Ballastless track bottom defect detection device

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By designing a ballless rail bottom defect detection device including frame structure, walking components and detection mechanism, the problem that the prior art cannot effectively detect defects in the bottom area of ballless rail bottom is solved, and efficient and accurate night detection is achieved, which significantly reduces labor costs.

CN119551030APending Publication Date: 2025-03-04阿普特斯光电科技(江苏)有限公司

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Patent Information

Application Number: CN202411973824.7
Authority / Receiving Office: CN · China
Patent Type: Applications(China)
Current Assignee / Owner
Filing Date: 2024-12-30
Publication Date: 2025-03-04

AI Technical Summary

Technical Problem

The prior art cannot effectively detect defects in the bottom area of the ballastless rail, and the manual detection efficiency is low, the detection rate is low, and it cannot be detected at night.

Method used

A defect detection device for bottom defects of ballless rails is designed, including a frame structure, a walking assembly and a detection mechanism. The detection mechanism consists of a driving component and a detection component. By moving the driving component along the X-axis, Y-axis, and Z-axis directions, the detection component is raised and lowered in the Z-axis direction, realizing flaw detection detection of the bottom of the rail and having the function of crossing the rail sleeper.

Benefits of technology

This device greatly improves the efficiency and accuracy of the bottom area detection of ballastless rails, can be inspected at night, save labor costs, realize dual-track simultaneous detection, and faster detection speed.

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Abstract

The invention discloses a ballastless track bottom defect detection device which comprises a frame structure which is formed by splicing or integrally forming a plurality of profiles. The walking assemblies are arranged at the four corners of the bottom of the mounting frame, and the walking assemblies are arranged on a rail; a detection mechanism; the detection mechanism is composed of a driving assembly and a detection piece installed on the driving assembly. The driving assembly is a component moving in the X-axis direction, the Y-axis direction and the Z-axis direction, the detection piece is installed on the component moving in the Z-axis direction in the driving assembly, and the detection piece is located at the bottom of the installation frame; when the device is used for detection, the device automatically bypasses the sleeper through the plurality of linear servo sliding tables, ingeniously avoids the blocking of the sleeper, and accurately feeds a detection piece into the bottom area of the ballastless track, so that the device greatly improves the detection efficiency and accuracy of the bottom area of the ballastless track, and the detection accuracy of the bottom area of the ballastless track is greatly improved. And the manual intervention and the cost in the detection process are also obviously reduced.

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Description

Technical Field

[0001] The invention belongs to the technical field of rail defect detection, and in particular relates to a ballastless rail bottom defect detection device. Background Art

[0002] Ballastless rail, also known as ballastless track, is a track structure that uses an integral foundation such as concrete and asphalt mixture to replace the granular gravel roadbed. In order to ensure the operation of the rail, the rail needs to be inspected for defects, and rail defect detection is a key technical task that focuses on identifying, measuring and analyzing various defects or damage that may exist on the railway track. These defects may include but are not limited to cracks, wear, fractures, deformation, corrosion, and deviations in the geometric dimensions of the track. Rail defect detection conducts a comprehensive and detailed inspection of the railway track through visual inspection, ultrasonic testing, magnetic particle testing, eddy current testing, laser scanning, infrared thermal imaging, and automated detection systems based on machine vision, etc., aiming to promptly discover potential problems on the track and ensure the safety and smoothness of railway traffic.

[0003] At present, in the defect detection work of ballastless rails, the detection devices of the existing technology mainly focus on the two sides and the top of the rails, which are easy to observe and touch. The widely used ultrasonic detection also has a detection blind spot. It can only detect the rail surface, rail waist and the rail bottom below the rail waist, and cannot achieve comprehensive detection. In addition, ultrasonic detection requires the use of coupling agents, which greatly increases the difficulty and cost of detection. At present, the rail bottom area, due to its structural influence, space limitations and the obstruction of sleepers, mainly relies on traditional manual visual inspection to make up for the shortcomings of machine inspection. Traditional manual visual inspection is that experienced rail flaw detectors extend mirrors into the rail bottom and observe whether there are damages, cracks, etc. on the rail bottom through mirror refraction. Through manual inspection, a rail flaw detector can detect 100 meters of rail bottom defects per hour on a single track. Due to the possible omissions in manual inspection, the detection rate cannot be guaranteed, and inspection can only be carried out during the day. Summary of the invention

[0004] The object of the present invention is to provide a ballastless rail bottom defect detection device to solve the problems mentioned in the above background technology that the existing detection device cannot detect the bottom area of the ballastless rail, the manual detection efficiency is low, the detection rate is low, and it is impossible to detect at night.

