A bolt anomaly detection device for rail vehicles
The automated detection technology, which combines thermal imaging modules with multimodal sensors, solves the problems of low efficiency and insufficient automation in the existing technology of bolt detection for rail vehicles, and realizes efficient and accurate bolt anomaly detection and track health assessment.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHENZHEN YJY BUILDING TECH
- Filing Date
- 2025-06-16
- Publication Date
- 2026-06-30
AI Technical Summary
In existing technologies, bolt inspection of rail vehicles is labor-intensive, inefficient, dependent on personnel experience, highly subjective, and poses safety risks. Furthermore, existing devices have limited detection methods, narrow applicability, and insufficient real-time performance and automation, making it difficult to comprehensively assess the health status of the track.
The system employs a thermal imaging module that integrates 3D laser scanning, multi-view vision, and high-precision thermal imaging technologies, combined with multimodal sensors and machine learning models, to achieve automated data analysis. An adjustable and precise tapping mechanism, driven by a motor and spring, is used to analyze bolt anomalies by combining vibration and acoustic signals.
It achieves efficient and automated bolt anomaly detection, reduces reliance on manual labor, improves detection accuracy and comprehensiveness, provides multi-dimensional data support for track health assessment, and reduces the impact of environmental interference.
Smart Images
Figure CN224436310U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of railway transportation technology, specifically a bolt abnormality detection device for rail vehicles. Background Technology
[0002] In the railway transportation sector, track safety is crucial for train operation stability and passenger safety. The integrity of rails and their connecting components (such as bolts) is key to maintaining normal track function. However, long-term train operation and environmental changes can easily lead to damage such as cracks, wear, loosening, and breakage in rails and bolts. Timely and accurate detection of these damages is of great significance for accident prevention. Existing detection technologies include manual inspection, which suffers from high workload, low efficiency, reliance on personnel experience, strong subjectivity, and safety risks. Machine vision-based detection methods are sensitive to factors such as ambient light and camera angle, and have high equipment maintenance and operation costs. Ultrasonic testing technology mainly targets defects in the rail itself, and its effectiveness in detecting damage to small components such as bolts is limited. Patent document CN222671552U discloses a bolt strength testing device. By setting a sliding clamping block and clamping unit within the clamping base, and utilizing different diameter shims in the inner and outer clamping plate grooves to adapt to different bolt types, it eliminates the need to replace limit plates and other clamps, reducing the types and number of clamps, saving time and costs, and improving detection efficiency and practicality. However, the device has problems such as limited detection methods, limited applicability, insufficient real-time performance and automation, and poor environmental adaptability. At the same time, the impact detection, which is an important detection method, also has problems such as limited detection, narrow coverage, reliance on manual labor, strong subjectivity, lack of data support and automation methods, and great interference from factors such as noise and weather. It is difficult to comprehensively assess the overall health status of the track and achieve high-frequency, real-time monitoring.
[0003] Based on this, a bolt abnormality detection device for rail vehicles is now provided, which can eliminate the drawbacks of existing devices. Utility Model Content
[0004] The purpose of this utility model is to provide a bolt abnormality detection device for rail vehicles, so as to solve the problems of large workload, low efficiency, reliance on personnel experience, strong subjectivity and safety risks in manual inspection in the background art.
[0005] To achieve the above objectives, this utility model provides the following technical solution:
[0006] A bolt anomaly detection device for rail vehicles includes: an integral outer shell structure, a robotic arm, a thermal imaging module, and a striking mechanism. The robotic arm is fixedly mounted on the top of the integral outer shell structure, and a first mounting bracket and a second mounting bracket are fixedly mounted on the exterior of the integral outer shell structure. The thermal imaging module, used for multi-dimensional visual inspection and thermal state analysis of the track surface, fasteners, bolts, and surrounding environment, is fixedly mounted on the exterior of the integral outer shell structure. A striking mechanism for precisely striking the rail is fixed between the first and second mounting brackets.
[0007] Based on the above technical solutions, this utility model also provides the following optional technical solutions:
[0008] In one alternative: the thermal imaging module includes a three-dimensional laser scanner fixedly mounted on the exterior of the overall housing structure, a three-view camera with a track fastener fixedly mounted on the front end of the overall housing structure, a robotic arm mounted on the top of the overall housing structure, and a visible light camera and an infrared camera fixedly mounted on the top of the robotic arm.
