A kind of calibration rail for factory-welded rail base material laser intelligent detection equipment

Abstract

This utility model belongs to the field of rail base material testing technology, and provides a calibration rail for laser intelligent testing equipment for welded rail base materials. The calibration rail includes: a calibration rail with scale lines at both ends; and an adjustment mechanism comprising two base plates, each with omnidirectional wheels movably mounted on its bottom and an adjustment frame fixedly mounted on its top. A support plate is movably mounted inside the adjustment frame, and the support plate is connected to the calibration rail by bolts. The calibration rail of this utility model consists of two mutually perpendicular rectangular blocks, replacing the complex curves of the rail, fundamentally solving the problem of inaccurate measurement of complex rail curves. Traditional testing methods suffer from large measurement errors when dealing with complex rail curves because standard measuring tools cannot perfectly fit them. The simple geometry of the calibration rail allows laser testing to more accurately capture dimensional information, greatly improving measurement accuracy.

Description

Technical Field

[0001] This utility model belongs to the field of rail base material testing technology, specifically relating to a calibration rail for a laser intelligent testing equipment for factory-welded rail base materials. Background Technology

[0002] In railway construction, the quality of rails directly affects the safety and stability of train operation. Before welding, the geometric dimensions of both rail ends of the base material must be rigorously inspected. The cross-sectional curve of a rail is extremely complex, composed of multiple arcs of different diameters and oblique lines of varying angles interwoven together. Accurately locating inspection points on these arcs and oblique lines using standard measuring tools is very difficult. Because the curvature of the arcs and oblique lines constantly changes, standard measuring tools cannot perfectly align with them, leading to significant measurement errors. For example, when measuring the fullness of the rail crown, the standard measuring tool may not accurately capture the highest point of the rail crown curve, resulting in a deviation between the measurement result and the actual value. Moreover, this measurement method relies on visual observation of gaps to determine whether the dimensions meet standards, which is inevitably influenced by the operator's experience. Operators with different levels of experience may have different judgments about gap size, and even the same operator's eyes are prone to fatigue after prolonged work, further affecting the accuracy of the judgment. With the development of technology, intelligent inspection equipment for rail base materials now employs non-contact laser measurement technology and incorporates software algorithms, enabling real-time detection of rail cross-sectional dimensions. Laser measurement technology has advantages such as high precision and non-contact operation, which can improve detection efficiency and accuracy to a certain extent.

[0003] However, due to the complex curves on the surface of steel rails—for example, the 60N steel rails used in high-speed rails have symmetrical arcs of R200, R60, R16, R8, R5, R25, R400, R20, R40, R4, and R2, plus multiple oblique lines—precise measurement is impossible. Moreover, there are various types of steel rails, each with different surface curves. Therefore, directly cutting a section of steel rail for laser inspection is not advisable. Digital inspection relies on program algorithms to provide two-dimensional coordinate values ​​for each point on the object being measured. Standard measuring instruments can only measure straight segments, not curved segments, which brings difficulties to the calibration of laser inspection. Utility Model Content

[0004] The purpose of this invention is to provide a calibration rail for laser intelligent inspection equipment of welded steel rail base material, so as to solve the problem that existing inspection equipment lacks an effective calibration structure.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] A calibration rail for a laser intelligent inspection equipment for welded steel rail base materials includes:

[0007] A calibration rail, wherein scale lines are provided at both ends;

[0008] The adjustment mechanism includes two base plates, each with a caster wheel movably mounted on its bottom and an adjustment frame fixedly mounted on its top. A support plate is movably mounted inside the adjustment frame and connected to a calibration rail by bolts. A threaded rod is movably mounted inside the support plate, and a knob is drivenly connected to one end of the threaded rod.

[0009] Preferably, the support plate is inserted into the inner wall of the adjustment frame, and a support plate is fixedly installed inside the adjustment frame near the bottom plate. A threaded rod is installed inside the support plate by threaded engagement, and one end of the threaded rod is movably installed on one side of the support plate by a bearing.

