Steel rail alignment device based on five-axis motion system and method thereof

Abstract

The invention discloses a steel rail alignment device based on a five-axis motion system and a method thereof, and relates to the technical field of steel rail production. The device comprises a fixed end rack, a five-axis movement system rack, a telescopic measuring head and six high-precision laser distance sensors, wherein a five-axis movement system corresponds to five movement directions of Y-axis translation, Z-axis translation, X-axis rotation, Y-axis rotation and Z-axis rotation; the method comprises the following steps: acquiring a reference distance value of a reference end steel rail and a real-time distance value of a movable end steel rail through a telescopic measuring head, sequentially adjusting each servo motor of a five-axis movement system according to a difference value between the reference distance value and the real-time distance value, and correcting a rotation angle and a translation position of the movable end steel rail until errors in five directions reach the standard. High-precision alignment with the horizontal error smaller than or equal to 0.1 mm and the inclination error smaller than or equal to 0.1 mm / m of the steel rail is achieved, the time consumed for single-time alignment is about 20 seconds, efficiency is greatly improved, manual operation errors and safety risks are avoided, and the high-precision and efficient alignment requirements before steel rail cementing are met.

Description

Technical Field

[0001] This application belongs to the technical field of rail production technology, and specifically relates to a rail alignment device and method based on a five-axis motion system. Background Technology

[0002] In the field of rail production and laying, the precise connection of two rail sections is the core link to ensure the safe and stable operation of railway lines. Especially in the seamless track bonding process, the connection accuracy directly determines the smoothness and service life of the track.

[0003] Currently, the mainstream method for aligning rails is still manual operation: operators measure deviations point by point using tools such as dial indicators and levels, and then manually adjust the rail's posture using tools such as crowbars and jacks. This method has significant limitations: on the one hand, manual measurement is easily affected by environmental vibrations, visual fatigue, and other factors, making it difficult to maintain a stable accuracy of 0.1mm. It often requires repeated adjustments, and a single alignment can take 5-8 minutes, severely restricting production efficiency; on the other hand, manually prying heavy rails is not only labor-intensive, but also carries the risk of equipment collisions or personnel injuries due to improper operation.

[0004] To overcome the bottlenecks of traditional processes, some companies have attempted to introduce automated equipment, but existing solutions have not yet formed a mature solution. One type of equipment relies on fixed mechanical reference positioning, ignoring the impact of cumulative errors such as guide rail wear and frame deformation on alignment accuracy over long-term use. In actual applications, the error often exceeds the standard by 3-5 times. Another type uses sensor monitoring, but can only achieve independent adjustment in a single direction, lacking multi-dimensional collaborative control logic. It requires 6-8 iterations to approach the accuracy requirements, resulting in limited efficiency improvement. Summary of the Invention

[0005] The purpose of this application is to provide a rail alignment device and method based on a five-axis motion system. This addresses the technical problems mentioned in the background art, such as low precision, poor efficiency, and high labor intensity in existing rail alignment processes, as well as the large mechanical errors and insufficient multi-dimensional adjustment coordination in some automated solutions.

[0006] To achieve the above objectives, this application adopts the following technical solution:

[0007] In the first aspect, a rail alignment device based on a five-axis motion system is provided, including a fixed end stand, a five-axis motion system stand, a telescopic measuring head, and multiple distance sensors;

[0008] The fixed end stand is used to place the reference end rail, and the five-axis motion system stand is used to place the movable end rail and is equipped with a five-axis motion system. The five-axis motion system includes drive components corresponding to the five motion directions of Y-axis translation, Z-axis translation, X-axis rotation, Y-axis rotation, and Z-axis rotation.

[0009] The multiple distance sensors are mounted on the retractable measuring head to collect the reference distance value of the rail surface at the reference end and the real-time distance value of the rail surface at the moving end.

[0010] The retractable measuring head has a retractable function, which is used to drive the distance sensor to switch the measuring position between the reference end rail and the moving end rail in order to obtain the reference distance value and the real-time distance value.

[0011] In one possible embodiment, the number of distance sensors is 6, and they are divided into 3 groups;

[0012] One set of distance sensors is used to measure the distance in the Z direction from the upper surface of the rail, and the other two sets of distance sensors are used to measure the distance in the Y direction from both sides of the rail.

[0013] The distance sensors in each group are spaced at a preset interval to calculate the tilt deviation of the rail using data from multiple measurement points.

[0014] In one possible embodiment, the retractable measuring head has a position locking function, which can lock its own position when the distance sensor collects a reference distance value or a real-time distance value, so as to ensure the position stability of the distance sensor during the measurement process.

[0015] Furthermore, the retractable measuring head can be positioned and engaged with the reference rail before measurement to ensure the accuracy of the reference distance value acquisition.

[0016] In one possible embodiment, the relative positions of the five-axis motion system platform and the fixed end platform are fixed, and both platforms are provided with rail positioning structures.

[0017] The rail positioning structure is used to limit the displacement of the rail in the non-adjustment direction during the alignment process, ensuring that the rail is adjusted only in the target direction under the drive of the five-axis motion system during the alignment process.

[0018] In one possible embodiment, the distance sensor is a high-precision laser distance sensor with a measurement accuracy of not less than 0.001 mm, used to accurately collect distance data on the rail surface, providing data support for the precision control of rail alignment.

[0019] In one possible embodiment, the driving component of the five-axis motion system is a servo motor, and when the platform rotates clockwise along the X-axis, Y-axis, and Z-axis, the corresponding rotary servo motor is in the positive direction;

[0020] When the platform translates along the positive Z-axis and positive Y-axis, the corresponding translation servo motor is in the positive direction. By clearly defining the direction of motion, precise drive control of the moving end rail is achieved.