[0005] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a ballastless rail bottom defect detection device, comprising a frame structure, which is formed by splicing or integrally forming a plurality of profiles; a walking assembly, which is placed at the four corners of the bottom of the frame, and the walking assembly is placed on the rail; a detection mechanism; the detection mechanism is composed of a driving assembly and a detection piece installed on the driving assembly; the driving assembly is a component that moves along the X-axis, Y-axis, and Z-axis directions, and the detection piece is installed on the component that moves along the Z-axis direction in the driving assembly, the detection piece is located in the internal position of the frame, and is moved to the bottom position of the rail by the driving assembly, so as to realize the flaw detection of the bottom position of the rail, when encountering a sleeper, the driving assembly can directly cross the sleeper by first retracting along the X-axis direction, then lifting along the Z-axis, and finally descending along the Z-axis, and when it moves to the bottom area of another section of the rail, the detection piece is extended again to realize the detection of the bottom end surface of the rail.

[0006] As a preferred technical solution in the present invention, the driving component includes a linear servo slide 1 installed inside the frame along the Y-axis, and a linear servo slide 2 slidably installed on the linear servo slide 1 and reciprocatingly moved along the Y-axis direction by the drive of the linear servo slide 1, and also includes a linear servo slide 3 installed on the linear servo slide 2 and reciprocatingly moved along the X-axis direction by the drive of the linear servo slide 2. The detection component is installed on the linear servo slide 3 and is reciprocated and lifted along the Z-axis direction by the linear servo slide 3. Before detection, the line scan camera is inside the frame. When it moves to the detection area of the rail, the linear servo slide 1 drives the linear servo slide 2 to adjust the position in the Y-axis direction, and the linear servo slide 2 drives the linear servo slide 3 to adjust the position in the X-axis direction. At this time, the line scan camera is in the external position of the rail to be detected. At this time, the line scan camera is driven by the linear servo slide 3 to extend the line scan camera into the bottom area of the rail, thereby realizing the movement of the detection component in space to meet the detection requirements of the bottom end surface of the rail.

[0007] As a preferred technical solution in the present invention, a mounting frame is also installed on the inner side of the frame, and both ends of the linear servo slide 1 are installed in the mounting frame, thereby realizing the installation of the linear servo slide 1 and further completing the installation of the entire drive assembly.

[0008] As a preferred technical solution in the present invention, a mounting plate is also installed in the middle position of the outer surface of the frame, and a servo motor is installed on the side of the mounting plate facing the inside of the frame, and a driving gear and a driven gear are arranged on the side of the mounting plate facing the outside of the frame, wherein the driving gear is installed on the output end of the servo motor, and the driven gear is installed on the driving gear through shaft rotation, the driving gear and the driven gear are meshed for transmission, and the driving gear is driven by the rotation of the servo motor, and then the driven gear is driven by the driving gear to achieve rotation, and a mounting rod is fixed on the driving gear and the driven gear, and a photoelectric module is installed on the mounting rod, wherein the photoelectric module is not drawn in the figure, and when the detection device is moving, the bottom area of the sleeper is scanned by the photoelectric module to avoid obstacles in the bottom area of the sleeper that affect subsequent detection, and to prompt the staff, and when crossing an obstacle, the obstacle in the forward direction can be avoided by gradually unfolding to a horizontal state in the direction of the mounting rod.

[0009] As a preferred technical solution in the present invention, the mounting rod, the driving gear and the driven gear are all located in the inner area of the rail.

