sectional profile 96 at one time. Compared with changing the position and taking points multiple times, it can further save detection time. In addition, based on the cross-sectional profile 96, 600-1600 feature points can be extracted during data processing. Compared with the existing detection of about 20 points, the accuracy of the generated weld milling reference is higher. The milling control device 8 controls the activity of the milling device 5 according to the weld milling reference to perform milling processing on the weld of the rail and improve the quality of milling processing.

[0028] It should be noted that "the clamp 3 is used to clamp the rail weld on both sides opposite in the first direction" means that there is at least one pair of clamps 3, and each pair of clamps 3 includes two clamps 3. In a pair of clamps 3, one clamp 3 is located on one side of the rail weld in the first direction, and the other clamp 3 is located on the other side of the rail weld in the first direction. It can be understood that the number of positioning stations is matched with the number of clamps 3.

[0029] Specifically, in the embodiments of the present invention, there are two clamps 3, and the detection device and the milling device 5 are both located between the two clamps 3, so as to collect the cross-sectional profile 96 of the rail weld on both sides opposite in the first direction, and also to facilitate the milling of the weld.

[0030] To better capture the cross-sectional profile 96 of the rail weld, the detection device includes a 2D vision recognition camera 4 and a data processing unit. The 2D vision recognition camera 4 is used to capture the cross-sectional profile 96 of the rail weld on both sides opposite to each other in the first direction. The data processing unit is communicatively connected to the 2D vision recognition camera 4 and the milling control device 8, respectively, and is used to sequentially generate point cloud data, curves, and surfaces from the cross-sectional profile 96 captured by the 2D vision recognition camera 4, and to form the weld milling reference with the surfaces. The number of cross-sectional profiles 96 on either side of the first direction is at least two.

[0031] In the technical solution of this invention, a 2D vision recognition camera 4 is used to acquire the cross-sectional profiles 96 of the weld seam 95 of the rail on both sides opposite to each other in the first direction. The 2D vision recognition camera 4 does not contact the rail, and the corresponding cross-sectional profiles of the rail can be quickly acquired by shooting, avoiding the problem of long detection cycles caused by the need to acquire multiple different positions by contact in the existing method. It should be noted that "any side in the first direction" refers to either one side of the first direction or the other side of the first direction. The number of acquired cross-sectional profiles 96 is at least two, so the number of cross-sectional profiles 96 corresponding to both sides is at least four. The data processing unit sequentially generates point cloud data, curves, and 3D surfaces from each cross-sectional profile 96, that is, forms at least four 3D surfaces. The weld seam milling reference generated based on at least four 3D surfaces can improve the milling accuracy of the milling device 5. It is understandable that in each cross-sectional profile, the data processing unit can extract 600-1600 feature points, which correspond to 600-1600 point cloud data. Based on the point cloud data, a corresponding curve is formed, which in turn forms a 3D surface.

[0032] To better capture the cross-sectional profile 96 of the rail weld, the milling equipment 100 based on visual recognition to guide the rail weld further includes a mounting plate 6. The mounting plate 6 is mounted on the frame 1 and positioned on opposite sides of the rail weld 95 in a second direction. The mounting plate 6 can move in a first direction, a second direction, and a third direction. The second direction corresponds to the lateral direction of the rail, the third direction corresponds to the height direction of the rail, the first direction is perpendicular to the second direction, and the first and second directions form a horizontal plane. The third direction is perpendicular to both the first and second directions. Two 2D visual recognition cameras 4 are used, positioned at corresponding locations. The mounting plate 6 is used to mount two 2D vision recognition cameras 4, which are positioned opposite each other. In this way, the two 2D vision recognition cameras 4 can simultaneously capture the cross-sectional profile 96 of the rail weld on opposite sides in the second direction. That is, one 2D vision recognition camera 4 captures half of the cross-sectional profile, and the other 2D vision recognition camera 4 captures the other half of the cross-sectional profile. The half cross-sectional profile and the other half of the cross-sectional profile captured by the two 2D vision recognition cameras 4 at the same time form a cross-sectional profile 96, which improves the acquisition efficiency. Moreover, the 2D vision recognition cameras 4 can move with the mounting plate 6 to realize the acquisition of multiple cross-sectional profiles 96, so that the formed weld milling reference is more in line with the characteristics of the actual rail weld and improves the milling accuracy.

