Steel rail welded joint straightness measuring equipment and self-calibration method thereof

Abstract

The invention provides steel rail welded joint straightness measuring equipment and a self-calibration method thereof, and belongs to the technical field of steel rail quality detection. The steel rail welded joint straightness measuring equipment comprises a rack, one end of the rack is provided with a contact part used for making contact with a to-be-measured steel rail, the other end of the rack is provided with a linear guide rail, and the linear guide rail is parallel to the to-be-measured steel rail; the straightness detector is movably arranged on the linear guide rail; the driving device is connected with the straightness detector and drives the straightness detector to move along the linear guide rail; and the straightness calibration rail is detachably mounted on the contact component and is parallel to the linear guide rail. According to the self-calibration method for measuring the straightness of the steel rail welded joint, the accuracy and the efficiency of measuring the straightness of the steel rail welded joint are remarkably improved through accurate data acquisition and analysis steps, human intervention is reduced, the operation complexity is reduced, and the continuity and the reliability of measurement are also improved.

Description

Technical Field

[0001] The invention relates to the technical field of rail quality detection, and in particular to a rail weld joint straightness measuring device and a self-calibration method thereof. Background Art

[0002] Rail welding joints (also called joints) are an important part of seamless lines, and good joint straightness is the key to ensuring the smooth operation of high-speed trains. After rail welding, the straightness of the joints needs to be tested one by one to ensure the smoothness of the railway track.

[0003] The straightness of the rail weld joint is measured at the longitudinal center line of the rail top surface and the longitudinal line on the side working edge of the rail head at a distance of 16mm from the rail top surface. When measuring, the rail surface at 500mm on both sides of the weld center line should be used as the reference point, the measurement length should be 1m, and the weld should be centered.

[0004] Generally, an automatic detection ruler is used to measure the straightness of the welded joint, and its display window directly displays the straightness deviation. If there is any objection to the measurement result of the automatic detection ruler, a detection ruler and a feeler gauge can be used to measure and confirm the joint.

[0005] The automatic detection ruler is equipped with a distance sensor, which can perform non-contact measurement of the straightness of the welded joint. The operator places the automatic detection ruler on the top surface of the rail welded joint to detect the running surface, or on the side of the rail welded joint to detect the guide surface. After clicking the detection button of the automatic detection ruler, the sensor inside the automatic detection ruler scans the surface of the rail to obtain relative distance data, and then calculates the data to draw a curve and display it on the computer software communicating with it.

[0006] However, after the automatic measuring ruler has been subjected to high-frequency and large-scale measurements, collisions, or slight deformation due to force, the test results often show large deviations. This deviation is often not detected by the inspectors, resulting in incorrect judgments on the straightness of the rails and inability to determine whether the detection accuracy meets the requirements. In order to solve the above technical defects, the manufacturers of automatic measuring rulers require users to send the measuring rulers to the manufacturers for precision calibration regularly to ensure the detection accuracy of the measuring rulers, which not only greatly increases the workload, but also seriously affects the progress of the work.

[0007] In view of this, the inventor has designed a rail weld joint straightness measuring device and a self-calibration method thereof based on many years of production design experience in this field and related fields and after repeated experiments, in order to solve the problems existing in the prior art. Summary of the invention

[0008] The object of the present invention is to provide a rail weld joint straightness measuring device and a self-calibration method thereof, which can self-correct the detection data of the rail weld joint straightness.

[0009] In order to achieve the above-mentioned invention object, the present invention proposes a rail weld joint straightness measuring device, wherein the rail weld joint straightness measuring device comprises: a frame, one end of which is provided with a contact component for contacting the rail to be measured, and the other end of which is provided with a linear guide rail, and the linear guide rail is parallel to the rail to be measured; a straightness detector, which is movably arranged on the linear guide rail; a driving device, which is connected to the straightness detector and drives the straightness detector to move along the linear guide rail; a straightness calibration rail, which is detachably mounted on the contact component and is parallel to the linear guide rail.

