Automatic top adjusting device and method for turnout steel rail

Abstract

The invention provides an automatic jacking and adjusting device and method for a turnout steel rail. The automatic jacking and adjusting device comprises a press machine, a feeding system, a discharging system, a lifting device and an intelligent jacking head at the execution tail end of the press machine. A track turner and a track auxiliary observation device are arranged in an auxiliary manner; the system further comprises an online detection system and an offline detection system. The system further comprises a data transmission and storage module and a data processing module, and the data transmission and storage module is used for transmitting and storing detected data and transmitting and storing data processed by the data processing module. The data transmission and storage module realizes interaction and association of turnout steel rail product information based on an enterprise information system; and the data processing module is used for processing the detected data, generating field processing process guidance information and generating a final detection report. The automatic jacking and adjusting device realizes automatic jacking and adjusting of the turnout steel rail, and is accurate, labor-saving, efficient and convenient.

Description

Technical Field

[0001] The invention belongs to the technical field of physical measurement and testing, and in particular relates to an automatic top-adjusting device and method for a turnout rail. Background Art

[0002] In the processing of high-speed turnout point rails, the top adjustment process has always used relatively primitive means. Top adjustment is divided into straightening and top bending. The cross-sections of turnout point rails and heart rails are complex and changeable, so roller straightening methods similar to rail straightening cannot be used. Instead, a three-point pressure straightening method is used, which mainly relies on the workers' experience to reversely bend multiple times to gradually reduce the curvature of the point rail to achieve the purpose of straightening.

[0003] Straightening is to bend the initially bent point rail in the opposite direction, so that the point rail undergoes irreversible plastic deformation and improves the straightness of the point rail. Top bending is to perform elastic-plastic bending deformation on the curved point rail after machining according to design requirements, so that the point rail reaches the specified radius of curvature after unloading. Straightening is divided into vertical straightening and horizontal straightening. Concave bending and convex bending of the point rail are deformations that often occur during processing, especially after the rail head is quenched, the point rail often has concave bending, so the point rail needs to be straightened in the plane. The main difference between vertical straightening and horizontal straightening is that the direction of the straightening force is different, which is suitable for straightening the upward and downward bending deformation and the left and right bending deformation of the point rail respectively. In production, vertical straightening and horizontal straightening are often carried out one after another. Top bending is to bend the point rail in the plane, bending the straight point rail into a specified radius of curvature.

[0004] In the current processing, the straightening pressure point and bending amount are determined by workers based on experience. The straightness of the entire length range is visually inspected, and the local straightness of the point rail is detected using tools such as a ruler to determine the loading offset and bending amount. The loading head is used to reversely load and unload at the maximum bending part, and the straightening effect is detected, and then a second loading is performed. This process is repeated until the part meets the straightening error range requirements. The entire point rail is tested, and then another curved part is straightened until it is completely straightened. The entire straightening process is a process of repeated trials, with low production efficiency, high labor intensity, and low straightening quality. The experience and technology of the workers are the determining factors of the straightening quality.

[0005] At present, the top adjustment and inspection of turnout rails at home and abroad are mainly manual, and the hydraulic equipment of the open-loop system is used to achieve the top bending of the rails. The controllability of the top adjustment is poor, and it is highly dependent on manual experience. In addition, the finished product inspection method is to use various measuring tools such as flat rulers, feeler gauges, bending templates, tape measures, etc. for inspection, and its measurement efficiency and accuracy are relatively low. In addition, the turning of the top adjustment station of long and large rails is currently mainly done by manual prying with a crowbar, which is labor-intensive and poses a safety hazard.

[0006] Therefore, domestic turnout manufacturers have improved the tools or optimized the processes for the top bending process. Generally speaking, the automation of turnout rail component top adjustment is an objective requirement and an inevitable trend of development. The straightening technology of long rail components is one of the key technologies in the manufacturing of turnouts, especially high-speed turnouts. The precision forming of rail components is a key production process in turnouts. Improving the forming quality of rail components is the basis for improving the accuracy of high-speed turnouts and is a key factor in eliminating assembly errors, especially the control of dimensions such as gauge, contact tightness, and suspended slab. Therefore, the following technical solutions are proposed. Summary of the Invention

[0007] The technical problem solved by the present invention: Provide an automatic turnout rail top adjustment device and method to solve the technical problem of automatic turnout rail top adjustment.

[0008] The technical solution adopted by the present invention: An automatic turnout rail top adjustment device includes a feeding system on one side of the pressure and a discharging system on the other side of the press; it also includes a lifting device and an intelligent top head at the execution end of the press; the press is assisted with a rail flipper and a rail auxiliary observation device; it also includes an on-line detection system and an off-line detection system; it also includes a data transmission and storage module and a data processing module. The data transmission and storage module is used for the transmission and storage of detected data, and the transmission and storage of data processed by the data processing module; the data transmission and storage module realizes the interaction and association of turnout rail product information based on the enterprise information system; the data processing module is used for the processing of detected data and the generation of on-site processing process guidance information and the generation of the final detection report.

[0009] In the above technical solution, as a preferred technical solution of the present invention: The enterprise information system is an EPR system.

[0010] In the above technical solution, as a preferred technical solution of the present invention: The data transmission and storage module is connected to an independent storage server by wireless transmission; the data processing module is installed on mobile terminals and non-mobile terminals; the mobile terminal is a tablet computer or a mobile phone; the non-mobile terminal is a PC computer or a dedicated storage server.

[0011] In the above technical solution, as a preferred technical solution of the present invention: The on-line detection device and the off-line detection device are one or any combination of two or more of a laser sensor, an image vision camera, a lidar, and a grating scale.

[0012] In the above technical solution, as a preferred technical solution of the present invention: the feeding system has an upwardly inclined feeding and stacking rack and a downwardly inclined feeding chute; the feeding and stacking rack is used for storing the rail members to be processed, and the feeding and stacking rack is provided with a sliding hook I for pushing the materials upward; a rail sensor is provided at the turning transition position between the feeding and stacking rack and the feeding chute, and the rail sensor is used to trigger the sliding hook I to stop pushing the materials; a hydraulic cylinder I is arranged at the lowest point of the feeding chute; the feeding chute is used for transporting the rail members to the power roller path connected to the press.

[0013] The discharging system has a downwardly inclined discharging chute, and an offline detection system is provided in the discharging stacking area at the end of the discharging chute; a discharging transfer area is provided at the starting end of the top of the discharging chute and is connected to the press, and the discharging transfer area is supported and lifted by a hydraulic cylinder II; a sliding hook II is provided at the connection between the discharging transfer area and the discharging chute; the sliding hook II is used to hook the rail limb moving workpiece.

[0014] In the above technical solution, as a preferred technical solution of the present invention: the lifting device is composed of multiple hydraulic platforms distributed between the power roller paths; the hydraulic platforms are provided with hydraulic power by a hydraulic pump station, and the hydraulic rods of multiple groups of hydraulic platforms are lifted synchronously; the lifting error of the hydraulic rods is less than 0.5 mm.

[0015] In the above technical solution, as a further improvement of the present invention: the intelligent punch head includes a hydraulic punch head, and the hydraulic punch head is integrally connected with the execution end of the hydraulic cylinder of the press; a rectangular groove and a positioning groove are provided at the bottom end of the hydraulic punch head; a laser sensor I is installed in the rectangular groove; the positioning groove includes a horizontal guide rail and a vertical guide rail; the horizontal guide rail and the vertical guide rail are used to realize the horizontal and vertical movement of the laser sensor I; a T-shaped punch head is also installed on the horizontal guide rail, the T-shaped punch head is fixed to the hydraulic punch head by a pin, and a pressure sensor is installed at the front end of the T-shaped punch head. The pressure sensor is used for triggering a signal for counting the working feed displacement, and the pressure sensor is also used for accurately controlling the loading torque of the press.

[0016] In the above technical solution, as a preferred technical solution of the present invention: the rail flipper is composed of multiple groups of flippers evenly arranged along the track direction; each group of flippers is composed of a pair of motors and speed reducers, driving gears, and passive gears; the passive gear is a semi-circular ring tooth structure and its movement range is limited by a limiter; the pair of motors and speed reducers respectively drive the pair of driving gears to rotate, the pair of driving gears respectively mesh with the passive gears and drive their respective passive gears to rotate, the rotating passive gears clamp the rail members and drive the rail members to flip, and balls and shock-absorbing springs are provided at the ends of the passive gears in contact with the rail members.

[0017] In the above technical solution, as a preferred technical solution of the present invention: the track auxiliary observation device has a camera; the camera is installed at the execution end of the horizontal moving rod; the horizontal moving rod is installed at the execution end of the lifting rod; the shooting direction of the camera is the same as the visual direction of the operator; the horizontal moving rod and the lifting rod are respectively driven to displace by motors; the image of the camera is output through a liquid crystal screen.

[0018] In the above technical solution, as a preferred technical solution of the present invention: the online detection mode of the online detection system corresponds the detection to the working step rhythm of the top adjustment, decomposes the online detection and each top adjustment process into the actions of each unit, and divides the whole rail piece into several online detection units, where each 1000 - 1200 mm is a detection unit, and the overlapping area of each top adjustment or online detection action is 300 - 500 mm, which is used to ensure that the influence of the next top adjustment action on the completed area is controlled; the online detection sensor of the online detection system is driven by a motor to scan the contour data of a certain height on the side of the rail piece within a short time and transmit it to the software for fitting; during a single processing process of the rail piece by the online detection system, before and after the rail piece is loaded with torque, the bending condition of the rail piece within the single processing range is quickly scanned, and the relative position between the intelligent top head and the rail piece remains unchanged during the quick scan.

