CN104359983A - Centering system and method for steel rail flaw detection device - Google Patents

Centering system and method for steel rail flaw detection device Download PDF

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Publication number
CN104359983A
CN104359983A CN201410608424.6A CN201410608424A CN104359983A CN 104359983 A CN104359983 A CN 104359983A CN 201410608424 A CN201410608424 A CN 201410608424A CN 104359983 A CN104359983 A CN 104359983A
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rail
wheel
ultrasound wave
flaw detection
detection device
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CN104359983B (en
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钟艳春
石永生
张玉华
王卫东
顾世平
杨国涛
许建明
徐其瑞
马运忠
李培
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China Academy of Railway Sciences Corp Ltd CARS
Infrastructure Inspection Institute of CARS
Beijing IMAP Technology Co Ltd
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China Academy of Railway Sciences Corp Ltd CARS
Infrastructure Inspection Institute of CARS
Beijing IMAP Technology Co Ltd
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  • Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)

Abstract

The invention provides a centering system and method for a steel rail flaw detection device. The steel rail flaw detection device comprises an ultrasonic wave detection wheel. The system comprises a sensor for acquiring the outline data of a steel rail, a control module for determining deviation of the ultrasonic wave detection wheel and a steel rail center line according to the outline data, and a servo driver for regulating the ultrasonic wave detection wheel to realize centering according to the deviation. Through adoption of the system and method disclosed by the invention, a steel rail flaw detection vehicle can realize centering at a high operating speed, the defect of low flaw-detection speed caused by that a small-scale vehicle is hung under a large-scale steel flaw detection vehicle is overcome, and the steel rail flaw detection at a high operating speed is realized, so that the working efficiency is improved.

Description

A kind of center support system of steel rail flaw detection device and method
Technical field
The present invention relates to detection technique, is a kind of center support system and method for steel rail flaw detection device concretely.
Background technology
The function of rail is that guided vehicle wheel advances, and bears the immense pressure from wheel.In-service rail bears repeatedly rolling of wheel for a long time, inevitably there is fatigue defect and defect.Therefore in order to ensure the safe operation of locomotive, need often to carry out carrying out flaw detection to in-service rail, there is the hurt in rail in Timeliness coverage, to adopt remedial measures, takes precautions against in possible trouble.
Ultrasonic rail inspection car detects rail defects and failures according to the ultrasonic echo of rail defects and failures reflection, when using ultrasonic probe to carry out rail examination, 0 degree of ultrasonic probe must be made to aim at the geometric center lines of rail section.When ultrasonic probe aims at rail section center line, as shown in Figure 1, if rail does not have hurt, ultrasonic probe can receive stronger flange of rail echo (end ripple) signal, if rail has hurt ultrasonic probe will receive hurt echoed signal, thus detects the hurt of rail; And when ultrasonic probe departs from rail, as shown in Figure 2, end ripple signal intensity will weaken and even disappears, be thus just difficult to even can not detect rail defects and failures.
Due to circuit irregularity and take turns right serpentine locomotion, rail-defect detector car is detected a flaw when advancing on the line inevitably yaw, yaw motion, if ultrasonic probe is directly contained on inspection car car body, this transverse movement of car body makes ultrasonic probe be difficult to aim at rail, and the catenary motion of car body is also very large, ultrasonic probe is also difficult to adapt to.
In prior art, for reducing the vertical and transverse movement of car body to the impact of ultrasonic inspection, ultrasonic probe is generally all arranged on flaw detection traveling dolly, and the transverse direction of traveling dolly and catenary motion are much smaller compared with the motion of inspection car car body.Rail is aimed at, the mechanical expanding wheel construction of low speed flaw detection trolley many employings changeable wheelbase for making ultrasonic probe.As shown in Figure 3, the pressure gas that cylinder 301 rear end passes to certain pressure is followed the tracks of when giving, cylinder just acts on the wheel that rises on 302 pressure, thus the right wheel rim of wheel that makes to rise is close to inside the rail head of rail 303 all the time, the wheel that rises like this aims at rail center all the time to center, and visit wheel carrier Shang Tanlun center and Zhang Lundui center is in same longitudinal surface, therefore ensure that and visit wheel central plane and rail central plane overlaps, thus realize probe centering.