[0009] In one alternative embodiment: the striking mechanism includes a striking actuator fixedly disposed between a first mounting bracket and a second mounting bracket; a striking hammer is slidably disposed on the inner wall of the first mounting bracket, the second mounting bracket, and the striking actuator; a sliding plate is slidably disposed on the inner wall of the striking actuator; a spring is fixedly disposed on the inner wall of the striking actuator; the top of the spring is fixedly connected to the bottom of the sliding plate; a screw is rotatably disposed between the first mounting bracket and the second mounting bracket; the screw is threadedly connected to the sliding plate; and a transmission rod is rotatably disposed at the top of the striking hammer.
[0010] In one alternative: the inner wall of the overall housing structure is fixedly provided with a drive mechanism for driving the hammer to strike.
[0011] In one alternative embodiment: the drive mechanism includes a motor bracket fixedly mounted on the inner wall of the overall housing structure, a drive motor fixedly mounted on the top of the motor bracket, a drive bracket rotatably mounted on the outside of the overall housing structure, a support rod fixedly mounted on the front end of the drive bracket, a dial wheel adapted to the support rod rotatably mounted on the front end of the drive bracket, and the output end of the drive motor fixedly connected to the central shaft of the dial wheel.
[0012] In one alternative: a multimodal sensor array is fixedly mounted on the exterior of the overall housing structure.
[0013] In one alternative: the circumferential surface of the sliding plate is provided with a sliding protrusion, the circumferential surface of the striking actuator is provided with a sliding groove that matches the sliding protrusion, the inner wall of the sliding protrusion is provided with a threaded hole that is threadedly connected to the screw, and an adjusting nut is fixedly provided at the top of the screw.
[0014] In one alternative: the circumferential surface of the actuating wheel is provided with a lever adapted to the support rod.
[0015] In one alternative: the robotic arm has a six-degree-of-freedom structure with a maximum extension radius of 1.2m.
[0016] In one alternative: a 3D laser scanner uses the Time-of-Flight (TOF) principle to create a 3D model of the track surface and acquire structural data.
[0017] Compared with the prior art, the beneficial effects of this utility model are as follows:
[0018] 1. This utility model integrates 3D laser scanning, multi-view vision, and high-precision thermal imaging technologies through a thermal imaging module, enabling comprehensive acquisition of structural and thermal state data of tracks, fasteners, and bolts. The 3D laser scanner achieves millimeter-level 3D modeling, accurately identifying deformation and cracks; the track fasteners are covered from multiple angles by a three-view camera, avoiding blind spots; and the infrared camera, with a thermal sensitivity of ≤0.05℃, monitors minute temperature anomalies in real time. Combined with edge computing and machine learning models, the system automatically analyzes and integrates data, significantly improving the detection efficiency and accuracy of defects such as bolt loosening and corrosion, while reducing reliance on manual labor and the impact of environmental interference.
[0019] 2. This invention achieves adjustable and precise tapping through the linkage of a drive motor and a spring. The tapping force can be flexibly controlled by adjusting the screw to adapt to different bolt tightening conditions; multi-modal sensors simultaneously collect vibration, sound wave, and force feedback signals to comprehensively determine bolt connection abnormalities. Automated tapping and data fusion analysis avoid the subjectivity of manual tapping, enhancing the consistency and reliability of detection. At the same time, high-frequency, multi-angle tapping covers the entire length of the rail, effectively improving the comprehensiveness of detection and providing multi-dimensional data support for track health status assessment. Attached Figure Description
[0020] Figure 1 This is a schematic diagram of the structure of this utility model.
[0021] Figure 2 This is a schematic diagram of the three-view camera structure of the track fastener in this utility model.
[0022] Figure 3 This is a schematic diagram of the striking actuator in this utility model.
[0023] Figure 4 This is a schematic diagram of the striking mechanism in this utility model.
[0024] Figure 5 This is a schematic diagram of the drive mechanism in this utility model.
