CN104477209A - Railway locomotive vehicle wheel online scratch automatic detection system and method - Google Patents
Railway locomotive vehicle wheel online scratch automatic detection system and method Download PDFInfo
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Abstract
The invention discloses a railway locomotive vehicle wheel online scratch automatic detection system which comprises an on-line induction module, an off-line induction module, n swinging rod detection modules, a database storage module, an upper computer communication module and a scratch data analysis module. The swinging rod detection modules include a left swinging rod detection module, a right swinging rod detection module and a scratch data acquisition module, the on-line induction module is arranged at an entering end of working rails, the off-line induction module is arranged at a leaving end of the working rails, the left swinging rod detection module and the right swinging rod detection module are symmetrically arranged on the inner sides of the two working rails respectively, the n swinging rod detection modules are arranged on the inner sides of the working rails at intervals, the total length of the swinging rod detection modules is larger than the circumference of a wheel, n is an integer obtained by adding 1 to values of L1/L2, the L1 refers to the circumference of the wheel, and the L2 refers to the length of a single swinging rod detection module. The invention further discloses a method based on the system. Information such as scratch depth, length and position can be accurately judged, and detection accuracy is improved.
Description
Technical Field
The invention relates to the technical field of detection of wheel states of railway rolling stock, in particular to an online automatic detection system and method for wheels of the railway rolling stock.
Background
The wheel is one of the important parts of the running gear of the railway locomotive, and the running of the wheel directly influences the safe running. In recent years, railway vehicles in China experience a plurality of times of great acceleration, and show unprecedented good development situation from ordinary trains, express trains, motor train units to high-speed rails. However, the force between the wheels and the rails of the railway rolling stock is increasing, and the dynamic load of the wheels is also increasing. At the same time, the steady increase in the speed and capacity of railway transport means that higher demands are placed on high-speed passenger transport, where especially the safety of the wheels of a railway rolling stock is of particular importance. Under a plurality of factors, the potential safety hazard problem caused by the scratch phenomenon of the round part of the roller of the tread becomes an important source of the railway locomotive vehicle fault and accident. The safety problem of the wheel gradually becomes the key for ensuring the safe operation of the vehicle, and the defect abnormity of any type of the wheel can restrict the development of the rail transit industry in China.
At present, the method for detecting the scratch of the wheels of the railway rolling stock mainly comprises two types of static detection and dynamic detection: the static detection is completed when the vehicle is static, and the method has the greatest advantages that the wheels can be completely and comprehensively detected, the precision is high, the detection time is long, and the process is relatively complex; the dynamic detection is carried out when the vehicle normally runs, so the detection efficiency is higher than that of the static detection, the detection automation degree is high, the turnover time of the vehicle is not occupied, the wheel information data are convenient to store, the detection rate is high, and the attention is paid in recent years. The most common and relatively mature dynamic detection method is a scratch detection system constructed by using a vibration acceleration method and a parallelogram method. Fig. 1 is a schematic view of a scratch detection system using a vibration acceleration method, in which an acceleration measurement sensor for measuring abnormal vibration caused by scratch and a wheel count sensor for detecting passing of wheels are installed on a steel rail, sensors capable of reading a car number, a noise level and the like are further installed beside the rail, data output by the sensors are transmitted to a data collection module beside a line, and then the data collection module communicates with a data processing module to analyze and process the collected data. The vibration acceleration method has high misjudgment rate and is easy to miss detection under the condition of low speed, so that the detection precision is lower. Fig. 2a is a schematic diagram of a scratch detection system by utilizing a parallelogram method, and fig. 2b is a schematic diagram of a detection part of the scratch detection system by utilizing the parallelogram method, and the scratch detection system is composed of a four-bar mechanism and displacement sensors which are in one-to-one correspondence with the four-bar mechanism, wherein the four-bar mechanism is fixed on a steel rail in a parallelogram layout, and the displacement sensors are fixed on the steel rail at one side of the four-bar mechanism through a support. The device can only operate in one direction, destructive impact can be caused when the train operates in the reverse direction, and maintenance is inconvenient.
In an invention patent with application publication number CN 102785679a, an on-line detection device for wheel tread surface scratch and out-of-roundness is disclosed, fig. 3 is a schematic cross-sectional structure diagram of the on-line detection device for wheel tread surface scratch and out-of-roundness, which mainly comprises: working rail 1 and track grip block 2, the upside of track grip block 2 sets up detection device 3, and detection device 3 includes shell 4, is equipped with rocker arm support 5 and rocker arm pendulum rod 6 in the cavity of shell 4, and rocker arm pendulum rod 6 inlays between the upside of rocker arm support 5 and the last casing of shell 4, and the anterior segment of rocker arm pendulum rod 6 stretches out and is equipped with measuring stick 7 on the front end that shell 4 outside working rail 1 extends setting and rocker arm pendulum rod 6, is equipped with driving gear 8 rather than fixed continuous and coaxial setting on the rear end of rocker arm pendulum rod 6, and the outside of driving gear 8 is equipped with the driven gear 9 rather than the meshing links to each other, be equipped with the rotary encoder rather than coaxial setting on driven gear 9. Other components are: a return spring 10, a clamping plate 11 and a lifting device 12. In the patent application, the wheel tread is contacted with the measuring rod, and the wheel rim can not be pressed on the measuring rod; the swing rod detection module places the outside of work track in this patent application, consequently need be used for guaranteeing that the wheel does not walk snakelike guardrail device at work track inboard installation, increases such guardrail device and has increased the cost.