[0019] In the above technical solution, as a preferred technical solution of the present invention: the offline detection system is composed of 3 - 5 groups of scanning mechanisms; each group of scanning mechanisms consists of an X-axis guide rail, a Z-axis guide rail and a laser scanning head Ⅰ; the X-axis guide rail realizes the movement of the laser scanning head Ⅰ in the horizontal direction, and the Z-axis guide rail realizes the movement of the laser scanning head Ⅰ in the vertical direction; the laser scanning head Ⅰ has two laser measurement points aligned up and down, the upper laser measurement point is used for the detection of the side curve of the track, and the lower laser measurement point is used for the detection of the overall distribution of the track.

[0020] In the above technical solution, as a further improvement of the present invention: the offline detection system further includes a group of laser scanning heads Ⅱ respectively arranged on both sides of the processing platform, and the two groups of laser scanning heads Ⅱ scan the same workpiece from both sides respectively; on one side of the working edge, it is scanned only once to complete the drawing of the side arc of the rail piece; on the non-working edge side, it is scanned twice on the processing section to complete the measurement of at least two height points of the tip of the rail piece, so as to complete the calculation of the slope of the hypotenuse of the rail piece and be used to judge the close-fitting condition of the rail piece.

[0021] The present invention also claims protection for a method for automatic top adjustment of turnout rails, including any automatic top adjustment device for turnout rails, and comprising the following steps:

[0022] Before processing: pull the rail piece into the top adjustment processing station of the press through the feeding system.

[0023] During processing: The lifting device operates to lift the rail component, placing the rail component on a plane. The rail component information is identified or input through machine vision or manual input, and the rail component process information pre-stored in the enterprise information system is associated and obtained. The appropriate intelligent head execution parameters are matched through digital simulation. The relative displacement of the intelligent head's top adjustment operation adopts closed-loop control, and the start-stop signal of the intelligent head is obtained by cooperating with the pressure sensor on the intelligent head. The top adjustment operation of the intelligent head adopts a segmented processing method. The processing strategy is given through a fuzzy algorithm, and the top adjustment linear structure of the rail component is fed back through an on-line detection system for target judgment and strategy compensation of the top adjustment operation. Among them, the rail flipper is manually controlled for the station adjustment of the rail component, thereby realizing the forward or lateral top adjustment processing of the rail component. The rail auxiliary observation device is used for manual safety observation of the processing state of the rail component.

[0024] After processing: The rail component is fed into the blanking stockpiling area through the blanking system; the off-line detection system judges the qualification of the linear type of the entire length range of the rail component. After forming data through the data processing module, a data post-processing report is generated to guide processing, and it is associated with the enterprise information system through wireless transmission to obtain basic standard information and store the final analysis data.

[0025] In the above technical solution, as a preferred technical solution of the present invention, the following steps are included:

[0026] After the "raw material" is processed in the previous step, it is transported by the overhead crane to the stockpiling area of the "loading system"; for the raw materials that need to mark the bending points, in the stockpiling area, workers use a ruler to measure and label them with sticker labels for the identification of the machine bending points.

[0027] At the start of processing, the "loading system" pushes the workpieces to be processed in the stockpiling area one by one onto the "processing power roller path"; after being transported by the "processing power roller path", the tip of the workpiece to be processed reaches near the top bending head; according to the process requirements, it can be selected whether to use the "rail flipper" to flip the workpiece to be processed by 90° for processing.

[0028] Before each processing starts, "pre-processing scanning" needs to be carried out for pre-processing measurement scanning, which is used to obtain the natural bending state of the track before processing, and the result is sent to the computer for comparison with the processing target curve, and the recommended processing data is output.

[0029] After the worker selects the processing data, the top bending head automatically completes the "top bending processing".

[0030] After removing the torque, "result scanning" is immediately performed; based on the scanning results, it can be determined whether the current bending effect meets the expectations; if it is qualified, the next part to be bent is continuously conveyed through the "power roller path" into the processing area, and the processes of "pre-processing scanning", "bending processing", and "result scanning" are repeated; if it is unqualified, the system records the process of this error generation and "records data", and sends a manual operation request to the operator; after the system receives the request, the operator can manually perform secondary processing; after the processing is completed and it is confirmed that the result meets the expectations and is qualified, the system will record the parameters of this secondary processing and correct the algorithm according to the weight.

[0031] After completing the bending processing of the entire length, the processed part will be moved to the "lifting device" of the offline scanning system; here, the processed part will be lifted upward by a certain distance, completely separated from the support of the "power roller path" and kept in a horizontal state. After waiting for the "offline scanning" to complete the data scanning, the system will compare the scanning results with the pre-stored results in the database. Those that pass the comparison will be automatically transferred to the "material discharging system"; those that fail the comparison will display the location of the defect, return the processed part to the "processing power roller path", and prompt the on-site workers for further processing.

[0032] In the above technical solution, as a preferred technical solution of the present invention: the specific measurement process of the on-line detection is as follows:

[0033] Step 1, trigger scanning: Before performing the processing operation, ensure that the information of the processed part and the current process step have been correctly input.

[0034] Step 2, automatic position adjustment of the scanning head and completion of scanning: The starting position, measurement height, and measurement speed of the scanning head are automatically adjusted according to the type and parameters of the current processed part; after the adjustment is in place, the scanning head performs a scanning movement in the horizontal direction at the fastest speed.

[0035] Step 3, automatically generate the original bending data of the processed part and specifically propose processing suggestions: For the data points obtained by scanning in Step 2, they are spliced by software to form a complete image; on the operation interface, the bending degree and bending direction of the current processed part, as well as processing suggestions, are displayed in a graphical manner.

[0036] Step 4, complete the straightening operation according to the processing suggestions: Complete the straightening operation according to the processing suggestions in Step 3, and the on-line detection function can be triggered again to repeat the processes of Step 2 and Step 3, and compare the spliced image with the standard image at the current position to display the remaining error.

[0037] When performing a bottom surface scan on the heel pressing section, the specific measurement process of the on-line detection is as follows:

[0038] Step 501: The staff first flips the rail to ensure that the bottom surface of the rail faces the direction of the scanning head.

[0039] Step 502: Completely park the follow-end profiling section of the flipped rail within the online scanning range and activate the corresponding function on the operation panel.

[0040] Step 503: The system automatically scans the bottom surface contour of the follow-end profiling section of the rail within the entire scanning range and measures the bottom surface inclination of the follow-end profiling section of the rail.

[0041] Advantages of the present invention compared with the prior art:

[0042] 1. The automatic top-adjustment device and method of the present invention are applicable to the top-adjustment of rail components such as the stock rail, switch rail, and crossing rail of turnouts. It uses machine vision such as laser detection technology and visual image detection technology and various automated industrial integration technologies to achieve automated top-adjustment operations. It combines on-line and off-line detection of rail components, correlates the detection results with product data, realizes data transmission and storage, and realizes the traceability of the whole process and the whole life cycle of product top-adjustment, making the top-adjustment operation of the product more accurate, labor-saving, efficient, and convenient.

[0043] 2. The present invention uses a pressure sensor as the starting signal and adopts a closed-loop control method for top-adjustment, solving the problem of precision machining of rail components such as stock rails, switch rails, and crossing rails with different rail types, different variable cross-sections, and different materials.

[0044] 3. The present invention adopts a segmented machining method and, at the same time, through the cooperation of on-line detection and off-line detection, effectively meets the requirements of high-efficiency production of products, and the overall complexity of the equipment is small, and the floor area requirement is low.

[0045] 4. The top-adjustment operation of the present invention adopts a fuzzy algorithm, trains the system through the operation of highly skilled personnel, and records the manual or machine top-bending experience coefficient to improve the establishment of the top-adjustment data knowledge base and enhance the intelligent and precise level of top-adjustment.

[0046] 5. The setting of the rail flipper and the rail auxiliary observation device of the present invention solves the problems of high labor intensity and insufficient safety in manually flipping the rail and observing the working conditions at close range.

[0047] 6. The present invention is divided into two parts: on-line detection and off-line overall detection, realizing the automatic detection of the geometric parameters of the rail line type. Specifically, a non-contact detection scheme is adopted, and the measurement using a laser and a vision system is used to replace the manual measurement method using tools such as a tape measure, a suspension line, a straightedge, and a bending template for top-adjustment detection, improving the detection accuracy and reducing the labor intensity. Brief Description of the Drawings

[0048] Figure 1 It is a schematic diagram of the detection parameters of the turnout rail of the present invention;

[0049] Figure 2(a) is the process flow diagram of the present invention;

[0050] Figure 2(b) is the sticker label diagram of the turnout rail of the invention;

[0051] Figure 3 is the system structure block diagram of the device of the present invention;

[0052] Figure 4(a) is the three-dimensional structure schematic diagram of the device of the present invention;

[0053] Figure 4(b) is the front view of the device of the present invention;

[0054] Figure 5(a) is the three-dimensional view of the feeding system of the present invention;

[0055] Figure 5(b) is the front view of the feeding system of the present invention;

[0056] Figure 6(a) is the three-dimensional view of the discharging system of the present invention;

[0057] Figure 6(b) is the front view of the discharging system of the present invention;

[0058] Figure 7 is the hydraulic lifting schematic diagram of the power raceway of the present invention;

[0059] Figure 8(a) is the structural schematic of the intelligent plug of the present invention Figure 1 ;

[0060] Figure 8(b) is the second structural schematic diagram of the intelligent plug of the present invention;

[0061] Figure 9(a) is the structural schematic of the track flipper of the present invention Figure 1 ;

[0062] Figure 9(b) is the second structural schematic diagram of the track flipper of the present invention;

[0063] Figure 10 is the structural schematic diagram of the track auxiliary observation device of the present invention;

[0064] Figure 11 is the schematic diagram of the detection method of the machine vision of the on-line detection system of the present invention;

[0065] Figure 12 is the structural schematic diagram of the off-line detection system of the present invention;

[0066] Figure 13(a) is the structural schematic of the upper and lower double laser scanning heads Ⅰ of the present invention Figure 1 ;

[0067] Figure 13(b) is the second structural schematic diagram of the upper and lower double laser scanning heads Ⅰ of the present invention;

[0068] Figure 13(c) is a schematic diagram of the close-fitting detection for calculating the inclined plane angle by two scans of the present invention;

