Steel rail full-section profile online detection method and detection device

Abstract

The embodiment of the invention relates to a steel rail full-section profile online detection method and device, and the method comprises the steps: determining the position relation of a transmitting path lens assembly; the parallel light source laser emits a first wavelength parallel laser beam and a second wavelength parallel laser beam to the emission path lens assembly according to the emission instruction; the emission path lens assembly transmits the first wavelength parallel light beam to the first side surface of the detected steel rail, and reflects and refracts the second wavelength parallel light beam to the second side surface of the detected steel rail; the receiving path lens assembly receives the diffuse reflection light of the first / second side surface and focuses and emits first / second laser light; the area array type detector converts the first / second laser rays into first / second electric signals and then sends the first / second electric signals to the signal processing system; and the signal processing system processes the first / second electric signals to generate first / second side contour section curves, and synthesizes the first side contour section curve and the second side contour section curve, so that the full-section contour detection of the detected steel rail is realized.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of rail profile detection, and particularly relates to a rail full-section profile online detection method and a detection device. BACKGROUND

[0002] Rail maintenance is one of the important work of railway system maintenance, which aims to ensure the safety of railway operation, prolong the service life of rail, improve the transportation efficiency and reduce the operation cost. The rail maintenance work includes rail profile detection and rail line grinding work. Among them, the rail profile detection is an important means to evaluate the state of the rail, and the detection result is a key index to evaluate the state of the rail, which can provide a scientific basis for the rail line grinding work.

[0003] The rail profile detection has two ways of contact measurement and non-contact measurement. The contact measurement of rail has the problems of low precision, low efficiency of manual operation, high labor intensity and the like, and is difficult to meet the demand of the rapid development of railway. Therefore, the non-contact measurement based on the structure three-dimensional measurement technology of linear laser is widely used.

[0004] At present, the non-contact measurement based on the structure three-dimensional measurement technology of linear laser mainly arranges multiple profile sensors on both sides of the rail, which are respectively used for acquiring the local section profile of the inner and outer sides of the rail, and then the rail full-section profile is obtained by splicing the local section profile. However, this measurement method involves multiple profile sensors, each sensor has unique optical and electrical characteristics. In the calibration process, these characteristics need to be considered comprehensively, and the parameters of each sensor need to be adjusted to ensure that the laser emitted by them is in the same plane. This not only needs high-precision calibration equipment and technology, but also consumes a lot of time and effort. In addition, each profile sensor has its own independent coordinate system and measurement reference. In the splicing process, if the different coordinate systems and references cannot be accurately converted, the spliced profile data will deviate in space position. Therefore, the coplanar installation error of the laser emission end and the unreasonable extraction of the splicing center will cause the splicing error of the full section, which greatly affects the measurement accuracy. SUMMARY

[0005] The present application aims at the defects of the prior art, and provides a rail full-section profile online detection method and a detection device.

[0006] To achieve the above-mentioned purpose, in a first aspect, the present application provides a rail full-section profile online detection method, which comprises:

[0007] The positional relationship of the transmitting path lens assembly is determined such that the light received by the first and second side surfaces of the rail under test covers the measurement area of ​​the rail under test, and there is an overlapping area on the top of the rail under test.

[0008] The signal processing system sends a transmission command to the parallel light source laser;

[0009] According to the emission command, the parallel light source laser emits a first wavelength parallel laser beam and a second wavelength parallel laser beam toward the emission path mirror assembly.

[0010] The transmitting path lens assembly transmits the first wavelength parallel light beam to the first side surface of the rail under test, and reflects and refracts the second wavelength parallel light beam to the second side surface of the rail under test;

[0011] The receiving path lens assembly receives diffuse reflected light from the first side surface and focuses it to emit a first laser beam, and receives diffuse reflected light from the second side surface and focuses it to emit a second laser beam.

[0012] The array detector converts the first laser beam into a first electrical signal and the second laser beam into a second electrical signal, and then sends the first and second electrical signals to the signal processing system; the first electrical signal includes a first timing sequence, and the second electrical signal includes a second timing sequence.

[0013] The signal processing system processes the first electrical signal to generate a first side profile cross-sectional curve, processes the second electrical signal to generate a second side profile cross-sectional curve, and synthesizes the first side profile cross-sectional curve and the second side profile cross-sectional curve to achieve full-section profile detection of the rail under test.

[0014] Preferably, the signal processing system processes the first electrical signal to generate a first side profile cross-sectional curve, processes the second electrical signal to generate a second side profile cross-sectional curve, and synthesizes the first side profile cross-sectional curve and the second side profile cross-sectional curve, specifically including:

[0015] The signal processing system extracts the center line of the first wavelength parallel laser beam based on the first electrical signal to obtain the first pixel coordinates; and extracts the center line of the second wavelength parallel laser beam based on the second electrical signal to obtain the second pixel coordinates.

