Railway wagon brake beam 3d vision detection system

Abstract

The utility model discloses a railway freight car brake beam 3D vision detection system, including sign frame device, lifting device, gantry and measuring robot, sign frame device is located at the measuring station department of existing brake beam conveying line, gantry is located at the rear of measuring station, and existing brake beam conveying line is set through sign frame device and gantry, and one pair of lifting device is equipped with in the both sides of existing brake beam conveying line, and lifting device is located below sign frame device, and the fixed measuring robot of gantry, and the measuring arm end of measuring robot is installed with binocular structure light three -dimensional scanner, and measuring robot is connected with robot control cabinet, and existing brake beam conveying line, sign frame device, lifting device, binocular structure light three -dimensional scanner and robot control cabinet are connected with general control cabinet. Cooperation existing brake beam conveying line design, and with the aid of sign frame device, the utility model can complete 3D vision detection to two brake beams once.

Description

Technical Field

[0001] This utility model relates to a 3D vision inspection system for railway freight car brake beams, belonging to the field of brake beam inspection. Background Technology

[0002] Brake beams are an important component of the basic braking system of railway vehicles, mainly used to transmit braking force to the brake shoes to stop the vehicle. Damage or malfunction of the brake beam directly affects driving safety. Brake beams mainly include composite brake beams, channel steel brake beams, and integrated brake cylinder type brake beams, etc. Their structural components are roughly the same, generally including beam frame, support, safety chain clamp, safety chain, brake shoe support, and slider wear sleeve. Figure 1 The diagram shows the structure of the combined brake beam 90, which mainly consists of a beam frame 91, a support column 92, a safety chain clamp 93, a safety chain (not shown), brake shoe supports 94, and a slider wear sleeve 95. During long-term use, railway departments need to periodically inspect the brake beam. Inspections include measuring the total length of the beam frame, the center distance between the two brake shoe supports, the distance from the center of the two brake shoe supports to the center of the support column, and checking the remaining thickness of the slider wear sleeve. This information is used to determine the quality of the brake beam and serve as a basis for subsequent brake beam maintenance. Currently, most existing inspection methods still rely on manual measurement by workers using template calipers. This method has poor accuracy and repeatability, resulting in inaccurate determinations of whether the brake beam is qualified or unqualified. This significantly impacts subsequent brake beam maintenance, compromising maintenance quality. Furthermore, this method is labor-intensive, time-consuming, and requires improvement. Utility Model Content

[0003] The purpose of this invention is to provide a 3D vision inspection system for railway freight car brake beams, which uses 3D vision to detect relevant indicators of the brake beams, resulting in high inspection efficiency and saving time and effort.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A 3D vision inspection system for railway freight car brake beams includes a marker frame device, a lifting device, a gantry frame, and a measuring robot. The marker frame device is located at the measuring station of an existing brake beam conveyor line. The gantry frame is located behind the measuring station. The existing brake beam conveyor line runs through the marker frame device and the gantry frame. A pair of lifting devices are provided on both sides of the existing brake beam conveyor line, with the lifting devices located below the marker frame device. The measuring robot is fixed on the gantry frame. A binocular structured light 3D scanner is installed at the end of the measuring arm of the measuring robot. The measuring robot is connected to a robot control cabinet. The existing brake beam conveyor line, the marker frame device, the lifting device, the binocular structured light 3D scanner, and the robot control cabinet are connected to a main control cabinet.

[0006] The advantages of this utility model are:

[0007] This invention enables 3D vision-based inspection of relevant indicators for brake beams. Combined with existing brake beam conveyor line designs and a marker holder device, it allows for the simultaneous inspection of two brake beams, resulting in high efficiency, reduced worker workload, and guaranteed accuracy in 3D vision measurement. The accurate determination of brake beam pass / fail status contributes to improved subsequent brake beam maintenance quality and is suitable for widespread application. This invention is applicable to the inspection of brake beams for railway freight cars K2, K4, K5, and K6 bogies. Attached Figure Description

[0008] Figure 1 This is a schematic diagram of an existing combined braking beam.

