Steel rail external dimension detection system

Abstract

The invention is suitable for the technical field of track detection, and provides a steel rail external dimension detection system which comprises a visual detection module which is in rigid connection with the ground, so that vibration generated during steel rail transmission is prevented from being transmitted to the visual detection module; the detection module is used for performing appearance detection and size detection on the end part of the steel rail when the steel rail is in a static state and performing appearance detection and size detection on the middle section of the steel rail when the steel rail is in a transmission process to obtain three-dimensional image data of the steel rail; the end parts comprise end surfaces at two ends of the steel rail and end part outer surfaces at two ends; the end parts and the middle section of the steel rail form a complete outer surface of the steel rail; the supporting guide module is used for controlling the conveying direction of steel rails. The supporting and guiding module and the steel rail measurement assembly are arranged in a split mode, so that vibration generated during steel rail transmission is further prevented from being transmitted to the visual detection module, interference of the vibration on the visual detection module during measurement is avoided, and the detection precision of the steel rail external dimension detection system is improved.

Description

Technical Field

[0001] The present application belongs to the field of track detection technology, and in particular, relates to a rail appearance dimension 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, the existing rail appearance inspection and size inspection devices have low inspection accuracy when performing defect inspection and are difficult to meet actual needs. Summary of the invention

[0004] The embodiment of the present application provides a rail appearance dimension detection system, which can solve the problem of low detection accuracy in the prior art and difficulty in meeting actual needs.

[0005] In a first aspect, an embodiment of the present application provides a rail appearance dimension detection system, comprising:

[0006] A visual inspection module is rigidly connected to the ground and is used to perform appearance inspection and size inspection on the end of the rail when the rail is in a stationary state, and to perform appearance inspection and size inspection on the middle section of the rail when the rail is in a transmission process, so as to obtain three-dimensional image data of the rail; the end and the middle section of the rail constitute the complete outer surface of the rail; the end includes the end faces at both ends of the rail and the outer surfaces of the ends at both ends; the three-dimensional image data includes the three-dimensional profile of the rail, the appearance inspection result and the size inspection result of the end, and the appearance inspection result and the size inspection result of the middle section;

[0007] The support and guide module is used to control the transmission direction of the rail; the support and guide module and the visual inspection module are separately arranged.

[0008] Optionally, the visual inspection module includes a rail measuring component, an electric control box, a servo component and a ground rail slide, and the rail measuring component, the electric control box and the servo component are integrated into the ground rail slide;

[0009] The rail measuring assembly is used to perform appearance inspection and size inspection on the end of the rail when the rail is in a stationary state, and to perform appearance inspection and size inspection on the middle section of the rail when the rail is in a transmission process;

[0010] The electric control box is used to send control instructions to the servo component, the rail measuring component and the ground rail slide respectively;

[0011] The servo component is used to control the visual inspection module to move on the ground rail slide under the control instruction.

[0012] Optionally, the support and guide module includes an encoder;

[0013] The encoder is used to encode the movement of the rail when the rail is in the transmission process, and send the encoded displacement signal to the rail measurement component;

[0014] The rail measuring component is also used to determine a first speed of the rail according to the displacement signal, determine a first scanning speed of the rail measuring component according to the first speed, and perform appearance inspection and size inspection on the middle section of the rail at the first scanning speed.

[0015] Optionally, the encoder is further used to encode the collected movement amount of the visual inspection module when the visual inspection module moves, and send the encoded movement signal to the rail measurement component;

[0016] The rail measuring component is also used to determine a second speed of the visual inspection module according to the movement signal, determine a second scanning speed of the rail measuring component according to the second speed, and perform appearance inspection and size inspection on the end of the rail at the second scanning speed.

[0017] Optionally, the rail measuring component is further used to determine the fill light intensity according to the first speed, and perform appearance inspection and size inspection on the middle section of the rail under the fill light intensity.

[0018] Optionally, the rail measuring assembly is arranged on an integrated welded steel frame.

[0019] Optionally, the rail measurement assembly includes a first measurement unit and a second measurement unit;

[0020] The first measuring unit is used to perform appearance inspection and size inspection on the end of the rail when the rail is in a stationary state, and to perform appearance inspection and size inspection on the periphery of the rail when the rail is in a transmission process;

[0021] The second measuring unit is used to perform appearance inspection and size inspection on the bottom of the rail when the rail is in the process of being transported; the periphery and the bottom of the rail constitute the middle section of the rail.

[0022] Optionally, the support and guide module further includes: a front-end support and guide component, a middle support and guide component, and a rear-end support and guide component;

[0023] The front end support guide assembly, the middle support guide assembly and the rear end support guide assembly are all used to support the rails during the transmission process and control the rails to be at the same height.

