Non-contact measuring device and measuring method for radial runout of train wheel

Abstract

A non-contact measuring device for radial runout of a train wheel is used for detecting the train wheel on a track and comprises a data acquisition module, a data analysis module, a data processing module and a data display module which are in signal connection in sequence. The data acquisition module comprises a plurality of groups of out-of-rail modules, and each group of out-of-rail modules comprises a first laser transmitter, a first high-speed camera and a wheel sensor; the data acquisition module further comprises an in-rail module, and the in-rail module comprises a second laser transmitter and a second high-speed camera. In addition, the invention further provides a non-contact type train wheel radial run-out measuring method. By designing the non-contact measuring device, the train wheels can be measured in real time in the running process of the train, so that the problem of radial run-out of the train wheels can be managed and controlled efficiently in real time; the method is high in practicability and has high popularization significance.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of train track technology, and in particular to a non-contact train wheel radial run-out measuring device and method. BACKGROUND

[0002] Electric passenger cars, engineering vehicles, and transport vehicles may produce wheel out-of-round conditions during operation due to factors such as wheel manufacturing material, process, and operation mode. When the out-of-round condition reaches a certain degree, the wheel will have a serious impact on train operation quality and safety. Generally, the out-of-round wheel of the train is measured by a lathe contact method, but the lathe measurement requires coordination and scheduling of multiple departments, and the measurement work is time-consuming and inefficient. Of course, there are also line laser scanning detection devices, but the general laser scanning detection device has a large amount of scanning data and can only scan a local area of the train, and cannot achieve whole-wheel circumference detection. SUMMARY

[0003] Therefore, it is necessary to provide a non-contact train wheel radial run-out measuring device to solve the above problems in the prior art.

[0004] A non-contact train wheel radial run-out measuring device for detecting a train wheel on a track, comprising a data acquisition module, a data analysis module, a data processing module, and a data display module, wherein the data acquisition module, the data analysis module, the data processing module, and the data display module are sequentially signal connected. The data acquisition module comprises a plurality of off-track modules, each of the plurality of off-track modules comprises a first laser emitter, a first high-speed camera, and a wheel sensor, the first laser emitter, the first high-speed camera, and the wheel sensor are all installed on the outer side of the track, and the first laser emitter and the first high-speed camera are both signal connected with the wheel sensor, wherein the first laser emitter is a multi-line laser emitter, which can emit multiple linear lasers at the same time. The data acquisition module further comprises an on-track module, the on-track module comprises a second laser emitter and a second high-speed camera, the second laser emitter and the second high-speed camera are both installed on the inner side of the track and are signal connected with each other, and the second high-speed camera is also provided corresponding to the wheel sensor along the inner and outer directions of the track.

[0005] Further, the first laser emitter, the first high-speed camera, and the wheel sensor of any two adjacent off-track modules are interpenetrated and staggered.

[0006] Further, the first laser emitter and the second laser emitter are both inclined, the included angle between the central optical axis and the track plane is 20°-60°, and the included angle between adjacent linear lasers of the first laser emitter and the second laser emitter is less than 1°.

[0007] In addition, the application also provides a non-contact train wheel radial run-out measurement method.

[0008] A non-contact train wheel radial run-out measurement method measures the radial run-out of a train wheel on a track by using a non-contact measurement device. The non-contact measurement device includes a data acquisition module, a data analysis module, a data processing module, and a data display module, which are sequentially signal connected. The data acquisition module includes multiple sets of off-track modules, each of which includes a first laser emitter, a first high-speed camera, and a wheel sensor. The first laser emitter, the first high-speed camera, and the wheel sensor are all installed on the outside of the track, and the first laser emitter and the first high-speed camera are both signal connected with the wheel sensor. The first laser emitter is a multi-line laser emitter that can emit multiple lines of linear laser at the same time. The data acquisition module also includes an on-track module, which includes a second laser emitter and a second high-speed camera. The second laser emitter and the second high-speed camera are both installed on the inside of the track and are signal connected with each other. The second high-speed camera is also correspondingly arranged with the wheel sensor along the inside and outside directions of the track. The non-contact train wheel radial run-out measurement method includes the following steps:

[0009] Step 1: Calibrate parameters. Use a calibration board to calibrate the parameters of the first laser emitter, the second laser emitter, the first high-speed camera, and the second high-speed camera.