[0033] Furthermore, in order to better mill the rail weld, there are two milling devices 5, which are mounted on corresponding mounting plates 6 and arranged opposite each other. In this way, the milling devices 5 can simultaneously mill the weld on both sides opposite each other in the second direction, which improves the milling efficiency. Moreover, the milling devices 5 can move with the mounting plates 6 in the first, second, and third directions to better mill the weld.

[0034] For better positioning and clamping of the rails, please refer to... Figures 4 to 6 The clamp 3 includes a bottom support structure 31, a top clamping structure 32, and a lateral clamping structure. The bottom support structure 31 is located on one side of the rail weld in the third direction to support the rail. The top clamping structure 32 is located on the other side of the rail weld in the third direction and can move in the third direction to clamp the top 91 of the rail. The lateral clamping structure is located on both sides of the rail weld in the second direction and can move in the second direction to clamp both sides of the rail.

[0035] By adopting the above technical solution, the bottom support structure 31 can contact the bottom 94 of the rail to support the rail. When the top clamping structure 32 moves toward the bottom support structure 31, it can clamp the top 91 of the rail. The lateral clamping structure is located on both sides of the rail and can clamp both sides of the rail. In this way, the rail can be clamped more stably, which facilitates the milling of the weld.

[0036] To prevent the rail itself from bending or even twisting, which could cause interference between the clamping structure in the second direction and the pressing structure in the third direction during the clamping process and thus affect the clamping effect of the rail, in one embodiment of the present invention, the top pressing structure 32 includes a first support rod 322 movable in the third direction, a mounting seat 323 disposed on the first support rod 322, and a pressing head 324 movably disposed on the mounting seat 323, and a first elastic element 325 is disposed between the pressing head 324 and the mounting seat 323.

[0037] By adopting the above technical solution, the first support rod 322 can move in the third direction to drive the clamping head 324 to move toward the rail, so as to apply a pre-clamping force to the top 91 of the rail. Since the clamping head 324 is movably set on the mounting base 323, the clamping head 324 has room to move during the lateral clamping process. After the lateral clamping, the pressure of the clamping head 324 on the top 91 of the rail is increased to better clamp the rail. This can effectively avoid the clamping effect of the rail being affected by the irregularity of the rail during the clamping process of the clamp 3, and can also reduce the generation of harsh noise. Furthermore, a first elastic element 325 is provided between the mounting base 323 and the clamping head 324. The first elastic element 325 can be a butterfly spring. The first elastic element 325 has the function of shock absorption and buffering, so that the clamping head 324 can press the top 91 of the rail more stably.

[0038] In another embodiment of the invention, see [reference] Figures 7 to 10 The lateral clamping structure includes a first lateral clamping structure and a second lateral clamping structure. The first lateral clamping structure includes a second support rod 332 movable in a second direction and a clamping head 33 disposed on the second support rod 332. The second lateral clamping structure includes a third support rod 342 movable in a second direction and a clamping member 34 movably disposed on the third support rod 342, and the clamping member 34 is disposed opposite to the clamping head 33.

[0039] By adopting the above technical solution, when laterally clamping the rail, the second support rod 332 is driven to move towards the rail, so that the clamping head 33 fits against one side 92 of the rail, but does not act on the rail. The third support rod 342 is driven to move towards the rail, so that the clamping member 34 applies a pre-clamping force to the other side 93 of the rail. Since the clamping member 34 is movably mounted on the third support rod, the clamping member 34 has room to move during the clamping process of the clamping head 324 clamping the top 91 of the rail. After the top of the rail is clamped, the force of the clamping member 34 acting on the other side 93 of the rail is increased, so that the clamping head 33 and the clamping member 34 can better clamp the rail laterally. This can effectively avoid the clamping effect of the rail being affected by the irregularity of the rail during the clamping process, and can also reduce the generation of harsh noise.

[0040] See Figure 5 To ensure that the clamping head 324 effectively clamps the top 91 of the rail, the clamping head 324 is further mounted on the mounting base 323 via a guide assembly. The guide assembly includes a guide portion 324a and a mating portion 323a. The guide portion 324a is disposed on the clamping head 324 and faces the mounting base 323, while the mating portion 323a is disposed on the mounting base 323 and corresponds to the guide portion 324a. One of the guide portion 324a and the mating portion 323a is a guide rod, and the other is a guide hole.

