Splicing non-contact steel rail straightness detection device

Abstract

The invention provides a splicable non-contact steel rail straightness detection device, and belongs to the technical field of steel rail detection. Aiming at the problem that a non-contact steel rail straightness detection device is difficult to carry, the invention provides a splicable non-contact steel rail straightness detection device which comprises a first detection mechanism, a second detection mechanism, a non-contact detection unit and a data processing module, after the end surfaces of the first detection mechanism and the second detection mechanism are aligned and spliced, the non-contact detection unit can pass through the splicing port and continuously slide in the first detection mechanism and the second detection mechanism, and continuous detection data and calibration data are obtained; the data processing module obtains a reference slope and a slope increment relative to the reference slope according to the plurality of calibration data, and corrects the detection data in the corresponding range according to the reference slope and the slope increment. The device is divided into two sections, can provide a complete detection length reference by aligning and splicing the end surfaces when in use, and is divided into two sections when not in use, so that the overall length is shortened, and the device is convenient to carry.

Description

Technical Field

[0001] The present application relates to the technical field of rail detection, and particularly to a splicable non-contact rail flatness detection device. Background Art

[0002] Existing rail flatness detection devices are mainly divided into three types: the first is mechanical manual detection, where the device is placed on the rail and a feeler gauge or a measuring slider is used to measure the flatness change; the second is contact electronic detection, where a string of hundreds of contact detection heads are closely arranged at the bottom of the device to contact the rail to measure the flatness change; the third is non-contact electronic detection, where a laser displacement sensor is used for ranging to measure the flatness change. The above three flatness detection devices all have an integral structure.

[0003] The existing rail flatness detection devices have the following disadvantages:

[0004] (1) Mechanical manual detection is manual operation. If a feeler gauge is used as the detection basis, the detection efficiency is slow; if a measuring slider is used as the detection basis, the measurement accuracy is low, and human eye reading may cause errors, resulting in a slow detection efficiency.

[0005] (2) Contact electronic detection arranges a string of hundreds of contact detection heads on the contact surface between the device and the rail. The device is difficult to produce and install, and due to space limitations, it is difficult to increase or change the detection density.

[0006] (3) Non-contact electronic detection uses a laser displacement sensor for detection, but currently existing products all have an integral structure, with a length of about 1.2 m, and it is relatively inconvenient to carry onto the track. Summary of the Invention

[0007] The purpose of the present application is to solve the problem in the prior art that it is difficult to carry a non-contact rail flatness detection device. Therefore, the present application provides a splicable non-contact rail flatness detection device. By dividing the longer rail flatness detection device into two sections through the first detection mechanism and the second detection mechanism, during use, a complete detection length reference can be provided by aligning and splicing the end faces. When not in use, it can be disassembled into two sections to shorten the overall length, thereby facilitating carrying. At the same time, the detection data is corrected by the calibration data obtained by the calibration block, improving the detection reliability.

[0008] An embodiment of the present application provides a splicable non-contact rail flatness detection device, which includes a first detection mechanism and a second detection mechanism that are separately arranged and can be aligned and spliced through end faces, and a non-contact detection unit arranged in the first detection mechanism or the second detection mechanism. The non-contact detection unit is connected to a data processing module;

[0009] After the end faces of the first detection mechanism and the second detection mechanism are aligned and spliced, the non-contact detection unit can pass through the splicing interface and continuously slide within both of them, and continuous detection data can be obtained;

[0010] Calibration blocks are provided near the splicing interface on both the first detection mechanism and the second detection mechanism. The calibration blocks have calibration surfaces for blocking the detection signals of the non-contact detection unit, and the non-contact detection unit obtains calibration data through the calibration surfaces;

[0011] The data processing module obtains a reference slope and a slope increment relative to the reference slope based on multiple pieces of the calibration data, and corrects the detection data within a corresponding range based on the reference slope and the slope increment.

[0012] With the above technical solution, the long rail straightness detection device is divided into two sections by the first detection mechanism and the second detection mechanism. During use, a complete detection length reference can be provided through end-face alignment and splicing. When not in use, it can be split into two sections to shorten the overall length, making it convenient to carry. Moreover, calibration blocks are provided near the splicing interface. Since the calibration blocks are arranged between the non-contact detection unit and the rail detection surface, there are obvious differences between the calibration data and the detection data. Therefore, the position of the non-contact detection unit relative to the splicing interface can be quickly and accurately judged by the differences between the calibration data and the detection data and the differences in the acquisition order of different calibration data. Furthermore, the detection data within the corresponding position range is corrected by the reference slope and the slope increment obtained from multiple pieces of calibration data, eliminating the interference to the detection path of the non-contact detection unit caused by the splicing error of the splicing interface, that is, the detection error caused by the detection path splicing error of the non-contact detection unit, ensuring the detection accuracy and reliability, and thus improving the detection reliability.

[0013] In some embodiments, the multiple pieces of calibration data include the calibration data before the non-contact detection unit passes through the splicing interface, the calibration data when passing through the splicing interface, and the calibration data after passing through the splicing interface.

[0014] With the above technical solution, the position range of the contactless detection unit relative to the splicing interface is divided into three sections, and the detection data within the corresponding position range is corrected by the calibration data at the corresponding positions, ensuring the comprehensiveness of the correction and further improving the detection reliability.

