Steel rail defect laser additive data processing method and system

Abstract

The invention provides a steel rail defect laser additive data processing method and system, relates to the technical field of steel rail defect laser additive repair, and aims to generate a laser power adjustment instruction by analyzing a speed change curve of a laser head on a predicted motion path and combining a speed power function. In the process of executing the movement of the laser head, the actual instantaneous speed corresponding to the specific movement instruction point is obtained in real time, and the output power of the laser is synchronously adjusted, so that the deviation between the actual movement and the predicted movement is effectively compensated, and the uniformity and stability of laser energy input are ensured. Compared with the prior art, a more reasonable laser power adjusting strategy can be planned in advance, and blindness in the repairing process is avoided; the influence of dynamic characteristics of mechanical motion on energy input is effectively compensated, and the uniformity and stability of laser energy input are ensured. According to the overall scheme, structural defects in the repairing layer can be remarkably reduced, and repairing quality and reliability are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of laser additive repair of rail defects, in particular to a laser additive data processing method and system for rail defects. BACKGROUND

[0002] In the field of modern rail maintenance, laser additive repair technology is widely used to repair surface defects of rails to extend their service life and ensure safe operation. The core of such repair systems is the data processing software, which is responsible for converting the collected three-dimensional defect information into executable motion trajectories and process parameters for laser additive equipment. However, in practical applications, due to material properties, equipment kinematic limitations, and deficiencies in existing data processing logic, hidden structural defects may form within the repair layer, affecting the long-term reliability of the repair.

[0003] Specifically, in modern laser additive repair systems for rail defects, the core data processing software plays a crucial role in converting the collected three-dimensional defect data into executable motion trajectories and process parameters for laser additive equipment. To ensure repair efficiency, this software typically prioritizes processing speed in its "laser filling path generation logic" at the design stage. Therefore, a common and computationally efficient strategy is to use a "reciprocal raster" filling path, where the laser head scans back and forth in a zigzag trajectory within the area to be repaired. This path has the advantages of simple geometry, easy algorithm implementation, and the ability to quickly cover large areas, thereby shortening the overall repair time. To match this path strategy, a standard "laser power and scanning speed correlation function" is used. This function is based on ideal conditions, assuming that laser energy can be uniformly applied to the material surface, and that the powder supply is stable and uniform. It binds the output power of the laser with the scanning speed through a predetermined mathematical relationship to maintain a relatively constant energy density input throughout the repair process. However, when the equipment begins to execute the pre-set "reciprocal raster" filling path, an inherent physical limitation presents new challenges. At the edges of the filling area, when the laser head needs to make a 180-degree turn to change the scanning direction, the motion control system cannot achieve instantaneous turning. It must instruct the laser head to "slow down to zero, reverse, and accelerate again" to complete this action. This deceleration-stop-acceleration process results in a significant increase in the dwell time of the laser spot at these corner points. However, the standard power function in current data processing software is not fully associated with the motion state, and it does not correspondingly and significantly reduce the output power when the laser head slows down. This means that at these corners, the laser still outputs power according to its speed during uniform scanning, while the spot stays in the local area for a longer time, resulting in a sudden increase in energy input per unit area.

[0004] The superimposed effect of the "power not timely adjustment" and "light spot long stay" at the corner point will form a local "heat peak". This energy peak will not only cause the substrate to be over-melted in this area, but more importantly, it will instantly vaporize those "fine particles" that are located at the periphery of the powder beam and are more sensitive to heat due to their fine characteristics. These particles, due to their large specific surface area, can be melted and integrated into the molten pool under normal power, but under the action of this energy peak, they will quickly reach the vaporization temperature, directly change into metal vapor, and form tiny bubbles inside the molten pool. With the rapid solidification of the molten pool, these tiny bubbles formed at the heat peak will be "frozen" inside the repair layer. Due to the regularity of the "reciprocal grating" path, these bubbles will be regularly distributed along all the "corners" of the filling path, thus forming a series of linear "micro-porous bands". From the outside of the repaired steel rail, its surface is smooth and the size is accurate, and no visible defects can be found by the naked eye or conventional surface detection methods. However, the inside of the repair area has actually produced "structural weaknesses" due to the regular distribution of micro-pores. These weaknesses will become the starting point of stress concentration under the repeated action of train load during the long-term service of the steel rail, significantly reducing the fatigue resistance of the repair area, and thus burying the potential failure risk.

[0005] Therefore, it is an urgent problem for those skilled in the art to provide a steel rail defect laser additive data processing method and system for solving the above problems. SUMMARY

[0006] In order to solve the problems of the prior art, the present application provides a steel rail defect laser additive data processing method and system, which aims to solve the problem that due to the material characteristics, kinematic constraints of the equipment, and the shortcomings of the existing data processing logic, hidden structural defects may be formed inside the repair layer in the existing steel rail laser additive repair technology, thereby affecting the long-term reliability of the repair.

[0007] Based on the above purposes, the technical scheme provided by the present application is as follows: In a first aspect, the present application discloses a steel rail defect laser additive data processing method, applied to a steel rail defect laser additive repair scene, comprising the following steps: Obtaining three-dimensional geometric data of the target steel rail defect, generating a motion trajectory instruction of the laser head according to a preset strategy; Analyzing the motion trajectory instruction to generate a speed change curve of the laser head on the predicted motion path; According to the speed change curve on the predicted motion path and the speed-power function, a laser power adjustment instruction is obtained; During the laser head moving process, the motion trajectory instruction and the laser power adjustment instruction are received, the actual instantaneous speed corresponding to a specific motion instruction point is obtained according to the motion trajectory instruction, and the laser output power is adjusted synchronously.

[0008] Through the technical scheme, the synchronous adjustment of the laser head motion speed and the laser power can be realized, hidden structural defects in the repair layer can be effectively avoided, and the long-term reliability of the repair is improved.

[0009] Further, in the steel rail defect laser additive data processing method, the speed-power function is obtained based on the following steps: Designing the laser head scanning target steel rail defects under a plurality of first scanning speeds; Performing metallographic analysis on the target steel rail defects; According to the metallographic analysis result, determining the first ideal power corresponding to each first scanning speed, fitting the first scanning speed and the first ideal power, and obtaining the speed-power function.

[0010] Through the technical scheme, the speed-power function can be obtained by fitting the experimental data, providing a data basis for the subsequent accurate adjustment of the laser power, and thus the repair quality is improved.

[0011] On the basis, the application further proposes that the laser power adjustment instruction is obtained according to the speed change curve on the predicted motion path and the speed-power function, including the following steps: According to the speed change curve, obtaining the first instantaneous speed corresponding to each motion instruction point on the predicted motion path; According to the first instantaneous speed and the speed-power function, obtaining the first power corresponding to each motion instruction point; Integrating the first power corresponding to all motion instruction points in time sequence to generate the laser power adjustment instruction.

[0012] Through the technical scheme, the laser power adjustment instruction can be dynamically calculated and generated according to the speed change on the predicted path, ensuring the accurate delivery of laser energy and further improving the repair effect.

[0013] In some preferred embodiments, in the steel rail defect laser additive data processing method, the specific motion instruction point is obtained based on the following steps: According to the speed change curve, obtaining the first instantaneous speed corresponding to each motion instruction point on the predicted motion path; Calculating the first derivative and the second derivative of the first instantaneous speed corresponding to each motion instruction point; According to the first derivative, determining the extreme point; Firstly judging whether the second derivative is of opposite signs on both sides of the extreme point; If the first judgment result is yes, it is defined as a specific motion instruction point.