[0021] Secondly, a method based on the first aspect is provided, including the following steps:

[0022] S1: The retractable measuring head drives the distance sensor to collect the reference distance value of the rail surface at the reference end;

[0023] S2: The retractable measuring head drives the distance sensor to switch to the movable end rail to collect the real-time distance value on the surface of the movable end rail;

[0024] S3: Based on the difference between the reference distance value and the real-time distance value, control the movement of the drive component in the Y-axis rotation direction of the five-axis motion system, and adjust the moving end rail to rotate around the Y-axis until the deviation in this direction meets the preset accuracy requirements.

[0025] S4: Based on the difference between the reference distance value and the real-time distance value, control the action of the drive component in the Z-axis rotation direction of the five-axis motion system, and adjust the moving end rail to rotate around the Z-axis until the deviation in this direction meets the preset accuracy requirements.

[0026] S5: Based on the difference between the reference distance value and the real-time distance value, control the action of the drive component in the X-axis rotation direction of the five-axis motion system, and adjust the moving end rail to rotate around the X-axis until the deviation in this direction meets the preset accuracy requirements.

[0027] S6: Calculate the Z-axis translation based on the difference between the reference distance value and the real-time distance value, control the movement of the drive component in the Z-axis translation direction of the five-axis motion system, and drive the movable end rail to translate along the Z-axis until the deviation in this direction meets the preset accuracy requirements;

[0028] S7: Calculate the Y-axis translation based on the difference between the reference distance value and the real-time distance value, control the movement of the drive component in the Y-axis translation direction of the five-axis motion system, and drive the movable end rail to translate along the Y-axis until the deviation in this direction meets the preset accuracy requirements;

[0029] S8: Check whether the deviations of the moving end rail in the five directions of X-axis rotation, Y-axis rotation, Z-axis rotation, Y-axis translation, and Z-axis translation all meet the preset accuracy requirements. If they do, the alignment is complete; if not, repeat S3 to S7 until the deviations in all directions meet the requirements.

[0030] In one possible embodiment, in step S3, the deviation between the reference distance value and the real-time distance value collected by two sets of distance sensors used to measure the distance in the Z direction on the upper surface of the rail is calculated, and the forward and reverse movements of the drive component in the Y-axis rotation direction are controlled according to the magnitude and direction of the deviation.

[0031] In step S4, the deviation between the reference distance value and the real-time distance value collected by a set of distance sensors used to measure the distance in the Y direction on one side of the rail is calculated, and the forward and reverse movements of the drive component controlling the rotation direction of the Z axis are controlled according to the magnitude and direction of the deviation.

[0032] In one possible embodiment, in step S5, the average deviation between the two sides is calculated by using the reference distance value and the real-time distance value collected by two sets of distance sensors that are used to measure the distance between the two sides in the Y direction. Then, the drive component in the X-axis rotation direction is controlled to move in the forward and reverse directions based on the difference between the average deviations between the two sides.

[0033] In one possible embodiment, the preset accuracy requirements for the three directions of X-axis rotation, Y-axis rotation, and Z-axis rotation are tilt error ≤ 0.1 mm / m, and the preset accuracy requirements for the two directions of Y-axis translation and Z-axis translation are horizontal error ≤ 0.1 mm.

[0034] The actual deviation in each direction is calculated by collecting multiple sets of distance data from the distance sensor, and it is determined whether the actual deviation falls within the error range of the preset accuracy requirement, so as to determine whether the adjustment in each direction meets the standard.

[0035] Compared with the prior art, this application has the following beneficial effects:

[0036] This application provides a rail alignment device based on a five-axis motion system. The high flatness design of the fixed end frame and the five-axis motion system frame, along with the adjustable pressure plate, ensures the stability of rails of different specifications and avoids initial deviations caused by improper fixing. The retractable measuring head 1 enables rapid switching of measurement positions without the need for manual sensor movement, significantly shortening measurement preparation time. At the same time, the setting of multiple distance sensors covers the distance acquisition requirements of key rail surfaces, providing a comprehensive and accurate data foundation for subsequent multi-dimensional alignment adjustments. This avoids the problems of single measurement dimensions and cumbersome position switching in traditional alignment equipment from a hardware perspective.

[0037] In one possible implementation, the position locking function of the retractable measuring head, combined with its positioning design, fundamentally solves the measurement error problem caused by the unstable position of traditional measuring devices. The positioning coordination with the reference rail during baseline distance value acquisition ensures the accuracy of the baseline data, providing a reliable reference for subsequent deviation calculations. Position locking during real-time distance value acquisition ensures the stability of the measurement data, preventing incorrect adjustment direction due to measuring head shaking or displacement. This dual-protection mechanism significantly improves the reliability of distance data, laying a data foundation for the precise adjustment of the five-axis motion system, while reducing repeated adjustments caused by data deviations and improving alignment efficiency.

[0038] In one possible implementation, the correspondence between the forward and reverse movements of each servo motor and the adjustment direction of the rail is established. This creates a clear mapping between the motor drive direction and the rail attitude adjustment requirements, avoiding adjustment direction errors caused by ambiguity in the movement direction and ensuring that each adjustment action accurately responds to control commands. This explicit setting of the movement direction not only reduces invalid adjustment actions and improves alignment efficiency but also provides clear motion parameter basis for the writing of automated control programs, ensuring the stability and repeatability of the alignment process for different operators and different batches.

[0039] In one possible implementation, the fixed relative position of the five-axis motion system platform and the fixed end platform avoids alignment reference shifts caused by platform displacement, ensuring that the relative position of the two rail sections remains within a controllable range, providing a stable premise for alignment adjustments based on relative distance differences. The rail positioning structure on the platform effectively limits the non-adjustment direction displacement of the rails during the alignment process, ensuring that the driving force of the five-axis motion system acts only in the target adjustment direction, avoiding secondary deviations caused by additional rail displacement, ensuring precise and effective adjustment actions, and reducing repeated calibrations caused by non-adjustment direction displacement, thus improving the stability and efficiency of the alignment process.

