Video inspection system for inspection of rail components and method thereof

• US 7,755,660 B2
• Filed: 05/03/2004
• Issued: 07/13/2010
• Est. Priority Date: 05/02/2003
• Status: Active Grant

• Current Assignee: ENSCO, Incorporated (Teris LLC)
• Original Assignee: ENSCO, Incorporated (Teris LLC)
• Inventors: Carr, Gary A., Nejikovsky, Boris, Parniani, Toofan, Diaz, Christian
• Primary Examiner(s): Rao; Andy S.
• Assistant Examiner(s): Pe; Geepy
• Application Number:
  US10/836,629
• Publication Number:
  US 20040263624A1
• Time in Patent Office: 2,262 Days
• Field of Search: 348/143, 348/148, 348/159, 348/135
• US Class Current: 348/143
• 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 23/042 Track changes detection
• CPC Class Codes: B61L 23/044 Broken rails
• CPC Class Codes: B61L 23/045 Rail wear

Abstract

A video inspection system and method for facilitating inspection of a rail component while traveling on the railroad track. The system includes a light source that provides illumination to a rail of the railroad track, a triggering device for automatically providing a trigger signal, a camera adapted to provide an image of the illuminated rail component, and a computing device adapted to capture the image provided by the camera based on the trigger signal. A method for inspecting rail components is also provided, the method including the steps of illuminating a rail of the railroad track, automatically providing a trigger signal, providing a camera adapted to provide an image of the rail component, and capturing the image of the rail component that is provided by the camera based on the trigger signal.

Claims

1. A video inspection system mountable on a railcar or a vehicle adapted to travel on a railroad track, said railroad track including individual rails, said video inspection system being adapted to facilitate inspection of predetermined rail components while traveling on the railroad track, said video inspection system comprising:

a light source adapted to provide illumination to at least one rail of the railroad track to illuminate visible surfaces of the predetermined rail components on upper and/or side surfaces of the rail;

a sensor adapted to provide an output signal upon detection of the predetermined rail components indicative of the presence of the predetermined rail components;

a camera adapted to provide an image of each predetermined rail component detected by said sensor;

a trigger generator adapted to convert said output signal from said sensor to a trigger signal, wherein the trigger generator is activated upon detection of each predetermined rail component; and

a computing device adapted to capture and store said image of each predetermined rail component provided by said camera and to compare each predetermined rail component to a pattern indicative of damage or a defect in each predetermined rail component.

2. The video inspection system of claim 1, wherein said computing device further includes an interface device that captures said image provided by said camera based on said trigger signal.

3. The video inspection system of claim 1, further comprising an encoder that provides pulse signals corresponding to a speed of the vehicle or railcar.

4. The video inspection system of claim 3, wherein said computing device further includes a counter/timer device that allows capturing of constant resolution images from said camera, independent of the speed of the vehicle or railcar.

5. The video inspection system of claim 1, further comprising a positioning means for determining the position of the railcar or the vehicle, and for providing position data indicative of said determined position.

6. The video inspection system of claim 5, wherein said computing device is further adapted to correlate said captured image of each predetermined rail component with said position data to allow determination of the location at which said image was captured.

7. The video inspection system of claim 5, wherein said positioning means includes a GPS receiver.

8. The video inspection system of claim 1, wherein said sensor is a distance sensor, and said output signal from said sensor is indicative of the presence of each predetermined rail component.

9. The video inspection system of claim 8, wherein said distance sensor is a laser based sensor positioned above, and pointed towards, the rail of the railroad track.

10. The video inspection system of claim 1, wherein said sensor is a vibration sensor, and said output signal from said sensor is indicative of the presence of each predetermined rail component.

11. The video inspection system of claim 10, wherein said vibration sensor is at least one accelerometer secured to a frame member of the railcar or the vehicle.

12. The video inspection system of claim 1, wherein said camera is a line scan camera and said light source provides continuous illumination.

13. The video inspection system of claim 1, wherein said camera is an area scan camera and said light source is a strobe light that provides flash illumination.

14. The video inspection system of claim 1, wherein said computing device includes a digital image processing software for analyzing said captured images.

15. The video inspection system of claim 14, wherein said digital image processing software includes a pattern recognition software for identifying presence of a defect or damage to each predetermined rail component.

27. The video inspection system of claim 1, wherein said sensor is a camera adapted to collect images of the rail and each predetermined rail components, and the predetermined rail components are identified by pattern recognition algorithms of the images.

28. The video inspection system of claim 27, wherein said camera sensor is the same camera used in image acquisition of the rail and the predetermined rail components.

29. The video inspection system of claim 14, wherein said digital image processing software includes a pattern recognition software for identifying presence of a defect in, damage to, or anomaly of each predetermined rail component.

48. The video inspection system of claim 1, wherein the predetermined rail component includes a joint bar, a switch frog, and a switch point.

