Long steel rail joint surface quality scanning equipment

Abstract

The utility model discloses long steel rail joint surface quality scanning equipment, which belongs to the technical field of rail traffic detection and comprises a detection cabin, a multi-dimensional scanning system and a self-adaptive lighting system. I-shaped steel rail channel openings are symmetrically formed in the middle parts of the front and rear opposite wall surfaces of the detection cabin body. The multi-dimensional scanning system comprises four slide rails which are orthogonally distributed in the detection cabin and scanning terminals which are mounted on the slide rails and consist of three-dimensional laser scanners and industrial cameras; meanwhile, self-adaptive lighting systems are installed on the four sliding rails. Furthermore, millimeter-level-precision three-dimensional shape point cloud data spiral scanning and multi-angle image acquisition can be realized through a multi-dimensional scanning system, basic data are provided for subsequent specific defect detection, the defects of manual measurement and inspection of long steel rail base welding joint alignment tolerance, joint welding rib allowance and joint surface quality are overcome, and the working efficiency is improved. And the production efficiency and the quality of a welded joint are favorably improved.

Description

Technical Field

[0001] This utility model relates to the field of rail transit inspection technology, specifically a surface quality scanning device for long rail joints. Background Technology

[0002] Currently, at the long rail production base, the measurement of misalignment of welded joints requires manual measurement using a corrugated ruler, and the post-weld push-out allowance requires manual measurement using a template, with different templates used for different measurement locations. Similarly, the surface quality inspection of joints at each welding station in the long rail base still requires manual visual inspection of various parts of the joint using a mirror. Manual inspection and measurement have inherent uncertainties, leading to measurement deviations and missed surface quality defects. The misalignment and surface quality of joints produced on the hot line of the long rail base play a crucial role in subsequent cold line production; good welded joints can significantly improve the production efficiency of subsequent stations. Utility Model Content

[0003] To address the aforementioned issues, this invention proposes a surface quality scanning device for long rail joints, which can achieve high-precision and high-efficiency acquisition of surface images and point cloud data of rail welds.

[0004] This utility model relates to a surface quality scanning device for long rail joints, comprising a detection chamber, a multi-dimensional scanning system, and an adaptive lighting system.

[0005] The testing chamber is a cubic box structure; symmetrical I-shaped steel rail passages are opened in the middle of the front and rear opposite walls.

[0006] The multi-dimensional scanning system includes a four-way adjustment mechanism and a scanning terminal. The four-way adjustment mechanism consists of four slide rails installed inside the detection chamber. Slide rail A is installed along the vertical direction of the detection chamber, positioned in the middle of the inner left side wall. Slide rail B is installed on the inner right side wall of the detection chamber, symmetrical to slide rail A. Slide rail C is installed along the front-rear direction of the detection chamber, positioned in the middle of the inner bottom wall. Slide rail D is installed on the inner top wall of the detection chamber, symmetrical to slide rail C.

[0007] There are four scanning terminals, each consisting of a 3D laser scanner and an industrial camera; the four scanning terminals are slidably mounted on four slide rails.

[0008] Therefore, the aforementioned multi-dimensional scanning system can achieve helical scanning of three-dimensional topographic point cloud data with millimeter-level precision, as well as multi-angle image acquisition.

[0009] The advantages of this utility model are:

[0010] 1. The surface quality scanning equipment for long rail joints of this utility model can accurately and specifically acquire surface images and point cloud data of the welded joint, which can be used as practical data for subsequent quality inspection work, thus improving production efficiency and the quality of welded joints.

[0011] 2. The surface quality scanning equipment for long rail joints of this utility model has the advantages of automation, simple installation and wide applicability.

[0012] 3. The surface quality scanning device for long rail joints of this utility model has a wide range of applications. It can be used not only in long rail production bases, but also as a handheld portable device for mobile welding applications along railway lines, thus filling the gap in automatic monitoring technology for the quality of long rail welded joints. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of the long rail joint surface quality scanning device of this utility model.

[0014] Figure 2 This is a schematic diagram showing the location of the sealing door of the detection chamber in the surface quality scanning equipment for long rail joints of this utility model;

[0015] Figure 3 This is a schematic diagram of the installation method of the multi-dimensional scanning system and adaptive lighting system in the surface quality scanning equipment for long rail joints of this utility model.