[0010] Step 2: Collect data. When the train passes through the train track where the data acquisition module is arranged, the wheel sensor will detect the passing of the train wheel and control the first laser emitter, the second laser emitter, the first high-speed camera, and the second high-speed camera to work. The first laser emitter and the second laser emitter will respectively emit multiple lines of linear laser to irradiate on the inside and outside of the train wheel, and the first high-speed camera and the second high-speed camera will synchronously capture and collect the laser spot image data on the inside and outside of the train wheel.

[0011] Step 3: Calculate depth information. Calculate the depth information of the wheel surface by using a triangulation algorithm. The formula for calculating the depth information is where B is the baseline distance of the first high-speed camera and the corresponding first laser emitter or the baseline distance of the second high-speed camera and the corresponding second laser emitter, f is the focal length of the first high-speed camera or the second high-speed camera, x is the parallax, and A is the depth information.

[0012] Step 4: Plane fitting. According to the image data collected by the on-track module, perform plane fitting using the three-dimensional data measured by the on-track module, and regard the fitted plane as the inside distance plane.

[0013] Step 5: Record the measuring point, take the inner side distance plane as the calculation reference, convert the three-dimensional data measured by the track-out module into a unified coordinate system according to the image data collected by the track-out module, and find the point on the train wheel tread which is perpendicular to the inner side distance plane and has a distance of z=70mm from the inner side distance plane, and record it as the measuring point;

[0014] Step 6: Rolling circle fitting, sequentially perform rolling circle fitting on the recorded measuring points obtained by the same track-out module to obtain rolling circles and calculate the corresponding rolling circle diameters Di, where i is the serial number of the current track-out module, and the value is 1, 2, 3…n;

[0015] Step 7: Traverse the optimal rolling circle diameter, find the maximum value Dmax and the minimum value Dmin from the rolling circle diameters of all track-out modules, and traverse and obtain the optimal rolling circle diameter Do from the minimum diameter Dmin to the maximum diameter Dmax with a step of 0.1mm, and the traversal formula is Where Li is the distance from a measuring point to the center of the fitted circle, and N is a fixed value;

[0016] Step 8: Calculate the radial runout, determine the optimal rolling circle through the optimal rolling circle diameter Do, and then obtain the radius R and the center coordinates (Ox, Oy) of the optimal rolling circle, calculate the distance Si between the measuring point coordinates and the center coordinates of the optimal rolling circle according to the radius R, the center coordinates (Ox, Oy) of the optimal rolling circle and the measuring point coordinates (xi, yi), and the calculation formula is According to the definition of radial runout, the radial runout NC is calculated, and the calculation formula is NC=max{S1, S2, … Sn}.

[0017] Further, in the step 1, the calibration plate includes a first calibration plate, a second calibration plate and a third calibration plate, wherein a single side of the first calibration plate is provided with a group of calibration patterns, a single side of the second calibration plate is provided with two groups of calibration patterns, and the two groups of calibration patterns on the second calibration plate are arranged in a left-right interval, and two sides of the third calibration plate are respectively provided with a group of calibration patterns, and the two groups of calibration patterns on the third calibration plate are arranged in a staggered manner.

[0018] Further, in the step 1, the parameters of the first laser emitter and the second laser emitter are calibrated using the first calibration plate, and when calibrating, the first calibration plate is placed vertically on the track plane, and then the first calibration plate is moved horizontally and perpendicularly to the track direction to estimate the light plane parameters.

[0019] Further, in the step 1, the first high-speed camera of the two adjacent groups of off-track modules is jointly parameter calibrated by using a second calibration plate, and the two sets of calibration patterns of the second calibration plate are respectively placed in front of the two adjacent groups of first high-speed cameras during calibration, and the parameters of the two groups of first high-speed cameras are calibrated synchronously.

[0020] Further, in the step 1, the first high-speed camera and the second high-speed camera are jointly parameter calibrated by using a third calibration plate, and the two sets of calibration patterns of the third calibration plate are respectively placed in front of the first high-speed camera and the second high-speed camera during calibration, and the parameters of the first high-speed camera and the second high-speed camera are calibrated synchronously.

