Steel rail appearance detection system

Abstract

The invention is suitable for the technical field of track detection, and provides a steel rail appearance detection system, which comprises a plurality of appearance measurement modules and a plurality of end surface measurement modules, each appearance measurement module is used for detecting the outer surfaces of the end parts of the two ends of the steel rail when the steel rail is static, so that the detection accuracy of the outer surfaces of the end parts is improved; the outer surface of the middle section of the steel rail is detected when the steel rail moves, so that the detection efficiency of the outer surface of the middle section of the steel rail is improved; each end face measuring module is used for detecting the end faces of the two ends of the steel rail when the steel rail is static, and the detection accuracy of the end faces is improved; wherein the appearance detection result of the outer surface of the end part comprises the geometric dimension of the end part, and the appearance detection result of the end surface comprises the geometric dimension of the end surface. According to the system, manual participation is not needed, the labor cost is reduced, the duration is shortened, errors are reduced, the detection accuracy is improved, and measurement of the end geometric dimension and the end face geometric dimension is achieved.

Description

Technical Field

[0001] The present application belongs to the field of track detection technology, and in particular, relates to a rail appearance detection system. Background Art

[0002] At present, surface defect detection is an indispensable key link in the manufacturing industry. It has been widely used in many industrial manufacturing fields such as aviation, ceramics, automobile parts manufacturing, metals, and electronic components and equipment. For example, during the transportation of rails, various defects often appear on the surface of the rails due to collisions during transportation and factors such as rail production quality. These defects seriously affect the quality and performance indicators of welded joints. Therefore, it is particularly important to detect defects on the surface of rails.

[0003] However, existing rail welding plants usually use pure manual inspection, which is not only time-consuming and labor-intensive, but also has large measurement errors. At the same time, since the rails are usually in a fast-moving state during the appearance inspection, the appearance defects of the rails cannot be seen when relying on the human eye for appearance inspection. It can be seen that the existing technology has the problems of long time consumption, high labor costs, large detection errors and low detection accuracy. Summary of the invention

[0004] The embodiment of the present application provides a rail appearance inspection system, which can solve the problems of long time consumption, high labor cost, large inspection error and low inspection accuracy in the prior art.

[0005] In a first aspect, an embodiment of the present application provides a rail appearance detection system, comprising a plurality of appearance measurement modules and a plurality of end face measurement modules; wherein:

[0006] Each of the appearance measurement modules is used to perform appearance inspection on the outer surfaces of the ends of the rail when the rail is in a stationary state, and to perform appearance inspection on the outer surface of the middle section of the rail when the rail is in a transmission process;

[0007] Each of the end face measurement modules is used to perform appearance inspection on the end faces at both ends of the rail when the rail is in the static state; wherein the end outer surfaces at both ends of the rail, the end faces at both ends and the middle section outer surface constitute the complete outer surface of the rail; the appearance inspection result of the end outer surface includes the measured end geometric dimensions; the appearance inspection result of the end face includes the measured end face geometric dimensions.

[0008] Optionally, each of the appearance measurement modules is specifically used for:

[0009] When the head end of the rail is transferred to the end detection area and is in a stationary state, performing an appearance inspection on the end outer surface of the head end currently located in the end detection area; and

[0010] When the end of the rail is transported to the end detection area and is in a stationary state, an appearance inspection is performed on the end outer surface of the end currently located in the end detection area.

[0011] Optionally, each of the appearance measurement modules is specifically used for:

[0012] When the head end or the tail end of the rail is transmitted to the end detection area and is in a stationary state, by moving within the range corresponding to the end detection area, the end outer surface related data of the head end or the tail end is collected to perform an appearance inspection on the end outer surface.

[0013] Optionally, each of the end surface measurement modules is specifically used for:

[0014] When each appearance measurement module is used to perform appearance inspection on the outer surface of the head end or the tail end of the rail, appearance inspection is performed on the end face of the head end or the tail end currently located in the end inspection area; wherein the appearance inspection of the end face of the head end or the tail end is completed by different end face measurement modules.

[0015] Optionally, a first sampling frequency used by each appearance measurement module to perform appearance detection on the outer surface of the end portion when in a stationary state is different from a second sampling frequency used to perform appearance detection on the outer surface of the middle portion during transmission, and the second sampling frequency is greater than the first sampling frequency.

[0016] Optionally, each of the appearance measurement modules only includes a three-dimensional measurement unit; wherein:

[0017] Each of the three-dimensional measurement units is used to collect point cloud data of the outer surface of the end portion and the outer surface of the middle portion for appearance inspection.

[0018] Optionally, each of the appearance measurement modules includes a three-dimensional measurement unit and a two-dimensional camera unit; wherein:

[0019] Each of the three-dimensional measurement units is used to collect point cloud data of the outer surface of the end portion and the outer surface of the middle portion for appearance inspection;

[0020] Each of the two-dimensional camera units is used to photograph the outer surface of the middle section of the rail when the rail is in the transmission process, and perform appearance inspection on the outer surface of the middle section based on the image data obtained by the photography.

[0021] Optionally, the rail appearance detection system further includes a speed measurement module;

[0022] The speed measurement module is used to obtain the transmission speed of the rail when the rail is in the transmission process, and send the transmission speed to each appearance measurement module;

[0023] Each of the appearance measurement modules is further used to determine a deformation ratio based on the transmission speed, determine a processing method for the collected point cloud data and / or image data of the middle section outer surface based on the deformation ratio, and process the point cloud data and / or image data according to the processing method to obtain an appearance detection result of the middle section outer surface.

[0024] Optionally, the rail appearance detection system further includes a processing module; the processing module is specifically used for:

[0025] Receiving the detection results sent by each of the appearance measurement modules and each of the end surface measurement modules, the detection results including the appearance detection results of the end outer surface, the middle section outer surface and each of the end surfaces;

[0026] Respectively comparing the appearance inspection results of the end outer surface, the middle outer surface and each end surface with the standard inspection results of the corresponding parts;

[0027] When any of the appearance inspection results of the end outer surface, the middle outer surface and each of the end surfaces does not match the standard inspection result, the rail appearance inspection failure information is output.