[0015] In some embodiments, three calibration surfaces are provided on the calibration surface. The three calibration surfaces are located on the same horizontal plane and are sequentially arranged at intervals along the detection direction of the non-contact detection unit. Moreover, when the non-contact detection unit passes through the three calibration surfaces, it respectively obtains the calibration data before passing through the splicing interface, the calibration data when passing through the splicing interface, and the calibration data after passing through the splicing interface;

[0016] The non-contact detection unit can obtain at least two pieces of the calibration data distributed in sequence along its detection direction after passing through the calibration surface;

[0017] The data processing module determines the reference slope according to at least two pieces of the calibration data of the calibration surface near the starting end of the detection direction, and determines the slope increment relative to the reference slope according to the calibration data obtained from adjacent calibration surfaces.

[0018] In some embodiments, both the first detection mechanism and the second detection mechanism include a strip-shaped housing. A detection groove is formed on one side of the housing along its length direction. The calibration block is arranged close to the detection groove and can block part of the detection groove;

[0019] A slide rail and a driving mechanism are arranged in the housing. The non-contact detection unit can slide along the slide rail driven by the driving mechanism, and the detection end faces the detection groove to obtain the detection data and the calibration data;

[0020] The splicing interface is the splicing interface of the slide rails corresponding to the first detection mechanism and the second detection mechanism;

[0021] The housing of the first detection mechanism and the housing of the second detection mechanism are provided with a positioning mechanism and a clamping mechanism near the splicing interface to enable the two to be aligned, spliced, and locked.

[0022] By adopting the above technical solutions, the non-contact detection unit is restricted by the slide rail, improving the detection path accuracy of the non-contact detection unit; and, through the positioning mechanism and the clamping mechanism, the alignment and splicing accuracy of the first detection mechanism and the second detection mechanism are ensured, thereby ensuring the detection reliability.

[0023] In some embodiments, the driving mechanism includes a motor and a gear-rack transmission assembly parallel to the slide rail. The non-contact detection unit is connected to the gear-rack transmission assembly and the slide rail through a mounting seat;

[0024] The gear-rack transmission assembly and the slide rail are respectively arranged on adjacent side surfaces of the housing.

[0025] By adopting the above technical solutions, the non-contact detection unit is driven by the gear-rack transmission assembly, that is, the non-contact detection unit continuously moves on the first detection mechanism and the second detection mechanism through two racks, facilitating the separation and splicing of the first detection mechanism and the second detection mechanism; and, the gear-rack transmission assembly and the slide rail are respectively arranged on adjacent side surfaces of the housing, which can limit the non-contact detection unit in two directions, further improving the detection path accuracy of the non-contact detection unit.

[0026] In some embodiments, the non-contact detection unit is connected to the slide rail through a first slider and a second slider arranged in sequence along the detection direction, and the detection end of the non-contact detection unit is located between the first slider and the second slider;

[0027] After the end faces of the first detection mechanism and the second detection mechanism are aligned and spliced, the multiple calibration surfaces arranged along the detection direction are, in sequence, a first calibration surface, a second calibration surface, and a third calibration surface located on the first detection mechanism, and a fourth calibration surface, a fifth calibration surface, and a sixth calibration surface located on the second detection mechanism; and,

[0028] The first calibration surface, the second calibration surface, and the third calibration surface are respectively used to obtain the calibration data of the non-contact detection unit when the first slider passes before the splicing interface, passes through the splicing interface, and after passing through the splicing interface and before the second slider passes through the splicing interface;

[0029] The fourth calibration surface, the fifth calibration surface, and the sixth calibration surface are respectively used to obtain the calibration data of the non-contact detection unit when the first slider passes after the splicing interface and before the second slider passes through the splicing interface, passes through the splicing interface, and after passing through the splicing interface.

[0030] By adopting the above technical solution, the non-contact detection unit is connected to the slide rail through the first slider and the second slider, improving the smoothness of its movement, thereby improving the detection accuracy and precision.

[0031] In some embodiments, the processing steps of the data processing module include:

[0032] Determine the reference slope through the at least two calibration data of the first calibration surface, and correct the detection data obtained when both the first slider and the second slider are located on the slide rail of the first detection mechanism through the reference slope;

[0033] Determine the slope change trend and value when the first slider and the second slider are respectively located on the slide rails of the first detection mechanism and the second detection mechanism through the multiple calibration data from the second calibration surface to the fifth calibration surface, and correct the detection data obtained in the corresponding range through the slope change trend and value;

[0034] Determine the slope increment through the at least two calibration data of the sixth calibration surface, and correct the detection data obtained when both the first slider and the second slider are located on the slide rail of the second detection mechanism through the slope increment.

[0035] In some embodiments, the slope change trend and value are determined based on the calibration data of the second calibration surface to the fifth calibration surface when the first slider and the second slider are respectively located on the slide rails of the first detection mechanism and the second detection mechanism, and the detection data obtained within the corresponding range is corrected based on the slope change trend and value, including:

[0036]

[0037] Where x is the detection data, y is the corrected detection data, △k is the slope increment within the corresponding range of the detection data, A is the distance from the plane where the first slider and the second slider are located to the detection end of the non-contact detection unit, and B is the distance from the support point of the second slider to the plane where the vertical line of the detection end is located.

[0038] In some embodiments, the positioning mechanism includes at least three positioning pins and matching positioning slots;

[0039] The at least three positioning pins are provided on one of the housing of the first detection mechanism and the housing of the second detection mechanism, and the matching positioning slots are provided on the other.

[0040] With the above technical solution, positioning is achieved through the cooperation of the positioning pins and the positioning slots, with a simple structure and high positioning accuracy.

