CN102230915B - Device and method for flaw detection of small crawler-type rails based on three-way ultrasonic diffraction - Google Patents
Device and method for flaw detection of small crawler-type rails based on three-way ultrasonic diffraction Download PDFInfo
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Abstract
The invention provides a device and a method for flaw detection of small crawler-type rails based on three-way ultrasonic diffraction. The device provided by the invention comprises a three-way crawler-type travel system, an ultrasonic detection master control system and a plurality of three-way ultrasonic diffraction detection sub-systems, wherein, all the three-way ultrasonic diffraction detection sub-systems and the ultrasonic detection master control system are configured on the three-way crawler-type travel system, and the three-way detector of each three-way ultrasonic diffraction detection sub-system is embedded in the crawler of the three-way crawler-type travel system. The method provided by the invention comprises the following steps: by means of the operations of all the three-way ultrasonic diffraction detection sub-systems and the ultrasonic detection master control system, carrying out crawler-type flaw detection, thus largely increasing the data sampling time in an areaof the rail at the same detection speed; and simultaneously based on the three-way structure, carrying out flaw estimation by means of the propagation sound path of diffracted waves so as to be not sensitive to the energy and amplitude of received echo pulses, thereby still ensuring accurate work in the detection condition with large energy attenuation.
Description
Technical field
The invention belongs to the rail technical field of nondestructive testing, be specifically related to a kind of steel rail flaw detection device and method of utilizing ultrasonic diffraction and three-dimensional crawler type to roll into.
Background technology
Along with the high speed development of railway traffic transportation, rail transportation circuit is more and more busier, and vehicle density also increases thereupon.And the rail on transportation route is in the process of bearing heavy transport task, because train causes friction, extruding, bending and percussive action to rail, rail inevitably can produce various damages, for observable outer damage such as corrosion, crushing of rail head, peel off fast, side grinding etc. and can in time process; The residual core wound that causes with white point of being mingled with that exists for rail inside is by naked eyes None-identified, and these internal injuries retain in the serious traffic safety hidden danger such as the transversal crack that will cause rail in the rail of day and night operation, rail head fracture for a long time.These invisible internal injuries only have by rail flaw detector and could find, then according to result of detection, rail are carried out respective handling in time.
Technical, it is that the rail Non-Destructive Testing has brought faster, more accurate, more humane application that the acoustic characteristic that ultrasound wave is good and recent two decades come the tremendous development of computing machine and Digital Electronic Technique.And traditional pulse echo method has been widely used in the rail examination field as the main flow of Ultrasonic NDT.It utilizes ultrasonic probe to being examined workpiece emission ultrasonic pulse, and according to the energy size that is reflected by workpiece, defect and phase information as the foundation of judging defective.In the rail examination field, thereby it is relatively ripe technically due to prolonged application for pulse echo method.Yet, it relies on the energy size of reflection wave on principle, belong to the detection method to energy-sensitive, in actual applications, echo amplitude sensitivity characteristic due to pulse echo method, often performance is not good in quantitative context of detection to make it, and this is also one of the reason that can not more effectively control of the missed detection risk that utilizes classic method to carry out rail examination.On the other hand, in rail examination, the harmfulness of the crack defect vertical with Rail Surface is often very large, and for this orientation defective vertical with detection faces, conventional pulse echo detection method is usually because be difficult to accomplish that incident acoustic wave is vertical with the reflecting surface of defective, cause the difficulty of defect detection, if when needing the quantitative informations such as position, length of this class defective, conventional supersonic testing method is usually helpless.
The technology of utilizing the ultrasonic diffraction principle to carry out Non-Destructive Testing has overcome many deficiencies of conventional pulse echo method, has wide application space, and has brought new opportunity for modern rail examination technology.Its physical basis is the Huygens' principle that was proposed in 1690 by Dutch physicist Huygens.This principle is pointed out, the each point that the fluctuation in medium is passed to can be regarded the new wave source of launching sound wave as, wave front later on constantly, and the enveloping surface of the wavelet wavefront that can be sent by these new wave sources is made.Ultrasound wave is the emission ultrasound wave from probe to examined object, when ultrasound wave runs into such as linear discontinuities such as crackles, can produce diffraction at the most advanced and sophisticated position of defective, according to Huygens' principle, the edge of each defective can be regarded hyperacoustic signal source as, and outwards launches the ultrasonic diffraction ripple.Utilizing the ultrasonic diffraction principle to detect a flaw is exactly to record these diffracted wave signals, as the foundation of judging damage.At the beginning of 21 century, the ultrasonic diffraction time difference method that is proposed by Britain country Non-Destructive Testing center imports China into, and the method progressively is applied at China's field of non destructive testing.Yet it has but brought some other defectives when making up traditional pulse echo method deficiency.For example, poor to the transverse defect detectability, in the defect map of ultrasonic diffraction time difference method, easily transverse defect is mistaken for point defect; Because straight-through ripple and near surface flaw diffracted wave are easily obscured inferior positions such as causing such defect detection poor effect.
