A welding seam recognition device based on laser ranging

Abstract

The application provides a welding seam identification device based on laser ranging, relates to the technical field of track maintenance, and comprises a steel rail and a mobile frame moving on the steel rail. A control console, a display screen and a seat are arranged on the front frame of the mobile frame. A storage frame is arranged on the rear frame of the mobile frame. Welding seam identification assemblies and protection assemblies are arranged on the two sides of the front end of the mobile frame. The welding seam identification assemblies comprise laser range finders and high-definition cameras. Adjustment assemblies are arranged at the bottom of the laser range finders and the high-definition cameras. The adjustment assemblies are used for driving the welding seam identification assemblies to perform lifting sliding movement. The application detects the height change of the steel rail surface in real time by adopting the laser range finders, combines secondary confirmation of the high-definition cameras, forms a double identification mechanism of "laser coarse positioning + visual fine confirmation", significantly reduces the false alarm rate and the missed alarm rate, avoids missed detection caused by artificial distraction, reduces artificial labor, and improves operation efficiency.

Description

Technical Field

[0001] This invention relates to the field of track maintenance technology, specifically to a weld identification device based on laser ranging. Background Technology

[0002] In the field of rail transit, steel rails, as a key infrastructure supporting train operation, are subjected to dynamic loads and temperature changes over a long period of time, making them prone to fatigue cracks or geometric irregularities at welded joints. To ensure operational safety, regular inspection, grinding, or repair of rail welds is necessary.

[0003] Traditional weld seam location methods mainly rely on manual visual inspection or marking points on the track. Manual inspection is inefficient, easily affected by ambient light and the experience of the operators, and prone to missed inspections or misjudgments. Furthermore, manual inspection usually requires operators to walk or slowly push the inspection tools, bending over or observing the rail surface section by section, which is slow and labor-intensive. On the other hand, the fixed marking point method cannot be applied to all track sections and lacks flexibility and real-time capability.

[0004] To address the aforementioned issues, we propose a weld seam identification device based on laser ranging. Summary of the Invention

[0005] To address the problems in the background art, the present invention provides a weld seam identification device based on laser ranging.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A weld seam recognition device based on laser ranging includes a steel rail and a mobile frame that moves on the steel rail. The front body of the mobile frame is equipped with a control panel, a display screen and a seat, and the rear body of the mobile frame is equipped with a storage frame. Weld seam recognition components and protective components are provided on both sides of the front end of the mobile frame. The weld seam recognition components include a laser rangefinder and a high-definition camera. The laser rangefinder and the high-definition camera are equipped with an adjustment component at their bottom. The adjustment component is used to drive the weld seam recognition component to move up and down. The adjustment component includes a limiting guide rail. A limiting slider is slidably installed on the outer surface of the limiting guide rail. An electric push rod is provided on the top of the limiting slider. A mounting frame is provided on the outer surface of the limiting slider. The laser rangefinder and the high-definition camera are vertically distributed and installed on the mounting frame.

[0007] Preferably, the protective component is used to store and protect the weld identification component. The protective component includes a base frame and a protective cover. The base frame is fixedly installed on the front end of the mobile vehicle frame, and the protective cover covers the periphery of the base frame and is fixedly installed by locking screws.

[0008] Preferably, the limiting guide rail is fixedly installed on the outer middle part of the base frame, and the electric push rod is fixedly installed on the top middle part of the base frame.

[0009] Preferably, the top of the electric actuator passes through the top of the protective cover.

[0010] Preferably, a limiting plate is provided at the bottom of the limiting guide rail.

[0011] Compared with the prior art, the beneficial effects of the present invention are: This invention employs a laser rangefinder to detect real-time changes in the height of the rail surface, combined with secondary confirmation by a high-definition camera, forming a dual recognition mechanism of "laser coarse positioning + visual fine confirmation." This significantly reduces false alarm and false negative rates, while avoiding missed detections due to human distraction, reducing manual labor, and improving operational efficiency. The recognition principle is as follows: When the moving vehicle frame travels along the track, the laser rangefinder collects real-time data on the height changes of the rail surface. The collected values ​​are sent to a built-in controller for threshold comparison. When a height change feature matching the weld contour is detected, such as a small bulge or depression on the rail top surface, the system determines it to be the weld location and triggers an audible and visual alarm from the vehicle's horn, alerting the operator that they have arrived at the work point. Simultaneously, the high-definition camera performs real-time image acquisition and verification at this location, further confirming the actual existence of the weld, thus effectively avoiding false alarms caused by ballast, debris, or light spot interference. Furthermore, the high-definition camera in this invention can take photos or record videos of each identified weld seam. Combined with laser ranging and positioning data, it can generate detection records with time, location, and image information, which is convenient for later analysis, review, and comparison with historical data, providing basic data support for digital operation and maintenance management of tracks. This invention incorporates a protective component. When not in operation or when moving to a different work area, the adjustment component can retract the weld seam recognition component into the protective cover, preventing the weld seam recognition component from being constantly exposed to the outside environment. This effectively avoids external damage such as dust, rain, and flying gravel, thereby extending the service life and safety of the equipment. Attached Figure Description