[0010] The present invention also proposes a self-calibration method for measuring the straightness of a rail weld joint, wherein the self-calibration method comprises: using a straightness detector to scan a straightness calibration rail at least once, and uniformly collecting relative distance data between the straightness detector and the straightness calibration rail; drawing an approximate scanning trajectory curve according to the relative distance data between the straightness detector and the straightness calibration rail; removing the straightness calibration rail, and using the straightness detector to scan a rail to be measured, and uniformly collecting relative distance data between the straightness detector and the rail to be measured; drawing an actual detection trajectory curve according to the relative distance data between the straightness detector and the rail to be measured; and drawing a calibrated straightness curve according to the approximate scanning trajectory curve and the actual detection trajectory curve.

[0011] Compared with the prior art, the present invention has the following characteristics and advantages:

[0012] The rail weld joint straightness measuring device and the self-calibration method thereof proposed in the present invention, by integrating a straightness calibration rail and a driving device, can not only automatically monitor and correct the deviation that may occur in the measuring device after high-frequency use, thereby ensuring the accuracy of the measurement results, but also realize rapid on-site calibration, eliminating the need to frequently send the measuring device back to the manufacturer for calibration. The rail weld joint straightness measuring device and the self-calibration method thereof proposed in the present invention reduce the reliance on manual calibration, avoid errors caused by human factors, and also ensure the stability and reliability of the measuring device in long-term operation.

[0013] The rail weld joint straightness measuring device proposed in the present invention has a detachable straightness calibration rail design, and the rail weld joint straightness measuring device can quickly adapt to different measurement environments and requirements, thereby improving the versatility and convenience of the device.

[0014] The rail weld joint straightness measuring device proposed in the present invention can automatically correct the deviation of straightness detection, provide a basis for the integration of more advanced sensor technology and data processing algorithms in the future, lay a foundation for the realization of intelligent measurement and data analysis, and can provide a new efficient, accurate and economical solution for the measurement and maintenance work in the railway industry.

[0015] The self-calibration method for measuring the straightness of rail welded joints proposed by the present invention can accurately identify and correct the deviation in the measurement by comparing the approximate scanning trajectory curve with the actual detection trajectory curve, and draw a calibrated straightness curve. The flexibility and adaptability of the self-calibration method for measuring the straightness of rail welded joints enable it to be used in different occasions and conditions, while reducing the dependence on professional calibration services and the costs associated with equipment calibration.

[0016] The self-calibration method for measuring the straightness of rail weld joints proposed in the present invention significantly improves the accuracy and efficiency of measuring the straightness of rail weld joints through precise data acquisition and analysis steps, which not only reduces human intervention and operational complexity, but also improves the continuity and reliability of measurement. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings described herein are only for explanation purposes and are not intended to limit the scope of the present invention in any way. In addition, the shapes and proportional dimensions of the various components in the figures are only schematic, used to help understand the present invention, and are not specifically limited to the shapes and proportional dimensions of the various components of the present invention. Those skilled in the art can select various possible shapes and proportional dimensions to implement the present invention according to the teachings of the present invention.

[0018] Figure 1 It is a schematic diagram of a rail weld joint straightness measuring device of the present invention;

[0019] Figure 2 A schematic diagram of a scanning trajectory of the distance measuring sensor of the present invention;

[0020] Figure 3 is a schematic diagram of a straightness calibration rail of the present invention;

[0021] Figure 4 It is an approximate scanning trajectory curve diagram obtained after scanning the straightness calibration rail in the present invention;

[0022] Figure 5 A schematic diagram showing a comparison between an approximate scanning trajectory curve and an actual detection trajectory curve in the present invention;

[0023] Figure 6 FIG. 4 is a flatness curve diagram after self-calibration in an example of the present invention.

