Multifunctional intelligent inspection device for steel rail

Abstract

The utility model discloses a multifunctional intelligent inspection device for a steel rail, which comprises a support rod, a flat plate support mounted on one side of the top of the support rod, an industrial tablet computer mounted on the flat plate support, a push rod mounted on the other side of the top of the support rod in a hinged manner, and acquisition and detection mechanisms mounted on two sides of the support rod, traveling mechanisms are mounted on two sides of the bottoms of the two side acquisition and detection mechanisms. According to the utility model, color image data of all rail surface states of an acquisition section and 3D point cloud data of fasteners can be acquired and stored in the memory, the processor simultaneously processes and calculates the color image data and the point cloud data in real time, and the result is sent to a man-machine interaction interface on the industrial tablet computer by the processor to be displayed. And the detection result is stored in the memory, so that the field working condition is highly restored, the detection effect and the detection efficiency are improved, the labor time cost is reduced, the rail surface state and the fastener state are continuously detected, the detection precision is high, and the implementation is convenient.

Description

Technical Field

[0001] The utility model belongs to the technical field of rail inspection, and particularly relates to a multifunctional intelligent inspection device for rails. Background Art

[0002] The rail is a key component of railway infrastructure, and its surface condition directly affects the operation safety of trains. With the increase of railway transportation speed and transportation volume, defects such as cracks, corrugations, and chunks will appear on the rail surface, resulting in additional vibrations and noises during train operation, directly affecting the comfort of passengers, and may increase the maintenance cost of trains. Currently, the mainstream methods are manual inspections or the identification of grayscale images collected by black and white line array cameras through deep learning methods. However, manual inspections are affected by environmental factors, and the intelligent identification of black and white images has serious misdetection situations and cannot highly restore the on-site working conditions, with great limitations.

[0003] At the same time, fasteners are important connecting components in the track structure, mainly used to fix rails, which is of great significance to railway operation safety. In actual railway lines, fasteners often have various problems such as fractures, losses, and loosening, directly affecting the safe operation of trains. However, the existing fastener condition detection results are basically through manual inspections, and there are deviations in the fastener defect standards among different inspectors, resulting in low detection efficiency and high labor time costs.

[0004] Therefore, there is an urgent need for a multifunctional intelligent inspection device for rails to solve the above problems. Summary of the Utility Model

[0005] Aiming at the problems raised in the above background art, the purpose of the utility model is to provide a multifunctional intelligent inspection device for rails.

[0006] To achieve the above technical purpose, the technical scheme adopted by the utility model is as follows:

[0007] A multifunctional intelligent inspection device for rails includes a support rod. On one side of the top of the support rod, a flat plate bracket is installed, and an industrial tablet computer is installed on the flat plate bracket. On the other side of the top of the support rod, a push rod is hinged and installed. On both sides of the support rod, acquisition and detection mechanisms are installed, and on both sides of the bottom of the acquisition and detection mechanisms on both sides, traveling mechanisms are installed;

[0008] The acquisition and detection mechanism includes an installation box, in which a support bracket is installed. An image acquisition color line array camera is installed at the middle position of the support bracket. Lasers and white lasers are installed on the left and right sides of the image acquisition color line array camera on the support bracket. 3D industrial cameras and 2D industrial cameras are installed at the lower ends on both sides of the image acquisition color line array camera on the support bracket. Detection windows are provided at the bottom of the installation box corresponding to the image acquisition color line array camera, lasers, white lasers, 3D industrial cameras and 2D industrial cameras, and light-transmitting glasses are installed in the detection windows. An odometer is installed on the outer side of the installation box at the connection with the support rod. The odometer is connected to an encoder, and the encoder is installed on one side of the traveling mechanism. The 3D industrial camera, 2D industrial camera and encoder are all provided with communication interfaces. The communication interfaces are connected to a communication bus, and the communication bus is connected to a processor and a memory. The output end of the image acquisition color line array camera is connected to the memory, and the communication bus is also connected to an industrial tablet computer.

[0009] Further defined, a power supply rack is installed on the outer side of the installation box, and a power supply is installed in the power supply rack. Such a structural design facilitates the installation of the power supply and power supply use.

[0010] Further defined, handles are also installed on the front and rear sides of the installation box. Such a structural design facilitates the effect of assisting in handling.

[0011] Further defined, the traveling mechanism includes a traveling installation frame. Traveling wheels are installed at the bottom of the traveling installation frame. The encoder is installed on one side of the traveling installation frame and is connected to the traveling wheels. An auxiliary plate arranged in an L-shaped structure is installed on the other side of the traveling installation frame, and a reference roller is installed at the bottom of the auxiliary plate. Such a structural design facilitates stable movement on the rail.