[0028] Optionally, the appearance detection result of the middle section outer surface carries a detection time, and the detection time includes a plurality of times when each appearance measurement module samples the middle section outer surface;

[0029] The processing module is further used to determine the defect position of the defect in the outer surface of the middle section according to the transmission speed of the rail and the detection time when the defect is obtained when there is a defect on the outer surface of the middle section.

[0030] Optionally, the rail appearance detection system further includes a humidity detection module;

[0031] The humidity detection module is used to obtain the humidity value of the rail before performing appearance inspection on the rail, and send the humidity value to the processing module;

[0032] The processing module is further configured to output a dehumidification prompt message when it is detected that the humidity value is greater than or equal to a set humidity, and stop the appearance inspection of the rail until the humidity value is less than the set humidity.

[0033] Optionally, the rail appearance detection system further includes a camera module;

[0034] The camera module is used to photograph the barcode information on the rail and send the photographed barcode image to the processing module;

[0035] The processing module is used to perform image recognition on the barcode image to determine the identification code of the rail.

[0036] Compared with the prior art, the embodiments of the present invention have the following beneficial effects:

[0037] A rail appearance detection system provided by an embodiment of the present application includes multiple appearance measurement modules and multiple end face measurement modules; wherein each appearance measurement module is used to detect the end outer surfaces at both ends of the rail when the rail is stationary, thereby improving the detection accuracy of the end outer surfaces; and to detect the outer surface of the middle section of the rail when the rail is moving, thereby improving the detection efficiency of the outer surface of the middle section of the rail; each end face measurement module is used to detect the end faces at both ends of the rail when the rail is stationary, thereby improving the detection accuracy of the end faces; wherein the end outer surfaces at both ends of the rail, the end faces at both ends and the middle section outer surface constitute the complete outer surface of the rail; the appearance detection result of the end outer surface includes the end geometric dimensions, and the appearance detection result of the end face includes the end face geometric dimensions. The rail appearance detection system provided by the present application does not require manual participation, which not only reduces labor costs and shortens time, but also reduces errors, improves detection accuracy, and also realizes the measurement of end geometric dimensions and end face geometric dimensions. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0039] Figure 1 It is a structural schematic diagram of a rail appearance detection system provided in one embodiment of the present application;

[0040] Figure 2 It is a partial physical structure diagram of a rail appearance inspection system provided in one embodiment of the present application;

[0041] Figure 3 This is a schematic diagram of end face detection provided by an embodiment of the present application;

[0042] Figure 4 is a structural schematic diagram of a rail appearance inspection system provided by another embodiment of the present application;

[0043] Figure 5 It is a structural schematic diagram of a rail appearance detection system provided in yet another embodiment of the present application. DETAILED DESCRIPTION

[0044] In the following description, specific details such as specific system structures, technologies, etc. are provided for the purpose of illustration rather than limitation, so as to provide a thorough understanding of the embodiments of the present application. However, it should be clear to those skilled in the art that the present application may also be implemented in other embodiments without these specific details. In other cases, detailed descriptions of well-known systems, devices, circuits, and methods are omitted to prevent unnecessary details from obstructing the description of the present application.

[0045] It should be understood that when used in the present specification and the appended claims, the term "comprising" indicates the presence of described features, wholes, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components and / or combinations thereof.

[0046] It should also be understood that the term “and / or” used in the specification and appended claims refers to any and all possible combinations of one or more of the associated listed items, and includes these combinations.

[0047] As used in the specification and appended claims of this application, the term "if" can be interpreted as "when" or "uponce" or "in response to determining" or "in response to detecting", depending on the context. Similarly, the phrase "if it is determined" or "if [described condition or event] is detected" can be interpreted as meaning "uponce it is determined" or "in response to determining" or "uponce [described condition or event] is detected" or "in response to detecting [described condition or event]", depending on the context.

[0048] In addition, in the description of the present application specification and the appended claims, the terms "first", "second", "third", etc. are only used to distinguish the descriptions and cannot be understood as indicating or implying relative importance.

[0049] References to "one embodiment" or "some embodiments" etc. described in the specification of this application mean that one or more embodiments of the present application include specific features, structures or characteristics described in conjunction with the embodiment. Therefore, the statements "in one embodiment", "in some embodiments", "in some other embodiments", "in some other embodiments", etc. that appear in different places in this specification do not necessarily refer to the same embodiment, but mean "one or more but not all embodiments", unless otherwise specifically emphasized in other ways. The terms "including", "comprising", "having" and their variations all mean "including but not limited to", unless otherwise specifically emphasized in other ways.

[0050] At present, surface defect detection is an indispensable key link in the manufacturing industry. It has been widely used in many industrial manufacturing fields such as aviation, ceramics, automobile parts manufacturing, metals, and electronic components and equipment. For example, during the transportation of rails, various defects often appear on the surface of the rails due to collisions during transportation and factors such as rail production quality. These defects seriously affect the quality and performance indicators of welded joints. Therefore, it is particularly important to detect defects on the surface of rails.

[0051] However, the existing rail appearance inspection is not comprehensive enough, which reduces the accuracy of rail appearance defect detection. Therefore, in all embodiments of the present application, a rail appearance inspection system is provided to achieve all-round inspection of the rails to improve the accuracy of rail appearance defect detection.

[0052] See also Figure 1 , Figure 1 1 is a schematic diagram of the structure of a rail appearance inspection system provided by an embodiment of the present application. For ease of explanation, only the parts related to this embodiment are shown, which are described in detail as follows:

[0053] like Figure 1 As shown, the rail appearance inspection system 1 includes: a plurality of appearance measurement modules 10 (four are shown in the figure as an example) and a plurality of end face measurement modules 20 (two are shown in the figure as an example). The plurality of appearance measurement modules 10 are respectively located at each side of a rail conveyor belt (not shown in the figure) in the rail appearance inspection system 1, and the plurality of end face measurement modules 20 are respectively located at both ends of the rail conveyor belt. The sides of the rail conveyor belt include but are not limited to the upper side, the lower side, the left side and the right side. The rail conveyor belt is used to transport rails.