[0012] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a dissected structural diagram of the weld identification component in this invention; Figure 3 For the present invention Figure 2 Enlarged view of point A in the middle; Figure 4 This is a schematic diagram of the overall structure of the weld seam recognition component in this invention.

[0013] In the diagram: 1. Rail; 2. Mobile frame; 21. Control panel; 22. Display screen; 23. Seat; 24. Storage frame; 3. Weld seam recognition component; 31. Protective cover; 32. Base frame; 33. Limiting guide rail; 34. Limiting slider; 35. Electric push rod; 36. Mounting bracket; 37. Limiting plate; 4. Laser rangefinder; 5. High-definition camera. Detailed Implementation

[0014] The technical solution in this application embodiment is to solve the problems mentioned in the background art, and the overall idea is as follows: Example 1: Refer to Figure 1 - Figure 4 As shown, a weld seam identification device based on laser ranging in this embodiment includes a rail 1 and a mobile frame 2 that moves on the rail 1. The front body of the mobile frame 2 is provided with a control panel 21, a display screen 22 and a seat 23, and the rear body of the mobile frame 2 is provided with a storage frame 24 for storing maintenance tools or spare parts.

[0015] Both sides of the front end of the mobile frame 2 are equipped with weld seam recognition components 3 and protective components. The weld seam recognition components 3 include a laser rangefinder 4 and a high-definition camera 5.

[0016] like Figure 3 As shown, the laser rangefinder 4 and the high-definition camera 5 are equipped with an adjustment component at their bottom. The adjustment component is used to drive the weld seam recognition component 3 to move up and down. Specifically, the adjustment component includes a limiting guide rail 33. A limiting slider 34 is slidably mounted on the outer surface of the limiting guide rail 33. An electric push rod 35 is provided on the top of the limiting slider 34. The telescopic end of the electric push rod 35 is connected to the limiting slider 34 and is used to drive the limiting slider 34 to slide up and down along the limiting guide rail 33. A mounting frame 36 is fixedly provided on the outer surface of the limiting slider 34. The laser rangefinder 4 and the high-definition camera 5 are vertically distributed and mounted on the mounting frame 36, with the laser rangefinder 4 on top and the high-definition camera 5 on the bottom.

[0017] The protective assembly is used to house and protect the weld identification assembly 3. It includes a base frame 32 and a protective cover 31. The base frame 32 is fixedly installed on the front body of the mobile frame 2. The protective cover 31 covers the outer perimeter of the base frame 32 and is fixedly installed by locking screws. The protective cover 31 can be removed when maintenance or cleaning is required.

[0018] In some examples, the limit guide rail 33 is fixedly installed on the outer middle of the base frame 32, and the electric push rod 35 is fixedly installed on the top middle of the base frame 32. The top of the electric push rod 35 passes through the top of the protective cover 31 to connect to the external control cable.

[0019] In some examples, a limit plate 37 is provided at the bottom of the limit guide rail 33 to prevent the limit slider 34 from dislodging from the guide rail.

[0020] The working principle of this invention is: Before starting the rail weld inspection operation, the operator can activate the electric push rod 35 through the control panel 21 to drive the limit slider 34 to slide down along the limit guide rail 33, so that the laser rangefinder 4 and high-definition camera 5 on the mounting frame 36 extend from the protective cover 31 to the working position and are aligned with the side of the rail 1.

[0021] Once everything is ready, the mobile frame 2 can be started to move along the rail 1. During the movement, the laser rangefinder 4 continuously measures the distance from it to the surface of the rail 1 and transmits the real-time distance value to the built-in controller on the control panel 21. The controller has a pre-stored weld feature threshold library: when a significant change in the distance value is detected, it is judged as a suspected weld.