On the other hand, the China railways net improves and significantly raises speed rail examination speed and efficient are had higher requirement.Its speed per hour of China in 2009 builds up mileage is the longest in the world, overall trip speed is the highest military wide high ferro passenger traffic the Shinkansen has reached 350 kilometers.Yet the speed per hour of existing large-scale rail-defect detector car but still rests on tens kilometers, and small-sized hand propelled inspection car speed per hour only only has several kilometers, and this can not satisfy the needs of day by day busy, efficient railway transportation and maintenance far away.Unlikely echo is lost to guarantee ultrasonic probe that the enough data sampling time is arranged to be to control the inspection car road speed for the main cause that limits current motor-driven inspection car speed per hour.Yet current motor-driven inspection car is when high-speed cruising, because its probe and the duration of contact of rail a certain fixed position are too short and generally can not satisfy the needs of flaw detection at a high speed.
in disclosed Chinese invention patent application CN1225453A on August 11st, 1999, proposed a kind ofly change the conventional liquid couplant and adopt solid-state couplant to carry out the method for rail examination, the method utilizes ultrasonic beam directly to be coupled in rail by solid-state slide plate, reduced the hysteresis that occurs when using coupling liquid, it can reduce to a certain extent echo and lose, yet still there are some shortcomings and deficiencies in the method: at first, the time of adopting solid-state couplant not sample from increasing in fact probe data, actual inspection speed can not increase substantially, and solid-state couplant affects detection capability and changes complicated after wearing and tearing, the second, adopt traditional pulse echo method to carry out defects detection, be difficult to detect running into the orientation defective vertical with detection faces, and can not accurately quantitatively detect the size of defective.
Summary of the invention
For exist in ultrasonic rail examination technical field at present some such as inspection speed be difficult to improve, inefficiency, the defect detection rate vertical with detection faces is low and quantitatively detect the deficiencies such as performance is not good, the present invention proposes a kind of crawler type steel rail flaw detection device and method based on three-way ultrasonic diffraction.The present invention adopts crawler type to roll into to replace traditional wheel to drive the inspection car walking, thereby the data sampling time to rail a certain zone is increased greatly.On the other hand, the track structure of this failure detector driving system is three-dimensional, and utilizes the structure of described device to realize a kind of more accurate method of detection.
For reaching the desired purpose of the present invention, will adopt following technical scheme:
Should based on the crawler type steel rail flaw detection device of three-way ultrasonic diffraction, comprise three-dimensional crawler type driving system, several three-way ultrasonic diffraction detection subsystem and Ultrasonic Detection master control system.Wherein, all three-way ultrasonic diffraction detection subsystem and Ultrasonic Detection master control system are installed on three-dimensional crawler type driving system, drive described crawler type steel rail flaw detection device based on three-way ultrasonic diffraction by three-dimensional crawler type driving system and advance; The three-dimensional of embedded each three-way ultrasonic diffraction detection subsystem probe on the crawler belt of described three-dimensional crawler type driving system; All three-way ultrasonic diffraction detection subsystem all with Ultrasonic Detection master control system parallel join; And the Ultrasonic Detection master control system manages each three-way ultrasonic diffraction detection subsystem of concurrent working.
Three-dimensional crawler type driving system of the present invention comprises 3 groups of crawler belts, and the crawler belt that wherein is positioned at rail top is main crawler belt, and the crawler belt of the left and right sides is auxiliary crawler belt, is responsible for driving flaw detection trolley by main crawler belt and advances.3 groups of crawler belts are along equal embedded some ultrasonic probes on the direction of rail trend, be close to respectively during detection rail directly over and the left and right sides.Along the length of rail trend, the crawler belt of embedded ultrasonic probe is divided into some detections subareas (being assumed to be N) according to crawler belt, wherein in each subarea, each side crawler belt carries 1 ultrasonic probe, because have 3 groups of crawler belts, so 3 ultrasonic probes are carried in each subarea of dividing altogether on three directions.On a certain section perpendicular to the rail trend, these 3 ultrasonic probes that carry in the subarea are namely 1 group of three-dimensional probes of three-way ultrasonic diffraction detection subsystem; With the different frequency concurrent working, and each detects the subarea and is responsible for detection by a corresponding three-way ultrasonic diffraction detection subsystem all three-dimensional probes of being close to rail when detecting.Due to this track structure, when failure detector was advanced, the time that every group of three-dimensional probe rests on a certain fixed test zone of rail increased greatly than classic method, thereby has the longer data sampling time.
Described three-way ultrasonic diffraction detection subsystem comprises control module, pressure transducer, couplant preparation device, ultrasound wave emission and receives switching channel, one group of three-dimensional probe, waveform acquisition module, DSP module, data memory module and breakdown diagnosis module.Wherein control module is connected respectively with pressure transducer, couplant preparation device, ultrasound wave emission and reception switching channel and one group of three-dimensional probe; Three-dimensional probe is except with control module is connected, still launches with reception switching channel and waveform acquisition module with ultrasound wave to be connected; The waveform acquisition module is connected with the DSP module; Data memory module and breakdown diagnosis module are connected to each other, and all are connected with the DSP module.Wherein, control module is responsible for receiving the response signal of pressure transducer and is sent order to control their work to the couplant preparation device that is attached thereto, ultrasound wave emission with reception switching channel and one group of three-dimensional probe; Pressure transducer is installed on the three-way ultrasonic diffraction detection subsystem and is responsible for detecting on the crawler belt in subarea, and its is responsible for continuing the crawler belt pressure in this detection of monitoring subarea and whether breaks through a certain default threshold value; The couplant preparation device is responsible for the preparation of couplant before detecting beginning; Ultrasound wave emission and emission and the reception of reception switching channel for this each sub-Probe Ultrasonic Searching of group three-dimensional probe of switching; One group of three-dimensional probe is responsible for emission and reception ultrasonic signal when detecting; The waveform acquisition module is responsible for the waveform signal that acquisition testing arrives; The signal that the DSP module is responsible for gathering carries out denoising and hiding signal extraction is processed; The breakdown diagnosis module is responsible for the signal analysis after the DSP resume module is obtained the rail failure information of being examined; Data memory module is used for signal and the breakdown diagnosis result after buffer memory DSP resume module.