[0024] Optionally, the front end support guide assembly and the rear end support guide assembly both include a clamping mechanism, and the clamping mechanism is used to clamp the rail;

[0025] The intermediate support guide assembly includes an angle guide limit mechanism, and the angle guide limit mechanism is used to control the transmission direction of the rail and the movement range of the rail.

[0026] Optionally, the rail appearance dimension detection system further includes: a vibration detection module;

[0027] The vibration detection module is used to collect the vibration amplitude of the rail when the rail is in the transmission process, and send the vibration amplitude to the rail measurement component;

[0028] The rail measurement component is also used to determine the deformation ratio based on the vibration amplitude, determine the processing method of the point cloud data and / or image data corresponding to the middle section collected 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 and size detection result corresponding to the middle section.

[0029] Compared with the prior art, the embodiments of the present invention have the following beneficial effects:

[0030] A rail appearance and size detection system provided in an embodiment of the present application includes a visual detection module and a support and guide module. The visual detection module is rigidly connected to the ground, thereby preventing the vibration generated during the transmission of the rail from being transmitted to the visual detection module, and is used to perform appearance detection and size detection on the end of the rail when the rail is in a stationary state, and perform appearance detection and size detection on the middle section of the rail when the rail is in the transmission process, to obtain three-dimensional image data of the rail; the end includes the end faces at both ends of the rail and the end outer surfaces at both ends, and the end and the middle section of the rail constitute the complete outer surface of the rail; the three-dimensional image data includes the three-dimensional contour of the rail, the appearance detection result and size detection result of the end, and the appearance detection result and size detection result of the middle section; the support and guide module is used to control the transmission direction of the rail; the support and guide module is separately arranged from the rail measurement component, thereby further preventing the vibration generated during the transmission of the rail from being transmitted to the visual detection module, and further avoiding the interference of the above-mentioned vibration on the visual detection module during measurement. Therefore, the system improves the measurement accuracy of the visual detection module and also improves the detection accuracy of the rail appearance and size detection system. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] 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.

[0032] Figure 1 It is a structural schematic diagram of a rail appearance dimension detection system provided in an embodiment of the present application;

[0033] Figure 2 is a structural schematic diagram of a rail appearance dimension detection system provided by another embodiment of the present application;

[0034] Figure 3 is a structural schematic diagram of a rail appearance dimension detection system provided by yet another embodiment of the present application;

[0035] Figure 4 This is a schematic diagram of an application scenario of a rail appearance dimension detection system provided by an embodiment of the present application;

[0036] Figure 5 is a schematic diagram of an application scenario of a rail appearance dimension detection system provided by another embodiment of the present application;

[0037] Figure 6 is a schematic diagram of an application scenario of a rail appearance dimension detection system provided by yet another embodiment of the present application;

[0038] Figure 7is a structural schematic diagram of a rail appearance dimension detection system provided by yet another embodiment of the present application;

[0039] Figure 8 It is a structural schematic diagram of a rail appearance dimension detection system provided in yet another embodiment of the present application. DETAILED DESCRIPTION

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] However, the existing rail appearance detection and size detection devices have low detection accuracy when performing defect detection and are difficult to meet actual needs. Therefore, the present application proposes a rail appearance size detection system to improve the detection accuracy of rails.

[0048] See also Figure 1 , Figure 1 1 is a schematic diagram of the structure of a rail appearance dimension detection system provided by an embodiment of the present application. For the sake of convenience, only the parts related to this embodiment are shown, which are described in detail as follows:

[0049] like Figure 1 As shown, the rail appearance dimension detection system 1 includes: a visual detection module 10 and a support and guidance module 20. Among them:

[0050] The visual inspection module 10 is rigidly connected to the ground and is used to perform appearance inspection and size inspection on the end of the rail when the rail is in a stationary state, and to perform appearance inspection and size inspection on the middle section of the rail when the rail is in a transmission process, so as to obtain three-dimensional image data of the rail; the end and the middle section of the rail constitute the complete outer surface of the rail; the three-dimensional image data includes the three-dimensional contour of the rail, the appearance inspection result and the size inspection result of the end, and the appearance inspection result and the size inspection result of the middle section.

[0051] The support and guide module 20 is used to control the transmission direction of the rail; the support and guide module and the visual inspection module are separately arranged.

[0052] It should be noted that the visual inspection module 10 is not connected to the support and guide module 20 .

[0053] In practical applications, the visual inspection module 10 may include at least one camera.