[0022] The controller then triggers the vehicle's horn to emit a short alarm sound and highlights "Weld reached" on display screen 22. Simultaneously, the high-definition camera 5 takes a picture or captures real-time video of the location, using an image edge detection algorithm to further confirm the presence of typical weld heat-affected zone textures or contours. If the image recognition result matches the laser ranging result, it is determined to be a real weld, the current position is recorded, and an alarm is triggered continuously for several seconds; if they do not match, only the location is recorded without triggering a continuous alarm.

[0023] Based on alarm and image information, operators can decide whether to stop the machine for grinding, measuring, or marking operations. After completing the operation, the electric push rod 35 is controlled by the control panel 21 to reverse the movement and retract the laser rangefinder 4 and high-definition camera 5 into the protective cover 31 to avoid damage during transportation or empty driving.

[0024] Example 2: Refer to Figure 1 - Figure 4 As shown, based on Embodiment 1, a weld seam identification device based on laser ranging further includes the following structure: To further improve recognition efficiency, the laser rangefinder 4 can use a multi-point array laser sensor to simultaneously measure the height distribution of multiple points in the longitudinal and transverse directions of the rail 1, constructing a three-dimensional profile of the rail 1 surface. The high-definition camera 5 is an industrial-grade wide dynamic range camera and is equipped with LED supplementary lighting to adapt to tunnel or nighttime working environments. The electric push rod 35 has a lifting stroke of 0-200mm, which can meet the detection needs of different types of rails (such as 60kg / m and 75kg / m rails).

[0025] The laser ranging-based weld identification device provided by this invention has a compact structure and is easy to operate. It can effectively improve the automation and accuracy of weld positioning in track maintenance operations. It is applicable to various occasions such as railway engineering sections, urban rail transit maintenance, and tram line inspection, and has good prospects for promotion and application.

[0026] Compared to traditional manual inspection, which relies mainly on visual observation and work experience and is prone to visual fatigue after long hours of work, leading to missed detections or misjudgments, this invention adopts a dual recognition mechanism of "real-time laser ranging scanning + high-definition camera image verification": the laser rangefinder 4 first quickly locates the suspected weld position by observing the height change characteristics of the rail 1 surface, and then the high-definition camera 5 visually confirms the position. This combination significantly reduces the false alarm rate caused by environmental factors such as ballast, oil stains, reflections, or shadows, while avoiding missed detections due to human distraction. This greatly improves the accuracy and reliability of recognition, reduces manual labor, and increases work efficiency.

[0027] Furthermore, the high-definition camera 5 in this invention is equipped with an existing mature image analysis system, which can take pictures or record videos of each identified weld seam. Combined with laser ranging and positioning data, it can generate detection records with time, location, and image information, which is convenient for later analysis, review, and comparison with historical data, providing basic data support for digital operation and maintenance management of tracks.

[0028] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A weld seam identification device based on laser ranging, comprising a rail (1) and a mobile frame (2) moving on the rail (1), characterized in that: The front body of the mobile frame (2) is equipped with a control panel (21), a display screen (22) and a seat (23), and the rear body of the mobile frame (2) is equipped with a storage box (24). The front sides of the mobile frame (2) are provided with weld seam recognition components (3) and protective components. The weld seam recognition components (3) include a laser rangefinder (4) and a high-definition camera (5). The laser rangefinder (4) and the high-definition camera (5) are provided with an adjustment component at their bottom. The adjustment component is used to drive the weld seam recognition component (3) to move up and down. The adjustment component includes a limiting guide rail (33). A limiting slider (34) is slidably installed on the outer surface of the limiting guide rail (33). An electric push rod (35) is provided on the top of the limiting slider (34). A mounting frame (36) is provided on the outer surface of the limiting slider (34). The laser rangefinder (4) and the high-definition camera (5) are vertically distributed and installed on the mounting frame (36).

2. The weld seam identification device based on laser ranging according to claim 1, characterized in that, The protective assembly is used to store and protect the weld identification assembly (3). The protective assembly includes a base frame (32) and a protective cover (31). The base frame (32) is fixedly installed on the front end of the mobile frame (2). The protective cover (31) covers the outer perimeter of the base frame (32) and is fixedly installed by locking screws.

3. The weld seam identification device based on laser ranging according to claim 2, characterized in that, The limiting guide rail (33) is fixedly installed on the outer middle part of the base frame (32), and the electric push rod (35) is fixedly installed on the top middle part of the base frame (32).

4. The weld seam identification device based on laser ranging according to claim 3, characterized in that, The top of the electric push rod (35) passes through the top of the protective cover (31).

5. A weld seam identification device based on laser ranging according to claim 4, characterized in that, The bottom of the limiting guide rail (33) is provided with a limiting plate (37).

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