[0040] A method based on a five-axis motion system, through precise step-by-step adjustment of the five-axis direction, combined with real-time error monitoring and closed-loop control, not only controls the horizontal error of rail alignment to within 0.001mm and the tilt error to within 0.003mm / m, far exceeding the industry standard of 0.1mm horizontal error and 0.1mm / m tilt error, but also reduces the time for a single alignment to 20 seconds, improving efficiency by 15-24 times compared to traditional manual alignment. At the same time, it avoids the subjective errors and safety risks of manual operation, achieving high precision, automation and high efficiency in rail alignment.

[0041] In one possible implementation, the X-axis rotation is controlled by calculating the difference in average deviations on both sides of the rail. This allows for precise capture of the rail's cross-sectional deflection deviation, avoiding the problem that measuring only one side cannot reflect the overall deflection. The comparison of the average deviations on the left and right sides directly relates to the degree of rail rotation around the X-axis. For example, when the average deviation on the left is smaller than that on the right, it indicates that the left side of the rail is "backward" relative to the reference end and needs to be rotated clockwise for adjustment. This quantitative method of deviation judgment ensures the accuracy of X-axis rotation adjustment. At the same time, the calculation of the average deviation can offset the small measurement errors of a single sensor, improving the reliability of the deviation data and providing a more accurate basis for rotation adjustment, ensuring that the rail cross-sectional orientation is consistent with the reference end. Attached Figure Description

[0042] Figure 1 A schematic diagram of a method based on a five-axis motion system provided in this application;

[0043] Figure 2 A front view of a rail alignment device based on a five-axis motion system provided in this application;

[0044] Figure 3 The sensor state before the retractable measuring head extends during the alignment control calculation process provided in this application;

[0045] Figure 4 A diagram showing the state of a retractable measuring head extending from a sensor, as provided in this application.

[0046] The attached diagram is labeled as follows: 1. Telescopic measuring head; 2. Reference end rail; 3. Fixed end stand; 4. Five-axis motion system stand; 5. Movable end rail. Detailed Implementation

[0047] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0048] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0049] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly defined. The specific embodiments of this application will be further described in detail below with reference to the accompanying drawings.

[0050] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0051] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0052] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0053] like Figure 1 , Figure 2 and Figure 3 As shown, a rail alignment device based on a five-axis motion system is provided, which may include a fixed end stand 3, a five-axis motion system stand 4, a telescopic measuring head 1, and 6 distance sensors.

[0054] The fixed end stand 3 is used to place the reference end rail 2, and the five-axis motion system stand 4 is used to place the movable end rail 5 and is equipped with a five-axis motion system.

[0055] Specifically, Q235 steel can be used to weld and manufacture the fixed end frame 3 and the five-axis motion system frame 4. The table size of both is 2000mm×500mm, and the flatness of the table is controlled within ≤0.02mm / m. Each table is equipped with 4 sets of adjustable steel rail pressure plates to accommodate steel rails with a specification of 60-75kg / m.

[0056] The five-axis motion system includes five servo motors, corresponding to the five motion directions of Y-axis translation, Z-axis translation, X-axis rotation, Y-axis rotation, and Z-axis rotation, respectively.

[0057] Optionally, a 60kg / m reference end rail 2 is placed on the fixed end platform 3, and a movable end rail 5 of the same specification is placed on the five-axis motion system platform 4. The five-axis motion system is equipped with five servo motors, which correspond to the five motion directions of Y-axis translation, Z-axis translation, X-axis rotation, Y-axis rotation, and Z-axis rotation, respectively.

[0058] The six distance sensors are mounted on the retractable measuring head 1 and are divided into three groups. Two sensors are in one group to measure the distance in the Z direction on the upper surface of the rail, and the other four sensors are in two groups to measure the distance in the Y direction on both sides of the rail. The spacing between the sensors in each group is fixed.

[0059] Optionally, six high-precision laser distance sensors are installed on the retractable measuring head 1, divided into three groups: two sensors are installed on the upper part of the measuring head to measure the distance in the Z direction on the upper surface of the rail; the other four sensors are divided into two groups and installed on the left and right sides of the measuring head respectively to measure the distance in the Y direction on both sides of the rail. The spacing between the sensors in each group is fixed.

[0060] The retractable measuring head 1 has a horizontal telescopic function. Before measurement, it can be clamped on the reference end rail 2 of the fixed end platform 3 to collect the reference distance value. During measurement, it can extend to the upper part of the movable end rail 5 of the five-axis motion system platform 4 and lock the position to collect the real-time distance value.

[0061] Before measurement, the retractable measuring head 1 is clamped at the web of the reference end rail 2 by a pneumatic gripper to collect the reference distance value; during measurement, the measuring head is controlled to extend horizontally above the movable end rail 5, and after locking the position by a mechanical pawl, the real-time distance value is collected.

[0062] In this embodiment, the high flatness design and adjustable pressure plate of the fixed end stand 3 and the five-axis motion system stand 4 ensure the stability of the placement of rails of different specifications and avoid the initial deviation caused by improper fixing of the rails. The telescopic function of the telescopic measuring head 1 enables rapid switching of the measurement position without the need for manual movement of the sensor, which greatly shortens the measurement preparation time. At the same time, the setting of multiple distance sensors covers the distance acquisition requirements of the key surfaces of the rails, providing a comprehensive and accurate data foundation for subsequent multi-dimensional alignment adjustments. From the hardware level, this avoids the problems of single measurement dimension and cumbersome position switching of traditional alignment equipment.

[0063] In one possible embodiment, the distance sensors are numbered six and divided into three groups;

[0064] One set of distance sensors is used to measure the distance in the Z direction from the upper surface of the rail, and the other two sets of distance sensors are used to measure the distance in the Y direction from both sides of the rail.

[0065] The distance sensors in each group are spaced at a preset interval to calculate the tilt deviation of the rail using data from multiple measurement points.

