轮对几何尺寸自动与动态在线测量方法的研究
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摘要
轮对是列车非常重要的走行部件,其质量好坏对铁路的安全运行有着至关重要的影响。车轮属于损耗品,运行一段时间后会产生磨损和缺陷。列车速度的大幅提高,加快了轮对磨损和缺陷产生的速度,给我国高速列车的运行带来巨大的安全隐患。车轮几何尺寸自动测量技术与动态在线测量技术能够在轮对的生产、检修以及运行阶段对轮对质量进行检测,是实现铁路高速发展的重要保证。
本论文对车轮几何尺寸自动测量与在线动态测量技术展开研究,取得的主要创新成果包括：
1.提出了一种激光扫描自动测量车轮几何参数的方法。这种方法采用两个激光视觉传感器对轮对进行三维扫描,然后通过计算机对点云数据进行处理,计算出车轮直径、踏面磨耗、轮缘厚度以及轮辋宽等参数,对被测车轮与激光视觉传感器的相对位置和姿态没有严格要求,提高了测量精度。实验结果证明了这种方法的有效性,能够在制造轮对的工厂或者车辆段的检修车间内实现对车轮全面、准确、快速的测量。
2.提出了一种使用双涡流传感器和单个激光位移传感器动态测量车轮直径的方法,具有成本低、测量精度高、结构简单的优点。经过对影响车轮直径动态测量精度的主要因素进行仿真和分析,在理论上证明了这种车轮直径动态测量方法的精度为士0.37mm。铁路现场的结果在实验上证明了这种方法可以适应现场复杂的环境,而且具有比较高的测量精度,可以满足铁路相关部门对轮径现场测量精度的要求。
3.在理论上分析了轨道振动所引起的车轮直径动态测量误差。本论文利用有限元的方法分析了轨道的振动,并结合车轮直径动态在线测量原理,分析了轨道振动对直径动态测量结果的影响。论文还进一步分析了测量系统中传感器的安装方式、列车通过测量系统的速度这两个因素对动态测量结果的影响。
The wheel is a key component of railway vehicles and belongs to consumables. The quality of train wheels have an important effect on the safety of rail transportation. With the continuous increase of the rail vehicle's speed, the wear of wheel is becoming more and more serious, which will certainly bring potential safety hazard to the operation of railway. The wheel geometric parameters automatic measuring technique and dynamically measuring technique can test the wheel quality during the stages of wheel production, regular inspection, and operation. Thus the study on this topic can ensure the safety of railway operation. The main innovative achievements of this dissertation are as follows:
1. A method for automatically measuring wheel geometric parameters by laser scanning is presented in this dissertation. The wheel tread can be scanned by the line structured light vision sensors, and the geometric parameters including wheel diameter, flange thickness, tread wear and rim width can be calculated after processing the point cloud data. This is different from the traditional methods which measure the geometric parameters by comparing a measured profile to the standard profile of wheel tread. This method doesn't require keeping strick relative positon between the line structured light and the wheel. The feasibility of this method is demonstrated by experimental results.
2. A simple method for dynamically measuring the diameters of train wheels that uses a relative measurement system is proposed. Only a laser displacement transducer and eddy current sensors are used to dynamically measure the wheel diameter when a train passes through the measurement device, and a simple equation for computing the diameter is given. The main factors influencing the measurement uncertainty were analyzed and simulated, The theoretical analysis indicated that the measurement device has a measurement uncertainty of±0.37mm, which agrees with the site experimental results, and the measurement system can satisfy the requirements of dynamically measuring the train diameters in situ.
3. The finite element method is used to analyze the influence of vibrations on the dynamical measurement results of train wheel diameter. Meanwhile, the influences of the installation method of laser displacement transducer and the train running speed on the dynamical measurment results are simulated and discussed.
本论文对车轮几何尺寸自动测量与在线动态测量技术展开研究,取得的主要创新成果包括：
1.提出了一种激光扫描自动测量车轮几何参数的方法。这种方法采用两个激光视觉传感器对轮对进行三维扫描,然后通过计算机对点云数据进行处理,计算出车轮直径、踏面磨耗、轮缘厚度以及轮辋宽等参数,对被测车轮与激光视觉传感器的相对位置和姿态没有严格要求,提高了测量精度。实验结果证明了这种方法的有效性,能够在制造轮对的工厂或者车辆段的检修车间内实现对车轮全面、准确、快速的测量。
2.提出了一种使用双涡流传感器和单个激光位移传感器动态测量车轮直径的方法,具有成本低、测量精度高、结构简单的优点。经过对影响车轮直径动态测量精度的主要因素进行仿真和分析,在理论上证明了这种车轮直径动态测量方法的精度为士0.37mm。铁路现场的结果在实验上证明了这种方法可以适应现场复杂的环境,而且具有比较高的测量精度,可以满足铁路相关部门对轮径现场测量精度的要求。
3.在理论上分析了轨道振动所引起的车轮直径动态测量误差。本论文利用有限元的方法分析了轨道的振动,并结合车轮直径动态在线测量原理,分析了轨道振动对直径动态测量结果的影响。论文还进一步分析了测量系统中传感器的安装方式、列车通过测量系统的速度这两个因素对动态测量结果的影响。
The wheel is a key component of railway vehicles and belongs to consumables. The quality of train wheels have an important effect on the safety of rail transportation. With the continuous increase of the rail vehicle's speed, the wear of wheel is becoming more and more serious, which will certainly bring potential safety hazard to the operation of railway. The wheel geometric parameters automatic measuring technique and dynamically measuring technique can test the wheel quality during the stages of wheel production, regular inspection, and operation. Thus the study on this topic can ensure the safety of railway operation. The main innovative achievements of this dissertation are as follows:
1. A method for automatically measuring wheel geometric parameters by laser scanning is presented in this dissertation. The wheel tread can be scanned by the line structured light vision sensors, and the geometric parameters including wheel diameter, flange thickness, tread wear and rim width can be calculated after processing the point cloud data. This is different from the traditional methods which measure the geometric parameters by comparing a measured profile to the standard profile of wheel tread. This method doesn't require keeping strick relative positon between the line structured light and the wheel. The feasibility of this method is demonstrated by experimental results.
2. A simple method for dynamically measuring the diameters of train wheels that uses a relative measurement system is proposed. Only a laser displacement transducer and eddy current sensors are used to dynamically measure the wheel diameter when a train passes through the measurement device, and a simple equation for computing the diameter is given. The main factors influencing the measurement uncertainty were analyzed and simulated, The theoretical analysis indicated that the measurement device has a measurement uncertainty of±0.37mm, which agrees with the site experimental results, and the measurement system can satisfy the requirements of dynamically measuring the train diameters in situ.
3. The finite element method is used to analyze the influence of vibrations on the dynamical measurement results of train wheel diameter. Meanwhile, the influences of the installation method of laser displacement transducer and the train running speed on the dynamical measurment results are simulated and discussed.
引文
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