[0014] Through the technical scheme, the key motion instruction point can be accurately identified through mathematical analysis of the speed change curve, a more accurate reference point is provided for subsequent laser power synchronous adjustment, and the response speed and precision of adjustment are improved.

[0015] As an optional solution, after the speed-power function is obtained, the following steps are further included: Designing a plurality of laser heads scanning target steel rail defects at different second scanning speeds; Performing metallographic analysis on the target steel rail defects; According to the metallographic analysis result, determining the second ideal power corresponding to each second scanning speed; Analyzing and fitting the second light radiation intensity obtained under the combination of different second scanning speeds and second ideal powers, and establishing a light radiation reference function to compensate the first power.

[0016] Through the technical scheme, the light radiation reference function is established, the light radiation intensity is introduced as a compensation factor, the adjustment of the laser power is further optimized, and the stability and consistency of the repair are improved.

[0017] In order to enhance the function, after obtaining the first power corresponding to each motion instruction point according to the first instantaneous speed and the speed-power function, the following steps are further included: According to the first instantaneous speed and the first power, obtaining the first light radiation intensity; According to the light radiation reference function and the pre-processed first light radiation intensity, obtaining a light radiation residual value; According to the light radiation residual value and the preset historical residual accumulation, obtaining a power compensation value to compensate the first power.

[0018] Through the technical scheme, the light radiation residual value and the historical residual accumulation are used to dynamically calculate the power compensation value, the real-time fine adjustment of the laser power is realized, the uncertainty in the actual repair process is effectively dealt with, and the repair quality is further improved.

[0019] To perfect the scheme, after obtaining the power compensation value according to the light radiation residual value and the preset historical residual accumulation to compensate the first power, the following steps are further included: According to the first power and the power compensation value, obtaining the compensated first power; Integrating all the compensated first powers corresponding to the motion instruction points in time sequence to generate a new laser power adjustment instruction to update the laser power adjustment instruction.

[0020] By the technical scheme, the calculated power compensation value can be applied to the original power to generate more accurate laser power adjustment instructions, ensure the accuracy of laser energy delivery, and thus obtain more ideal repair effect.

[0021] In actual application, in the process of moving the laser head, the following steps are further included: When the laser head moves by one unit distance, a corresponding digital pulse signal is acquired by a grating encoder installed on the movement axis of the laser head and input into the controller; In the process of moving the laser head, the controller controls the laser to deliver energy according to the digital pulse signal corresponding to each unit distance and the currently synchronously adjusted laser output power, so as to ensure that the energy density delivered in the unit distance is consistent with the expectation of the laser power adjustment instruction.

[0022] By the technical scheme, the movement distance of the laser head can be monitored in real time by the grating encoder, and the accurate delivery of laser energy can be realized in combination with the currently synchronously adjusted laser output power, so as to ensure the uniformity of energy density in the repair process and effectively avoid overburning or underburning.

[0023] In a second aspect, the application further discloses a steel rail defect laser additive data processing system, which is applied to a steel rail defect laser additive repair scene and includes: A movement trajectory instruction module is configured to acquire three-dimensional geometric data of a target steel rail defect, and generate a movement trajectory instruction of a laser head according to a preset strategy; A speed change curve module is configured to analyze the movement trajectory instruction and generate a speed change curve of the laser head on a predicted movement path; A laser power adjustment instruction module is configured to obtain a laser power adjustment instruction according to the speed change curve on the predicted movement path and a speed-power function; A power adjustment module is configured to receive the movement trajectory instruction and the laser power adjustment instruction in the process of moving the laser head, acquire an actual instantaneous speed corresponding to a specific movement instruction point according to the movement trajectory instruction, and synchronously adjust the output power of the laser.

[0024] By the technical scheme, a system for implementing the above steel rail defect laser additive data processing method can be provided, the system can work cooperatively, the synchronous adjustment of the movement speed of the laser head and the laser power can be realized, the problem of internal structural defects of a repair layer in the prior art can be effectively solved, and the long-term reliability of repair is improved.

[0025] Preferably, the system further includes: A grating encoder is installed on the movement axis of the laser head and is configured to acquire a corresponding digital pulse signal when the laser head moves by one unit distance; A controller is configured to control the laser to emit energy according to the digital pulse signal corresponding to each unit distance and the laser output power synchronously adjusted in the process of moving the laser head, so as to ensure that the energy density emitted in the unit distance is consistent with the expected laser power adjustment instruction.

[0026] By the technical solution, the spatial domain closed-loop control based on physical displacement is introduced, and the theoretical energy uniformity is realized on the real workpiece without any doubt. It compensates for all underlying errors and external disturbances, and finally realizes the technical advantages directly into the significant improvement of the microstructure and macro performance of the repair layer, thereby greatly enhancing the reliability, accuracy and industrial applicability of the entire technical solution.

[0027] The steel rail defect laser additive data processing method disclosed in the application obtains three-dimensional geometric data of the target steel rail defect and generates a motion trajectory instruction of the laser head, and then analyzes the instruction to generate a speed change curve. On this basis, the laser power adjustment instruction is obtained according to the speed change curve and the speed-power function. In the process of moving the laser head, the method can receive the motion trajectory instruction and the laser power adjustment instruction, and obtain the actual instantaneous speed corresponding to a specific motion instruction point according to the motion trajectory instruction, and synchronously adjust the output power of the laser. The method effectively solves the problem of internal structure defects of the repair layer caused by material properties, kinematic limitations of equipment and insufficient existing data processing logic in the laser additive repair process. By synchronously adjusting the motion speed of the laser head and the output power of the laser in real time, the application can ensure uniform emission of laser energy on the entire repair path, avoid local overheating or insufficient energy, thereby significantly improving the quality and uniformity of the repair layer, effectively prolonging the service life of the steel rail, and enhancing the operation safety. BRIEF DESCRIPTION OF DRAWINGS

[0028] In order to more clearly illustrate the technical solutions in the embodiments of the application or the prior art, the drawings needed to be used in the embodiments or the prior art description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative labor.

[0029] Figure 1 A flowchart of a steel rail defect laser additive data processing method provided by an embodiment of the application is shown in the figure. Figure 2 A flowchart of obtaining a speed-power function provided by an embodiment of the application is shown in the figure. Figure 3 A flowchart of step S3 provided by an embodiment of the application is shown in the figure. Figure 4A flowchart for obtaining a specific motion instruction point is provided for the embodiments of the present application. Figure 5 A flowchart for executing a laser head movement process is provided for the embodiments of the present application. Figure 6 A structural schematic diagram of a steel rail defect laser additive data processing system is provided for the embodiments of the present application. DETAILED DESCRIPTION

[0030] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0031] The embodiments of the present application are written in a progressive manner.

[0032] In the field of modern rail maintenance, laser additive repair technology is widely used to repair rail surface defects to prolong the service life and ensure the operation safety. The core of such repair systems is the data processing software, which is responsible for converting the collected three-dimensional defect information into executable motion trajectories and process parameters for laser additive equipment. However, in actual application, due to material properties, equipment kinematics limitations and the shortcomings of existing data processing logic, hidden structural defects may be formed inside the repair layer, thereby affecting the long-term reliability of the repair.