[0069] Figure 14 is the data flow diagram of the present invention;

[0070] Figure 15 is the network structure diagram of the device of the present invention;

[0071] Figure 16 is the schematic diagram of the software structure;

[0072] Figure 17 is the schematic diagram of finding the optimal parameters by the Bayesian method;

[0073] Figure 18 is the straightening force under different loading spans;

[0074] Figure 19 is the schematic diagram of the structure of the ball and the shock-absorbing spring;

[0075] In the figure: 1 - press, 2 - loading system, 3 - unloading system, 4 - lifting device, 5 - intelligent top head, 6 - rail flipper, 7 - rail auxiliary observation device, 8 - on-line detection system, 9 - off-line detection system, 10 - power roller track; 201 - loading stacking rack, 202 - loading chute, 203 - sliding hook Ⅰ, 204 - rail sensor, 205 - hydraulic cylinder Ⅰ; 301 - unloading chute, 302 - unloading stacking area, 303 - unloading transfer area, 304 - hydraulic cylinder Ⅱ, 305 - sliding hook Ⅱ; 401 - hydraulic platform; 501 - hydraulic top head, 502 - rectangular groove, 503 - positioning groove, 5031 - horizontal guide rail, 5032 - vertical guide rail, 504 - laser sensor Ⅰ, 505 - T-shaped top head, 506 - pressure sensor; 601 - motor and speed reducer, 602 - driving gear, 603 - driven gear, 604 - ball and shock-absorbing spring; 701 - camera, 702 - horizontal moving rod, 703 - lifting rod; 901 - X-axis guide rail, 902 - Z-axis guide rail, 903 - laser scanning head Ⅰ, 9031 - laser measurement point. Specific embodiments

[0076] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the attached Figure 1-19 , it is obvious that the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present invention.

[0077] An automatic turnout rail jacking and adjusting device provided by the present invention includes two parts: hardware and software. Among them, (such as Figure 3, as shown in Figure 4, the hardware part includes a feeding system 2 on one side of the press 1 and a discharging system 3 on the other side of the press 1. It also includes a lifting device 4 below the press 1 and an intelligent punch head 5 at the execution end of the press 1; the press 1 is additionally provided with an orbital turner 6 and an orbital auxiliary observation device 7; it also includes an on-line detection system 8 and an off-line detection system 9. It also includes a data transmission and storage module and a data processing module. The data transmission and storage module is used for the transmission and storage of the detected data, and the transmission and storage of the data processed by the data processing module; the data transmission and storage module realizes the interaction and association of turnout rail product information based on the enterprise information system; the data processing module is used for the processing of the detected data and the generation of on-site processing process guidance information and the generation of the final detection report. The hardware part is realized by means of transformation, upgrading, installation, etc. of the existing technology.

[0078] (as Figure 16 shown) The software system includes a server side, a query side, an operation side, and a collection side; the server side runs on a storage server; the query side runs on the operating systems of tablet computers, mobile phones, and dedicated servers, the operation side runs on the operation panel of a human-machine interface device, and the collection side runs on an industrial control computer.

[0079] (as Figure 15 shown) All the main equipment installed at the work site is connected to an independent equipment subnet through Gigabit Ethernet. The equipment subnet is connected to the factory network through the main router outlet. The storage server is placed in the computer room and is directly connected to the factory network. The bandwidth within the subnet is defaulted to 1000MB / S, and the bandwidth requirement of the factory network is 100MB / S.

[0080] The storage server is connected to the main control system through the network. The storage server is responsible for saving all the data generated during the processing that needs to be stored for a long time. The capacity of the storage server should at least meet the storage requirement of the detection data of 10,000 processed parts, and can be expanded according to the demand. Enterprise-level security disks are used in the storage server, and a raid5 redundant storage array is established to effectively ensure the security of the data.

[0081] This device is transformed according to the material theory. The material theory mainly refers to establishing an effective data model of the top bending method through materials science research methods. In the model, it is necessary to consider the self-factors such as the type, material, cross-sectional area, and initial bending degree of the processed parts, and it is also necessary to introduce external influencing factors such as the processing environment and processing method. After setting the input quantity in the model, the computer can give suggestions on the top bending processing method. At the same time, the model has a certain degree of adjustability, and the result can be corrected by changing the operation parameters. (as Figure 17As shown in the figure), after learning a large amount of cumulative data through the Bayesian method, the model can quickly and relatively accurately provide processing guidance for the processing personnel within the effective range. Among them, an appropriate theoretical model can learn and record the data results formed by each top bending, and conduct practice and verification in a timely manner when encountering similar situations in the future to deepen the learning results. As long as enough data is accumulated, most of the problems encountered in production can be solved, greatly reducing the operation difficulty of the top bending process.

[0082] It should be noted that: the hydraulic system of the existing press 1 is improved to a servo hydraulic system. Compared with the existing hydraulic system, the press 1 of the present invention adopts a servo hydraulic system, which has a fast response speed, high control precision, large load stiffness, and greater control power. The system uses an AC servo motor as the hydraulic power source and a proportional control method. By setting the speed, position, pressure, or target stroke, the servo system can automatically adjust the operation of the motor to form a liquid pressure within the necessary range. This closed-loop control method is the basis for achieving precise processing.

[0083] The transformation of the power roller path 10 mainly focuses on the motor, controller, and transmission system. Each roller of the existing power roller path 10 is driven by a separate motor, and there is no linkage control between the motors. When there are differences in the operation of the motors, high internal losses may occur. The present invention considers multi-motor linkage or an improvement method in which all rollers are uniformly driven by a single high-power and high-precision motor in a long-chain manner. In terms of motor drive, the original system uses multiple AC asynchronous motors as the power source and is directly connected to the power grid for power supply. The present invention will add a variable frequency speed regulation device to the motor to achieve multiple functions such as soft start-stop, precise speed control, and brake control. Achieving precise control of the axial position of the workpiece is the basis for improving processing accuracy and processing efficiency.

[0084] The operation panel includes components such as a display screen, keyboard, and operation handle (joystick). The operation panel can receive and display data and issue operation instructions, and is the interface for equipment use and adjustment. The operator can operate the loading and unloading system through the touch screen and operation handle (joystick) on the operation panel, or precisely adjust the speed of the intelligent punch head 5, or set the travel parameters of the intelligent punch head 5 and let the system automatically perform the pushing operation. The operation panel is also equipped with a barcode scanning device. After the workpiece to be processed is lifted and fixed, the graphic code on the workpiece can be scanned through the barcode scanning device to obtain relevant processing information.

[0085] The main equipment at the work site of the present invention includes various sensors, a general controller, and a human-machine interface, which are connected into an independent equipment subnet through a network system. The equipment subnet accesses the factory network through the main router outlet. The storage server is placed in the computer room and is directly connected to the factory network.

[0086] The acquisition end is mainly responsible for three parts of work: underlying device driver, data acquisition, and data processing. The underlying sensor devices are connected to the master controller through the serial interface of the RS232 protocol, the Ethernet interface of the TCP / IP protocol, analog quantities, etc. The transmission forms and formats of each type of data are different. The software and hardware of the acquisition end support all data transmission forms required for detection and can drive all underlying hardware devices. Based on this, all calls to the underlying hardware are made through the acquisition end. During the scanning process, there is a certain time difference in the real-time data returned by various sensors. The software and hardware platform of the acquisition end has powerful parallel computing capabilities, which can ensure the real-time and correctness of data acquisition and fusion. After all real-time data is fused, it becomes raw data. Compared with the acquisition task, the real-time requirement of the data processing task is relatively low and it has strong sliceability. The data processing part of the acquisition end adopts a Master-Slave structure, which can make the best use of the remaining hardware resources to perform mathematical processing such as filtering and fitting on the fused data as quickly as possible without affecting data acquisition. The raw data after processing will become curve data and be written into the local high-speed database for subsequent calls.

[0087] The operating terminal human-machine interface software, as the only interface for operators to interact with the equipment, runs on the human-machine interface tablet computer. The main functions of the software include: displaying the operating status of the equipment; scanning and inputting the information of the workpiece to be processed currently, retrieving and displaying relevant processing information and processing standard data through the factory's ERP system; configuring the operating parameters, detection methods, detection accuracy, etc. of the detection equipment, and controlling the detection process; displaying the detection results; directly and indirectly controlling and operating some auxiliary processing equipment. Before the scanning starts, the operator inputs (scans) the serial number of the workpiece to be processed and the necessary process parameters at the operating terminal. After obtaining the serial number, it communicates with the oracle 11g database of the factory's ERP system, grabs the processing parameters of the current workpiece to be processed, including information such as track model, mechanical structure, processing requirements, etc., and displays them on the screen for the operator to check. At the same time, search for the corresponding recommended processing parameters from the local database; if there are no corresponding recommended processing parameters, calculate them through the finite element model. During the acquisition process, the operating terminal receives the operator's instructions and controls the detection process. After the control instructions are parsed, they are transmitted to the acquisition terminal through socket to take effect. The specific data acquisition and processing are the responsibility of the acquisition terminal, and the operating terminal can directly retrieve the processed curve data from the high-speed database of the acquisition terminal through the network. By comparing the curve data with the processing standard data obtained from the ERP system, it prompts the operator whether the current processing result meets the expectations. After the processing is completed, the operating terminal will package the current curve data, processing standard data, processing additional information, etc. into a result data with the serial number as the only identifier and upload it to the server. For auxiliary processing equipment, such as the track flipper, etc., it can be directly controlled through the cooperation of the operating terminal and the operation panel.

[0088] The server runs in the storage server. Its main function is to grab, process, and save the necessary result data from the acquisition terminal under the guidance of the operating terminal, and provide interfaces for querying and modifying. At the same time, the server is also responsible for regularly sorting and backing up the historical data, and monitoring the disk operating status to ensure data security. Every specified time, based on the saved data, it forms a processing weekly (monthly) report and sends it to the specified contact email. The configuration of the server adopts a web interface. After logging in through the administrator account, the configuration is carried out on the web page.

