阅读说明：本技术 一种低成本便携式轮轴曲面微划痕非接触检测装置及方法 (Low-cost portable axle curved surface micro-scratch non-contact detection device and method ) 是由 窦艳红 黄雷 关维琦 王硕 魏岩军 赵梓朝 张立秋 于 2021-08-06 设计创作，主要内容包括：一种低成本便携式轮轴曲面微划痕非接触检测装置,属于曲面划痕深度检测技术领域,为了解决现有技术存在的问题,共聚焦传感器通过精密连接夹具安装于位移滑台上；快速定位夹具由类V型座和磁力吸附装置组成,类V型座的中心与位移滑台运动轴线垂直,并通过磁力吸附装置吸附于被测轮轴上,类V型座的中心与被测轮轴母线平行；集成控制器由位移控制器和电机驱动器组成；计算机用于对共聚焦传感器进行状态控制,同时将其采集到的数据进行处理,并对集成控制器发送控制指令,计算机通过自适应曲率滤波算法,根据被测轮轴的曲率半径、表面反射率和共聚焦传感器高频率采样特性,自动消除被测轮轴曲率半径对划痕深度的影响,并自动生成划痕检测报告。(A low-cost portable axle curved surface micro-scratch non-contact detection device belongs to the technical field of curved surface scratch depth detection, and aims to solve the problems in the prior art, a confocal sensor is arranged on a displacement sliding table through a precision connecting clamp; the quick positioning fixture consists of a V-shaped seat and a magnetic adsorption device, the center of the V-shaped seat is perpendicular to the movement axis of the displacement sliding table and is adsorbed on the measured wheel shaft through the magnetic adsorption device, and the center of the V-shaped seat is parallel to the generatrix of the measured wheel shaft; the integrated controller consists of a displacement controller and a motor driver; the computer is used for carrying out state control on the confocal sensor, processing the acquired data and sending a control instruction to the integrated controller, and the computer automatically eliminates the influence of the curvature radius of the measured wheel shaft on the scratch depth and automatically generates a scratch detection report according to the curvature radius of the measured wheel shaft, the surface reflectivity and the high-frequency sampling characteristic of the confocal sensor through a self-adaptive curvature filtering algorithm.)

1. A low-cost portable wheel axle curved surface micro-scratch non-contact detection device is characterized by comprising a confocal sensor (1), a displacement sliding table (2), a quick positioning clamp (3), a precise connecting clamp (5), an integrated controller (6) and a computer (7);

the confocal sensor (1) is used for collecting scratch surface data of a measured wheel shaft (4) and is arranged on the displacement sliding table (2) through a precision connecting clamp (5), so that the confocal sensor (1) is ensured to be vertical to the transverse displacement axis of the displacement sliding table (2);

the quick positioning fixture (3) consists of a V-shaped seat and a magnetic adsorption device, the center of the V-shaped seat is perpendicular to the movement axis of the displacement sliding table (2) and is adsorbed on the measured wheel shaft (4) through the magnetic adsorption device, and the center of the V-shaped seat is parallel to the bus of the measured wheel shaft (4), so that the requirements of quick and accurate installation and positioning on site are met;

the integrated controller (6) consists of a displacement controller and a motor driver, so that the motor drive and the displacement of the displacement sliding table (2) are integrally controlled, and the portability requirement of field detection of the device is met;

the computer (7) is used for carrying out state control on the confocal sensor (1), processing the acquired data and sending a control instruction to the integrated controller (6), and the computer (7) automatically eliminates the influence of the curvature radius of the measured wheel axle (4) on the scratch depth and automatically generates a scratch detection report according to the curvature radius, the surface reflectivity and the high-frequency sampling characteristic of the confocal sensor of the measured wheel axle (4) through a self-adaptive curvature filtering algorithm.

2. The low-cost portable wheel axle curved surface micro-scratch non-contact detection device according to claim 1, characterized in that the displacement sliding table (2) provides high-precision linear displacement with a measurement range of 0-10 mm and a straightness below 2 μm, and a measurement light path is ensured to be perpendicular to a bus of the measured wheel axle (4).

3. A low-cost portable axle curved surface micro-scratch non-contact detection method is characterized by comprising the following steps:

placing a tested wheel shaft (4) on a stable table top, and placing a plurality of tested samples together for batch detection under the condition of ensuring no vibration and no air flow interference according to the field condition;

calibrating a detection device consisting of the confocal sensor (1), the displacement sliding table (2) and the rapid positioning fixture (3) through a special calibrator to ensure that the initial working state of the device is intact;

step three, stably adsorbing the detection device to the surface of the measured wheel shaft (4), and ensuring that a bus of the measured wheel shaft (4) is vertical to a measurement optical axis;

thirdly, the position of the detected scratch is determined through manual adjustment and visual observation, the detection device is transversely moved to an initial detection position, and if the initial position is not appropriate, the quick positioning clamp (3) can be properly adjusted for fine adjustment;

fourthly, the computer (7) controls the displacement sliding table (2) to move and sends out a synchronous signal to enable the confocal sensor (1) to start to synchronously acquire displacement data;

and step five, the computer (7) automatically eliminates the influence of the curvature radius of the measured wheel axle (4) on the scratch depth according to the curvature radius of the measured wheel axle, the surface reflectivity and the high-frequency sampling characteristic of the confocal sensor through a self-adaptive curvature filtering algorithm, and automatically generates a scratch detection report through the computer, so that whether the wheel axle meets the requirement of continuous use is judged.