[0041] In some embodiments, two clamping mechanisms are provided, and the two clamping mechanisms are respectively provided on the opposite sides of the housing of the first detection mechanism and the housing of the second detection mechanism;

[0042] The clamping mechanism is an eccentric clamping mechanism and includes a clamping claw and a matching claw slot. The claw slot includes a first slot body and a second slot body that are symmetrically arranged and respectively located on the corresponding sides of the housing of the first detection mechanism and the housing of the second detection mechanism. During clamping, the clamping claw is inserted and drives the first slot body and the second slot body to squeeze against each other.

[0043] With the above technical solution, bilateral cross-clamping of the connection can further improve the clamping reliability, thereby ensuring the connection stability between the first detection mechanism and the second detection mechanism during use and ensuring the detection reliability.

[0044] In some embodiments, the slide rail is provided on the housing through a slide rail mounting seat, and the splicing end surface of the slide rail mounting seat is flush with the splicing end surface of the housing. One of the two slide rails partially extends out of the splicing end surface of the corresponding slide rail mounting seat, and the other retracts relative to the corresponding slide rail mounting seat to be adapted to the partially extended slide rail.

[0045] Adopting the above technical solution improves the accuracy and precision of the splicing of the two slide rails, thereby improving the detection accuracy and precision.

[0046] In some embodiments, locking seats and matching locking blocks are respectively arranged at both ends of the housing. The two housings can be arranged side by side and are locked by inserting the locking blocks into the corresponding locking seats and then inserting pins.

[0047] Adopting the above technical solution enables the first detection mechanism and the second detection mechanism to be connected as a whole when not in use, which further facilitates carrying.

[0048] Other features and corresponding beneficial effects of this application are described and explained in the following part of the specification, and it should be understood that at least some of the beneficial effects are obvious from the description in the specification of this application. Description of the Drawings

[0049] Figure 1 Structural schematic diagram of the assembled first detection mechanism and second detection mechanism in this application;

[0050] Figure 2 Internal structural schematic diagram of the first detection mechanism in this application;

[0051] Figure 3 Partial structural schematic diagram of the first detection mechanism and the second detection mechanism before assembly in this application;

[0052] Figure 4 Structural schematic diagram of the clamping mechanism in this application;

[0053] Figure 5 Structural schematic diagram of the connection end of the housing of the first detection mechanism in this application;

[0054] Figure 6 Structural schematic diagram of the assembled first detection mechanism and the second detection mechanism in the non-use state in this application;

[0055] Figure 7 Schematic diagram of the use state of this application for detecting the top surface of the rail;

[0056] Figure 8 Schematic diagram of the use state of this application for detecting the side surface of the rail;

[0057] Figure 9 Structural schematic diagram of the calibration block;

[0058] Figure 10 Schematic diagram of the state of this application in stage two.

[0059] Explanation of the reference numerals in the drawings:

[0060] 1. First detection mechanism; 2. Second detection mechanism; 3. Electric control box;

[0061] 100. Housing; 101. Connecting end; 110. Detection groove; 111. Calibration block; 120. Slide rail; 130. Gear-rack transmission assembly; 140. Mounting seat; 150. Drag chain; 160. Reference cushion block; 170. Fixed lateral reference block; 180. Rotating lateral reference block; 181. Second magnet; 190. Flap; 191. First magnet; 192. Magnetic attraction block;

[0062] 210. Positioning pin; 220. Positioning groove;

[0063] 300. Clamping mechanism; 310. Clamping jaw; 320. Jaw groove;

[0064] 410. Locking seat; 420. Plug pin. Detailed implementation manners

[0065] The following specific embodiments illustrate the implementation manners of the present application. Those skilled in the art can easily understand other advantages and effects of the present application from the content disclosed in this specification. Although the description of the present application will be introduced in conjunction with preferred embodiments, this does not mean that the features of this application are limited to this implementation manner. On the contrary, the purpose of introducing the application in conjunction with the implementation manner is to cover other alternatives or modifications that may be extended based on the claims of the present application. In order to provide a deep understanding of the present application, many specific details will be included in the following description. The present application can also be implemented without these details. In addition, in order to avoid confusing or obscuring the key points of the present application, some specific details will be omitted in the description. It should be noted that, without conflict, the embodiments in the present application and the features in the embodiments can be combined with each other.

[0066] It should be noted that in this specification, similar reference numerals and letters indicate similar items in the following drawings. Therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings.

[0067] In the description of the present application, it should be noted that the orientation or positional relationship indicated by terms such as "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation to the present application. In addition, the terms "first", "second", "third" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Therefore, the features defined with "first", "second", etc. may explicitly or implicitly include one or more of such features. In the description of the present invention, unless otherwise specified, the meaning of "a plurality" is two or more. Unless otherwise clearly specified and defined, the terms "mounted", "connected", "coupled" shall be construed broadly. For example, it may be a fixed connection, a detachable connection, or an integral connection; it may be a mechanical connection or an electrical connection; it may be directly connected or indirectly connected through an intermediate medium, and it may be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to specific circumstances.

[0068] It should be noted that when detecting railway tracks in the wild or performing cross-regional operations, the space of the transportation tool is often limited. However, the length of the current conventional non-contact rail straightness detection device is about 1.2 m, which is too long to be placed in an ordinary vehicle or a small tool storage box, making it inconvenient to carry. At the same time, the excessive length also makes it easy to be damaged during the carrying process.

[0069] Please refer to Figure 1-5 , Figure 1 which is a schematic structural diagram of the assembled first detection mechanism 1 and second detection mechanism 2 in the present application; Figure 2 which is a schematic internal structural diagram of the first detection mechanism 1 in the present application; Figure 3 which is a partial schematic structural diagram of the first detection mechanism 1 and the second detection mechanism 2 before assembly in the present application; Figure 4 which is a schematic structural diagram of the clamping mechanism 300 in the present application; Figure 5 which is a schematic structural diagram of the connection end of the housing 100 of the first detection mechanism 1 in the present application.