Adopt the mode centering of mechanical expanding wheel, though simple and reliable for structure, good centering requirement can be realized when detecting a flaw traveling dolly slow running, but along with the raising of travelling speed, the lateral movement velocity of taking turns that rises improves thereupon, because transverse acceleration increases with the square law of speed, so the horizontal centering acting force of probe needed for centering is along with the raising meeting increase fast of speed.When inspection car travelling speed brings up to 80km/h by 40km/h, the lateral movement velocity of dolly is original 2 times, and horizontal centering acting force is then original 4 times, and this very large transverse force is very disadvantageous for the safe traveling of flaw detection trolley.
Further, in prior art, for realizing rail examination under high-speed cruising condition, steel rail flaw detection device is arranged on below bogie, and adopt electromagnetic sensor to measure to visit the position deviation of wheel and rail center line, servo control mechanism controls to visit the lateral attitude of wheel on rail.
Electromagnetic sensor may have current vortex sensor group and differential transformer two kinds of modes, the group of current vortex sensor shown in Fig. 4 centering schematic diagram, differential transformer centering schematic diagram as shown in Figure 5 by metering system.
The horizontal centering sensor of the current vortex sensor group of Fig. 4 is adopted to reflect horizontal relative deviation by the output signal deviation of two current vortex sensors, when sensor group is to rail center, the output voltage of two eddy current probes is consistent, voltage deviation is 0, the output signal that sensor group departs from two eddy current probes in rail center just has deviation, it is more that sensor departs from rail center, then deviation output voltage is larger, and such two current vortex sensors just constitute a centering sensor.
When adopting the differential transformer of Fig. 5, rail has just become to do the dynamic iron core of differential transformer, as added driving voltage on intermediate coil, when sensor is to rail center, the induced voltage of two secondary windings is identical, when sensor departs from rail, the induced voltage of two secondary windings will be variant, and two limit induced voltage signals are carried out processing the output signal that just can obtain a reflection relative deviation.
In prior art, adopt electromagnetic sensor measuring position deviation, servo control mechanism controls to visit the mode that wheel position realizes centering, because in-service steel rail line is laid on field, expose to the sun and rain, invariably cannot can produce corrosion, electromagnetic sensor, owing to having ferromagnetism, therefore can attract iron rust to come up and glue on a sensor, through after a while, electromagnetic sensor will be stained with iron rust, cause electromagnetic sensor to lose efficacy, thus cause center support system to lose efficacy.
Summary of the invention
For accurately, measure ultrasound wave rapidly and visit the position deviation of taking turns between rail center line, and as little as possible by the interference of external environment, embodiments provide a kind of center support system of steel rail flaw detection device, steel rail flaw detection device comprises ultrasound wave and visits wheel, and system comprises:
Sensor, for gathering the outline data of rail;
According to the wide data of described rail, control module, for determining that described ultrasound wave visits the deviation of wheel and rail center line;
Servo-driver, visits wheel for ultrasound wave according to described deviation adjusting and realizes centering.
Meanwhile, present invention also offers a kind of centering method of steel rail flaw detection device, described steel rail flaw detection device comprises ultrasound wave and visits wheel, and described method comprises:
Gather the wide data of rail of rail;
Determine that described ultrasound wave visits the deviation of wheel and rail center line according to the wide data of described rail;
According to described deviation adjusting, ultrasound wave is visited wheel and is realized centering.
Present invention achieves the centering under rail-defect detector car high-speed cruising, overcome under adopting large-scale rail-defect detector car and hang the low shortcoming of dolly inspection speed, realize the rail examination under high-speed cruising, improve work efficiency, and rail-defect detector car can enroll service chart together with existing lorry under high-speed cruising, do not need to carry out rail examination in the skylight phase, avoid the time taking the skylight phase, save a large amount of rail examination time, substantially increase the business efficiency of railway operation.Meanwhile, the present invention adapts to multiple rail type, the rail under multiple behaviour in service, and not by the impact of the factors such as weather, in the rainy day, snow sky normally can carry out carrying out flaw detection, and practicality is good.The present invention substantially increases the recall rate of rail defects and failures, decreases the hurt rate of false alarm because rail die misalignment occurs, can find to there is hurt in in-service rail timely and accurately, very large to ensure that the safety of railway operation plays a part greatly.
