Rail Wear Measurement Using Structured Light Projection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current dynamic measurement devices for rail wear are limited by the performance of image sensors and acquisition hardware, making them inadequate for precise and timely measurement of corrugation wear, which can lead to increased transportation costs and safety risks.
Innovation Solution
A vehicle dynamic measurement device equipped with a vision sensor, a computer, and a milometer, utilizing a raster projector to project multiple light planes perpendicular to the rail, allowing for high-speed acquisition of multiple rail cross-section feature profiles, and calculating vertical wear, horizontal wear, and corrugation wear using structured-light vision and digital signal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-line vision sensor is used to project one light plane, then the device structure is simple, but the measurement precision and information utilization are insufficient
Solution Approach 1:
The single light plane is segmented into multiple light planes (first light plane, second light plane, etc.) that are projected at different angles. Each light plane captures different feature profiles of the rail cross-section, thereby increasing measurement precision without significantly complicating the device structure.
Solution Approach 2:
The invention transitions from a single-line (1D) vision sensor to a multi-plane (2D/3D) structured light system. By projecting light planes at different angles and capturing their intersections with the rail, the system obtains three-dimensional surface information, dramatically improving measurement precision and information utilization.
2Productivity
If image sensing and acquisition hardware performance is improved to increase sampling rate, then the measurement precision improves, but the device cost and complexity increase
Solution Approach 1:
Instead of requiring a single high-performance sensor to capture all information at once, the system segments the measurement task across multiple light planes and their intersections. This allows the use of standard image sensors while achieving high sampling rates through the geometric arrangement of multiple light planes.
Solution Approach 2:
The invention replaces the need for high-performance image sensing hardware with a geometric-optical approach. By using multiple light planes intersecting at known angles, the system derives high-precision measurements from standard sensors, substituting hardware performance requirements with geometric configuration.
3Productivity
If multiple light planes are projected to increase sampling rate, then the productivity improves, but the device complexity increases
Solution Approach 1:
The vision sensor system is designed to perform multiple functions: it captures feature profiles from multiple light planes simultaneously, extracts three-dimensional surface information, and measures various rail parameters (vertical wear, horizontal wear, corrugation). This multi-functionality increases productivity without proportionally increasing device complexity.
Solution Approach 2:
The system uses multiple light planes as optical copies of the measurement field, each providing a different perspective of the rail cross-section. These optical copies are captured simultaneously by the vision sensor, enabling high sampling rates without requiring multiple physical sensors or complex mechanical scanning systems.
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
This solution increases the sampling rate and precision of rail wear measurement without requiring improved image sensing and acquisition hardware, enabling effective on-line dynamic measurement of corrugation wear and reducing measurement time and costs.
Implementation Method 1
a raster projector which is used for projecting more than one light plane perpendicular to the measured rail
Implementation Method 2
acquiring an image including several rail cross-section feature profiles
Data Source
AI summary
The invention discloses a vehicle dynamic measurement device for comprehensive parameters of rail wear, which comprises a vision sensor, a computer and a milometer. A high-speed image acquisition card and a measurement module are installed in the computer. The vision sensor comprises imaging system for rail cross-section and a raster projector which can project more than one light plane perpendicular to the measured rail. The measurement module is used for calculating vertical wear, horizontal wear, the amplitude and wavelength of corrugation wear. The invention also discloses a vehicle dynamic measurement method for comprehensive parameters of rail wear. The invention can increase the sampling rate of image sensing and acquisition hardware equipment with no need of improving the performance of it, thereby satisfy high-speed on-line dynamic measurement requirements for corrugation wear, and the amplitude and wavelength of corrugation wear can be calculated more precisely.