How to solve the defects of the prior art is a great difficult problem to be solved urgently in the technical field of the detection of the wheel state of the locomotive vehicle.
Disclosure of Invention
The invention provides an automatic online detection system and method for railway locomotive wheels to scratch, which overcomes the defects of the prior art, the invention places a swing rod detection module at the inner side of a detection working track to save the cost of the whole system, the wheel rim contacts and the swing rod horizontally placed in the invention ensures that the wheel rim can be pressed on the swing rod all the time, and the information such as the position, the speed and the like of the current wheel can be accurately judged; the detection method improves the detection precision and is convenient to use.
The invention adopts the following technical scheme for solving the technical problems:
the invention provides an online automatic detection system for wheel scratches of a railway rolling stock, which comprises an incoming line induction module, an offline induction module, n swing rod detection modules, a database storage module, an upper computer communication module and a scratch data analysis module, wherein the incoming line induction module is used for detecting the wheels of the railway rolling stock; the swing rod detection module comprises a left swing rod detection module, a right swing rod detection module and a scratch data acquisition module; the left swing rod detection module and the right swing rod detection module are mutually symmetrical and are respectively arranged on the inner sides of the two working rails, n swing rod detection modules are arranged on the inner sides of the working rails at intervals, the total length is greater than the circumference of a wheel, and n is L1/L2Adding 1 to the value of (A) and then taking an integer, L1Is the wheel circumference, L2Detecting the length of the module for a single swing link; wherein:
the system comprises an incoming line induction module, a database storage module and a data processing module, wherein the incoming line induction module is arranged at an incoming end of a working rail and used for outputting a locomotive incoming line mark signal to the database storage module when a railway locomotive drives into a detection area of the incoming line induction module at a preset speed;
the off-line sensing module is arranged at the leaving end of the working rail and used for outputting a locomotive vehicle off-line mark signal to the database storage module when the railway locomotive vehicle drives away from the detection area of the off-line sensing module at a preset speed;
the left swing rod detection module and the right swing rod detection module are used for collecting angle change data of wheel rim pressing when the wheel rim is pressed down and outputting the angle change data to the scratch data collection module;
the scratch data acquisition module is used for receiving the angle change data of the wheel rim pressing output by the left swing rod detection module and the right swing rod detection module and outputting the angle change data to the upper computer communication module;
the database storage module is used for receiving locomotive incoming line marking signals and locomotive off-line marking signals;
the upper computer communication module is used for reading the locomotive incoming line marking signals and the locomotive off-line marking signals in the database storage module in real time; after the upper computer communication module reads a group of complete locomotive vehicle incoming line mark signals and locomotive vehicle off-line mark signals from the database storage module, reading angle change data of wheel rim pressing from the scratch data acquisition module and outputting the angle change data to the scratch data analysis module;
and the scratch data analysis module is used for analyzing and processing the angle change data of the wheel rim pressing to obtain the scratch information of the wheel.
As a further optimized scheme of the online automatic detection system for the wheel scratches of the railway locomotive vehicle, the left swing rod detection module and the right swing rod detection module respectively comprise swing rods which are in contact with wheel rims and are horizontally placed, a gear mechanism and rotary encoders which are arranged on the swing rods and are coaxial with the gear mechanism; when the swing rod is pressed down by the wheel rim of the wheel, the swing rod generates angle change, and the gear mechanism is used for amplifying the angle change of the swing rod and then processing and outputting angle change data to the scratch data acquisition module through the rotary encoder.
As a further optimized scheme of the online automatic detection system for the wheel scratches of the railway rolling stock, the swing rod detection module further comprises two wheel positioning induction modules arranged at two ends of the left swing rod detection module or the right swing rod detection module; when the railway rolling stock passes through the detection area of the wheel positioning sensing module, a trigger signal is output to the scratch data acquisition module, the scratch data acquisition module obtains time according to the received trigger signal and calculates the speed of the wheel according to the position parameter stored in advance, and when the speed is within the preset speed, the obtained information of the scratch of the wheel is effective.
As a further optimized scheme of the automatic online detection system for the wheels of the railway locomotive, the incoming line induction module and the offline induction module are photoelectric switch type sensors.
As a further optimized scheme of the online automatic detection system for the wheel scratches of the railway rolling stock, the wheel positioning induction module is an eddy current type proximity switch or a capacitance type proximity switch or a Hall type proximity switch or a photoelectric type proximity switch or an ultrasonic type proximity switch or a microwave type proximity switch.