[0012] Further defined, positioning and assembly grooves are also provided on both sides of the bottom of the installation box, and the traveling mechanism is installed in the positioning and assembly grooves. Such a structural design facilitates the positioning and installation of the traveling mechanism.

[0013] The beneficial effects of the present utility model are as follows: Through the image acquisition color line array camera, lasers, white lasers, 3D industrial cameras and 2D industrial cameras, the present utility model can collect and store the color image data of all rail surface states and the 3D point cloud data of fasteners in the acquisition section into the memory during the moving process. The processor simultaneously performs real-time processing and calculation on the color image data and point cloud data. The results are sent by the processor to the human-computer interaction interface on the industrial tablet computer for display, and the results are saved in the memory, highly restoring the on-site working conditions, improving the detection effect and detection efficiency, reducing the manual time cost, achieving continuous detection of the rail surface state and fastener state, with high detection accuracy and convenient implementation. Brief Description of the Drawings

[0014] The utility model can be further illustrated by the non - limiting embodiments shown in the drawings;

[0015] Figure 1 It is a schematic structural diagram of a multi - functional intelligent inspection device for steel rails according to an embodiment of the utility model;

[0016] Figure 2 It is a schematic internal structure diagram of the acquisition and detection mechanism of a multi - functional intelligent inspection device for steel rails according to an embodiment of the utility model;

[0017] Figure 3 It is a schematic bottom structure diagram of the acquisition and detection mechanism of a multi - functional intelligent inspection device for steel rails according to an embodiment of the utility model;

[0018] Figure 4 It is a schematic structural diagram of the traveling mechanism of a multi - functional intelligent inspection device for steel rails according to an embodiment of the utility model;

[0019] Figure 5 It is a schematic detection corresponding structure diagram of a multi - functional intelligent inspection device for steel rails according to an embodiment of the utility model

[0020] Figure 6 It is a schematic storage connection structure diagram of a multi - functional intelligent inspection device for steel rails according to an embodiment of the utility model. The main element symbols are explained as follows:

[0021] Support rod 1, flat plate bracket 2, industrial tablet computer 3, push rod 4, acquisition and detection mechanism 5, traveling mechanism 6, installation box 7, support bracket 8, image acquisition color line - array camera 9, laser 10, white laser 11, 3D industrial camera 12, 2D industrial camera 13, detection window 14, light - transmitting glass 15, mileage counter 16, encoder 17, communication interface 18, communication bus 19, processor 20, memory 21, power supply rack 22, power supply 23, handle 24, traveling installation rack 25, running wheel 26, auxiliary plate 27, reference wheel 28, positioning and assembly groove 29. Detailed Embodiments

[0022] In order to enable those skilled in the art to better understand the present utility model, the technical solutions of the present utility model will be further described below with reference to the drawings and embodiments.

[0023] Embodiment 1, as shown in Figure 1 , Figure 2 , Figure 3 and Figure 4As shown in the figure, a multifunctional intelligent inspection device for steel rails. On one side of the top of the support rod 1, a flat plate bracket 2 is installed, and an industrial tablet computer 3 is installed on the flat plate bracket 2. On the other side of the top of the support rod 1, a push rod 4 is hinged and installed. On both sides of the support rod 1, acquisition and detection mechanisms 5 are installed. On both sides of the bottom of the acquisition and detection mechanisms 5 on both sides, traveling mechanisms 6 are installed;

[0024] The acquisition and detection mechanism 5 includes an installation box 7. Inside the installation box 7, a support bracket 8 is installed. In the middle position of the support bracket 8, an image acquisition color line array camera 9 is installed. On the left and right sides of the image acquisition color line array camera 9 on the support bracket 8, a laser 10 and a white laser 11 are installed. At the lower ends of both sides of the image acquisition color line array camera 9 on the support bracket 8, a 3D industrial camera 12 and a 2D industrial camera 13 are installed. At the bottom of the installation box 7, detection windows 14 are provided corresponding to the image acquisition color line array camera 9, the laser 10, the white laser 11, the 3D industrial camera 12, and the 2D industrial camera 13. Transparent glasses 15 are installed in the detection windows 14. On the outside of the installation box 7 at the connection with the support rod 1, a mileage counter 16 is installed. The mileage counter 16 is connected to an encoder 17. The encoder 17 is installed on one side of the traveling mechanism 6. The 3D industrial camera 12, the 2D industrial camera 13, and the encoder 17 are all provided with communication interfaces 18. The communication interfaces 18 are connected to a communication bus 19. The communication bus 19 is connected to a processor 20 and a memory 21. The output end of the image acquisition color line array camera 9 is connected to the memory 21. The communication bus 19 is also connected to the industrial tablet computer 3.