[0066] Optionally, the number of distance sensors can be set to 6 and divided into 3 groups:

[0067] Two sensors are installed as a group on the upper measuring arm of the telescopic measuring head 1, spaced 100mm apart along the length of the rail, and are used to measure the distance in the Z direction on the upper surface of the rail; the other four sensors are divided into two groups of two, with two sensors in each group installed on the left and right measuring arms of the measuring head, spaced 100mm apart along the height of the rail, and are used to measure the distance in the Y direction on both sides of the rail.

[0068] In this embodiment, the grouping and preset spacing of the six distance sensors enable omnidirectional distance monitoring of the upper surface and both sides of the rail, avoiding the limitation of a single sensor measurement failing to reflect the overall attitude of the rail. By comparing data from multiple measurement points, the tilt deviation of the rail in different directions can be accurately calculated. For example, the Z-direction distance difference between the two upper groups of sensors can be directly correlated with the rail's tilt around the Y-axis, providing a quantitative basis for subsequent rotation adjustments. Simultaneously, the 100mm intra-group spacing matches the industry's 0.1mm / m tilt accuracy requirement, ensuring that accuracy judgment requirements can be met through simple difference calculations, thus improving the convenience and accuracy of deviation calculation.

[0069] In one possible embodiment, the retractable measuring head 1 has a position locking function, which can lock its own position when the distance sensor collects a reference distance value or a real-time distance value, so as to ensure the position stability of the distance sensor during the measurement process.

[0070] Furthermore, the retractable measuring head 1 can be positioned and engaged with the reference end rail 2 before measurement to ensure the accuracy of the reference distance value acquisition.

[0071] Optionally, the retractable measuring head 1 incorporates an electromagnetic locking mechanism and a pneumatic clamping assembly:

[0072] When collecting baseline distance values, the measuring head is tightly fitted to the web of the baseline rail 2 via a pneumatic clamping assembly, while the electromagnetic locking mechanism is energized and locked to ensure no relative displacement between the measuring head and the rail. During the data collection process, the sensor position fluctuation is ≤0.001mm. When switching to the movable rail 5 to collect real-time distance values, after the measuring head extends horizontally into position, the electromagnetic locking mechanism locks it again. Monitoring by a laser displacement sensor shows that the position deviation of the measuring head after locking is ≤0.002mm, and the fluctuation of the collected real-time distance data is ≤0.001mm, effectively avoiding data deviation caused by measuring head displacement.

[0073] In this embodiment, the position locking function and positioning design of the retractable measuring head 1 fundamentally solve the measurement error problem caused by the unstable position of traditional measuring devices. The positioning coordination with the reference end rail 2 during reference distance value acquisition ensures the accuracy of the reference data, providing a reliable reference for subsequent deviation calculations; the position locking during real-time distance value acquisition ensures the stability of the measurement data, avoiding incorrect adjustment direction due to measuring head shaking or displacement. This dual-protection mechanism significantly improves the reliability of distance data, laying a data foundation for the precise adjustment of the five-axis motion system, while reducing repeated adjustments caused by data deviations and improving alignment efficiency.

[0074] In one possible embodiment, the relative positions of the five-axis motion system platform 4 and the fixed end platform 3 are fixed, and both platforms are provided with rail positioning structures.

[0075] The rail positioning structure is used to limit the displacement of the rail in the non-adjustment direction during the alignment process, ensuring that the rail is adjusted only in the target direction under the drive of the five-axis motion system during the alignment process.

[0076] Specifically, the fixed end platform 3 and the five-axis motion system platform 4 can be fixed to the concrete foundation of the workshop floor using four M16 expansion bolts. A precision level is used for calibration to ensure that the relative height difference between the two platforms is ≤0.05mm and the relative parallelism is ≤0.03mm / m.

[0077] On the platforms of the two test stands, a set of rail positioning structures is set every 500mm along the length of the rail. The structure includes a side guide plate and an end limiting block.

[0078] During the alignment process, the movable end rail 5, driven by the five-axis motion system, only translates along the Y-axis, translates along the Z-axis, and rotates around the X, Y, and Z axes. According to the displacement sensor, the displacement of the rail along the non-adjustment direction is ≤0.003mm, and no additional offset occurs.

[0079] In this embodiment, the fixed relative positions of the five-axis motion system platform 4 and the fixed end platform 3 prevent alignment reference shifts caused by platform displacement, ensuring that the relative positions of the two rail sections are always within a controllable range, providing a stable premise for alignment adjustments based on relative distance differences. The rail positioning structure on the platform effectively limits the non-adjustment direction displacement of the rails during the alignment process, ensuring that the driving force of the five-axis motion system acts only in the target adjustment direction, avoiding secondary deviations caused by additional rail displacement, ensuring accurate and effective adjustment actions, and reducing repeated calibrations caused by non-adjustment direction displacement, thus improving the stability and efficiency of the alignment process.

[0080] In one possible embodiment, the distance sensor is a high-precision laser distance sensor with a measurement accuracy of not less than 0.001 mm, used to collect distance data in the Z and Y directions on the surface of the rail.

[0081] Specifically, a high-precision laser distance sensor with a measurement accuracy of 0.001mm can be selected. The sensor output signal is a 4-20mA analog signal, which is converted into a digital signal by the signal conditioning module and then transmitted to the PLC control system.

[0082] When collecting the distance in the Z direction from the upper surface of the reference rail 2, the two sensors on the upper side collected data 10 times consecutively. The average value of the data from sensor 1 was 50.234 mm, with a maximum deviation of 0.0008 mm; the average value of the data from sensor 2 was 50.232 mm, with a maximum deviation of 0.0007 mm.

[0083] When collecting data from the moving end rail 5, the average value of the data collected by sensor 1 was 50.245 mm with a deviation of 0.0009 mm; the average value of the data collected by sensor 2 was 50.240 mm with a deviation of 0.0008 mm. The data showed good stability with no obvious fluctuations and could accurately reflect the actual distance on the rail surface.

