Apparatus and method for gathering data from sensors oriented at an oblique angle relative to a railway track

Patent metadata

Field	Value
Publication number	US-10870441-B2
Application number	US-202016742057-A
Country	US
Kind code	B2
Filing date	Jan 14, 2020
Priority date	Jun 1, 2018
Publication date	Dec 22, 2020
Grant date	Dec 22, 2020

Abstract

A system and method for inspecting a railway track using sensors oriented at an oblique angle relative to a rail vehicle on which the system is traveling. The orientation of the sensors allows for different data to be gathered regarding a particular rail including rail design specifications (gathered based on manufacturer markings detected and analyzed by the system), rail seat abrasion values based on direct measurement of rails from the oblique angle, and other analysis of rail features including joint bars, rail welds, bond wires, rail holes, and broken rails. The use of an air blower, ducts, and one or more air distribution lids over the sensors helps remove debris from blocking the sensors and structured light generators.

First claim

What is claimed is:

1. A method for analyzing the side of a rail of a railway track comprising:
i. scanning the first side of a first rail of a railway track with an optical scanning system using a first sensor that is attached adjacent to a rail vehicle and oriented at an oblique angle relative to a railway track bed surface supporting rails on which the rail vehicle is moving wherein the first sensor obtains data regarding the first side of the first rail;
ii. generating a first 3D profile of the first side of the first rail based on the data gathered by the first sensor using a system controller;
iii. analyzing the first 3D profile using a processor, such processor operating using a machine vision algorithms;
iv. scanning the second side of the first rail of the railway track with the optical scanning system using a second sensor that is attached adjacent to the rail vehicle and oriented at an oblique angle relative to the undercarriage of the rail vehicle wherein the second sensor obtains data regarding the second side of the first rail;
v. generating a second 3D profile of the second side of the first rail based on the data gathered by the second sensor using the system controller;
vi. scanning the first side of a second rail of the railway track with the optical scanning system using a third sensor that is attached adjacent to the rail vehicle and oriented at an oblique angle relative to the undercarriage of the rail vehicle wherein the third sensor obtains data regarding the first side of the second rail;
vii. generating a third 3D profile of the first side of the second rail based on the data gathered by the third sensor using the system controller;
viii. scanning the second side of the second rail of the railway track with the optical scanning system using a fourth sensor that is attached adjacent to the rail vehicle and oriented at an oblique angle relative to the undercarriage of the rail vehicle wherein the fourth sensor obtains data regarding the second side of the second rail;
ix. generating a fourth 3D profile of the second side of the second rail based on the data gathered by the fourth sensor using the system controller; and
x. analyzing the second 3D profile, the third 3D profile and the fourth 3D profile using the processor, such processor operating using a machine vision algorithm.

2. The method of claim 1 further comprising:
i. generating a 3D elevation map of the first side of the first rail by combining a plurality of 3D profiles including the first 3D profile using a processor;
ii. analyzing alpha-numeric markings on the first side of the first rail shown in the 3D elevation map using the processor operating an optical character recognition algorithm;
iii. referencing the 3D elevation map to geo-spatial coordinates using the processor by synchronizing the plurality of 3D profiles forming the 3D elevation map with the location of the rail vehicle when those 3D profiles were generated using a GNSS receiver; and
iv. storing the referenced 3D elevation map to a data storage device using a processor.

3. The method of claim 2 further comprising:
i. accessing a database stored on a computer readable using a processor wherein the first database includes manufacturing data regarding the physical characteristics of specified rails cross-referenced with alpha-numeric rail markings located on the sides of the specified rails;
ii. cross-referencing the alpha-numeric markings in the elevation map with manufacturing data in the database using the processor; and
iii. measuring a physical characteristic of the first side of the first rail using the processor to analyze the first 3D profile;
iv. comparing the physical characteristic of the first side of the first rail shown in the first 3D profile with a same type of physical characteristic of a rail found in the database matching the alpha-numeric markings that were detected by the processor; and
v. determining the condition of the first physical characteristic of the first side of the first rail being scanned based on the comparison between the first physical characteristic of the first side of the first rail being scanned and the same type of physical characteristic of the specified rails found in the database.

4. The method of claim 1 further comprising controlling the temperature of the inside of a first sensor enclosure in which the first sensor is located using a temperature controller in communication with a thermal sensor and a heating and cooling device.

5. The method of claim 1 further comprising:
i. synchronizing activation of the first sensor, the second sensor, the third sensor, and the fourth sensor using the system controller in communication with an encoder;
ii. combining the first 3D profile from the first sensor, the second 3D profile from the second sensor, the third 3D profile from the third sensor and the fourth 3D profile from the fourth sensor into a single combined 3D profile scan; and
iii. referencing the combined 3D profile scan to geo-spatial coordinates by synchronizing encoder pulses with GNSS receiver position data from a GNSS receiver.

6. The method of claim 1 further comprising:
i. generating a 3D elevation map of the first side of the first rail by combining a plurality of 3D profiles including the first 3D profile using the processor;
ii. determining whether there is an elevation variation in the 3D elevation map using the processor operating a machine vision algorithm; and
iii. if there is an elevation variation in the elevation map,
1. determining the likely cause of the elevation variation based on the size and shape of the elevation variation using the processor operating a machine vision algorithm;
2. assigning a specific type of rail component identity to that elevation variation using the processor;
3. analyzing the elevation variation under the presumption that the elevation variation coincides with the assigned specific type of rail component using the processor; and
4. saving the elevation map, the identity of the assigned rail component, and any measurements made during the analysis of the elevation variation to a data storage device using the processor.

7. The method of claim 1 further comprising:
i. calibrating the first sensor to determine the real world unit width of a pixel in a 3D profile;
ii. locating a pixel representing a rail base bottom using the processor operating a machine vision algorithm;
iii. determining whether a tie is present in the 3D profile using the processor operating a machine vision algorithm; and
iv. if a tie is present in the 3D profile:
1. locating a pixel representing the top of the tie using the processor operating a machine vision algorithm;
2. calculating the thickness of a pad under the first rail using the processor; and
3. determining the amount of rail seat abrasion on the tie under the first rail based on the calculated thickness of the pad using the processor.

8. The method of claim 1 further comprising:
i. calibrating the first sensor to determine the real world unit width of a pixel in a 3D profile;
ii. locating a pixel representing a rail base bottom using the processor operating a machine vision algorithm;
iii. determining whether a tie is present in the 3D profile using the processor operating a machine vision algorithm; and
iv. if a tie is present in the 3D profile:
1. locating a pixel representing the top of the tie using the processor operating a machine vision algorithm; and
2. calculating the plate cut under the first rail using the processor.

9. The method of claim 1 further comprising adjusting the power to a structured light generator based on the light intensity of the most recent 3D profile scan made by the first s

Assignees

• Tetra Tech

Inventors

• Mesher Darel

Classifications

• G01S19/48

  by combining or switching between position solutions derived from the satellite radio beacon positioning system and position solutions derived from a further system · CPC title

• B61L23/047

  Track or rail movements · CPC title

• G01B11/25

  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}) · CPC title

• B61L23/00

  Control, warning or like safety means along the route or between vehicles or trains · CPC title

• B61L23/045 Primary

  Rail wear · CPC title