[0070] The embodiment of the present application provides a splicable non-contact rail straightness detection device, which includes a first detection mechanism 1 and a second detection mechanism 2 that are separately arranged and can be aligned and spliced through end faces, and a non-contact detection unit arranged in the first detection mechanism 1 or the second detection mechanism 2. That is, the first detection mechanism 1 and the second detection mechanism 2 are two completely separated sections. When stored, the two sections can be placed side by side to shorten the overall length, thus facilitating portability; when detecting, connection is achieved through end-face alignment and splicing, providing a complete detection length reference for the non-contact detection unit. That is, the non-contact detection unit can pass through the splicing interface and continuously slide within the first detection mechanism 1 and the second detection mechanism 2, and continuous detection data can be obtained.

[0071] At the same time, compared with the folding method, that is, the first detection mechanism 1 and the second detection mechanism 2 are folded through hinges, this method has higher docking accuracy and repeatability, thus ensuring the detection accuracy. When ensuring the flexibility of the hinges, there must be some gaps between the components of the hinges. These gaps will cause the accuracy and repeatability to not be guaranteed when converting from the storage state to the detection state, and will cause a slightly larger deviation from the previous time after each combination, and the folding method is not convenient for installing positioning pins to enhance the positioning accuracy.

[0072] Compared with the telescopic method, that is, the first detection mechanism 1 and the second detection mechanism 2 are telescopically connected, this method can effectively control the overall size and weight of the device, thus further facilitating portability. Usually, if the purpose of telescoping is to be achieved, a mechanism similar to a slide rail needs to be additionally added between the first detection mechanism 1 and the second detection mechanism 2, which greatly increases the overall width or height and weight of the device, and the operation method is also difficult to implement, and various driving methods are not convenient for telescoping along with the overall length.

[0073] It should be noted that the non-contact detection unit is a prior art, and the non-contact detection unit in the existing rail straightness detection technology can be adopted. Usually, this unit includes a laser displacement sensor, and non-contact detection is achieved through the laser displacement sensor. At the same time, the detection unit slides along the first detection mechanism 1 and the second detection mechanism 2 to achieve detection within the specified detection range.

[0074] It should also be noted that the detection device usually further includes an electric control box 3, and the electric control box 3 provides necessary power supply and control for the non-contact detection unit. In a specific embodiment, the electric control box 3 is arranged at the outer top end of the first detection mechanism 1 or the second detection mechanism 2, thus facilitating the operation and observation by the operator.

[0075] In one embodiment, the first detection mechanism 1 and the second detection mechanism 2 have substantially the same structure. Specifically, both the first detection mechanism 1 and the second detection mechanism 2 include a strip-shaped housing 100. On one side of the housing 100, a detection groove 110 is formed along its length direction. A driving mechanism and a slide rail 120 are arranged inside the housing 100. The non-contact detection unit can slide along the slide rail 120 driven by the driving mechanism, and the detection end faces the detection groove 110, so as to realize detection.

[0076] In one embodiment, the housings 100 of the first detection mechanism 1 and the second detection mechanism 2 both have communication ends 101, and the two communication ends 101 can be communicated, so that the slide rails 120 of the two are aligned and spliced end to end, and the detection grooves 110 of the two are aligned and spliced end to end. The non-contact detection unit can continuously slide on the slide rails 120 of the two, and obtain corresponding detection data through the detection grooves 110 of the two.

[0077] In one embodiment, the slide rail 120 is arranged on the housing through a slide rail mounting seat, and the splicing end face of the slide rail mounting seat is flush with the splicing end face of the housing 100. One of the two slide rails 120 partially protrudes from the splicing end face of the corresponding slide rail mounting seat, and the other retracts relative to the corresponding slide rail mounting seat to be adapted to the partially protruding slide rail 120. This method improves the splicing accuracy and accuracy of the two slide rails 120, thereby improving the detection accuracy and accuracy.

[0078] In one embodiment, the non-contact detection unit is connected to the slide rail 120 through a first slider and a second slider arranged in sequence along the detection direction, and the detection end of the non-contact detection unit is located between the first slider and the second slider, which can improve the smoothness of the movement of the non-contact detection unit, thereby improving the detection accuracy and accuracy.

[0079] In one embodiment, the driving mechanism includes a motor and a gear-rack transmission assembly 130 parallel to the slide rail 120, that is, the non-contact detection unit is continuously moved on the first detection mechanism and the second detection mechanism through two racks, which is convenient for the separation and splicing of the first detection mechanism and the second detection mechanism. Preferably, it is a helical gear-rack assembly.

[0080] Further preferably, the gear-rack transmission assembly 130 and the slide rail 120 are respectively arranged on adjacent side surfaces of the housing 100, and the non-contact detection unit is connected to the gear-rack transmission assembly 130 and the slide rail 120 through a mounting seat 140, so as to realize stable and reliable sliding.

[0081] It can be understood that the gear in the gear-rack transmission assembly 130 is connected to the motor, and the mounting seat 140 is connected to the gear and the slide rail 120.

[0082] Moreover, to enable the connecting cable between the non-contact detection unit and the electric control box 3 to move synchronously, stably and reliably with the non-contact detection unit, a drag chain 150 is provided in the first detection mechanism 1 or the second detection mechanism 2. The cable is protected by the drag chain 150 and moves synchronously with the non-contact detection unit.