[0025] In this embodiment, during use, the traveling mechanism 6 at the bottom of the acquisition and detection mechanism 5 is placed at the starting point. The push rod 4 drives the support rod 1, the support rod 1 drives the acquisition and detection mechanisms 5 on both sides, and the acquisition and detection mechanism 5 drives the traveling mechanism 6 to move on the rail. When the traveling mechanism 6 moves, it drives the encoder 17 to rotate. When the encoder 17 rotates, it generates a differential signal (TTL level), triggering the image acquisition color linear array camera 9, the 3D industrial camera 12, and the 2D industrial camera 13 to take pictures. By activating the laser 10 and the white laser 11 as the fill light source for the image acquisition color linear array camera 9, the acquired image features are prominent, which is conducive to image recognition. The 3D industrial camera 12 is used to obtain the point cloud data of the fasteners on the rail, and the 2D industrial camera 13 is used to obtain the rail surface state image and the 2D image of the fasteners. Then, the collected image data is transmitted to the memory 21 for storage. At the same time, the mileage counter 16 receives the pulse signal generated by the encoder 17 and converts it into mileage, and binds the mileage with the acquired pictures. Finally, after the acquisition and detection mechanism 5 is pushed to the end position, all the color image data of the rail surface state and the 3D point cloud data of the fasteners in the acquisition section are stored in the memory 21. The processor 20 simultaneously performs real-time processing and calculation on the color image data and the point cloud data, and the results are sent by the processor to the human-computer interaction interface on the industrial tablet computer 3 for display, and the results are saved in the memory 21.

[0026] Among them, the image acquisition color linear array camera 9 is used to acquire the rail surface image.

[0027] By using a high-brightness white laser as the fill light source for the image acquisition color linear array camera 9, the acquired image features are prominent, which is conducive to image recognition.

[0028] A 3D measurement is formed by the structured light source generated by the 3D industrial camera 12 and the laser 10.

[0029] The point cloud data of the fasteners is acquired through 3D measurement, and the height difference between the upper surface of the elastic tongue and the bottom surface of the rail is calculated.

[0030] The difference between the distance between the top surface of the anchor bolt and the upper surface of the base plate and the standard value is calculated by acquiring the point cloud data of the fasteners through 3D measurement.

[0031] The height difference between the rail bottom and the top surface of the rail bearing table is calculated by acquiring the point cloud data of the fasteners through 3D measurement.

[0032] The gap between the longitudinal limit boss of the base plate and the rail bottom is calculated by acquiring the point cloud data of the fasteners through 3D measurement.

[0033] Collect color pictures of the rail surface by using a 2D industrial camera 13, a white laser 11, and an image acquisition color linear array camera 9, and identify rail surface damages using existing deep learning object detection algorithms, including rail welding joints, surface spalling, fish-scale patterns, abrasions, abnormal light bands, corrugations, rail surface cracks, etc.

[0034] The structured light source generated by a 3D industrial camera 12 and a laser 10 forms a 3D measurement to collect point cloud data of the fastener points on both sides of each rail. Calculate the height difference between the upper surface of the elastic tongue and the bottom surface of the rail, the difference between the distance between the top surface of the anchor bolt and the upper surface of the tie plate and the standard value, the height difference between the bottom of the rail and the top surface of the bearing rail table, the gap between the longitudinal limit boss of the tie plate and the bottom of the rail, and identify the fastener installation status and component defects using existing deep learning object detection algorithms, including whether the fastener installation is skewed, reverse installed, etc. Component defects refer to the missing of fasteners, gauge blocks, insulating blocks (insulating gauge blocks), screw spikes, T-bolts, anchor bolts, and broken elastic bars.

[0035] Example 2, as Figure 2 shown, on the basis of Example 1, the following structure is added to this example. A power supply rack 22 is installed on the outside of the installation box 7, and a power supply 23 is installed inside the power supply rack 22.

[0036] In this example, during the detection process, power supply can be provided through the power supplies 23 on both sides, and by setting the power supply rack 22, the power supply 23 can be conveniently and stably installed.

[0037] Example 3, as Figure 2 shown, on the basis of Example 1, the following structure is added to this example. Handles 24 are also installed on the front and back sides of the installation box 7.

[0038] In this example, during use, the handles 24 can assist in carrying the installation box 7.

