Design Of Portable Rail Profile Detection System

With the rapid development of the railway industry,the increase of high-speed and heavy-haul trains,rail wear is also more and more serious.The change of the rail profile size makes the contact area of the wheel and rail increases,increasing operational resistance,resulting in increased likelihood of accidents during train operation.At present,most of the rail profile detection in China is done by manual operation.The manual measurement is inefficient,and the operation is inconvenient,which is not conducive to detect whether the rail wear and deformation occur in time.Therefore,it is very important to study and design a rail profile detection system for railway operation safety.In this paper,the design of the portable rail profile detection system is studied in the following aspects:(1)A data calibration and registration algorithm is proposed based on the shooting principle and layout of Gocator 3D laser sensor.The method first calibrated the double sensors through single hole calibration blocks,and then used iterative closest point optimization algorithm to further optimize the projection matrix,and finally realized the multi section rail profile data registration.Based on the Hough transform,the matching of rail profile and standard contour data is achieved,and the maximum vertical error and lateral error are 0.18 mm.The results show that the accuracy of the data registration algorithm meets the detection error requirements.(2)Based on the three-dimensional design software Solid Works,a simple and easy-to-carry rail profile detection car is designed.The car is mainly composed of cross beam,longitudinal beam,rail profile measuring mechanism,push rod,push rod support mechanism,walking wheel and other key components.At the same time,the finite element analysis software ANSYS is used to check the static analysis of the car frame under the working condition.The results show that the frame structure meets the strength requirement.Modal analysis of the frame structure is carried out,and the six-order naturalfrequency of the frame is extracted and the characteristics of each mode of the frame are analyzed.The results show that the frame structure has enough rigidity and can run smoothly on the track.(3)The data acquisition software of rail profile detection system is developed based on C#,including data acquisition module,data registration module,sensor parameter setting module and data management module.The data acquisition module to realize the communication between host computer and sensor data acquisition,communication and other functions.Data registration module calibration and data correction of sensors.Sensor parameter setting module set some related parameters according to requirements before data acquisition.Data management module is responsible registration rail profile data for storage management.The field test of the rail profile detection system shows that the system meets the requirements of rail profile detection tolerance,and has the characteristics of fast detection speed,good detection accuracy and reliable performance.It has certain engineering application value.