[0016] According to the preset coordinate transformation parameters, the coordinate system of the first pixel coordinate is transformed to obtain the first side contour section curve, and the coordinate system of the second pixel coordinate is transformed to obtain the second side contour section curve.

[0017] The first side profile curve and the second side profile curve are synthesized to obtain the full profile curve of the measured rail.

[0018] Secondly, embodiments of the present invention provide a rail full-section profile detection device, the rail full-section profile detection device comprising: a parallel light source laser, a transmitting path lens assembly, a receiving path lens assembly, an array detector, and a signal processing system;

[0019] The parallel light source laser is located above one side of the rail being measured and is used to emit a first wavelength parallel laser beam and a second wavelength parallel laser beam.

[0020] The transmitting path lens assembly is located on one side of the parallel light source laser and above the rail under test. It is used to transmit the first wavelength parallel light beam to the first side surface of the rail under test and to reflect and refract the second wavelength parallel light beam to the second side surface of the rail under test.

[0021] The receiving path lens assembly is located above the rail being measured and on the opposite side of the transmitting path lens assembly. It is used to receive diffuse reflected light from the first side surface and focus and emit a first laser beam, and to receive diffuse reflected light from the second side surface and focus and emit a second laser beam.

[0022] The array detector is located directly above the receiving path lens assembly, and is used to convert the first laser beam into a first electrical signal and the second laser beam into a second electrical signal, and then send the first electrical signal and the second electrical signal to the signal processing system; the first electrical signal includes a first timing sequence, and the second electrical signal includes a second timing sequence;

[0023] The signal processing system is electrically connected to the array detector and is used to process the first electrical signal to generate a first side profile cross-sectional curve, process the second electrical signal to generate a second side profile cross-sectional curve, and synthesize the first side profile cross-sectional curve and the second side profile cross-sectional curve to realize the detection of the full cross-sectional profile of the rail under test.

[0024] Preferably, the parallel light source laser is a tunable dual-wavelength laser.

[0025] Preferably, the transmitting path mirror assembly includes: a semi-transparent and semi-reflective mirror, a plane mirror, and a first prism; the semi-transparent and semi-reflective mirror is disposed above the rail being measured; the plane mirror is disposed parallel to the semi-transparent and semi-reflective mirror; the first prism is located on the opposite side of the parallel light source laser and its bottom surface faces between the semi-transparent and semi-reflective mirror and the plane mirror.

[0026] More preferably, the positions of the semi-transparent mirror, the plane mirror, and the first prism satisfy the following relationship:

[0027] B1 = B0 / sinα;

[0028]

[0029] Where m is the number of times the second-wavelength parallel laser beam is reflected by the plane mirror; B0 is the length of the first / second-wavelength parallel laser beam; B1 is the horizontal distance between the first / second-wavelength parallel laser beams; B2 is the distance from the rightmost reflection point of the second-wavelength parallel laser beam in the semi-transparent mirror to the rightmost exit point on the first prism; B3 is the horizontal distance from the rightmost reflection point of the second-wavelength parallel laser beam in the semi-transparent mirror to the leftmost exit point on the first prism; B4 is the horizontal distance between the lowest points of the measured cross-section of the rail being measured; and α is the angle between the parallel laser beam and the horizontal plane. L is the angle between the second wavelength parallel laser beam and the horizontal plane; L is the distance from the semi-transparent mirror to the plane mirror; L1 is the distance between the top surface of the rail being measured and the semi-transparent mirror; L2 is the distance between the lowest point of the rail being measured and the semi-transparent mirror; L3 is the length of the bottom edge of the first prism.

[0030] More preferably, the structure and material of the first prism satisfy the following relationship:

[0031] θ2=θ3=ε1=ε2;

[0032] θ 1＝ 90°-(α-ε1);

[0033] sinθ1 / sinθ2=cos(α-ε1) / sinε1=n2 / n1;

[0034]

[0035] Where ε1 is the angle between the upper side of the first triangular prism and the horizontal plane; ε2 is the angle between the lower side of the first triangular prism and the horizontal plane; θ1 is the incident angle of the light entering the first triangular prism; θ2 is the internal refraction angle of the first triangular prism; θ3 is the internal incident angle of the first triangular prism; θ4 is the exit angle of the light; and α is the angle between the first wavelength parallel laser beam and the horizontal plane. n1 is the angle between the second wavelength parallel laser beam and the horizontal plane; n2 is the air refractive index; and n2 is the refractive index of the first prism.

[0036] Preferably, the receiving path lens assembly includes: a second triangular prism, a third triangular prism, a first focusing lens, and a second focusing lens; the second triangular prism and the third triangular prism are symmetrically arranged, the first focusing lens and the second focusing lens are symmetrically arranged, and the first focusing lens is positioned directly opposite the second triangular prism, the second focusing lens is symmetrically arranged with the first focusing lens, and is positioned directly opposite the third triangular prism.