[0039] Example 4, as Figure 3 and Figure 4 shown, on the basis of Example 1, the following structure is added to this example. The traveling mechanism 6 includes a traveling mounting frame 25. A traveling wheel 25 is installed at the bottom of the traveling mounting frame 25. An encoder 17 is installed on one side of the traveling mounting frame 25 and is connected to the traveling wheel 26. An auxiliary plate 27 with an L-shaped structure is installed on the other side of the traveling mounting frame 25, and a reference contact wheel 28 is installed at the bottom of the auxiliary plate 27.

[0040] In this example, during use, first place the traveling wheel 25 on the surface of the rail, and at the same time make the reference contact wheel 28 at the bottom of the auxiliary plate 27 fit the side of the rail. During movement, the reference contact wheel 28 can prevent the traveling wheel 25 from derailing. At the same time, when the traveling wheel 25 moves, it drives the encoder 17 to rotate and generate signals.

[0041] Example 5, as Figure 3 shown, on the basis of Example 1, the following structure is added in this example. Positioning and assembly grooves 29 are further provided on both sides of the bottom of the installation box 7, and the traveling mechanism 6 is installed in the positioning and assembly grooves 29.

[0042] In this example, during installation, by providing the positioning and assembly grooves 29, the traveling mechanism 6 can be positioned and installed in the positioning and assembly grooves 29, which is convenient for installation and use.

[0043] The above embodiments only exemplarily illustrate the principles and effects of the present invention, rather than limiting the present invention. Any person familiar with this technology can modify or change the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or changes completed by those with ordinary knowledge in the technical field without departing from the spirit and technical idea disclosed by the present invention should still be covered by the claims of the present invention.

Claims

1. A multifunctional intelligent inspection device for rails, characterized in that: It comprises a support rod (1), a tablet bracket (2) is installed on one side of the top of the support rod (1), an industrial tablet computer (3) is installed on the tablet bracket (2), a push rod (4) is hingedly installed on the other side of the top of the support rod (1), a collection and detection mechanism (5) is installed on both sides of the support rod (1), and a walking mechanism (6) is installed on both sides of the bottom of the collection and detection mechanism (5) on both sides; The acquisition and detection mechanism (5) comprises an installation box (7), a support bracket (8) is installed in the installation box (7), an image acquisition color line array camera (9) is installed in the middle of the support bracket (8), a laser (10) and a white laser (11) are installed on the left and right sides of the image acquisition color line array camera (9) of the support bracket (8), a 3D industrial camera (12) and a 2D industrial camera (13) are installed on the lower ends of the image acquisition color line array camera (9) of the support bracket (8), and a detection window (14) is provided at the bottom of the installation box (7) at locations corresponding to the image acquisition color line array camera (9), the laser (10), the white laser (11), the 3D industrial camera (12) and the 2D industrial camera (13), and the Translucent glass (15) is installed in the detection window (14); an mileage counter (16) is installed on the outside of the installation box (7) at the connection with the support rod (1); the mileage counter (16) is connected to an encoder (17); the encoder (17) is installed on one side of the walking mechanism (6); the 3D industrial camera (12), the 2D industrial camera (13) and the encoder (17) are all provided with a communication interface (18); the communication interface (18) is connected to a communication bus (19); the communication bus (19) is connected to a processor (20) and a memory (21); the output end of the image acquisition color linear array camera (9) is connected to the memory (21); and the communication bus (19) is also connected to the industrial tablet computer (3).

2. A multifunctional intelligent inspection device for rails according to claim 1, characterized in that: A power supply rack (22) is installed on the outside of the installation box (7), and a power supply (23) is installed in the power supply rack (22).

3. A multifunctional intelligent inspection device for rails according to claim 2, characterized in that: Handles (24) are also installed on the front and rear sides of the installation box (7).

4. A multifunctional intelligent inspection device for rails according to claim 3, characterized in that: The walking mechanism (6) comprises a walking mounting frame (25), a walking wheel (26) is installed at the bottom of the walking mounting frame (25), the encoder (17) is installed on one side of the walking mounting frame (25) and connected to the walking wheel (26), an auxiliary plate (27) arranged in an L-shaped structure is installed on the other side of the walking mounting frame (25), and a reference wheel (28) is installed at the bottom of the auxiliary plate (27).

5. A multifunctional intelligent inspection device for rails according to claim 4, characterized in that: Both sides of the bottom of the installation box (7) are also provided with positioning and assembly grooves (29), and the walking mechanism (6) is installed in the positioning and assembly grooves (29).

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