[0084] In this embodiment, a laser distance sensor with a measurement accuracy of no less than 0.001 mm ensures high precision and stability in the acquisition of rail surface distance data, effectively avoiding measurement errors caused by insufficient sensor accuracy. This provides a reliable data basis for calculating the difference between the reference distance value and the real-time distance value. The high-precision distance data accurately reflects the positional deviation between the two rail sections, making the adjustment of the five-axis motion system more targeted. This avoids over-adjustment or under-adjustment due to inaccurate data, ensuring that the final alignment accuracy meets the industry's high standards of ≤0.1 mm horizontal error and ≤0.1 mm / m tilt error.

[0085] In one possible embodiment, the driving component of the five-axis motion system is a servo motor, and when the platform rotates clockwise along the X-axis, Y-axis, and Z-axis, the corresponding rotary servo motor is in the positive direction;

[0086] When the platform translates along the positive Z-axis and positive Y-axis, the corresponding translation servo motor is in the positive direction. By clearly defining the direction of motion, precise drive control of the moving end rail 5 is achieved.

[0087] A high-precision laser distance sensor with a measurement accuracy of 0.001mm was selected. The sensor output signal is a 4-20mA analog signal, which is converted into a digital signal by a signal conditioning module and then transmitted to the PLC control system. When collecting the distance in the Z direction from the upper surface of the reference rail 2, the sensor continuously collected data 10 times, with an average value of 50.234mm and a maximum deviation of 0.0008mm. When collecting data from the moving rail 5, the average value was 50.245mm, with a maximum deviation of 0.0009mm. The data showed good stability, with no significant fluctuations due to environmental interference, and accurately reflected the actual distance on the rail surface.

[0088] A laser distance sensor with a measurement accuracy of no less than 0.001mm ensures high precision and stability in the acquisition of distance data from the rail surface, effectively avoiding the shortcomings of traditional tools such as dial indicators and levels, which suffer from low measurement accuracy and susceptibility to environmental vibrations. High-precision distance data can accurately capture minute deviations between two rail sections, providing a reliable basis for fine-tuning the five-axis motion system. This avoids over- or under-adjustment due to insufficient data accuracy, ensuring that the final alignment accuracy meets the industry's high standards of ≤0.1mm horizontal error and ≤0.1mm / m tilt error. Simultaneously, stable data acquisition performance reduces the number of repeated measurements, improving overall alignment efficiency.

[0089] In one possible embodiment, a method based on a five-axis motion system may include the following steps:

[0090] The rail to be aligned is a 60kg / m standard rail. The reference rail 2 is placed on the fixed end platform 3 and fixed by the pressure plate. The movable end rail 5 is placed on the worktable of the five-axis motion system platform 4.

[0091] Six high-precision laser distance sensors are used. Two sensors are grouped together with a spacing of 100mm and installed on the upper measuring arm of the telescopic measuring head 1 to measure the distance in the Z direction on the upper surface of the rail. The other four sensors are divided into two groups with a spacing of 100mm each and are installed on the left and right measuring arms of the measuring head respectively to measure the distance in the Y direction on both sides of the rail.

[0092] S1: The reference distance values ​​of the surface of the reference end rail 2 are collected by the six distance sensors on the retractable measuring head 1. The reference distance values ​​include the Z-direction distance values ​​z1 and z2 of the upper surface of the reference end rail 2 measured by two sensors, and the Y-direction distance values ​​y1, y2, y3 and y4 of both sides of the reference end rail 2 measured by four sensors.

[0093] Specifically, the reference distance values ​​are obtained as follows: the retractable measuring head 1 is clamped on the reference end rail 2, the sensor is activated to collect data, and the reference distance values ​​are obtained: Z direction z1 = 50.234mm, z2 = 50.232mm; Y direction left side y1 = 30.115mm, y2 = 30.113mm, right side y3 = 30.114mm, y4 = 30.112mm.

[0094] S2: Extend the retractable measuring head 1 horizontally to the surface of the movable end rail 5 and lock it in place. Collect the real-time distance values ​​z1', z2', y1', y2', y3', and y4' of the movable end rail 5 through 6 distance sensors.

[0095] Specifically, real-time distance value acquisition: The control measuring head extends horizontally above the movable end rail 5 and locks, acquiring the real-time distance values ​​of the movable end rail 5: Z direction z1' = 50.245mm, z2' = 50.240mm; Y direction left side y1' = 30.120mm, y2' = 30.118mm, right side y3' = 30.118mm, y4' = 30.116mm.

[0096] S3: Adjust the Y-axis rotary motor of the five-axis motion system so that the movable end rail 5 rotates around the Y-axis:

[0097] If z1-z1'>z2-z2', then the Y-axis rotary motor moves in the negative direction, driving the movable end rail 5 to rotate counterclockwise;

[0098] If z1-z1'≤z2-z2', the Y-axis rotary motor moves in the positive direction, driving the movable end rail 5 to rotate clockwise; when |z1-z1'-z2+z2'|≤0.01mm, the Y-axis rotation stops.

[0099] Specifically, Y-axis rotation adjustment:

[0100] Calculate z1-z1'=50.234-50.245=-0.011mm, z2-z2'=50.232-50.240=-0.008mm. Since -0.011<-0.008, control the Y-axis rotary motor to move in the positive direction, driving the movable end rail 5 to rotate clockwise around the Y-axis. Monitor the error value in real time. When |(-0.011)-(-0.008)|=|-0.003|≤0.01mm, stop the Y-axis rotation.

[0101] S4: Adjust the Z-axis rotary motor of the five-axis motion system so that the movable end rail 5 rotates around the Z-axis:

[0102] If y1-y1'>y2-y2', then the Z-axis rotary motor moves in the negative direction, driving the movable end rail 5 to rotate counterclockwise;

[0103] If y1-y1'≤y2-y2', then the Z-axis rotary motor moves in the positive direction, driving the movable end rail 5 to rotate clockwise.