[0021] In summary, the non-contact train wheel radial run-out measuring device and the measuring method have the advantages that: the non-contact measuring device can measure the train wheel in real time during the train movement, so that the train wheel radial run-out problem can be controlled in real time and efficiently, the multi-line laser emitter structure is adopted, the scanning measurement of the train wheel is more comprehensive, and the measured radial run-out data is more accurate; the modular and intelligent design of the measuring device, together with the specially designed measuring method, can quickly and accurately measure and calculate the radial run-out data of the train wheel and timely display, which is more convenient for monitoring personnel to control the running state of the train; the application has strong practicability and strong popularization significance. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 It is a layout structure diagram of the data acquisition module in the non-contact train wheel radial run-out measuring device.

[0023] Figure 2 It is an enlarged schematic view of part of the structure. Figure 1

[0024] Figure 3 It is a side view schematic view of part of the structure. Figure 1

[0025] Figure 4 It is a working state schematic view of part of the structure. Figure 1

[0026] Figure 5 It is a structure schematic view of the first calibration plate of the non-contact train wheel radial run-out measuring method.

[0027] Figure 6 It is a structure schematic view of the second calibration plate of the non-contact train wheel radial run-out measuring method.

[0028] Figure 7 ​​​It is a front structure schematic view of the third calibration plate of the non-contact train wheel radial run-out measurement method in the application.

[0029] Figure 8 It is a back structure schematic view of the third calibration plate of the non-contact train wheel radial run-out measurement method in the application. DETAILED DESCRIPTION

[0030] In order to make the purpose, technical scheme and advantages of the application clearer, the application will be further described in detail below in combination with the drawings and examples. It should be understood that the specific examples described herein are only used to explain the application and not to limit the application.

[0031] As shown in the drawings, Figures 1 to 8 The application provides a non-contact train wheel radial run-out measurement method, which measures the radial run-out of a train wheel on a track by using a non-contact measurement device.

[0032] The non-contact measurement device comprises a data acquisition module 100, a data analysis module (not shown in the drawings), a data processing module (not shown in the drawings) and a data display module (not shown in the drawings), and the data acquisition module 100, the data analysis module, the data processing module and the data display module are sequentially signal connected. It can be understood that the data analysis module, the data processing module and the data display module are all related computer, network communication and display devices commonly used in the art. Since they are all public and prior art commonly used in the art, they will not be described again.

[0033] The data acquisition module 100 comprises a plurality of track-out modules 10, and the plurality of track-out modules 10 comprise a first laser emitter 11, a first high-speed camera 12 and a wheel sensor 13. The first laser emitter 11, the first high-speed camera 12 and the wheel sensor 13 are all installed on the outside of the track, and the first laser emitter 11 and the first high-speed camera 12 are both signal connected with the wheel sensor 13. The first laser emitter 11 is a multi-line laser emitter, which can emit multiple linear lasers at the same time.

[0034] The multi-line laser emitter can simultaneously irradiate multiple linear light spots on the surface of the train wheel, cooperate with the image shooting function of the high-speed camera, and can capture and collect three-dimensional data such as the shape and posture of the train wheel in a larger range, so as to make the subsequent measurement of the radial run-out of the train wheel more comprehensive and accurate.

[0035] The data acquisition module 100 further comprises a track-in module 20, and the track-in module 20 comprises a second laser emitter 21 and a second high-speed camera 22. The second laser emitter 21 and the second high-speed camera 22 are both installed on the inside of the track and are signal connected with each other. The second high-speed camera 22 is also provided corresponding to the wheel sensor 13 along the inside and outside direction of the track.

[0036] Specifically, in the present embodiment, the first laser emitter 11, the first high-speed camera 12 and the wheel sensor 13 of any two adjacent groups of the off-track module 10 are arranged in an interleaved manner. The interleaved arrangement can greatly optimize the reduction of the space occupied by the multiple groups of the off-track module 10 beside the track, so that the installation and layout of the measuring device have a wider range of application. The first laser emitter 11 and the second laser emitter 21 are both arranged in an inclined manner, with the center optical axis of the laser emitter forming an angle of 20°-60° with the track plane, and the angle between the adjacent linear lasers of the first laser emitter 11 and the second laser emitter 21 being less than 1°. The laser emitters arranged in a moderate inclined manner can cover a larger range of the irradiated wheel surface, and the more intensive multiple linear lasers can enable the data acquisition module 100 to capture more measurement points.