As a scheme for further optimizing the online automatic detection system for the railway rolling stock wheels, the scratch data acquisition module comprises a controller unit, an encoder data receiving unit, an encoder data decoding unit, a storage unit, a communication unit and a wheel positioning data receiving unit; the angle change data of the wheel rim pressing is received by the encoder data receiving unit, decoded by the encoder data decoding unit and then sent to the controller unit; the wheel positioning data receiving unit receives the trigger signal output by the wheel positioning sensing module and then sends the trigger signal to the controller unit; the controller unit outputs the received angle change data after decoding processing to the storage unit and finally outputs the angle change data to the upper computer communication module through the communication unit.
As a scheme for further optimizing the automatic online detection system for the wheels of the railway locomotive, the preset speed is constant and is 1km/h-20 km/h.
The invention discloses a detection method of an online automatic detection system for railway locomotive vehicle wheels, which comprises the following steps:
step one, presetting a head area range and a tail area range on a curve;
step two, converting the angle change data of wheel rim pressing into depth displacement data of wheel rim pressing, and obtaining an original curve by taking a sampling point as an abscissa and a depth displacement value as an ordinate; fitting data curves in the head region and the tail region of the original curve to obtain a new curve, subtracting depth displacement values corresponding to the same sampling points on the new curve and the original curve respectively to obtain a first difference value, and performing envelope curve and smooth interpolation processing on the first difference value to form a scratch schematic curve; when the ordinate of a certain sampling point on the scratch schematic curve meets a preset scratch depth threshold range, the wheel is scratched at the moment, and information of the position, the depth and the length of the scratch is obtained;
step three, analyzing a middle area curve of the original curve except the head area and the tail area, firstly finding a highest point corresponding to the maximum depth displacement value in the middle area, and setting the highest point as an initial sampling point from the first sampling point position of the middle area;
A. sequentially finding out a point with the same depth displacement value as the initial sampling point according to the sampling time sequence of the sampling point, respectively subtracting the abscissa of the point from the abscissa of the initial point to obtain a second difference value, if the second difference value meets the preset scratch length threshold range, subtracting the ordinate of the highest point from the ordinate of the initial point to obtain a third difference value, and if the third difference value also meets the preset scratch depth threshold range, scratching the wheel at the moment to obtain the information of the position, the depth and the length of the scratch;
B. and B, when the second difference value does not meet the preset scratch length threshold range or the third difference value does not meet the preset scratch depth threshold range, repositioning the sampling point at the next moment, setting the sampling point as a new starting point, and repeating the step A.
And step four, outputting and alarming the abrasion condition of the railway locomotive vehicle wheels according to the abrasion position, depth and length information obtained in the step.
The invention relates to a detection method of an online automatic detection system for the wheel abrasion of a railway locomotive, which comprises the following steps that in the first step, a head area range on a curve is preset, sampling points are used as sampling time sequences, and the first 200 sampling points on the curve are selected; the tail area range takes the sampling points as a sampling time sequence, and the last 100 sampling points on the curve are selected.
The invention relates to a detection method of an online automatic detection system for railway locomotive vehicle wheels, which comprises the following steps of: when the wheel rim is in contact with the two ends of the swing rod detection modules, namely the wheel rim is pressed down and leaves the corresponding swing rod detection modules, a jumping curve can be generated, the actual vehicle passing data is comprehensively analyzed to form an interval range where the jumping curve occurs, and a head area range and a tail area range are obtained.
Compared with the prior art, the invention adopting the technical scheme has the following technical effects:
(1) the swing rod detection module comprises a swing rod which is in contact with the wheel rim and is horizontally arranged, so that the wheel rim can be always pressed on the swing rod, and angle data of the wheel rim pressing can be accurately acquired; the automatic online detection system for the wheel abrasion of the railway rolling stock can also accurately judge the information such as the position, the speed and the like of the current wheel;
(2) the swing rod detection module is arranged on the inner side of the detection working rail, so that a rail protection device which is originally installed in the working rail and used for ensuring that the wheels do not move in a snake shape is not needed, the cost of the whole system is saved, the detection precision can be ensured, and the swing rod detection module is convenient to use.
(3) The system analysis method can accurately read and analyze the scratch data, judge the information such as the depth, the length, the position and the like of the scratch and improve the detection accuracy.
Drawings
Fig. 1 is a schematic diagram of a scratch detection system using a vibration acceleration method in the related art.
Fig. 2a is a schematic diagram of a scratch detection system using a parallelogram method in the related art.
Fig. 2b is a schematic view of a detection portion of a scratch detection system using a parallelogram method in the related art.
FIG. 3 is a schematic cross-sectional view of an on-line device for detecting wheel tread surface scratches and out-of-roundness.
FIG. 4 is a schematic diagram of a rail vehicle wheel in-line gouging system.
Fig. 5 is a structure view of the trackside installation of the automatic detection system for online scratch of the wheels of the railway rolling stock.
FIG. 6 is a schematic diagram of a pendulum detection module.
FIG. 7 is a block diagram of a data acquisition module of the automatic online scratch detection system for railway rolling stock wheels.
FIG. 8 is a flow chart of a railroad locomotive vehicle wheel on-line scuffing automatic detection system scuffing analysis.
FIG. 9 is a flow chart of a scratch analysis module analysis method of the automatic online detection system for railway rolling stock wheel scratches.
Fig. 10 is a partial triangular wave scratch data of an example of simulation data for processing an intermediate area by the scratch data analysis module.
