Locomotive Axle Encoder Coupling for Lost-Motion-Free Image Capture
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Solution Overview
Problem
Existing machine vision systems on locomotives require inefficient and burdensome bench testing for calibration, leading to costly and time-consuming processes, and are unable to be calibrated effectively in the field due to environmental conditions and component wear, resulting in distorted images and asynchronous trigger signals.
Innovation Solution
A system and method that integrates a rotary encoder with a machine vision system for field calibration, using image analysis to synchronize the encoder and camera, filter erroneous electrical signals, and generate trigger signals for high-quality image capture, eliminating the need for bench testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rotary encoders with rotational free motion are used, then the system is simpler to manufacture, but the axle can rotate one or two degrees before engagement, causing lost motion and image distortion
Solution Approach 1:
The mechanical coupler is pre-configured with engagement features that automatically engage the encoder with the axle at the precise moment of rotation, eliminating the 1-2 degree lost motion of traditional encoders. This preliminary engagement mechanism ensures that the encoder is ready to capture motion immediately without requiring bench testing or manual adjustment.
2Measurement precision
If bench testing calibration environment is used, then calibration can be performed, but the process is time-consuming and costly, requiring removal and reattachment of the machine vision system
Solution Approach 1:
The system performs self-calibration in the field using the mechanical coupler's inherent engagement characteristics. The encoder and camera are automatically synchronized through the mechanical coupling mechanism without requiring external bench testing equipment or operator intervention for removal and reattachment, eliminating the time-consuming calibration process while maintaining accuracy.
Solution Approach 2:
The mechanical coupler is pre-designed with built-in calibration features that enable automatic synchronization of the encoder and camera in the field. This preliminary design eliminates the need for subsequent bench testing and manual calibration adjustments, allowing the system to be calibrated in-place during normal operation.
3Reliability
If traditional calibration processes are used, then synchronization can be attempted, but the process is burdensome requiring repetitive passing over the same track stretch
Solution Approach 1:
The mechanical coupler automatically maintains synchronization between the encoder and camera through its rigid mechanical connection. The system self-corrects for wear and environmental conditions in real-time during field operation, eliminating the need for repetitive calibration passes and manual adjustments by operators.
4Manufacturing precision
If mechanical coupler is used to minimize lost motion, then image quality is improved, but the device complexity increases
Solution Approach 1:
The mechanical coupler is divided into modular segments including an encoder adapter, coupling mechanism, and mounting features. This segmentation allows the complex functionality to be achieved through simple, standardized components that can be manufactured independently and assembled, reducing overall complexity while maintaining precision.
Data Source
AI summary
A system and method for monitoring a roadway by comparing captured images to image inconsistencies caused by lost or unnecessary motion and for minimizing lost or unnecessary motion of an axle of a vehicle and filtering erroneous pulses of an electrical signal to generate a trigger signal to capture images is presented. The system enables the minimization of image artifacts causing distortion in an image. The system can take images of a target, compute an object pixel size of the image to ensure calibration of longitudinal measurements, and calibrate the rotary encoder with the camera of the machine vision system. The system can enable calibration of the locomotive components in the field to compensate for the misalignment of the machine vision system and provide safe travels.