Technical Field

The invention relates to the technical field of curved surface scratch depth detection, in particular to a device and a method for detecting the scratch depth of the surface of a high-precision wheel shaft.

Background

The locomotive axle belongs to the core motion transmission part and the structure safety part of the railway passenger car body, and the quality of the locomotive axle directly influences the running safety and the service life of a train. In the locomotive axle maintenance process, the scratch depth of the bearing seat of the locomotive axle is much smaller, and the bearing seat can be repaired again for continuous use, but the repair premise is to ensure that the scratch depth is within 0.1mm, and the locomotive axle with scratches larger than 0.1mm is directly scrapped. Meanwhile, the width of the scratch is also narrow and is generally (0.2-1) mm, and the traditional contact sensor, the laser triangulation method laser and the light cutting method sensor are difficult to accurately measure. Meanwhile, the locomotive axle bearing mounting seat is provided with the curvature radius, so that the detection difficulty of the scratch depth is increased, and the problem always puzzles manufacturers of high-speed railway axles, so that the rejection rate of the axles is high.

The scratch depth detection of the wheel axle needs 30 wheels every day, the detection is calculated according to the available proportion of 10%, at least 3 repairable wheel axles can be reserved every day, if equipment is successfully developed, the efficiency of the wheel axle overhaul scrapping screening rate is improved, and the safety factor of a locomotive is effectively guaranteed.

Disclosure of Invention

The invention provides a low-cost portable axle curved surface micro-scratch non-contact detection device and method, aiming at solving the problem that the prior art is difficult to accurately measure the axle curved surface micro-scratch.

The invention adopts the following technical scheme:

a low-cost portable axle curved surface micro-scratch non-contact detection device is characterized by comprising a confocal sensor, a displacement sliding table, a quick positioning clamp, a precise connection clamp, an integrated controller and a computer;

the confocal sensor is used for collecting scratch surface data of the measured wheel axle and is arranged on the displacement sliding table through a precise connecting clamp, so that the confocal sensor is ensured to be vertical to the transverse displacement axis of the displacement sliding table;

the quick positioning fixture consists of a V-shaped seat and a magnetic adsorption device, the center of the V-shaped seat is perpendicular to the movement axis of the displacement sliding table and is adsorbed on a measured wheel shaft through the magnetic adsorption device, and the center of the V-shaped seat is parallel to the bus line of the measured wheel shaft, so that the requirement of quick and accurate installation and positioning on site is met;

the integrated controller consists of a displacement controller and a motor driver, so that the motor drive and the displacement of the displacement sliding table are integrally controlled, and the portability requirement of field detection of the device is met;

the computer is used for carrying out state control on the confocal sensor, processing the acquired data and sending a control instruction to the integrated controller, and the computer automatically eliminates the influence of the curvature radius of the measured wheel shaft on the scratch depth and automatically generates a scratch detection report according to the curvature radius, the surface reflectivity and the high-frequency sampling characteristic of the confocal sensor of the measured wheel shaft through a self-adaptive curvature filtering algorithm.

The displacement sliding table provides high-precision linear displacement with a measuring range of 0-10 mm and a straightness below 2 mu m, and a measuring light path is ensured to be perpendicular to a bus of a measured wheel shaft.

A low-cost portable axle curved surface micro-scratch non-contact detection method is characterized by comprising the following steps:

placing a tested wheel shaft on a stable table top, and placing a plurality of tested samples together for batch detection under the condition of ensuring no vibration and no air flow interference according to the field condition;

calibrating a detection device consisting of a confocal sensor, a displacement sliding table and a rapid positioning fixture through a special calibrator to ensure that the initial working state of the device is intact;

step three, stably adsorbing the detection device to the surface of the measured wheel shaft, and ensuring that the generatrix of the measured wheel shaft is vertical to the measurement optical axis;

thirdly, determining the position of the detected scratch through manual adjustment and visual observation, and traversing the detection device to an initial detection position, wherein if the initial position is not appropriate, the quick positioning clamp can be properly adjusted for fine adjustment;

fourthly, the computer controls the displacement sliding table to move and sends out a synchronous signal to enable the confocal sensor to start to synchronously acquire displacement data;

and fifthly, the computer automatically eliminates the influence of the measured wheel axle radius on the scratch depth through the self-adaptive curvature filtering algorithm according to the measured wheel axle radius of curvature, the surface reflectivity and the high-frequency sampling characteristic of the confocal sensor, and automatically generates a scratch detection report.