16. A video inspection system mountable on a railcar and/or a vehicle adapted to travel on a railroad track, said railroad track including individual rails, said video inspection system being adapted to facilitate inspection of predetermined rail components while traveling on the railroad track, said video inspection system comprising:

a light source adapted to provide illumination to at least one rail of the railroad track to illuminate visible surfaces of the predetermined rail components on upper and/or side surfaces of the rail;

a distance sensor that is pointed toward the rail of the railroad track, said distance sensor being adapted to provide an output signal indicating the presence of each predetermined rail component upon detection of said predetermined rail components;

a trigger generator adapted to convert said output signal from said distance sensor to a trigger signal, wherein the trigger generator is activated upon detection of each predetermined rail component;

a camera adapted to provide an image of each predetermined rail component;

a computing device adapted to capture and store said image of each predetermined rail component provided by said camera and to compare each predetermined rail component to a pattern indicative of damage or a defect in the rail component, said computing device including a memory device for storing said captured image to allow retrieval of said stored image; and

a position means for determining the position of the railcar or the vehicle, and for providing position data indicative of said determined position;

wherein said computing device is further adapted to correlate said captured image of each predetermined rail component with said position data to allow determination of the location at which said image was captured.

17. The video inspection system of claim 16, wherein said distance sensor is a laser based distance sensor.

18. The video inspection system of claim 16, further comprising a trigger generator for converting said output signal from said distance sensor to a trigger signal, and wherein said computing device includes an interface device adapted to capture said image provided by said camera based on said trigger signal.

19. The video inspection system of claim 16, wherein said computing device includes a digital image processing software with a pattern recognition software for identifying presence of a defect or damage to each predetermined rail component.

49. The video inspection system of claim 16, wherein the predetermined rail component includes a joint bar, a switch frog, and a switch point.

20. A method for inspecting predetermined rail components of a railroad track, said railroad track including individual rails, while traveling on the railroad track comprising the steps of:

illuminating at least one rail of the railroad track to illuminate visible surfaces of the predetermined rail components on upper and/or side surfaces of the rail;

providing a camera adapted to provide an image of each predetermined rail component;

detecting the presence of said predetermined rail component using a sensor;

providing an output signal indicating the presence of each predetermined rail component;

converting the output signal to a trigger signal with a trigger generator, wherein the trigger generator is activated upon detection of each predetermined rail component; and

capturing and storing said image of each predetermined rail component that is provided by said camera and comparing each predetermined rail component to a pattern indicative of damage or a defect in each predetermined rail component.

21. The method of claim 20, further including the step of determining the position at which said image was captured and correlating said captured image of each predetermined rail component with said determined position.

22. The method of claim 20, further including the step of digitally processing said captured image to identify at least one of defect and damage to each predetermined rail component.

30. The method of claim 20, further including the identification of each predetermined rail component by evaluating the signature output of a distance sensor(s), where said distance sensor(s) is a laser.

31. The method of claim 20, further including the identification of each predetermined rail component by evaluating the signature output of a vibration(s) sensor.

32. The method of claim 20, further including the identification of each predetermined rail component by applying pattern recognition software to images acquired of the rail and the predetermined rail components by said camera.

50. The method of claim 20, wherein the predetermined rail component includes a joint bar, a switch frog, and a switch point.

23. A method for inspecting predetermined rail components of a railroad track, said railroad track including individual rails, while traveling on the railroad track comprising the steps of:

illuminating at least one rail of the railroad track to illuminate visible surfaces of the predetermined rail components on upper and/or side surfaces of the rail;

detecting the presence of the predetermined rail components based on the signature of the output of a vibration sensor to provide an output signal indicative of the presence of the redetermined rail components;

providing a camera adapted to provide an image of each predetermined rail component;

converting the output signal to a trigger signal with a trigger generator, wherein the trigger generator is activated upon detection of each predetermined rail component; and

capturing and storing said image of each predetermined rail component that is provided by said camera and comparing each predetermined rail component to a pattern indicative of damage or a defect based on said trigger signal.

24. The method of claim 23, further including the step of determining the position at which said image was captured.

25. The method of claim 24, further including the step of correlating said captured image of each predetermined rail component with said determined position.

26. The method of claim 23, further including the step of digitally processing said captured image to identify at least one of defect and damage to each predetermined rail component.

51. The method of claim 23, wherein the predetermined rail component includes a joint bar, a switch frog, and a switch point.

33. A video inspection system mountable on at least one of a railcar or a vehicle adapted to travel on a railroad track, said railroad track including individual rails, said video inspection system being adapted to facilitate inspection of a predetermined rail components while traveling on the railroad track, said video inspection system comprising:

a light source adapted to provide illumination to at least one rail of the railroad track to illuminate visible surfaces of the predetermined rail components on upper and/or side surfaces of the rail;

a vibration sensor that is mounted on the railcar and/or vehicle, said vibration sensor being adapted to provide an output signal indicating the presence of each predetermined rail component upon detection of said predetermined rail component;

a trigger generator adapted to convert said output signal from said vibration sensor to a trigger signal, wherein the trigger generator is activated upon detection of each predetermined rail component;

a camera adapted to provide an image of each predetermined rail component based on the trigger signal;

a computing device adapted to capture and store said image of each predetermined rail component provided by said camera and to compare each predetermined rail component to a pattern indicative of damage or a defect in each predetermined rail component based on said trigger signal from said distance sensor, said computing device including a memory device for storing said captured image to allow retrieval of said stored image; and

a position means for determining the position of the railcar and/or the vehicle, and for providing position data indicative of said determined position;

wherein said computing device is further adapted to correlate said captured image of each predetermined rail component with said position data to allow determination of the location at which said image was captured.