[0089] The main function of the query terminal is to query, display, and modify the detection result data. The software can be deployed on any PC installed with the Windows 10 operating system and connected to the storage server through the factory intranet. To ensure data security, it is necessary for the user to log in to the account for verification. During the design, the permission levels can be classified according to the user types. After logging in, the user can filter the result data according to the attributes such as the serial number of the processed part, drawing number, processing time, qualification mark, etc. to quickly find the target data required.

[0090] Regarding the measured data, the on-line scanning mainly uses a laser line scanning sensor to perform sliding scanning on the side and bottom surfaces of the track, and restore its bending curve and the bottom surface distortion angle. Through scanning in the test scenario, the state of the track deformation can be basically restored completely through the data.

[0091] In the above embodiments, as a preferred embodiment of the present invention: the enterprise information system is an EPR system. Among them, regarding the development of the detection data real-time and post-processing system, it includes the establishment and transmission functions of the standard and detection databases, the real-time display and feedback of the detection data, the software development of various forms of data post-processing and analysis, the development of the top adjustment experience machine learning program and the macro program, the association of the detection data and the top adjustment experience parameters with the product data, realizing data transmission and storage, and can trace the whole process and the whole life cycle. By adopting the EPR system, the real-time sharing of data and the seamless connection of processes are realized. This integration ensures the consistency and accuracy of the data, avoids the information island phenomenon, and significantly improves the operation efficiency of the enterprise. It can also improve the working efficiency of the automated process. Realize powerful data analysis and decision support. The EPR system reduces waste by optimizing inventory and production plans, effectively controls and reduces costs.

[0092] In the above embodiments, as a preferred embodiment of the present invention: the data transmission and storage module is connected to an independent storage server by wireless transmission; the data processing module is installed on mobile terminals and non-mobile terminals as carriers; the mobile terminals are tablet computers or mobile phones; the non-mobile terminals are PC computers or dedicated storage servers. The wireless transmission method gets rid of the limitation of physical connection, enabling the data transmission and storage module to be deployed more flexibly at the required locations. The independent storage server also provides a larger storage space and higher data security. At the same time, through wireless connection, it is convenient to exchange and share data with other systems. The wireless transmission method makes it easier for newly added data transmission nodes or storage servers to access the system without the need for complex wiring or physical connection. Compared with the wired transmission method, the wireless transmission method has lower costs in aspects such as wiring and maintenance, which helps to reduce the overall system cost. Mobile terminals (such as tablet computers and mobile phones) are portable and can access and process data anytime and anywhere, improving work efficiency and flexibility. Non-mobile terminals (such as PC computers and dedicated storage servers) provide more stable and powerful processing capabilities and are suitable for scenarios that require high-performance computing or a large amount of data processing. Different carriers can meet the needs and preferences of different users. Mobile terminals and non-mobile terminals can work collaboratively through a wireless network to achieve real-time synchronization and sharing of data. This collaborative work mode helps to improve the work efficiency and collaboration ability of the team, and at the same time makes the data easier to obtain and utilize. Tablet computers have a larger screen size and higher resolution, suitable for complex graphic processing and data analysis. Mobile phones are portable and real-time, and can access and process data anytime and anywhere. PC computers provide more stable and powerful computing capabilities and are suitable for scenarios that require high-performance computing or a large amount of data processing. Dedicated storage servers provide high-performance storage solutions that can meet the needs of a large amount of data storage and high-speed access.

[0093] In the above embodiments, as a preferred embodiment of the present invention: the on-line detection device 8 and the off-line detection device 9 are one or any combination of two or more of a laser sensor, an image vision camera, a lidar, and a grating scale. The laser sensor may specifically be a phase laser rangefinder, a laser profile sensor, etc. The principle of phase laser ranging: The emitted laser is intensity-modulated, and the phase change amount of the modulation signal during the spatial propagation of the laser is utilized. According to the wavelength of the modulation wave, the distance represented by this phase delay is calculated. That is, the indirect method of measuring the phase delay is used to replace the direct measurement of the time required for the laser to travel back and forth, thereby realizing the measurement of the distance. Phase laser rangefinders are generally used in precision ranging. Due to their high precision, generally at the millimeter level, in order to effectively reflect the signal and limit the measured target to a specific point commensurate with the instrument's precision, a reflector called a cooperative target is configured for such rangefinders. Compared with time-of-flight measurement, phase measurement has higher precision and better repeatability. The working principle of a laser profile scanning sensor is based on optical triangulation: The light emitted by a semiconductor laser forms an X-plane light curtain through a lens and forms a contour line on an object. The light reflected from this line is collected by a lens and projected onto a two-dimensional CMOS array. The profile graph of the target object thus formed is analyzed and processed by a signal processor. The length of the contour line is measured along the X-axis, and the height of the contour line is measured along the Z-axis. The laser profile sensor has characteristics such as non-contact, high precision, high speed, and absolute measurement. It can directly output the two-dimensional contour data of the measured target and can realize the scanning measurement of the three-dimensional shape through lateral movement. The laser sensor can accurately measure the distance and position of an object by emitting a laser beam and receiving the reflected signal. The lidar can create high-quality three-dimensional point cloud data by emitting and receiving laser pulses. The grating scale is a high-precision displacement measurement sensor that measures displacement based on the Moiré fringe principle of the grating. The image vision camera can capture the image information of an object, and through image processing algorithms, the feature information of the object can be extracted for applications such as target detection, recognition, and tracking. The three-dimensional imaging ability of the lidar and the image information acquisition ability of the image vision camera can complement each other, improving the accuracy and comprehensiveness of environmental perception. By combining different types of sensors, a more complex and powerful detection system can be constructed.

[0094] In the above technical scheme, as a preferred embodiment of the present invention: (as shown in FIG. 5 ) the feeding system 2 has a feeding stacking rack 201 inclined upward and a feeding slide 202 inclined downward; the feeding stacking rack 201 is used to store the rails to be processed, and the feeding stacking rack 201 is provided with a sliding hook Ⅰ 203 for pushing upward; a rail sensor 204 is provided at the transition position between the feeding stacking rack 201 and the feeding slide 202, and the rail sensor 204 is used to trigger the sliding hook Ⅰ 203 to stop pushing; a hydraulic cylinder Ⅰ 205 is provided at the lowest point of the feeding slide 202; the feeding slide 202 is used to transfer the rails to the power roller 10 connected to the press 1. Among them, after the workpiece to be processed stops sliding, the hydraulic cylinder Ⅰ 205 will shrink downward and remain in a shrinking state during the entire subsequent processing process. At this time, the overall height of the lower half of the feeding slide 202 is lower than the power roller 10, and will not interfere with the workpiece to be processed on the power roller 10. The loading system 2 must ensure that only one workpiece to be processed is moved to the processing platform at a time. The loading stocker 201 has an inclination angle of 15°; the sliding hook I 203 is used to resist the rail limb position of the workpiece to be processed placed on the stand to prevent it from moving toward the upper feed chute 202. When the rail sensor 204 detects that the workpiece to be processed has been successfully transferred to the loading chute 202, it will notify the main control system to stop the sliding hook I 203 from moving forward. The workpiece to be processed transferred to the loading chute 202 will slowly slide to the central position of the power roller 10 under the action of gravity. At the end position of the loading chute 202, a short-distance hydraulic cylinder I 205 is provided. After the workpiece to be processed stops sliding, the hydraulic cylinder I 205 will retract downward and remain in a retracted state throughout the subsequent processing process. At this time, the overall height of the lower half of the loading chute 202 is lower than the power roller 10, and will not interfere with the workpiece to be processed on the power roller 10.

[0095] It should be noted that the workpieces to be processed need to be hoisted to the loading and stacking rack 201 in sequence through the overhead crane. The area follows the first-in-first-out rule, and the track that needs to be processed first should be placed close to the raceway. When placing, the workpieces should be kept parallel as much as possible. There is no need to deliberately keep intervals between the workpieces, but the workpieces should not be stacked. After the placement is stable, the operator needs to label some of the workpieces to be processed that must be marked with bending points (as shown in Figure 2(b)).

[0096] When a new loading operation is required, the operator starts the loading process through the controller, and the device automatically moves the sliding hook I 203 inward. The design height of the loading stacking rack 201 is slightly higher than the area of ​​the power roller 10, so during the movement, a workpiece to be processed close to the power roller 10 will fall onto the power roller 10 first. A laser detection sensor is installed on the power roller 10. When the laser detection sensor detects that the workpiece is rolling down, the system will automatically stop the operation of the sliding hook I 203 to prevent subsequent parts from falling. Under the action of gravity, the workpiece to be processed slides to the specified position and separates from the loading slide 202, and the operator can axially transfer the workpiece to be processed through the power roller 10. The loading process can also be manually controlled by the operator.

[0097] (As shown in Figure 6) The material unloading system 3 has a material unloading chute 301 inclined downward, and a material unloading pile area 302 is provided at the end of the material unloading chute 301, and the material unloading pile area 302 is provided with an offline detection system 9; the top starting end of the material unloading chute 301 is connected with the press 1 and a material unloading transfer area 303 is provided, and the material unloading transfer area 303 is supported and lifted by a hydraulic cylinder II 304; a sliding hook II 305 is provided at the connection between the material unloading transfer area 303 and the material unloading chute 301; the sliding hook II 305 is used to hook the rail limb to move the workpiece to the left or right, and the workpiece that passes the inspection can be directly transferred by the material unloading system 3 and sent directly to the material unloading pile area 302. In the process, the hydraulic cylinder II 304 is tightened, and the platform is lower than the power roller 10, which does not affect the processing process. When offline inspection or handling of workpieces is required, hydraulic cylinder II 304 is extended, the platform rises to the specified position and remains horizontal, and a limit structure is added to ensure repeated positioning accuracy to 0.2-0.5mm.