[0024] Description of the accompanying drawings:

[0025] 10. Frame; 11. Guide rail;

[0026] 12. Column; 13. Contact parts;

[0027] 20. Driving device; 30. Flatness detector;

[0028] 40. Distance measuring sensor; 50. Clamping mechanism;

[0029] 60. Straightness calibration rail; 70. Support roller;

[0030] 80. Rails. DETAILED DESCRIPTION

[0031] The details of the present invention can be more clearly understood with reference to the accompanying drawings and the description of the specific embodiments of the present invention. However, the specific embodiments of the present invention described herein are only used for the purpose of explaining the present invention and cannot be understood as limiting the present invention in any way. Under the guidance of the present invention, technicians can conceive of any possible variations based on the present invention, which should all be considered to belong to the scope of the present invention.

[0032] The present invention provides a device for measuring the straightness of a rail weld joint, wherein the device comprises: a frame 10, one end of which is provided with a contact component 13 for contacting a rail 80 to be measured, and the other end of which is provided with a linear guide rail, the linear guide rail being parallel to the rail 80 to be measured; a straightness detector 30, which is movably arranged on the linear guide rail; a driving device 20, which is connected to the straightness detector 30 and drives the straightness detector 30 to move along the linear guide rail; and a straightness calibration rail 60, which is detachably mounted on the contact component 13 and is parallel to the linear guide rail.

[0033] like Figure 1 As shown, the rail weld joint straightness measuring device comprises: a frame 10, a rail 80, a support roller 70, a clamping mechanism 50, a straightness calibration rail 60, a straightness detector 30 and a driving device 20. The frame 10 is a structure composed of three main parts: a guide rail 11, a column 12 and a contact part 13. The contact part 13 is located at one end of the frame 10 and directly contacts the rail 80 to be measured. Its design allows it to move along the rail 80 for straightness measurement. A distance sensor 40 is installed on the contact part 13 to collect data related to the distance from the surface of the rail 80. The other end opposite to the contact part 13 is the guide rail 11, which provides a path for the straightness detector 30 to move along the length direction. The distance sensor 40 is disposed in the straightness detector 30 . When the driving device 20 drives the straightness detector 30 to move along the guide rail 11 , the distance sensor 40 scans the surface of the rail 80 , thereby acquiring relative distance data from the surface of the rail 80 .

[0034] The rail weld joint straightness measuring device proposed in the present invention has a detachable straightness calibration rail 60 design, which enables the rail weld joint straightness measuring device to quickly adapt to different measurement environments and requirements, thereby improving the versatility and convenience of the device.

[0035] The present invention further proposes a self-calibration method for measuring the straightness of a rail weld joint, wherein the self-calibration method comprises: using a straightness detector 30 to scan a straightness calibration rail 60 at least once, and uniformly collecting relative distance data between the straightness detector 30 and the straightness calibration rail 60; drawing an approximate scanning trajectory curve according to the relative distance data between the straightness detector 30 and the straightness calibration rail 60; removing the straightness calibration rail 60, and using the straightness detector 30 to scan a rail 80 to be measured, and uniformly collecting relative distance data between the straightness detector 30 and the rail 80 to be measured; drawing an actual detection trajectory curve according to the relative distance data between the straightness detector 30 and the rail 80 to be measured; and drawing a calibrated straightness curve according to the approximate scanning trajectory curve and the actual detection trajectory curve.

[0036] Specifically, due to the installation accuracy of the guide rail 11 in the horizontal direction, the vibration of the mechanism during movement, the slight deformation of the flatness detector 30, the settlement of the equipment and other factors, the scanning trajectory of the ranging sensor has a certain deviation from the horizontal line. Figure 2 In order to eliminate the error caused by the scanning trajectory deviation, as shown in Figure 3 As shown, a straightness calibration rail 60 with a length of L and a flatness in the entire length range that meets the specified value is set. The calibration rail can be regarded as having a straightness data of 0 in the entire length.