[0037] Preferably, the signal processing system includes: a logic control module, a digital signal processing system, and a laser emission control module; the logic control module receives the electrical signal sent by the area array detector, processes the electrical signal into a digital signal, and sends the digital signal to the digital signal processing system; the digital signal processing system processes the digital signal to obtain the overall profile and full cross-section of the rail under test; the laser emission control module receives the emission command issued by the digital signal processing system and sends the emission command to the parallel light source laser.

[0038] Preferably, the rail full-section profile detection device also includes a housing;

[0039] The housing is installed on the outside of the parallel light source laser, the transmitting path lens assembly, the receiving path lens assembly, and the array detector.

[0040] The online detection method for the full cross-sectional profile of rails provided in this invention employs a signal processing system to send a transmission command to a parallel light source laser, causing the laser to alternately emit two parallel laser beams of different wavelengths. Then, the propagation direction of the light is altered by a transmitting path mirror assembly, allowing the two parallel laser beams of different wavelengths to be directed onto the inner and outer surfaces of the rail being measured. Diffuse reflected light from the inner and outer surfaces of the rail is collected by a receiving path mirror assembly and received by a single array detector. After processing by the signal processing system, the overall profile of the rail is obtained. This online detection method eliminates the need for multi-sensor calibration, and further optimizes the coplanarity control of the laser beams while achieving the full cross-sectional profile detection function, thereby effectively improving the measurement accuracy of the full cross-sectional profile. Attached Figure Description

[0041] Figure 1 A flowchart of the online detection method for the full cross-sectional profile of rails provided in this embodiment of the invention;

[0042] Figure 2 This is a schematic diagram of the structural frame of the rail full-section profile detection device provided in an embodiment of the present invention;

[0043] Figure 3 This is a three-dimensional structural schematic diagram of the rail full-section profile detection device provided in an embodiment of the present invention;

[0044] Figure 4 This is a schematic diagram showing the positional relationship between the receiving path lens assembly and the transmitting path lens assembly provided in an embodiment of the present invention;

[0045] Figure 5 This is a schematic diagram of the light path of the transmitting path lens assembly provided in an embodiment of the present invention;

[0046] Figure 6 This is a schematic diagram showing the positional relationship of each component of the transmitting path lens assembly provided in an embodiment of the present invention;

[0047] Figure 7 A schematic diagram of the angles in the light propagation path of the first prism provided in an embodiment of the present invention;

[0048] Figure 8 This is a schematic diagram of the light path of the receiving path lens assembly provided in an embodiment of the present invention.

[0049] Figure 9 This is a schematic diagram showing the positional relationship of each component in the receiving path lens assembly provided in an embodiment of the present invention. Detailed Implementation

[0050] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0051] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0052] Figure 1 This is a flowchart of the online detection method for the full cross-sectional profile of rails provided in the embodiments of the present invention. The following is in conjunction with... Figure 1 The technical solution of the present invention will be described with reference to specific embodiments.

[0053] This invention provides an online detection method for the full-section profile of rails, specifically including the following: Figure 1 The steps shown are as follows:

[0054] Step 110: Determine the positional relationship of the transmitting path lens assembly so that the light received by the first and second side surfaces of the rail covers the measurement area of ​​the rail and there is an overlapping area at the top of the rail.

[0055] Specifically, determining the positional relationship of the transmitting path lens assembly mainly includes adjusting and determining the positional relationship parameters of each component in the transmitting path lens assembly. When the light received by the first and second side surfaces of the rail covers the measurement area of ​​the rail, and there is an overlapping area at the top of the rail, the integrity of the full-section measurement of the rail profile can be guaranteed.

[0056] Step 120: The signal processing system sends a transmission command to the parallel light source laser;

[0057] The signal processing system includes functions such as processing, control, calculation, and storage. The parallel source laser can specifically be a tunable dual-wavelength laser, emitting a highly parallel laser beam with uniform energy distribution across its cross-section and minimal influence from external environmental factors. The parallel source laser is located above one side of the rail being measured and can alternately emit a first-wavelength parallel laser beam and a second-wavelength parallel laser beam. The transmission command includes synchronization control signals for specific wavelengths and timing parameters, specifically the first wavelength, the second wavelength, a first timing control signal, and a second timing control signal.

[0058] Step 130: The parallel light source laser emits a first wavelength parallel laser beam and a second wavelength parallel laser beam toward the emission path mirror assembly according to the emission command.

[0059] In this design, the first wavelength parallel laser beam can be transmitted through the transmitting path mirror assembly, while the second wavelength parallel laser beam can be reflected by the transmitting path mirror assembly. After receiving the transmission command, the parallel source laser parses and executes the wavelength and timing parameters in the command through a preset communication protocol, and then drives the parallel source laser.