[0033] As shown in Figure 1 Based on this, a steel rail defect laser additive data processing method is provided, applied to a steel rail defect laser additive repair scene, including the following steps: S1. Obtain three-dimensional geometric data of the target steel rail defect, and generate motion trajectory instructions of the laser head according to a preset strategy; S2. Analyze the motion trajectory instructions to generate a speed change curve of the laser head on the predicted motion path; S3. Obtain laser power adjustment instructions according to the speed change curve on the predicted motion path and a speed-power function; S4. During the execution of the laser head movement process, receive the motion trajectory instructions and the laser power adjustment instructions, obtain the actual instantaneous speed corresponding to a specific motion instruction point according to the motion trajectory instructions, and synchronously adjust the output power of the laser.

[0034] The rail defect in the laser additive data processing method for rail defects refers to various damages existing on the surface or inside of the rail, such as wear, cracks, spalling, etc. These defects will affect the normal use of the rail and the safety of train operation. Laser additive repair is a technology that uses laser as a heat source to melt metal powder and accumulate layer by layer to repair or rebuild damaged parts. This technology has the advantages of high repair precision, small heat-affected zone, and high material utilization rate.

[0035] The acquisition of the three-dimensional geometric data of the target rail defect in step S1 can be achieved in various ways. For example, a three-dimensional scanner can be used to scan the rail defect area to generate point cloud data, and then a three-dimensional geometric model of the defect can be reconstructed by data processing software. Another way is to use industrial CT (Computed Tomography) technology for non-destructive testing of rail defects to obtain three-dimensional information of their internal structure. In addition, high-precision three-dimensional data of the defect surface can be obtained through laser ranging sensors or structured light projection technology; the preset strategy can be set according to the type, size, depth of the defect, and the characteristics of the repair material, etc. For example, for linear defects, the laser head can be set to scan straight along the defect direction; for planar defects, the laser head can be set to scan reciprocally or spirally. The motion trajectory instructions usually include a series of coordinate points of the laser head in three-dimensional space and the motion speed information of each point. These instructions can be pre-programmed G code or similar numerical control instructions for directly controlling the motion system of the laser additive device; The analysis of the motion trajectory instructions in step S2 to generate the velocity variation curve of the laser head on the predicted motion path means that in the actual laser additive process, the motion speed of the laser head is not constant, especially at the corners of the trajectory or the acceleration and deceleration sections, the speed will change significantly. Therefore, the preset motion trajectory instructions need to be analyzed to calculate the instantaneous speed of the laser head at each point on the entire predicted motion path, so as to obtain a continuous velocity variation curve. This can be accurately calculated by kinematics model or simulation software; The velocity-power function in step S3 is a function that describes the relationship between the motion speed of the laser head and the required laser power. This function can be obtained by experimental calibration or theoretical modeling. For example, when the motion speed of the laser head is fast, the laser power may need to be increased accordingly to ensure sufficient energy input; conversely, when the speed is slow, the power may need to be reduced to avoid overheating. By substituting the predicted velocity variation curve into the velocity-power function, the ideal laser power at each point on the entire motion path can be calculated, and then the laser power adjustment instructions can be generated. These instructions usually exist in the form of time sequence or position sequence, which are used to control the output power of the laser in real time; In the execution of the laser head movement in step S4, the motion trajectory instruction and the laser power adjustment instruction are received, the actual instantaneous speed corresponding to a specific motion instruction point is obtained according to the motion trajectory instruction, and the output power of the laser is adjusted synchronously. The actual motion speed of the laser head may deviate from the predicted speed due to factors such as mechanical inertia and friction during the actual movement of the laser head. Therefore, it is necessary to monitor the actual instantaneous speed of the laser head in real time. For example, the real-time position and speed information can be obtained through an encoder or a displacement sensor installed on the motion shaft of the laser head. When it is detected that the actual instantaneous speed of the laser head deviates from the predicted speed, the system will adjust the output power of the laser synchronously according to the pre-generated laser power adjustment instruction, so as to ensure that the energy density of the laser energy input into the rail defect area remains stable at different speeds, thereby avoiding defects in the repair layer caused by uneven energy input.

[0036] Steps S1 to S4 realize fine control of laser energy input by introducing analysis of the speed change curve of the laser head on the predicted motion path and generating a laser power adjustment instruction in combination with a speed-power function. During the execution of the laser head movement, the actual instantaneous speed corresponding to a specific motion instruction point is obtained in real time, and the output power of the laser is adjusted synchronously, effectively compensating for the deviation between the actual motion and the predicted motion, and ensuring the uniformity and stability of the laser energy input.

[0037] Compared with the traditional constant power or simple empirical adjustment method, the advantages of the present application are as follows: first, by analyzing the speed change curve on the predicted motion path, a more reasonable laser power adjustment strategy can be planned in advance, avoiding blindness in the repair process; second, in the actual execution process, the actual instantaneous speed of the laser head is obtained in real time and the laser power is adjusted synchronously, effectively compensating for the influence of the dynamic characteristics of mechanical motion on energy input, and ensuring the uniformity and stability of the laser energy input. This fine control method can significantly reduce the structural defects in the repair layer and improve the repair quality and reliability.

[0038] As shown in Figure 2 Further, in the steel rail defect laser additive data processing method, the speed-power function is obtained based on the following steps: A1. Designing a laser head to scan a target rail defect at a plurality of first scanning speeds; A2. Performing metallographic analysis on the target rail defect; A3. According to the metallographic analysis result, determining a first ideal power corresponding to each first scanning speed, fitting the first scanning speed and the first ideal power, and obtaining a speed-power function.

[0039] The laser head scans the target steel rail defect at multiple first scanning speeds in step A1, which means that before the actual additive repair, the target steel rail defect is scanned by laser additive at different laser head scanning speeds through experiments. The first scanning speed can be understood as the moving speed of the laser head relative to the steel rail defect during scanning, and the purpose is to simulate various speed conditions that may be encountered during actual repair, so as to obtain experimental data of material response under different speeds; The metallographic analysis of the target steel rail defect in step A2 is to analyze the microstructure of the steel rail defect area after laser additive repair under different speeds after completing the scanning experiment. Metallographic analysis usually includes grinding, polishing, etching and other treatments on the cross section of the repaired area, and then observing its organizational structure, grain size, defect (such as pore, crack) distribution, etc. through optical microscope or scanning electron microscope. The purpose is to evaluate the metallurgical quality and defect of the additive layer under different scanning speed and power combinations, and to provide objective basis for subsequent determination of ideal power; The first ideal power corresponding to each first scanning speed is determined according to the metallographic analysis results in step A3, which means that according to the quality of the additive layer revealed by metallographic analysis, such as density, hardness, grain structure and other indicators, it is judged which power can obtain the best repair effect under a certain first scanning speed. The first ideal power is the laser output power that makes the additive layer reach the preset quality standard (such as no obvious pores, cracks, uniform and dense organization); fitting the first scanning speed and the first ideal power to obtain the speed power function means that the data points of multiple first scanning speeds and their corresponding first ideal power obtained in the experiment are fitted by mathematical method. The fitting process can use linear regression, polynomial fitting, exponential fitting and other mathematical models to establish a function that can describe the relationship between speed and ideal power. The speed power function will be an important basis for generating subsequent laser power adjustment instructions, ensuring that the laser power can be adjusted in real time and accurately when the laser head moving speed changes, so as to maintain stable additive quality.