[0037] The self-calibration method for measuring the straightness of rail welded joints proposed by the present invention can accurately identify and correct the deviation in the measurement by comparing the approximate scanning trajectory curve with the actual detection trajectory curve, and draw a calibrated straightness curve. The flexibility and adaptability of the self-calibration method for measuring the straightness of rail welded joints enable it to be used in different occasions and conditions, while reducing the dependence on professional calibration services and the costs associated with equipment calibration.

[0038] In an optional embodiment of the present invention, a clamping mechanism 50 for clamping the straightness calibration rail 60 is provided on the contact part 13. The clamping mechanism 50 is used to clamp the straightness calibration rail 60, allowing the straightness calibration rail 60 to be stably mounted on the contact part 13, ensuring that the calibration rail remains parallel to the steel rail 80 to be measured during the measurement process. The clamping mechanism 50 is provided on the contact part 13, which can ensure the stability of the calibration rail during the measurement process, thereby providing a reliable reference benchmark, which is crucial for improving the measurement accuracy. The clamping mechanism 50 takes into account the convenience of operation and the stability of the calibration rail, so that the straightness calibration rail 60 can be quickly and firmly mounted on the measuring equipment. In addition, the clamping mechanism 50 also allows the fast disassembly of the straightness calibration rail 60, so as to quickly switch to the actual steel rail 80 measurement work after the calibration is completed, which greatly improves the working efficiency of the measuring equipment, and also enhances the adaptability of the measuring equipment, so that it can adapt to different measurement environments and requirements, and improves the versatility and flexibility of the equipment.

[0039] In an optional embodiment of the present invention, a plurality of support rollers 70 for supporting the straightness calibration rail 60 are provided on the contact component 13, and the plurality of support rollers 70 are sequentially spaced along the length direction of the straightness calibration rail 60. The above structure ensures the stability and parallelism of the calibration rail during the measurement process. The support rollers 70 can effectively bear the weight of the straightness calibration rail 60 to prevent any form of deformation or displacement during the measurement process. The precise setting of the spacing of the support rollers 70 sequentially spaced along the length direction of the straightness calibration rail 60 can ensure that the straightness calibration rail 60 is uniformly stressed over the entire length, thereby ensuring the accuracy and reliability of the measurement data. At the same time, the support rollers 70 are also convenient for installation and adjustment, so that the straightness calibration rail 60 can be quickly adjusted to the correct position according to actual measurement requirements. By arranging a plurality of sequentially spaced support rollers 70 on the contact component 13 to support the straightness calibration rail 60, the stability of the straightness calibration rail 60 during the measurement process is ensured. The evenly distributed support rollers 70 reduce the deformation of the calibration rail due to its own weight or external force, thereby maintaining the accuracy during the measurement process.

[0040] In an optional example, support rollers 70 with a spacing of no more than 600 mm are used to ensure that the straightness calibration rail 60 does not deform.

[0041] In an optional embodiment of the present invention, the straightness detector 30 has a distance sensor 40, and the distance sensor 40 is arranged toward the rail 80 to be measured. The distance sensor 40 directly faces the surface of the rail 80 and can accurately measure the distance between the rail 80 and the sensor. The distance sensor 40 is integrated in the straightness detector 30. When the driving device 20 drives the straightness detector 30 to move along the guide rail 11, the distance sensor 40 scans the surface of the rail 80, thereby obtaining the relative distance data with the surface of the rail 80. The arrangement of the distance sensor 40 toward the rail 80 to be measured allows the device to dynamically collect data during the measurement process, which can ensure the accuracy and real-time nature of the measurement results. In addition, the distance sensor 40 also allows the device to be flexibly adjusted under different measurement environments and conditions to meet the measurement requirements of different rails 80.