[0010] Preferably, a driven bevel gear is movably mounted on the side of the support plate away from the threaded rod, and the driven bevel gear is connected to the threaded rod via a shaft drive. An L-shaped plate is fixedly mounted on the side of the adjustment frame near the base plate, and a driving bevel gear is movably mounted on the side of the L-shaped plate near the driven bevel gear via a bearing.

[0011] Preferably, the driving bevel gear meshes with the driven bevel gear, an adjusting rod is fixedly connected between the driving bevel gears, and a knob is movably mounted on the side of the L-shaped plate away from the driving bevel gear, the knob being connected to the shaft of the driving bevel gear via a drive connection.

[0012] Preferably, the adjusting frame has symmetrically provided limiting grooves on both sides, and limiting blocks are movably installed inside the limiting grooves. The limiting blocks slide against the inner wall of the limiting grooves, and the side of the limiting blocks closest to the inside of the adjusting frame is fixedly connected to the support plate.

[0013] Compared with the prior art, the beneficial effects of this utility model are:

[0014] (1) The calibration rail of this utility model is composed of two mutually perpendicular rectangular blocks to replace the complex curve of the rail, which fundamentally solves the problem of the difficulty in accurately measuring the complex curve of the rail. When facing the complex curve of the rail, the traditional detection method has a large measurement error because the standard measuring tool cannot fit perfectly. The simple geometry of the calibration rail allows the laser detection to capture the size information more accurately, which greatly improves the accuracy of the measurement. In actual detection, the calibration rail provides a stable reference benchmark for laser detection. The laser detector can be calibrated based on the precise size of the calibration rail, thereby ensuring that the measurement error of the cross-sectional size of the rail base material is controlled within a very small range. The design of the calibration rail makes the measurement results repeatable. No matter at different detection times or by different operators, as long as the calibrated calibration rail is used, consistent and accurate measurement results can be obtained, which provides a reliable guarantee for the quality of the rail.

[0015] (2) This utility model takes into account that different models of rail production lines have different heights and dimensions. If the height of the calibration rail is fixed, it is difficult to ensure that it is consistent with the height of various rail base materials, thus affecting the calibration accuracy. By setting an adjustment mechanism, the calibration rail can not only be moved in the production workshop, but also the support plate can be moved up and down through the screw rod and knob operation, so as to synchronously change the height of the calibration rail and make it perfectly match the height of the rail base material. This precise adjustment capability ensures the calibration accuracy of the laser detection equipment on rail production lines of different specifications, improves the accuracy and reliability of the detection results, and ensures that the calibration rail can calibrate the laser detection equipment in a standard and standardized manner under any circumstances. This unified calibration benchmark avoids calibration differences caused by different operators' operating habits or environmental factors, making the calibration process more standardized and regulated. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0017] Figure 2 This is a schematic diagram of the calibration rail structure of this utility model;

[0018] Figure 3 This is a schematic diagram of the support plate structure of this utility model;

[0019] Figure 4 This is a schematic diagram of the laser detector calibration and alignment structure of this utility model.

[0020] Figure 5 This is a cross-sectional view of a 60N type steel rail.

[0021] In the diagram: 1. Calibration rail; 11. Scale line; 2. Adjustment mechanism; 21. Base plate; 22. Caster wheel; 23. Adjustment frame; 24. Support plate; 25. Support plate; 26. Threaded rod; 27. Driven bevel gear; 28. L-shaped plate; 29. ​​Driven bevel gear; 210. Adjustment rod; 211. Knob; 212. Limiting groove; 213. Limiting block. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0023] Example 1:

[0024] Please see Figure 1 - Figure 4 As shown, a calibration rail for a laser intelligent inspection equipment for welded steel rail base materials includes:

[0025] Calibration rail 1, with scale lines 11 at both ends;

[0026] Adjustment mechanism 2 includes two base plates 21. Universal wheels 22 are movably installed at the bottom of both base plates 21. Adjustment frames 23 are fixedly installed at the top of both base plates 21. Support plates 24 are movably installed inside the adjustment frames 23. Support plates 24 are connected to the calibration rail 1 by bolts. Threaded rods 26 are movably installed inside the support plates 24. A knob 211 is connected to one end of the threaded rods 26.