[0016] In the picture:

[0017] 101 - Inspection chamber; 102 - Sealed door; 103 - Rail passage entrance

[0018] 201-Sliding rail; 202-3D laser scanner; 203-4K industrial camera

[0019] 204-Skateboard Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings.

[0021] This utility model relates to a surface quality scanning device for long rail joints. The device adopts a modular box structure, including a detection chamber 101, a multi-dimensional scanning system, and an adaptive lighting system. Figure 1 As shown.

[0022] The testing chamber 1 is a cubic box supported by 304 stainless steel, with a length of 1000mm in the front-to-back direction (Y-axis direction), a width of 600mm in the left-to-right direction (X-axis direction), and a height of 800mm in the Z-axis direction, exhibiting good corrosion resistance and structural strength. Symmetrical I-shaped rail passage openings 103 are located in the middle of the front and rear side walls of the testing chamber 1. The circumferential dimension of the passage openings is 20mm larger than the 75mm rail profile specification size, facilitating the entry and exit of the rails.

[0023] The inner wall of the testing chamber 1 is lined with a 20mm thick rubber vibration damping layer, and the surface of the vibration damping layer is coated with a 5mm thick matte coating, effectively reducing external vibration and light interference. Meanwhile, the left side wall of the testing chamber 1 has openings on both sides, each equipped with a 400mm wide and 800mm high rectangular quick-opening sealing door 102, facilitating the maintenance and repair of the equipment inside the testing chamber 1. Figure 2 As shown.

[0024] The aforementioned testing chamber 1 is also equipped with electrically operated lifting supports at the four corners of its bottom, which are placed on the ground; the height of the testing chamber 1 is adjusted by the electrically operated lifting supports. The travel of the electrically operated lifting supports is ±50mm.

[0025] The multi-dimensional scanning system includes a four-way adjustment mechanism and a scanning terminal. The four-way adjustment mechanism consists of four orthogonally distributed precision slide rails 201 installed inside the detection chamber 1, with a repeatability of ±0.05mm in the X / Y / Z axes, and each of the four slide rails 201 is 300mm long.

[0026] Let the four slide rails 201 mentioned above be slide rails A to D, and their distribution within the detection chamber 1 be as follows:

[0027] Slide rail A is set along the Z-axis and installed on the middle wall of the inner side wall of the left side of the detection chamber 1.

[0028] Slide rail B is set along the Z-axis and installed in the middle of the inner wall of the right side of the detection chamber 1, symmetrical to slide rail A.

[0029] The slide rail C is set along the Y-axis and installed at the middle position of the inner wall of the bottom surface of the detection chamber 1;

[0030] Slide rail D is set along the Y-axis and installed in the middle of the inner wall of the top surface of the detection chamber 1, symmetrical to slide rail C.

[0031] Therefore, the aforementioned slide rails A to D are respectively located at the detection positions on the left side of the rail web, the right side of the rail web, and the bottom and head of the rail as they pass through the rail channel.

[0032] The scanning terminal consists of four sets, including a high-precision 3D laser scanner 202 and a 4K industrial camera 203, which are arranged side by side and fixedly mounted on a sliding plate 204. Figure 3As shown, four scanning terminals are slidably connected to four slide rails via sliding plates 204, so that the 3D laser scanner 202 and the 4K industrial camera 203 on each slide rail 202 move synchronously along the slide rail.

[0033] The aforementioned high-precision 3D laser scanner 202 has a scanning frequency of 50kHz and a dot pitch of 0.1mm. The 4K industrial camera 203 has 20 megapixels and a frame rate of 30fps. The lens axes of both are oriented towards the rail and perpendicular to the slide rail on which the lens is located.

[0034] The adaptive lighting system 3 consists of four lighting devices, each employing a ring-shaped LED array. These devices are mounted on the slide plates 203 of the four scanning terminals, arranged side-by-side with the 3D laser scanner 201 and the 4K industrial camera 203 on the slide plates 203, positioned between them. The ring-shaped LED array has a color temperature of 6000K and an adjustable illuminance range of 500-5000 Lux, and its dimming is synchronized with the scanning terminals. The control board receives dimming commands from the scanning terminals via a communication module, parses them, generates PWM signals, and sends these signals to the driving circuit of the ring-shaped LED array to adjust the LED brightness.