[0040] Steps A1 to A3 are the specific implementation details of obtaining the speed-power function, which is systematically obtained through experimental design, metallographic analysis and data fitting. Specifically, by designing laser head scanning of target rail defects at multiple first scanning speeds, various speed conditions that may occur during laser additive repair can be fully covered, thereby obtaining raw data of material response at different speeds. Subsequently, metallographic analysis is performed on the target rail defects, which enables objective evaluation of repair quality at different scanning parameters from a microscopic perspective, thereby accurately determining the first ideal power corresponding to each first scanning speed. It is precisely due to this rigorous method based on actual experiments and microscopic analysis that the obtained speed-power function can accurately reflect the internal relationship between speed and ideal power, thereby providing a reliable basis for subsequent accurate adjustment of laser power.

[0041] In some preferred embodiments, the following is described by a specific example. Assuming that when obtaining the speed-power function, the following experiment can be designed: first, set multiple first scanning speeds of the laser head on the target rail defect for additive scanning, for example, it can be set to 5 mm / s, 10 mm / s, 15 mm / s and 20 mm / s. For each first scanning speed, different laser powers are tried through multiple experiments, and metallographic analysis is performed on the additive area after each experiment. For example, when the first scanning speed is 10 mm / s, metallographic analysis shows that when the laser power is 1500 W, the additive layer has a dense structure, no obvious pores and cracks, and fine and uniform grains, which is determined as the first ideal power at this speed. Similarly, the first ideal power at other speeds can be determined. For example, 5 mm / s corresponds to 1200 W, 15 mm / s corresponds to 1800 W, and 20 mm / s corresponds to 2200 W. Finally, these speed and ideal power data points (5, 1200), (10, 1500), (15, 1800), (20, 2200) are input into the data processing software, and a mathematical function describing the relationship between speed and ideal power, i.e. the speed-power function, is fitted by using polynomial fitting or linear regression method. For example, the function can be in the form of P = aV + b, where P is the laser power, V is the scanning speed, and a and b are fitting coefficients. This function will be used for subsequent real-time adjustment of laser power.

[0042] As shown in Figure 3 Based on the above, the present application further proposes that, according to the speed change curve on the predicted motion path and the speed-power function, a laser power adjustment instruction is obtained, including the following steps: B1. According to the speed change curve, obtain the first instantaneous speed corresponding to each motion instruction point on the predicted motion path; B2. Obtain a first power corresponding to each motion instruction point according to the first instantaneous speed and the speed-power function; B3. Integrate the first powers corresponding to all motion instruction points in time sequence to generate a laser power adjustment instruction.

[0043] The speed change curve in step B1 can be understood as a function or data set of the speed of the laser head changing with time or position on the predetermined motion path. The curve reflects the expected motion speed of the laser head at different position points during the repair process. The motion instruction point refers to a discretized point on the motion trajectory of the laser head, each point corresponding to a specific position and time, and can be associated with an instantaneous speed. The first instantaneous speed refers to the instantaneous speed value of the laser head at each specific motion instruction point on the predicted motion path; The speed-power function in step B2 is a function describing the relationship between the laser scanning speed and the required laser power, which is usually obtained through experimental calibration and data fitting to ensure that the desired additive effect can be obtained at different scanning speeds. The first power refers to the laser output power required at the first instantaneous speed of the laser head at a specific motion instruction point, which is obtained by consulting or calculating the speed-power function; The laser power adjustment instruction in step B3 is a series of instructions formed by integrating the first powers corresponding to all motion instruction points in time sequence, which is used to control the output power of the laser in real time during the actual movement of the laser head, so that it matches the instantaneous speed of the laser head.

[0044] Steps B1 to B3 are specific implementation details of step S3, which ensure the accuracy of power output in the laser additive repair process by refining the generation process of laser power adjustment instructions. Specifically, first, by analyzing the speed change curve of the laser head on the predicted motion path, the corresponding first instantaneous speed at each motion instruction point can be obtained. Since the quality of laser additive repair is closely related to the laser energy density, and the energy density is jointly affected by the laser power and the scanning speed, when the speed of the laser head changes, the laser power needs to be adjusted accordingly to maintain stable energy input. Second, using the pre-obtained speed-power function, the required first power can be accurately calculated according to the first instantaneous speed at each motion instruction point. This speed-power function is fitted based on a large amount of experimental data and can reflect the optimal power required to achieve ideal additive effect at different scanning speeds. Finally, integrating these calculated first power values in chronological order forms a complete laser power adjustment instruction. These instructions are executed in real time when the laser head actually moves, thereby achieving dynamic matching of laser power and instantaneous speed of the laser head. This refined power adjustment mechanism can effectively avoid uneven energy density caused by speed changes, thereby improving the quality and stability of additive repair. This effectively solves the problem of unstable additive quality caused by mismatch between laser power and scanning speed in traditional methods. Thus, it can ensure that the laser energy density remains within the optimal range throughout the repair process, thereby significantly improving the quality, uniformity and reliability of steel rail defect laser additive repair, reducing the need for secondary processing after defect repair, and prolonging the service life of the repaired parts.

[0045] As shown in Figure 4 In some preferred embodiments, the specific motion instruction point in the steel rail defect laser additive data processing method is obtained based on the following steps: C1. Obtain the first instantaneous speed corresponding to each motion instruction point on the predicted motion path according to the speed change curve; C2. Calculate the first derivative and second derivative of the first instantaneous speed corresponding to each motion instruction point; C3. Determine the extreme point according to the first derivative; C4. First determine whether the second derivative has different signs on both sides of the extreme point; C5. If the first determination result is yes, define it as a specific motion instruction point.

[0046] The specific motion instruction point refers to a key point on the laser head motion path where the speed change trend changes significantly. These points usually correspond to the positions of the laser head when it is accelerating, decelerating, or turning, etc. The first instantaneous speed refers to the instantaneous speed value of the laser head at each motion instruction point on the predicted motion path. By obtaining these instantaneous speeds, the motion state of the laser head can be quantitatively described; The calculation of the first and second derivatives of the first instantaneous speed in step C2 aims to analyze the rate and trend of speed change. The first derivative reflects the speed change rate, i.e., acceleration; the second derivative reflects the acceleration change rate, i.e., the inflection point of the speed change trend.

[0047] The determination of extreme points according to the first derivative in step C3 means identifying points where the speed reaches a local maximum or minimum. These extreme points are key turning points of speed change; The judgment of whether the second derivative has different signs on both sides of the extreme point in step C4 is used to further confirm whether the extreme point is a true inflection point, i.e., a point where the speed change trend changes. For example, when the second derivative changes from positive to negative or from negative to positive on both sides of the extreme point, it indicates that the point is an inflection point of the speed change rate, and the motion state of the laser head has changed essentially at this point.

[0048] If the first judgment result is yes in step C5, the point is defined as a specific motion instruction point. In this way, the key control points of the laser head on the complex motion path can be accurately identified.

[0049] Steps C1 to C5 are the specific implementation details of obtaining the specific motion instruction point. By deeply analyzing the speed change curve of the laser head on the predicted motion path, especially using the first and second derivatives to identify the specific motion instruction point, the problem of accurately capturing key speed change points during high-speed or complex motion of the laser head is solved. Further, by calculating the first derivative of the first instantaneous speed, the increasing and decreasing trend of the speed can be identified, and the second derivative can reveal the inflection point of the speed change rate. When the second derivative has different signs on both sides of the extreme point, it indicates that the point is a true turning point of the speed change trend, such as from acceleration to deceleration, or from a convex curve to a concave curve. These points are key positions where the motion state of the laser head changes significantly. Accurate identification of these points can provide more accurate basis for subsequent laser power synchronous adjustment. Thus, it ensures that the laser power can be more closely matched with the actual instantaneous speed during the motion of the laser head, especially in areas with dramatic speed changes, thereby ensuring the uniformity and quality of additive repair.