[0041] By adopting the above technical solution, the clamping head 324 acts more stably on the top of the rail through the setting of the guide part 324a and the mating part 323a. When clamping the top of the rail, the guide rod can move along the guide hole until the clamping head 324 contacts the mounting base 323, and the first elastic member 325 is in a state of compression deformation.

[0042] Specifically, the guide portion 324a is a guide rod, and there are at least two guide portions 324a distributed around the circumference of the clamping head 324. The mating portion 323a is a guide hole, and the number of mating portions 323a matches the number of guide portions 324a. The first elastic element 325 is located within the inner circumference of the multiple guide rods. This allows the clamping head 324 to act more stably on the top of the rail. It is understood that the guide rod passes through the corresponding guide hole, and the end of the guide rod is provided with a limiting element 326, which contacts the edge of the guide hole to facilitate the installation of the clamping head 324 on the mounting base 323.

[0043] In the technical solution of the present invention, the first support rod 322 includes the piston rod of the first hydraulic cylinder 321; and / or, the second support rod 332 includes the piston rod of the second hydraulic cylinder 331, and the third support rod 342 includes the piston rod of the third hydraulic cylinder 341; and / or, the lateral clamping structure further includes a position sensor 35, which is disposed on the second support rod 332 with its detection end facing the clamping member 34, for detecting whether the clamping head 33 is in contact with the side of the rail.

[0044] By adopting the above technical solution, the first support rod 322, the second support rod 332 and the third support rod 342 can be made of hydraulic cylinder piston rods. By controlling the extension and retraction of the corresponding piston rods, the rail can be clamped or released.

[0045] A position sensor 35 is installed on the second support rod 332 to effectively detect whether the clamping head 33 is in contact with one side 92 of the rail. The position sensor 35 is communicatively connected to the milling control device 8, which can control the movement of the first support rod 322, the second support rod 332, and the third support rod 342. When the clamping head 33 needs to be in contact with the rail, the second support rod 332 is controlled to move towards the rail. The position sensor 35 can detect the position of the clamping head 33 in real time and send the detected position signal to the milling control device 8. When the clamping head 33 is detected to be in contact with the rail, the milling control device 8 controls the second support rod 332 to stop moving. At this time, the clamping head 33 is in contact with one side 92 of the rail, but does not act on the rail. At this time, there is a gap between the position sensor 35 and the rail. Specifically, the position sensor 35 is installed on one side of the clamping head 33 via a connector 351.

[0046] To ensure that the clamping member 34 acts stably on the other side 93 of the rail, the clamping member 34 includes a connecting plate 345, a pressing plate 343, and a second elastic member 344. The connecting plate 345 is hinged to the third support rod 342 and has a connecting end away from the third support rod 342. The pressing plate 343 is hinged to the connecting end and has a clamping surface 343a facing the clamping head 33. The second elastic member 344 is disposed between the connecting plate 345 and the pressing plate 343.

[0047] By adopting the above technical solution, the third support rod 342 is driven to move towards the rail, causing the connecting plate 345 and the clamping plate 343 to move, so that the clamping surface 343a contacts the other side 93 of the rail. This allows the clamping member 34 to apply a pre-clamping force to the other side 93 of the rail. After the top of the rail is clamped, the force exerted by the clamping surface 343a on the other side of the rail is increased to achieve better clamping of the rail. It should be noted that the second elastic member 344 can be a disc spring.

[0048] Further, see Figure 10 The clamping surface 343a is inclined in a direction away from the clamping head 33.

[0049] By adopting the above technical solution, the clamping surface 343a in contact with the rail is inclined away from the clamping head 33. After the clamping surface 343a pre-presses the other side 93 of the rail, the included angle α formed by the clamping surface 343a and the other side 93 of the rail is 1~10°. The included angle α can further improve the stability of the clamp 3 clamping the rail and can better adapt to the phenomenon of rail twisting.