[0035] When this utility model of automatic surface quality monitoring equipment for long rail joints is applied, it is placed on the transmission path of the rail. The position of the detection chamber 1 on the ground is adjusted by adjusting the left and right positions, and the height of the detection chamber 1 is adjusted by the electric lifting support feet installed at the bottom of the detection chamber 1. The axis of the front and rear passage openings of the detection chamber 1 is aligned with the axis of the rail being tested.

[0036] Subsequently, the multi-dimensional scanning system was activated, and the movement of the rail was controlled to transport the rail weld to the middle position of the inspection chamber 1, placing it within the scanning range of the multi-dimensional scanning system. The 3D laser scanner 202 and industrial camera 203 then scanned and acquired images of the weld. The specific process is as follows:

[0037] a) The 3D laser scanner 202 scans the weld along a preset path (linear speed 2m / min) and can obtain 3D topographic point cloud data with millimeter-level accuracy through spiral scanning.

[0038] b) The industrial camera 203 performs multi-angle image acquisition, capturing one image for each set distance moved.

[0039] The accurate three-dimensional topographic point cloud data and multi-angle image data collected by the long rail joint surface image acquisition device of this utility model can be used as data for subsequent specific defect detection. After processing by the controller, the weld error variable and the push-out allowance of different parts of the joint can be calculated by fusing and analyzing the three-dimensional topographic point cloud data and multi-angle image data, and a 360° panoramic visualization joint model with typical defect annotations can be generated.

Claims

1. A surface quality scanning device for long rail joints, characterized in that: This includes the detection chamber, a multi-dimensional scanning system, and an adaptive lighting system; The testing chamber is a cubic box structure; symmetrical I-shaped steel rail passage openings are opened in the middle of the front and rear opposite walls; The multi-dimensional scanning system includes a four-way adjustment mechanism and a scanning terminal. The four-way adjustment mechanism consists of four slide rails installed inside the detection chamber. Of the four slide rails, slide rail A is installed along the vertical direction of the detection chamber, located in the middle of the inner wall of the left side of the chamber; slide rail B is installed on the inner wall of the right side of the chamber, symmetrical to slide rail A; slide rail C is installed along the front-rear direction of the detection chamber, located in the middle of the inner wall of the bottom surface of the chamber; and slide rail D is installed on the inner wall of the top surface of the chamber, symmetrical to slide rail C. There are four sets of scanning terminals, each consisting of a 3D laser scanner and an industrial camera; the four sets of scanning terminals are slidably mounted on four slide rails. The adaptive lighting system consists of four sets of lighting equipment, each installed on one of the four slide rails.

2. The surface quality scanning device for long rail joints as described in claim 1, characterized in that: The inner wall of the testing chamber is lined with a rubber vibration isolation layer, and the surface of the vibration isolation layer is coated with a matte coating.

3. The surface quality scanning device for long rail joints as described in claim 1, characterized in that: The test chamber has openings on both sides of the left side wall, and quick-opening sealing doors are installed at the openings.

4. The surface quality scanning device for long rail joints as described in claim 1, characterized in that: The test chamber is equipped with electrically operated lifting supports at the four corners of its bottom.

5. The surface quality scanning device for long rail joints as described in claim 1, characterized in that: The 3D laser scanner, industrial camera, and lighting equipment are all mounted on a sliding plate, which is connected to the slide rail.

6. The surface quality scanning device for long rail joints as described in claim 1, characterized in that: The lighting equipment is positioned between the 3D laser scanner and the industrial camera.

7. The surface quality scanning device for long rail joints as described in claim 1, characterized in that: The lighting equipment uses a ring-shaped LED array.

8. The surface quality scanning device for long rail joints as described in claim 1, characterized in that: The lens axes of both the 3D laser scanner and the industrial camera are oriented towards the rail and perpendicular to the rail they are mounted on.

9. The surface quality scanning device for long rail joints as described in claim 1, characterized in that: The circumferential dimension of the passage opening is greater than 75 rail profile dimensions by 20mm.

Images