[0050] In an actual laser additive repair process, due to the influence of various factors such as material batch difference, environmental temperature fluctuation, and laser performance attenuation, relying only on the pre-fitted speed-power function may not completely guarantee the accuracy and stability of the laser power, which may lead to inconsistency or defects in the additive repair quality. If the above problems are not solved, the metallurgical quality, bonding strength and final repair effect of the repair layer may be affected.

[0051] Based on this, as an optional solution, after obtaining the speed-power function, the following steps are further included: Designing the laser head to scan the target rail defect at a plurality of second scanning speeds; Performing metallographic analysis on the target rail defect; According to the metallographic analysis result, determining the second ideal power corresponding to each second scanning speed; Analyzing and fitting the second light radiation intensity obtained under the combination of different second scanning speeds and second ideal powers, and establishing a light radiation reference function to compensate for the first power.

[0052] The laser head scans the target steel rail defect at a plurality of second scanning speeds is to perform additional experiments after obtaining the initial speed-power function in order to further optimize power control. These experiments involve setting second scanning speeds that are different from the first scanning speed used to obtain the speed-power function, causing the laser head to scan the target steel rail defect. The second scanning speeds can be a series of pre-set speed values designed to cover the range of speeds that may be encountered during actual repair, in order to obtain more comprehensive data; the metallographic analysis of the target steel rail defect is to conduct detailed examination and evaluation of the microstructure of the additive repair area after laser scanning at different second scanning speeds. Metallographic analysis typically includes grinding, polishing, and etching the cross-section of the repair layer, and observing its organizational morphology, grain size, defects (such as pores, cracks), etc. under a metallographic microscope to judge the repair quality; determining the second ideal power corresponding to each second scanning speed according to the results of metallographic analysis is to deduce the laser power value that can achieve the best repair effect at a specific second scanning speed, i.e. the second ideal power, according to the repair quality revealed by the metallographic analysis. This process may involve multiple iterations of experiments and analysis to accurately lock the ideal power point; analyzing and fitting the second light radiation intensity obtained at different combinations of second scanning speed and second ideal power to establish a light radiation reference function is to measure the second light radiation intensity produced by the laser when outputting these second ideal powers simultaneously after determining the second ideal power. Light radiation intensity is a direct physical manifestation of laser output power, which can be monitored in real time by photoelectric detectors and other devices. By collecting data on different second scanning speeds, second ideal powers, and their corresponding second light radiation intensities, data analysis and mathematical fitting are performed to establish a light radiation reference function that reflects the relationship between laser power and actual light radiation intensity. This function can be used for subsequent power compensation to ensure consistency between actual output power and desired power; the purpose of compensating the first power is to use the established light radiation reference function to modify the first power calculated according to the speed-power function. This compensation mechanism can correct power deviations caused by various uncertain factors, making the actual laser energy applied to the steel rail defect more accurate, thereby improving the quality and stability of additive repair.

[0053] The above steps are specific implementation details after obtaining the speed-power function. By introducing an additional experimental step, i.e., designing multiple laser head scans of the target rail defect at various second scan speeds, and combining metallographic analysis to determine the second ideal power, the actual ideal power data under different working conditions is obtained. On this basis, by analyzing and fitting the second light radiation intensity obtained at these second ideal powers, a light radiation reference function is established. This light radiation reference function can more accurately reflect the output characteristics of the laser under actual working conditions, including its possible nonlinearity, drift, or deviation affected by the environment. It is precisely because of the establishment of this reference function based on actual light radiation intensity that the first power calculated preliminarily according to the speed-power function can be compensated using this function. This compensation mechanism can effectively correct the actual deviation of the laser output power, ensuring that the laser energy applied to the rail defect during laser additive repair is more consistent with the expected ideal energy, thereby overcoming the limitations that may exist when relying solely on the pre-set speed-power function, significantly improving the accuracy and robustness of laser power control during laser additive repair of rail defects.

[0054] In some preferred embodiments, the following is described by a specific example. Assuming that after obtaining the initial speed-power function, in order to further refine the power control, a series of second scan speeds can be designed, such as 50 mm / s, 60 mm / s, 70 mm / s, etc. At each second scan speed, the corresponding second ideal power is determined through multiple experiments and combined with metallographic analysis, for example, at 50 mm / s, the second ideal power is 1000 W; at 60 mm / s, the second ideal power is 1200 W; at 70 mm / s, the second ideal power is 1400 W. At the same time, the laser outputs these second ideal powers, and a high-precision photodetector is used to measure the corresponding second light radiation intensity in real time. For example, at a power of 1000 W, the measured light radiation intensity is X units; at a power of 1200 W, the measured light radiation intensity is Y units; at a power of 1400 W, the measured light radiation intensity is Z units. After collecting these data points, the least squares method or other fitting algorithms can be used to fit the relationship between the second scan speed, the second ideal power, and the second light radiation intensity into a light radiation reference function, such as a polynomial function or an exponential function. When a first power corresponding to a certain motion command point is calculated according to the speed-power function later, for example, 1100 W, the light radiation reference function can be used to calculate a compensation value based on the actual light radiation intensity of the current laser, thereby correcting the first power of 1100 W to make it closer to the accurate power required in practice, ensuring the repair quality.

[0055] In actual laser additive repair process, due to the slight fluctuation of material properties, laser state or environmental factors, even if the power is adjusted based on the preset speed-power function and light radiation reference function, there may be deviation between the actual light radiation intensity and the ideal state, which affects the quality and stability of additive repair. If the above problems are not solved, it may cause the combination of additive layer and base material to be not firm, the organization to be not uniform or other defects.

[0056] To enhance the function, after obtaining the first power corresponding to each motion instruction point according to the first instantaneous speed and the speed-power function, the following steps are further included: Obtaining the first light radiation intensity according to the first instantaneous speed and the first power; Obtaining the light radiation residual value according to the light radiation reference function and the pre-processed first light radiation intensity; Obtaining the power compensation value according to the light radiation residual value and the preset historical residual accumulation, to compensate the first power.

[0057] Wherein, obtaining the first light radiation intensity according to the first instantaneous speed and the first power means that during the movement of the laser head, the light radiation sensor (such as photodiode or spectrometer) installed on or near the laser head measures the actual light radiation intensity emitted by the laser at the current instantaneous speed and the calculated first power in real time. The measurement value represents the actual energy density acting on the workpiece, and the purpose is to obtain real-time feedback information of laser output; obtaining the light radiation residual value according to the light radiation reference function and the pre-processed first light radiation intensity means that the first light radiation intensity obtained in real time is pre-processed (such as filtering, denoising or calibration) as needed, and then compared with the ideal light radiation intensity predicted by the pre-established light radiation reference function (which describes the ideal light radiation intensity at different speeds and powers); the light radiation residual value is the deviation between the actual measurement value and the ideal prediction value, which quantifies the real-time difference between the laser output and the expected target; in actual application, according to the light radiation residual value and the preset historical residual accumulation, the power compensation value is obtained to compensate the first power, which means that after calculating the current light radiation residual value, the system will combine the preset historical residual accumulation information (such as through sliding average, integral term or more complex control algorithm, such as integral part of proportional-integral-derivative (PID) controller) to comprehensively evaluate the trend and cumulative effect of power deviation. Based on this comprehensive evaluation, a power compensation value is calculated. The compensation value can be positive (when the actual light radiation is low) or negative (when the actual light radiation is high), and the purpose is to real-time correct the original first power, so as to ensure that the actual energy of the laser output can more accurately match the optimal energy level required by the additive repair process.