[0083] In one embodiment, a positioning mechanism and a clamping mechanism are provided at two communicating ends 101 of the housing 100 of the first detection mechanism 1 and the housing 100 of the second detection mechanism 2, so that the two are aligned, spliced and locked, ensuring the accuracy and stability of the alignment and splicing of the two, and thus ensuring the detection reliability.

[0084] In one embodiment, the positioning mechanism includes at least three positioning pins 210 and matching positioning grooves 220. One of the two communicating ends 101 is provided with positioning pins 210, and the other is provided with positioning grooves 220. The positioning is realized by the cooperation of the positioning pins 210 and the positioning grooves 220. The structure is simple and the positioning accuracy is relatively high.

[0085] In a specific embodiment, the cross-section of the housing 100 is square. For example, a carbon fiber square tube can be used. Four positioning pins 210 are provided and are respectively located at the four corners.

[0086] In one embodiment, two clamping mechanisms are provided, and the two clamping mechanisms are respectively arranged on the opposite sides of the housing 100 of the first detection mechanism 1 and the housing 100 of the second detection mechanism 2, and are preferably symmetrically arranged about the center of the connection between the two, that is, bilateral cross-clamping is realized for the connection, which can further improve the clamping reliability, thereby ensuring the connection stability between the first detection mechanism 1 and the second detection mechanism 2 during use, the overall rigidity of the detection device, and ensuring the detection reliability.

[0087] In a specific embodiment, the clamping mechanism is an eccentric clamping mechanism and includes a clamping claw 310 and a matching claw groove 320. The claw groove 320 includes a first groove body and a second groove body that are symmetrically arranged and are respectively arranged on the corresponding sides of the housing 100 of the first detection mechanism 1 and the housing 100 of the second detection mechanism 2. When clamping, the clamping claw 310 is embedded and drives the first groove body and the second groove body to be relatively squeezed.

[0088] In one embodiment, a calibration block 111 is provided on the housing 100 at the detection groove 110. The calibration block 111 has a calibration surface for blocking the detection groove 110, and the calibration block 111 is arranged close to the splicing port of the housing 100, so that the non-contact detection unit obtains a calibration signal through the calibration surface of the calibration block 111.

[0089] It should be noted that even if the splicing interfaces of the first detection mechanism 1 and the second detection mechanism 2, such as the slide rail 120 in a specific embodiment, can be seamlessly aligned when leaving the factory, during long-term use, gaps and skews will inevitably occur, resulting in a height difference, an angle difference, etc. between the first detection mechanism 1 and the second detection mechanism 2. The non-contact detection unit vibrates when passing through the connection between the two, resulting in poor accuracy of the detection signal in this section.

[0090] It should be noted that since the calibration block 111 is arranged between the non-contact detection unit and the rail detection surface, therefore, there are obvious differences between the calibration data and the detection data, that is, the calibration data is significantly smaller than the detection data, and the deviation between the two cannot be caused by the unevenness of the rail. In this way, by arranging the calibration block 111 close to the splicing interface, the non-contact detection unit can slide from the first detection mechanism 1 to the second detection mechanism 2, and a calibration signal significantly different from the detection signal can be obtained, so that the abnormal detection signal generated by the vibration of the non-contact detection unit caused by the structural connection can be distinguished from the detection signal. By processing the calibration signal, the detection reliability can be improved.

[0091] In one embodiment, the non-contact detection unit is connected with a data processing module. The data processing module obtains a reference slope and a slope increment relative to the reference slope according to a plurality of calibration data, and corrects the detection data in the corresponding range according to the reference slope and the slope increment. That is, by the difference between the calibration data and the detection data and the difference in the obtaining order of different calibration data, the position of the non-contact detection unit relative to the splicing interface is quickly and accurately judged. Furthermore, the detection data in the corresponding position range is corrected by the reference slope and the slope increment obtained from a plurality of calibration data, eliminating the interference to the detection path of the non-contact detection unit caused by the splicing error of the splicing interface, that is, the detection error of the non-contact detection unit caused by the detection path splicing error, ensuring the detection accuracy and reliability, and thus improving the detection reliability.

[0092] In one embodiment, the plurality of calibration data includes the calibration data before the non-contact detection unit passes through the splicing interface, the calibration data when passing through the splicing interface, and the calibration data after passing through the splicing interface. That is, the position range of the contact detection unit relative to the splicing interface is divided into three sections, and the detection data in the corresponding position range is corrected by the calibration data at the corresponding position, ensuring the comprehensiveness of the correction and further improving the detection reliability.

[0093] In one embodiment, a flip cover 190 and a first magnet 191 are provided at the connecting end 101 of the housing 100. When the flip cover 190 is in the open state, it is magnetically attracted and attached to the side surface of the housing 100 through the first magnet 191. When in the closed state, it is locked by a clamping mechanism, so as to protect the internal components of the housing 100 in the non-use state through the flip cover 190, which can extend the service life of the detection device. Moreover, when in use, the flip cover 190 is fixed to the housing 100 by magnetic attraction, and when not in use, the flip cover 190 is fixed to the housing 100 by a clamping mechanism. The structure is simple, the overall volume and weight of the detection device can be controlled, and thus it is further convenient to carry.

[0094] Preferably, the flip cover 190 is made of aluminum alloy. At this time, a magnetic attraction block 192 corresponding to the first magnet 191 is provided on the flip cover 190.

[0095] Please refer to Figure 6 , Figure 6 which is a schematic diagram of the assembled structure of the first detection mechanism 1 and the second detection mechanism 2 in the non-use state in this application.