For above and other object of the present invention, feature and advantage can be become apparent, preferred embodiment cited below particularly, and coordinate institute's accompanying drawings, be described in detail below.
Accompanying drawing explanation
In order to be illustrated more clearly in the embodiment of the present invention or technical scheme of the prior art, be briefly described to the accompanying drawing used required in embodiment or description of the prior art below, apparently, accompanying drawing in the following describes is only some embodiments of the present invention, for those of ordinary skill in the art, under the prerequisite not paying creative work, other accompanying drawing can also be obtained according to these accompanying drawings.
Fig. 1 carries out the schematic diagram of ultrasonic probe at rail center when flaw detection is measured in prior art;
Fig. 2 is the schematic diagram carrying out ultrasonic probe lateral runout rail center when flaw detection is measured in prior art;
Fig. 3 is mechanical expanding of the prior art wheel centering schematic diagram;
Fig. 4 is current vortex sensor group centering schematic diagram of the prior art;
Fig. 5 is differential transformer centering schematic diagram of the prior art;
Fig. 6 is the schematic diagram of the center support system of steel rail flaw detection device disclosed by the invention;
Fig. 7 is the block diagram of control module in the embodiment of the present invention;
Fig. 8 is the schematic diagram of the embodiment of the present invention;
Fig. 9 is the process flow diagram of the centering method of steel rail flaw detection device disclosed by the invention;
Figure 10 is according to the process flow diagram determining deviation in the embodiment of the present invention;
Figure 11 is the schematic diagram of one embodiment of the invention;
Figure 12 is that the ultrasound wave of the embodiment of the present invention visits wheel automatic centering system control block diagram;
Figure 13 is the schematic diagram of an embodiment of the present invention;
Figure 14 is the schematic diagram of an embodiment of the present invention.
Embodiment
Below in conjunction with the accompanying drawing in the embodiment of the present invention, be clearly and completely described the technical scheme in the embodiment of the present invention, obviously, described embodiment is only the present invention's part embodiment, instead of whole embodiments.Based on the embodiment in the present invention, those of ordinary skill in the art, not making the every other embodiment obtained under creative work prerequisite, belong to the scope of protection of the invention.The position deviation that ultrasound wave is visited between wheel and rail center line is measured, and is ultrasonic rail flaw detection automatic centering very important content.Accurately, measure ultrasound wave rapidly and visit the position deviation of taking turns between rail center line, and as little as possible by the interference of external environment, be technical matters to be solved by this invention.
The center support system of a kind of steel rail flaw detection device disclosed by the invention, wherein, steel rail flaw detection device comprises ultrasound wave and visits wheel, and as shown in Figure 6, be the schematic diagram of system disclosed by the invention, this system comprises:
Sensor 601, for gathering the outline data of rail;
According to the wide data of rail, control module 602, for determining that described ultrasound wave visits the deviation of wheel and rail center line;
Servo-driver 603, visits wheel for ultrasound wave according to deviation adjusting and realizes centering.
Wherein, as shown in Figure 7, control module 602 comprises:
Position determination unit 6021, for visiting the position data of wheel on rail according to rail wide data determination ultrasound wave;
Distance determining unit 6022, for according to the range data between position data determination sensor and rail.
Deviation data determining unit 6023, visits the deviation of taking turns with rail center line for the ultrasound wave range data determination ultrasound wave visited between wheel and sensor according to range data and pre-stored.
In addition, servo-driver comprises:
Controlled quentity controlled variable determination module, for visiting the deviation determination controlled quentity controlled variable of wheel and rail center line according to described ultrasound wave.
As shown in Figure 8, center support system of the present invention also comprises:
Servomotor 605, realizes centering for adjusting described ultrasound wave spy wheel according to controlled quentity controlled variable.