[0098] It should be noted that the unloading system 3 also assumes the function of offline detection. After the processing is completed, the workpiece is completely moved from the power roller 10 to the unloading transfer area 303, and is first completely scanned by the offline detection system 9, and the inspection results are issued in a short time. After the offline detection is completed, the laser scanning head of the offline detection system 9 returns to the initial position, and the hydraulic platform 401 of the lifting device 4 descends to place the workpiece back on the power roller 10. The hydraulic platform 401 is designed with a slotted structure, and a sliding hook II 305 is arranged in the slot. Before unloading, the sliding hook II 305 is parked on the side away from the unloading chute 301. After the hydraulic platform 401 is lowered into place, the height of the sliding hook II 305 is just higher than the rail limb placed on the power roller 10. When unloading is required, the sliding hook II 305 moves toward one side of the unloading chute 301, buckles the rail limb in the middle position, and pushes it to the edge of the hydraulic platform 401 to enter the unloading chute 301. After entering the unloading chute 301, the workpiece slides down to the unloading and stacking area 302 for storage under its own gravity.

[0099] In the above embodiments, as a preferred embodiment of the present invention: (as Figure 7 shown) the lifting device 4 is composed of a plurality of hydraulic platforms 401 distributed between the power raceways 10; the hydraulic platforms 401 are provided with hydraulic power by a hydraulic pump station, and the hydraulic rods of multiple groups of hydraulic platforms 401 are lifted and lowered synchronously; the lifting error of the hydraulic rods is less than 0.5 mm. Further: the lifting device 4 meets the use requirement of repeat positioning accuracy of ±0.2 mm, and the distance between the power raceways 10 is 1.5 meters. Only when the lifting device 4 performs a lifting operation can it be ensured that when being measured, the bottom surface of the workpiece is at the same height, avoiding the influence of the track bending caused by gravity factors on the final measurement result.

[0100] In the above embodiments, as a further improved embodiment of the present invention: (as shown in Figure 8) the intelligent top head 5 includes a hydraulic top head 501, and the hydraulic top head 501 is integrated with the execution end of the hydraulic cylinder of the press 1; a rectangular groove 502 and a positioning groove 503 are provided at the bottom end of the hydraulic top head 501; a laser sensor I 504 is installed in the rectangular groove 502; the positioning groove 503 includes a horizontal guide rail 5031 and a vertical guide rail 5032; the horizontal guide rail 5031 and the vertical guide rail 5032 are used to realize the horizontal and vertical movement of the laser sensor I 504; a T-shaped top head 505 is further installed on the horizontal guide rail, the T-shaped top head 505 is fixed to the hydraulic top head 501 by a pin, and a pressure sensor 506 is installed at the front end of the T-shaped top head 505. The pressure sensor 506 is used for the trigger signal of the in-process displacement counting, and the pressure sensor 506 is also used for accurately controlling the loading torque of the press 1.

[0101] Among them, the intelligent top head 5 is the part in direct contact between the press 1 and the workpiece. A pressure sensor 506 is arranged inside the intelligent top head 5. When processing the track, in cooperation with the main control system, the loading torque can be more accurately controlled and overload can be prevented. The laser sensor I 504 is the core sensor of the online scanning system, installed inside the rectangular groove 502, and can scan the half contour of the track from the side driven by the horizontal guide rail 5031 and the vertical guide rail 5032. For different workpieces, the basis for adjusting the fulcrum distance is the bending moment change gradient during part straightening and the initial bending of the part. The deformation gradients should be as consistent as possible to achieve a better straightening effect. The intelligent top bending head can, under the control of the host computer, calculate and prompt the optimal control top bending loading point in the axial direction, and actively assist the worker to operate to achieve the best top bending effect.

[0102] In order to simplify the research process, the following basic assumptions are adopted for pressure straightening:

[0103] (1) Continuity: It is assumed that the deforming body is composed of continuous media, and physical quantities such as stress, strain, and displacement are continuously changing.

[0104] (2) Homogeneity: Assume that the microstructure and chemical composition of each particle in the deformed body are uniform and identical, and the physical properties of each part are the same.

[0105] (3) Isotropy: Assume that the physical and mechanical properties of each particle in the deformed body are the same in all directions.

[0106] (4) The initial stress is zero. The object is in a natural equilibrium state before being subjected to a force, that is, the stress generated inside the object during deformation is caused by the external force.

[0107] (5) The body force is zero. Body forces such as gravity, magnetic force, and inertial force are extremely small compared to the surface force and can be ignored.

[0108] (6) Volume invariance. Assume that the volume of the object remains unchanged before and after plastic deformation.

[0109] Based on this assumption, through the finite element analysis method, the mechanical model analysis of the straightening of the rail in the transverse and vertical directions can be carried out, and the elastic-plastic region distribution, straightening stress, residual stress, straightening deflection of the switch rail, and residual geometric shape can be calculated, and the theoretical model can be verified through experiments.

[0110] Through theoretical research, it is found that during the straightening process, the loading position of the bending moment has a very significant impact on the top bending result. The combination of the straightening pressure point and the fulcrum of the switch rail is related to the initial bending shape of the switch rail. The problem of the combination of the pressure point and the fulcrum is actually the problem of formulating the straightening process plan, and it is also the key problem to solve whether the part can be effectively straightened. For the straightening of a single-radial bend, the pressure point should be selected as close as possible to the point with the largest initial bending deformation, and the fulcrums should be symmetrically distributed on both sides of the pressure point as much as possible. For a determined initial bending deformation value, the straightening bending moment must also be a fixed value. Therefore, the larger the distance between the fulcrums, the smaller the straightening force. The bending moment change gradient value is equal to the fulcrum reaction force value. For a part with a known section modulus of resistance to bending, if the distance between the fulcrums is increased, the bending moment change gradient is correspondingly reduced. On the contrary, if the distance between the fulcrums is shortened, it is equivalent to increasing the bending moment change gradient value. Therefore, for a given initial bending deformation of the part, its initial bending deformation gradient is a fixed value. Adjusting the distance between the fulcrums can always make the bending moment change gradient approximately equal to the initial bending deformation gradient. For different workpieces, there are various possibilities for their initial cambers. The basis for adjusting the distance between the fulcrums is the bending moment change gradient during the straightening of the part and the initial bending of the part. The deformation gradients should be as consistent as possible to achieve a better straightening effect. The intelligent top head 5 can, under the control of the main machine, calculate and prompt the optimal control top bending loading point in the axial direction, and actively assist the worker in operation to achieve the best top bending effect. For workpieces with a larger bending degree, it is necessary to reduce the magnitude of the plastic deformation formed by each loading. The workpiece can reach the final target shape through multiple loadings according to the setting. In addition, the intelligent top head 5 is also designed with a pressure sensor 506, which can, when processing the track, cooperate with the main control system to more accurately control the loading torque and prevent overload. The laser sensor I 504 is the core sensor for on-line scanning, installed inside the intelligent top head 5 and driven by the horizontal guide rail 5031, and can scan the half contour of the track from the side.

[0111] In the above embodiment, as a preferred embodiment of the present invention: (as shown in FIG. 9) the rail flipper 6 is composed of multiple groups of flippers evenly arranged along the rail direction; each group of flippers is composed of a pair of motors and speed reducers 601, driving gears 602, and driven gears 603; the driven gear 603 is a semi-circular ring tooth piece structure and its movement range is limited by a limiter; the pair of motors and speed reducers 601 respectively drive the pair of driving gears 602 to rotate, the pair of driving gears 602 respectively mesh with the driven gear 603 and drive their respective driven gears 603 to rotate, and the rotating driven gears 603 clamp the rail member and drive the rail member to flip. The end of the driven gear 603 in contact with the rail member is provided with a ball and a shock-absorbing spring 604, (such as Figure 19The ball and the shock-absorbing spring 604 as shown are used to reduce the friction and impact between the track and the tilter during the flipping and leveling processes. To ensure the effective flipping of longer rail components, the track tilter 6 will be arranged in multiple consecutive groups to ensure that there is no problem of lateral slip when the rail component is overturned or righted. The setting of the track tilter 6 is beneficial to improving the automation degree and usage efficiency of the equipment, reducing the labor intensity of the operator, and reducing the possibility of mistakes and accidents.

[0112] In the above embodiments, as a preferred embodiment of the present invention: (as Figure 10 shown) The track auxiliary observation device 7 has a camera 701; the camera 701 is installed at the execution end of the horizontal moving rod 702; the horizontal moving rod 702 is installed at the execution end of the lifting rod 703; the shooting direction of the camera 701 is the same as the visual direction of the operator; the horizontal moving rod 702 and the lifting rod 703 are respectively driven by motors, and the linear displacement of the camera 701 is realized through transmission mechanisms such as a lead screw-nut screw pair; the image of the camera 701 is output through a liquid crystal screen. The bracket of the track auxiliary observation device 7 is designed to be floating, with adjustable viewing angle and focus. The image collected by the camera 701 is directly output on the liquid crystal screen on the console, with auxiliary alignment lines set, which can display the bending state of the current workpiece in real time and effectively reduce the operation risk.

[0113] In the above embodiments, as a preferred embodiment of the present invention: (as Figure 11 shown) The online detection mode of the online detection system 8 corresponds the detection steps to the rhythm of each step of top adjustment. The online detection and each top adjustment process are decomposed into the actions of each unit, and the whole rail component is divided into several online detection units, where each 1000 - 1200 mm is a detection unit, and the overlapping area of each top adjustment or online detection action is 300 - 500 mm, which is used to ensure that the influence of the next top adjustment action on the completed area can be controlled; the online detection sensor of the online detection system 8 is driven by a motor to scan the contour data of a certain height on the side of the rail component within a short time and transmit it to the software for fitting; during a single processing process of the rail component by the online detection system 8, before and after the rail component is loaded with torque, the bending condition of the rail component within the single processing range is quickly scanned, and the relative position of the intelligent top head 5 and the rail component remains unchanged during the quick scan.