[0050] In the technical solution of the present invention, the milling equipment 100 for guiding rail welds based on visual recognition further includes: The tool holder 7 is mounted on the frame 1 and is rotatable, and the tool holder 7 has a tool pick-up and put-out station; Multiple milling cutters are mounted circumferentially on the tool holder 7. The projections of the multiple milling cutters onto the horizontal plane formed by the first and second directions are annular, and the angle between the axis of each milling cutter and the horizontal plane formed by the first and second directions does not exceed 20°; and, A milling cutter transfer device is mounted on the frame 1 and is movable. The range of motion of the milling cutter transfer device covers the tool pick-and-place station and the milling station, and is used to transfer the milling cutter on the tool holder 7 located at the tool pick-and-place station to the milling device 5 located at the milling station, and / or transfer the milling cutter on the milling device 5 located at the milling station to the tool holder 7 located at the tool pick-and-place station.

[0051] By adopting the above technical solution, the tool holder 7 has a tool pick-up and drop-off station. When milling is required, the tool holder 7 is controlled to rotate, so that the milling cutter that meets the current milling operation moves to the tool pick-up and drop-off station. The milling cutter transfer device moves to the tool pick-up and drop-off station to pick up the milling cutter at the tool pick-up and drop-off station and transports the picked-up milling cutter to the milling device 5. The milling cutter is also installed on the first mounting slot 51 of the milling device 5. After the milling cutter installation is completed, the milling device 5 moves so that the milling cutter performs milling operation on the preset position of the weld. After the operation is completed, the milling cutter transfer device picks up the milling cutter from the milling device 5 and transports the picked-up milling cutter to the tool pick-up and drop-off station to install the milling cutter on the tool holder 7. The method of picking up the milling cutter again is the same as above, and will not be described again here, to perform milling operation on another preset position of the weld. In this way, the milling operation of the entire weld is completed.

[0052] Specifically, the tool holder 7 is provided with multiple second mounting slots 71 for mounting various milling cutters. When milling is required, the tool holder rotates to rotate the preset milling cutter to the pick-and-place position, which is convenient for the milling cutter transfer device to pick it up. When the milling cutter needs to be replaced, the milling cutter transfer device takes out the milling cutter from the current milling device and transports it to the pick-and-place position. At the same time, the tool holder rotates to rotate the preset second mounting slot to the pick-and-place position so that the milling cutter transfer device can put the milling cutter back. Then, another milling cutter is picked up. The method of picking up the milling cutter is the same as above, and will not be described again here.

[0053] It should be noted that the milling control device 8 controls the order of picking up and placing multiple milling cutters, as well as the milling position of the cutters, based on the weld milling reference. The tool holder 7 and the cutter transfer device are electrically connected to the milling control device 8. The milling control device 8 can control the rotation of the tool holder 7 and the movement of the cutter transfer device. The projection of each milling cutter onto the horizontal plane formed by the first and second directions is annular, and the angle between the axis of each milling cutter and the horizontal plane formed by the first and second directions does not exceed 20°. This facilitates the picking up and placing of milling cutters by the cutter transfer device, effectively reducing the time for picking up and changing cutters and improving the milling efficiency of the weld.

[0054] Furthermore, in order to better mill the rail welds, refer to... Figures 11 to 18The plurality of milling cutters include a first milling cutter 721, a second milling cutter 722, a third milling cutter 723, a fourth milling cutter 724, a fifth milling cutter 725, a sixth milling cutter 726, and a seventh milling cutter 727. The first milling cutter is used to mill the top of the guide rail and one side of the top of the guide rail. The second milling cutter is used to mill the lower jaw of the rail head and the upper part of the rail web. The third milling cutter is used to mill the lower part of the rail web and the upper jaw of the rail bottom. The fourth milling cutter is used to mill the bottom of the guide rail and one side of the bottom of the guide rail. The fifth milling cutter is used to mill the lower chamfer on the side of the rail top and the upper chamfer on the side of the rail bottom. The sixth milling cutter is used to finish mill the upper jaw of the rail bottom. The seventh milling cutter is used to finish mill the bottom of the guide rail. Only after significantly improving the machining cycle can the combined effect of multiple milling cutters be considered to achieve truly better full-section milling of rail welds. The first, second, third, fourth, and fifth milling cutters are used for rough milling of the rail welds, the sixth milling cutter is used for finish milling of the upper jaw of the rail bottom of the rail weld, and the seventh milling cutter is used for finish milling of the bottom of the guide rail of the rail weld. In this way, the requirements of ultrasonic flaw detection can be better met.

[0055] The present invention also proposes a method for milling rail welds, which includes a milling device 100 for guiding rail welds based on visual recognition. The specific structure of the milling device 100 for guiding rail welds based on visual recognition is as described in the above embodiments. Since the present method for milling rail welds adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be described in detail here.