[0096] In one embodiment, locking seats 410 and matching locking blocks are respectively provided at both ends of the housing 100. Two housings 100 can be arranged side by side, and are locked by inserting the locking blocks into the corresponding locking seats 410 and then inserting pins 420, so that when not in use, the first detection mechanism 1 and the second detection mechanism 2 can be connected as a whole, which is further convenient to carry.

[0097] Please refer to Figure 7-8 , Figure 7 which is a schematic diagram of the use state of this application for detecting the top surface of the rail; Figure 8 which is a schematic diagram of the use state of this application for detecting the side surface of the rail.

[0098] In one embodiment, a reference cushion block 160 is provided at the end of the housing 100 away from its connecting end 101. The reference cushion block 160 and the detection groove 110 are arranged on the same side of the housing 100 for contacting the detection surface of the rail, and the reference surface of the reference cushion block 160 is parallel to the slide rail 120, that is, the detection reference of the entire detection device is provided through the reference cushion block 160, improving the detection reliability.

[0099] Preferably, a magnet is provided inside the reference cushion block 160, so that the reference cushion block 160 can be fixed to the rail by magnetic attraction, improving the stability of the detection device during the detection process, thereby further improving the detection reliability, and the operation is convenient, the structure is simple, the overall volume and weight of the detection device can be controlled, and thus it is further convenient to carry. At the same time, the magnetic attraction fixation makes the fixed position of the detection device and the rail flexible, that is, it can be fixed to the top surface of the rail or the side surface of the rail, thus taking into account the all-round flatness detection of the rail and improving the versatility of this detection device.

[0100] In one embodiment, a fixed lateral reference block 170 is provided on one side of the reference cushion block 160. The fixed lateral reference block 170 is used to abut against the side surface of the rail, and the detection groove 110 is located at the detection position on the top surface of the rail.

[0101] In one embodiment, a rotatable lateral reference block 180 is provided on one side of the reference cushion block 160. The rotatable lateral reference block 180 can rotate between a first position and a second position. When the rotatable lateral reference block 180 is in the first position, the rotatable lateral reference block 180 is flush with the reference cushion block 160; when the rotatable lateral reference block 180 is in the second position, the rotatable lateral reference block 180 is perpendicular to the reference cushion block 160 and is used to abut against the top surface of the rail, and the detection groove 110 is located at the detection position on the side surface of the rail.

[0102] Preferably, a second magnet 181 is provided on the housing 100 at the second position, and when the rotatable lateral reference block 180 rotates to the second position, it is magnetically fixed to the housing 100 by the second magnet 181.

[0103] In one embodiment, except for the parts with special functions and requirements, most of the components of this detection device can be made of 6061 aluminum alloy, and some parts without strength requirements are made of POM material. Under the condition of ensuring strength, the overall mass can be reduced as much as possible, and the overall design is lightweight.

[0104] Please refer to Figure 9 , Figure 9 which is a schematic structural diagram of the calibration block in this application.

[0105] In one embodiment, three calibration surfaces are provided. The three calibration surfaces are located on the same horizontal plane and are sequentially spaced along the detection direction of the non-contact detection unit. Moreover, when the non-contact detection unit passes through the three calibration surfaces, it respectively obtains the calibration data before passing through the splicing interface, the calibration data when passing through the splicing interface, and the calibration data after passing through the splicing interface.

[0106] The non-contact detection unit can obtain at least two calibration data distributed sequentially along its detection direction when passing through the calibration surface.

[0107] The data processing module determines the reference slope based on at least two calibration data of the calibration surface close to the starting end of the detection direction, and determines the slope increment relative to the reference slope based on the calibration data obtained from adjacent calibration surfaces.

[0108] In one embodiment, the non-contact detection unit is connected to the slide rail through a first slider and a second slider arranged sequentially along the detection direction, and the detection end of the non-contact detection unit is located between the first slider and the second slider;

[0109] After the end faces of the first detection mechanism and the second detection mechanism are aligned and spliced, a plurality of calibration surfaces arranged along the detection direction are successively the first calibration surface, the second calibration surface, and the third calibration surface located on the first detection mechanism, and the fourth calibration surface, the fifth calibration surface, and the sixth calibration surface located on the second detection mechanism; and,

[0110] The first calibration surface, the second calibration surface, and the third calibration surface are successively used to obtain the calibration data of the first slider of the non-contact detection unit before passing through the splicing interface, when passing through the splicing interface, and after passing through the splicing interface and before the second slider passes through the splicing interface;

[0111] The fourth calibration surface, the fifth calibration surface, and the sixth calibration surface are successively used to obtain the calibration data of the first slider of the non-contact detection unit after passing through the splicing interface and before the second slider passes through the splicing interface, when passing through the splicing interface, and after passing through the splicing interface.

[0112] In one embodiment, the processing steps of the data processing module include:

[0113] Phase 1: Determine the reference slope through at least two calibration data of the first calibration surface, and correct the detection data obtained when both the first slider and the second slider are on the slide rail of the first detection mechanism through the reference slope;

[0114] Phase 2: Determine the slope change trend and value when the first slider and the second slider are respectively on the slide rails of the first detection mechanism and the second detection mechanism through a plurality of calibration data from the second calibration surface to the fifth calibration surface, and correct the detection data obtained in the corresponding range through the slope change trend and value;

[0115] Phase 3: Determine the slope increment through at least two calibration data of the sixth calibration surface, and correct the detection data obtained when both the first slider and the second slider are on the slide rail of the second detection mechanism through the slope increment.

[0116] Please refer to Figure 10 , Figure 10 which is the state diagram of the device in Phase 2.