[0037] The non-contact train wheel radial run-out measurement method comprises the following steps:

[0038] Step 1: Calibrate parameters, use a calibration plate to calibrate the parameters of the first laser emitter 11, the second laser emitter 21, the first high-speed camera 12 and the second high-speed camera 22;

[0039] Specifically, the calibration plate comprises a first calibration plate 30, a second calibration plate 40 and a third calibration plate 50, wherein the first calibration plate 30 has a single face provided with a group of calibration patterns, the second calibration plate 40 has a single face provided with two groups of calibration patterns, and the two groups of calibration patterns on the second calibration plate 40 are arranged in a left-right interval, and the third calibration plate 50 has two faces each provided with a group of calibration patterns, and the two groups of calibration patterns on the third calibration plate 50 are arranged in a staggered manner;

[0040] The first calibration plate 30 is used to calibrate the parameters of the first laser emitter 11 and the second laser emitter 21. When calibrating, the first calibration plate 30 is placed vertically on the track plane, and then the first calibration plate 30 is moved horizontally and perpendicularly to the track direction to estimate the optical plane parameters at multiple positions;

[0041] The second calibration plate 40 is used to jointly calibrate the parameters of the first high-speed cameras 12 of the two adjacent groups of the off-track module 10. When calibrating, the two groups of calibration patterns of the second calibration plate 40 are placed in front of the two adjacent groups of the first high-speed cameras 12, respectively, and the parameters of the two groups of the first high-speed cameras 12 are calibrated synchronously;

[0042] The third calibration plate 50 is used to jointly calibrate the parameters of the first high-speed camera 12 and the second high-speed camera 22. When calibrating, the two groups of calibration patterns of the third calibration plate 50 are placed in front of the first high-speed camera 12 and the second high-speed camera 22, respectively, and the parameters of the first high-speed camera 12 and the second high-speed camera 22 are calibrated synchronously;

[0043] Step 2: Collecting data, when the train passes through the train track where the data collection module 100 is arranged, the wheel sensor 13 detects the passing of the train wheel and controls the first laser emitter 11, the second laser emitter 21, the first high-speed camera 12 and the second high-speed camera 22 to work, wherein the first laser emitter 11 and the second laser emitter 21 respectively emit multiple linear laser beams to irradiate on the inner and outer sides of the train wheel, and the first high-speed camera 12 and the second high-speed camera 22 respectively synchronously capture and collect the laser spot image data of the inner and outer sides of the train wheel;

[0044] Step 3: Calculating depth information, calculating the depth information of the wheel surface by the triangulation algorithm, and the formula for calculating the depth information is wherein B is the baseline distance of the first high-speed camera and the corresponding first laser emitter or the baseline distance of the second high-speed camera and the corresponding second laser emitter, f is the focal length of the first high-speed camera or the second high-speed camera, x is the parallax, and A is the depth information;

[0045] Step 4: Plane fitting, according to the image data collected by the track-in module 20, using the three-dimensional data measured by the track-in module 20 (the three-dimensional data refers to the coordinate information (X, Y) of the measured side of the train wheel and the depth information A, wherein the coordinate information (X, Y) can be directly measured by the high-speed camera cooperating with the laser, and the depth information A can be obtained by step 3) to perform plane fitting, and the fitted plane is regarded as the inner side distance plane;

[0046] Step 5: Recording measurement points, taking the inner side distance plane as the calculation reference, according to the image data collected by the track-out module 10, converting the three-dimensional data measured by the track-out module 10 to a unified coordinate system through rotation and translation, and finding a point on the tread of the train wheel which is perpendicular to the outer side of the inner side distance plane and has a distance of z=70mm, and recording it as a measurement point;

