AUTOMATED TURNOUT INSPECTION

• US 20110064273A1
• Filed: 09/11/2009
• Published: 03/17/2011
• Est. Priority Date: 09/11/2009
• Status: Active Grant

• Current Assignee: Harsco Corporation
• Original Assignee: Harsco Corporation
• Inventors: Zarembski, Allan M., Palese, Joseph W., Euston, Todd L.
• Granted Patent: US 8,345,948 B2
• Time in Patent Office: Days
• US Class Current: 382/104
• CPC Class Codes: B61K 9/08 Measuring installations for surveying permanent way applications of measuring apparatus or devices for track building purposes E01B35/00; measuring techniques G01
• CPC Class Codes: B61L 2205/04 Satellite based navigation systems, e.g. global positioning system [GPS]
• CPC Class Codes: B61L 23/045 Rail wear

Abstract

A method of inspecting a turnout of a track includes the steps of: capturing images of the components of the turnout; converting each image into a set of coordinates that traces the transverse cross-section of a rail profile; analyzing the rail profile to determine if the rail profile is a profile of arunning rail portion or a component. Upon determination that the image represents a component, taking measurements of the rail profile and applying virtual gauges to the rail profile to check for potentially dangerous conditions of the component; and generating a summary of each cross-section of the rail profile of the component indicating problem areas. The method is used for identifying certain classes of switch or turnout rail conditions which can lead to derailments, and for enhancing the turnout inspection approach currently used. The use of this method as an integrated part of the rail profile monitoring program will reduce reliance on field measurements and will also allow more frequent, comprehensive, and convenient analysis of turnout condition.

Claims

1. A method of inspecting a turnout of a track, the method comprising the steps of:

capturing images of running rail portions and components of the turnout;

converting each image into a set of coordinates that traces the transverse cross-section of a profile of the image of each respective running rail portion and each respective component;

analyzing the profile to determine if the profile is a profile of a running rail portion or a component;

upon determination that the profile of the image represents a component, taking measurements of the profile and applying virtual gauges to the profile to check for potentially dangerous conditions of the component;

generating a summary of each cross-section of the profile of the component indicating problem areas.

2. The method of inspecting the turnout of the track as recited in claim 1 whereby the analyzing of the rail profile and the generation of the summary occur offline.

3. The method of inspecting the turnout of the track as recited in claim 1 whereby the analyzing of the rail profile and the generation of the summary occur in real-time.

4. The method of inspecting the turnout of the track as recited in claim 1 whereby the images are captured from a moving train at intervals of less than six inches.

5. The method of inspecting the turnout of the track as recited in claim 1 whereby the component is a switch rail.

6. The method of inspecting the turnout of the track as recited in claim 1 whereby the component is a frog.

7. The method of inspecting the turnout of the track as recited in claim 1 whereby the precise location of each respective image is obtained and associated with the respective image to allow image and its respective coordinates to be identified to a specific and exact location of the track.

8. The method of inspecting the turnout of the track as recited in claim 1 whereby the summary generated of each cross-section of the profile of the component will visually indicate the problem areas

9. A method of inspecting a switch rail of a track, the method comprising the steps of:

capturing images of the switch rail;

converting each image into a set of coordinates that traces the transverse cross-section of a profile of the switch rail;

applying data analysis logic to check that the shape the profile of the switch rail is consistent with expected profile shapes of the switch rail;

applying data quality filters to the coordinates to remove stray points, lines, and other extraneous (non-essential) data points captured in the image;

overlaying the coordinates of a profile of an original section as a reference over the coordinates of the profile of the image;

comparing measurements of the profile of the image of the switch rail to the profile of the original section;

electronically applying gauges to the profile of the switch rail;

using the measurements and the gauge readings to determine if the switch rail has problem areas;

generating a summary of each cross-section of the profile of the switch rail indicating the problem areas.

10. The method of inspecting the switch rail as recited in claim 9 wherein the application of the data analysis logic checks that the shape of the profile is consistent with expected profile shape of the switch rail spaced from a stock rail indicating that the switch rail is in an open position relative to the stock rail.

11. The method of inspecting the switch rail as recited in claim 10 comprising the additional steps applying data analysis logic to determine if both the switch rail and stock rail are both within the image and wherein the coordinates overlaid are of a profile of an original open section as a reference over the coordinates of the profile of the image.

12. The method of inspecting the switch rail as recited in claim 9 wherein the application of the data analysis logic checks that the shape of the profile is consistent with expected profile shape of the switch rail in close proximity to a stock rail indicating that the switch rail is in a closed position relative to the stock rail and wherein the coordinates overlaid are of a profile of an original closed section as a reference over the coordinates of the profile of the image.

13. The method of inspecting the switch rail as recited in claim 9 wherein the gauges are a set of coordinate points which can be translated to be applied at the appropriate position and location of the image, whereby the gauges provide the ability to measure how close the switch rail is to meeting a failure condition.

14. The method of inspecting the switch rail as recited in claim 9 whereby the precise location of each respective image is obtained and associated with the respective image to allow image and its respective coordinates to be identified to a specific and exact location of the track.

15. The method of inspecting the switch rail as recited in claim 9 whereby the overlaying of the coordinates, the comparing of the measurements, the applying of the gauges and the generation of the occur in real-time.

16. A method of inspecting a frog of a track, the method comprising the steps of:

capturing images of the frog;

converting each image into a set of coordinates that traces the transverse cross-section of a profile of the frog;

applying data analysis logic to check that the shape the profile of the frog is consistent with expected profile shapes of the frog;

applying data quality filters to the coordinates to remove stray points, lines, and other extraneous (non-essential) data points captured in the image;

setting the profile of the frog to a fixed reference point;

comparing measurements of the profile of the image of the frog to a profile of an original section;

electronically applying gauges to the profile of the frog;

using the measurements and the gauge readings to determine if the frog has problem areas;

generating a summary of each cross-section of the profile of the frog indicating the problem areas.

17. The method of inspecting the frog as recited in claim 17 wherein the gauges are a set of coordinate points which can be translated to be applied at the appropriate position and location of the image, whereby the gauges provide the ability to measure how close the frog is to meeting a failure condition.

18. The method of inspecting the frog as recited in claim 17 whereby the precise location of each respective image is obtained and associated with the respective image to allow image and its respective coordinates to be identified to a specific and exact location of the track.

19. The method of inspecting the frog as recited in claim 17 whereby the setting of the profile of the frog, the comparing of the measurements, the applying of the gauges and the generation of the occur in real-time.

20. A method of inspecting a track, the method comprising the steps of:

capturing images of portions of a rail;

converting each image into a set of coordinates that traces the transverse cross-section of a profile of each respective image of the rail;

applying a virtual electronic gauge to each respective profile to check for potentially dangerous conditions of the rail.