铁路客车轴承滚动体缺陷视觉检测系统研究

Study on the Visual Defect Detection System for Bearing Rollers of Railway Passenger Cars

针对当前铁路客车轴承裂纹人工评判缺陷劳效低下,耗时费眼,主观因素影响大的现状,在不改变现有探伤设备的前提下,以代替人眼为目标,融合机器视觉与磁粉检测技术优势,研制了一种轴承滚动体缺陷自动检测的高效评判系统。文中从需求分析、重要指标、硬件结构、软件界面、检测算法等方面展开了相机机械支撑结构、光源打光方案、人机交互界面、缺陷识别算法的设计,通过现场试验证实,该系统能够达到轴承缺陷快速、准确、高效识别的目标,能做够科学管理检测数据,基本确定了“机器初检+人工复核”的新型作业模式,该系统的研制对提高铁路车辆检修智能化水平、减轻作业强度、提高作业效率具有重要意义。

Facing the current situation of low efficiency,long time consumption and difficulty of visual check and important influence of subjective factors of the artificial judgment of cracks on bearings of railway passenger car,an efficient automatic defect detection and judgment system for bearing rollers has been developed to replace human eyes,integrating the technological advantages of machine vision and magnetic powder detection and with no need to change the existing detection equipment.The article describes the design of mechanical support structure of camera,lighting schemes of light sources,man-machine interface and defect identification algorithm from the aspects of demand analysis,important indices,hardware structure,software interface and detection algorithm.The on-site test has verified that this system can achieve the goal of rapid,exact and efficient identification of bearing defects and manage the detection data in a scientific manner and it has basically determined the new operation mode of“preliminary detection by machine+human verification”.The research and development of this system has important significance for increasing the intelligent inspection and repair level of railway vehicles,reducing the intensity of operation and improving the efficiency of operation.