[0054] It should be noted that the number of appearance measurement modules 10 can be determined according to actual needs and is not limited here. For example, the number of appearance measurement modules 10 can be 4, 6, 8, etc.

[0055] In some possible embodiments, when the number of appearance measurement modules 10 is four, the four appearance measurement modules 10 can be respectively arranged at the top, bottom, left and right of an appearance detection frame (not shown in the figure) in the rail appearance detection system 1, so that the outer surface of the rail passing through the appearance detection frame can be inspected.

[0056] The number of the end surface measurement modules 20 may be two.

[0057] In practical applications, each appearance measurement module 10 may be a three-dimensional line laser measuring instrument.

[0058] Each end surface measurement module 20 may also be a three-dimensional line laser measuring instrument.

[0059] In the embodiment of the present application, each appearance measurement module 10 is used to perform appearance inspection on the outer surfaces of the ends of the rail when the rail is in a stationary state, and to perform appearance inspection on the outer surface of the middle section of the rail when the rail is in a transmission process.

[0060] Each end surface measurement module 20 is used to perform appearance inspection on the end surfaces of the rails at both ends when the rails are in a stationary state. The end outer surfaces at both ends of the rails, the end surfaces at both ends and the outer surface of the middle section constitute the complete outer surface of the rails; the appearance inspection result of the end outer surface includes the measured geometric dimensions of the end.

[0061] In the embodiment of the present application, in order to realize all-round inspection of the rails, the inspection modes of the rail appearance inspection system 1 include but are not limited to: end inspection mode and rail middle section outer surface inspection mode. Among them, the end inspection mode specifically refers to the mode of inspecting the end outer surface and end faces of the two ends of the rails.

[0062] The length of the outer surface of the end portion can be determined according to actual needs and is not limited here. For example, the length of the outer surface of the end portion can be 3 meters.

[0063] It should be noted that, since the two ends of the rails usually need to be welded together with the ends of other rails, the geometric dimensions of the ends will have an important impact on the welding process with the ends of other rails, that is, seriously affecting the quality and performance indicators of the welded joints; in addition, more accurate geometric dimensions of the end of the rail can be obtained when the rail is stationary, therefore, the rail appearance inspection system 1 can determine that the rail is in end inspection mode when the rail is in a stationary state.

[0064] In order to improve the detection rate of the outer surface of the middle section of the rail, the rail appearance detection system 1 can determine that the rail is in the middle section outer surface detection mode when the rail is in the transmission process.

[0065] Based on this, when the rail is in a stationary state, it means that the rail is in an end detection mode. Therefore, each appearance measurement module 10 can perform appearance detection on the end outer surfaces of both ends of the rail to obtain appearance detection results of the end outer surfaces of both ends of the rail.

[0066] It should be noted that the appearance inspection of the outer surfaces of the ends of the rails includes the appearance information inspection of the outer surfaces of the ends of the rails and the geometric dimensions inspection of the ends of the rails.

[0067] The appearance inspection result of the end outer surface includes but is not limited to the appearance information of the end outer surface and the geometric dimensions of the end.

[0068] It should be noted that the end geometry covers the shape and size of the end of the rail, including but not limited to length, width, thickness and any specific measurements related to the end shape (such as end twisting, straightness, etc.).

[0069] In some possible embodiments, since each appearance measurement module 10 measures the outer surface of the end of the rail at both ends to obtain point cloud data, and point cloud data refers to a set of vectors in a three-dimensional coordinate system, each appearance measurement module 10 can determine the geometric size of the end based on the three-dimensional coordinates in the measured point cloud data.

[0070] In one embodiment of the present application, in order to improve the detection accuracy of both ends of the rail, the scanning frequency of each appearance measurement module 10 for appearance detection of the outer surface of the end of the rail in a stationary state can be determined as a first frequency. The first frequency can be determined according to actual needs and is not limited here.

[0071] Based on this, in this embodiment, when the rail is in a stationary state, each appearance measurement module 10 can perform appearance detection on the outer surfaces of the ends of the rail based on the first frequency.

[0072] It should be noted that, since the rail is stationary at this time, the first frequency can be set to a smaller value.

[0073] Since the rail includes a head end and an end end, in another embodiment of the present application, each appearance measurement module 10 can specifically perform an appearance inspection on the end outer surface of the head end currently located in the end detection area when the head end of the rail is transmitted to the end detection area and is in a stationary state; and perform an appearance inspection on the end outer surface of the end currently located in the end detection area when the end end of the rail is transmitted to the end detection area and is in a stationary state.

[0074] It should be noted that, since the end face is adjacent to the end, the end detection area can be determined according to the position range of each end face measurement module 10. As an example, the end detection area can be a set area adjacent to the position range of each end face measurement module 10. The length of the set area can be determined according to the length of the outer surface of the end.

[0075] Therefore, the head end / end of the rail is transmitted to the end detection area, which specifically means that the head end / end of the rail is transmitted to a set area adjacent to the measurement range of the corresponding end surface measurement module 10 .

[0076] In another embodiment of the present application, in order to achieve the measurement accuracy of the end geometric dimensions, each appearance measurement module 10 can collect the end outer surface related data of the head end or the end end by moving within the range corresponding to the end detection area when the head end or the end end of the rail is transmitted to the end detection area and is in a stationary state, so as to perform appearance inspection on the end outer surface. The end outer surface related data includes but is not limited to: point cloud data and image data.

[0077] Specifically, taking the example that the appearance measurement modules 10 are all three-dimensional line laser measuring instruments, when the head end of the rail is transmitted to the end detection area corresponding to the head end and is in a stationary state, that is, when the rail is in a stationary state in the end detection area corresponding to the head end, each three-dimensional line laser measuring instrument can move from the initial position to the first set position of the set range corresponding to the above-mentioned end detection area, and move within the set range, so that each three-dimensional line laser measuring instrument can collect relevant data of the end outer surface of the head end during the movement, so as to realize comprehensive appearance information detection of the end outer surface of the head end, and detection of the end geometric dimensions of the head end.