Described Ultrasonic Detection master control system comprises computing machine main control module, mileage Displaying Meter, alarm module and display module.Mileage Displaying Meter, alarm module and display module are connected with the computing machine main control module successively, and all three-way ultrasonic diffraction detection subsystem and computing machine main control module parallel join.The data of each three-way ultrasonic diffraction detection subsystem collection will be incorporated the computing machine main control module into and gather and in time handle it.The computing machine main control module is responsible for monitoring the duty of all three-way ultrasonic diffraction detection subsystem, if certain subsystem is in state of activation and has completed current breakdown diagnosis and the work of data file, all the data archive information with it send it back the computing machine main control module, and control this subsystem and enter dormant state; The mileage Displaying Meter is responsible for showing the total kilometrage number of this device flaw detection and is worked as time mileage number of flaw detection; Alarm module is responsible for to point out current certain rail to be examined the zone, damage being arranged according to the order that the computing machine main control module the is sent alarm of ringing; Display module is responsible for showing current result of detection.
In the method for detection of this crawler type steel rail flaw detection device, the work of three-way ultrasonic diffraction detection subsystem comprises following concrete steps:
Step 6, the probe B that draws from step 5 receive that the diffracted wave sound path of waveform is
, the probe C receive that the diffracted wave sound path of waveform is for the 1st time
And probe C receives that the diffracted wave sound path of waveform is for the 2nd time
, known velocity of wave is again
, the defect point of establishing the generation diffraction is respectively apart from the position of probe A, B, C
,
,
, following system of equations is arranged:
Section in the vertical rail trend of being examined the zone of this three-way ultrasonic diffraction detection subsystem sets up plane right-angle coordinate, solves according to above-mentioned
,
,
The fixed position of value and probe A, B, C, can determine the particular location of this defective in the coordinate system of setting up, simultaneously according to each probe receive the phase information of waveform can judge fault location that diffraction occurs such as bubble, be mingled with, the specific nature of crackle upper prong, crackle lower prong etc.If examined the fault location that there are a plurality of generation diffraction in the zone, can draw the repeatedly diffracted wave data that each probe receives in step 5, list a plurality of system of equations according to many groups sound path data with said method, can try to achieve each defective locations that diffraction occurs, if defective is crack defect, can also calculate according to the particular location of crackle upper prong and crackle lower prong the length information of crackle.
The work of the Ultrasonic Detection master control system of described crawler type steel rail flaw detection device comprises following concrete steps:
Whether step 2, computing machine main control module monitor certain sub-systems is in state of activation and has completed breakdown diagnosis and data storage work, is to jump to next step, continues monitoring otherwise jump to step 1; Of particular note, no matter whether monitor the subsystem that satisfies above-mentioned condition, the computing machine main control module all continues uninterruptedly to carry out to the monitoring of each three-way ultrasonic diffraction detection subsystem.
By the above-mentioned technical scheme of setting forth as can be known, the present invention has creatively adopted and has been close to the wheel driving inspection car walking that rail is left and right, the replacement of the three-dimensional crawler type driving system of upper three sides is traditional; Simultaneously, based on this three-dimensional structure, a kind of method of detection that utilizes ultrasonic diffraction has been proposed; On the other hand, whole crawler-type steel rail failure detector is divided into a plurality of subsystem parallel detections, and all subsystems are by the master control system unified management.Compare with technology with existing steel rail flaw detection device, it has following concrete advantage:
1, due to the characteristics of track structure, relative position between its can be when driving one section rail zone that keeps crawler belt certain and the inspection of this place in relatively long-time remains unchanged, and pops one's head in too short to rail certain sampling time when inspection car is walked at a high speed and defective that cause echo to be lost so overcome.Thereby under the prerequisite in identical sampling time of needs, compare with classic method, this device can be with road speed operation more at a high speed.
2, the track structure of this device is three-dimensional.Compare with traditional pulse echo method based on the method for detection that utilizes ultrasonic diffraction that this three-dimensional structure proposes, it is to utilize diffraction wave propagation sound path to carry out defect estimation, thereby its docking regains energy, amplitude big or small insensitive of wave impulse, still can accurately work in the larger testing environment of energy attenuation.
3, traditional pulse echo detection method is when detecting the defective vertical with Rail Surface, because be difficult to usually accomplish that incident wave is vertical with the defect reflection face and cause undetected; And three-way ultrasonic diffraction detection method proposed by the invention utilizes the principle of ultrasonic diffraction and do not require for whether incident wave and defect reflection face be vertical, thereby for this defective, these apparatus and method can be brought into play larger advantage and accurately detect; Simultaneously, still has the advantage that traditional pulse echo method has when detecting transverse defect.
4, the three-way ultrasonic diffraction detection method of the present invention's proposition, due to it based on the multiple directions image data, therefore have equally accurate testing result for transverse defect and near surface flaw, and that these advantages are based on the ultrasonic diffraction time difference method of single direction is not available.