Meanwhile, the invention also discloses a kind of centering method of steel rail flaw detection device, as shown in Figure 9, the method comprises:
Step S901, gathers the wide data of rail of rail;
According to the wide data of rail, step S902, determines that described ultrasound wave visits the deviation of wheel and rail center line;
Step S903, according to deviation adjusting, ultrasound wave is visited wheel and is realized centering.
Wherein, as shown in Figure 10, visit wheel according to rail wide data determination ultrasound wave to comprise with the deviation of rail center line:
Step S9021, visits the position data of wheel on rail according to rail wide data determination ultrasound wave;
Step S9022, according to the range data between position data determination sensor and rail;
Step S9023, the ultrasound wave range data determination ultrasound wave visited between wheel and sensor according to range data and pre-stored visits the deviation of taking turns with rail center line.
As shown in figure 11, be the schematic diagram of one embodiment of the invention, the ultrasound wave of the present embodiment is visited wheel automatic centering system structure and is made up of distance measuring sensor 1101, computer for controlling 1102, servo-driver 1103, servomotor 1104.It is wide that distance measuring sensor measures rail 1105 rail, obtain current ultrasonic and visit wheel 1106 position, the data of measurement are sent in computer for controlling 1102, the rail range data of coming is passed according to distance measuring sensor 1101, computer for controlling is according to the software woven, calculate the distance between current sensor 1101 and rail 1105, during owing to installing, the position that distance measuring sensor 1101 and ultrasound wave are visited between wheel 1106 is relatively-stationary, therefore can calculate according to the distance between sensor 1101 and rail 1105 deviation that ultrasound wave visits wheel 1106 and rail 1105 center line, servo-driver 1103 uses corresponding control algolithm to obtain corresponding controlled quentity controlled variable according to deviation, and drive servomotor 1104, servomotor drives ultrasound wave to visit wheel and moves corresponding distance along the direction of reducing deviation, thus ultrasound wave spy wheel 1106 and rail 1105 center line are coincided, realize automatic centering.
Because rail-defect detector car detection speed in testing process quickly, thus requires that this system has very fast reaction velocity, when the present invention can ensure rail-defect detector car high-speed cruising, the lateral attitude deviation of ultrasonic probe controls in the scope that can normally detect a flaw.
The ultrasound wave of the embodiment of the present invention visits wheel automatic centering system control block diagram as shown in figure 12, the deviation data that computer for controlling receiving sensor gathers and the control preset are expected, control algolithm according to pre-stored generates controlled quentity controlled variable, controls the left and right spy wheel carrier of center support system, realizes automatic centering.
Distance measuring sensor in the embodiment of the present invention adopts two-dimensional laser sensor, laser sensor is measured inside rail, obtain rail laser automatic centering system below, as shown in figure 13: two-dimensional laser sensor can measure the wide information of rail inside rail head of rail, computer for controlling calculates according to the wide information of the rail obtained, calculate the deviate that ultrasound wave visits wheel and rail center line, corresponding control algolithm is used to obtain corresponding controlled quentity controlled variable according to deviation computer for controlling, controlled quentity controlled variable passes to servo-driver, servo-driver drives servomotor according to the drive volume obtained, servomotor drives ultrasound wave to visit wheel and moves corresponding distance along the direction of reducing deviation, thus ultrasound wave spy wheel and rail center line are coincided, realize automatic centering.
In addition, when specifically implementing, laser sensor also both can be measured outside rail, obtained rail laser automatic centering system schematic diagram below, as shown in figure 14.
In the embodiment of the present invention, the centering under adopting servo-drive system to achieve rail-defect detector car high-speed cruising, overcomes under adopting large-scale rail-defect detector car and hangs the low shortcoming of dolly inspection speed, achieve the rail examination under high-speed cruising, improve work efficiency; And under high-speed cruising rail-defect detector car can with enroll service chart together with existing lorry, do not need to carry out rail examination in the skylight phase, avoid the time taking the skylight phase, save a large amount of rail examination time, substantially increase the business efficiency of railway operation.
