Dual Camera System for Unobstructed Track Tamping
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Solution Overview
Problem
Existing track construction machines lack comprehensive, unobstructed real-time imaging capabilities for remote control of tamping units, leading to inefficiencies in positioning and operation.
Innovation Solution
A dual-camera system is positioned in front of and behind the tamping unit, capturing overlapping image sections which are merged to provide an unobstructed view of the track, combined with lighting and sensor systems to enhance positioning accuracy and visibility, and a method that includes real-time three-dimensional modeling and suggested tamping positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single camera system is used to capture the track area, then the device complexity is reduced, but the imaging coverage is obstructed by the tamping unit components
Solution Approach 1:
The imaging system is divided into multiple camera systems (first camera system in front of the tamping unit, second camera system behind it) that each capture specific segments of the track area. This segmentation allows each camera to capture areas that would otherwise be obscured by the tamping unit components, achieving complete coverage without requiring a single complex camera arrangement.
Solution Approach 2:
The patent merges the image sections captured by multiple camera systems into a single comprehensive image display. By combining the views from the front and rear camera systems, the operator receives a complete, unobstructed image of the entire track area beneath and around the tamping unit, eliminating the visibility gaps that would exist with a single camera.
2Ease of manufacture
If camera axes are oriented vertically downwards, then the image capture is simple, but larger image sections cannot be captured without obscuring areas
Solution Approach 1:
The camera axes are oriented obliquely downwards rather than vertically downwards. This asymmetric orientation allows the cameras to capture larger image sections of the track area without the camera components themselves obscuring the view. The oblique angle enables the camera to see around and beneath the tamping unit components while maintaining a relatively simple mounting configuration.
3Device complexity
If the tamping unit is fixed relative to the camera systems, then the device complexity is reduced, but the positioning precision for specific sleepers is limited
Solution Approach 1:
The tamping unit is made movable relative to the camera systems through displacement drives that can adjust the position of the tamping unit in the working direction and perpendicular to it, as well as rotate it around a vertical axis. This dynamic positioning capability allows the operator to precisely position the tamping unit over specific sleepers while maintaining the camera systems in fixed positions, thereby achieving high positioning precision without requiring the entire imaging system to be complex.
Solution Approach 2:
The displacement movements of the displacement drives are continuously recorded and evaluated, providing real-time feedback on the position of the tamping unit. This feedback information is displayed to the operator, enabling precise positioning control. The geometric relationships of the mounting points and orientations of the camera systems also provide position information that is displayed, further enhancing the positioning precision through multiple feedback sources.
4Use of energy by moving object
If standard lighting conditions are used, then the energy consumption is low, but the visibility in poor lighting conditions is insufficient
Solution Approach 1:
Lighting devices with downward-directed light beams are positioned in advance within the detected surface areas of the track to generate light markings before the tamping operation begins. This preliminary lighting setup ensures that the track area is properly illuminated for the camera systems to capture clear images, even in poor lighting conditions, while the lighting can be activated only when needed for the specific operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise, efficient remote control of tamping units by providing comprehensive, real-time images and positioning assistance, enhancing operational accuracy and safety, especially in poor lighting conditions.
Implementation Method 1
a camera for transmitting real-time images to an output device is arranged in one working direction in front of the tamping unit
Implementation Method 2
a lighting device with downward-directed light beams for generating a light marking is arranged in the detected surface areas of the track
Implementation Method 3
a tamping unit comprising tamping tools that can be lowered into the ballast bed, vibrated, and adjusted relative to one another
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Track-building machine (1) for tamping a ballast bed (8) of a track (5), having a machine frame (3) which can move on rail bogies (2) and having a tamping unit (4) which comprises tamping tools (11) which can be lowered into the ballast bed (8), can be caused to vibrate and can be adjusted relative to one another, wherein a camera (30) for transmitting real-time recordings to an output device (16) is arranged in a working direction (13) upstream of the tamping unit (4). In the working direction (13) upstream of the tamping unit (4) there is arranged a first camera system (14) in order to capture a first surface region (23) of the track (5) as a first image detail (24, 25). In the working direction (13) downstream of the tamping unit (4) there is additionally arranged a second camera system (15) in order to capture a second surface region (26) of the track (5) as a second image detail (27, 28), wherein the captured image details (24, 25, 27, 28) partially overlap and wherein the output device (16) is designed to output the image details (24, 25, 27, 28) in a combined image.