[0054] It should be noted that, in order to improve the measurement accuracy of the rail, the camera can be a high-speed, high-resolution camera, and the processing speed of the camera can reach the first speed range, the supported acquisition frequency can reach the first frequency range, and the image acquisition resolution can be greater than or equal to the first size. The first speed range can be [150, +∞], the first frequency range can be [8, +∞], and the first size can be [0.08, +∞].

[0055] In the embodiment of the present application, in order to realize all-round detection of the rails, the detection modes of the rail appearance and size detection system 1 include but are not limited to: end detection mode and middle section detection mode of the rails. Among them, the end detection mode specifically refers to a mode for performing appearance detection and size detection on the end outer surfaces at both ends of the rails and the end faces at both ends. The middle section detection mode specifically refers to a mode for performing appearance detection and size detection on the outer surface of the middle section of the rails.

[0056] 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 2.5 to 3 meters.

[0057] 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 end geometric dimensions 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 end geometric dimensions of the rails can be obtained when the rails are stationary, therefore, the rail appearance dimension detection system 1 can determine that the rail is in end detection mode when the rails are in a stationary state.

[0058] In order to improve the detection rate of the outer surface of the middle section of the rail, the rail appearance dimension detection system 1 can determine that the rail is in the middle section detection mode when the rail is in the transmission process.

[0059] Based on this, when the rail is in a stationary state, it means that the rail is in end detection mode. Therefore, the visual inspection module 10 can perform appearance inspection and size inspection on the ends of the rail to obtain appearance inspection results and size inspection results of the ends of the rail.

[0060] In one embodiment of the present application, in order to improve the detection accuracy of both ends of the rail, the visual inspection module 10 can determine the scanning frequency of the appearance inspection and size inspection of the outer surface and end face of the end of the rail in a stationary state as the first frequency. The first frequency can be determined according to actual needs and is not limited here.

[0061] Based on this, in this embodiment, when the rail is in a stationary state, the visual inspection module 10 can perform appearance inspection and size inspection on the end outer surfaces and end faces at both ends of the rail based on the first frequency.

[0062] It should be noted that, since the rail is stationary at this time, the first frequency can be set to a smaller value.

[0063] It should be noted that the appearance inspection and size inspection of the ends of the rails include inspection of appearance information of the outer surfaces of the ends of the rails and inspection of geometrical dimensions of the ends of the rails.

[0064] The appearance inspection results of the end include but are not limited to the appearance information of the outer surface of the end and the appearance information of the end face, and the size inspection results of the end include but are not limited to the geometric dimensions of the end and the geometric dimensions of the end face.

[0065] 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.).

[0066] 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, rail top flatness and rail crown fullness.

[0067] In some possible embodiments, since the visual inspection module 10 measures the end of the rail to obtain point cloud data, and point cloud data refers to a set of vectors in a three-dimensional coordinate system, the visual inspection module 10 can determine the end geometric dimensions based on the three-dimensional coordinates in the measured point cloud data.

[0068] 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 detection mode, that is, the middle section of the rail needs to be inspected for appearance and size. Therefore, the visual inspection module 10 can perform appearance inspection and size inspection on the outer surface of the middle section of the rail to obtain the appearance inspection result and size inspection result of the outer surface of the middle section of the rail.

[0069] In practical applications, since the moving speed of the rails during the transmission process is very fast, in one embodiment of the present application, in order to improve the detection accuracy of both ends of the rails, the visual inspection module 10 can determine the scanning frequency of the appearance inspection and size inspection of the outer surface of the middle section of the rails during the transmission process as the second frequency. The second frequency can be determined according to actual needs and is not limited here.

[0070] It should be noted that the second frequency is greater than the first frequency.

[0071] Based on this, in this embodiment, when the rail is in the transmission process, the visual inspection module 10 can perform appearance inspection and size inspection on the outer surface of the middle section of the rail based on the second frequency.

[0072] 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.

[0073] It should be noted that when the rail is in the process of being transported, the visual inspection module 10 remains stationary.

[0074] 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.

[0075] In some possible embodiments, performing appearance inspection and size 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.

[0076] Therefore, in this embodiment, the appearance inspection result of the middle section outer surface of the rail includes but is not limited to the appearance information of the middle section outer surface, and the size inspection result of the middle section outer surface of the rail includes but is not limited to the geometric size of the middle section.

[0077] 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.

[0078] In the embodiment of the present application, through the above-mentioned method, the visual inspection module 10 performs appearance inspection and size inspection on the end of the rail when the rail is in a stationary state, and performs appearance inspection and size inspection on the middle section of the rail, that is, the outer surface of the middle section when the rail is in the transmission process, so as to obtain three-dimensional image data of the rail. The three-dimensional image data includes the overall three-dimensional profile of the rail, the appearance inspection results and size inspection results of the end, and the appearance inspection results and size inspection results of the middle section.