[0060] Step 140: The transmitting path lens assembly transmits a first wavelength parallel beam to the first side surface of the rail under test, and reflects and refracts a second wavelength parallel beam to the second side surface of the rail under test.

[0061] Specifically, the transmitting path lens assembly can decompose parallel laser beams of different wavelengths into two different propagation paths: transmitted light and reflected light, so that the parallel laser beams can irradiate both sides of the rail being tested.

[0062] Step 150: The receiving lens assembly receives diffuse reflected light from the first side surface and focuses it to emit a first laser beam, and receives diffuse reflected light from the second side surface and focuses it to emit a second laser beam.

[0063] Specifically, the receiving lens assembly mainly focuses and emits diffused light.

[0064] Step 160: The array detector converts the first laser beam into a first electrical signal and the second laser beam into a second electrical signal, and then sends the first electrical signal to the signal processing system.

[0065] Specifically, the area array detector preferably uses a CMOS chip, which has the advantages of low cost, low power consumption, and high integration, thus reducing costs. The first electrical signal includes a first timing sequence, and the second electrical signal includes a second timing sequence.

[0066] Step 170: The signal processing system processes the first electrical signal to generate a first side profile profile curve, processes the second electrical signal to generate a second side profile profile curve, and synthesizes the first side profile profile curve and the second side profile profile curve to achieve full-section profile detection of the rail under test.

[0067] Specifically, firstly, the signal processing system extracts the center line of the first wavelength parallel laser beam based on the first electrical signal to obtain the first pixel coordinates; and secondly, it extracts the center line of the second wavelength parallel laser beam based on the second electrical signal to obtain the second pixel coordinates.

[0068] Here, the signal processing system converts the first electrical signal and the second electrical signal into a first digital signal and a second digital signal. Then, using the gray-scale centroid method, the center lines of the first wavelength parallel laser beam and the second wavelength parallel laser beam are extracted with sub-pixel precision, thereby obtaining their respective pixel coordinates.

[0069] Secondly, according to the preset coordinate transformation parameters, the coordinate system of the first pixel coordinate is transformed to obtain the first side contour section curve, and the coordinate system of the second pixel coordinate is transformed to obtain the second side contour section curve.

[0070] Specifically, the coordinate system transformation involves converting the first pixel coordinates and the second similar coordinates into coordinates within the same world coordinate system with physical dimensions. This ensures that the left and right contour curves are on the same reference. The first side contour profile curve includes a first world coordinate point cloud, and the second side contour profile curve includes a second world coordinate point cloud.

[0071] Finally, the first side profile curve and the second side profile curve are synthesized to obtain the full profile curve of the measured rail.

[0072] Specifically, the signal processing system uses weighted averaging or curve fitting to fuse data in the overlapping area at the top of the rail to optimize accuracy, ultimately generating a continuous, complete, and accurate full-section profile of the rail.

[0073] The online detection method for the full cross-sectional profile of rails provided in this invention employs a signal processing system to send a transmission command to a parallel light source laser, causing the laser to alternately emit two parallel laser beams of different wavelengths. Then, the propagation direction of the light is altered by a transmitting path mirror assembly, allowing the two parallel laser beams of different wavelengths to be directed onto the inner and outer surfaces of the rail being measured. Diffuse reflected light from the inner and outer surfaces of the rail is collected by a receiving path mirror assembly and received by a single array detector. After processing by the signal processing system, the overall profile of the rail is obtained. This online detection method eliminates the need for multi-sensor calibration, and further optimizes the coplanarity control of the laser beams while achieving the full cross-sectional profile detection function, thereby effectively improving the measurement accuracy of the full cross-sectional profile.

[0074] This invention also provides a rail full-section profile detection device, such as... Figure 2 As shown, the detection device specifically includes: a parallel light source laser 100, a transmitting path lens assembly 200, a receiving path lens assembly 300, an array detector 400, and a signal processing system 500.

[0075] The parallel light source laser 100 can specifically be a tunable dual-wavelength laser, which emits a laser beam with very high parallelism, uniform energy distribution across the beam cross-section, and is less affected by external environmental factors. The parallel light source laser 100 is specifically located above one side of the rail being measured and can alternately emit a first-wavelength parallel laser beam and a second-wavelength parallel laser beam.

[0076] Combination Figure 3 , Figure 4 and Figure 5 As shown, the transmitting path lens assembly 200 is located on one side of the parallel light source laser 100 and above the rail being measured. It can transmit a first wavelength parallel beam to the first side (right side) surface of the rail being measured, and reflect and refract a second wavelength parallel beam to the second side (left side) surface of the rail being measured. It should be noted that the coordinate system involved in this application has the x-axis along the length of the rail, the y-axis along the width of the rail, and the z-axis along the height of the rail. The origin is located at the highest point of the centerline of the rail's measurement cross-section, and this coordinate system satisfies the right-hand coordinate system.

