Wheel set rim defect acquisition device and detection system
The wheel rim defect detection system uses face array cameras and high-exposure flashlights for automated and accurate detection, addressing inefficiencies in manual inspection and enhancing defect detection accuracy.
Patent Information
- Application Number
- CN202422088186.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-27
- Publication Date
- 2025-07-15
- Estimated Expiration
- 2034-08-27
AI Technical Summary
In the prior art, the detection of the rim defect of railway vehicles relies on manual inspection, is inefficient and is susceptible to occlusion, and cannot be fully tested.
A wheel-to-wheel rim defect acquisition device is designed, and a detection module composed of a surface array camera and a high-exposure fill light is used to realize automated detection using the principle of dark field detection, combined with the data analysis module and the alarm module.
It realizes automatic and accurate detection of wheel rim defects, improves detection efficiency, and can cover and detect wheels of different sizes and driving directions in full circumference to avoid the influence of shading.
Smart Images
Figure CN223100725U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of railway tracks, in particular to a wheel set rim defect acquisition device and a detection system. Background Art
[0002] The wheel contour of a railway vehicle usually consists of two parts: the tread and the rim. The rim is further divided into the inner side and the outer side. When the train passes through a curved track, the outer side of the wheel rim will contact the outer rail of the curve, resulting in friction and extrusion. Its main functions include guiding and preventing derailment, etc. However, during the long-term running of the train on the railway track, there will inevitably be problems of rim defects, mainly caused by accidental impacts, derailment accidents, or material defects existing in the wheels themselves. There are also cases where there are accumulations on the track or the rim contacts the rail bolts, causing damage.
[0003] After the rim is defective, when the vehicle passes through the turnout, it is easy for the wheel to bite on the switch rail, resulting in a vehicle derailment accident. Currently, the judgment of wheel set rim defects mainly relies on manual inspection. That is, after the vehicle returns to the depot, by using lighting methods such as a flashlight under the vehicle or on both sides, observe whether there are defects in the wheel rim, and then measure the size of the defect with a caliper. This traditional method requires the cooperation of multiple people, with a large workload and low work efficiency. There is also the problem that some rims are blocked by other devices (such as brake shoes), which is not convenient for inspection. Content of the Utility Model
[0004] Based on this, it is necessary to provide a wheel set rim defect acquisition device in view of the deficiencies in the prior art.
[0005] A wheel set rim defect acquisition device includes a plurality of detection modules arranged along the train track. The detection module includes an induction device and a detection device. The detection device includes a line array camera and a high-exposure fill light. The line array camera is arranged on the side close to the train track, and the high-exposure fill light is arranged outside the line array camera.
[0006] Further, there are two sets of detection devices in the detection module, and the two sets of detection devices are respectively arranged on the inner and outer sides of the train track.
[0007] Further, the detection modules respectively include a plurality of forward detection modules and reverse detection modules, and the orientations of the plurality of forward detection modules and reverse detection modules are opposite.
[0008] Further, the optical axis of the line array camera and the optical axis of the high-exposure fill light are not on the same reflected light path of the train wheel.
[0009] Further, the included angle between the optical axis of the line array camera and the side of the train track is 60° - 80°, and the included angle between the optical axis of the high-exposure fill light and the side of the train track is 20° - 50°.
[0010] Furthermore, the wheel set rim defect acquisition device further includes a calibration paper, which is smoothly attached to the rim surface of the train wheel, and a checkerboard pattern is also provided on the calibration paper.
[0011] In addition, the present utility model also provides a wheel set rim defect detection system.
[0012] A wheel set rim defect detection system includes an acquisition device, a data analysis module and an alarm module. The data analysis module is signal-connected to the acquisition device and the alarm module. The acquisition device is the above-mentioned wheel set rim defect acquisition device, which includes a plurality of detection modules arranged along the train track. The detection module includes an induction device and a detection device. The detection device includes a line array camera and a high-exposure supplementary light. The line array camera is arranged on the side close to the train track, and the high-exposure supplementary light is arranged outside the line array camera.
[0013] Furthermore, there are two groups of detection devices in the detection module, and the two groups of detection devices are respectively arranged on the inner and outer sides of the train track.
[0014] Furthermore, the detection modules respectively include a plurality of forward detection modules and reverse detection modules, and the orientations of the plurality of forward detection modules and reverse detection modules are opposite.
[0015] Furthermore, the optical axis of the line array camera and the optical axis of the high-exposure supplementary light are not on the same reflected light path of the train wheel.
[0016] Furthermore, the included angle between the optical axis of the line array camera and the side surface of the train track is 60° - 80°, and the included angle between the optical axis of the high-exposure supplementary light and the side surface of the train track is 20° - 50°.
[0017] Furthermore, the wheel set rim defect acquisition device further includes a calibration paper, which is smoothly attached to the rim surface of the train wheel, and a checkerboard pattern is also provided on the calibration paper.
[0018] Furthermore, the alarm module includes an alarm display and an audible and visual alarm, and both the alarm display and the audible and visual alarm are signal-connected to the data analysis module.