5, one of every sub-systems group of probe is comprised of the probe that is positioned at 3 of rail, and it can be launched by ultrasound wave more neatly and the reception switching channel carries out hyperacoustic emission and reception on different directions, gathers multi-group data; And estimate the position of steel rail defect according to the multi-group data that gathers, especially for the helpless crack defect vertical with Rail Surface of traditional pulse echo method, it and can calculate the length information of this orientation crackle except detecting this defective.
6, whole crawler type steel rail flaw detection device is being divided into a plurality of subsystems along subregion on the direction of rail trend, the concurrent working when detecting of all subsystems, and by the main system managed together.This parallel schema has further improved flaw detection efficient.
7, building database is to all flaw detection data unified management and storage in the Ultrasonic Detection master control system in the present invention, and convenience is zone, unremitting efficient flaw detection greatly.Utilize the method to utilize the data in database to complete various subsequent treatment and report analysis after all scheduled plan zone flaw detections are completed, also can ring according to instant alarm device and do instant processing.In efficient flaw detection, have dirigibility concurrently.
Description of drawings
Fig. 1 is three-dimensional crawler type driving system structural representation in the present invention;
Fig. 2 is the structured flowchart that the present invention realizes the three-way ultrasonic diffraction detection subsystem;
Fig. 3 is the structured flowchart that the present invention realizes the Ultrasonic Detection master control system
Fig. 4 is the detection method process flow diagram of three-way ultrasonic diffraction detection subsystem in the present invention;
Fig. 5 is the detection method process flow diagram of Ultrasonic Detection master control system in the present invention;
Fig. 6 is the ultrasonic wave diffraction schematic diagram;
Fig. 7 is that the present invention realizes the schematic diagram that three-way ultrasonic diffraction detects;
The schematic diagram of three-dimensional Ultrasonic Detection when wherein Fig. 7 a is the rail not damaged;
Fig. 7 b is the rail schematic diagram that three-way ultrasonic diffraction detects when crack defect is arranged;
The waveform legend that when Fig. 7 c1 is based on defective shown in Fig. 7 b, probe B receives;
The waveform legend that when Fig. 7 c2 is based on defective shown in Fig. 7 b, probe C receives for the first time;
Fig. 7 c3 is based on the waveform legend that the probe C of defective shown in Fig. 7 b receives for the second time.
Embodiment
Below in conjunction with embodiment and accompanying drawing, the present invention is done further detailed elaboration, but embodiments of the present invention are not limited to this.
Embodiment
As shown in Figure 1, three-dimensional crawler type driving system of the present invention is made of 3 groups of crawler belts, and the crawler belt that wherein is positioned at rail 3 tops is main crawler belt 1, and the crawler belt of the left and right sides is auxiliary crawler belt 2, is responsible for driving flaw detection trolley by main crawler belt 1 and advances.3 groups of crawler belts are along equal embedded some ultrasonic probes on the direction of rail trend, be close to respectively during detection rail 3 directly over and the left and right sides.Along the length of rail trend, the crawler belt of embedded ultrasonic probe is divided into some detections subareas (being assumed to be N) according to crawler belt, wherein in each subarea, each side crawler belt carries 1 ultrasonic probe, because have 3 groups of crawler belts, so 3 ultrasonic probes are carried in each subarea of dividing altogether on three directions.On a certain section perpendicular to the rail trend, these 3 ultrasonic probes that carry in the subarea are namely 1 group of three-dimensional probes of three-way ultrasonic diffraction detection subsystem; With the different frequency concurrent working, and each detects the subarea and is responsible for detection by a corresponding three-way ultrasonic diffraction detection subsystem all three-dimensional probes of being close to rail 3 when detecting.Due to this track structure, when failure detector was advanced, the time that every group of three-dimensional probe rests on a certain fixed test zone of rail increased greatly than classic method, thereby has the longer data sampling time.
As shown in Figure 2, described three-way ultrasonic diffraction detection subsystem comprises control module, pressure transducer, couplant preparation device, ultrasound wave emission and receives switching channel, one group of three-dimensional probe, waveform acquisition module, DSP module, data memory module and breakdown diagnosis module.Wherein control module is connected respectively with pressure transducer, couplant preparation device, ultrasound wave emission and reception switching channel and one group of three-dimensional probe; Three-dimensional probe is except with control module is connected, still launches with reception switching channel and waveform acquisition module with ultrasound wave to be connected; The waveform acquisition module is connected with the DSP module; Data memory module and breakdown diagnosis module are connected to each other, and all are connected with the DSP module.Wherein, control module is responsible for receiving the response signal of pressure transducer and is sent order to control their work to the couplant preparation device that is attached thereto, ultrasound wave emission with reception switching channel and one group of three-dimensional probe; Pressure transducer is installed on the three-way ultrasonic diffraction detection subsystem and is responsible for detecting on the crawler belt in subarea, and its is responsible for continuing the crawler belt pressure in this detection of monitoring subarea and whether breaks through a certain default threshold value; The couplant preparation device is responsible for the preparation of couplant before detecting beginning; Ultrasound wave emission and emission and the reception of reception switching channel for this each sub-Probe Ultrasonic Searching of group three-dimensional probe of switching; One group of three-dimensional probe is responsible for emission and reception ultrasonic signal when detecting; The waveform acquisition module is responsible for the waveform signal that acquisition testing arrives; The signal that the DSP module is responsible for gathering carries out denoising and hiding signal extraction is processed; The breakdown diagnosis module is responsible for the signal analysis after the DSP resume module is obtained the rail failure information of being examined; Data memory module is used for signal and the breakdown diagnosis result after buffer memory DSP resume module.This failure detector is in traveling process, certain crawler belt zone, place of detecting the subarea will at a time begin to be close to rail, the pressure that this moment, pressure transducer detected will reach a certain threshold value that sets in advance, it will trigger the three-way ultrasonic diffraction detection subsystem of being responsible for this detection subarea and enter state of activation, control module produces control signal, start the couplant preparation device, and control the work of three-dimensional probe; Send into the DSP module through the Wave data of waveform acquisition module collection and carry out denoising and hiding signal extraction; Signal after processing is used for carrying out the rail failure analysis on the one hand, its storage is prepared against called from now on the other hand; And last breakdown diagnosis result is also sent into data memory module.Complete after time all working of detection, the flaw detection information in data memory module will be sent into the Ultrasonic Detection master control system and carry out subsequent treatment under the computing machine master control module controls of Ultrasonic Detection master control system.