Fig. 11 is a partial rectangular wave scratch data of an example of simulation data for processing an intermediate area by the scratch data analysis module.
Fig. 12 is a partial sine wave scratch data of an example of simulation data for processing a middle region by the scratch data analysis module.
Fig. 13 is an example a of scratch-free data processed by the scratch data analysis module for actual live through the middle area of the vehicle.
Fig. 14 is an example b of scratch-free data processed by the scratch data analysis module for actual live through the middle area of the vehicle.
Fig. 15 is an example c of scratch-free data processed by the scratch data analysis module for actual live through the middle area of the vehicle.
Fig. 16 is an example of scratch data analysis module processing a set of intermediate zone scratch data collected by actual vehicle passes on site.
Fig. 17 is an example of the scratch data analysis module processing scratch data collected in the head area and the tail area of another set of actual vehicles passing on site.
The reference numerals in the figures are to be interpreted: 1-a working rail, 2-a rail clamping block, 3-a detection device, 4-a shell, 5-a rocker arm bracket, 6-a rocker arm swing rod, 7-a measuring rod, 8-a driving gear, 9-a driven gear, 10-a return spring, 11-a clamping plate and 12-a lifting device.
Detailed Description
The technical scheme of the invention is further explained in detail by combining the attached drawings:
fig. 4 is a schematic diagram of the on-line rail vehicle wheel scuffing system. The utility model provides a railway rolling stock wheel is scotch automatic check out system on line, includes inlet wire response module, off-line response module, pendulum rod detection module, database storage module, host computer communication module, scotch data analysis module, scotch data acquisition module, wheel location response module. The main data signals of the whole system are roughly oriented as follows: the incoming line induction module and the off-line induction module generate incoming line and off-line marking signals and store the incoming line and off-line marking signals into the database storage module, and the upper computer communication module identifies the group of marking signals in the database storage module; when the locomotive passes through the detection area, the swing rod detection module collects field measured data and sends the data to the scratch data collection module, the scratch data collection module is sent to the upper computer communication module, the scratch data analysis module is called finally, the collected data are analyzed and judged, if scratches exist, alarming at different levels of scratches is carried out, and a report record file is formed. The system can be used for detecting locomotive wheels in an online automatic scratch mode, classifying, analyzing and processing collected data, and accurately and quickly judging whether the wheel tread roller circle has a scratch phenomenon.
Fig. 5 is a structural view of the trackside installation of the automatic online wheel scratch detection system for a railway rolling stock. An automatic online detection system for wheel abrasion of a railway rolling stock comprises an incoming line induction module, an offline induction module, n swing rod detection modules, a database storage module, an upper computer communication module and an abrasion data analysis module; the swing rod detection module comprises a left swing rod detection module, a right swing rod detection module and a scratch data acquisition module; wherein,
and the incoming line induction module and the off-line induction module are arranged. The incoming line induction module can be arranged at the entrance end of the working rail, and when a railway locomotive drives into the detection area of the incoming line induction module at a preset speed, an incoming line marking signal of the locomotive is generated and output to the database storage module; the off-line sensing module can be arranged at the departing end of the working rail, and when the railway locomotive drives away from the detection area of the off-line sensing module at a preset speed, a locomotive off-line marking signal is generated and output to the database storage module;
the left swing rod detection module and the right swing rod detection module are mutually symmetrical and are respectively arranged on the inner sides of the two working rails, n swing rod detection modules are arranged on the inner sides of the working rails at intervals, the total length is greater than the circumference of a wheel, and n is L1/L2Adding 1 to the value of (A) and then taking an integer, L1Is the wheel circumference, L2The length of a single swing rod detection module is considered, the wheel diameters of detected vehicle wheels are different, the system is used for detecting the wheel tread scratch of a railway locomotive vehicle, the wheel diameters of the system are generally larger, taking an electric locomotive as an example, the wheel diameters of the system are 1250mm, and the whole effective detection length is larger than 3925 mm. Meanwhile, due to the limitation of production and processing and the limitation of the length of the swing rod detection module, the length of the swing rod detection module adopted by people in general is 1200 mm. Through calculation, the length requirement of one circle of the detected wheel diameter can be met only by combining four groups of swing rod detection modules. The swing rods are placed next to each other to generate a detection blind area, so that the design requirements are met by placing four sections of swing rod detection modules at intervals, and the spacing distance between the second swing rod detection module and the third swing rod detection module is larger than that between the first swing rod detection module and the second swing rod detection module. The principle is as follows: the first circle of the wheel starts from the first swing rod and ends when leaving the middle of the second swing rod and the third swing rod detection module, namely the first circle cannot reach the third swing rod. The second circle begins to pass through the third swing rod detection module, and the position of the third swing rod detection module, which is mapped on the wheel, comprises the position of the first swing rod detection module and the position of the second swing rod detection module, which is mapped on the wheel at intervals. And then continuously passing through a section of interval area to reach a fourth swing rod detection module, wherein the position of the fourth swing rod detection module, which is mapped on the wheel, comprises the position of the interval between the second swing rod and the third swing rod, which is mapped on the wheel. Thus, the entire wheel tread surface cycle will be mapped onto the swing link detection module. In addition, the influence brought by different wheel diameters and abrasion is also considered, and the requirement can be met by changing the spacing distance between the swing rods;
the left swing rod detection module and the right swing rod detection module are used for collecting angle change data of wheel rim pressing when the wheel rim is pressed down and outputting the angle change data to the scratch data collection module;
the scratch data acquisition module is used for receiving the angle change data of the wheel rim pressing output by the left swing rod detection module and the right swing rod detection module and outputting the angle change data to the upper computer communication module;
the database storage module is used for receiving locomotive incoming line marking signals and locomotive off-line marking signals;
the upper computer communication module is used for reading the locomotive incoming line marking signals and the locomotive off-line marking signals in the database storage module in real time; after the upper computer communication module reads a group of complete locomotive vehicle incoming line mark signals and locomotive vehicle off-line mark signals from the database storage module, reading angle change data of wheel rim pressing from the scratch data acquisition module and outputting the angle change data to the scratch data analysis module;
and the scratch data analysis module is used for analyzing and processing the angle change data of the wheel rim pressing to obtain the scratch information of the wheel.
