In order to detect the abrasion of rails, a new point cloud alignment method combining 4-points congruent sets (4PCS) coarse alignment based on internal shape signature (ISS) and K-dimensional iterative closest points (KD-ICP) fine alignment is proposed, and for the first time, the combined algorithm is applied to the detection of rail wear. Due to the large amount of 3D rail point cloud data collected by the 3D line laser sensor, the original data are first downsampled by voxel filtering. Then, ISS feature points are extracted from the processed point cloud data for 4PCS coarse alignment, and the feature points are quantitatively analyzed, which in turn provides good alignment conditions for fine alignment. Then, the K-dimensional tree structure is used for the near-neighbor search to improve the alignment efficiency of the ICP algorithm. Finally, the total rail wear is calculated by combining the fine alignment results with the wear calculation formula. The experimental results show that when the number of ISS feature points extracted is 4496, the 4PCS coarse alignment algorithm based on ISS feature points is higher than the original 4PCS algorithm as well as the other algorithms in terms of alignment accuracy; the ICP fine alignment algorithm based on the kd-tree is less than the original ICP algorithm as well as the other algorithms in terms of the time consumed. Further, the proposed new ISS-4PCS + KD-ICP two-stage point cloud alignment method is superior to the original 4PCS + ICP algorithm both in terms of alignment accuracy and runtime. The combined algorithm is applied to the detection of rail wear for the first time, which provides a reference for the non-contact rail wear detection method. The high accuracy and low time consumption of the proposed algorithm lays a good foundation for the calculation of rail wear in the next step.

The dual-arm cooperative operation mode can effectively address the problems of insufficient load capacity and limited motion flexibility of traditional single-arm robots during the installation of construction boards. However, the selection of the end-effector grasping position of dual-arm robots will significantly affect their motion performance during handling operations. To address this issue, this study proposes an end-effector grasping strategy for sheet installation in the dual-arm cooperative operation mode of a dual-arm robot, which determines the optimal grasping position to ensure the robot’s good operational performance. We developed a dual-arm robot prototype for board installation and established a kinematic model of the robot’s manipulators. Based on the dexterity index’s service sphere, we obtained the dexterity envelope surfaces of the robot end-effector at different grasping distances and analyzed the relationship between grasping distance and dexterity. The mechanical model of the robot was established, and simulations were performed for each joint. The effects of different grasping points on the torque, stiffness, and stability at the robot’s key points were investigated, and the end-effector grasping range of the robot with optimal mechanical performance was analyzed. Finally, the proposed robot grasping strategy was verified on the robot prototype. The results demonstrate that the strategy is feasible and effective, helping to improve the robot’s operational performance.