As shown in Figure 3, described Ultrasonic Detection master control system comprises computing machine main control module, mileage Displaying Meter, alarm module and display module.Mileage Displaying Meter, alarm module and display module are connected with the computing machine main control module successively, and all three-way ultrasonic diffraction detection subsystem and computing machine main control module parallel join.The data of each three-way ultrasonic diffraction detection subsystem collection will be incorporated the computing machine main control module into and gather and in time handle it.The computing machine main control module is responsible for monitoring the duty of all three-way ultrasonic diffraction detection subsystem, if certain subsystem is in state of activation and has completed current breakdown diagnosis and the work of data file, all the data archive information with it send it back the computing machine main control module, and control this subsystem and enter dormant state; The mileage Displaying Meter is responsible for showing the total kilometrage number of this device flaw detection and is worked as time mileage number of flaw detection; Alarm module is responsible for to point out current certain rail to be examined the zone, damage being arranged according to the order that the computing machine main control module the is sent alarm of ringing; Display module is responsible for showing current result of detection.
As shown in Figure 4, in the present invention, the workflow of three-way ultrasonic diffraction detection subsystem comprises the following steps:
Step 6, the probe B that draws from step 5 receive that the diffracted wave sound path of waveform is
, the probe C receive that the diffracted wave sound path of waveform is for the 1st time
And probe C receives that the diffracted wave sound path of waveform is for the 2nd time
, known velocity of wave is again
, the defect point of establishing the generation diffraction is respectively apart from the position of probe A, B, C
,
,
, following system of equations is arranged:
Section in the vertical rail trend of being examined the zone of this three-way ultrasonic diffraction detection subsystem sets up plane right-angle coordinate, solves according to above-mentioned
,
,
The fixed position of value and probe A, B, C, can determine the particular location of this defective in the coordinate system of setting up, simultaneously according to each probe receive the phase information of waveform can judge fault location that diffraction occurs such as bubble, be mingled with, the specific nature of crackle upper prong, crackle lower prong etc.If examined the fault location that there are a plurality of generation diffraction in the zone, can draw the repeatedly diffracted wave data that each probe receives in step 5, list a plurality of system of equations according to many groups sound path data with said method, can try to achieve each defective locations that diffraction occurs, if defective is crack defect, can also calculate according to the particular location of crackle upper prong and crackle lower prong the length information of crackle.
As shown in Figure 5, in the present invention, the workflow of Ultrasonic Detection master control system comprises the following steps:
Whether step 2, computing machine main control module monitor certain sub-systems is in state of activation and has completed breakdown diagnosis and data storage work, is to jump to next step, continues monitoring otherwise jump to step 1; Of particular note, no matter whether monitor the subsystem that satisfies above-mentioned condition, the computing machine main control module all continues uninterruptedly to carry out to the monitoring of each three-way ultrasonic diffraction detection subsystem.
As shown in Figure 6, wherein dash area is the crack-like defect of being examined the zone, and ultrasound wave is emitted to by probe and is subjected to inspection regional, as runs into suchlike linear discontinuities, and incident wave will be at the most advanced and sophisticated diffraction phenomena that produces of defective.According to Huygens' principle, the edge of each defective can be regarded hyperacoustic another signal source as, outwards launches diffracted wave.In the figure, after incident wave 1 entered and examined the zone, because the defect area shown in dash area and the undamaged inspection district's acoustic impedance that is subjected to differ greatly, so incident wave 1 will launch on their acoustic interface, formation reflection wave 2; Simultaneously, some energy will pass defect area and form transmitted wave 3; Due to the diffraction phenomena at the defective tip, at the upper prong formation diffracted wave 4 of defective, and form diffracted wave 5 at the lower prong of defective.Utilize the method for ultrasonic diffraction to detect a flaw, the diffracted wave information that main dependence receives is also recorded them, as the foundation of defects detection.