[0078] Afterwards, each three-dimensional line laser measuring instrument can return to the initial position to realize the appearance inspection of the outer surface of the middle section of the rail. After completing the appearance inspection of the outer surface of the middle section of the rail, and when the end of the rail is transmitted to the end inspection area corresponding to the end and is in a stationary state, that is, when the rail is in a stationary state in the end inspection area corresponding to the end, each three-dimensional line laser measuring instrument can move from the initial position to the second set position of the set range corresponding to the above-mentioned end inspection area, and move within the set range, so that each three-dimensional line laser measuring instrument can collect relevant data of the end outer surface of the end during the movement, so as to realize comprehensive appearance information inspection of the end outer surface of the end, and inspection of the end geometric dimensions of the end.

[0079] For example, taking the number of appearance measurement modules 10 as four, see Figure 2 , Figure 2 FIG. 1 is a partial physical structure diagram of a rail appearance inspection system provided in an embodiment of the present application. Figure 2 As shown, multiple appearance measurement modules 10 are installed on the appearance detection frame, and multiple appearance measurement modules 10 are respectively arranged on the top, bottom, left and right of the appearance detection frame. When the head end or the end of the rail is transferred to the end detection area and is in a stationary state, Figure 2 Each appearance measurement module 10 provided on the appearance inspection frame can be moved to a first set position within a set range corresponding to the end inspection area, and move within the set range based on a set speed.

[0080] Among them, the first set position, the second set position and the set speed can be set according to actual needs and are not limited here.

[0081] In the embodiment of the present application, when the rail is in a stationary state, it means that the rail is in an end detection mode. Therefore, each end face measurement module 20 can perform appearance detection on the end faces at both ends of the rail to obtain appearance detection results of the end faces at both ends of the rail.

[0082] It should be noted that the appearance inspection of the end faces at both ends of the rail includes the appearance information inspection of the end faces at both ends of the rail and the geometric dimensions inspection of the end faces at both ends of the rail.

[0083] The appearance inspection results of the end face include but are not limited to the appearance information and geometric dimensions of the end face.

[0084] It should be noted that the end face geometric dimensions mainly involve various measurements and specifications related to the end face, including but not limited to the end face inclination (including vertical and horizontal directions), rail head width, rail height, rail bottom width, rail waist width, rail bottom edge thickness and rail crown fullness, etc.

[0085] In some possible embodiments, since each end face measurement module 20 measures the end faces at both ends of the rail to obtain point cloud data, and point cloud data refers to a set of vectors in a three-dimensional coordinate system, each end face measurement module 20 can determine the end face geometric dimensions based on the three-dimensional coordinates in the measured point cloud data.

[0086] In one embodiment of the present application, since both ends of the rail include a head section and a tail section, when each appearance measurement module 10 is used to perform appearance inspection on the outer surface of the head end or the tail end of the rail, each end face measurement module 20 performs appearance inspection on the end face of the head end or the tail end currently located in the end inspection area. The appearance inspection of the end face of the head end or the tail end is completed by different end face measurement modules 20.

[0087] Specifically, when each appearance measurement module 10 performs appearance measurement on the outer surface of the head end of the rail, it means that the head end of the rail is in the end detection area, that is, the head end of the rail is in the measurement range of a certain end face measurement module. Therefore, the end face measurement module can detect the appearance information of the head end of the rail and the end face geometric dimensions of the head end.

[0088] When each appearance measurement module 10 performs appearance measurement on the outer surface of the end of the rail, it means that the end of the rail is in the end detection area, that is, the end of the rail is in the measurement range of another end surface measurement module. Therefore, the other end surface measurement module can perform appearance detection on the end of the rail and detect the end surface geometric dimensions of the end.

[0089] In another embodiment of the present application, in order to improve the success rate and accuracy of end face detection, when detecting the end face of the head end or the end end of the rail, the end face measurement module 20 corresponding to the head end or the end end can be moved from the initial position to the second set position to successfully collect complete head end or end end face related data, so as to achieve comprehensive appearance information detection of the end face and detection of the end face geometric dimensions. The end face related data includes point cloud data of the end face.

[0090] The second set position specifically refers to the position of the end surface measurement module 20 when the end surface of the head end or the tail end is located in the central area within the measurement range of the corresponding end surface measurement module 20.

[0091] Afterwards, when the end surface measurement module 20 corresponding to the head end or the tail end completes all detections of the end surface of the corresponding head end or the tail end, the end surface measurement module 20 corresponding to the head end or the tail end may return to the initial position.

[0092] It can be understood that when the outer surfaces of the ends of the rail and the outer surface of the middle section of the rail are detected, each end surface measurement module 20 is in the initial position.

[0093] For example, see Figure 3 , Figure 3 FIG. 1 is a schematic diagram of end face detection provided by an embodiment of the present application. Figure 3 As shown, a detection mechanism 2 is located at one end of the rail conveyor belt, and each detection structure 2 is provided with a transmission port, which is used to transmit the rail (such as Figure 3 As shown in (a) in FIG. 1 , a certain end face measurement module 20 may be arranged below the transmission port. When the rail is transmitted to a position at a first distance from the transmission port and is suspended (as shown in FIG. 1 ), the end face measurement module 20 may be arranged below the transmission port. Figure 3 As shown in (b) in FIG. 1 , it is shown that at this time, a certain end face of the rail can be subjected to relevant detection. Therefore, the end face measurement module 20 can be moved from the bottom of the transmission port (i.e., the initial position) to a position opposite to the end face of the rail (i.e., the second set position, i.e., as shown in FIG. 1 ). Figure 3 After completing the relevant inspection of the end face, the end face measurement module 20 can return from the second set position to the initial position (as shown in (c) in FIG. Figure 3 (as shown in (d) in the figure).