[0009] Figure 2 This is a schematic diagram of the composition of the 3D vision inspection system for railway freight car brake beams of this utility model.

[0010] Figure 3 This is a front view schematic diagram of the sign holder device.

[0011] Figure 4 yes Figure 3 A left-side view diagram.

[0012] Figure 5 This is a three-dimensional schematic diagram of the sign holder device.

[0013] Figure 6 This is a front view schematic diagram of the lifting device.

[0014] Figure 7 This is a three-dimensional schematic diagram of the lifting device.

[0015] Figure 8 This is another three-dimensional schematic diagram of the lifting device. Detailed Implementation

[0016] like Figures 1 to 8As shown, this utility model proposes a 3D vision inspection system for railway freight car brake beams, which includes a marker frame device 40, a lifting device 50, a gantry frame 20, and a measuring robot 30. The marker frame device 40 is located at the measuring station of the existing brake beam conveyor line 10, and the gantry frame 20 is located behind the measuring station. The existing brake beam conveyor line 10 passes through the marker frame device 40 and the gantry frame 20. A pair of lifting devices 50 are provided on both sides of the existing brake beam conveyor line 10, and the lifting devices 50 are located below the marker frame device 40. The measuring robot 30 is fixed on the gantry frame 20, and the measuring arm of the measuring robot 30 is attached to the end of the measuring arm. A binocular structured light 3D scanner 80 is installed at the end. The measuring robot 30 is connected to the robot control cabinet 70 via a cable. The robot control cabinet 70 is used to control the operation of the measuring robot 30. The existing brake beam conveyor line 10, the sign frame device 40, the lifting device 50, the binocular structured light 3D scanner 80, and the robot control cabinet 70 are connected to the main control cabinet 60 via cables. The main control cabinet 60 is used to control the operation of the existing brake beam conveyor line 10, the sign frame device 40, and the lifting device 50, send control commands to the robot control cabinet 70, and receive measurement data from the binocular structured light 3D scanner 80.

[0017] In practical implementation, due to the large size of the brake beam and the variety of data to be measured (such as length, width, height, relative position, and curved surfaces), this invention adopts a 3D measurement scheme. Furthermore, the 3D measurement scheme mainly uses three acquisition methods: line laser, multi-beam cross laser, and structured light. However, considering that the brake beam lacks a geometric reference for measurement, the line laser method cannot be used. Also, the brake beam detection cycle time requirement is high, so multi-beam cross laser is abandoned. Finally, considering various factors such as the brake beam's detection cycle time requirement, detection index requirements, and the material and characteristics of the brake beam itself, this invention adopts a binocular structured light 3D scanner, preferably blue structured light. Here, the binocular structured light 3D scanner 80 is an existing 3D data sensing and measurement instrument.

[0018] In practical implementation, this utility model can perform up to 11 tests on the brake beam, such as the full length of the brake beam frame, the center distance between the two brake shoe supports, the distance from the center of the two brake shoe supports to the center of the support column, the arc surface of the brake shoe support, the remaining thickness of the slider wear sleeve, and the safety chain clip. These tests are based on the three-dimensional measurement of the binocular structured light 3D scanner 80. The test process is repeatable and the test efficiency is guaranteed.

[0019] This utility model defines the front and rear directions. The position where the brake beam arrives first on the existing brake beam conveyor line 10 is called the front, and the position where it arrives last is called the rear.

[0020] like Figure 2The existing brake beam conveyor line 10 includes a conveyor frame with a conveyor chain mounted on it. The conveyor chain is used to convey a pallet 11, that is, the pallet 11 is conveyed along the length of the conveyor frame. The pallet 11 is provided with two pairs of brackets 110, each pair of brackets 110 is used to support a brake beam 90. A stop (not shown in the figure) is installed on the conveyor frame at the measurement station. A detection sensor is installed in front of the stop to detect whether the pallet 11 has moved to the measurement station. The operation of the stop and the conveyor chain is controlled by the main control cabinet 60. When the pallet 11, which is supporting the brake beam 90, moves to the measurement station, the detection sensor detects it, so the stop rises to block the pallet 11, the conveyor chain stops running, and the brake beam 90 on the pallet 11 stops at the measurement station, waiting for the measurement operation.