[0114] It should be noted that for the processing of the curved switch rail, the main processing process is divided into two sections. At the position near the tip, the main processing purpose is to straighten the rail; at the position near the root end, the main processing purpose is to bend the rail to form a certain curvature. Before starting the processing, the worker uses a special tape measure to measure the demarcation point of the two processes and affixes a special disposable label (as shown in Fig. 2(b)). During the processing, the machine vision system of the on-line detection system 8 on the processing platform can automatically identify the label, so as to adjust the current processing state and data model.

[0115] In the above embodiment, as a preferred embodiment of the present invention: (as Figure 12 shown) the off-line detection system 9 is composed of 3 to 5 groups of scanning mechanisms; each group of scanning mechanisms is composed of an X-axis guide rail 901, a Z-axis guide rail 902 and a laser scanning head I 903; the X-axis guide rail 901 realizes the movement of the laser scanning head I 903 in the horizontal direction, and the Z-axis guide rail 902 realizes the movement of the laser scanning head I 903 in the vertical direction to adapt to the off-line detection of various workpieces of this model. After the top bending processing of the rail part is completed, the overall shape is detected along the whole length. The overall shape is detected along the whole length by using a segmented fast point scanning method, and the length change range of the workpiece is 0 - 25m.

[0116] (As shown in Fig. 13) The laser scanning head I 903 has two laser measurement points 9031 aligned up and down, which can meet the detection that the tip height is lower than the gauge baseline. Among them, the upper laser measurement point is used for the side curve detection of the track, and the lower laser measurement point is used for the overall distribution detection of the track.

[0117] In the above embodiment, as a further improved embodiment of the present invention: the off-line detection system 9 further includes a group of laser scanning heads II respectively arranged on both sides of the processing platform. The two groups of laser scanning heads II scan the same workpiece from both sides respectively; on one side of the working edge, it is scanned only once to complete the drawing of the side arc of the rail part; on the non-working edge side, it is scanned twice in the processing section to complete the measurement of at least two height points of the tip of the rail part, so as to complete the slope calculation of the hypotenuse of the rail part and judge the tightness of the rail part.

[0118] Regarding the offline detection system 9: For a curved switch rail, according to the drawing requirements, the working surface profile is detected at a certain height, which should be several continuous arcs. During the detection process, the laser scans the curve shape at a specified height on the working surface and fits and compares it with the ideal curve in the database. Before the detection starts, the processed workpiece is completely conveyed to the detection area by the power roller conveyor. According to the length and placement method of the workpiece, the system will call the lifting platform to gently lift the workpiece from the power roller conveyor 10. At the position near the root end, the lifting height of the platform will be reduced to make the workpiece in a completely horizontal state. When it is confirmed that the lifting of the workpiece is completed, the laser scanning head I 903 will advance from the processing area to the root end at a pre-given height and complete the scanning of the side curve of the track during the movement. Subsequently, the side curve of the entire track is transmitted to the system for restoration. The curve takes the intermediate joint position as a fixed point, is compared with the ideal curve, and all parts with excessive errors are displayed in the graphical interface. On the non-working surface side, after scanning back and forth twice to form the angle data of the top inclined plane, the theoretical judgment of the close-fitting condition can be carried out.

[0119] It should be noted that: Online detection refers to detecting the local parameter indicators and states of the workpiece during and after processing by adding external detection equipment, so as to provide data feedback for subsequent processing and the establishment and optimization of the theoretical model. This is a fast, online processing effect detection, providing reference for the single bending operation of workers. Offline detection refers to collecting the complete detection results of the processed workpiece with high precision and automation after the overall processing is completed. The data is used for the certification and assessment of the processing results and the optimization of the data model. The data detection is based on an image system using laser as a signal, and can adapt to workpieces with different heights and placement methods. The measurement process is basically automated and not affected by the operator factors, and the accuracy of the results it can provide is much higher than that of the existing manual measurement.

[0120] The working principle of the present invention is as Figure 1 shown, which are the parameters of the workpiece to be detected. The system detection items (precision implements relevant standards such as TB3307 and TB412) are as follows:

[0121] (1) Offline detection: The total length L of the workpiece, with a value range of 0 - 25 m and an accuracy of ±1 mm;

[0122] (2) Offline detection: At a specific position of the workpiece, the length D from the end position on the theoretical center line, with an accuracy of ±1 mm;

[0123] (3) Offline detection: The lateral bending degree of the workpiece. It is expressed by the offset x, with a value range of 0 - 1200 mm and an accuracy of ±0.2 mm.

[0124] (4) Offline inspection: The bevel angle at the tip of the non-working surface of the workpiece. It is judged by two-point measurement, and the value range is: 1 / 4, 1 / 3, 1 / 5.06, 1 / 8, 1 / 4.47, etc., and the tolerance is: ±1 / 80;

[0125] (5) Online inspection: The total length L of the processing area, with a range of 0 - 8000 (23815, No. 42) mm, and the positioning accuracy is ±1 mm;

[0126] (6) Online inspection: The longitudinal or transverse bending degree within the specified range of the workpiece. It is expressed by the offset x, with a value range of ±100 mm and an accuracy of ±0.5 mm.

[0127] (7) Online inspection: The maximum bottom surface twist degree within the specified area. The range is from -30° to +30°, and the accuracy is 0.1°.

[0128] (8) Equivalent concepts: Straightness (rail top, rail bottom, straight edge), skew angle, flatness, etc.; The results can be judged by post-processing and analyzing the original data.

[0129] An automatic top - adjustment method for turnout rails provided by the present invention includes any of the above - mentioned automatic top - adjustment devices for turnout rails, and comprises the following steps:

[0130] Before processing: The rail part is pulled into the top - adjustment processing station of the press 1 through the feeding system 2.

[0131] During processing: The lifting device 4 works to lift the rail part so that the rail part is in a plane; The rail part information is identified or input through machine vision or manual input, and the rail part process information pre - stored in the enterprise information system is associated and obtained; The appropriate intelligent top - head 5 execution parameters are matched through digital simulation, and the relative displacement of the top - adjustment operation of the intelligent top - head 5 adopts closed - loop control, and the start - stop signal of the intelligent top - head 5 is obtained by cooperating with the pressure sensor 506 on the intelligent top - head 5; The top - adjustment operation of the intelligent top - head 5 adopts a segmented processing method, and the processing strategy is given through a fuzzy algorithm, and the top - adjustment linear structure of the rail part is fed back through the online detection system 8 for target judgment and strategy compensation of the top - adjustment operation; Among them, the rail flipper 6 is used for the station adjustment of the rail part in an artificial control manner to realize the forward or lateral top - adjustment processing of the rail part; The rail auxiliary observation device 7 is used for artificial safety observation of the processing state of the rail part.

[0132] After processing: The rail part is lowered into the blanking stacking area 302 through the blanking system 3; And the offline detection system 9 judges the qualification of the linear type of the whole length range of the rail part, forms a data post - processing report through the data processing module for guiding processing, and is associated with the enterprise information system through wireless transmission to obtain basic standard information and store the final analysis data.

[0133] In the above embodiments, as a preferred embodiment of the present invention, an automatic top - adjustment method for turnout rails provided by the present invention includes the following steps (as shown in Figure 2):

[0134] After the "raw material" is processed in the previous step, it is transported by the overhead crane to the stacking area of the "loading system"; for the raw materials that need to mark the bending points, in the stacking area, workers use a ruler to measure and label them with sticker labels as shown in Figure 2(b) for the identification of the machine bending points.

[0135] At the start of processing, the "loading system" pushes the workpieces to be processed in the stacking area one by one onto the "processing power roller track"; after being transported by the "processing power roller track", the tip of the workpiece to be processed reaches near the top - bending head; according to the process requirements, it can be selected whether to use the "track flipper" to flip the workpiece to be processed by 90° for processing.

[0136] Before each processing starts, "pre - processing scanning" needs to be carried out for pre - processing measurement and scanning, which is used to obtain the natural bending state of the track before processing, and the result is sent to the computer for comparison with the processing target curve, and the recommended processing data is output. Among them, the process of pressure straightening mainly determines the fulcrum distance of straightening, the bending amount (loading amount), and the pressure head speed (straightening power). The determination of the bending amount is related to the initial curvature of the switch rail and the straightening part. After the pressure point and the fulcrum are determined, the determination of the bending amount is the key step of straightening. Processing with an accurate bending amount can achieve the processing target after the unloading support distance and elastic recovery.

[0137] After the worker selects the processing data, the top - bending head automatically completes the "top - bending processing".

[0138] After removing the torque, "result scanning" is immediately carried out; according to the scanning result, it can be determined whether the current top - bending effect meets the expectation; if it is qualified, the next part that needs to be top - bent is continuously transported through the "power roller track" into the processing area, and the processes of "pre - processing scanning", "top - bending processing", and "result scanning" are repeated; if it is unqualified, the system records the process of this error generation and "records data", and sends a manual operation request to the operator; after the system receives the request, the operator can perform secondary processing manually; after the processing is completed and it is confirmed that the result meets the expectation and is qualified, the system will record the parameters of this secondary processing and correct the algorithm according to the weight.

[0139] After the top bending process for the entire length is completed, the workpiece will be moved onto the "lifting device" of the off-line scanning system; here, the workpiece will be lifted upward by a certain distance, completely separated from the support of the "power roller track" and maintained in a horizontal state. After the "off-line scanning" finishes data scanning, the system will compare the scanning results with the pre-stored results in the database. Those that pass the comparison will be automatically transferred to the "blanking system"; those that fail the comparison will display the location of the defect, return the workpiece to the "processing power roller track", and prompt the on-site workers for further processing.

[0140] It should be noted that: the higher the maturity of the device of the present invention, the more likely it is to achieve the final processing effect after the first processing, greatly improving work efficiency. Using the material theory model for derivation can provide certain prediction of processing parameters from the perspective of materials science. However, since its model is calculated using a definite function, it is theoretically difficult to perform reverse correction for the errors that occur in the actual processing process.