[0058] The above step is the specific implementation details after obtaining the first power corresponding to each motion instruction point. By introducing a real-time light radiation intensity measurement and feedback mechanism, the problems of hysteresis and inaccuracy in traditional power adjustment are solved. Specifically, during the movement of the laser head, the first light radiation intensity is obtained in real time, and it is compared with the pre-established light radiation reference function to dynamically calculate the light radiation residual value. The residual value directly reflects the deviation between the current laser output and the ideal state. Further, in combination with the preset historical residual accumulation, the system can more comprehensively evaluate the trend and cumulative effect of power deviation, thereby generating a more accurate power compensation value. The power compensation value is used to adjust the first power in real time, ensuring that the energy output of the laser can accurately match the needs of additive repair, effectively dealing with various uncertainty factors that may occur in the actual processing process, ensuring the stability and consistency of the laser additive repair process of the rail defect, and significantly improving the overall performance and reliability of the repaired part.

[0059] In some preferred embodiments, the following is described by a specific example. Assuming that during the laser additive repair process, the laser head moves at a certain first instantaneous speed, and a first power is calculated according to the speed-power function. At this time, through the real-time light radiation sensor installed near the laser head, the actual first light radiation intensity at the current time can be obtained. For example, if the light radiation reference function predicts the light radiation intensity to be X at the instantaneous speed and the first power, and the actual measured pre-processed first light radiation intensity is Y, then the light radiation residual value is Y-X. If Y is greater than X, it means that the actual energy output is too high; if Y is less than X, it means that the actual energy output is too low. The system will calculate a power compensation value according to this residual value, in combination with the accumulated residual data in the past period of time (for example, through a sliding average window or an integral term in a PID controller). For example, if the residual value is continuously negative (the actual energy is low), the system will calculate a positive power compensation value, which will be added to the original first power, thereby increasing the output power of the laser, making it closer to the ideal state. Conversely, if the residual value is continuously positive (the actual energy is high), a negative power compensation value will be calculated to reduce the output power of the laser. Through this real-time feedback and compensation mechanism, even in the case of complex repair paths or changes in material properties, the accurate delivery of laser energy can be ensured, thereby ensuring the quality of additive repair.

[0060] To perfect the scheme, after obtaining the power compensation value according to the light radiation residual value and the preset historical residual accumulation to compensate for the first power, the following steps are further included: Obtaining the compensated first power according to the first power and the power compensation value; The compensated first power corresponding to all motion instruction points is integrated in time sequence to generate a new laser power adjustment instruction to update the laser power adjustment instruction.

[0061] The compensated first power is obtained by combining the first power corresponding to each motion instruction point obtained according to the speed-power function with the power compensation value obtained according to the light radiation residual value and the preset historical residual accumulation. This combination is usually realized by mathematical operation, for example, if the power compensation value represents an increment or decrement, the power compensation value can be directly added to or subtracted from the first power to obtain a revised and more accurate compensated first power. The purpose is to revise the initially calculated laser power in real time and dynamically to adapt to various uncertain factors in the actual additive process; integrating the compensated first power corresponding to all motion instruction points in time sequence to generate a new laser power adjustment instruction can be understood as arranging and packaging all compensated first power values according to the time sequence of the motion instruction points of the laser head on the predicted motion path to form a complete instruction sequence that can be directly executed by the laser controller. The new laser power adjustment instruction will replace or update the original laser power adjustment instruction to ensure that the laser can be adjusted according to the latest compensated power value during the subsequent movement. The purpose is to provide an instant and accurate power control scheme to guide the actual operation of the laser head.

[0062] The above steps are specific implementation details after obtaining the power compensation value, which solves the problem of only obtaining the compensation value without explicitly applying it by explicitly applying the calculated power compensation value to the original first power and further generating a new laser power adjustment instruction. Specifically, by combining the power compensation value with the first power, the laser output power at each motion instruction point is ensured to be finely revised, so that the actual additive repair process can be more accurately reflected. Subsequently, by integrating these compensated power values in time sequence, a complete and executable instruction sequence is formed, so that the laser can output according to these real-time adjusted power instructions, thereby realizing accurate control of laser energy delivery, effectively compensating for power deviations caused by environmental changes, material property fluctuations and other factors, realizing a closed loop of the compensation mechanism and actual application, thereby providing a more reliable and efficient solution for laser additive repair of rail defects, and ultimately improving repair efficiency and repair quality.

[0063] In some preferred embodiments, the following is illustrated by a specific example. Assume that at a certain motion instruction point, the original first power calculated according to the speed-power function is 1000 watts. Through light radiation intensity analysis and historical residual accumulation, the calculated power compensation value is +50 watts (indicating that 50 watts of power needs to be increased to achieve the ideal effect). According to the scheme of the present application, the compensated first power will be calculated as 1000 watts + 50 watts = 1050 watts.

[0064] For all motion instruction points of the laser head on the predicted motion path, the respective compensated first powers will be calculated in a similar manner. For example, if there are multiple time points T1, T2, T3...Tn corresponding to motion instruction points on the path, and the respective compensated first powers P1', P2', P3'...Pn' are calculated for each point. The present application integrates these compensated power values P1', P2', P3',..., Pn' in chronological order to form a continuous power instruction sequence. This sequence is then encapsulated into a new laser power adjustment instruction, such as an array or data stream containing time stamps and corresponding power values. When the laser head actually moves to the T1 point, the laser will output P1' power; when it moves to the T2 point, it will output P2' power, and so on. In this way, the output power of the laser can respond in real time and accurately to the speed changes on the path and environmental feedback, ensuring that the energy input during the additive repair process is always in the best state, thereby obtaining high-quality repair layers.

[0065] In actual laser additive repair processes, the actual instantaneous speed of the laser head may deviate slightly from the predicted speed due to factors such as mechanical inertia, control accuracy, or external interference. This deviation can cause uneven energy deposition per unit distance, which in turn affects the metallurgical quality and mechanical properties of the additive repair layer. If the above problems are not addressed, it may lead to uneven organization, hardness fluctuations, or insufficient bonding strength in the repair area, thereby reducing the overall reliability of the repaired part.

[0066] As shown in Figure 5 Based on this, during the execution of the laser head movement, the following steps are further included: D1. When the laser head moves by one unit distance, the corresponding digital pulse signal is obtained through the grating encoder installed on the motion axis of the laser head and input into the controller; D2. During the movement of the laser head, the controller controls the laser to deposit energy according to the digital pulse signal corresponding to each unit distance and the current synchronized adjusted laser output power, to ensure that the energy density deposited per unit distance is consistent with the expectation of the laser power adjustment instruction.