[0094] It should be noted that, combined with Figure 3 The end face measurement module 20 may also be disposed on the side of the transmission port or above the transmission port.

[0095] In the embodiment of the present application, when the rail is in the transmission process, it means that the rail is in the middle section outer surface detection mode. Therefore, each appearance measurement module 10 can perform appearance detection on the middle section outer surface of the rail to obtain the appearance detection result of the middle section outer surface of the rail.

[0096] It should be noted that the transmission speed of the rail during the transmission process can be 0.8m / s or 1m / s, and the maximum transmission speed of the rail can be 2m / s.

[0097] In some possible embodiments, performing appearance inspection on the outer surface of the middle section of the rail includes performing appearance information inspection on the outer surface of the middle section of the rail and inspecting geometric dimensions of the middle section of the rail.

[0098] Therefore, in this embodiment, the appearance inspection result of the outer surface of the middle section of the rail includes but is not limited to the appearance information of the outer surface of the middle section and the geometric dimensions of the middle section.

[0099] It should be noted that the geometric dimensions of the middle section include but are not limited to the length, width and height of the middle section of the rail.

[0100] In some other possible embodiments, since each appearance measurement module 10 measures the outer surface of the middle section of the rail to obtain point cloud data, and point cloud data refers to a set of vectors in a three-dimensional coordinate system, each appearance measurement module 10 can determine the geometric dimensions of the middle section based on the three-dimensional coordinates in the measured point cloud data.

[0101] In some possible embodiments, since the rail appearance inspection system usually first performs appearance inspection on the end outer surface and end face of one end of the rail, and then inspects the outer surface of the middle section of the rail, and when performing appearance inspection on the end outer surface of one end of the rail, each appearance measurement module 10 has moved to the end inspection area, therefore, after performing appearance inspection on the end outer surface and end face of one end of the rail, before the rail changes from stationary to moving, each appearance measurement module 10 can return to the initial position to achieve appearance inspection of the outer surface of the middle section of the rail.

[0102] It should be noted that when the rail is in the process of being transported, each appearance measurement module 10 does not move.

[0103] Since in actual application, the moving speed of the rail during the transmission process is very fast, therefore, in one embodiment of the present application, in order to improve the detection accuracy of both ends of the rail, each appearance measurement module 10 can determine the scanning frequency of the appearance detection of the outer surface of the middle section of the rail in the transmission process as the second frequency. The second frequency can be determined according to actual needs and is not limited here.

[0104] It should be noted that the second frequency is greater than the first frequency.

[0105] Based on this, in this embodiment, when the rail is in the transmission process, each appearance measurement module 10 can perform appearance detection on the outer surface of the middle section of the rail based on the second frequency.

[0106] It should be noted that, since the moving speed of the rail is too fast at this time, in order to improve the measurement accuracy, the second frequency needs to be set to a larger value.

[0107] In another embodiment of the present application, each appearance measurement module 20 may only include a three-dimensional measurement unit.

[0108] Specifically, each three-dimensional measurement unit is used to collect point cloud data of the end outer surface and the middle outer surface for appearance inspection.

[0109] It should be noted that each three-dimensional measurement unit may be a three-dimensional camera.

[0110] In yet another embodiment of the present application, in order to improve the accuracy of appearance detection of rails, each appearance measurement module 10 includes a three-dimensional measurement unit and a two-dimensional camera unit.

[0111] Specifically, each three-dimensional measurement unit is used to collect point cloud data of the end outer surface and the middle outer surface for appearance inspection.

[0112] Each two-dimensional camera unit is used to photograph the outer surface of the middle section of the rail when the rail is in the transmission process, and to perform appearance inspection on the outer surface of the middle section based on the image data obtained by the photography.

[0113] It should be noted that each three-dimensional measurement unit may be a three-dimensional camera, and each two-dimensional imaging unit may be a two-dimensional camera.

[0114] In this embodiment, since the three-dimensional measurement unit cannot detect slight scratches and stains on the outer surface of the middle section of the rail, in order to improve the detection accuracy of the outer surface of the middle section of the rail, each two-dimensional camera unit can photograph the outer surface of the middle section of the rail when the rail is in the transmission process, and perform appearance detection on the outer surface of the middle section based on the image data obtained by the capture, so as to obtain the appearance detection result of the outer surface of the middle section in combination with the point cloud data of the outer surface of the middle section.

[0115] In the embodiment of the present application, in order to improve the detection efficiency of the rail appearance detection system, the rail appearance detection system 1 can first perform an appearance detection on the end face of the head end and the outer surface of the end of the rail through each appearance measurement module 10 and the end face measurement module 20 corresponding to the head end of the rail, and then perform an appearance detection on the outer surface of the middle section of the rail through each appearance measurement module 10; finally, perform an appearance detection on the end face and the outer surface of the end of the rail through each appearance measurement module 10 and the end face measurement module 20 corresponding to the end of the rail, thereby completing the appearance detection of the rail.

[0116] In another embodiment of the present application, please continue to refer to Figure 1 The rail appearance detection system 1 may further include a processing module 30. The processing module 30 is communicatively connected with the plurality of appearance measurement modules 10 and the plurality of end surface measurement modules 20 respectively.

[0117] It should be noted that the above-mentioned communication connection methods include but are not limited to wireless communication connection and wired communication connection.

[0118] In this embodiment, the processing module 30 is specifically used for:

[0119] Receive the test results sent by each appearance measurement module and each end face measurement module, the test results including the appearance test results of the end outer surface, the middle outer surface and each end face;

[0120] Compare the appearance inspection results of the end outer surface, the middle outer surface and each end surface with the standard inspection results of the corresponding parts;

[0121] When any of the appearance inspection results of the end outer surface, the middle outer surface and each end surface does not match the standard inspection result, the rail appearance inspection failure information is output.

[0122] It should be noted that the appearance inspection result of the end outer surface includes the appearance information of the end outer surface and the end geometric dimensions, the appearance inspection result of the middle section outer surface includes the appearance information of the middle section outer surface, and the appearance inspection result of the end face includes the appearance information of the end face.

