Train Wheel Tread Imaging Array with Computational Stitching
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Solution Overview
Problem
Current methods for inspecting train wheel treads for defects, such as those in Berndt and Hershey's patents, lack the use of an array of lights and cameras to capture high-resolution images effectively, which is crucial for timely detection of damage that could lead to ride quality issues, reduced component lifespan, and potential derailments.
Innovation Solution
An array of LED lights and area scan cameras positioned between or outside the rails, controlled by dedicated software, captures high-resolution images of the wheel tread as it moves, with the software reassembling these images into a linear format for easy defect inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an array of lights and cameras is used to capture high-resolution images of the wheel tread, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The inspection system is divided into multiple independent cameras, each capturing a specific section of the wheel tread. This segmentation allows each camera to be simpler while the collective system achieves comprehensive high-resolution coverage. The wheel tread is divided into multiple image sections that are later stitched together computationally.
Solution Approach 2:
A computational stitching process acts as an intermediary between the individual camera captures and the final complete image. This software-based mediator combines multiple simplified camera inputs into a comprehensive high-resolution output, avoiding the need for a single complex camera system.
2Productivity
If the train moves at high speed, then productivity is improved, but measurement precision deteriorates
Solution Approach 1:
The lights are activated in advance before the wheel tread enters the imaging zone, ensuring proper illumination is established before capture begins. This preliminary action allows the system to maintain synchronized operation at high speeds while ensuring image quality.
Solution Approach 2:
Multiple cameras continuously capture images as the wheel tread passes through the inspection zone, creating an uninterrupted sequence of images. This continuous capture approach maintains measurement precision even at high train speeds by ensuring no part of the wheel tread is missed.
3Measurement precision
If multiple cameras capture different sections of the wheel tread, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The computational stitching process automatically assembles the images captured by multiple cameras into a complete wheel tread representation without requiring manual intervention. This self-service automation minimizes time loss while maintaining comprehensive coverage.
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 enables timely and effective detection of wheel tread defects, preventing derailments and maintaining ride quality by providing high-resolution images of the entire wheel tread, thus ensuring the integrity of the wheel tread and other rotating components.
Implementation Method 1
The array of lights is most likely an array of LED light produced in the visible spectrum
Implementation Method 2
The cameras in the system are area scan cameras operating in the visible spectrum
Data Source
AI summary
As a train passes over an array of cameras and lights that have been positioned between the rails of a train system, images are captured of the wheel tread. The number of cameras that will be used in the array may vary depending on the end user of the train system and its specific requirements. Software will capture the images of the portion of each wheel tread and reassemble the images in a linear format. The linear format for each wheel tread will provide an image that can be easily analyzed by the end user of the train system.