[0079] In one embodiment of the present application, in order to achieve all-round detection of the rail end, when the rail is in a stationary state, the visual inspection module 10 can move from the initial position to the end inspection area to successfully collect relevant data of the rail end. The relevant data of the end includes point cloud data of the end.

[0080] Based on this, see Figure 2 , Figure 2 FIG. 1 is a schematic diagram of the structure of a rail appearance dimension detection system provided by another embodiment of the present application. Figure 2 As shown, the visual inspection module 10 may specifically include: a rail measuring component 11, an electric control box 12, a servo component 13 and a ground rail slide 14. Among them:

[0081] A rail measuring assembly 11, used for performing appearance inspection and size inspection on the end of the rail when the rail is in a stationary state, and performing appearance inspection and size inspection on the middle section of the rail when the rail is in a transmission process;

[0082] The electric control box 12 is used to send control instructions to the servo component 13, the rail measuring component 11 and the ground rail slide 14 respectively;

[0083] The servo component 13 is used to control the visual inspection module 10 to move on the ground rail slide 14 under the control instruction.

[0084] At the same time, the rail measuring assembly 11 and the ground rail slide 14 also move under the above control instructions.

[0085] It should be noted that the rail measuring component 11, the electric control box 12 and the servo component 13 can be integrated into the ground rail slide 14 to eliminate the signal interference error caused by the long distance between the control part (such as the electric control box and the servo component) and the visual detection part (such as the rail measuring component).

[0086] In this embodiment, the electric control box 12 is used to receive the rail detection instruction sent by the operating console 30 in the rail appearance dimension detection system 1. Afterwards, when the electric control box 12 detects that the rail is in a stationary state, it means that the rail end needs to be detected at this time, so the electric control box 12 can send a control instruction to the servo component 13. The control instruction is used to instruct the visual inspection module 10 to move to the end detection area.

[0087] In some possible embodiments, in order to achieve efficient processing of the data collected by the rail measurement component 11, the operating console 30 may include two sets of high-performance industrial computers.

[0088] In some other possible embodiments, the operation console 30 may adopt a distributed design and use a high-performance fast interface and a network port to separate the operation from the equipment operation.

[0089] In this embodiment, the servo component 13 can control the visual inspection module 10 to move on the ground rail slide based on the control instruction, so that the visual inspection module 10 moves to the end inspection area, so that the rail measurement component 11 can detect the end of the rail.

[0090] In practical applications, the rail measurement assembly 11 may include multiple 3D laser cameras.

[0091] In some possible embodiments, in order to ensure that the rail measurement component 11 does not shake when the visual inspection module 10 moves, so as to improve the detection accuracy of the rails, the rail measurement component 11 can be set on an integrated welded steel frame in the visual inspection module 10.

[0092] In another embodiment of the present application, in order to achieve all-round detection of the rails and improve the detection accuracy and precision of the rails, the rail measurement component 11 may specifically include: a first measurement unit and a second measurement unit;

[0093] The first measuring unit is used to perform appearance inspection and size inspection on the end of the rail when the rail is in a stationary state, and to perform appearance inspection and size inspection on the periphery of the rail when the rail is in a transmission process;

[0094] The second measuring unit is used to perform appearance inspection and size inspection on the bottom of the rail when the rail is in the process of being transported; the periphery and the bottom of the rail constitute the middle section of the rail.

[0095] In this embodiment, the periphery of the rail includes the upper side, the left side and the right side of the rail.

[0096] In order to achieve all-round detection of the circumference of the rail, the first measuring unit may include a plurality of 3D laser measuring instruments.

[0097] Since the second measuring unit is used to perform appearance inspection and dimension inspection on the bottom of the rail, the second measuring unit may only include a 3D laser measuring instrument.

[0098] In the embodiment of the present application, during the appearance inspection and size inspection of the rails, the support and guide module 20 can control the transmission direction of the rails and support the rails so that the rails can move along the set direction, thereby ensuring that the transmission direction of the rails will not deviate during the entire appearance inspection and size inspection process, and at the same time always remain in the same plane, reducing the up and down vibration of the rails.

[0099] In some possible embodiments, the supporting and guiding module 20 is provided with guiding wheels, so that the supporting and guiding module 20 can be guided in the transmission direction of the aerial rail by the guiding wheels.

[0100] It should be noted that the support and guide module 20 and the visual inspection module 10 are separately arranged to prevent the vibration generated by the rail during transmission from being transmitted to the visual inspection module 10, resulting in the visual inspection module 10 being unable to accurately detect the rail.