[0019] In summary, the beneficial effects of the wheel set and wheel flange defect acquisition device and detection system of the present utility model are as follows: By designing a detection module on the train track and train wheels that can automatically control and acquire wheel image data, and using a data analysis module to analyze and process the image data, the automatic detection of wheel sets and wheel flange defects of the wheels can be achieved, greatly improving the efficiency of defect detection; and the light source in the detection device uses a high-exposure supplementary light, which can provide sufficient light for the area array camera to capture and detect, enabling the detection device to accurately detect the train wheels running at high speed; the optical axes of the area array camera and the high-exposure supplementary light in the detection module are set on different reflected light paths, so as to detect and analyze the defects on the wheel surface using the principle of dark field detection, which is more accurate than the conventional bright field detection; multiple groups of detection modules are set in the acquisition device, which can detect train wheels of different sizes; and the multiple groups of detection modules are arranged bidirectionally, which can not only achieve the full circumference detection of the train wheels, avoid the problem that the train wheels cannot be fully detected due to occlusion, but also detect the train wheels in different driving directions; the present utility model has strong practicability and has strong popularization significance. BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Figure 1 FIG. is a top view of the installation structure of the first embodiment of the acquisition device of a wheel set and wheel flange defect detection system in the present utility model;
[0021] Figure 2 is Figure 1 a side view of a part of the structure in;
[0022] Figure 3 FIG. is a schematic diagram of the dark field detection principle of a wheel set and wheel flange defect detection system in the present utility model;
[0023] Figure 4 FIG. is a schematic diagram of the structure of a calibration paper in a wheel set and wheel flange defect detection system in the present utility model;
[0024] Figure 5 FIG. is a top view of the installation structure of the second embodiment of the acquisition device of a wheel set and wheel flange defect detection system in the present utility model. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0025] In order to make the objectives, technical solutions and advantages of the utility model clearer, the following further describes the utility model in detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the utility model and are not used to limit the utility model.
[0026] As Figures 1 to 4As shown, this is the first embodiment of a wheel set and wheel flange defect detection system in the present utility model. A wheel set and wheel flange defect detection system is provided, which includes a collection device 100, a data analysis module (not shown in the figure), and an alarm module (not shown in the figure). The data analysis module is signal-connected to the collection device 100 and the alarm module.
[0027] The collection device 100 is a wheel set and wheel flange defect collection device 100, which includes a number of detection modules 10 arranged along the train track A. The detection module 10 includes an induction device 11 and a detection device 12. The detection device 12 includes a line array camera 121 and a high-exposure fill light 122. The line array camera 121 is arranged on the side close to the train track A, and the high-exposure fill light 122 is arranged outside the line array camera 121.
[0028] A single set of detection modules 10 can detect images of a certain circumferential length. By installing multiple detection modules 10 at a certain interval, the entire circumference can be covered. Through the combined detection of multiple groups of detection modules 10, the detection device 12 can acquire the ability to collect images of the inner and outer sides of the entire circumference of the wheel flange, and can also ensure the detection of train wheels B of different sizes. The high-exposure fill light 122 can provide sufficient light for the line array camera 121 to capture and detect, enabling the detection device 12 to accurately detect the train wheels B running at high speed.
[0029] Specifically, in this embodiment, there are two sets of detection devices 12 of the detection module 10, and the two sets of detection devices 12 are respectively arranged on the inner and outer sides of the train track A. The detection carried out on the inner and outer sides of the train track A can complete the curved surface visual coverage and detection of the entire wheel flange part of the train wheel B, making the detection result more comprehensive and reliable.
[0030] Specifically, in this embodiment, the included angle between the optical axis of the line array camera 121 and the side surface of the train track A is 60° - 80°, and the included angle between the optical axis of the high-exposure fill light 122 and the side surface of the train track A is 20° - 50°. The normal state of the surface of the wheel flange of the train wheel B can be regarded as a smooth plane, while the defects on the surface of the wheel flange are often rough and uneven depressions. According to the principle of dark field detection, when the light emitted by the high-exposure fill light 122 hits the smooth plane, it is reflected at the same angle as the incident angle and will not be received by the line array camera 121, thus forming a dark field in the imaging of the line array camera 121; while when the light emitted by the high-exposure fill light 122 hits the rough and uneven depression, diffuse reflection will occur, and at this time, a part of the light will be received by the line array camera 121, thus forming a bright field in the imaging of the line array camera 121. Compared with the conventional bright field detection method, dark field detection can maximize the distinction between the wheel flange defect area and the normal area, and further make the detection result of the detection device 12 more accurate.
[0031] The wheel set flange defect acquisition device 100 further includes a calibration paper 20, which is smoothly attached to the flange surface of the train wheel B, and a checkerboard pattern is also provided on the calibration paper 20. After the detection module 10 captures the image of the calibration paper 20, the data analysis module can identify and analyze the checkerboard corner points, and establish a mapping relationship diagram map between the image and the actual size of the flange surface using the change in the corner point spacing. The field of view of the area array camera 121 is divided into two directions, X / Y, and map includes the proportional relationships in these two directions.