When as shown in Figure 7, wherein Fig. 7 a and Fig. 7 b are respectively the rail not damaged and the schematic diagram that detects of the three-way ultrasonic diffraction of rail when crack defect is arranged.As shown in Fig. 7 a, Fig. 7 b, ultrasonic probe A is positioned at perpendicular to directly over the cross-section of the rail that moves towards direction along rail, and ultrasonic probe B, C lay respectively at the both sides of this cross-section of the rail; Set up as shown in the figure plane right-angle coordinate, wherein probe A is positioned at the mid point of its place line segment, and line segment length is
, probe B apart from the length of the initial point of foundation coordinate system is
As shown in Figure 7a, in the undamaged situation of rail, at first by probe A emission ultrasound wave, probe B, the received direction that only has of C are respectively
With
Direct wave; Afterwards, probe B emission ultrasound wave, the direction of still only having that probe C receives is
Direct wave.Owing to can't detect any diffracted wave except direct wave, so can judge that this is examined regional zero defect.As shown in Figure 7b, wherein dash area is crack defect, and of particular note, this figure is clear in order to explain, and omission marks
With
The direct wave of direction.At first, by probe A emission ultrasound wave, probe B, C receive ultrasound wave, and this incident wave will be at upper prong U and lower prong L place's generation diffraction phenomena of defective, and the upper prong U of defective and lower prong L can regard the sound source of an emission diffracted wave as.Thereby in this process, probe B is except receiving
Outside the direction direct wave, also priority is received diffracted wave
With
In like manner, probe C is also like this.As shown in Fig. 7 c1, what at first probe B received is
The direction direct wave,
Constantly receive the upper prong diffracted wave
,
Constantly receive the lower prong diffracted wave
Wherein, direct wave is opposite with the phase place of upper prong diffracted wave, and the upper prong diffracted wave is also opposite with the phase place of lower prong diffracted wave, therefore, is easy to they are distinguished on phase place.As shown in Fig. 7 c2, what at first probe C received is
The direction direct wave,
Constantly receive the upper prong diffracted wave
,
Constantly receive the lower prong diffracted wave
Subsequently, we switch probe B emission ultrasound wave, and probe C receives ultrasound wave, and the probe A break-off.As shown in Fig. 7 c3, this moment is because through path between probe B, C has been blocked in the existence of defective, transmitted wave will arrive at probe C but the ultrasound wave of some energy will penetrate defective formation, but because the transmitted wave energy is relatively too small, and it can be ignored, here, more clear for making diagram, also omit and indicate this transmitted wave.Therefore, probe C exists
Constantly receive the upper prong diffracted wave
,
Constantly receive the lower prong diffracted wave
Thus, suppose ultrasonic in being examined rail velocity of wave be
, establish defective upper prong U and be respectively apart from the distance of probe A, B, C
,
,
Defective lower prong L is respectively apart from the distance of probe A, B, C
,
,
First find the solution the upper prong position, formula 1 arranged,
Separate it, try to achieve formula 2,
In the plane right-angle coordinate of setting up before, the coordinate of establishing the defective upper prong is
, the coordinate of defective lower prong is
, can release formula 3,
In formula 2 substitution formula 3, solving equations can be tried to achieve the position coordinates of defective upper prong
In like manner, for the defective lower prong, formula 4 is arranged still,
In the coordinate system of setting up, can get formula 5,
In formula 4 substitution formula 5, solving equations can be tried to achieve the position coordinates of defective lower prong
Thus, obtain being examined in the zone position coordinates of lower prong on defective, simultaneously by the diffracted wave phase information that receives as the foundation of judging defect property.For most of crack defect, the method is easy to draw the quantitative information of defective.
The present invention utilizes the three-dimensional track structure and carries out rail examination based on the three-way ultrasonic diffraction detection method that this structure proposes, overcome traditional steel rail flaw detection device and the defectives such as method efficient is low, speed is slow, loss is high, quantitatively detect poor performance, energy amplitude sensitivity, had larger advantage in modern rail examination is used.If need to estimate more accurately defective locations in three-dimensional system of coordinate, can be by increase many group three-dimensional probes in each three-way ultrasonic diffraction detection subsystem, in order to the Z axis data sampling, set up simultaneously three-dimensional system of coordinate with accurate estimation defective locations in detection.
Above-described embodiment is the better embodiment of the present invention; but embodiments of the present invention are not restricted to the described embodiments; other any do not deviate from change, the modification done under Spirit Essence of the present invention and principle, substitutes, combination, simplify; all should be the substitute mode of equivalence, within being included in protection scope of the present invention.
Claims (6)
1. crawler type steel rail flaw detection device based on three-way ultrasonic diffraction, it is characterized in that comprising three-dimensional crawler type driving system, Ultrasonic Detection master control system and several three-way ultrasonic diffraction detection subsystem, wherein, all three-way ultrasonic diffraction detection subsystem and Ultrasonic Detection master control system are installed on three-dimensional crawler type driving system, drive described crawler type steel rail flaw detection device based on three-way ultrasonic diffraction by three-dimensional crawler type driving system and advance; The three-dimensional of embedded each three-way ultrasonic diffraction detection subsystem probe on the crawler belt of described three-dimensional crawler type driving system; All three-way ultrasonic diffraction detection subsystem all with Ultrasonic Detection master control system parallel join; And the Ultrasonic Detection master control system is controlled each three-way ultrasonic diffraction detection subsystem of concurrent working; Described three-dimensional crawler type driving system comprises three groups of crawler belts, and the crawler belt that wherein is positioned at rail top is main crawler belt, and the crawler belt of the left and right sides is auxiliary crawler belt, is responsible for driving three-dimensional crawler type driving system by main crawler belt and advances; 3 groups of crawler belts are along equal embedded some ultrasonic probes on the direction of rail trend, be close to respectively during detection rail directly over and the left and right sides; Along the length of rail trend, the crawler belt of embedded ultrasonic probe is divided into some detections subareas according to crawler belt, wherein in each subarea, each side crawler belt carries a ultrasonic probe, each subarea of division directly over and carry altogether three ultrasonic probes on the direction of three of the left and right sides; On a certain section perpendicular to the rail trend, three ultrasonic probes that carry in described subarea are namely one group of three-dimensional probes in described three-way ultrasonic diffraction detection subsystem; With the different frequency concurrent working, and each detects the subarea and is responsible for detection by a corresponding three-way ultrasonic diffraction detection subsystem all three-dimensional probes of being close to rail when detecting.