[0042] In an optional embodiment of the present invention, the contact component 13 is a rail car that enables the measuring device to move along the rail 80 and directly contact the rail 80 to be measured. As the contact component 13, the rail car not only provides a stable platform to support the entire measuring device, but also allows the device to move quickly and accurately along the rail 80 to achieve efficient measurement of the straightness of the rail weld joint. The design of the rail car takes into account the compatibility with the rail 80 and the smoothness of movement, ensuring the stability and data accuracy during the measurement process. In addition, the design of the rail car also allows the equipment to be flexibly adjusted in different measurement environments and conditions to adapt to the measurement requirements of different rails 80, including welded joints of different lengths and different positions. The stability of the rail car can reduce vibration and deviation during the measurement process, enhance the adaptability of the equipment, and enable it to work stably in different track environments, including curved and straight tracks.

[0043] In another optional embodiment of the present invention, when the straightness detector 30 is used to scan the straightness calibration rail 60 or the rail 80 to be tested, the detection data per meter should be greater than or equal to 500 to ensure high density and high precision of the data, so that in actual operation, the distance sensor 40 will collect data at a very high frequency, thereby generating a detailed data set, which can accurately reflect the actual straightness of the rail 80. In this way, even if there are slight irregularities on the surface of the rail 80, they can be accurately captured and recorded, providing a solid foundation for subsequent data processing and analysis. In addition, this high-precision measurement method also helps to discover potential problems of the rail 80 in advance, so as to carry out maintenance and repair in time, avoiding possible safety accidents and cost losses.

[0044] In the present invention, the straightness calibration rail 60 is scanned by the straightness detector 30, and the relative distance data between the distance measuring sensor 40 and the surface of the rail 80 are uniformly collected, and the data are transmitted to the computer for storage; at the same time, the corresponding number of rotations of the driving device 20 relative to each distance data is stored. Further, in order to make the data result accurately express the straightness of the rail 80, the detection data per meter should be no less than 500.

[0045] In another optional embodiment of the present invention, the straightness calibration rail 60 is scanned twice using a straightness detector 30. When the maximum difference between the approximate scanning trajectory curves obtained by the two scans is less than or equal to 0.02 mm, it is determined that the accuracy of the measuring device meets the requirements. In the self-calibration method for measuring the straightness of a rail weld joint, the straightness calibration rail 60 is scanned twice independently using a straightness detector 30, the purpose of which is to verify the accuracy and stability of the measuring device. Specifically, after the first scan, the relative distance data of the straightness calibration rail 60 is collected and stored, and the first approximate scanning trajectory curve is drawn accordingly. Subsequently, a second scan is performed, and data is collected again and a second approximate scanning trajectory curve is drawn. The maximum difference between the two curves is used to evaluate the accuracy of the measuring device. If the maximum difference between the two curves is less than or equal to 0.02 mm, it is determined that the accuracy of the measuring device meets the requirements, and subsequent precise measurement work can be performed. By introducing two scanning steps and comparing the maximum difference in the self-calibration method, the rail weld joint straightness measuring device of the present invention achieves strict control of the measurement accuracy, and can ensure that the measuring device has reached a high-precision state before the actual measurement, thereby avoiding the problem of inaccurate measurement results caused by equipment errors. By setting a maximum difference threshold of 0.02mm, the present invention sets a clear standard for the accuracy of the measuring equipment, so that the operator can quickly determine whether the equipment is ready and whether further calibration is required. This self-calibration mechanism not only improves the accuracy of the measurement, but also improves the efficiency of the measurement process because it allows potential measurement deviations to be quickly identified and corrected. In addition, this method also reduces dependence on external calibration services, reduces long-term operating costs, and improves the autonomy and flexibility of the measuring equipment.