[0141] The present invention trains multiple groups of neural networks, uses the data generated in actual processing, and continuously corrects the network to achieve a better processing parameter prediction effect. The output quantities required by the neural network of the present invention are: bending amount (loading amount), loading support distance. The network input quantities are: the cross-sectional state of the switch rail, initial curvature, processing range, processing target parameters. (As Figure 18 shown) For the same processing amount, as the loading support distance increases, the straightening force decreases non-linearly. Because the bending modulus of the cutting section of the switch rail is small, the total straightening force is also small, and the safe utilization space of the equipment is large. Different rail materials have different parameters, so the rail type also needs to be input to select the corresponding neural network.

[0142] Common network types include BP (Back Propagation), RBF (Radial Basis Function), FNN (Fuzzy Neural Network), etc. When one or more adjustable parameters (weights or thresholds) of the network have an impact on any output, such a network is called a global approximation network. Since for each input, every weight on the network needs to be adjusted, the learning speed of the global approximation network is very slow, such as the BP network. If only a few connection weights in a certain local area of the input space affect the output, then the network is called a local approximation network, such as the RBF network.

[0143] After testing, the RBF network can approximate any non-linear function, can handle the difficult-to-analyze regularities within the system, has good generalization ability, and has a very fast learning convergence speed. It has been successfully applied to non-linear function approximation, time series analysis, data classification, pattern recognition, information processing, image processing, system modeling, control, and fault diagnosis, etc.

[0144] The radial basis function (RBF) method for multivariate interpolation was proposed by Powell in 1985. A radial basis function is a real-valued function whose value depends only on the distance from the origin, that is, Φ(x) = Φ(‖x‖), or it can also be the distance to an arbitrary point c, where point c is called the center point, that is, Φ(x, c) = Φ(‖x - c‖).

[0145] Any function Φ that satisfies the property Φ(x) = Φ(‖x‖) is called a radial basis function. The standard one generally uses the Euclidean distance (also called the Euclidean radial basis function), although other distance functions are also possible. The most commonly used radial basis function is the Gaussian kernel function, in the form of k(||x - xc||) = exp{-||x - xc||^2 / (2*σ)^2)}, where x_c is the center of the kernel function and σ is the width parameter of the function, which controls the radial range of the function.

[0146] RBF usually has only three layers, namely the input layer, the middle layer, and the output layer. Among them, the middle layer mainly calculates the value of the Radial Basis Function (RBF) of the Euclidean distance between the input x and the sample vector c (memory sample), and the output layer makes a linear combination of it.

[0147] The training of the RBF neural network can be divided into two stages:

[0148] The first stage is unsupervised learning, which selects memory samples / center points from the sample data; clustering can be used, or a randomly given method can also be chosen.

[0149] The second stage is supervised learning, which mainly calculates the relationship / weights between the samples after RBF transformation and the output, and can be calculated using the BP algorithm or simple mathematical formulas.

[0150] Generally speaking, the learning ability of the neural network can be improved by increasing the number of neurons and network layers, so that the obtained model can better conform to the data distribution scenario; however, in actual application scenarios, the number of layers of the neural network is generally not too large, because too deep layers may cause some problems in solving.

[0151] In the present invention, the selected RBF network. In the process of network training, in addition to the preliminary experimental data, a large amount of random data needs to be accumulated during the use of the device, including data of "processed in one step" or "reached the target after multiple processes", all of which can have a training effect on the neural network.

[0152] In the above embodiments, as a preferred embodiment of the present invention: The specific measurement process of on-line detection is as follows:

[0153] Step 1. Trigger scanning: Before performing the machining operation, ensure that the information of the workpiece and the current process step have been correctly input.

[0154] Step 2. Automatically adjust the position of the scanning head and complete scanning: The starting position, measuring height, and measuring speed of the scanning head are automatically adjusted according to the type and parameters of the current workpiece; after the adjustment is in place, the scanning head performs a scanning motion in the horizontal direction at the fastest speed.

[0155] Step 3. Automatically generate the original bending data of the workpiece and put forward targeted processing suggestions: For the data points obtained by scanning in Step 2, a complete image is formed through software splicing; on the operation interface, the bending degree and bending direction of the current workpiece, as well as processing suggestions, are displayed graphically.

[0156] Step 4. Complete the straightening operation according to the processing suggestions: Complete the straightening operation according to the processing suggestions in Step 3, and the online detection function can be triggered again to repeat the processes of Step 2 and Step 3, and compare the spliced image with the standard image at the current position to display the remaining error.

[0157] When performing a bottom surface scan on the heel end profiling section, the specific measurement process of the online detection is as follows:

[0158] Step 501. The staff first flips the track to ensure that the bottom surface of the track faces the direction of the scanning head.

[0159] Step 502. Completely park the heel end profiling section of the flipped track within the online scanning range and start the corresponding function on the operation panel.

[0160] Step 503. The system automatically scans the bottom surface contour of the heel end profiling section of the track within the entire scanning range and measures the bottom surface inclination of the heel end profiling section of the track.

[0161] It can be found from the above description that: (in combination with Figure 14 ) The automatic top adjustment device and method of the present invention are applicable to the top adjustment of rail components such as the stock rail, switch rail, and crossing rail of turnouts, and realize the automatic top adjustment operation by using machine vision such as laser detection technology and visual image detection technology and various automated industrial integration technologies, combine the online and offline detection of rail components, and associate the detection results with product data to realize data transmission and storage, and realize the whole process and full life cycle traceability of product top adjustment, making the top adjustment operation of the product more accurate, labor-saving, efficient, and convenient.

[0162] The present invention uses a pressure sensor as the starting signal and adopts a closed-loop control method for top adjustment, solving the problem of precision machining of rail components such as stock rails, switch rails, and crossing rails with different rail types, different variable cross-sections, and different materials.

[0163] The present invention adopts a segmented processing method and, through the cooperation of on-line detection and off-line detection, effectively meets the requirements of high-efficiency production of products. Moreover, the overall complexity of the equipment is small and the floor area requirement is low.

[0164] For the top adjustment operation of the present invention, a fuzzy algorithm is adopted. Through the operation of highly skilled personnel to train the system, the empirical coefficients of manual or machine top bending are recorded, and the establishment of the top adjustment data knowledge base is improved, so as to enhance the intelligent and precise level of top adjustment.

[0165] The settings of the rail flipper and the rail auxiliary observation device of the present invention solve the problems of high labor intensity and insufficient safety in manually flipping the rail and closely observing the working conditions.

[0166] The present invention is divided into two parts: on-line detection and off-line overall detection, which realizes the automatic detection of the geometric parameters of the rail line type. Specifically, a non-contact detection scheme is adopted, and the measurement using a laser and a vision system is used to replace the manual measurement method using tools such as a tape measure, a suspension line, a straightedge, and a bending template for top adjustment detection, so as to improve the detection accuracy and reduce the labor intensity.

[0167] It should be understood that although this specification is described according to an embodiment, this embodiment does not only include an independent technical solution. This narrative way of the specification is only for clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in this embodiment can also be appropriately arranged and combined to form other embodiments that can be understood by those skilled in the art.

[0168] The above-mentioned preferred embodiment is not used to limit the scope of implementation of the present invention. Therefore, all equivalent changes made to the content described in the claims of the present invention should be included within the scope of the claims of the present invention. It should be noted that the components and materials used in the above-mentioned embodiment are commercially available unless otherwise specified.

Claims

1. An automatic turnout rail jacking and adjusting device, characterized in that: It includes a loading system (2) on one side of a press (1) and an unloading system (3) on the other side of the press (1); it also includes a lifting device (4) and an intelligent punch head (5) at the execution end of the press (1); the press (1) is assisted with an orbital flipper (6) and an orbital auxiliary observation device (7); it also includes an on-line detection system (8) and an off-line detection system (9); it also includes a data transmission and storage module and a data processing module. The data transmission and storage module is used for the transmission and storage of data after detection, and the transmission and storage of data after being processed by the data processing module; the data transmission and storage module realizes the interaction and association of turnout rail product information based on the enterprise information system; the data processing module is used for the processing of data after detection, the generation of on-site processing process guidance information, and the generation of the final detection report.

2. The turnout rail automatic top adjustment device according to claim 1, characterized in that: The enterprise information system is an EPR system.

3. The turnout rail automatic top adjustment device according to claim 1, characterized in that: The data transmission and storage module is connected to an independent storage server by means of wireless transmission; the data processing module is installed with mobile terminals and non-mobile terminals as carriers; the mobile terminals are tablet computers or mobile phones; the non-mobile terminals are PC computers or dedicated storage servers.

4. The turnout rail automatic top adjustment device according to claim 1, characterized in that: The on-line detection device (8) and the off-line detection device (9) are one or any combination of two or more of a laser sensor, an image vision camera, a lidar, and a grating scale.

5. The turnout rail automatic top adjustment device according to claim 1, characterized in that: The loading system (2) has an upwardly inclined loading stock rack (201) and a downwardly inclined loading chute (202); the loading stock rack (201) is used for storing rail members to be processed, and the loading stock rack (201) is provided with a sliding hook I (203) for pushing the material upward; at the turning transition position between the loading stock rack (201) and the loading chute (202), a rail sensor (204) is provided, and the rail sensor (204) is used to trigger the sliding hook I (203) to stop pushing the material; a hydraulic cylinder I (205) is arranged at the lowest point of the loading chute (202); the loading chute (202) is used for transporting the rail members to a power roller path (10) connected to the press (1). The unloading system (3) has a downwardly inclined unloading chute (301), and an unloading stock area (302) is arranged at the end of the unloading chute (301), and the off-line detection system (9) is arranged in the unloading stock area (302); at the starting end of the top of the unloading chute (301), an unloading transfer area (303) is connected to the press (1), and the unloading transfer area (303) is supported and lifted by a hydraulic cylinder II (304); a sliding hook II (305) is arranged at the connection between the unloading transfer area (303) and the unloading chute (301); the sliding hook II (305) is used for hooking the rail limb to move the workpiece.