[0077] The transmitting path mirror assembly 200 may specifically include: a semi-transparent and semi-reflective mirror 201, a plane mirror 202, and a first prism 203. The semi-transparent and semi-reflective mirror 201, by depositing a multilayer dielectric film on a substrate, allows a first-wavelength parallel laser beam to be transmitted, while a second-wavelength parallel laser beam can be reflected. This decomposes the parallel laser beams of different wavelengths into two different propagation paths: transmitted light 21 and reflected light 22. By precisely controlling the thickness and refractive index of the multilayer dielectric film, the reflected light of the first-wavelength parallel laser beam is destructively interfered with out-of-phase light in the reflection direction, achieving efficient transmission. The second-wavelength parallel laser beam is constructively interfered with out-of-phase light in the reflection direction, and their energy superposition results in efficient reflection of the beam.

[0078] The semi-transparent and semi-reflective mirror 201 is placed above the rail, so that the transmitted light 21 directly illuminates the first side surface of the rail being measured.

[0079] The plane mirror 202 is arranged parallel to the semi-transparent mirror 201, and together they form a parallelogram structure. The plane mirror 202 can reflect the reflected light 22.

[0080] The function of the first triangular prism 203 is to change the propagation direction of the reflected light 22, thereby illuminating the second side surface of the rail being measured. The first triangular prism 203 is located on the opposite side of the parallel light source laser 100, with its bottom surface facing between the semi-transparent semi-reflective mirror 201 and the plane mirror 202.

[0081] Combination Figure 6 and Figure 7 As shown, to ensure the comprehensiveness and accuracy of the full-section profile measurement of the rail being measured, the following relationships can be satisfied by adjusting the positions of the semi-transparent mirror 201, the plane mirror 202, and the first triangular prism 203:

[0082] B1 = B0 / sinα;

[0083]

[0084] Where m is the number of times the second-wavelength parallel laser beam is reflected by the plane mirror; B0 is the length of the first / second-wavelength parallel laser beam; B1 is the horizontal distance between the first / second-wavelength parallel laser beams; B2 is the distance from the rightmost reflection point of the second-wavelength parallel laser beam in the semi-transparent mirror to the rightmost exit point on the first prism; B3 is the horizontal distance from the rightmost reflection point of the second-wavelength parallel laser beam in the semi-transparent mirror to the leftmost exit point on the first prism; B4 is the horizontal distance between the lowest points of the measured cross-section of the rail being measured; and α is the angle between the parallel laser beam and the horizontal plane. L is the angle between the second wavelength parallel laser beam and the horizontal plane; L is the distance from the semi-transparent mirror to the plane mirror; L1 is the distance between the top surface of the rail being measured and the semi-transparent mirror; L2 is the distance between the lowest point of the rail being measured and the semi-transparent mirror; L3 is the length of the bottom edge of the first prism.

[0085] In other words, when the position parameters of each component in the transmitting path lens assembly 200 meet the above conditions, the first wavelength parallel laser beam and the second wavelength parallel laser beam can completely cover the area to be measured of the rail under test, and there is an overlapping area on the top of the rail under test, ensuring the integrity of the rail full-section profile detection.

[0086] The material of the first prism 203 is adapted to the wavelength of the second-wavelength parallel laser beam. For example, when the parallel beam emitted by the parallel laser beam is an ultraviolet beam, the material of the first prism includes fused silica and ultraviolet-grade fused silica; when the parallel beam emitted by the parallel laser beam is an infrared beam, the material of the first prism includes K9 optical glass and BK7 optical glass. This is to achieve a beam with a preset wavelength... The light rays are angled to illuminate the second side surface of the rail, ensuring that the light propagates parallel to the bottom surface within the prism to minimize aberrations. The first prism employs a specific structure with a vertical bottom surface. In this configuration, the light path satisfies the symmetry condition (θ2=θ3=ε1=ε2), and its geometric and optical relationships are determined by Snell's law, such as... Figure 7 As shown, the details are as follows:

[0087] θ1 = 90° - (α - ε1);

[0088] sinθ1 / sinθ2=cos(α-ε1) / sinε1=n2 / n1;

[0089]

[0090] Where ε1 is the angle between the upper side of the first triangular prism and the horizontal plane; ε2 is the angle between the lower side of the first triangular prism and the horizontal plane; θ1 is the incident angle of the light entering the first triangular prism; θ2 is the internal refraction angle of the first triangular prism; θ3 is the internal incident angle of the first triangular prism; θ4 is the exit angle of the light; and α is the angle between the first wavelength parallel laser beam and the horizontal plane. n1 is the angle between the second wavelength parallel laser beam and the horizontal plane; n2 is the air refractive index; and n2 is the refractive index of the first prism.