[0046] like Figure 4 As shown, the curve is the approximate scanning trajectory curve of the distance measuring sensor 40. The travel distance of the sensor is calculated according to the number of revolutions of the driving device 20, and is set to d1, d2, d3...dn. The corresponding relative distance data is set to x1, x2, x3...xn. Establish n pairs of data points: (dn, xn), draw a scatter plot and connect the scatter points with straight lines to obtain an approximate curve graph. After each detection of the flatness measurement system is completed, n pairs of data points: (dn, yn) can be obtained in the same way, which is consistent with the horizontal coordinate data of the data point (dn, xn), and the representation on the curve graph is as follows Figure 5 As shown, the calibrated straightness data point can be expressed as (dn, yn-xn). Further operations are performed on the data point (dn, yn-xn), dn is converted to the detection length l, and the corresponding ordinate value yn-xn is evenly distributed on the horizontal axis of the range l, and the calibrated straightness curve can be obtained. Figure 6 The figure shows an example of a straightness curve. The straightness measurement system performs two calibration rail tests and data corrections before daily testing. After the first correction, if the second test result does not show a numerical point with an absolute value greater than 0.02mm, it means that the accuracy of the detection system meets the requirements. This ensures that the measurement accuracy of the measurement system within the L length range is less than the flatness of the calibration rail.

[0047] The detailed explanation of the above-mentioned embodiments is only intended to explain the present invention so as to facilitate a better understanding of the present invention. However, these descriptions cannot be interpreted as limitations on the present invention for any reason. In particular, the various features described in different embodiments may also be arbitrarily combined with each other to form other embodiments. Unless there is a clear description to the contrary, these features should be understood to be applicable to any embodiment and are not limited to the described embodiments.

Claims

1. A device for measuring the straightness of rail welded joints, characterized in that: The rail weld joint straightness measuring device comprises: A frame, one end of which is provided with a contact component for contacting the steel rail to be measured, and the other end of which is provided with a linear guide rail, wherein the linear guide rail is parallel to the steel rail to be measured; A straightness detector is movably arranged on the linear guide rail; A driving device, connected to the flatness detector and driving the flatness detector to move along the linear guide rail; A straightness calibration rail is detachably mounted on the contact component and is parallel to the linear guide rail.

2. The rail weld joint straightness measuring device according to claim 1, characterized in that: The contact component is provided with a clamping mechanism for clamping the straightness calibration rail.

3. The rail weld joint straightness measuring device according to claim 1, characterized in that: The contact component is provided with a plurality of supporting rollers for supporting the straightness calibration rail, and the plurality of supporting rollers are sequentially spaced along the length direction of the straightness calibration rail.

4. The rail weld joint straightness measuring device according to claim 1, characterized in that: The straightness detector has a distance measuring sensor, and the distance measuring sensor is arranged toward the rail to be measured.

5. The device for measuring the straightness of rail welded joints according to claim 1, characterized in that: The contact component is a rail car.

6. A self-calibration method for measuring the straightness of a rail weld joint, using a measuring device as claimed in any one of claims 1 to 5, characterized in that: The self-calibration method comprises: Scanning the straightness calibration rail at least once using a straightness detector to uniformly collect relative distance data between the straightness detector and the straightness calibration rail; Draw an approximate scanning trajectory curve according to the relative distance data between the straightness detector and the straightness calibration rail; The straightness calibration rail is removed, and the straightness detector is used to scan the rail to be tested, and the relative distance data between the straightness detector and the rail to be tested is evenly collected; Draw an actual detection trajectory curve according to the relative distance data between the straightness detector and the rail to be tested; A calibrated straightness curve is drawn according to the approximate scanning trajectory curve and the actual detection trajectory curve.

7. The self-calibration method for measuring the straightness of a rail weld joint according to claim 6, characterized in that: When the straightness tester is used to scan the straightness calibration rail or the rail to be tested, the test data per meter should be greater than or equal to 500.

8. The self-calibration method for measuring the straightness of a rail weld joint according to claim 6, characterized in that: The straightness detector is used to scan the straightness calibration rail twice. When the maximum difference between the approximate scanning trajectory curves obtained by the two scans is less than or equal to 0.02 mm, it is determined that the accuracy of the measuring device meets the requirements.

Images