The swing rod detection module also comprises two wheel positioning induction modules arranged at two sides of the left swing rod detection module or the right swing rod detection module; when the railway rolling stock passes through the detection area of the wheel positioning sensing module, a trigger signal is output to the scratch data acquisition module, the scratch data acquisition module obtains time according to the received trigger signal and calculates the speed of the wheel according to the position parameter stored in advance, and when the speed is within the preset speed, the obtained information of the scratch of the wheel is effective. The wheel alignment sensing module is arranged according to the number of the scratch data acquisition modules. A group of positioning induction sensors are formed by the proximity switches and correspond to a scratch data acquisition module.
The preset vehicle speed is constant and is 1km/h-20 km/h. The preset vehicle speed is an important condition for ensuring the detection precision of the system, and the passing vehicle speed is too high during detection, so that the data acquisition of the online automatic scratch detection system is incomplete, and the detection precision of the system is influenced.
The left swing rod detection module and the right swing rod detection module respectively comprise swing rods which are in contact with wheel rims and are horizontally placed, gear mechanisms and rotary encoders which are arranged on the swing rods and are coaxial with the gear mechanisms; when the swing rod is pressed down by the wheel rim of the wheel, the swing rod generates angle change, and the gear mechanism is used for amplifying the angle change of the swing rod and then processing and outputting angle change data to the scratch data acquisition module through the rotary encoder.
The incoming line induction module and the off-line induction module are both photoelectric switch type sensors.
The wheel positioning sensing module is an eddy current type proximity switch or a capacitance type proximity switch or a Hall type proximity switch or a photoelectric type proximity switch or an ultrasonic type proximity switch or a microwave type proximity switch.
FIG. 6 is a schematic diagram of a pendulum detection module. On the pendulum rod detection module was pressed in to wheel rim that does not have the tread scotch existence, can drive the rocking arm pendulum rod and produce certain angle of pushing down, and the wheel rim that exists as the tread scotch presses the pendulum rod detection module, can drive the rocking arm pendulum rod and produce the angle change, the transmission of rethread driving gear is for driven gear, the angle change of rocking arm pendulum rod also amplifies along with gear drive's drive ratio simultaneously, the rotary encoder of coaxial setting on the driven gear is data processing again, the angle change alpha that twice measurements obtained, and the radius of swing r of swinging arms is known, can obtain the wearing and tearing condition of tread promptly scotch degree of depth delta h computational formula:
Δh＝r*sinα；
the scratch data acquisition module comprises a controller unit, an encoder data receiving unit, an encoder data decoding unit, a storage unit, a communication unit and a wheel positioning data receiving unit; the angle change data of the wheel rim pressing is received by the encoder data receiving unit, decoded by the encoder data decoding unit and then sent to the controller unit; the wheel positioning data receiving unit receives the wheel positioning sensing module and outputs a trigger signal to the controller unit; the controller unit outputs the received angle change data after decoding processing to the storage unit and finally outputs the angle change data to the upper computer communication module through the communication unit. When the device is installed and set, one scratch data acquisition module is responsible for receiving data of the corresponding left swing rod detection module and the corresponding right swing rod detection module. FIG. 7 is a block diagram of a data acquisition module of the automatic online scratch detection system for railway rolling stock wheels. The basic workflow of the scratch data acquisition module is as follows: the wheel positioning data receiving unit receives a trigger signal that a wheel passes through and informs the controller unit, records the time of the received trigger signal, calculates the speed of the wheel according to a position parameter stored in advance, and the encoder data receiving unit receives scratch data actually collected on site and sends the scratch data to the encoder data decoding unit for decoding the data and then sends the data to the controller unit. The controller unit controls the whole system to work coordinately, stores data or communicates with an upper computer and the like.
When the scratch data of the complete wheel is collected on site, the data needs to be analyzed and processed. When the railway rolling stock passes through, the upper computer communication module repeatedly reads a group of incoming line and off-line mark signals from the database, and if the complete mark signals are received, the integrated data are read from the scratch data acquisition module to generate a detection data file. And the scratch data analysis software is used for analyzing and judging the collected database storage module, and if scratches exist, alarming according to different levels of scratches according to regulations and forming a report record file.