[0101] In the embodiment of the present application, the rail appearance dimension detection system 1 can solve the problems of rail deviation, sagging, vibration and shaking during the transmission of the rail by combining the visual detection module 10 and the support and guide module 20. At the same time, the visual detection module 10 and the support and guide module 20 are separately arranged, which also accurately avoids the mutual interference between the visual detection module 10 and the support and guide module 20.

[0102] In the embodiment of the present application, the rail appearance and size detection system 1 is a combination of a visual inspection module 10 and a support and guide module 20, and the visual inspection module 10 can perform appearance inspection and size inspection on the end of the rail when the rail is in a stationary state, and perform appearance inspection and size inspection on the middle section of the rail, that is, the outer surface of the middle section, when the rail is in a high-speed transmission process, so as to obtain three-dimensional image data of the rail. Based on this, the system can ensure that the rail can be detected in real time at a high speed (such as 1.2m / s), and the appearance inspection and size inspection of the entire length of the rail can be performed, and the support and guide module 20 can be used to avoid the problems of rail deviation, sagging, vibration and jitter during the transmission process of the rail, so that the detection accuracy of the system can reach 0.1mm, and the three-dimensional contour of the entire rail can be displayed.

[0103] From the above, it can be seen that a rail appearance dimension detection system provided in an embodiment of the present application includes a visual detection module and a support and guide module. The visual detection module is rigidly connected to the ground, thereby preventing the vibration generated during the transmission of the rail from being transmitted to the visual detection module, and is used to perform appearance detection and dimension detection on the end of the rail when the rail is in a stationary state, and to perform appearance detection and dimension detection on the middle section of the rail when the rail is in the transmission process; the end includes the end faces at both ends of the rail and the end outer surfaces at both ends, and the end and middle section of the rail constitute the complete outer surface of the rail; the support and guide module is used to control the transmission direction of the rail; the support and guide module is separately arranged from the rail measurement assembly, thereby further preventing the vibration generated during the transmission of the rail from being transmitted to the visual detection module, and further avoiding the interference of the above-mentioned vibration on the visual detection module during measurement. Therefore, the system improves the measurement accuracy of the visual detection module and also improves the detection accuracy of the rail appearance dimension detection system.

[0104] See also Figure 3 , Figure 3 This is a schematic diagram of the structure of a rail appearance dimension detection system provided by another embodiment of the present application. Figure 4 , Figure 4It is a schematic diagram of an application scenario of a rail appearance dimension detection system provided in an embodiment of the present application.

[0105] In this embodiment, since the length of the rail itself is usually long, if it is suspended for a long time, it is easy to cause the rail to shake, thereby affecting the detection of the rail by the rail appearance size detection system. Therefore, in order to improve the detection accuracy of the rail, Figure 3 and Figure 4 As shown, the support and guide module 20 may specifically include: a front-end support and guide component 21, a middle support and guide component 22, and a rear-end support and guide component 23. Among them:

[0106] The front end support guide assembly 21, the middle support guide assembly 22 and the rear end support guide assembly 23 are all used to support the rails during the transportation of the rails and to control the rails to be at the same height.

[0107] In this embodiment, the front end support guide assembly 21 may be located in the rail transmission entrance area, so that the rail may be transmitted along a set direction under the support and control of the front end support guide assembly 21 .

[0108] The rear end support guide assembly 23 may be located in the rail transmission exit area, so that the rail may be supported and controlled by the rear end support guide assembly 23 to complete overall appearance inspection and size inspection of the rail.

[0109] The intermediate support guide assembly 22 can be located between the front end support guide assembly 21 and the rear end support guide assembly 23 so that the rail will not shake in the middle stage of the transmission process due to being away from the front end support guide assembly 21 and not reaching the rear end support guide assembly 23.

[0110] It is understandable that the intermediate support guide assembly 22 can reduce the cantilever length of the rail, thereby avoiding the automatic sagging of the rail, and further avoiding the detection error of the visual inspection module 20 caused by the automatic sagging of the rail.

[0111] For example, please refer to Figure 4 The rail appearance dimension detection system can realize the transmission of the rail through the transmission port of the front end support guide assembly 21 and the transmission port of the rear end support guide assembly 23.

[0112] In one embodiment of the present application, in order to further ensure that the rails are always in the same plane during transmission and reduce the up and down vibration of the rails, the front end support guide assembly 21, the middle support guide assembly 22 and the rear end support guide assembly 23 all include height adjustment devices.

[0113] In this embodiment, the height adjustment device of the front end support guide assembly 21 is used to adjust the height of the front end support guide assembly 21, the height adjustment device of the middle support guide assembly 22 is used to adjust the height of the middle support guide assembly 22, and the height adjustment device of the rear end support guide assembly 23 is used to adjust the height of the rear end support guide assembly 23.