[0067] The unit distance in step D1 refers to the smallest measurable distance increment that the laser head moves on the motion axis, which can be set to a value of 0.1 mm, 0.05 mm or smaller, with the purpose of providing fine distance feedback. The grating encoder is a high-precision displacement sensor that converts mechanical displacement into electrical signals through optical principles, enabling accurate detection of the actual movement distance of the laser head and generating corresponding digital pulse signals. Each digital pulse signal represents that the laser head has moved a preset unit distance. These digital pulse signals are input into the controller in real time, which is the core control unit of the entire laser additive system, responsible for processing various sensor data and issuing control instructions; The energy density in step D2 refers to the laser energy per unit area acting on the steel rail defect when the laser head moves a "unit distance" on the repair path; the expected laser power adjustment instruction refers to a series of power values calculated in advance to maintain an "ideal and constant" energy density when the laser head moves at a "predicted instantaneous speed".

[0068] Steps D1 to D2 are specific implementation details during the execution of the laser head movement process, which effectively solves the problem of uneven energy delivery that may exist in traditional solutions by introducing a grating encoder to monitor the actual displacement of the laser head in real time, and based on this and the current synchronously adjusted laser output power, the energy delivery per unit distance is realized. Specifically, when the laser head executes the motion trajectory instruction, the grating encoder can accurately perceive that it has moved a unit distance and immediately sends a digital pulse signal to the controller. After receiving these signals, the controller executes the following closed-loop control process: 1. Displacement-time conversion and speed confirmation: The controller records the time interval between receiving two consecutive unit distance pulse signals Based on the preset, accurate unit distance , the controller calculates the actual average speed of the laser head in this displacement .

[0069] This is done to obtain a physically displacement-based, indisputable true speed value for subsequent accurate calculations.

[0070] 2. Actual energy density calculation: The controller synchronously reads the actual average output power of the laser during this time interval (this value can be obtained from the internal sensor feedback of the laser or from the calibrated instruction value output by the controller).

[0071] Subsequently, the controller calculates the actual energy density delivered on the unit distance just completed The essence of the calculation formula is: ; Since the spot area and are constant within a certain period, the calculation is logically equivalent to . Here, represents a true measure of the energy that has been deposited on the workpiece.

[0072] 3. Comparison of expected and actual values and deviation generation: At the same time, the controller queries the pre-generated laser power adjustment instructions according to the current position of the laser head, obtaining the expected laser power and the expected movement speed at that position.

[0073] Based on these expected values, the controller calculates the expected energy density (likewise, ).

[0074] The controller then calculates the energy density deviation . This quantifies the sum of all errors between the theoretical design and actual execution.

[0075] 4. Generation of power compensation amount: The controller applies a proportional-integral (PI) control algorithm to this deviation value to generate a real-time power compensation amount .

[0076] Its control law can be expressed as: ; Where: Kp (proportional gain) provides fast immediate response to correct the current deviation; Ki (integral gain) is used to accumulate and eliminate persistent static deviation, ensuring long-term accuracy.

[0077] This compensation amount can be positive or negative.

[0078] 5. Real-time update of power instructions and forward-looking output: The controller does not modify past instructions, but makes forward-looking adjustments. It obtains the expected reference power required for the next control period based on the movement path.

[0079] The calculated power compensation amount is superimposed on it to generate and output a new, closed-loop corrected power instruction: ; This new instruction is immediately sent to the laser to guide its execution in the next unit distance of movement.

[0080] Through the cycle execution of the above steps, the system realizes a high-frequency closed-loop control triggered by physical displacement. The technical effect is that no matter what deviation between the actual speed and the expected speed is caused by mechanical inertia, transmission error or external interference, the system can continuously fine-tune the laser power in real time through the above feedback mechanism, so as to ensure that the laser energy density deposited on the rail defect in each small unit distance segment is highly consistent with the ideal value, thereby fundamentally eliminating overburning, underburning and microstructure defects caused by uneven energy, and significantly improving the uniformity, density and final mechanical properties of the additive repair layer.

[0081] As shown in FIG. 1, in a first aspect, the present application discloses a steel rail defect laser additive repair system, which is applied to a steel rail defect laser additive repair scene and includes: Figure 6 A motion trajectory instruction module is configured to obtain three-dimensional geometric data of a target steel rail defect, and generate a motion trajectory instruction of a laser head according to a preset strategy. A speed change curve module is configured to analyze the motion trajectory instruction, and generate a speed change curve of the laser head on a predicted motion path. A laser power adjustment instruction module is configured to obtain a laser power adjustment instruction according to the speed change curve on the predicted motion path and a speed-power function. A power adjustment module is configured to receive the motion trajectory instruction and the laser power adjustment instruction during the movement of the laser head, obtain an actual instantaneous speed corresponding to a specific motion instruction point according to the motion trajectory instruction, and synchronously adjust the output power of the laser. The motion trajectory instruction module can be a computer system configured with a three-dimensional scanning interface and a data processing unit. The computer system receives point cloud data from a three-dimensional scanner, runs a preset path planning algorithm, and generates a series of numerical control instructions containing position and speed information. In some implementations, the module can also generate the motion trajectory instruction by manually inputting or loading a defect model and a repair strategy from a preset database.

[0082] The speed curve change module can be a motion controller or an independent computing unit. The module is configured to analyze the position and time information in the motion trajectory instruction, and calculate the instantaneous speed of the laser head on the entire predicted path based on a kinematic model, so as to form a continuous speed change curve. For example, the module can use an interpolation algorithm or motion simulation software to accurately calculate the speed curve. ​The laser power adjustment instruction module can be a digital signal processor (DSP) or an embedded controller, which internally stores a pre-calibrated speed-power function. When receiving the speed change curve, the module substitutes each speed value in the curve into the speed-power function to calculate the corresponding ideal laser power value, and generates laser power adjustment instructions in time sequence or position sequence. For example, the module can quickly calculate the power value through a lookup table or a mathematical model; The power adjustment module can be a real-time controller integrated in the laser additive device control system, which is configured to receive instructions from the motion trajectory instruction module and the laser power adjustment instruction module. The module is also connected with a speed sensor or encoder for real-time monitoring of the actual instantaneous speed of the laser head. When detecting a deviation between the actual speed and the predicted speed, the module will adjust the output power of the laser in real time according to the preset power adjustment algorithm to ensure the uniformity of energy input. For example, the module can use a PID controller or other feedback control algorithm to achieve precise power adjustment.

[0083] The present application aims to provide a steel rail defect laser additive data processing system, through the cooperative work of various functional modules inside it, to realize fine control of the motion trajectory of the laser head and the laser power, in order to solve the problem of hidden structural defects that may be formed in the repair layer in the prior art, thereby improving the repair quality and reliability. The core of the system is to effectively integrate the speed change prediction during the motion of the laser head, the generation of laser power adjustment instructions, and real-time power adjustment through modular design, to ensure the uniformity and stability of laser energy input.

[0084] Compared with the traditional system, the advantages of the present application are: first, through the cooperation of the motion trajectory instruction module and the speed change curve module, a more reasonable laser power adjustment strategy can be planned in advance, avoiding the blindness in the repair process; second, the laser power adjustment instruction module can generate accurate power adjustment instructions according to the predicted speed change curve and the speed-power function; finally, the power adjustment module, in the actual execution process, acquires the actual instantaneous speed of the laser head in real time and adjusts the laser power synchronously, effectively compensating for the influence of the dynamic characteristics of mechanical motion on energy input, ensuring the uniformity and stability of laser energy input. This fine control method can significantly reduce the structural defects in the repair layer, improving the repair quality and reliability.