Meanwhile, the present invention adapts to multiple rail type, the rail under multiple behaviour in service, and not by the impact of the factors such as weather, in the rainy day, snow sky normally can carry out carrying out flaw detection, and practicality is good.The present invention adopts servo-drive system to realize rail examination automatic centering, substantially increase the recall rate of rail defects and failures, decrease the hurt rate of false alarm because rail die misalignment occurs, the hurt existed in in-service rail can be found timely and accurately, to ensureing that the safety of railway operation plays a significant role.Overcome the shortcoming adopting the mode of mechanical expanding wheel to realize centering, eliminate the pretightning force between traveling dolly steel wheel and rail, achieve the rail examination under high-speed case.
Servo-drive system in the present invention can ensure that rail-defect detector car is when high-speed cruising, overcome rail-defect detector car to detect a flaw on the line the impact that flaw detection that yaw when advancing, yaw motion bring lost efficacy, ensure that the lateral attitude deviation of ultrasonic probe controls in the scope that can normally detect a flaw, ensure that rail examination carries out accurately and effectively.The present invention applies to large-scale rail-defect detector car and realizes on seamed high-speed steel rail, is equally applicable to the field that centering is higher in Non-Destructive Testing process.
Apply specific embodiment in the present invention to set forth principle of the present invention and embodiment, the explanation of above embodiment just understands method of the present invention and core concept thereof for helping; Meanwhile, for one of ordinary skill in the art, according to thought of the present invention, all will change in specific embodiments and applications, in sum, this description should not be construed as limitation of the present invention.

Claims (10)

1. a center support system for steel rail flaw detection device, described steel rail flaw detection device comprises ultrasound wave and visits wheel, and it is characterized in that, described system comprises:
Sensor, for gathering the outline data of rail;
According to the wide data of described rail, control module, for determining that described ultrasound wave visits the deviation of wheel and rail center line;
Servo-driver, visits wheel for ultrasound wave according to described deviation adjusting and realizes centering.
2. the center support system of steel rail flaw detection device as claimed in claim 1, it is characterized in that, described control module comprises:
Position determination unit, for visiting the position data of wheel on rail according to described rail wide data determination ultrasound wave.
3. the center support system of steel rail flaw detection device as claimed in claim 2, it is characterized in that, described control module also comprises:
Distance determining unit, for according to the range data between described position data determination sensor and rail.
4. the center support system of steel rail flaw detection device as claimed in claim 3, it is characterized in that, described control module comprises:
Deviation data determining unit, visits the deviation of taking turns with rail center line for the ultrasound wave range data determination ultrasound wave visited between wheel and sensor according to described range data and pre-stored.
5. the center support system of steel rail flaw detection device as claimed in claim 4, it is characterized in that, described servo-driver comprises:
Controlled quentity controlled variable determination module, for visiting the deviation determination controlled quentity controlled variable of wheel and rail center line according to described ultrasound wave.
6. the center support system of steel rail flaw detection device as claimed in claim 5, it is characterized in that, described system also comprises:
Servomotor, realizes centering for adjusting described ultrasound wave spy wheel according to described controlled quentity controlled variable.
7. a centering method for steel rail flaw detection device, described steel rail flaw detection device comprises ultrasound wave and visits wheel, and it is characterized in that, described method comprises:
Gather the wide data of rail of rail;
Determine that described ultrasound wave visits the deviation of wheel and rail center line according to the wide data of described rail;
According to described deviation adjusting, ultrasound wave is visited wheel and is realized centering.
8. the centering method of steel rail flaw detection device as claimed in claim 7, is characterized in that, described comprises with the deviation of rail center line according to rail wide data determination ultrasound wave spy wheel:
The position data of wheel on rail is visited according to described rail wide data determination ultrasound wave;
According to the range data between position data determination sensor and rail;
The ultrasound wave range data determination ultrasound wave visited between wheel and sensor according to described range data and pre-stored visits the deviation of taking turns with rail center line.
9. the centering method of steel rail flaw detection device as claimed in claim 8, it is characterized in that, described method also comprises:
The deviation determination controlled quentity controlled variable of wheel and rail center line is visited according to described ultrasound wave.
10. the centering method of steel rail flaw detection device as claimed in claim 9, it is characterized in that, described method also comprises:
Adjust described ultrasound wave spy wheel according to described controlled quentity controlled variable and realize centering.