[0025] Figure reference numerals: 1. Overall shell structure; 2. 3D laser scanner; 3. Track fastener three-view camera; 4. Robotic arm; 5. Visible light camera; 6. Infrared camera; 7. First mounting bracket; 8. Second mounting bracket; 9. Striking actuator; 10. Striking hammer; 11. Sliding plate; 12. Spring; 13. Screw; 14. Transmission rod; 15. Motor bracket; 16. Drive motor; 17. Drive bracket; 18. Support rod; 19. Actuating wheel. Detailed Implementation
[0026] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments.
[0027] In one embodiment, such as Figures 1-5 As shown, a bolt anomaly detection device for rail vehicles includes: an integral outer shell structure 1, a robotic arm 4, a thermal imaging module, and a striking mechanism. The robotic arm 4 is fixedly mounted on the top of the integral outer shell structure 1. A first mounting bracket 7 and a second mounting bracket 8 are fixedly mounted on the outside of the integral outer shell structure 1. A thermal imaging module for multi-dimensional visual inspection and thermal state analysis of the track surface, fasteners, bolts, and surrounding environment is fixedly mounted on the outside of the integral outer shell structure 1. A striking mechanism for precisely striking the rail is fixed between the first mounting bracket 7 and the second mounting bracket 8.
[0028] The outer casing structure 1 is externally mounted with a multimodal sensor array, which includes acoustic sensors, vibration sensors, and force feedback sensors. The outer casing structure 1 is made of aluminum alloy frame, with a top mounting platform and a four-wheel drive chassis at the bottom, with wheelbase matching standard rail spacing. The side walls of the casing have ventilation holes and waterproof / breathable membranes. The internal layout is divided into a sensor compartment, a control compartment, and a power supply compartment. The sensor compartment contains shock-absorbing brackets for securing the sensors. The control compartment houses an industrial computer and communication module, connected to each sensor via cables. The power supply compartment integrates a lithium battery pack. The overall casing has an IP65 protection rating. An edge computing device is also installed on the multimodal sensor array. This edge computing device performs real-time processing on the signals collected by the multimodal sensor array, including signal feature extraction, filtering, spectrum analysis, and automatically identifying anomalies in the rails and their connecting components based on machine learning or deep learning models. The control compartment has reserved RS485, Ethernet and wireless communication interfaces to support access to external trackside equipment data; the sensor compartment bracket adopts a modular quick-release structure; the robotic arm's 4 end effector interfaces are compatible with grippers or obstacle removal tools; the power compartment is designed with dual battery slots to support hot-switching uninterrupted power supply, with voltage fluctuation range controlled within ±5%.
[0029] In one embodiment, such as Figure 2 and Figure 3As shown, the thermal imaging module includes a three-dimensional laser scanner 2 fixedly installed outside the overall shell structure 1, a track fastener three-view camera 3 fixedly installed at the front end of the overall shell structure 1, a robotic arm 4 installed at the top of the overall shell structure 1, and a visible light camera 5 and an infrared camera 6 fixedly installed at the top of the robotic arm 4.
[0030] A 3D laser scanner 2 is connected to the end of a robotic arm 4 via a universal joint. The robotic arm 4 is a six-degree-of-freedom structure with a maximum extension radius of 1.2m. The 3D laser scanner 2 uses the TOF principle, a scanning frequency of 100kHz, and a point cloud density of 5mm. It can perform 3D modeling of the track's cross-sections, track bed boundaries, and confined spaces under the drive of a railcar. A visible light camera 5 uses a wide-angle lens that can rotate freely 360 degrees, with a focal length range of 50mm-2000mm. It is used to capture global visible light images of the track surface and sleepers, with an image resolution of no less than 4096×2160 pixels. The track fastener three-view camera 3 consists of three industrial cameras arranged at angles of 30° overhead, 90° side, and 45° upward, respectively, fixed to the bottom of the sensor compartment. The lenses are 20cm away from the track fasteners, and synchronous triggering enables simultaneous multi-view imaging of the fastener bolts, spring clips, and pads.