[0117] In some embodiments, Phase 2 further includes:

[0118]

[0119] where x is the detection data, y is the corrected detection data, △k is the slope increment of the corresponding range of the detection data, A is the distance from the plane where the first slider and the second slider are located to the detection end (such as the laser emission port) of the non-contact detection unit, that is, Figure 10 the blue line in Figure 10 and B is the distance from the support point of the second slider to the plane where the perpendicular line to the detection end (such as the laser perpendicular line) is located, that is,

[0120] The following uses a specific usage process to illustrate this correction method. The non-contact detection unit includes a laser displacement sensor, and during detection, it moves from the first detection mechanism to the second detection mechanism.

[0121] At this time, when the first slider passes through the splicing interface, the calibration surfaces passed by the laser are a, b, c in sequence (corresponding to the states before contacting the interface, passing through the interface, and after separating from the interface respectively), and a1, a2, b1, b2, c1, c2 are the reading point positions respectively;

[0122] When the second slider passes through the splicing interface, the calibration surfaces passed by the laser are d, e, f in sequence (corresponding to the states before contacting the interface, passing through the interface, and after separating from the interface respectively), and d1, d2, e1, e2, f1, f2 are the reading point positions respectively.

[0123] According to the test, it is found that the slope change has three stages:

[0124] In the first stage, both sliders are on the first slide rail. This slope is the reference slope and is a fixed value, that is, the data of one unit displacement compensates more slope compared to the previous data.

[0125] Under normal circumstances, when the device leaves the factory, the first calibration block has been leveled. Therefore, the slope of this stage is 0, and the detected data x = the corrected detected data y;

[0126] In the second stage, the two sliders are on two different slide rails respectively, and the slope is in a linear change state (for example, it is set that there is an included angle of 0.1° between the two slide rails, and the change value of the slope k is approximately -0.00001531 / mm);

[0127] In the third stage, both sliders are on the second slide rail, and the slope is a fixed value, that is, the data of one unit displacement compensates more k compared to the previous data (for example, it is set that there is an included angle of 0.1° between the two slide rails, and the slope k = tan(0.1°) = 0.001745331).

[0128] That is to say, in the first stage, the two data read on the a surface are the normal values of the first detection mechanism and are stable. Suppose the values are recorded as x, that is, a1 = x, a2 = x.

[0129] In the second stage, its linear function can be obtained through multiple slope measurements.

[0130] At the same time, it can also be confirmed and calibrated by selecting points, and the second stage can be further divided into three stages for correction. This method has a small amount of calculation, and the error range meets the detection requirements. Specifically,

[0131] When the first slider starts to contact the interface and passes through, the laser will pass through the b calibration surface to read the data b1, b2. If b1 = y1, b2 = y2;

[0132] Therefore, for the data measured during the period when the first slider touches and then leaves, the slope increment of the function formed by (a2, x) and (b1, y1) needs to be added additionally;

[0133] When the first slider just detaches from the interface, the laser will pass through the c calibration surface to read the data c1 and c2. If c1 = z1 and c2 = z2;

[0134] Before the second slider touches the interface, the laser will pass through the d calibration surface to read the data d1 and d2. If d1 = m1 and d2 = m2;

[0135] Therefore, for the data measured during the period when the first slider leaves the interface until the second slider touches the interface, the slope increment of the function formed by (c2, z2) and (d1, m1) needs to be added additionally;

[0136] When the second slider starts to touch the interface and passes through, the laser will pass through the e calibration surface to read the data e1 and e2. If e1 = n1 and e2 = n2;

[0137] When the second slider just detaches from the interface, the laser will pass through the f calibration surface to read the data f1 and f2. If f1 = r1 and f2 = r2;

[0138] Therefore, for the data measured during the period when the second slider touches and then leaves, the slope increment of the function formed by (e2, n2) and (f1, r1) needs to be added additionally.

[0139] In the third stage, after the second slider completely detaches from the interface and moves in the second detection mechanism, its data needs to satisfy the slope increment of the function formed by (f1, r1) and (f2, r2).

[0140] Taking the laser at 1 point per millisecond as an example, the theoretical value of the plane is 17 (i.e., the theoretical value measured on the rail measurement surface), the calibration theoretical value is 12, the included angle between the two slide rails is 0.1°, A = 69.2, B = 47.3, and the obtained data is as follows in the table:

[0141]

[0142] Among them, the data at points 31 and 32 are the calibration data of surface a, the data at points 42 and 43 are the calibration data of surface b, the data at points 53 and 54 are the calibration data of surface c, the data at points 125 and 126 are the calibration data of surface d, the data at points 136 and 137 are the calibration data of surface e, and the data at points 147 and 148 are the calibration data of surface f.

[0143] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than limiting them; although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A spliceable non-contact rail straightness detection device, characterized in that It includes a first detection mechanism and a second detection mechanism that are separately arranged and can be aligned and spliced through end faces, and a non-contact detection unit arranged in the first detection mechanism or the second detection mechanism. The non-contact detection unit is connected with a data processing module; After the end faces of the first detection mechanism and the second detection mechanism are aligned and spliced, the non-contact detection unit can pass through the splicing interface and continuously slide within the two, and continuous detection data is obtained; Calibration blocks are arranged near the splicing interface of the first detection mechanism and the second detection mechanism. The calibration blocks have calibration surfaces for blocking the detection signals of the non-contact detection unit, and the non-contact detection unit obtains calibration data through the calibration surfaces; The data processing module obtains a reference slope and a slope increment relative to the reference slope according to a plurality of the calibration data, and corrects the detection data in a corresponding range according to the reference slope and the slope increment.