[0047] Step 6: Rolling circle fitting, sequentially fitting the recorded measurement points obtained by the same track-out module 10 to obtain a rolling circle and calculate the corresponding rolling circle diameter Di, wherein i is the serial number of the current track-out module 10, and the value is 1, 2, 3…n;

[0048] Step 7: Iterating the optimal rolling circle diameter, finding the maximum value Dmax and the minimum value Dmin from the rolling circle diameters of all track-out modules 10, and iterating and obtaining the optimal rolling circle diameter Do from the minimum diameter Dmin to the maximum diameter Dmax with a step of 0.1mm, and the iteration formula is wherein Li is the distance from a measurement point to the center of the fitted circle, and N is a fixed value, and adding the fixed value N is to increase the upper and lower limit range of iteration, so as to prevent missing the optimal circle;

[0049] Step 8: calculate the radial runout, determine the optimal rolling circle by the optimal rolling circle diameter Do, and then obtain the radius R of the optimal rolling circle and the coordinates (Ox, Oy) of the center of the circle; calculate the distance Si between the coordinates of the measuring point (xi, yi) and the coordinates of the center of the optimal rolling circle according to the radius R of the optimal rolling circle, the coordinates (Ox, Oy) of the center of the circle and the coordinates of the measuring point (xi, yi); the calculation formula is Then, the radial runout NC is calculated according to the definition of the radial runout, and the calculation formula is NC = max{S1, S2, …, Sn}.

[0050] In summary, the beneficial effects of the non-contact train wheel radial runout measuring device and measuring method are as follows: by designing a non-contact measuring device, the train wheel can be measured in real time during the movement of the train, so that the problem of train wheel radial runout can be controlled in real time and efficiently; the measuring device adopts a multi-line laser emitter structure, which can more comprehensively scan and measure the train wheel, and thus the measured radial runout data is more accurate; the measuring device adopts modular and intelligent design, and can quickly and accurately measure and calculate the radial runout data of the train wheel by using the specially designed measuring method, and timely display, which is more convenient for monitoring personnel to control the running state of the train; the application has strong practicability and strong popularization significance.

[0051] The above-described embodiments only express one implementation of the application, and the description is more specific and detailed, but it cannot be understood as limiting the scope of the application. It should be noted that for ordinary skilled persons in the art, without departing from the concept of the application, a number of modifications and improvements can be made, which belong to the protection scope of the application. Therefore, the protection scope of the application should be subject to the appended claims.

Claims

1. A non-contact train wheel radial run-out measuring device for detecting a train wheel on a track, characterized by: The application relates to a non-contact train wheel radial run-out measuring device and a measuring method thereof.

2. The non-contact train wheel radial run-out measuring device of claim 1, wherein: Any two adjacent groups of the track-out modules are arranged in interpenetration and interlacing mode.

3. The non-contact train wheel radial run-out measuring device of claim 2, wherein: The first laser emitter and the second laser emitter are both arranged in an inclined mode, the included angle between the central optical axis and the track plane is 20-60 DEG, and the included angle between adjacent linear lasers of the first laser emitter and the second laser emitter is less than 1 DEG.