2. the crawler type steel rail flaw detection device based on three-way ultrasonic diffraction according to claim 1, it is characterized in that described three-way ultrasonic diffraction detection subsystem comprises control module, pressure transducer, couplant preparation device, ultrasound wave emission and receives switching channel, one group of three-dimensional probe, waveform acquisition module, DSP module, data memory module and breakdown diagnosis module, wherein control module is connected respectively with pressure transducer, couplant preparation device, ultrasound wave emission and reception switching channel and one group of three-dimensional probe; Three-dimensional probe is except with control module is connected, still launches with reception switching channel and waveform acquisition module with ultrasound wave to be connected; The waveform acquisition module is connected with the DSP module; Data memory module and breakdown diagnosis module are connected to each other, and all are connected with the DSP module; Wherein, control module is responsible for receiving the response signal of pressure transducer and is sent order to control their work to the couplant preparation device that is attached thereto, ultrasound wave emission with reception switching channel and one group of three-dimensional probe; Pressure transducer is installed on the three-way ultrasonic diffraction detection subsystem and is responsible for detecting on the crawler belt in subarea, and its is responsible for continuing the crawler belt pressure in this detection of monitoring subarea and whether breaks through default threshold value; The couplant preparation device is responsible for the preparation of couplant before detecting beginning; Ultrasound wave emission and emission and the reception of reception switching channel for this each sub-Probe Ultrasonic Searching of group three-dimensional probe of switching; One group of three-dimensional probe is responsible for emission and reception ultrasonic signal when detecting; The waveform acquisition module is responsible for the waveform signal that acquisition testing arrives; The signal that the DSP module is responsible for gathering carries out denoising and hiding signal extraction is processed; The breakdown diagnosis module is responsible for the signal analysis after the DSP resume module is obtained the rail failure information of being examined; Data memory module is used for signal and the breakdown diagnosis result after buffer memory DSP resume module.
3. the crawler type steel rail flaw detection device based on three-way ultrasonic diffraction according to claim 1, it is characterized in that described Ultrasonic Detection master control system comprises computing machine main control module, mileage Displaying Meter, alarm module and display module, mileage Displaying Meter, alarm module and display module are connected with the computing machine main control module successively, and all three-way ultrasonic diffraction detection subsystem and computing machine main control module parallel join; The data of each three-way ultrasonic diffraction detection subsystem collection are incorporated the computing machine main control module into and are gathered and process; The computing machine main control module is responsible for monitoring the duty of all three-way ultrasonic diffraction detection subsystem, if certain subsystem is in state of activation and has completed current breakdown diagnosis and the work of data file, all the data archive information with it send it back the computing machine main control module, and control this subsystem and enter dormant state; The mileage Displaying Meter is responsible for showing the total kilometrage number of this device flaw detection and is worked as time mileage number of flaw detection; Alarm module is responsible for to point out current certain rail to be examined the zone, damage being arranged according to the order that the computing machine main control module the is sent alarm of ringing; Display module is responsible for showing current result of detection.
4. utilize the method for detection of the described crawler type steel rail flaw detection device based on three-way ultrasonic diffraction of claim 3, the course of work that comprises Ultrasonic Detection master control system and three-way ultrasonic diffraction detection subsystem is characterized in that the work of Ultrasonic Detection master control system comprises the steps:
Step 1, the computing machine main control module continuous firing of Ultrasonic Detection master control system, it monitors the duty of each three-way ultrasonic diffraction detection subsystem: dormant state and state of activation; Further, its monitoring is in detection progress and the data processing progress of the three-way ultrasonic diffraction detection subsystem of state of activation;
Whether step 2, computing machine main control module monitor certain three-way ultrasonic diffraction detection subsystem is in state of activation and has completed breakdown diagnosis and data storage work, is to jump to next step, continues monitoring otherwise jump to step 1; Of particular note, no matter whether monitor certain three-way ultrasonic diffraction detection subsystem and be in state of activation and completed breakdown diagnosis and data storage work, the computing machine main control module all continues uninterruptedly to carry out to the monitoring of each three-way ultrasonic diffraction detection subsystem;
Step 3, the breakdown diagnosis data that this that monitors are in state of activation and completed the three-way ultrasonic diffraction detection subsystem of relevant work deposit the database of computing machine main control module in, simultaneously, switch this three-way ultrasonic diffraction detection subsystem and enter dormant state; Even subsystem is in dormant state, the pressure transducer of this subsystem is still in running order;
Step 4, the computing machine main control module judges again for the current detection information that deposits database in whether it belongs to rail damage information is arranged; If rail has wound, display module demonstrates the current damage information that deposits database in, the alarm device of ringing simultaneously, and deposit the failure detector mileage information of counting of current appearance damage in database;
Step 5 is selected whether to continue each three-way ultrasonic diffraction detection subsystem of monitoring, is still to continue monitoring; Otherwise finish, close whole failure detector.