[0021] In this utility model, the structural composition of the existing brake beam conveyor line 10 is well known in the art and will not be described in detail here.

[0022] In practical applications, the marker frame device 40, lifting device 50, gantry frame 20 and measuring robot 30 are enclosed in a protective net (not shown in the figure) to provide safety isolation.

[0023] like Figures 6 to 8 The lifting device 50 is used to lift the brake beam 90 away from the existing brake beam conveyor line 10 for measurement operations, and to ensure the stability of the brake beam during the measurement operations. Specifically, the lifting device 50 includes a lifting support frame 51, a rectangular first lifting frame 53 and a rectangular second lifting frame 55. A first slide rail 54 and a second slide rail 56 are vertically mounted on the lifting support frame 51. A strip-shaped first slider 532 is vertically mounted on the first lifting frame 53, and a strip-shaped second slider 552 is vertically mounted on the second lifting frame 55. The first lifting frame 53 slides on the first slide rail 54 via the first slider 532, enabling it to move up and down. The second lifting frame 55 slides on the second slide rail 56 via the second slider 552, enabling it to move up and down. Typically, the first slide rail 54... The second slide rail 56 is provided in pairs, the first lifting frame 53 is provided with a pair of first sliders 532, and the second lifting frame 55 is provided with a pair of second sliders 552. The first lifting frame 53 is connected to the piston of the servo electric cylinder 52 so as to perform lifting and lowering movements under the drive of the servo electric cylinder 52. The servo electric cylinder 52 is connected to the main control cabinet 60. The first lifting frame 53 and the second lifting frame 55 are respectively provided with a stop block 533 and a lifting block 553 on their opposite sides. The stop block 533 is used to rise together with the first lifting frame 53 to stop the lifting block 553, thereby driving the second lifting frame 55 to rise.

[0024] Furthermore, the tops of the first lifting frame 53 and the second lifting frame 55 are respectively provided with a first support block 531 and a second support block 551. Preferably, the first support block 531 and the second support block 551 are formed with triangular grooves to securely support the brake beam. When the first lifting frame 53 and the second lifting frame 55 rise to the set height, the first support block 531 is higher than the second support block 551. That is, the lifting device 50 lifts two brake beams at once, and the two brake beams are at different heights to facilitate the binocular structured light 3D scanner 80 to perform angular scanning.

[0025] In actual implementation, after the measurement operation is completed, the first lifting frame 53 of the lifting device 50 descends to its initial position under the drive of the servo electric cylinder 52. At this time, the abutment block 533 no longer provides support to the lifting block 553. Therefore, the second lifting frame 55 descends together with the first lifting frame 53 under the gravity of the brake beam 90. That is, both the first lifting frame 53 and the second lifting frame 55 descend to their initial positions so that the brake beam 90 falls back onto the bracket 110 of the tray 11.

[0026] In actual design, such as Figure 7 Generally, the vertical dimension of the first lifting frame 53 is larger than that of the second lifting frame 55, but this is not restricted.

[0027] like Figure 6 Rubber pads 57 are provided on the top surface of the abutment block 533 and the bottom surface of the lifting block 553 to prevent the steel abutment block 533 from being damaged when it collides with the lifting block 553.

[0028] In addition, such as Figure 8 In practical applications, the lifting support frame 51 is provided with holes 510 for the cable leading out of the servo electric cylinder 52.

[0029] like Figures 3 to 5 The sign holder device 40 is used to provide scanning marks for the binocular structured light 3D scanner 80 when capturing images. Specifically, the sign holder device 40 includes two T-shaped supports 41 located on both sides of the existing brake beam conveyor line 10. A first sign holder 42 and a second sign holder 43 are arranged in parallel between the two T-shaped supports 41. The first sign holder 42 is fixed between the two T-shaped supports 41. The two ends of the second sign holder 43 are each movably positioned between the two T-shaped supports 41 via a lifting cylinder 44. The lifting cylinder 44 is connected to the main control cabinet 60, and the main control cabinet 60 synchronously drives the two lifting cylinders 44. Under the drive of the lifting cylinders 44, the second sign holder 43 moves up and down.