[0123] Among them, each of the above appearance information is used to describe whether there is a defect.

[0124] In this embodiment, the standard test results of various parts of the rail specifically refer to the test results corresponding to the standard rail without any appearance defects.

[0125] When the processing module detects that any of the appearance inspection results of each end outer surface, the middle outer surface and each end face does not match the corresponding standard inspection result, it indicates that the rail has defects. Therefore, the processing module can output information that the rail appearance inspection is unqualified.

[0126] In some possible embodiments, since minor defects can be ignored, the above-mentioned appearance inspection results can also include defect sizes, and the standard inspection results of various parts of the rail can refer to the inspection results corresponding to standard rails with defect sizes less than a preset threshold. The preset threshold can be determined according to actual needs and is not limited here.

[0127] Based on this, in this embodiment, when the processing module detects that any of the appearance inspection results of each end outer surface, the middle outer surface and each end face do not match the corresponding standard inspection result, it means that the size of the defect in the rail is greater than or equal to the preset threshold. Therefore, the processing module can output the information that the rail appearance inspection is unqualified.

[0128] In other possible embodiments, when the appearance inspection results of the outer surface of the middle section carry the inspection time, in order to determine the specific location of the defect existing on the outer surface of the middle section, the processing module 30 can specifically determine the defect position of the defect in the outer surface of the middle section according to the transmission speed of the rail and the inspection time when the defect is obtained when there is a defect on the outer surface of the middle section.

[0129] It should be noted that the above detection moments include a plurality of moments when each appearance measurement module 10 samples the outer surface of the middle section.

[0130] In this embodiment, when determining that there is a defect on the outer surface of the middle section of the rail, the processing module 30 can determine the defect detection time of the appearance inspection result corresponding to the defect, and calculate the distance that the rail has moved when each appearance measurement module 10 detects the defect based on the transmission speed of the rail and the defect detection time. Afterwards, the processing module 30 can determine the defect position of the defect in the outer surface of the middle section based on the initial inspection position of the rail at the start time of the appearance inspection on the outer surface of the middle section of the rail and the distance that the rail has moved.

[0131] See also Figure 4 , Figure 4 FIG. 1 is a schematic diagram of the structure of a rail appearance detection system provided by another embodiment of the present application. Figure 4 As shown, the rail appearance detection system 1 in this embodiment further includes: a speed measurement module 40 . The speed measurement module 40 is connected to each appearance measurement module 10 .

[0132] Specifically, the speed measuring module 40 is used to obtain the transmission speed of the rail when the rail is in the transmission process, and send the transmission speed to each appearance measuring module 10 .

[0133] Each appearance measurement module 10 is further used to determine the deformation ratio based on the transmission speed, determine the processing method of the collected point cloud data and / or image data of the middle section outer surface based on the deformation ratio, and process the point cloud data and / or image data according to the processing method to obtain the appearance detection result of the middle section outer surface.

[0134] In practical applications, the speed of the rail during transmission may be uneven and very fast; at the same time, in high-speed scenarios, the point cloud data and / or image data of the middle section outer surface measured by each appearance measurement module 10 will be deformed, and at different speeds, the deformation ratio of each appearance measurement module 10 is different. Therefore, in order to ensure that tiny defects in the rail can be accurately detected in uneven high-speed scenarios, and whether the defects exceed the acceptable range can be determined by the length, width and height dimensions, in this embodiment, when the rail is in the transmission process, the speed measurement module 40 can detect the transmission speed of the rail in real time, and send the transmission speed to each appearance measurement module 10 in real time.

[0135] Afterwards, each appearance measurement module 10 can determine the deformation ratio of each appearance measurement module 10 in real time based on the transmission speed obtained in real time, and determine the processing method of the collected point cloud data and / or image data of the middle section outer surface in real time based on the deformation ratio determined in real time, and process the collected point cloud data and / or image data in real time according to the processing method determined in real time to obtain an accurate appearance detection result of the middle section outer surface. The processing method refers to the method of scaling the point cloud data and / or image data.

[0136] The above processing methods include but are not limited to: stretching and compression.

[0137] In this embodiment, the correspondence between different transmission speeds and different deformation ratios can be set according to actual needs and is not limited here.

[0138] It can be seen from the above that the rail appearance detection system provided in this embodiment can avoid the problem of deformation of the collected point cloud and / or image caused by the rapid transmission of the rail, thereby improving the measurement precision and measurement accuracy of each appearance measurement module.

[0139] See also Figure 5 , Figure 5 FIG. 1 is a schematic diagram of the structure of a rail appearance detection system provided by another embodiment of the present application. Figure 5 As shown, the rail appearance detection system 1 in this embodiment further includes: a humidity detection module 50 , and the humidity detection module 50 is connected to the processing module 30 .

[0140] Specifically, the humidity detection module 50 is used to obtain the humidity value of the rail before performing appearance inspection on the rail, and send the humidity value to the processing module 30 .

[0141] The processing module 30 is also used to output a dehumidification prompt message when it is detected that the humidity value is greater than or equal to the set humidity, and stop the appearance inspection of the rail until the humidity value is less than the set humidity.

[0142] In practical applications, the humidity detection module 50 may be a humidity sensor.

[0143] It should be noted that the humidity setting can be determined according to actual needs and is not limited here.

[0144] In practical applications, when the humidity on the outer surface or end of the rail is high, it is easy to interfere with the appearance measurement module 10 and the end face measurement module 20, resulting in the inability of the appearance measurement module 10 and the end face measurement module 20 to accurately detect the appearance defects and end geometric dimensions of the rail. Therefore, in this embodiment, after receiving the humidity value sent by the humidity detection module 50, the processing module 30 can compare the humidity value with the set humidity.

[0145] When the processing module 50 detects that the surface humidity of the rail is greater than or equal to the set humidity, it means that the humidity of the rail is relatively high at this time, which is likely to affect subsequent measurements. Therefore, the processing module 50 can output a dehumidification prompt message and stop the appearance inspection of the rail.