[0114] In another embodiment of the present application, in order to prevent the rail from swinging left and right during transportation, the front end support guide assembly 21 and the rear end support guide assembly 22 both include a clamping mechanism.

[0115] In this embodiment, the above-mentioned clamping mechanisms are all used to clamp the rails to limit the left-right swinging amplitude of the rails, thereby reducing the detection error of the visual detection module 20 caused by the left-right swinging of the rails.

[0116] For example, see Figure 5 , Figure 5 Schematic diagram of an application scenario of a rail appearance dimension detection system provided by another embodiment of the present application. Figure 5 As shown, the arrow parts are the clamping mechanisms respectively included in the front end support guide assembly 21 and the rear end support guide assembly 22.

[0117] In yet another embodiment of the present application, in order to reduce the impact force generated when the rail moves forward, thereby reducing the vibration of the rail during transmission, the intermediate support guide assembly 22 may include: an angle guide limit mechanism.

[0118] Among them, the angle guide limiting mechanism is used to control the transmission direction of the rail and the movement range of the rail.

[0119] For example, see Figure 6 , Figure 6 FIG. 1 is a schematic diagram of an application scenario of a rail appearance dimension detection system provided by another embodiment of the present application. Figure 6 As shown, the arrow portion is the angle guide limiting mechanism included in the intermediate support guide assembly 22.

[0120] It can be seen from the above that the rail appearance dimension detection system provided in this embodiment can ensure that the rails are always in the same plane during transmission through the front-end support guide assembly, the middle support guide assembly and the rear-end support guide assembly, thereby reducing the vibration of the rails during transmission and improving the detection accuracy of the rails.

[0121] See also Figure 7 , Figure 7 FIG. 1 is a schematic diagram of the structure of a rail appearance dimension detection system provided by another embodiment of the present application. Figure 7 As shown, in this embodiment, the rail appearance dimension detection system 1 may further include an encoder group 40. Among them:

[0122] The encoder group 40 is located at the rail transmission entrance area and the rail transmission exit area, and is used to encode the movement amount of the rail collected when the rail is in the transmission process, and send the encoded displacement signal to the rail measurement component;

[0123] The rail measuring component 11 is also used to determine a first speed of the rail according to the displacement signal, determine a first scanning speed of the rail measuring component according to the first speed, and perform appearance inspection and size inspection on the middle section of the rail at the first scanning speed.

[0124] In this embodiment, the encoder group 40 may include a first encoder and a second encoder, wherein the first encoder may be located at a rail transmission entrance area, and the second encoder may be located at a rail transmission exit area.

[0125] In practical applications, an encoder is a precision measuring device that can accurately convert physical quantities such as the position, speed, and angle of mechanical motion into digital signals or electrical signals.

[0126] In this embodiment, the encoder group 40 can encode the collected movement amount of the rail when the rail is in the transmission process, and send the encoded displacement signal to the rail measurement component 11.

[0127] Afterwards, the rail measuring component 11 can calculate the first speed of the rail during the transmission process according to the received displacement signal, and determine the first scanning speed of the rail measuring component 11 according to the first speed, so that the first scanning speed of the rail measuring component 11 is synchronized with the first speed of the rail, so that the rail measuring component 11 can perform appearance inspection and size inspection on the middle section of the rail at the first scanning speed, thereby realizing accurate inspection of the middle section of the rail.

[0128] It should be noted that the first speed is positively correlated with the first scanning speed, that is, the greater the first speed, the greater the first scanning speed; and the smaller the first speed, the smaller the first scanning speed.

[0129] In some possible embodiments, in order to ensure that the rail measuring component 11 can still accurately detect the rails in a dynamic environment, the rail measuring component 11 can also determine the fill light intensity according to the first speed to enhance the brightness of the rail measuring component 11, so that the rail measuring component 11 can perform appearance inspection and size inspection on the middle section of the rail under the fill light intensity.

[0130] It should be noted that the first speed is positively correlated with the fill light intensity, that is, the greater the first speed, the greater the fill light intensity; and the smaller the first speed, the smaller the fill light intensity.

[0131] In some other possible embodiments, after receiving the displacement signal sent by the encoder group, the rail measuring component 11 can determine the movement amount of the rail according to the displacement signal. Afterwards, after the rail measuring component 11 detects that the movement amount of the rail reaches the set threshold, it indicates that it is time to measure the middle section of the rail. Therefore, the rail measuring component 11 can take a picture of the middle section of the rail to achieve appearance detection and size detection of the outer surface of the middle section of the rail.

