Rail measurement system

• US 7,659,972 B2
• Filed: 08/21/2008
• Issued: 02/09/2010
• Est. Priority Date: 08/22/2007
• Status: Active Grant

• Current Assignee: KLD Labs, Inc.
• Original Assignee: KLD Labs, Inc.
• Inventors: Magnus, Steven, Magnus, Daniel
• Primary Examiner(s): Toatley, Jr.; Gregory J
• Assistant Examiner(s): Stock, Jr.; Gordon J
• Application Number:
  US12/229,244
• Publication Number:
  US 20090073428A1
• Time in Patent Office: 537 Days
• Field of Search: None
• US Class Current: 356/237.1
• 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 23/047 Track or rail movements
• CPC Class Codes: B61L 23/048 Road bed changes, e.g. road bed erosion
• CPC Class Codes: G01B 11/25 by projecting a pattern, e.g. one or more lines, moiré fringes on the object G01B11/255 takes precedence ; image analysis for depth or shape recovery G06T7/50

Abstract

A system and method of continuously measuring the profile of a rail in real time is disclosed. The rail which the profile is obtained in position on a track bed, The system includes a means for transmitting a beam of light at a selected wavelength onto the rail to illuminate a portion of the rail. The light is preferably a beam of laser light. A digital image of said illuminated portion of said rail is recorded. The digital image is manipulated to filter all light except for the selected wavelength. Rail wear is determined from the digital image created by the selected wavelength of light.

Claims

1. A method of continuously measuring a profile of rails in real time where said rails are in position on a track bed comprising

transmitting a first beam of light at a selected wavelength onto a gauge side of a running rail to illuminate a portion of said running rail,

transmitting a second beam of light at a selected wavelength onto a profile of a conductor rail to illuminate a portion of said conductor rail,

recording a digital image of said illuminated portions of said rails at a first and second sensor head, each of said first and second sensor heads having an image acquisition means and wherein one acquisition means is angled to capture a profile of the gauge side of said running rail while a second image acquisition means is angled to capture the profile of said conductor rail

manipulating said digital images to filter all but said selected wavelengths, determining rail wear from said digital images created by the selected wavelengths of light.

2. The method according to claim 1 wherein said beams of light are monochromatic.

3. The method according to claim 1 wherein said lights are coherent and directional projecting.

4. The method according to claim 1 wherein said first beam of light has a different wavelength than said second beam of light.

5. The method according to claim 4 wherein a first camera records the digital image by said first beam of light and a second camera records the digital image created by the second beam of light.

6. The method according to claim 5 wherein the digital image recorded by the first camera is filtered at the same wavelength as the first beam of light and the digital image recorded by the second camera is filtered at the same wavelength as the second beam of light.

7. A method for providing a detailed rail profile analysis of rail samples in real-time comprising computing one or more rail dimensional measurements, obtained by at least two sensor heads wherein each sensor head has an image acquisition means being comprised of a source of laser light and a digital camera and wherein one image acquisition means is angled to capture a profile of a gauge side of a running rail while a second image acquisition means is angled to capture a profile of a conductor rail, comparing the measurements so obtained to a representative new rail measurement, compiling a rail wear analysis for said samples.

8. The method according to claim 7 wherein each camera and laser is fixed to one another so any positional movement over a camera field of view represents track movement.

9. The method according to claim 7 wherein rail samples are captured after a user defined period of time between acquisitions.

10. The method according to claim 7 wherein one or more of a conductor rail vertical position, conducted rail lateral position, conductor rail/running rail profile, track gauge, conductor rail temperature and conductor rail wear are measured.

11. The method according to claim 7 wherein a distance traveled is measured using an encoder wheel attached to an axle of a truck.

12. The method according to claim 7 wherein one or more of a rail profile, new rail size identification, rail height, vertical wear, rail width, lateral wear, lip flow, rail inclination (rotation), gauge of the running rail, and a gauge face angle can be calculated.

13. The method according to claim 11 wherein after a preset distance, determined by counting a number of wheel encoder pulses, the sensor heads activate the lasers and acquire a video image.

14. The method according to claim 12 wherein there are four sensor heads.

15. The method according to claim 14 wherein the sensor heads are mounted underneath a vehicle in pairs over left and right rails.

16. The method according to claim 15 wherein each pair of sensor heads has one sensor head angled to capture the profile of the conductor rail and the other sensor head angled to capture the profile of the running rail.

17. A method for providing a detailed rail profile analysis of rail samples in real time comprising computing one or more rail dimensional measurements obtained by at least two sensor heads wherein each sensor head has an image acquisition means and wherein one image acquisition means is angled to capture a profile of a gauge side of a running rail while a second image acquisition means is angled to capture a profile of a conductor rail.

18. The method according to claim 17 wherein each pair of sensor heads has one sensor head angled to capture the profile of the conductor rail and the other sensor head angled to capture the profile of the running rail.

19. The method according to claim 17 wherein rail samples are captured after a user defined period of time between acquisitions.

20. The method according to claim 17 wherein a distance traveled is measured using an encoder wheel attached to an axle of a truck.

21. The method according to claim 17 wherein one or more of the conductor rail vertical position, conductor rail lateral position, conductor rail/running rail profile, track gauge, conductor rail temperature and conductor rail wear are measured.

22. The method according to claim 20 wherein after a preset distance, determined by counting a number of wheel encoder pulses, the sensor heads activate the lasers and acquire a video image.

23. The method according to claim 21 wherein one or more of a rail profile, new rail size identification, rail height, vertical wear, rail width, lateral wear, lip flow, rail inclination (rotation), gauge of the running rail, and a gauge face angle can be calculated.

24. The method according to claim 23 wherein there are four sensor heads.

25. The method according to claim 24 wherein the sensor heads are mounted underneath a vehicle in pairs over left and right rails.

26. A system that continuously measures a profile of rails in real time where said rails are in position on a track bed comprising

a means for transmitting a first beam of light at a selected wavelength onto a gauge side of a running rail to illuminate a portion of said running rail,

a means for transmitting a second beam of light at a selected wavelength onto a profile of a conductor rail to illuminate a portion of said conductor rail,

a means for recording a digital image of said illuminated portions of said rails, at a first and second sensor head, each of said first and second sensor heads having an image acquisition means and wherein one acquisition means is angled to capture a profile of the gauge side of said running rail while a second image acquisition means is angled to capture the profile of said conductor rail

a means for manipulating said digital images to filter all but said selected wavelengths to determine rail wear from said digital images created by the selected wavelengths of light.