34. The video inspection system of claim 33, wherein said vibration sensor is an accelerometer.

35. The video inspection system of claim 33, further comprising a trigger generator for converting said output signal from said vibration sensor to a trigger signal, and wherein said computing device includes an interface device adapted to capture said image provided by said camera based on said trigger signal.

36. The video inspection system of claim 33, wherein said computing device includes a digital image processing software with a pattern recognition software for identifying presence of a defect or damage to each predetermined rail component.

52. The video inspection system of claim 33, wherein the predetermined rail component includes a joint bar, a switch frog, and a switch point.

37. A video inspection system mountable on a railcar and/or a vehicle adapted to travel on a railroad track, said railroad track including individual rails, said video inspection system being adapted to facilitate inspection of predetermined rail components while traveling on the railroad track, said video inspection system comprising:

a light source adapted to provide illumination to at least one rail of the railroad track to illuminate visible surfaces of the predetermined rail components on upper and/or side surfaces of the rail;

a camera sensor that is pointed toward at least one rail of the railroad track, said camera sensor being adapted to provide images to a pattern recognition software for the purpose of indicating the presence of each predetermined rail component upon detection of said predetermined rail component;

a pattern recognition software which produces a trigger signal, wherein the trigger generator is activated upon detection of each predetermined rail component;

a camera adapted to provide an image of each predetermined rail component based on the trigger signal;

a computing device adapted to capture and store said image of each predetermined rail component provided by said camera and to compare each predetermined rail component to a pattern indicative of damage or a defect in each predetermined rail component, said computing device including a memory device for storing said captured image to allow retrieval of said stored image; and

a position means for determining the position of the railcar and/or the vehicle, and for providing position data indicative of said determined position;

wherein said computing device is further adapted to correlate said captured image of each predetermined rail component with said position data to allow determination of the location at which said image was captured.

38. The video inspection system of claim 37, wherein said camera sensor provides images to a pattern recognition software which determines the presence of each predetermined rail component.

39. The video inspection system of claim 37, wherein said computing device includes a digital image processing software with a pattern recognition software for identifying presence of a defect or damage to each predetermined rail component.

53. The video inspection system of claim 37, wherein the predetermined rail component includes a joint bar, a switch frog, and a switch point.

40. A method for inspecting predetermined rail components of a railroad track, said railroad track including individual rails, while traveling on the railroad track comprising the steps of:

illuminating at least one rail of the railroad track to illuminate visible surfaces of the predetermined rail components on upper and/or side surfaces of the rail;

detecting the presence of the predetermined rail components based on the signature of the output of a distance sensor to provide an output signal, where said distance sensor is a laser sensor;

providing a camera adapted to provide an image of each predetermined rail component;

converting the output signal to a trigger signal with a trigger generator, wherein the trigger generator is activated upon detection of each predetermined rail component; and

capturing and storing said image of each predetermined rail component that is provided by said camera and comparing each predetermined rail component to a pattern indicative of damage or a defect based on said trigger signal.

41. The method of claim 40, further including the step of determining the position at which said image was captured relative to a railroad track location.

42. The method of claim 41, further including the step of correlating said captured image of each predetermined rail component with said determined position.

43. The method of claim 40, further including the step of digitally processing said captured image to identify at least one of defect and damage to each predetermined rail component.

54. The method claim 40, wherein the predetermined rail component includes a joint bar, a switch frog, and a switch point.

44. A method for inspecting predetermined rail components of a railroad track, said railroad track including individual rails, while traveling on the railroad track comprising the steps of:

illuminating at least one rail of the railroad track to illuminate visible surfaces of the predetermined rail components on upper and/or side surfaces of the rail;

detecting the presence of the predetermined rail components using pattern recognition software applied to images acquired of the rail from a camera sensor;

providing a camera adapted to provide an image of each predetermined rail component;

capturing and storing said image of each predetermined rail component that is provided by said camera and comparing each predetermined rail component to a pattern indicative of damage or a defect based on said trigger signal.

45. The method of claim 44, further including the step of determining the position at which said image was captured relative to a railroad track location.

46. The method of claim 45, further including the step of correlating said captured image of each predetermined rail component with said determined position.

47. The method of claim 44, further including the step of digitally processing said captured image to identify at least one of defect and damage to each predetermined rail component.

55. The method claim 44, wherein the predetermined rail component includes a joint bar, a switch frog, and a switch point.