FIG. 8 is a flow chart of the automatic online scratch detection system for railway rolling stock wheels, the core idea of the analysis algorithm is to perform segmentation processing on scratch data, the scratch data is analyzed by using a traditional analytical method in the head and tail regions of the data, and an analysis mode similar to the image transverse filling search is used in the middle region of the data. And summarizing the results of the two-stage analysis, comprehensively judging whether the scratch phenomenon exists in the given scratch length and scratch depth threshold range, and outputting the position, size, curve and the like of the scratch data.
The invention discloses a detection method of an online automatic detection system for railway locomotive vehicle wheels, which comprises the following steps:
step one, presetting a head area range and a tail area range on a curve;
step two, converting the angle change data of wheel rim pressing into depth displacement data of wheel rim pressing, and obtaining an original curve by taking a sampling point as an abscissa and a depth displacement value as an ordinate; fitting data curves in the head region and the tail region of the original curve to obtain a new curve, subtracting depth displacement values corresponding to the same sampling points on the new curve and the original curve respectively to obtain a first difference value, and performing envelope curve and smooth interpolation processing on the first difference value to form a scratch schematic curve; when the ordinate of a certain sampling point on the scratch schematic curve meets a preset scratch depth threshold range, the wheel is scratched at the moment, and information of the position, the depth and the length of the scratch is obtained; according to actual vehicle passing data on site and past detection experience of current workers, the existence of scratches is characterized by length and depth, and another group of general parameters during detection are obtained through comprehensive analysis and induction: namely a preset scratch length threshold range and a scratch depth threshold range, and fig. 9 is a flow chart of a scratch analysis module analysis method of the railway locomotive vehicle wheel online scratch automatic detection system. (ii) a
Step three, analyzing a middle area curve of the original curve except the head area and the tail area, firstly finding a highest point corresponding to the maximum depth displacement value in the middle area, and setting the highest point as an initial sampling point from the first sampling point position of the middle area; (ii) a
A. Sequentially finding out a point with the same depth displacement value as the initial sampling point according to the sampling time sequence of the sampling point, respectively subtracting the abscissa of the point from the abscissa of the initial point to obtain a second difference value, if the second difference value meets the preset scratch length threshold range, subtracting the ordinate of the highest point from the ordinate of the initial point to obtain a third difference value, and if the third difference value also meets the preset scratch depth threshold range, scratching the wheel at the moment to obtain the information of the position, the depth and the length of the scratch;
B. and when the second difference value does not meet the preset scratch length threshold range or the third difference value does not meet the preset scratch depth threshold range, repositioning the sampling point at the next moment, and setting the sampling point as a new starting point to repeat the step A.
And step four, outputting and alarming the abrasion condition of the railway locomotive vehicle wheels according to the abrasion position, depth and length information obtained in the step.
The head area range on the curve preset in the first step is to select the first 200 sampling points on the curve by taking the sampling points as a sampling time sequence; the tail area range takes the sampling points as a sampling time sequence, and the last 100 sampling points on the curve are selected.
The method for presetting the head area range and the tail area range on the curve comprises the following steps: and when the wheel rim is contacted with the two ends of the swing rod detection modules, namely the wheel rim is pressed down and leaves the corresponding swing rod detection modules, the jumping curve is generated, the actual vehicle passing data is comprehensively analyzed to form the interval range of the jumping curve, and the head region range and the tail region range are obtained.
Fig. 10, 11, and 12 are examples of data for the scratch data analysis module to process the middle area to verify the accuracy of the middle area detection method. Fig. 10 is partial triangular wave scratch data of an example of simulation data in which the scratch data analysis module processes the middle area, fig. 11 is partial rectangular wave scratch data of an example of simulation data in which the scratch data analysis module processes the middle area, and fig. 12 is partial sinusoidal wave scratch data of an example of simulation data in which the scratch data analysis module processes the middle area. Three groups of scratch data are respectively simulated by using scratch data simulation software, and the local scratch forms of the three groups of scratch data respectively represent triangular waves, rectangular waves and sine waves, namely curves shown in figures 10, 11 and 12. They all had a data length of 1200mm, scratch start positions of 600mm, scratch lengths of 40mm, and scratch depths of 0.5 mm. In the figure, for the convenience of intuitive understanding, the head and tail regions of the curve of the original data are processed, the middle region is reserved, and the curve is filled with a dark color until local scratch information meeting a preset scratch length threshold range and a preset scratch depth threshold range is found. The scratch analysis module yielded the results of: the 1 st shaft, the left wheel and the 1 st swing rod represent triangular wave data, the 2 nd swing rod is rectangular wave data, and the 3 rd swing rod is sine wave data. Three sets of scratch information derived by the scratch analysis software were: triangular wave data, position 608.0mm, length 58.0mm, depth 0.48 mm; square wave data, position 596.0mm, length 50.0mm, depth 0.58 mm; sine wave data, position 602.0, length 46.0mm, depth 0.51 mm; compared with the actually given initial position of 600.0mm, the length of the scratch of 40.0mm and the depth of the scratch of 0.50mm, the method can accurately identify the information of the depth and the length of the scratch and meet the detection precision requirement of the system.