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CN105445379A (en) * 2015-12-30 2016-03-30 中国船舶科学研究中心上海分部 Aligning mechanism of large double-track flaw detection car
CN105818837A (en) * 2016-05-10 2016-08-03 中国铁道科学研究院 Rail flaw detection vehicle adopting automatic centering manner
CN106274978A (en) * 2016-08-22 2017-01-04 合肥德泰科通测控技术有限公司 Rail-defect detector car intellectuality center support system
CN107289861A (en) * 2017-07-31 2017-10-24 上海市东方海事工程技术有限公司 A kind of automatic centering system detected a flaw for track and centering detection method
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
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CN109100422A (en) * 2018-08-27 2018-12-28 上海市东方海事工程技术有限公司 Rail examination and video monitoring integrated system based on asynchronous encoder
CN112406949A (en) * 2020-02-08 2021-02-26 姜易斋 Wheeled probe ultrasonic wave automatic centering system
CN113002574A (en) * 2021-03-22 2021-06-22 神华新朔铁路有限责任公司 Centering system, centering method and controller for steel rail flaw detection vehicle
CN114295721A (en) * 2021-11-16 2022-04-08 国能朔黄铁路发展有限责任公司 Probe wheel pair centering structure, rail flaw detection vehicle and probe wheel pair centering method
CN116039696A (en) * 2022-11-22 2023-05-02 北京新科启源科技有限公司 Steel rail ultrasonic wheel type detection wheel assembly with automatic centering function and flaw detection vehicle

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CN105445379B (en) * 2015-12-30 2018-06-29 中国船舶科学研究中心上海分部 Large-scale double track inspection car centering body
CN105445379A (en) * 2015-12-30 2016-03-30 中国船舶科学研究中心上海分部 Aligning mechanism of large double-track flaw detection car
CN105818837A (en) * 2016-05-10 2016-08-03 中国铁道科学研究院 Rail flaw detection vehicle adopting automatic centering manner
CN106274978A (en) * 2016-08-22 2017-01-04 合肥德泰科通测控技术有限公司 Rail-defect detector car intellectuality center support system
CN107289861A (en) * 2017-07-31 2017-10-24 上海市东方海事工程技术有限公司 A kind of automatic centering system detected a flaw for track and centering detection method
CN107289861B (en) * 2017-07-31 2023-07-21 上海市东方海事工程技术有限公司 Automatic centering system and centering detection method for rail flaw detection
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
CN108415243B (en) * 2018-04-20 2021-06-18 株洲时代电子技术有限公司 Automatic centering control method with abrasion compensation
CN108415243A (en) * 2018-04-20 2018-08-17 株洲时代电子技术有限公司 Automatic centering control method with wear compensation
CN108819963A (en) * 2018-04-20 2018-11-16 株洲时代电子技术有限公司 A kind of automatic centering control device with wear compensation
CN109100422A (en) * 2018-08-27 2018-12-28 上海市东方海事工程技术有限公司 Rail examination and video monitoring integrated system based on asynchronous encoder
CN109100422B (en) * 2018-08-27 2024-02-13 上海市东方海事工程技术有限公司 Rail flaw detection and video monitoring integrated system based on asynchronous encoder
CN112406949A (en) * 2020-02-08 2021-02-26 姜易斋 Wheeled probe ultrasonic wave automatic centering system
CN113002574A (en) * 2021-03-22 2021-06-22 神华新朔铁路有限责任公司 Centering system, centering method and controller for steel rail flaw detection vehicle
CN113002574B (en) * 2021-03-22 2022-08-19 神华新朔铁路有限责任公司 Centering system, centering method and controller for steel rail flaw detection vehicle
CN114295721A (en) * 2021-11-16 2022-04-08 国能朔黄铁路发展有限责任公司 Probe wheel pair centering structure, rail flaw detection vehicle and probe wheel pair centering method
CN116039696A (en) * 2022-11-22 2023-05-02 北京新科启源科技有限公司 Steel rail ultrasonic wheel type detection wheel assembly with automatic centering function and flaw detection vehicle
CN116039696B (en) * 2022-11-22 2024-01-30 北京新科启源科技有限公司 Steel rail ultrasonic wheel type detection wheel assembly with automatic centering function and flaw detection vehicle

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