[0132] In one embodiment of the present application, when the rail measuring component 11 needs to detect the end of the rail, since the rail is in a stationary state and the rail measuring component 11 is in a moving state, in order to improve the detection accuracy of the rail measuring component 11, the encoder group 30 is also used to encode the collected movement amount of the visual inspection module 10 when the visual inspection module 10 moves, and send the encoded movement signal to the rail measuring component 11.

[0133] Afterwards, the rail measuring component 11 can determine the second speed of the visual inspection module 10, that is, its own movement, according to the received movement signal, and determine its own second scanning speed according to the second speed, so that the second scanning speed of the rail measuring component 11 is synchronized with the second speed of its own movement, so that the rail measuring component 11 can perform appearance inspection and size inspection on the end of the rail at the second scanning speed, thereby realizing accurate detection of the end of the rail.

[0134] It should be noted that the second speed is positively correlated with the second scanning speed, that is, the greater the second speed, the greater the second scanning speed; and the smaller the second speed, the smaller the second scanning speed.

[0135] In some possible embodiments, after receiving the movement signal sent by the encoder group, the rail measuring component 11 can determine the movement amount of the visual inspection module 10, that is, itself, according to the movement signal. After that, after the rail measuring component 11 detects that its own movement amount reaches the set threshold, it indicates that it is time to measure the end of the rail. Therefore, the rail measuring component 11 can take a picture of the end of the rail to achieve appearance inspection and size inspection of the outer surface of the end of the rail, as well as appearance inspection and size inspection of the end face of the rail.

[0136] It can be seen from the above that the rail appearance dimension detection system provided in this embodiment can determine the scanning speed of the rail measurement component according to the speed of the rail movement, so that the rail speed is synchronized with the scanning speed, thereby improving the measurement accuracy of the rail measurement component.

[0137] See also Figure 8 , Figure 8 FIG. 1 is a schematic diagram of the structure of a rail appearance dimension detection system provided by another embodiment of the present application. Figure 8As shown, in this embodiment, the rail appearance dimension detection system 1 may further include a vibration detection module 50. Among them:

[0138] The vibration detection module 50 is used to collect the vibration amplitude of the rail when the rail is in the transmission process, and send the vibration amplitude to the rail measurement component 11.

[0139] The rail measurement component 11 is also used to determine the deformation ratio based on the vibration amplitude, determine the processing method of the point cloud data and / or image data corresponding to the collected middle section 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 results and size detection results corresponding to the middle section.

[0140] In practical applications, the vibration detection module 50 may be a vibration sensor.

[0141] In the present embodiment, since the rails are prone to vibrate during the transmission process, the rail measuring component and the point cloud data and / or image data corresponding to the measured middle section will be deformed. Therefore, in order to reduce the influence of the rail vibration on the measured point cloud data and / or image data, the rail measuring component 11 can determine the deformation ratio based on the vibration amplitude detected in real time, and determine the processing method of the point cloud data and / or image data corresponding to the collected middle section 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 and size detection result corresponding to the middle section.

[0142] The above processing methods include but are not limited to: stretching and compression.

[0143] In this embodiment, the correspondence between different vibration amplitudes and different deformation ratios can be set according to actual needs and is not limited here.

[0144] It can be seen from the above that the rail appearance dimension detection system provided in this embodiment can avoid the problem of deformation of the collected point cloud and / or image caused by the vibration of the rail during transmission, thereby improving the measurement precision and measurement accuracy of the rail measurement component.

[0145] In one embodiment of the present application, the rail appearance detection system 1 further includes: a speed measurement module. The speed measurement module is connected to the visual detection module 10 .

[0146] Specifically, 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 the visual inspection module 10.

[0147] The visual inspection module 10 is also used to determine the deformation ratio based on the transmission speed, determine the processing method of the point cloud data and / or image data of the collected 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 inspection result of the middle section outer surface.

[0148] 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 outer surface of the middle section measured by the visual inspection module 10 will be deformed, and the deformation ratio of the visual inspection module 10 is different at different speeds. 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 can detect the transmission speed of the rail in real time, and send the transmission speed to the visual inspection module 10 in real time.

[0149] Afterwards, the visual inspection module 10 can determine the deformation ratio of the visual inspection module 10 in real time based on the transmission speed obtained in real time, and determine the processing method of the point cloud data and / or image data of the middle section outer surface collected 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 an accurate appearance inspection result of the middle section outer surface. The processing method refers to the method of scaling the point cloud data and / or image data.

[0150] The above processing methods include but are not limited to: stretching and compression.

[0151] 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.

[0152] 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.

[0153] In another embodiment of the present application, the rail appearance inspection system 1 further includes: a base, wherein the base is used to carry the visual inspection module 10, the support guide module 20 and the rail.