[0027] Specifically, the support plate 24 is inserted into the inner wall of the adjusting frame 23. A support plate 25 is fixedly installed inside the adjusting frame 23 near the bottom plate 21. A threaded rod 26 is installed inside the support plate 24 by threaded engagement. One end of the threaded rod 26 is movably installed on one side of the support plate 25 through a bearing. A driven bevel gear 27 is movably installed on the side of the support plate 25 away from the threaded rod 26. The driven bevel gear 27 is shaft-driven connected to the threaded rod 26. An L-shaped plate 28 is fixedly installed on the side of the adjusting frame 23 near the bottom plate 21. A driving bevel gear 29 is movably installed on the side of the L-shaped plate 28 near the driven bevel gear 27 through a bearing.

[0028] As shown above, calibration rail 1 is made of aluminum alloy, precision machined, with a width of 50mm, a bottom width of 150mm, a total height of 190mm, and a bottom height of 20mm. The geometric dimension machining error is less than ±0.05mm. Calibration rail 1 is designed with reference to the cross-sectional dimensions of two types of rails welded by domestic rail welding plants: 60N for high-speed rail and 75N for heavy-haul railway. It consists of two mutually perpendicular rectangles composed of simple straight lines, replacing the complex profile of the rail surface. This design replaces complex curves with straight segments, is compatible with standard measuring tools and laser inspection systems, provides a traceable digital calibration benchmark, supports four-way laser synchronous calibration, and meets the multi-parameter detection requirements of straightness and torsion. Scale lines 11 are set at 50mm from both ends of calibration rail 1 to assist laser calibration. The laser model can be the Keyence VR-6000 series 3D profile measuring instrument.

[0029] The caster wheel 22 can easily move the calibration rail 1, and the caster wheel 22 is equipped with a self-locking structure, which can make the whole equipment stably placed in the testing area. The support plate 24 can move up and down inside the adjustment frame 23. The support plate 24 is connected to the side of the calibration rail 1 by a bolt structure, thereby driving the calibration rail 1 to adjust the calibration height. The threaded rod 26 can drive the support plate 24 to move up and down by rotating. The driven bevel gear 27 plays a driving role. By rotating the driven bevel gear 27, the threaded rod 26 is rotated synchronously. The driving bevel gear 29 meshes with the driven bevel gear 27, and the driving bevel gear 29 can drive the driven bevel gear 27 to rotate.

[0030] Specifically, the driving bevel gear 29 meshes with the driven bevel gear 27, and an adjusting rod 210 is fixedly connected between the driving bevel gears 29. A knob 211 is movably installed on the side of the L-shaped plate 28 away from the driving bevel gear 29. The knob 211 is connected to the shaft of the driving bevel gear 29 via a drive. Limiting grooves 212 are symmetrically opened on both sides of the adjusting frame 23. A limiting block 213 is movably installed inside the limiting groove 212. The limiting block 213 slides against the inner wall of the limiting groove 212. The side of the limiting block 213 closest to the inside of the adjusting frame 23 is fixedly connected to the support plate 24.

[0031] As can be seen from the above, the adjusting rod 210 connects the active bevel gears 29 on both sides, so that the active bevel gears 29 on both sides rotate synchronously, ensuring that the support plates 24 on both sides maintain the same height and rise and fall synchronously, so as to ensure that the calibration rail 1 is in a horizontal state. The limiting block 213 and the limiting groove 212 can limit the support plate 24, so that the support plate 24 can only move up and down in a straight line and will not detach from the adjusting frame 23. The knob 211 is used to drive the active bevel gears 29 on both sides to rotate synchronously.