[0104] Stop rotating the Z-axis when |y1-y1'-y2+y2'|≤0.01mm.

[0105] Specifically, Z-axis rotation adjustment:

[0106] Calculate y1-y1'=30.115-30.120=-0.005mm, y2-y2'=30.113-30.118=-0.005mm. Since -0.005≤-0.005, control the Z-axis rotary motor to move in the positive direction, driving the movable end rail 5 to rotate clockwise around the Z-axis. When |(-0.005)-(-0.005)|=0≤0.01mm, stop the Z-axis rotation.

[0107] S5: Adjust the X-axis rotary motor of the five-axis motion system so that the movable end rail 5 rotates around the X-axis:

[0108] like,

[0109]

[0110] Then the X-axis rotary motor moves in the negative direction, driving the movable end rail 5 to rotate counterclockwise;

[0111] like,

[0112]

[0113] Then the X-axis rotary motor moves in the positive direction, driving the movable end rail 5 to rotate clockwise;

[0114] when,

[0115]

[0116] When the time comes, stop rotating the X-axis.

[0117] Optional, X-axis rotation adjustment: Calculate the average difference on the left side:

[0118] [(30.115+30.113) / 2-(30.120+30.118) / 2]=(30.114-30.119)=-0.005mm, the average difference on the right side [(30.114+30.112) / 2-(30.118+30.116) / 2]=(30.113-30.117)=-0.004mm. Since -0.005<-0.004, the X-axis rotary motor is controlled to move in the positive direction, driving the movable end rail 5 to rotate clockwise around the X-axis. When |(-0.005)-(-0.004)|=0.001≤0.01mm, the X-axis rotation stops.

[0119] S6: Adjust the Z-axis translation motor of the five-axis motion system. Calculate the translation amount according to the formula l1=(z1+z2) / 2-(z1'+z2') / 2, and drive the movable end rail 5 to translate along the Z-axis so that |(z1+z2) / 2-(z1'+z2') / 2|≤0.1mm.

[0120] Optionally, the Z-axis translation adjustment is performed according to the formula:

[0121] l1=(50.234+50.232) / 2-(50.245+50.240) / 2=50.233-50.2425=-0.0095mm;

[0122] The Z-axis translation motor drives the movable end rail 5 to translate 0.0095mm along the negative Z-axis direction.

[0123] At this point, |50.233-50.2425+0.0095|=0≤0.1mm, which meets the accuracy requirements.

[0124] S7: Adjust the Y-axis translation motor of the five-axis motion system according to the formula:

[0125] The translation amount is calculated by l2 = (y1 + y2) / 2 - (y1' + y2') / 2, which drives the movable end rail 5 to translate along the Y-axis.

[0126] Make |(y1+y2) / 2-(y1'+y2') / 2|≤0.1mm.

[0127] Optional, the Y-axis translation adjustment:

[0128] According to the formula l2=(30.115+30.113) / 2-(30.120+30.118) / 2=30.114-30.119=-0.005mm;

[0129] The Y-axis translation motor is controlled to drive the movable end rail 5 to translate 0.005mm along the negative Y-axis direction. At this time, |30.114-30.119+0.005|=0≤0.1mm, which meets the accuracy requirements.

[0130] S8: Check whether the errors of the movable end rail 5 in the five directions of X-axis rotation, Y-axis rotation, Z-axis rotation, Y-axis translation, and Z-axis translation all meet the requirements. If they do, the alignment is complete; if not, repeat S3 to S7 until the error meets the standard.

[0131] In this embodiment, by precisely adjusting the five-axis direction step by step, combined with real-time error monitoring and closed-loop control, not only is the horizontal error of rail alignment controlled within 0.001mm and the tilt error controlled within 0.003mm / m, far exceeding the industry standard of 0.1mm horizontal error and 0.1mm / m tilt error, but the time for a single alignment is also shortened to 20 seconds, which is 15-24 times more efficient than traditional manual alignment. At the same time, it avoids the subjective error and safety risks of manual operation, and realizes high precision, automation and high efficiency of rail alignment.

[0132] In one possible embodiment, in step S3, the deviation between the reference distance value and the real-time distance value collected by two sets of distance sensors used to measure the distance in the Z direction on the upper surface of the rail is calculated, and the forward and reverse movements of the drive component in the Y-axis rotation direction are controlled according to the magnitude and direction of the deviation.

[0133] In step S4, the deviation between the reference distance value and the real-time distance value collected by a set of distance sensors used to measure the distance in the Y direction on one side of the rail is calculated, and the forward and reverse movements of the drive component controlling the rotation direction of the Z axis are controlled according to the magnitude and direction of the deviation.

[0134] Specifically, the reference values ​​z1 = 50.234mm and z2 = 50.232mm and the real-time values ​​z1' = 50.245mm and z2' = 50.240mm are collected by the two sensors on the upper side that measure the distance in the Z direction. The deviations z1 - z1' = -0.011mm and z2 - z2' = -0.008mm are calculated. Since -0.011mm < -0.008mm, the Y-axis rotation servo motor is controlled to rotate forward, driving the movable end steel rail 5 to rotate clockwise. The deviation value is monitored in real time, and the process stops when |z1 - z1' - z2 + z2'| = 0.003mm ≤ 0.01mm.

[0135] In step S4, the reference values ​​y1 = 30.115mm and y2 = 30.113mm and the real-time values ​​y1' = 30.120mm and y2' = 30.118mm are collected by the two sensors on the left that measure the distance in the Y direction. The deviations y1-y1' = -0.005mm and y2-y2' = -0.005mm are calculated. Since the deviations are equal, the Z-axis rotation servo motor is controlled to rotate forward for fine adjustment until the deviation is ≤0.01mm.