[0010] As a preferred technical solution in the present invention, the walking component includes a driving motor installed at the bottom of the frame, and a walking wheel installed on the output end of the driving motor, and the walking wheel is rollingly connected to the rail, so as to realize automatic walking of the entire device on the rail.

[0011] As a preferred technical solution in the present invention, deviation correction sensors are also installed at both ends of the outer side of the frame, and the deviation correction sensors are arranged adjacent to the walking wheels.

[0012] As a preferred technical solution in the present invention, the detection component is a line scan camera with a supplementary light source to achieve night operation, and position sensors are also installed on both sides of the line scan camera to avoid collision between the line scan camera and the sleeper.

[0013] As a preferred technical solution in the present invention, a front camera is also installed on the frame through a bracket.

[0014] As a preferred technical solution in the present invention, the frame body is composed of a base frame and an installation frame, and the driving assembly is fixed in the installation frame, wherein a mounting seat is installed in the base frame and the installation frame, and a lock is installed outside the base frame and the installation frame. A box body is also installed on the top of the installation frame, and a front camera is also installed on the installation frame through a bracket.

[0015] As a preferred technical solution in the present invention, the frame is an installation frame with an integrated structure.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] In the detection by the device of the present invention, compared with ultrasonic detection, the device greatly saves the process, is easy to use, and makes up for the limitation that ultrasonic detection equipment cannot detect the bottom area of the rail. Compared with traditional manual detection, the device greatly saves labor costs, can detect two tracks at the same time, and can detect 5000 The double-track bottom defect detection of meters is not limited by working hours and can be carried out at night. This device not only greatly improves the efficiency and accuracy of ballastless rail bottom area detection, but also significantly reduces manual intervention and costs during the detection process, changing the current situation where the bottom area defect detection can only rely on traditional manual detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the state of the present invention running on a rail;

[0019] Figure 2 It is a structural schematic diagram of the present invention;

[0020] Figure 3 A bottom view of the present invention;

[0021] Figure 4 A rear view of the present invention on a railroad track;

[0022] Figure 5 For the present invention Figure 4 A magnified schematic diagram of area A in the middle.

[0023] In the figure:

[0024] 101, mounting frame; 102, mounting frame; 103, linear servo slide 1; 104, linear servo slide 2; 105, linear servo slide 3; 106, line scan camera; 107, drive motor; 108, walking wheel; 109, deviation correction sensor; 110, mounting rod; 111, mounting plate; 112, servo motor; 113, drive gear; 114, driven gear; 115, mounting seat; 116, position sensor; 117, lock; 118, front camera;

[0025] 200. Railway tracks. DETAILED DESCRIPTION

[0026] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0027] Example 1

[0028] See also Figures 1 to 5 The present invention provides a technical solution: a ballastless rail bottom defect detection device, comprising

[0029] The frame structure is formed by splicing or integrally forming multiple profiles to form a frame structure;

[0030] The walking assembly is placed at the four corners of the bottom of the frame, and the walking assembly is placed on the rail 200;

[0031] Detection mechanism; the detection mechanism is composed of a driving assembly and a detection member installed on the driving assembly;

[0032] The driving assembly has a component that moves along the X-axis, Y-axis, and Z-axis directions. The detection component is installed on the component that moves along the Z-axis direction in the driving assembly. The detection component is located inside the frame and is moved to the bottom position of the rail 200 through the driving assembly, thereby realizing flaw detection of the bottom position of the rail 200. When encountering a sleeper, the driving assembly can directly cross the sleeper by first retracting along the X-axis direction, then lifting along the Z-axis, and finally descending along the Z-axis. When it moves to the bottom area of another section of the rail 200, the detection component is extended to realize detection of the bottom end surface of the rail 200.