[0031] In one embodiment, such as Figure 4 and Figure 5 As shown, the striking mechanism includes a striking actuator 9 fixedly disposed between a first mounting bracket 7 and a second mounting bracket 8. A striking hammer 10 is slidably disposed on the inner wall of the first mounting bracket 7, the second mounting bracket 8 and the striking actuator 9. A sliding plate 11 is slidably disposed on the inner wall of the striking actuator 9. A spring 12 is fixedly disposed on the inner wall of the striking actuator 9. The top of the spring 12 is fixedly connected to the bottom of the sliding plate 11. A screw 13 is rotatably disposed between the first mounting bracket 7 and the second mounting bracket 8. The screw 13 is threadedly connected to the sliding plate 11. A transmission rod 14 is rotatably disposed at the top of the striking hammer 10. A driving mechanism for driving the striking hammer 10 to strike is fixedly disposed on the inner wall of the overall housing structure 1.
[0032] The circumferential surface of the sliding plate 11 is provided with a sliding protrusion, and the circumferential surface of the striking actuator 9 is provided with a sliding groove that matches the sliding protrusion. The inner wall of the sliding protrusion is provided with a threaded hole that is threadedly connected to the screw 13. An adjusting nut is fixedly provided at the top of the screw 13. When the adjusting nut is turned, the screw 13 is rotated, which facilitates the sliding plate 11 to slide up and down.
[0033] The drive mechanism includes a motor bracket 15 fixedly mounted on the inner wall of the overall housing structure 1, a drive motor 16 fixedly mounted on the top of the motor bracket 15, a drive bracket 17 rotatably mounted on the outside of the overall housing structure 1, a support rod 18 fixedly mounted on the front end of the drive bracket 17, and a dial wheel 19 adapted to the support rod 18 rotatably mounted on the front end of the drive bracket 17. The output end of the drive motor 16 is fixedly connected to the central shaft of the dial wheel 19.
[0034] The circumferential surface of the actuating wheel 19 is provided with a lever that is adapted to the support rod 18. When the actuating wheel 19 rotates, the lever on its circumferential surface rotates and drives the support rod 18 to move, thereby driving the drive bracket 17 to rotate. Then, the spring 12 drives the transmission rod 14 and the drive bracket 17 to reset. Subsequently, the lever continues to actuate the support rod 18, thereby achieving a multiple-strike effect. A reducer is installed on the drive motor 16, which makes the actuating wheel 19 rotate slowly.
[0035] The output of the drive motor 16 drives the actuating wheel 19 to rotate. The lever on the circumferential surface of the actuating wheel 19 rotates and drives the support rod 18 to move, thereby driving the drive bracket 17 to rotate. The drive bracket 17 drives the transmission rod 14 to lift the hammer 10 and compress the spring 12. Subsequently, the spring 12 drives the transmission rod 14 and the drive bracket 17 to reset and release the stored energy, which is used to strike the track to detect bolt abnormalities. As the actuating wheel 19 rotates continuously, multiple strikes can be performed. By turning the adjusting nut at the top of the screw 13, the screw 13 is rotated, which facilitates the sliding plate 11 to slide up and down. As the position of the sliding plate 11 changes, the amount of stored energy in the spring 12 can be adjusted.
[0036] The above embodiments disclose a bolt anomaly detection device for rail vehicles. A 3D laser scanner 2 uses the Time-of-Flight (TOF) principle to create a 3D model of the track surface and acquire structural data. A three-view camera 3 simultaneously captures images of the fasteners at 30° overhead, 90° side, and 45° upward angles, covering details from multiple perspectives. A visible light camera 5 at the end of a robotic arm 4 captures visible light images of the track and bolts using a wide-angle lens, while an infrared camera 6 collects thermal imaging data. Combined with its thermal sensitivity of ≤0.05℃, the device detects abnormal heat distribution in the bolts and surrounding environment. The data is processed in real-time by an edge computing device, and a machine learning model is used to comprehensively determine defects such as bolt loosening, cracks, or corrosion.
[0037] The striking mechanism detects bolt anomalies by precisely striking the rail. A drive motor 16 rotates an actuating wheel 19, whose circumferential lever actuates a support rod 18. This causes the drive bracket 17 to rotate, pulling the transmission rod 14 to lift the striking hammer 10, compressing the spring 12 to store energy. When the lever disengages from the support rod 18, the spring 12 releases its energy, driving the striking hammer 10 to strike the rail. Adjusting the nut at the top of the screw 13 changes the position of the sliding plate 11, thereby adjusting the compression of the spring 12 to control the striking force. The vibration signal generated by the striking is collected by a vibration sensor, and combined with data from an acoustic sensor and a force feedback sensor, the abnormal characteristics of the bolt connection are analyzed.