[0146] Afterwards, during the dehumidification process, the humidity detection module 50 can send the humidity value of the rail at any time to the processing module 30 in real time, so that the processing module 30 can detect in real time whether the humidity value of the rail at any time is less than the set humidity, and start the appearance inspection of the rail when it is detected that the humidity value of the rail is less than the set humidity.

[0147] It can be seen from the above that the rail appearance inspection system provided in this embodiment avoids the interference of high humidity on the appearance measurement module and the end face measurement module, and further improves the accuracy of the rail appearance defect detection.

[0148] In one embodiment of the present application, in order to realize the movement of the rail and prevent the rail from being offset during the movement, the rail appearance detection system 1 may further include a mechanical transmission module (not shown in the figure). The mechanical transmission module is connected to the processing module 30 .

[0149] In this embodiment, the mechanical transmission module includes a servo motor, a rail conveyor belt and a hydraulic clamping valve. The hydraulic clamping valve plays a fixing role to prevent the rail from being offset during the transmission process and affecting the measurement accuracy. The rail conveyor belt is used to place the rail. The servo motor is used to control the rail conveyor belt to achieve the stationary and transmission of the rail.

[0150] For example, please refer to Figure 2 , Figure 2 The hydraulic clamping valve 41 is arranged at the same horizontal plane as the rail, and the hydraulic clamping valve 41 is respectively arranged at both ends of the rail conveyor belt.

[0151] In another embodiment of the present application, the surface of the rail carries barcode information, so the rail appearance detection system 1 may further include a camera module (not shown in the figure). The camera module is connected to the processing module 30. The barcode information may be a QR code or a barcode.

[0152] In this embodiment, the camera module can photograph the barcode information and send the photographed barcode image to the processing module 30 .

[0153] After obtaining the barcode image, the processing module 30 may perform image recognition on the barcode image to determine the identification code of the rail.

[0154] In some possible embodiments, the processing module 30 can obtain the appearance inspection results of each end outer surface, the middle outer surface and each end surface of the rail, and associate each appearance inspection result with the above-mentioned identification code to generate an appearance defect inspection report corresponding to the rail.

[0155] The following will be combined Figure 1 , Figure 4 as well as Figure 5 The working process of the rail appearance inspection system is described in detail:

[0156] When the humidity of the rail is high, it is easy to interfere with the appearance measurement module 10 and the end face measurement module 20, resulting in the inability of the appearance measurement module 10 and the end face measurement module 20 to accurately detect the appearance defects and end geometric dimensions of the rail. Therefore, before the appearance inspection of the rail, the humidity detection module 50 can perform humidity inspection on the rail to obtain the humidity value of the rail. Afterwards, after receiving the humidity value sent by the humidity detection module 50, the processing module 30 can compare the humidity value with the set humidity. When the processing module 30 detects that the humidity value is less than the set humidity, it means that the humidity of the rail is low at this time and will not interfere with subsequent measurements. Therefore, the rail appearance inspection system can start the appearance inspection of the rail.

[0157] Combination Figure 2In actual applications, one end of the rail usually passes through the rail conveyor and is first in the corresponding end detection area of ​​the rail appearance detection system. At this time, in order to improve the accuracy of the appearance detection of the end outer surface and end face, when one end of the rail enters its corresponding end detection area, the rail can be in a stationary state.

[0158] Based on this, on one hand, each appearance measurement module 10 can move to a first set position within a set range corresponding to the end detection area, and move within the set range based on a set speed, and collect point cloud data of the outer surface of the end at a first frequency. After completing the appearance inspection of the outer surface of the end, each appearance measurement module 10 can return to its respective initial position.

[0159] On the other hand, the end face measurement module 20 corresponding to the above-mentioned certain end can be horizontally moved to the second set position to successfully collect the complete end face related data of the certain end to achieve a complete appearance inspection of the end face. After completing the appearance inspection of the above-mentioned certain end, the end face measurement module 20 can return to the initial position.

[0160] After completing the appearance inspection of the end outer surface and the end face of the above-mentioned end, the rail can end the static state and start transmission.

[0161] On the one hand, each appearance measurement module 10 can perform appearance inspection on the outer surface of the middle section of the rail based on the second frequency. Among them, since the moving speed of the rail during the movement is uneven and the moving speed is very fast; at the same time, in the high-speed scene, the point cloud data and / or image measured by each appearance measurement module 10 will be deformed, and at different moving speeds, the deformation ratio of each appearance measurement module 10 is different. Therefore, in order to ensure that the tiny defects in the rail are accurately detected in the uneven high-speed scene, and whether the defects exceed the acceptable range can be judged by the length, width and height dimensions, each appearance measurement module 10 can determine the deformation ratio of each appearance measurement module 10 in real time based on the transmission speed of the rail sent by the speed measurement module 40 in real time, and determine the processing method of the point cloud data and / or image data of the collected middle section outer surface in real time based on the deformation ratio determined in real time, and process the point cloud data and / or image data collected in real time according to the processing method determined in real time to obtain accurate appearance inspection results of the middle section outer surface.

[0162] After the appearance inspection of the outer surface of the middle section of the rail is completed, the other end of the rail is about to enter its corresponding end inspection area. Therefore, after the rail is in the end inspection area, the rail can be in a static state.

[0163] On the one hand, each appearance measurement module 10 can move to a first set position within a set range corresponding to the end detection area, and move within the set range based on a set speed, and collect point cloud data of the outer surface of the end at a first frequency. After completing the appearance inspection of the outer surface of the end, each appearance measurement module 10 can return to its respective initial position.

[0164] On the other hand, the end face measurement module 20 corresponding to the above-mentioned certain end can be horizontally moved to the second set position to successfully collect the complete end face related data of the certain end to achieve a complete appearance inspection of the end face. After completing the appearance inspection of the above-mentioned certain end, the end face measurement module 20 can return to the initial position.