[0033] In this embodiment, the driving component includes a linear servo slide 103 installed inside the frame along the Y axis, and a linear servo slide 2 104 slidably installed on the linear servo slide 103 and reciprocating along the Y axis direction by the drive of the linear servo slide 103, and also includes a linear servo slide 3 105 installed on the linear servo slide 2 104 and reciprocating along the X axis direction by the drive of the linear servo slide 2 104. The detection part is installed on the linear servo slide 3 105 and reciprocates along the Z axis direction by the linear servo slide 3 105. Before the detection, the line scan camera 1 06 is inside the frame. When it moves to the detection area of the rail 200, the linear servo slide 103 drives the linear servo slide 2 104 to adjust the position in the Y-axis direction, and the linear servo slide 2 104 drives the linear servo slide 3 105 to adjust the position in the X-axis direction. At this time, the line scan camera 106 is outside the area to be detected of the rail 200. At this time, the line scan camera 106 is driven by the linear servo slide 3 105 to extend the line scan camera 106 into the bottom area of the rail 200, thereby realizing the movement of the detection component in space to meet the detection requirements of the bottom end surface of the rail 200.

[0034] In this embodiment, a mounting frame 102 is also installed on the inner side of the frame, and both ends of the linear servo slide 103 are installed in the mounting frame 102, thereby realizing the installation of the linear servo slide 103 and further completing the installation of the entire drive assembly.

[0035] In this embodiment, a mounting plate 111 is further installed at the middle position of the outer surface of the frame, and a servo motor 112 is installed on the side of the mounting plate 111 facing the inside of the frame, and a driving gear 113 and a driven gear 114 are arranged on the side of the mounting plate 111 facing the outside of the frame, wherein the driving gear 113 is installed on the output end of the servo motor 112, and the driven gear 114 is rotatably installed on the driving gear 113 through the shaft, and the driving gear 113 and the driven gear 114 are meshed for transmission, and the driving gear 113 is driven by the rotation of the servo motor 112, and then the driven gear 114 is driven by the driving gear 113 to realize rotation, and the driving gear 113 and the driven gear 114 are both fixedly provided with a mounting rod 110, wherein the mounting rod 110 is water-tight when not in operation. The mounting rod 110 is in a flat shape, and a photoelectric module is installed on the mounting rod 110, wherein the photoelectric module is not drawn in the figure. When the detection device is moving, the servo motor 112 drives the driving gear 113 and the driven gear 114 to transform the mounting rod 110 into a vertical shape, and scans the bottom area of the sleeper through the photoelectric module to avoid obstacles in the bottom area of the sleeper and affect subsequent detection. At the same time, the line scan camera 106 retreats to the inside of the frame, and when the front camera 118 detects an obstacle in front, the mounting rod 110 gradually unfolds to a horizontal shape in the direction of 100, so as to avoid obstacles in the forward direction, and after the entire detection work is completed, the mounting rod 110 will also be driven by the driving gear 113 and the driven gear 114 to rotate to a horizontal shape.

[0036] In this embodiment, the mounting rod 110 , the driving gear 113 , and the driven gear 114 are all located in the inner area of the rail 200 .

[0037] In this embodiment, the walking component includes a driving motor 107 installed at the bottom of the frame, and a walking wheel 108 installed on the output end of the driving motor 107. The walking wheel 108 is rollingly connected to the rail 200, so as to realize automatic walking of the entire device on the rail 200.

[0038] In this embodiment, deviation correction sensors 109 are further installed at both ends of the outer side of the frame, and the deviation correction sensors 109 are arranged adjacent to the walking wheels 108 .

[0039] In this embodiment, the detection component is a line scan camera with a supplementary light source to achieve nighttime operation. Position sensors 116 are also installed on both sides of the line scan camera 106 to avoid collision between the line scan camera 106 and the sleeper.

[0040] In this embodiment, a front camera 118 is also installed on the frame through a bracket, which can detect obstacles on the walking path of the device. The front camera 118 is on the same side as the mounting rod 110. When the front camera 118 detects an obstacle in front, the line scan camera 106 will also move into the frame to avoid collision with the obstacle and damage.

[0041] In this embodiment, the frame body is composed of a base frame and an installation frame 101, and the driving component is fixed in the installation frame 101, wherein a mounting seat 115 is installed in the base frame and the installation frame 101, and a lock 117 is installed outside the base frame and the installation frame 101. A box body is also installed on the top of the installation frame 101, and a front camera 118 is also installed on the installation frame 101 through a bracket. It is worth noting that the detection component in the present invention is an overall sunken design, which can reduce the Z-axis direction stroke, and the detection component can also be integrated inside the box body, thereby realizing modular assembly.