[0091] Combination Figure 4 and Figure 8As shown, the receiving path lens assembly 300 is located above the rail being measured and opposite the transmitting path lens assembly 200. It can receive diffuse reflected light from the first side surface and focus it to emit a first laser beam, and receive diffuse reflected light from the second side surface and focus it to emit a second laser beam. The principle of this rail full-section profile detection device adopts the symmetrical oblique-injection and oblique-receiver laser triangular method. The angle between the extended line of the center of the array detector 400 and the yoz plane is the same as that between the parallel light source laser 100 and the yoz plane, both being ω.

[0092] The receiving path lens assembly 300 may specifically include: a second triangular prism 301, a third triangular prism 302, a first focusing lens 303, and a second focusing lens 304. The second triangular prism 301 and the third triangular prism 302 are symmetrically arranged, the first focusing lens 303 and the second focusing lens 304 are symmetrically arranged, and the first focusing lens 303 is positioned directly opposite the second triangular prism 301, while the second focusing lens 304 is symmetrically arranged with the first focusing lens 303 and is positioned directly opposite the third triangular prism 302.

[0093] As described above, and in combination Figure 9 As shown, this rail full-section profile detection device adopts a symmetrical oblique-projection and oblique-receive laser triangulation method. The main light rays reflected back from the rail are at angles ζ1 and ζ2 with the xoz plane.

[0094] 2 remains essentially unchanged. The function of the second prism 301 and the third prism 302 is to change the path of the received light rays, ensuring that the path of the received light rays before and after the change is about y = y m or y = y n Symmetric, where y = y m or y = y n Parallel to the xoz plane, it is the plane containing the angle bisectors of the deflection angles δ1 and δ2. The materials and structures of the prisms of the second prism 301 and the third prism 302 are the same as those of the first prism 203, and their apex angle A and the refractive index n3 of the material must satisfy the optical relationship of the minimum deflection angle with the deflection angles δ1 and δ2.

[0095] The received light, after being altered by the second prism 301 and the third prism 302, is focused onto the array detector 400 by the first focusing mirror 303 and the second focusing mirror 304, such as... Figure 9 As shown. The corrections to the refractive index and the increase in the path length of the second prism 301 and the third prism 302 are minimal, and the optical path difference before and after the change is negligible. Therefore, the positional relationship of the three must satisfy:

[0096] W = B4 / 2 + 2*e

[0097] θ = 2*arctan(A / (2*f))

[0098] 1 / (a+b)+1 / υ=1 / f;

[0099] (a+b+υ)*sinζ1>h

[0100] a is the distance from the center point of the rail surface to the second or third prism; b is the distance from the second prism to the first focusing lens or from the third prism to the second focusing lens; υ is the distance from the first focusing lens to the area array detector or from the second focusing lens to the area array detector; f is the focal length of the first or second focusing lens; h is the distance between the top surface of the rail and the area array detector; ζ

[0101] 1 and ζ2 are the angles between the main light rays reflected back from the rail being measured and the xoz plane; θ is the horizontal field of view angle; W is the field of view width; e is the safety margin, taken as 10-20mm; B4 is the horizontal distance between the lowest points of the measured cross section of the rail being measured.

[0102] The area array detector 400 is located directly above the receiving path lens assembly. It can convert the first laser beam into a first electrical signal and the second laser beam into a second electrical signal, providing a data basis for subsequent processing and analysis. The first and second electrical signals are then emitted. The first electrical signal includes a first timing sequence, and the second electrical signal includes a second timing sequence. The area array detector 400 preferably uses a CMOS chip, which has advantages such as low cost, low power consumption, and high integration, thus reducing costs.

[0103] The signal processing system 500 is electrically connected to the array detector 400. It can process the first electrical signal to generate a first side profile cross-sectional curve, process the second electrical signal to generate a second side profile cross-sectional curve, and synthesize the first side profile cross-sectional curve and the second side profile cross-sectional curve to realize the detection of the full cross-sectional profile of the rail.

[0104] The signal processing system 500 may specifically include: a logic control module 501, a digital signal processing system 502, a data storage module 503, and a laser emission control module 504. Because the diffuse reflected light received by the area array detector 400 is typically weak, and the electrical signal after photoelectric conversion is also very weak, making effective subsequent processing difficult, the logic control module 501 receives the electrical signal sent by the area array detector 400, amplifies and filters the electrical signal to convert it into a digital signal, and sends the digital signal to the digital signal processing system 502. The digital signal processing system 502 processes the digital signal, for example, extracting, analyzing, and calculating features (such as key geometric information of the measured rail profile) to obtain accurate first and second side profile cross-sectional curves, and synthesizing them to obtain the overall profile full cross-section of the measured rail. It should be noted that the digital signal processing system 502 must pre-set calibration parameters and algorithms to eliminate system errors and compensate for environmental factors, ensuring the stability and reliability of the measurement results. The laser emission control module 504 receives the emission command issued by the digital signal processing system 502 and sends the emission command to the parallel light source laser 100. In addition, the digital signal processing system 502 sends the generated overall profile and cross-sectional data of the measured rail to the data storage module 503 for storage. The specific processing procedure of the signal processing system 500 is the same as described in the above method and will not be repeated here.