[0085] Preferably, it further comprises: A grating encoder is installed on the motion shaft of the laser head to obtain a corresponding digital pulse signal when the laser head moves a unit distance; The controller is configured to control the laser to emit energy according to the digital pulse signal corresponding to each unit distance and the current synchronously adjusted laser output power during movement of the laser head, so as to ensure that the energy density emitted in the unit distance is consistent with the expected laser power adjustment instruction.

[0086] In actual application, a grating encoder and a controller are further arranged, and the closed-loop control process of steps D1 to D2 is realized through the design of the grating encoder and the controller. The technical implementation and effects are as described above, the control is realized from the time-command domain to the space-physical domain, and the reliability and robustness of the steel rail defect laser additive data processing system are further improved.

[0087] In the embodiments provided in the present application, it should be understood that the disclosed method and system can be implemented in other manners. The above-described system embodiments are only schematic; for example, the division of the modules is only a logical function division, and there can be another division manner in actual implementation; for example, a plurality of modules or components can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the coupling or direct coupling or communication connection between the various components shown or discussed can be indirect coupling or communication connection through some interfaces, devices or modules, and can be electrical, mechanical or in other forms.

[0088] In addition, all the functional modules in the embodiments of the present application can be integrated in one processor, or each module can be a separate device, or two or more modules can be integrated in one device; each functional module in the embodiments of the present application can be realized in the form of hardware, or in the form of hardware plus software functional units.

[0089] Those skilled in the art can understand that all or part of the steps of the above method embodiments can be completed by program instructions and related hardware, and the above program instructions can be stored in a computer readable storage medium, and the program instructions are executed to perform the steps of the above method embodiments; and the above storage medium includes mobile storage devices, read only memory (ROM), magnetic discs or optical discs and various storage media that can store program codes.

[0090] Hereinafter, the terms "first" and "second" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Therefore, the features defined with "first" and "second" can explicitly or implicitly include one or more features.

[0091] If flow diagrams are used, the flow diagrams are used to illustrate the operations according to embodiments of the present application. It should be understood that the operations in the flow diagrams can be performed in a different order than that shown in the figures. Further, these operations can be performed concurrently or in different orders than that shown in the figures. Additionally, various operations can be added or omitted in accordance with these embodiments of the application.

[0092] The above provides a steel rail defect laser additive data processing method and system. The above description of the disclosed embodiments enables those skilled in the art to implement or use the present application. Various modifications to the embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A steel rail defect laser additive data processing method applied to a steel rail defect laser additive repair scene, characterized in that, The method comprises the following steps: acquiring three-dimensional geometric data of a target rail defect, and generating a movement trajectory instruction of a laser head according to a preset strategy; analyzing the movement trajectory instruction to generate a speed change curve of the laser head on a predicted movement path; obtaining a laser power adjustment instruction according to the speed change curve on the predicted movement path and a speed-power function; during the movement of the laser head, receiving the movement trajectory instruction and the laser power adjustment instruction, acquiring an actual instantaneous speed corresponding to a specific movement instruction point according to the movement trajectory instruction, and synchronously adjusting the output power of the laser.

2. The method of claim 1, wherein, The speed-power function is obtained based on the following steps: designing the laser head to scan the target rail defect at a plurality of first scanning speeds; performing metallographic analysis on the target rail defect; determining a first ideal power corresponding to each first scanning speed according to the metallographic analysis result, fitting the first scanning speed and the first ideal power, and obtaining the speed-power function.

3. The method of claim 2, wherein, The laser power adjustment instruction is obtained according to the speed change curve on the predicted movement path and the speed-power function, comprising the following steps: acquiring a first instantaneous speed corresponding to each movement instruction point on the predicted movement path according to the speed change curve; acquiring a first power corresponding to each movement instruction point according to the first instantaneous speed and the speed-power function; integrating the first power corresponding to all the movement instruction points in time sequence to generate the laser power adjustment instruction.

4. The method of claim 3, wherein, The specific movement instruction point is obtained based on the following steps: acquiring the first instantaneous speed corresponding to each movement instruction point on the predicted movement path according to the speed change curve; calculating a first derivative and a second derivative of the first instantaneous speed corresponding to each movement instruction point; determining an extreme point according to the first derivative; firstly judging whether the second derivative has different signs on both sides of the extreme point; if the first judgment result is yes, the specific movement instruction point is defined.

5. The method of claim 3, wherein, After obtaining the speed-power function, the following steps are further included: designing the laser head to scan the target rail defect at a plurality of second scanning speeds; performing metallographic analysis on the target rail defect; determining a second ideal power corresponding to each second scanning speed according to the metallographic analysis result; analyzing and fitting a second light radiation intensity obtained under the combination of different second scanning speeds and second ideal powers to establish a light radiation reference function to compensate the first power.

6. The steel rail defect laser additive data processing method of claim 5, wherein, After obtaining the first power corresponding to each movement instruction point according to the first instantaneous speed and the speed-power function, the following steps are further included: acquiring a first light radiation intensity according to the first instantaneous speed and the first power; acquiring a light radiation residual value according to the light radiation reference function and the preprocessed first light radiation intensity; acquiring a power compensation value according to the light radiation residual value and a preset historical residual accumulation to compensate the first power.

7. The method of claim 6, wherein, After obtaining the power compensation value according to the light radiation residual value and the preset historical residual accumulation to compensate the first power, the following steps are further included: According to the first power and the power compensation value, a compensated first power is obtained; In time sequence, all the compensated first powers corresponding to the motion instruction points are integrated to generate a new laser power adjustment instruction to update the laser power adjustment instruction.

8. The steel rail defect laser additive data processing method of claim 1 wherein, In the process of moving the laser head, the following steps are further included: When the laser head moves a unit distance, a corresponding digital pulse signal is obtained by a grating encoder installed on the motion shaft of the laser head and input into the controller; In the process of moving the laser head, the controller controls the laser to release energy according to the digital pulse signal corresponding to each unit distance and the currently synchronously adjusted laser output power, so as to ensure that the energy density released in the unit distance is consistent with the expectation of the laser power adjustment instruction.

9. A steel rail defect laser additive data processing system applied to a steel rail defect laser additive repair scene, characterized in that, Comprise: a motion trajectory instruction module for obtaining three-dimensional geometric data of a target rail defect, and generating a motion trajectory instruction of a laser head according to a preset strategy; a speed change curve module for analyzing the motion trajectory instruction and generating a speed change curve of the laser head on a predicted motion path; a laser power adjustment instruction module for obtaining a laser power adjustment instruction according to the speed change curve on the predicted motion path and a speed-power function; a power adjustment module for receiving the motion trajectory instruction and the laser power adjustment instruction in the process of moving the laser head, obtaining an actual instantaneous speed corresponding to a specific motion instruction point according to the motion trajectory instruction, and synchronously adjusting the laser output power.

10. The rail defect laser additive data processing system of claim 9, wherein, Further comprise: a grating encoder installed on the motion shaft of the laser head for obtaining a corresponding digital pulse signal when the laser head moves a unit distance; a controller for controlling the laser to release energy according to the digital pulse signal corresponding to each unit distance and the currently synchronously adjusted laser output power in the process of moving the laser head, so as to ensure that the energy density released in the unit distance is consistent with the expectation of the laser power adjustment instruction.

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