[0030] In actual implementation, the initial position of the second sign frame 43 is the same as that of the first sign frame 42. After the lifting device 50 lifts the two brake beams 90 into place, the second sign frame 43 descends to the predetermined height. At this time, the second sign frame 43 is lower than the first sign frame 42, and the positions of the first sign frame 42 and the second sign frame 43 relative to the two brake beams 90 are the same.

[0031] like Figure 5 The first marker frame 42 and the second marker frame 43 are rectangular frames with an opening 45, which allows the brake beam 90 to be exposed upwards. The top surfaces of the first marker frame 42 and the second marker frame 43 are affixed with dot-shaped scanning marks (not shown in the figure) for scanning alignment of the binocular structured light 3D scanner 80, so that the binocular structured light 3D scanner 80 can measure relevant indicators based on the aligned scanning marks.

[0032] In practical applications, the scanning mark can be a sticker, etc. In this invention, the lifting control of the second mark holder 43 is used to allow the brake beam to pass through and continue conveying after the measurement operation is completed.

[0033] In this utility model, the gantry frame 20 is made of welded steel profiles, and the structure adopts a gantry form to facilitate the passage of the brake beam.

[0034] In this invention, the robot control cabinet 70 generally includes a controller for controlling the operation of the measuring robot 30. The main control cabinet 60 generally includes a main controller, which is connected to the controller in the robot control cabinet 70 and to the servo electric cylinder 52, the lifting cylinder 44, and the binocular structured light 3D scanner 80. The design of the robot control cabinet 70 and the main control cabinet 60 is well known in the art and will not be described in detail here.

[0035] In this utility model, the measuring robot 30 is a mature technology and will not be described in detail here.

[0036] by Figure 2 Taking the combined brake beam shown as an example, the working process of this utility model will be explained:

[0037] On the existing brake beam conveyor line 10, each pallet 11 carries two brake beams 90 for transport. When they reach the measurement station, they are detected by the detection sensor, causing the stop to rise, the conveyor chain to stop, and the pallet 11 to stop at the measurement station. At this time, the lifting devices 50 on both sides simultaneously lift the two brake beams 90 off the pallet 11, creating a height difference. Simultaneously, the second sign frame 43 of the sign frame device 40 lowers to a predetermined height, and the first sign frame 42 and the second sign frame 43 also become a height difference, aligning with the two brake beams 90. Generally, the two brake beams 90 are partially exposed above the first sign frame 42 and the second sign frame 43 as needed.

[0038] Therefore, the measuring arm of the measuring robot 30 drives the binocular 3D structured light scanner 80 to move and sequentially align with each pair of scanning marks to scan and measure the corresponding components and parts of the two brake beams 90 in sequence. The measurement results are fed back to the main controller of the main control cabinet 60, which processes them accordingly and completes the detection of relevant indicators, making a judgment on whether the brake beam is qualified or unqualified (an audible and visual alarm can be issued if it is unqualified), providing data support for subsequent brake beam maintenance.

[0039] After the judgment is completed, the second sign frame 43 of the sign frame device 40 rises back to its initial position, and the first lifting frame 53 of each lifting device 50 simultaneously descends back to its initial position. Then, the two brake beams 90 fall back onto the tray 11. At this time, the stop lowers, the conveyor chain starts running, and the tray 11 carrying the two brake beams 90 after the test leaves the measurement station.

[0040] The advantages of this utility model are:

[0041] This invention enables 3D vision-based inspection of relevant indicators for brake beams. Combined with existing brake beam conveyor line designs and a marker holder device, it allows for the simultaneous inspection of two brake beams, resulting in high efficiency, reduced worker workload, and guaranteed accuracy in 3D vision measurement. The accurate determination of brake beam pass / fail status contributes to improved subsequent brake beam maintenance quality and is suitable for widespread application. This invention is applicable to the inspection of brake beams for railway freight cars K2, K4, K5, and K6 bogies.