[0105] As a preferred embodiment, the rail full-section profile detection device also includes a housing 600. The housing 600 covers the outside of the parallel light source laser 100, the transmitting path lens assembly 200, the receiving path lens assembly 300, and the area array detector 400.

[0106] The rail full-section profile detection device provided in this invention employs a parallel light source laser that alternately emits two parallel laser beams of different wavelengths. This ensures that the detection beams on both sides of the rail under test are on the same plane, improving the stitching accuracy of subsequent data processing. The device utilizes the positional relationship of a plane mirror, a semi-transparent mirror, and a first prism, along with the material and optical properties of the first prism, to alter the propagation direction of the light. This allows the two parallel laser beams of different wavelengths to be directed onto the inner and outer surfaces of the rail under test, respectively. Diffuse reflected light from the inner and outer surfaces of the rail is collected by a second prism, a third prism, a first focusing lens, and a second focusing lens, and then received by a single array detector. After processing by a signal processing system, the overall profile of the rail under test is obtained. This device has a simple structure, avoids multi-sensor calibration, completes the rail full-section profile detection, and more easily ensures the coplanarity of the detection laser beams, effectively improving the measurement accuracy of the rail full-section profile.

[0107] Those skilled in the art will further recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.

[0108] The steps of the methods or algorithms described in conjunction with the embodiments disclosed herein can be implemented in hardware, a software module executed by a processor, or a combination of both. The software module can be located in random access memory (RAM), main memory, read-only memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disk, removable disk, CD-ROM, or any other form of storage medium known in the art.

[0109] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for online detection of the full-section profile of a rail, characterized in that, The online detection method for the full-section profile of the rail includes: The positional relationship of the transmitting path lens assembly is determined such that the light received by the first and second side surfaces of the rail under test covers the measurement area of ​​the rail under test, and there is an overlapping area on the top of the rail under test. The signal processing system sends a transmission command to the parallel light source laser; According to the emission command, the parallel light source laser emits a first wavelength parallel laser beam and a second wavelength parallel laser beam toward the emission path mirror assembly. The transmitting path lens assembly transmits the first wavelength parallel light beam to the first side surface of the rail under test, and reflects and refracts the second wavelength parallel light beam to the second side surface of the rail under test; The receiving path lens assembly receives diffuse reflected light from the first side surface and focuses it to emit a first laser beam, and receives diffuse reflected light from the second side surface and focuses it to emit a second laser beam. The array detector converts the first laser beam into a first electrical signal and the second laser beam into a second electrical signal, and then sends the first and second electrical signals to the signal processing system; the first electrical signal includes a first timing sequence, and the second electrical signal includes a second timing sequence. The signal processing system processes the first electrical signal to generate a first side profile cross-sectional curve, processes the second electrical signal to generate a second side profile cross-sectional curve, and synthesizes the first side profile cross-sectional curve and the second side profile cross-sectional curve to achieve full-section profile detection of the rail under test.

2. The online detection method for the full cross-sectional profile of rails according to claim 1, characterized in that, The signal processing system processes the first electrical signal to generate a first side profile cross-sectional curve, processes the second electrical signal to generate a second side profile cross-sectional curve, and synthesizes the first and second side profile cross-sectional curves, specifically including: The signal processing system extracts the center line of the first wavelength parallel laser beam based on the first electrical signal to obtain the first pixel coordinates; and extracts the center line of the second wavelength parallel laser beam based on the second electrical signal to obtain the second pixel coordinates. According to the preset coordinate transformation parameters, the coordinate system of the first pixel coordinate is transformed to obtain the first side contour section curve, and the coordinate system of the second pixel coordinate is transformed to obtain the second side contour section curve. The first side profile curve and the second side profile curve are synthesized to obtain the full profile curve of the measured rail.