6. The automatic top adjustment device for turnout rails according to claim 1, characterized in that: The lifting device (4) is composed of a plurality of hydraulic platforms (401) distributed between the power roller paths (10); the hydraulic platforms (401) are provided with hydraulic power by a hydraulic pump station, and the hydraulic rods of multiple groups of hydraulic platforms (401) are lifted and lowered synchronously; the lifting error of the hydraulic rods is less than 0.5 mm.

7. The turnout rail automatic top adjustment device according to claim 1, characterized in that: The intelligent punch head (5) includes a hydraulic punch head (501), and the hydraulic punch head (501) is integrated with the execution end of the hydraulic cylinder of the press (1); a rectangular groove (502) and a positioning groove (503) are provided at the bottom end of the hydraulic punch head (501); a laser sensor I (504) is installed in the rectangular groove (502); the positioning groove (503) includes a horizontal guide rail (5031) and a vertical guide rail (5032); the horizontal guide rail (5031) and the vertical guide rail (5032) are used to realize the horizontal and vertical movement of the laser sensor I (504); a T-shaped punch head (505) is further installed on the horizontal guide rail, the T-shaped punch head (505) is fixed to the hydraulic punch head (501) by a pin, a pressure sensor (506) is installed at the front end of the T-shaped punch head (505), the pressure sensor (506) is used for the trigger signal of the working feed displacement counting, and the pressure sensor (506) is also used for accurately controlling the loading torque of the press (1).

8. The turnout rail automatic top adjustment device according to claim 1, characterized in that: The rail flipper (6) is composed of multiple groups of flippers evenly arranged along the rail direction; each group of flippers is composed of a pair of motors and speed reducers (601), a driving gear (602), and a driven gear (603); the driven gear (603) is a semi-circular tooth piece structure and its movement range is restricted by a limiter; the pair of motors and speed reducers (601) respectively drive the pair of driving gears (602) to rotate, the pair of driving gears (602) respectively mesh with the driven gear (603) and drive their respective driven gears (603) to rotate, and the rotating driven gears (603) clamp the rail piece and drive the rail piece to flip, and a ball and a shock-absorbing spring (604) are provided at the end of the driven gear (603) in contact with the rail piece.

9. The turnout rail automatic top adjustment device according to claim 1, wherein: The rail auxiliary observation device (7) has a camera (701); the camera (701) is installed at the execution end of the horizontal moving rod (702); the horizontal moving rod (702) is installed at the execution end of the lifting rod (703); the shooting direction of the camera (701) is the same as the visual direction of the operator; the horizontal moving rod (702) and the lifting rod (703) are respectively driven to displace by motors; the image of the camera (701) is output through a liquid crystal screen.

10. The turnout rail automatic top adjustment device according to claim 1, characterized in that: The online detection mode of the online detection system (8) corresponds the detection steps to the rhythm of each step of top adjustment. The online detection and each top adjustment process are decomposed into the actions of each unit, and the whole rail component is divided into several online detection units, where each 1000 - 1200 mm is a detection unit, and the overlapping area of each top adjustment or online detection action is 300 - 500 mm, which is used to ensure that the influence of the next top adjustment action on the completed area is controlled; the online detection sensor of the online detection system (8) is driven by a motor, scans the contour data of a certain height on the side of the rail component within a short time and transmits it to the software for fitting; during the single processing process of the rail component by the online detection system (8), before and after the rail component is loaded with torque, the bending condition of the rail component within the single processing range is quickly scanned, and the relative position of the intelligent top head (5) and the rail component remains unchanged during the quick scan.

11. The turnout rail automatic top adjustment device according to claim 1, characterized in that: The offline detection system (9) consists of 3 - 5 groups of scanning mechanisms; each group of scanning mechanisms consists of an X-axis guide rail (901), a Z-axis guide rail (902) and a laser scanning head I (903); the X-axis guide rail (901) realizes the movement of the laser scanning head I (903) in the horizontal direction, and the Z-axis guide rail (902) realizes the movement of the laser scanning head I (903) in the vertical direction; the laser scanning head I (903) has two laser measurement points (9031) aligned vertically. The upper laser measurement point is used for the detection of the side curve of the track, and the lower laser measurement point is used for the detection of the overall distribution of the track.

12. The turnout rail automatic top adjustment device according to claim 1 or 11, characterized in that: The offline detection system (9) also includes a group of laser scanning heads II respectively arranged on both sides of the processing platform. The two groups of laser scanning heads II scan the same workpiece from both sides; on one side of the working edge, it is scanned only once to complete the drawing of the side arc of the rail component; on the non-working edge side of the processing section, it is scanned twice to complete the measurement of at least two height points at the tip of the rail component, thereby completing the calculation of the slope of the hypotenuse of the rail component to judge the close-fitting condition of the rail component.

13. An automatic top - adjustment method for turnout rails, including the automatic top - adjustment device for turnout rails as described in any one of claims 1 - 12, characterized in that, It includes the following steps: Before processing: The rail component is pulled into the top adjustment processing station of the press (1) through the feeding system (2). During processing: The lifting device (4) works to lift the rail component so that the rail component is in a plane; the rail component information is identified or input through machine vision or manual input, and the rail component process information pre-stored in the enterprise information system is associated and obtained; the appropriate intelligent top head (5) execution parameters are matched through digital simulation, and the relative displacement of the intelligent top head (5) during the top adjustment operation adopts closed-loop control, and the start-stop signal of the intelligent top head (5) is obtained in cooperation with the pressure sensor (506) on the intelligent top head (5); the top adjustment operation of the intelligent top head (5) adopts a segmented processing method, a processing strategy is given through a fuzzy algorithm, and the top adjustment linear structure of the rail component is fed back by the online detection system (8) for target judgment and strategy compensation of the top adjustment operation; among them, the track flipper (6) is manually controlled to adjust the working position of the rail component, so as to realize the forward or lateral top adjustment processing of the rail component; the track auxiliary observation device (7) is used for manual safety observation of the processing state of the rail component. After processing: The rail parts are fed into the blanking stockpiling area (302) through the blanking system (3); and the off-line inspection system (9) judges the qualification of the linear shape of the whole length of the rail parts. After forming data through the data processing module, a post-processing report is generated to guide processing, and it is associated with the enterprise information system through wireless transmission to obtain basic standard information and store the final analysis data.

14. The automatic top adjustment method for turnout rails according to claim 13, wherein It includes the following steps: After the "raw materials" are processed in the previous step, they are transported to the stockpiling area of the "loading system" by the overhead crane; for the raw materials that need to mark the bending points, in the stockpiling area, the workers use a ruler to measure and label them with sticker labels for the identification of the machine bending points. When starting the processing, the "loading system" pushes the workpieces to be processed in the stockpiling area one by one onto the "processing power roller track"; after being transported by the "processing power roller track", the tip of the workpiece to be processed reaches near the top elbow; according to the process requirements, it can be selected whether to use the "track flipper" to flip the workpiece to be processed by 90° for processing. Before each processing starts, "pre-processing scanning" needs to be carried out for the pre-processing measurement and scanning, which is used to obtain the natural bending state of the track before processing, and the result is sent to the computer to be compared with the processing target curve, and the recommended processing data is output. After the worker selects the processing data, the top elbow automatically completes the "top bending processing". After removing the torque, "result scanning" is immediately carried out; according to the scanning result, it can be judged whether the current top bending effect meets the expectation; if it is qualified, the next part that needs to be top bent is continuously transported into the processing area through the "power roller track", and the processes of "pre-processing scanning", "top bending processing", and "result scanning" are repeated; if it is unqualified, the system records the process of this error generation and "records data", and sends a manual operation request to the operator; after receiving the request, the operator can manually perform secondary processing; after the processing is completed and it is confirmed that the result meets the expectation and is qualified, the system will record the parameters of this secondary processing and correct the algorithm according to the weight. After the top bending processing of the entire length is completed, the processed workpiece is moved to the "lifting device" of the off-line scanning system; here, the processed workpiece is lifted upward by a certain distance, completely separated from the support of the "power roller track" and kept in a horizontal state, waiting for the "off-line scanning" to complete the data scanning. After that, the system compares the scanning result with the result pre-stored in the database. The qualified ones will be automatically transferred to the "blanking system"; the unqualified ones will display the position of the defect, return the processed workpiece to the "processing power roller track", and prompt the on-site workers for further processing.

15. The automatic top adjustment method for turnout rails according to claim 13, wherein, The specific measurement process of on-line inspection is as follows: Step 1, trigger scanning: Before performing the processing operation, ensure that the information of the processed workpiece and the current process step have been correctly input. Step 2, automatic position adjustment of the scanning head and completion of scanning: The starting position, measurement height, and measurement speed of the scanning head are automatically adjusted according to the type and parameters of the current processed workpiece; after the adjustment is in place, the scanning head performs a scanning movement in the horizontal direction at the fastest speed. Step 3: Automatically generate the original bending data of the workpiece and specifically propose processing suggestions: For the data points obtained by scanning in Step 2, splice them through software to form a complete image; on the operation interface, display the bending degree and bending direction of the current workpiece in a graphical manner, as well as processing suggestions. Step 4: Complete the straightening operation according to the processing suggestions: Complete the straightening operation according to the processing suggestions in Step 3, and the online detection function can be triggered again. Repeat the processes in Steps 2 and 3, and compare the spliced image with the standard image at the current position to display the remaining error. Step 5: When performing a bottom surface scan on the heel end profiling section, the specific measurement process of the online detection is as follows: Step 501: The staff first flips the track to ensure that the bottom surface of the track faces the direction of the scanning head. Step 502: Completely park the heel end profiling section of the flipped track within the online scanning range and start the corresponding function on the operation panel. Step 503: The system automatically scans the bottom surface contour of the heel end profiling section of the track within the entire scanning range and measures the bottom surface inclination of the heel end profiling section of the track.

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