[0038] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.
Claims
1. A bolt abnormality detection device of a railway vehicle, comprising: The shell structure (1), the robotic arm (4), the thermal imaging module and the striking mechanism are provided. The robotic arm (4) is fixed on the top of the shell structure (1). The shell structure (1) is fixed with a first mounting bracket (7) and a second mounting bracket (8). The feature is that: the outer shell structure (1) is fixedly provided with a thermal imaging module for multi-dimensional visual inspection and thermal state analysis of the track surface, fasteners, bolts and surrounding environment, and a striking mechanism for accurately striking the rail is fixed between the first mounting bracket (7) and the second mounting bracket (8).
2. The bolt abnormality detection device of a railway vehicle according to claim 1, characterized by The thermal imaging module includes a three-dimensional laser scanner (2) fixedly installed outside the overall shell structure (1), a track fastener three-view camera (3) fixedly installed at the front end of the overall shell structure (1), a robotic arm (4) installed at the top of the overall shell structure (1), and a visible light camera (5) and an infrared camera (6) fixedly installed at the top of the robotic arm (4).
3. The bolt abnormality detection device of a railway vehicle according to claim 1, characterized by The striking mechanism includes a striking actuator (9) fixedly disposed between a first mounting bracket (7) and a second mounting bracket (8). A striking hammer (10) is slidably disposed on the inner wall of the first mounting bracket (7), the second mounting bracket (8) and the striking actuator (9). A sliding plate (11) is slidably disposed on the inner wall of the striking actuator (9). A spring (12) is fixedly disposed on the inner wall of the striking actuator (9). The top of the spring (12) is fixedly connected to the bottom of the sliding plate (11). A screw (13) is rotatably disposed between the first mounting bracket (7) and the second mounting bracket (8). The screw (13) is threadedly connected to the sliding plate (11). A transmission rod (14) is rotatably disposed at the top of the striking hammer (10).
4. The bolt abnormality detection device for rail vehicles according to claim 3, characterized in that, The inner wall of the overall shell structure (1) is fixed with a driving mechanism for driving the hammer (10) to strike.
5. A bolt anomaly detection device for rail vehicles according to claim 4, characterized in that, The driving mechanism includes a motor bracket (15) fixedly installed on the inner wall of the overall outer shell structure (1). A drive motor (16) is fixedly installed on the top of the motor bracket (15). A drive bracket (17) is rotatably installed on the outside of the overall outer shell structure (1). A support rod (18) is fixedly installed at the front end of the drive bracket (17). A turntable wheel (19) adapted to the support rod (18) is rotatably installed at the front end of the drive bracket (17). The output end of the drive motor (16) is fixedly connected to the central axis of the turntable wheel (19).
6. The bolt abnormality detection device for rail vehicles according to claim 1, characterized in that, A multimodal sensor array is fixedly mounted on the outside of the overall shell structure (1).
7. A bolt anomaly detection device for rail vehicles according to claim 3, characterized in that, The circumferential surface of the sliding plate (11) is provided with a sliding protrusion, and the circumferential surface of the striking actuator (9) is provided with a sliding groove that matches the sliding protrusion. The inner wall of the sliding protrusion is provided with a threaded hole that is threadedly connected to the screw (13). The top end of the screw (13) is fixedly provided with an adjusting nut.
8. A bolt abnormality detection device for rail vehicles according to claim 5, characterized in that, The circumferential surface of the actuating wheel (19) is provided with a lever that is adapted to the support rod (18).
9. A bolt anomaly detection device for rail vehicles according to claim 1, characterized in that, The robotic arm (4) is a six-degree-of-freedom structure with a maximum extension radius of 1.2m.
10. A bolt abnormality detection device for rail vehicles according to claim 2, characterized in that, The three-dimensional laser scanner (2) performs three-dimensional modeling of the track surface based on the TOF principle to obtain structural data.