3. A rail full-section profile detection device, characterized in that, The rail full-section profile detection device includes: a parallel light source laser, a transmitting path lens assembly, a receiving path lens assembly, an array detector, and a signal processing system; The parallel light source laser is located above one side of the rail being measured and is used to emit a first wavelength parallel laser beam and a second wavelength parallel laser beam. The transmitting path lens assembly is located on one side of the parallel light source laser and above the rail under test. It is used to transmit the first wavelength parallel light beam to the first side surface of the rail under test and to reflect and refract the second wavelength parallel light beam to the second side surface of the rail under test. The receiving path lens assembly is located above the rail being measured and on the opposite side of the transmitting path lens assembly. It is used to receive diffuse reflected light from the first side surface and focus and emit a first laser beam, and to receive diffuse reflected light from the second side surface and focus and emit a second laser beam. The array detector is located directly above the receiving path lens assembly, and is used to convert the first laser beam into a first electrical signal and the second laser beam into a second electrical signal, and then send the first electrical signal and the second electrical signal to the signal processing system; the first electrical signal includes a first timing sequence, and the second electrical signal includes a second timing sequence; The signal processing system is electrically connected to the array detector and is used to process the first electrical signal to generate a first side profile cross-sectional curve, process the second electrical signal to generate a second side profile cross-sectional curve, and synthesize the first side profile cross-sectional curve and the second side profile cross-sectional curve to realize the detection of the full cross-sectional profile of the rail under test.

4. The rail full-section profile detection device according to claim 3, characterized in that, The parallel light source laser is a tunable dual-wavelength laser.

5. The rail full-section profile detection device according to claim 3, characterized in that, The transmitting path mirror assembly includes: a semi-transparent and semi-reflective mirror, a plane mirror, and a first prism; the semi-transparent and semi-reflective mirror is positioned above the rail being measured; the plane mirror is arranged parallel to the semi-transparent and semi-reflective mirror; the first prism is located on the opposite side of the parallel light source laser and its bottom surface faces between the semi-transparent and semi-reflective mirror and the plane mirror.

6. The rail full-section profile detection device according to claim 5, characterized in that, The positions of the semi-transparent mirror, the plane mirror, and the first prism satisfy the following relationship: B1 = B0 / sinα; Where m is the number of times the second-wavelength parallel laser beam is reflected by the plane mirror; B0 is the length of the first / second-wavelength parallel laser beam; B1 is the horizontal distance between the first / second-wavelength parallel laser beams; B2 is the distance from the rightmost reflection point of the second-wavelength parallel laser beam in the semi-transparent mirror to the rightmost exit point on the first prism; B3 is the horizontal distance from the rightmost reflection point of the second-wavelength parallel laser beam in the semi-transparent mirror to the leftmost exit point on the first prism; B4 is the horizontal distance between the lowest points of the measured cross-section of the rail being measured; and α is the angle between the parallel laser beam and the horizontal plane. L is the angle between the second wavelength parallel laser beam and the horizontal plane; L is the distance from the semi-transparent mirror to the plane mirror; L1 is the distance between the top surface of the rail being measured and the semi-transparent mirror; L2 is the distance between the lowest point of the rail being measured and the semi-transparent mirror; L3 is the length of the bottom edge of the first prism.

7. The rail full-section profile detection device according to claim 5, characterized in that, The structure and material of the first prism satisfy the following relationship: i 2＝ i 3＝ e 1＝ e2; sinθ1 / sinθ2=cos(α-ε1) / sinε1=n2 / n1; Where ε1 is the angle between the upper side of the first triangular prism and the horizontal plane; ε2 is the angle between the lower side of the first triangular prism and the horizontal plane; θ1 is the incident angle of the light entering the first triangular prism; θ2 is the internal refraction angle of the first triangular prism; θ3 is the internal incident angle of the first triangular prism; θ4 is the exit angle of the light; and α is the angle between the first wavelength parallel laser beam and the horizontal plane. n1 is the angle between the second wavelength parallel laser beam and the horizontal plane; n2 is the air refractive index; and n2 is the refractive index of the first prism.

8. The rail full-section profile detection device according to claim 3, characterized in that, The receiving path lens assembly includes: a second triangular prism, a third triangular prism, a first focusing lens, and a second focusing lens; the second triangular prism and the third triangular prism are symmetrically arranged, the first focusing lens and the second focusing lens are symmetrically arranged, and the first focusing lens is positioned directly opposite the second triangular prism, the second focusing lens is symmetrically arranged with the first focusing lens, and is positioned directly opposite the third triangular prism.

9. The rail full-section profile detection device according to claim 3, characterized in that, The signal processing system includes a logic control module, a digital signal processing system, and a laser emission control module. The logic control module receives electrical signals sent by the area array detector, processes the electrical signals into digital signals, and sends the digital signals to the digital signal processing system. The digital signal processing system processes the digital signals to obtain the overall profile and full cross-section of the rail under test. The laser emission control module receives emission commands from the digital signal processing system and sends the emission commands to the parallel light source laser.

10. The rail full-section profile detection device according to claim 3, characterized in that, The rail full-section profile inspection device also includes a housing; The housing is installed on the outside of the parallel light source laser, the transmitting path lens assembly, the receiving path lens assembly, and the array detector.

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