[0042] The above describes the preferred embodiment of this utility model and the technical principles used therein. For those skilled in the art, any obvious changes such as equivalent transformations or simple substitutions based on the technical solution of this utility model without departing from the spirit and scope of this utility model shall fall within the protection scope of this utility model.

Claims

1. A 3D vision inspection system for railway freight car brake beams, characterized in that, The system includes a marker frame device, a lifting device, a gantry frame, and a measuring robot. The marker frame device is located at the measuring station of an existing brake beam conveyor line. The gantry frame is located behind the measuring station. The existing brake beam conveyor line runs through the marker frame device and the gantry frame. A pair of lifting devices are provided on both sides of the existing brake beam conveyor line, and the lifting devices are located below the marker frame device. The measuring robot is fixed on the gantry frame. A binocular structured light 3D scanner is installed at the end of the measuring arm of the measuring robot. The measuring robot is connected to a robot control cabinet. The existing brake beam conveyor line, the marker frame device, the lifting device, the binocular structured light 3D scanner, and the robot control cabinet are connected to a main control cabinet.

2. The 3D vision inspection system for railway freight car brake beams as described in claim 1, characterized in that, The existing brake beam conveyor line includes a conveyor frame, on which a conveyor chain is installed. The conveyor chain is used to convey a pallet. The pallet is provided with two pairs of brackets, each pair of brackets being used to support a brake beam. The conveyor frame is equipped with a stop at the measurement station, and a detection sensor is installed in front of the stop.

3. The 3D vision inspection system for railway freight car brake beams as described in claim 1, characterized in that, The sign frame device, the lifting device, the gantry frame, and the measuring robot are all enclosed within a protective net.

4. The 3D vision inspection system for railway freight car brake beams as described in any one of claims 1 to 3, characterized in that, The lifting device includes a lifting support frame, a first lifting frame, and a second lifting frame. A first slide rail and a second slide rail are vertically mounted on the lifting support frame. A first strip-shaped slider is vertically mounted on the first lifting frame, and a second strip-shaped slider is vertically mounted on the second lifting frame. The first lifting frame slides on the first slide rail via the first slider, enabling it to move up and down. The second lifting frame slides on the second slide rail via the second slider, enabling it to move up and down. The first lifting frame is connected to a servo electric cylinder to move up and down under the drive of the servo electric cylinder. A stop block and a lifting block are respectively provided on opposite sides of the first and second lifting frames. The stop block rises together with the first lifting frame to abut against the lifting block, thereby driving the second lifting frame to rise.

5. The 3D vision inspection system for railway freight car brake beams as described in claim 4, characterized in that, The top of the first lifting frame and the second lifting frame are respectively provided with a first support block and a second support block, wherein: when the first lifting frame and the second lifting frame rise to a set height, the first support block is higher than the second support block.

6. The 3D vision inspection system for railway freight car brake beams as described in claim 4, characterized in that, The top surface of the abutment block and the bottom surface of the lifting block are provided with rubber pads.

7. The 3D vision inspection system for railway freight car brake beams as described in any one of claims 1 to 3, characterized in that, The sign frame device includes two T-shaped supports on both sides of the existing brake beam conveyor line. A first sign frame and a second sign frame are arranged in parallel between the two T-shaped supports. The first sign frame is fixed between the two T-shaped supports, and the two ends of the second sign frame are each vertically and vertically positioned between the two T-shaped supports via a lifting cylinder.

8. The 3D vision inspection system for railway freight car brake beams as described in claim 7, characterized in that, The first and second sign frames are rectangular frames with openings, which are used to expose the brake beam upwards. The top surfaces of the first and second sign frames are affixed with dot-shaped scanning marks for alignment by the binocular structured light 3D scanner.

9. The 3D vision inspection system for railway freight car brake beams as described in claim 1, characterized in that, The gantry frame is made of welded steel profiles.

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