4. A method of measuring the radial run-out of a train wheel by using the non-contact train wheel radial run-out measuring device according to any one of claims 1 to 3, wherein the radial run-out of a train wheel on a track is measured. The non-contact train wheel radial run-out measuring method comprises the following steps: Step 1: parameter calibration, the parameters of the first laser emitter, the second laser emitter, the first high-speed camera and the second high-speed camera are calibrated by using a calibration plate; Step 2: data acquisition, when a train passes through a train track provided with the data acquisition module, the wheel sensor detects the passing of the train wheel and controls the first laser emitter, the second laser emitter, the first high-speed camera and the second high-speed camera to work, wherein the first laser emitter and the second laser emitter emit multiple linear lasers on the inner and outer sides of the train wheel, and the first high-speed camera and the second high-speed camera synchronously capture the laser spot image data on the inner and outer sides of the train wheel; Step 3: Calculate the depth information, calculate the depth information of the wheel surface by the triangulation algorithm, the formula for calculating the depth information is Wherein B is the baseline distance of the first high-speed camera and the corresponding first laser emitter or the baseline distance of the second high-speed camera and the corresponding second laser emitter, f is the focal length of the first high-speed camera or the second high-speed camera, x is the parallax, and A is the depth information. Step 4: plane fitting, according to the image data collected by the track-in module, the three-dimensional data measured by the track-in module is used for plane fitting, and the fitting plane is regarded as the inner side distance plane; Step 5: recording the measuring point, taking the inner side distance plane as the calculation reference, according to the image data collected by the track-out module, the three-dimensional data measured by the track-out module is converted into a unified coordinate system through rotation and translation, and a point on the train wheel tread which is perpendicular to the outer side of the inner side distance plane and has a distance of z=70mm is found and recorded as the measuring point; Step 6: rolling circle fitting, the recorded measuring points obtained by the same track-out module are sequentially fitted into rolling circles, the rolling circles are obtained, and the corresponding rolling circle diameters Di are calculated, wherein i is the serial number of the current track-out module, and the value is 1, 2, 3...n. Step 7: traversing the optimal rolling circle diameter, finding the maximum value Dmax and the minimum value Dmin from the rolling circle diameters of all off-track modules, traversing from the minimum diameter Dmin to the maximum diameter Dmax in steps of 0.1 mm to obtain the optimal rolling circle diameter Do, and the traversal formula is wherein Li is the distance from a measuring point to the center of the fitting circle, and N is a fixed value; Step 8: Calculate the radial runout, determine the optimal rolling circle by the optimal rolling circle diameter Do, and then obtain the radius R and the center coordinates (Ox, Oy) of the optimal rolling circle, calculate the distance Si between the measuring point coordinates and the center coordinates of the optimal rolling circle according to the radius R and the center coordinates (Ox, Oy) of the optimal rolling circle and the measuring point coordinates (xi, yi), and the calculation formula is Then calculate the radial runout NC according to the definition of the radial runout, and the calculation formula is NC = max{S1, S2, …, Sn}.

5. The method of claim 4, wherein: the non-contact train wheel radial runout measurement method further comprises: determining a distance between the train wheel and the train wheel sensor; and determining a distance between the train wheel and the train wheel sensor at a plurality of different times. In the step 1, the calibration plate comprises a first calibration plate, a second calibration plate and a third calibration plate, wherein the first calibration plate is provided with a group of calibration patterns on one side, the second calibration plate is provided with two groups of calibration patterns on one side, and the two groups of calibration patterns on the second calibration plate are arranged in a left-right interval, and the third calibration plate is provided with two groups of calibration patterns on two sides respectively, and the two groups of calibration patterns on the third calibration plate are arranged in a staggered manner.

6. The method of claim 5, wherein: the non-contact train wheel radial runout measurement method further comprises: determining a distance between the train wheel and the train wheel sensor; and determining a distance between the train wheel and the train wheel sensor based on the train wheel rotation speed. In the step 1, the first calibration plate is used to calibrate the parameters of the first laser emitter and the second laser emitter, and the first calibration plate is placed vertically on the track plane, and then the first calibration plate is moved horizontally and perpendicularly to the track direction to estimate the light plane parameters.

7. The method of claim 5, wherein: the non-contact train wheel radial runout measurement method further comprises: determining a distance between the train wheel and the train wheel sensor; and determining a distance between the train wheel and the train wheel sensor based on the train wheel rotation speed. In the step 1, the second calibration plate is used to jointly calibrate the parameters of the first high-speed cameras of the two adjacent groups of off-track modules, and the two groups of calibration patterns of the second calibration plate are placed in front of the two adjacent groups of first high-speed cameras respectively, and the parameters of the two groups of first high-speed cameras are calibrated synchronously.

8. The method of claim 5, wherein: the non-contact train wheel radial runout measurement method further comprises: determining a distance between the train wheel and the train wheel sensor; and determining a distance between the train wheel and the train wheel sensor based on the train wheel rotation speed. In the step 1, the third calibration plate is used to jointly calibrate the parameters of the first high-speed camera and the second high-speed camera, and the two groups of calibration patterns of the third calibration plate are placed in front of the first high-speed camera and the second high-speed camera respectively, and the parameters of the first high-speed camera and the second high-speed camera are calibrated synchronously.

Images