[0165] After completing the appearance inspection of the other end, it can be determined that the end inspection operation and the appearance defect inspection operation of the rail have been completed at this time. Therefore, the processing module 30 can compare the inspection results sent by each appearance measurement module 10 and each end face measurement module 20, that is, the appearance inspection results of the end outer surface, the middle outer surface and each end face, with the standard inspection results of their corresponding parts, and output the rail appearance inspection failure information when it is detected that any of the appearance inspection results of the end outer surface, the middle outer surface and each end face does not match the standard inspection result.

[0166] Based on this, the rail appearance inspection system completes the appearance inspection of the rails.

[0167] It should be understood that the size of the serial numbers of the steps in the above embodiments does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present application.

[0168] In the above embodiments, the description of each embodiment has its own emphasis. For parts that are not described or recorded in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0169] The embodiments described above are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, a person skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. Such modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application, and should all be included in the protection scope of the present application.

Claims

1. A rail appearance inspection system, characterized in that: It includes multiple appearance measurement modules and multiple end face measurement modules; among which: Each of the appearance measurement modules is used to perform appearance inspection on the outer surfaces of the ends of the rail when the rail is in a stationary state, and to perform appearance inspection on the outer surface of the middle section of the rail when the rail is in a transmission process; Each of the end face measurement modules is used to perform appearance inspection on the end faces at both ends of the rail when the rail is in the static state; wherein the end outer surfaces at both ends of the rail, the end faces at both ends and the middle section outer surface constitute the complete outer surface of the rail; the appearance inspection result of the end outer surface includes the measured end geometric dimensions; the appearance inspection result of the end face includes the measured end face geometric dimensions.

2. The rail appearance detection system according to claim 1, characterized in that: Each of the appearance measurement modules is specifically used for: When the head end of the rail is transferred to the end detection area and is in a stationary state, performing appearance inspection on the end outer surface of the head end currently located in the end detection area; as well as, When the end of the rail is transported to the end detection area and is in a stationary state, an appearance inspection is performed on the end outer surface of the end currently located in the end detection area.

3. The rail appearance detection system according to claim 2, characterized in that: Each of the appearance measurement modules is specifically used for: When the head end or the tail end of the rail is transmitted to the end detection area and is in a stationary state, by moving within the range corresponding to the end detection area, the end outer surface related data of the head end or the tail end is collected to perform an appearance inspection on the end outer surface.

4. The rail appearance detection system according to claim 2, characterized in that: Each of the end face measurement modules is specifically used for: When each appearance measurement module is used to perform appearance inspection on the outer surface of the head end or the tail end of the rail, appearance inspection is performed on the end face of the head end or the tail end currently located in the end inspection area; wherein the appearance inspection of the end face of the head end or the tail end is completed by different end face measurement modules.

5. The rail appearance detection system according to any one of claims 1 to 4, characterized in that: The first sampling frequency used by each appearance measurement module to detect the appearance of the end outer surface in a stationary state is different from the second sampling frequency used to detect the appearance of the middle outer surface in the transmission process, and the second sampling frequency is greater than the first sampling frequency.

6. The rail appearance detection system according to any one of claims 1 to 4, characterized in that: Each of the appearance measurement modules only includes a three-dimensional measurement unit; wherein: Each of the three-dimensional measurement units is used to collect point cloud data of the outer surface of the end portion and the outer surface of the middle portion for appearance inspection.

7. The rail appearance detection system according to any one of claims 1 to 4, characterized in that: Each of the appearance measurement modules includes a three-dimensional measurement unit and a two-dimensional camera unit; wherein: Each of the three-dimensional measurement units is used to collect point cloud data of the outer surface of the end portion and the outer surface of the middle portion for appearance inspection; Each of the two-dimensional camera units is used to photograph the outer surface of the middle section of the rail when the rail is in the transmission process, and perform appearance inspection on the outer surface of the middle section based on the image data obtained by the photography.

8. The rail appearance inspection system according to claim 7, characterized in that: The rail appearance detection system also includes a speed measurement module; The speed measuring module is used to obtain the transmission speed of the rail when the rail is in the transmission process, and send the transmission speed to each appearance measurement module; Each of the appearance measurement modules is further used to determine a deformation ratio based on the transmission speed, determine a processing method for the collected point cloud data and / or image data of the middle section outer surface based on the deformation ratio, and process the point cloud data and / or image data according to the processing method to obtain an appearance detection result of the middle section outer surface.

9. The rail appearance inspection system according to any one of claims 1 to 4 or 8, characterized in that: The rail appearance detection system further includes a processing module; the processing module is specifically used for: Receiving the detection results sent by each of the appearance measurement modules and each of the end surface measurement modules, the detection results including the appearance detection results of the end outer surface, the middle section outer surface and each of the end surfaces; Respectively comparing the appearance inspection results of the end outer surface, the middle outer surface and each end surface with the standard inspection results of the corresponding parts; When any of the appearance inspection results of the end outer surface, the middle outer surface and each of the end surfaces does not match the standard inspection result, the rail appearance inspection failure information is output.

10. The rail appearance inspection system according to claim 9, characterized in that: The appearance detection result of the middle section outer surface carries the detection time, and the detection time includes a plurality of times when each appearance measurement module samples the middle section outer surface; The processing module is further used to determine the defect position of the defect in the outer surface of the middle section according to the transmission speed of the rail and the detection time when the defect is obtained when there is a defect on the outer surface of the middle section.

11. The rail appearance inspection system according to any one of claims 1 to 4 or 8 or 10, characterized in that: The rail appearance detection system also includes a humidity detection module; The humidity detection module is used to obtain the humidity value of the rail before performing appearance inspection on the rail, and send the humidity value to the processing module; The processing module is further configured to output a dehumidification prompt message when it is detected that the humidity value is greater than or equal to a set humidity, and stop the appearance inspection of the rail until the humidity value is less than the set humidity.

12. The rail appearance inspection system according to any one of claims 1 to 4 or 8 or 10, characterized in that: The rail appearance detection system also includes a camera module; The camera module is used to photograph the barcode information on the rail and send the photographed barcode image to the processing module; The processing module is used to perform image recognition on the barcode image to determine the identification code of the rail.

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