Fig. 13, 14 and 15 show examples of scratch-free data collected by the scratch data analysis module processing three sets of actual field vehicles passing through, fig. 13 shows an example a of actual field vehicle passing-free data of the scratch data analysis module processing the middle area, fig. 14 shows an example b of actual field vehicle passing-free data of the scratch data analysis module processing the middle area, and fig. 15 shows an example c of actual field vehicle passing-free data of the scratch data analysis module processing the middle area. The scratch analysis module yielded the results of: no scratch information was found. The method accords with the actual result of manual rechecking of the wheels on site.
Fig. 16 is an example of scratch data analysis module processing a set of scratch data collected from actual passing vehicles on site in the middle area to verify the accuracy of the middle area detection method. The scratch analysis module yielded the results of: the starting position is 766.0mm, the length is 32.0mm, and the depth is 0.35 mm; the result of manual review of the wheel in situ was a 35mm scratch length and a 0.4mm scratch depth that met the detection accuracy requirements of the system, while the start position 1121.0mm, length 86.0mm, depth 0.16mm, did not meet the scratch length threshold range and was not considered herein as a scratch.
Fig. 17 is an example of scratch data collected by the scratch data analysis module in another set of actual vehicles passing on site, wherein the scratch data are used for verifying the accuracy of the detection method of the head region and the tail region. In the figure, e represents: curves of raw data, where f represents: curves after raw data fitting and translating downward, where g represents: and (3) carrying out a curve of threshold judgment, smooth interpolation and amplification treatment after difference value is carried out on the fitting data and the original data, wherein h in the graph represents: and (3) judging the scratch schematic curve after the envelope curve and the threshold value are processed, wherein the scratch analysis module obtains the following results: the initial position is 1174.0mm, the length is 28.0mm, the depth is 0.25mm, the threshold range of the scratch length is met, the scratch length is 35mm as a result of manual review of the wheel on site, and the scratch depth is 0.4mm, so that the detection precision requirement of the system is basically met.
In the practical engineering, the technical conditions are suitable for the automatic online scratch detection of the wheel tread roller circle before the railway rolling stock is put in storage, and the passing speed of the detection is as follows: 1-20km/h constant speed; wheel set parts for effective detection of scratches: the round part of the roller; scratch depth detection accuracy: plus or minus 0.2 mm; system supply voltage: AC220V (china), customizable in other regions; supply voltage of the trackside equipment: DC 24V; power supply of the trackside equipment: less than or equal to 50W; system operating temperature range: -40 ℃ to 70 ℃; the waterproof grade of equipment beside the track is as follows: IP 67.
In conclusion, the system disclosed by the invention is simple in structural design, convenient to use, low in manufacturing cost, and suitable for on-site environment under different conditions and online detection of tread scratches and out-of-roundness of wheel diameters of different vehicle types. In addition, the above embodiments are only for illustrating the technical idea of the present invention, and the protection scope of the present invention is not limited thereby, and any modification made on the basis of the technical solution according to the technical idea of the present invention falls within the protection scope of the present invention. The technology not related to the invention can be realized by the prior art.
Claims (10)
1. An online automatic detection system for wheel abrasion of a railway rolling stock is characterized by comprising an incoming line induction module, an offline induction module, n swing rod detection modules, a database storage module, an upper computer communication module and an abrasion data analysis module; the swing rod detection module comprises a left swing rod detection module, a right swing rod detection module and a scratch data acquisition module; the left swing rod detection module and the right swing rod detection module are mutually symmetrical and are respectively arranged at the inner sides of the two working rails, the n swing rod detection modules are arranged at the inner sides of the working rails at intervals, and the total length is more than that of the swing rod detection modulesWheel circumference, where n is L1/L2Adding 1 to the value of (A) and then taking an integer, L1Is the wheel circumference, L2Detecting the length of the module for a single swing link; wherein:
the system comprises an incoming line induction module, a database storage module and a data processing module, wherein the incoming line induction module is arranged at an incoming end of a working rail and used for outputting a locomotive incoming line mark signal to the database storage module when a railway locomotive drives into a detection area of the incoming line induction module at a preset speed;
the off-line sensing module is arranged at the leaving end of the working rail and used for outputting a locomotive vehicle off-line mark signal to the database storage module when the railway locomotive vehicle drives away from the detection area of the off-line sensing module at a preset speed;
the left swing rod detection module and the right swing rod detection module are used for collecting angle change data of wheel rim pressing when the wheel rim is pressed down and outputting the angle change data to the scratch data collection module;
the scratch data acquisition module is used for receiving the angle change data of the wheel rim pressing output by the left swing rod detection module and the right swing rod detection module and outputting the angle change data to the upper computer communication module;
the database storage module is used for receiving locomotive incoming line marking signals and locomotive off-line marking signals;
the upper computer communication module is used for reading the locomotive incoming line marking signals and the locomotive off-line marking signals in the database storage module in real time; after the upper computer communication module reads a group of complete locomotive vehicle incoming line mark signals and locomotive vehicle off-line mark signals from the database storage module, reading angle change data of wheel rim pressing from the scratch data acquisition module and outputting the angle change data to the scratch data analysis module;
and the scratch data analysis module is used for analyzing and processing the angle change data of the wheel rim pressing to obtain the scratch information of the wheel.