[0136] In this embodiment, the design of calculating the deviation using specific sets of sensor data in steps S3 and S4 makes the adjustment basis for each rotation direction more targeted, avoiding interference from irrelevant sensor data. For example, adjusting the Y-axis rotation using only the upper Z-axis sensor data directly correlates with the tilt deviation of the rail's horizontal plane, ensuring that the adjustment action is precisely applied to the target direction; adjusting the Z-axis rotation using only the Y-axis sensor data focuses on the tilt deviation of the rail's vertical plane, reducing the complexity of cross-calculation of multiple sets of data. This logic of "single-direction data corresponding to single-direction adjustment" reduces the computational difficulty of the control program, improves the adjustment response speed, and ensures the accuracy of rotation deviation correction, avoiding adjustment deviations caused by data association errors.

[0137] In one possible embodiment, in step S5, the average deviation between the two sides is calculated by using the reference distance value and the real-time distance value collected by two sets of distance sensors that are used to measure the distance between the two sides in the Y direction. Then, the drive component in the X-axis rotation direction is controlled to move in the forward and reverse directions based on the difference between the average deviations between the two sides.

[0138] Specifically, the reference values ​​y1 = 30.115mm and y2 = 30.113mm and the real-time values ​​y1' = 30.120mm and y2' = 30.118mm can be collected using the two sensors on the left. The average deviation on the left side can then be calculated as (30.115 + 30.113) / 2 - (30.120 + 30.118) / 2 = -0.005mm.

[0139] The baseline values ​​are collected by the two sensors on the right:

[0140] y3=30.114mm, y4=30.112mm;

[0141] The real-time values ​​are y3' = 30.118 mm and y4' = 30.116 mm.

[0142] Calculate the average deviation on the right side = (30.114 + 30.112) / 2 - (30.118 + 30.116) / 2 = -0.004 mm;

[0143] The average deviation difference between the two sides is -0.001mm. Since -0.005mm < -0.004mm, the X-axis rotation servo motor is controlled to rotate forward, driving the movable end steel rail 5 to rotate clockwise until the |average deviation difference between the two sides| ≤ 0.01mm, at which point the rotation stops.

[0144] In this embodiment, the X-axis rotation is controlled by calculating the difference in average deviations on both sides of the rail. This accurately captures the deflection deviation of the rail cross-section, avoiding the problem that measuring only one side cannot reflect the overall deflection. The comparison of the average deviations on the left and right sides is directly related to the degree of rail rotation around the X-axis. For example, when the average deviation on the left is smaller than that on the right, it indicates that the left side of the rail is "backward" relative to the reference end and needs to be rotated clockwise for adjustment. This quantitative deviation judgment method ensures the accuracy of X-axis rotation adjustment. At the same time, the calculation of the average deviation can offset the small measurement errors of a single sensor, improve the reliability of the deviation data, provide a more accurate basis for rotation adjustment, and ensure that the rail cross-section posture is consistent with the reference end.

[0145] In one possible embodiment, the preset accuracy requirements for the three directions of X-axis rotation, Y-axis rotation, and Z-axis rotation are tilt error ≤ 0.1 mm / m, and the preset accuracy requirements for the two directions of Y-axis translation and Z-axis translation are horizontal error ≤ 0.1 mm.

[0146] The actual deviation in each direction is calculated by collecting multiple sets of distance data from the distance sensor, and it is determined whether the actual deviation falls within the error range of the preset accuracy requirement, so as to determine whether the adjustment in each direction meets the standard.

[0147] The preset accuracy requirements for the X-axis rotation, Y-axis rotation, and Z-axis rotation directions are set as follows: tilt error ≤ 0.1 mm / m, and horizontal error ≤ 0.1 mm for Y-axis translation and Z-axis translation directions.

[0148] After adjustment, calculations are performed using sensor data:

[0149] The tilt error in the Y-axis rotation direction is:

[0150] |z1-z1'-z2+z2'| / 0.1m=0.003mm / 0.1m=0.03mm / m≤0.1mm / m;

[0151] Z-axis rotation direction tilt error = |y1-y1'-y2+y2'| / 0.1m = 0 / 0.1m = 0mm / m ≤ 0.1mm / m;

[0152] The tilt error in the X-axis rotation direction is:

[0153] |Average deviation difference between the two sides| / 0.1m=0.001mm / 0.1m=0.01mm / m≤0.1mm / m;

[0154] Z-axis translation horizontal error = |(z1+z2) / 2-(z1'+z2') / 2| = 0.0095mm ≤ 0.1mm;

[0155] The horizontal error of Y-axis translation is |(y1+y2) / 2-(y1'+y2') / 2| = 0.005mm ≤ 0.1mm, and all directions meet the preset accuracy requirements.

[0156] In this embodiment, the preset accuracy requirements and error calculation methods for each direction are clearly defined, making the judgment standard for alignment accuracy unified and quantifiable, avoiding the subjectivity and instability of traditional manual alignment based on "visual or experience-based judgment". The tilt error in the rotation direction and the horizontal error in the translation direction are set separately to match the different accuracy requirements for rail alignment in the industry, ensuring that the aligned rails meet both smoothness requirements and avoid additional vibrations during train operation. Simultaneously, the actual deviation is directly calculated using sensor data and compared with the preset accuracy, achieving automated judgment of the alignment result without manual intervention. This improves the standardization of the alignment process, ensuring consistent accuracy standards when different batches and different operators perform alignment operations, and guaranteeing the stability of rail bonding quality.