[0032] In use, first push calibration rail 1 to one side of the rail production line, positioning it in the middle of the four laser detectors. Then adjust the height of calibration rail 1 by rotating knob 211, which drives the driving bevel gear 29 to rotate. The driving bevel gear 29 then drives the driven bevel gear 27 to rotate, which in turn drives the threaded rod 26 to rotate. The threaded rod 26 drives the support plate 24 to move up and down, and the support plate 24 simultaneously drives the calibration rail 1 to move up and down until the height of calibration rail 1 matches the height of the rail base material. Next, align the laser detector with the scale line 11 and adjust its angle so that the laser line is perpendicular to the rail. After adjusting the laser detector's angle, remove calibration rail 1. Then start the production line, and the rail will pass through the middle of the laser detector. The system monitors the cross-sectional dimensions of the rails in real time, compares the collected cross-sectional dimensions with the standard rail outline, and executes the "Railway Industry Standard of the People's Republic of China TB / T2344.1-2020" to obtain test data such as rail height, rail head width, rail crown fullness, cross-sectional asymmetry, rail web thickness, rail base width, rail base edge thickness, and rail base indentation. The software is set to alarm in a timely manner if the error exceeds the qualified range. The rail welding plant needs to perform regular calibration in daily operations to ensure that the test accuracy remains unchanged. The calibration rail 1 is placed next to the test equipment. During calibration, the rail movement is stopped, and the calibration rail 1 is pushed into the position of the rail to be tested. The laser frame moves along the rail direction to calibrate the laser splicing accuracy. If any error is found, it is adjusted in time. The software is set with a fine adjustment function.

[0033] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

[0034] In the description of this utility model, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. "A plurality of" means two or more, unless otherwise explicitly specified.

[0035] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

Claims

1. A calibration rail for a laser intelligent inspection equipment for factory-welded steel rail base materials, characterized in that, include: A calibration rail (1) is provided with scale lines (11) at both ends; Adjustment mechanism (2) includes two base plates (21), both base plates (21) are movably mounted with casters (22) at the bottom, and both base plates (21) are fixedly mounted with adjustment frames (23) at the top. A support plate (24) is movably mounted inside the adjustment frame (23). The support plate (24) is connected to the calibration rail (1) by bolts. A threaded rod (26) is movably mounted inside the support plate (24). A knob (211) is connected to one end of the threaded rod (26).

2. The calibration rail for a laser intelligent inspection equipment for factory-welded steel rail base material according to claim 1, characterized in that, The support plate (24) is inserted into the inner wall of the adjustment frame (23). A support plate (25) is fixedly installed inside the adjustment frame (23) near the bottom plate (21). A threaded rod (26) is installed inside the support plate (24) by threaded engagement. One end of the threaded rod (26) is movably installed on one side of the support plate (25) by bearing.

3. The calibration rail for a laser intelligent inspection equipment for factory-welded steel rail base material according to claim 2, characterized in that, A driven bevel gear (27) is movably mounted on the side of the support plate (25) away from the threaded rod (26). The driven bevel gear (27) is shaft-driven connected to the threaded rod (26). An L-shaped plate (28) is fixedly mounted on the side of the adjustment frame (23) near the base plate (21). A driving bevel gear (29) is movably mounted on the side of the L-shaped plate (28) near the driven bevel gear (27) via a bearing.

4. The calibration rail for a laser intelligent inspection equipment for factory-welded steel rail base material according to claim 3, characterized in that, The driving bevel gear (29) meshes with the driven bevel gear (27), and an adjusting rod (210) is fixedly connected between the driving bevel gears (29). A knob (211) is movably installed on the side of the L-shaped plate (28) away from the driving bevel gear (29), and the knob (211) is connected to the shaft of the driving bevel gear (29) via a drive.

5. A calibration rail for a laser intelligent inspection equipment for factory-welded steel rail base materials according to claim 4, characterized in that, The adjustment frame (23) has symmetrically provided limiting grooves (212) on both sides. A limiting block (213) is movably installed inside the limiting groove (212). The limiting block (213) slides against the inner wall of the limiting groove (212). The side of the limiting block (213) closest to the inside of the adjustment frame (23) is fixedly connected to the support plate (24).

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