[0042] Example 2

[0043] The difference from the embodiment 1 is that in this embodiment, the frame body is an installation frame 101 of an integrated structure.

[0044] Although embodiments of the present invention have been shown and described (see the above detailed description for details), it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A ballastless rail bottom defect detection device, characterized in that: include The frame structure is formed by splicing or integrally forming multiple profiles to form a frame structure; A walking assembly is placed at the four corners of the bottom of the frame, and the walking assembly is placed on the rail (200); Detection mechanism; the detection mechanism is composed of a driving assembly and a detection member installed on the driving assembly; The driving assembly has a component that moves along the X-axis, Y-axis and Z-axis directions, the detection component is installed on the component that moves along the Z-axis direction in the driving assembly, the detection component is located inside the frame, and is moved to the bottom position of the rail (200) through the driving assembly.

2. The ballastless rail bottom defect detection device according to claim 1, characterized in that: The driving component includes a linear servo slide 1 (103) installed inside a frame along the Y-axis, and a linear servo slide 2 (104) slidably installed on the linear servo slide 1 (103) and reciprocatingly moved along the Y-axis direction by the drive of the linear servo slide 1 (103), and also includes a linear servo slide 3 (105) installed on the linear servo slide 2 (104) and reciprocatingly moved along the X-axis direction by the drive of the linear servo slide 2 (104). The detection component is installed on the linear servo slide 3 (105) and is reciprocated and lifted along the Z-axis direction by the linear servo slide 3 (105).

3. The ballastless rail bottom defect detection device according to claim 2, characterized in that: A mounting frame (102) is also installed on the inner side surface of the frame, and both ends of the linear servo slide (103) are installed in the mounting frame (102).

4. The ballastless rail bottom defect detection device according to claim 1, characterized in that: A mounting plate (111) is also installed at the middle position of the outer surface of the frame, and a servo motor (112) is installed on the side of the mounting plate (111) facing the inside of the frame, and a driving gear (113) and a driven gear (114) are arranged on the side of the mounting plate (111) facing the outside of the frame, wherein the driving gear (113) is installed on the output end of the servo motor (112), and the driven gear (114) is installed on the driving gear (113) by shaft rotation, and the driving gear (113) and the driven gear (114) are meshed and transmitted, and the driving gear (113) and the driven gear (114) are both fixedly provided with mounting rods (110), and a photoelectric module is installed on the mounting rods (110).

5. The ballastless rail bottom defect detection device according to claim 4, characterized in that: The mounting rod (110), the driving gear (113), and the driven gear (114) are all located in the inner area of the rail (200).

6. The ballastless rail bottom defect detection device according to claim 1, characterized in that: The travel assembly comprises a driving motor (107) installed at the bottom of the frame, and a travel wheel (108) installed on the output end of the driving motor (107), wherein the travel wheel (108) is rollingly connected to the rail (200).

7. The ballastless rail bottom defect detection device according to claim 6, characterized in that: Deviation correction sensors (109) are also installed at both ends of the outer side of the frame, and the deviation correction sensors (109) are arranged adjacent to the walking wheels (108).

8. The ballastless rail bottom defect detection device according to claim 1, characterized in that: The detection component is a line scan camera (106) with a supplementary light source, and position sensors (116) are installed on both sides of the line scan camera (106).

9. The ballastless rail bottom defect detection device according to claim 1, characterized in that: The frame body is composed of a bottom frame and a mounting frame (101), and the driving assembly is fixedly arranged in the mounting frame (101), wherein a mounting seat (115) is installed in the bottom frame and the mounting frame (101), and a lock buckle (117) is installed outside the bottom frame and the mounting frame (101), and a box body is also installed on the top of the mounting frame (101), and a front camera (118) is also installed on the mounting frame (101) through a bracket.

10. The ballastless rail bottom defect detection device according to claim 1, characterized in that: The frame body is an installation frame (101) of an integrated structure.