2. The automatic online detecting system for the scratches on the railway rolling stock wheel of claim 1, wherein the left swing link detecting module and the right swing link detecting module each comprise a swing link which is in contact with the wheel rim and is horizontally arranged, a gear mechanism, and a rotary encoder which is arranged on the swing link and is coaxial with the gear mechanism; when the swing rod is pressed down by the wheel rim of the wheel, the swing rod generates angle change, and the gear mechanism is used for amplifying the angle change of the swing rod and then processing and outputting angle change data to the scratch data acquisition module through the rotary encoder.
3. The system of claim 1, wherein the pendulum bar detection module further comprises two wheel alignment sensing modules disposed at opposite ends of the left pendulum bar detection module or the right pendulum bar detection module; when the railway rolling stock passes through the detection area of the wheel positioning sensing module, a trigger signal is output to the scratch data acquisition module, the scratch data acquisition module obtains time according to the received trigger signal and calculates the speed of the wheel according to the position parameter stored in advance, and when the speed is within the preset speed, the obtained information of the scratch of the wheel is effective.
4. The system of claim 1, wherein the incoming line sensing module and the outgoing line sensing module are both photoelectric switch type sensors.
5. The system of claim 3, wherein the wheel alignment sensing module is an eddy current type proximity switch, a capacitive type proximity switch, a Hall type proximity switch, a photoelectric type proximity switch, an ultrasonic type proximity switch, or a microwave type proximity switch.
6. The system of claim 3, wherein said scratch data collection module comprises a controller unit, an encoder data receiving unit, an encoder data decoding unit, a storage unit, a communication unit and a wheel positioning data receiving unit; the angle change data of the wheel rim pressing is received by the encoder data receiving unit, decoded by the encoder data decoding unit and then sent to the controller unit; the wheel positioning data receiving unit receives the trigger signal output by the wheel positioning sensing module and then sends the trigger signal to the controller unit; the controller unit outputs the received angle change data after decoding processing to the storage unit and finally outputs the angle change data to the upper computer communication module through the communication unit.
7. An automatic railway rolling stock wheel scratch detection system as claimed in claim 1, wherein said preset speed is constant and is 1km/h-20 km/h.
8. The method for detecting the automatic online rail vehicle wheel scratch detection system according to claim 1, comprising the following steps:
step one, presetting a head area range and a tail area range on a curve;
step two, converting the angle change data of wheel rim pressing into depth displacement data of wheel rim pressing, and obtaining an original curve by taking a sampling point as an abscissa and a depth displacement value as an ordinate; fitting data curves in the head region and the tail region of the original curve to obtain a new curve, subtracting depth displacement values corresponding to the same sampling points on the new curve and the original curve respectively to obtain a first difference value, and performing envelope curve and smooth interpolation processing on the first difference value to form a scratch schematic curve; when the ordinate of a certain sampling point on the scratch schematic curve meets a preset scratch depth threshold range, the wheel is scratched at the moment, and information of the position, the depth and the length of the scratch is obtained;
step three, analyzing a middle area curve of the original curve except the head area and the tail area, firstly finding a highest point corresponding to the maximum depth displacement value in the middle area, and setting the highest point as an initial sampling point from the first sampling point position of the middle area;
A. sequentially finding out a point with the same depth displacement value as the initial sampling point according to the sampling time sequence of the sampling point, respectively subtracting the abscissa of the point from the abscissa of the initial point to obtain a second difference value, if the second difference value meets the preset scratch length threshold range, subtracting the ordinate of the highest point from the ordinate of the initial point to obtain a third difference value, and if the third difference value also meets the preset scratch depth threshold range, scratching the wheel at the moment to obtain the information of the position, the depth and the length of the scratch;
B. and B, when the second difference value does not meet the preset scratch length threshold range or the third difference value does not meet the preset scratch depth threshold range, repositioning the sampling point at the next moment, setting the sampling point as a new starting point, and repeating the step A.
And step four, outputting and alarming the abrasion condition of the railway locomotive vehicle wheels according to the abrasion position, depth and length information obtained in the step.
9. The method as claimed in claim 8, wherein the preset head area range on the curve in the first step is a sampling sequence of sampling points, and the first 200 sampling points on the curve are selected; the tail area range takes the sampling points as a sampling time sequence, and the last 100 sampling points on the curve are selected.
10. The method for detecting the automatic online detecting system for the railway locomotive wheel scratches as claimed in claim 8, wherein the method for presetting the head area range and the tail area range on the curve is as follows: when the wheel rim is in contact with the two ends of the swing rod detection modules, namely the wheel rim is pressed down and leaves the corresponding swing rod detection modules, a jumping curve can be generated, the actual vehicle passing data is comprehensively analyzed to form an interval range where the jumping curve occurs, and a head area range and a tail area range are obtained.
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