2. The splicable non-contact rail straightness detection device according to claim 1, characterized in that The plurality of calibration data include the calibration data before the non-contact detection unit passes through the splicing interface, the calibration data when passing through the splicing interface, and the calibration data after passing through the splicing interface.

3. The splicable non-contact rail straightness detection device according to claim 2, characterized in that Three calibration surfaces are provided on the calibration surface. The three calibration surfaces are located on the same horizontal plane and are sequentially arranged at intervals along the detection direction of the non-contact detection unit. Moreover, when the non-contact detection unit passes through the three calibration surfaces, the calibration data before passing through the splicing interface, the calibration data when passing through the splicing interface, and the calibration data after passing through the splicing interface are respectively obtained; When the non-contact detection unit passes through the calibration surface, at least two of the calibration data distributed in sequence along its detection direction can be obtained; The data processing module determines the reference slope according to at least two of the calibration data of the calibration surface close to the starting end of the detection direction, and determines the slope increment relative to the reference slope according to the calibration data obtained from adjacent calibration surfaces.

4. The splicable non-contact rail straightness detection device according to claim 3, characterized in that, Both the first detection mechanism and the second detection mechanism include strip-shaped shells. A detection groove is opened on one side of the shell along its length direction. The calibration block is arranged close to the detection groove and can block part of the detection groove; A slide rail and a driving mechanism are arranged in the shell. The non-contact detection unit can slide along the slide rail driven by the driving mechanism, and the detection end faces the detection groove to obtain the detection data and the calibration data; The splicing interface is the splicing interface of the corresponding slide rails of the first detection mechanism and the second detection mechanism; The shells of the first detection mechanism and the second detection mechanism are provided with a positioning mechanism and a clamping mechanism near the splicing interface to align and splice and lock the two; 5. The splicable non-contact rail straightness detection device according to claim 4, characterized in that, The driving mechanism includes a motor and a gear-rack transmission component parallel to the slide rail. The non-contact detection unit is connected with the gear-rack transmission component and the slide rail through a mounting seat; The gear-rack transmission component and the slide rail are respectively arranged on adjacent side surfaces of the shell.

6. The spliceable non-contact rail straightness detection device according to claim 4 or 5, characterized in that, The non-contact detection unit is connected to the slide rail through a first slider and a second slider arranged in sequence along the detection direction, and the detection end of the non-contact detection unit is located between the first slider and the second slider; After the end faces of the first detection mechanism and the second detection mechanism are aligned and spliced, a plurality of the calibration surfaces arranged along the detection direction are, in sequence, a first calibration surface, a second calibration surface, and a third calibration surface located on the first detection mechanism, and a fourth calibration surface, a fifth calibration surface, and a sixth calibration surface located on the second detection mechanism; and, The first calibration surface, the second calibration surface, and the third calibration surface are respectively used to obtain the calibration data of the non-contact detection unit when the first slider passes before the splicing interface, passes through the splicing interface, and after passing through the splicing interface and before the second slider passes through the splicing interface; The fourth calibration surface, the fifth calibration surface, and the sixth calibration surface are respectively used to obtain the calibration data of the non-contact detection unit when the first slider passes through the splicing interface and before the second slider passes through the splicing interface, passes through the splicing interface, and after passing through the splicing interface; 7. The splicable non-contact rail straightness detection device according to claim 6, characterized in that The processing steps of the data processing module include: Determining the reference slope through at least two calibration data of the first calibration surface, and correcting the detection data obtained when both the first slider and the second slider are located on the slide rail of the first detection mechanism through the reference slope; Determining the slope change trend and value when the first slider and the second slider are respectively located on the slide rails of the first detection mechanism and the second detection mechanism through a plurality of calibration data from the second calibration surface to the fifth calibration surface, and correcting the detection data obtained in the corresponding range through the slope change trend and value; Determining the slope increment through at least two calibration data of the sixth calibration surface, and correcting the detection data obtained when both the first slider and the second slider are located on the slide rail of the second detection mechanism through the slope increment; 8. The splicable non-contact rail flatness detection device according to claim 7, characterized in that, Determining the slope change trend and value when the first slider and the second slider are respectively located on the slide rails of the first detection mechanism and the second detection mechanism through a plurality of calibration data from the second calibration surface to the fifth calibration surface, and correcting the detection data obtained in the corresponding range through the slope change trend and value, including: Where x is the detection data, y is the corrected detection data, △k is the slope increment of the corresponding range of the detection data, A is the distance from the plane where the first slider and the second slider are located to the detection end of the non-contact detection unit, and B is the distance from the support point of the second slider to the plane of the perpendicular line of the detection end; 9. The splicable non-contact rail straightness detection device according to claim 4, characterized in that, The positioning mechanism includes at least three positioning pins and matching positioning grooves; The at least three positioning pins are arranged on one of the housing of the first detection mechanism and the housing of the second detection mechanism, and the matching positioning grooves are arranged on the other.

10. The splicable non-contact rail straightness detection device according to claim 4, characterized in that, There are two clamping mechanisms, and the two clamping mechanisms are respectively arranged on the opposite sides of the housing of the first detection mechanism and the housing of the second detection mechanism; The clamping mechanism is an eccentric clamping mechanism and includes a clamping claw and a matching claw groove. The claw groove includes a first groove body and a second groove body that are symmetrically arranged and respectively arranged on the corresponding sides of the housing of the first detection mechanism and the housing of the second detection mechanism. When clamping, the clamping claw is embedded and drives the first groove body and the second groove body to squeeze relatively.

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