The invention has the beneficial effects that:

1. according to the low-cost portable axle curved surface micro-scratch non-contact detection device and method, the optical characteristics of a white light confocal sensor are utilized, and the light spot diameter meets the scratch detection requirement in a specific measurement range by controlling the measurement distance, the measurement position and the exposure intensity regulation algorithm, so that the measurement precision is greatly improved;

2. the invention adopts a self-adaptive curvature filtering algorithm, overcomes the uncertainty of scratch depth measurement caused by the appearance of a processed surface, and adopts a plurality of special operations such as a filtering algorithm combining the surface characteristic of a wheel shaft and the characteristic of a white light confocal sensor, a sampling point value-taking algorithm and the like;

3. according to the invention, the confocal sensor, the portable displacement sliding table and the control system are systematically and intensively designed, so that the volume and the weight of equipment are greatly reduced, the high-precision measurement of scratches of the locomotive axle (0-1 mm) can be realized, and the repairable locomotive axle with the scratch depth below 0.1mm is detected. The scratch of the wheel shaft can be detected in a working field, so that the complicated wheel shaft conveying and debugging equipment process is not needed, and the detection time and the detection cost are greatly reduced;

4. the invention adopts a non-contact measurement mode, and avoids generating new unknown scratches when the surface of the measured wheel shaft is detected.

Drawings

FIG. 1 is a schematic view of a low-cost portable apparatus for detecting micro scratches on a curved surface of a wheel axle in a non-contact manner according to the present invention;

in the figure: 1-confocal sensor, 2-displacement sliding table, 3-rapid positioning fixture, 4-measured wheel shaft, 5-precise connecting fixture, 6-integrated controller and 7-computer.

FIG. 2 is a flow chart of a low-cost portable axle curved surface micro-scratch non-contact detection method of the present invention.

Detailed Description

The present invention will be described in detail with reference to the accompanying drawings.

As shown in fig. 1, a low-cost portable axle curved surface micro-scratch non-contact detection device comprises a confocal sensor 1, a displacement sliding table 2, a rapid positioning fixture 3, a precise connection fixture 5, an integrated controller 6 and a computer 7.

Confocal sensor 1 is used for gathering 4 mar surface data of survey axles to install on displacement slip table 2 through accurate coupling jig 5, can guarantee that confocal sensor 1 is perpendicular with 2 lateral displacement axes of displacement slip table.

The displacement sliding table 2 bears the confocal sensor 1 through the precision connecting clamp 5, can provide high-precision linear displacement with a measuring range (0-10) mm and linearity below 2 mu m, and ensures that a measuring light path is vertical to a bus of the measured wheel shaft 4.

The quick positioning fixture 3 consists of a V-shaped seat and a magnetic adsorption device. The center of the V-shaped seat is perpendicular to the movement axis of the displacement sliding table 2 and is adsorbed on the measured wheel shaft 4 through a magnetic adsorption device, and the center of the V-shaped seat is parallel to the generatrix of the measured wheel shaft 4, so that the requirement of rapid and accurate installation and positioning on site can be met.

The integrated controller 6 consists of a displacement controller and a motor driver, can realize the integrated control of the motor drive and the displacement of the displacement sliding table 2, and meets the portability requirement of the field detection of the device;

the computer 7 is used for carrying out state control on the confocal sensor 1, processing the acquired data and sending a control instruction to the integrated controller 6, and the computer 7 integrates a self-adaptive scratch depth detection algorithm capable of eliminating the influence of the curvature radius of the measured wheel shaft 4 and outputs a detection report required by a client.

A low-cost portable axle curved surface micro-scratch non-contact detection method comprises the following steps:

placing a tested wheel shaft 4 on a stable table top, and placing a plurality of tested samples together for batch detection under the condition of ensuring no vibration and no air flow interference according to the field condition;

calibrating a detection device consisting of the confocal sensor 1, the displacement sliding table 2 and the rapid positioning fixture 3 through a special calibrator to ensure that the initial working state of the device is intact;

step three, stably adsorbing the detection device to the surface of the measured wheel shaft 4, and ensuring that the generatrix of the measured wheel shaft 4 is vertical to the measurement optical axis;

thirdly, the position of the detected scratch is determined through manual adjustment and visual observation, the detection device is transversely moved to an initial detection position, and if the initial position is not appropriate, the quick positioning clamp 3 can be properly adjusted for fine adjustment;

fourthly, the computer 7 controls the displacement sliding table 2 to move for 10mm displacement and sends out a synchronous signal to enable the confocal sensor 1 to start to synchronously acquire displacement data;

and step five, the computer 7 can automatically eliminate the influence of the curvature radius of the wheel shaft 4 to be measured on the scratch depth according to the curvature radius of the wheel shaft to be measured, the surface reflectivity and the high-frequency sampling characteristic of the confocal sensor through a self-adaptive curvature filtering algorithm, and automatically generates a scratch detection report through the computer, so that whether the wheel shaft meets the requirement of continuous use or not is judged.

The principle and the implementation mode of the invention are explained by applying specific examples, and the description of the above examples is only used for helping understanding the method and the core idea of the invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In summary, this summary should not be construed to limit the present invention.