[0032] The actual length of the defect in the image can be obtained through the following method. Let I be all the pixel sets on this line segment, mapI(x) be the proportional relationship corresponding to the X direction, and mapI(y) be the proportional relationship corresponding to the Y direction. Then:
[0033]
[0034] The same area can be calculated through the following method. Let I be all the pixel sets in this area, mapI(x) be the proportional relationship corresponding to the X direction, and mapI(y) be the proportional relationship corresponding to the Y direction. Then:
[0035]
[0036] By associating this proportional relationship with the true length and area of the wheel flange, the conversion relationship between the pixel size and the true size of the flange surface can be obtained, and this conversion relationship can be further used to calculate the area and length of the extracted defect.
[0037] The alarm module includes an alarm display (not shown in the figure) and an audible and visual alarm (not shown in the figure). Both the alarm display and the audible and visual alarm are signal-connected to the data analysis module. If the data analysis module determines that there are abnormal defects in the train wheel B, it will immediately send the alarm information to the alarm display, thereby displaying detailed abnormal alarm information to the staff, including the abnormal location, abnormal type, and abnormal degree, etc. At the same time, the audible and visual alarm will also emit a warning bell and flashing lights to warn of the abnormal state of the train wheel B.
[0038] Such as Figure 5As shown in the figure, this is the second embodiment of a wheel set and wheel flange defect detection system in the present utility model. This embodiment is basically the same as the first embodiment, and the difference lies in that: the detection module 10 respectively includes a number of forward detection modules 10a and reverse detection modules 10b, and the orientations of a number of the forward detection modules 10 and reverse detection modules 10 are opposite. When the train wheel B is blocked, the detection modules 10 installed in two directions respectively can ensure full circumferential coverage in this case. At the same time, according to the different situations of the train passing through in the forward and reverse directions, the detection device 12 can still achieve the detection of oncoming trains in two directions, thereby improving the detection efficiency.
[0039] In summary, the beneficial effects of a wheel set and wheel flange defect acquisition device and detection system of the present utility model are as follows: By designing a detection module 10 on the train track A and the train wheel B that can automatically control and collect wheel image data, and using a data analysis module to analyze and process the image data, the automatic detection of the wheel set and wheel flange defects of the wheels can be realized, greatly improving the efficiency of defect detection; and the light source in the detection device 12 uses a high-exposure supplementary light 122, which can provide sufficient light for the area array camera 121 to capture and detect, enabling the detection device 12 to accurately detect the train wheel B traveling at high speed; the optical axes of the area array camera 121 and the high-exposure supplementary light 122 in the detection module 10 are set on different reflected light paths, so as to detect and analyze the defects on the wheel surface using the principle of dark field detection, which is more accurate than the conventional bright field detection; multiple groups of detection modules 10 are provided in the acquisition device, which can detect train wheels B of different sizes; and multiple groups of detection modules 10 are arranged bidirectionally, which can not only achieve full circumferential detection of the train wheel B, avoiding the problem that the train wheel B cannot be fully detected due to being blocked, but also can detect the train wheel B in different traveling directions; the present utility model has strong practicability and has strong promotion significance.
[0040] The above embodiments only represent one implementation manner of the utility model, and the description is relatively specific and detailed, but it cannot be understood as a limitation on the scope of the utility model patent. It should be noted that for those of ordinary skill in the art, without departing from the inventive concept of the utility model, several modifications and improvements can still be made, and these all belong to the protection scope of the utility model. Therefore, the protection scope of the utility model patent should be subject to the appended claims.
Claims
1. A wheel set flange defect acquisition device, characterized in that: It includes several detection modules arranged along the train track. The detection module includes an induction device and a detection device. The detection device includes an area array camera and a high-exposure fill light. The area array camera is arranged on the side close to the train track, and the high-exposure fill light is arranged outside the area array camera. The detection modules respectively include several forward detection modules and reverse detection modules, and the orientations of several forward detection modules and reverse detection modules are opposite.
2. The wheel set and flange defect acquisition device according to claim 1, wherein: There are two groups of detection devices of the detection module, and the two groups of detection devices are respectively arranged on the inner and outer sides of the train track.
3. The wheel set flange defect acquisition device according to claim 1, characterized in that: The optical axis of the area array camera and the optical axis of the high-exposure fill light are not on the same reflected light path of the train wheel.
4. The wheel set and flange defect acquisition device according to claim 3, characterized in that: The included angle between the optical axis of the area array camera and the side of the train track is 60° to 80°, and the included angle between the optical axis of the high-exposure fill light and the side of the train track is 20° to 50°.
5. The wheel set flange defect acquisition device according to claim 1, characterized in that: It also includes a calibration paper, which is smoothly attached to the surface of the wheel flange of the train wheel, and a checkerboard pattern is also provided on the calibration paper.
6. A wheel set flange defect detection system, characterized in that: It includes a collection device, a data analysis module and an alarm module. The data analysis module is signal-connected to the collection device and the alarm module. The collection device is the wheel flange defect collection device according to any one of claims 1 to 5.
7. The wheel set flange defect detection system according to claim 6, characterized in that: The alarm module includes an alarm display and an audible and visual alarm, and both the alarm display and the audible and visual alarm are signal-connected to the data analysis module.