[0157] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them; although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications to the technical solutions described in the foregoing embodiments, or equivalent substitutions for some or all of the technical features, do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A rail alignment device based on a five-axis motion system, characterized in that, It includes a fixed end stand (3), a five-axis motion system stand (4), a telescopic measuring head (1), and multiple distance sensors; The fixed end stand (3) is used to place the reference end rail (2), and the five-axis motion system stand (4) is used to place the movable end rail (5) and is equipped with a five-axis motion system. The five-axis motion system includes drive components corresponding to the five motion directions of Y-axis translation, Z-axis translation, X-axis rotation, Y-axis rotation and Z-axis rotation respectively. The multiple distance sensors are installed on the retractable measuring head (1) to collect the reference distance value on the surface of the reference end rail (2) and the real-time distance value on the surface of the movable end rail (5); The retractable measuring head (1) has a retractable function, which is used to drive the distance sensor to switch the measuring position between the reference end rail (2) and the movable end rail (5) to obtain the reference distance value and the real-time distance value.

2. The rail alignment device based on a five-axis motion system according to claim 1, characterized in that, The distance sensors consist of 6 units, divided into 3 groups; One set of distance sensors is used to measure the distance in the Z direction from the upper surface of the rail, and the other two sets of distance sensors are used to measure the distance in the Y direction from both sides of the rail. The distance sensors in each group are spaced at a preset interval to calculate the tilt deviation of the rail using data from multiple measurement points.

3. The rail alignment device based on a five-axis motion system according to claim 1, characterized in that, The retractable measuring head (1) has a position locking function. When the distance sensor collects the reference distance value or the real-time distance value, it can lock its own position to ensure the position stability of the distance sensor during the measurement process. Furthermore, the retractable measuring head (1) can be positioned and matched with the reference end rail (2) before measurement to ensure the accuracy of the reference distance value acquisition.

4. The rail alignment device based on a five-axis motion system according to claim 1, characterized in that, The relative positions of the five-axis motion system platform (4) and the fixed end platform (3) are fixed, and both platforms are provided with rail positioning structures. The rail positioning structure is used to limit the displacement of the rail in the non-adjustment direction during the alignment process, ensuring that the rail is adjusted only in the target direction under the drive of the five-axis motion system during the alignment process.

5. The rail alignment device based on a five-axis motion system according to claim 1, characterized in that, The distance sensor is a high-precision laser distance sensor.

6. The rail alignment device based on a five-axis motion system according to claim 1, characterized in that, The driving component of the five-axis motion system is a servo motor, and when the platform rotates clockwise along the X-axis, Y-axis, and Z-axis, the corresponding rotary servo motor is in the positive direction; When the platform translates along the positive Z-axis and positive Y-axis, the corresponding translation servo motor is in the positive direction. By clearly defining the direction of motion, precise drive control of the moving end rail (5) is achieved.

7. A method based on the apparatus of any one of claims 1-6, characterized in that, Includes the following steps: S1: The retractable measuring head (1) drives the distance sensor to collect the reference distance value on the surface of the reference end rail (2); S2: The retractable measuring head (1) drives the distance sensor to switch to the movable end rail (5) and collects the real-time distance value on the surface of the movable end rail (5); S3: Based on the difference between the reference distance value and the real-time distance value, control the action of the drive component in the Y-axis rotation direction of the five-axis motion system, and adjust the moving end rail (5) to rotate around the Y-axis until the deviation in this direction meets the preset accuracy requirements; S4: Based on the difference between the reference distance value and the real-time distance value, control the action of the drive component in the Z-axis rotation direction of the five-axis motion system, and adjust the moving end rail (5) to rotate around the Z-axis until the deviation in this direction meets the preset accuracy requirements; S5: Based on the difference between the reference distance value and the real-time distance value, control the action of the drive component in the X-axis rotation direction of the five-axis motion system, and adjust the moving end rail (5) to rotate around the X-axis until the deviation in this direction meets the preset accuracy requirements; S6: Calculate the Z-axis translation based on the difference between the reference distance value and the real-time distance value, control the action of the drive component in the Z-axis translation direction of the five-axis motion system, and drive the movable end rail (5) to translate along the Z-axis until the deviation in this direction meets the preset accuracy requirements; S7: Calculate the Y-axis translation based on the difference between the reference distance value and the real-time distance value, control the action of the drive component in the Y-axis translation direction of the five-axis motion system, and drive the movable end rail (5) to translate along the Y-axis until the deviation in this direction meets the preset accuracy requirements; S8: Check whether the deviations of the moving end rail (5) in the five directions of X-axis rotation, Y-axis rotation, Z-axis rotation, Y-axis translation and Z-axis translation meet the preset accuracy requirements. If they meet the requirements, the alignment is completed. If they do not meet the requirements, repeat S3 to S7 until the deviations in all directions meet the standards.

8. The method based on a five-axis motion system according to claim 7, characterized in that, In step S3, the deviation between the reference distance value and the real-time distance value collected by two sets of distance sensors used to measure the distance in the Z direction on the upper surface of the rail is calculated, and the forward and reverse movements of the drive component in the Y-axis rotation direction are controlled according to the magnitude and direction of the deviation. In step S4, the deviation between the reference distance value and the real-time distance value collected by a set of distance sensors used to measure the distance in the Y direction on one side of the rail is calculated, and the forward and reverse movements of the drive component controlling the rotation direction of the Z axis are controlled according to the magnitude and direction of the deviation.

9. The method based on a five-axis motion system according to claim 7, characterized in that, In step S5, the reference distance value and real-time distance value collected by two sets of distance sensors used to measure the distance between the two sides of the rail in the Y direction are used to calculate the average deviation between the two sides. Then, the drive component of the X-axis rotation direction is controlled to move in the forward and reverse directions based on the difference between the average deviations of the two sides.

10. The method based on a five-axis motion system according to claim 7, characterized in that, The preset accuracy requirements for the three directions of X-axis rotation, Y-axis rotation, and Z-axis rotation are tilt error ≤ 0.1 mm / m, and the preset accuracy requirements for the two directions of Y-axis translation and Z-axis translation are horizontal error ≤ 0.1 mm. The actual deviation in each direction is calculated by collecting multiple sets of distance data from the distance sensor, and it is determined whether the actual deviation falls within the error range of the preset accuracy requirement, so as to determine whether the adjustment in each direction meets the standard.

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