5. method of detection according to claim 4 is characterized in that the work of described three-way ultrasonic diffraction detection subsystem comprises the steps:
Step 1, in failure detector was advanced, pressure transducer continued to be in the duty of detected pressures; The crawler belt zone of being responsible for detecting when certain three-way ultrasonic diffraction detection subsystem is rolled into to the rail close contact time, and the pressure that pressure transducer detects will be broken through a certain threshold value, and at this moment, this three-way ultrasonic diffraction detection subsystem enters state of activation;
Step 2, control module in the three-way ultrasonic diffraction detection subsystem is controlled the ultrasound wave emission and is received switching channel work, make probe (A) the emission ultrasound wave of rail top, and the ultrasonic probe (B, C) of rail both sides receives ultrasound wave, subsequently, record the waveform that the ultrasonic probe (B, C) of rail both sides receives;
Step 3, control module is controlled the ultrasound wave emission and is received switching channel work, make ultrasonic probe (B) the emission ultrasound wave of rail one side, be positioned at probe (A) break-off of rail top, and the ultrasonic probe (C) that is positioned at the rail opposite side receives ultrasound wave, subsequently, record the waveform that the ultrasonic probe (C) of this opposite side receives;
Step 4, judge all waveforms that this group three-dimensional ultrasonic probe (A, B, C) in this three-way ultrasonic diffraction detection subsystem receives remove outside direct wave whether still have diffracted wave, if without diffracted wave, the detection subarea not damaged be responsible for of this subsystem, do not carry out following steps; If diffracted wave detected, enter next step;
Step 5 makes waveform that the ultrasonic probe (C) of opposite side described in waveform that the ultrasonic probe (B, C) of rail both sides in step 2 detects and step 3 detects by the denoising of DSP module and hides signal extraction and process sound path, the phase information that draws the diffracted wave that they receive;
Step 6, the ultrasonic probe (B) of rail one side that draws from step 5 receives that the diffracted wave sound path of waveform is
, described opposite side ultrasonic probe (C) receive that the diffracted wave sound path of waveform is for the 1st time
And the 2nd time received that the diffracted wave sound path of waveform is
, known velocity of wave is
, the defect point of establishing the generation diffraction is respectively apart from the position of the three-dimensional ultrasonic probe (A, B, C) in this three-way ultrasonic diffraction detection subsystem
,
,
, following system of equations is arranged:
Separate it, try to achieve:
Section in the regional vertical rail trend of being examined of this three-way ultrasonic diffraction detection subsystem is set up plane right-angle coordinate, solves
,
,
The particular location of this defective can be determined in value and the fixed position of three-dimensional ultrasonic probe (A, B, C) in the coordinate system of setting up, receive that according to each probe the phase information of waveform can judge the specific nature of the fault location of generation diffraction simultaneously.
6. method of detection according to claim 5, the specific nature that it is characterized in that described fault location comprises bubble, is mingled with, crackle upper prong or crackle lower prong, if examined the fault location that there are a plurality of generation diffraction in the zone, draw the repeatedly diffracted wave data that each probe receives in the described step 5 of claim 5, list a plurality of system of equations according to many groups diffracted wave sound path data, can try to achieve each defective locations that diffraction occurs; If defective is crack defect, can also calculate according to the particular location of crackle upper prong and crackle lower prong the length information of crackle.
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| CN102565198B (en) * | 2011-12-27 | 2014-07-02 | 华南理工大学 | Wireless ultrasonic probe assembly for flaw detection of crawler-type steel rail and flaw detection method of wireless ultrasonic probe assembly |
| CN104020221B (en) * | 2014-05-30 | 2017-06-16 | 杨媛 | A kind of real-time broken rail detection localization method based on supersonic guide-wave |
| CN104931167B (en) * | 2015-07-08 | 2017-04-12 | 四川广正科技有限公司 | Fixed line feed apparatus of ultrasonic probe in ultrasonic wave stress measurement system |
| CN107727741A (en) * | 2017-10-24 | 2018-02-23 | 中国铁路总公司 | Railway track flaw detection wheel probe and railway track method of detection |
| CN108008016A (en) * | 2018-01-03 | 2018-05-08 | 国网安徽省电力有限公司电力科学研究院 | Power cable and connector nondestructive detection system and method based on X-ray and ultrasonic in combination detection |
| CN108195935A (en) * | 2018-03-15 | 2018-06-22 | 国电锅炉压力容器检验中心 | A kind of equipment corrosion testing device and detection method |
| CN108645920B (en) * | 2018-04-09 | 2020-12-22 | 华南理工大学 | Denoising and alignment-based direct wave suppression method for ultrasonic flaw detection of steel rail |
| CN108918689B (en) * | 2018-04-09 | 2021-02-19 | 华南理工大学 | System and method for eliminating ultrasonic detection direct wave through software and hardware combined adjustment |
| CN112598654B (en) * | 2020-12-25 | 2023-12-08 | 北京安铁软件技术有限公司 | Ultrasonic train wheel damage judging method and system |
| CN114460174A (en) * | 2022-02-08 | 2022-05-10 | 苏州伟恒检测技术有限公司 | Steel rail detection system and application |
| CN117269311B (en) * | 2023-09-19 | 2024-03-26 | 湖南安卓特种设备科技有限公司 | Pressure vessel defect detection device and method based on surface wave signal correlation analysis |
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