[0056] The above description is merely an exemplary embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A milling device for rail weld seams guided by visual recognition, characterized in that, include: The frame has a feeding station, a positioning station, an inspection station, and a milling station; A conveying device is provided corresponding to the feeding station for conveying steel rails with welded seams; A clamp is provided corresponding to the positioning station to clamp the weld seam of the rail on both sides opposite each other in a first direction, wherein the first direction corresponds to the length direction of the rail; The detection device, set up corresponding to the detection station, is used to non-contactly collect the cross-sectional profiles of the weld seam on both sides opposite to each other in the first direction, and generate a weld seam milling reference based on the cross-sectional profiles. A milling device, configured and movable corresponding to the milling station, is used to mill the weld seams of the rail; and, A milling control device, which is communicatively connected to the detection device and electrically connected to the milling device, is used to control the activity of the milling device according to the weld milling reference generated by the detection device; A 2D vision recognition camera is used to acquire the cross-sectional profile of the rail weld on both sides opposite each other in the first direction; and, The data processing unit is communicatively connected to the 2D vision recognition camera and the milling control device, respectively, and is used to sequentially generate point cloud data, curves, and surfaces from the cross-sectional contours acquired by the 2D vision recognition camera, and to form the weld milling reference from the surface. Wherein, on either side of the first direction, the cross-sectional profile is at least two; The bottom support structure is located on the side of the rail weld in the third direction to support the rail; A top clamping structure, located on the opposite side of the rail weld in a third direction and movable in that direction, clamps the top of the rail; and, The lateral clamping structure is located on both sides of the rail weld in the second direction and can move in the second direction to clamp both sides of the rail. Wherein, the second direction corresponds to the lateral direction of the rail, and the third direction corresponds to the height direction of the rail; The top clamping structure includes a first support rod movable in a third direction, a mounting base disposed on the first support rod, and a clamping head movably disposed on the mounting base, wherein a first elastic element is disposed between the clamping head and the mounting base; and / or, The lateral clamping structure includes a first lateral clamping structure and a second lateral clamping structure; The first lateral clamping structure includes a second support rod movable in a second direction, and a clamping head disposed on the second support rod; The second lateral clamping structure includes a third support rod movable in a second direction, and a clamping member movably disposed on the third support rod, wherein the clamping member is disposed opposite to the clamping head; A connecting plate is hinged to the third support rod, and the connecting plate has a connecting end away from the third support rod; A clamping plate is hinged to the connecting end, the clamping plate having a clamping surface facing the clamping head; A second elastic element is disposed between the connecting plate and the clamping plate; The clamping surface is inclined away from the clamping head; The milling equipment for guiding rail welds based on visual recognition also includes: A tool holder, mounted on the frame and rotatable, has a tool pick-up and drop-off station; Multiple milling cutters are mounted circumferentially on the tool holder. The projections of the multiple milling cutters onto the horizontal plane formed by the first and second directions are annular, and the angle between the axis of each milling cutter and the horizontal plane formed by the first and second directions does not exceed 20°; and, A milling cutter transfer device is mounted on the frame and is movable. The range of motion of the milling cutter transfer device covers the tool pick-and-place station and the milling station, for transferring the milling cutter on the tool holder located at the tool pick-and-place station to the milling device located at the milling station, and / or transferring the milling cutter on the milling device located at the milling station to the tool holder located at the tool pick-and-place station.

2. The milling equipment for guiding rail welds based on visual recognition as described in claim 1, characterized in that, The first elastic element includes a disc spring; and / or, The clamping head is mounted on the mounting base via a guide assembly, the guide assembly comprising: A guide portion is disposed on the clamping head and faces the mounting base; A mating part is provided on the mounting base and is provided corresponding to the guide part; One of the guide part and the mating part is a guide rod, and the other is a guide hole.

3. The milling equipment for guiding rail welds based on visual recognition as described in claim 1, characterized in that, The first support rod includes the piston rod of the first hydraulic cylinder; and / or, The second support rod includes the piston rod of the second hydraulic cylinder, and the third support rod includes the piston rod of the third hydraulic cylinder; and / or, The lateral clamping structure also includes a position sensor, which is mounted on the second support rod with its detection end facing the clamping member, to detect whether the clamping head is in contact with the side of the rail.

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