[0154] In this embodiment, the system can press and limit the rails through the base and the support guide module 20, thereby reducing the vibration of the rails. Figure 8Corresponding to the embodiment, the system includes a vibration detection module 50, so that the visual detection module 10 can compensate for the deformation caused by the vibration of the rail, so as to further improve the detection accuracy of the system.

[0155] 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.

[0156] 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.

[0157] 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 dimension detection system, characterized in that: include: A visual inspection module is rigidly connected to the ground and is used to perform appearance inspection and size inspection on the end of the rail when the rail is in a stationary state, and to perform appearance inspection and size inspection on the middle section of the rail when the rail is in a transmission process, so as to obtain three-dimensional image data of the rail; the end and the middle section of the rail constitute the complete outer surface of the rail; the end includes the end faces at both ends of the rail and the outer surfaces of the ends at both ends; the three-dimensional image data includes the three-dimensional profile of the rail, the appearance inspection result and the size inspection result of the end, and the appearance inspection result and the size inspection result of the middle section; The support and guide module is used to control the transmission direction of the rail; the support and guide module and the visual inspection module are separately arranged.

2. The rail appearance dimension detection system according to claim 1, characterized in that: The visual inspection module includes a rail measurement component, an electric control box, a servo component and a ground rail slide, and the rail measurement component, the electric control box and the servo component are integrated into the ground rail slide; The rail measuring assembly is used to perform appearance inspection and size inspection on the end of the rail when the rail is in a stationary state, and to perform appearance inspection and size inspection on the middle section of the rail when the rail is in a transmission process; The electric control box is used to send control instructions to the servo component, the rail measuring component and the ground rail slide respectively; The servo component is used to control the visual inspection module to move on the ground rail slide under the control instruction.

3. The rail appearance dimension detection system according to claim 2, characterized in that: The rail appearance dimension detection system also includes an encoder group; The encoder group is located at the rail transmission entrance area and the rail transmission exit area, and is used to encode the movement amount of the rail collected when the rail is in the transmission process, and send the encoded displacement signal to the rail measurement component; The rail measuring component is also used to determine a first speed of the rail according to the displacement signal, determine a first scanning speed of the rail measuring component according to the first speed, and perform appearance inspection and size inspection on the middle section of the rail at the first scanning speed.

4. The rail appearance dimension detection system according to claim 3, characterized in that: The encoder group is also used to encode the collected movement amount of the visual inspection module when the visual inspection module moves, and send the encoded movement signal to the rail measurement component; The rail measuring component is also used to determine a second speed of the visual inspection module according to the movement signal, determine a second scanning speed of the rail measuring component according to the second speed, and perform appearance inspection and size inspection on the end of the rail at the second scanning speed.

5. The rail appearance dimension detection system according to claim 3, characterized in that: The rail measuring component is also used to determine the fill light intensity according to the first speed, and perform appearance inspection and size inspection on the middle section of the rail under the fill light intensity.

6. The rail appearance dimension detection system according to claim 2, characterized in that: The rail measuring assembly is arranged on an integrated welded steel frame.

7. The rail appearance dimension detection system according to claim 2, characterized in that: The rail measuring assembly comprises a first measuring unit and a second measuring unit; The first measuring unit is used to perform appearance inspection and size inspection on the end of the rail when the rail is in a stationary state, and to perform appearance inspection and size inspection on the periphery of the rail when the rail is in a transmission process; The second measuring unit is used to perform appearance inspection and size inspection on the bottom of the rail when the rail is in the process of being transported; the periphery and the bottom of the rail constitute the middle section of the rail.

8. The rail appearance dimension detection system according to claim 1, characterized in that: The support and guide module also includes: a front-end support and guide assembly, a middle support and guide assembly, and a rear-end support and guide assembly; The front end support guide assembly, the middle support guide assembly and the rear end support guide assembly are all used to support the rails during the transmission process and control the rails to be at the same height.

9. The rail appearance dimension detection system according to claim 8, characterized in that: The front end support guide assembly and the rear end support guide assembly both include a clamping mechanism, and the clamping mechanism is used to clamp the rail; The intermediate support guide assembly includes an angle guide limit mechanism, and the angle guide limit mechanism is used to control the transmission direction of the rail and the movement range of the rail.

10. The rail appearance dimension detection system according to any one of claims 2 to 9, characterized in that: The rail appearance dimension detection system further includes: a vibration detection module; The vibration detection module is used to collect the vibration amplitude of the rail when the rail is in the transmission process, and send the vibration amplitude to the rail measurement component; The rail measurement component is also used to determine the deformation ratio based on the vibration amplitude, determine the processing method of the point cloud data and / or image data corresponding to the middle section collected 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 and size detection result corresponding to the middle section.

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