CN106274977A - The direct current Magnetic Flux Leakage Testing System of a kind of trigger-type drainage pattern and method thereof - Google Patents
The direct current Magnetic Flux Leakage Testing System of a kind of trigger-type drainage pattern and method thereof Download PDFInfo
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- CN106274977A CN106274977A CN201610603203.9A CN201610603203A CN106274977A CN 106274977 A CN106274977 A CN 106274977A CN 201610603203 A CN201610603203 A CN 201610603203A CN 106274977 A CN106274977 A CN 106274977A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61K—AUXILIARY EQUIPMENT SPECIALLY ADAPTED FOR RAILWAYS, NOT OTHERWISE PROVIDED FOR
- B61K9/00—Railway vehicle profile gauges; Detecting or indicating overheating of components; Apparatus on locomotives or cars to indicate bad track sections; General design of track recording vehicles
- B61K9/08—Measuring installations for surveying permanent way
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/72—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
- G01N27/82—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
- G01N27/83—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws by investigating stray magnetic fields
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Abstract
The invention discloses the direct current Magnetic Flux Leakage Testing System of a kind of trigger-type drainage pattern, including: sensor array, block isolating circuit, amplifying circuit, filter circuit, triggering circuit, capture card, industrial computer, the most connected in series;Displacement transducer, mileage coder, triggering circuit are the most connected in series.Wherein, sensor array, there are 48 road Hall elements, the radial direction at every rail is patrolled and examined BX, horizontal BY, is perpendicular to Rail Surface BZ direction and arranges 16 tunnels respectively;Capture card is trigger-type drainage pattern, and it triggers signal is provided by triggering circuit;Trigger circuit to be serially connected between capture card and filter circuit, 48 described tunnel detectable voltage signals are carried out threshold decision process;Displacement transducer can measure the lift-off value between sensor array and tested Rail Surface, and mileage coder can obtain railway track and patrol and examine mileage.Defect and magnetic leakage can be detected under the conditions of different polling rates and be difficult to lose data by the present invention;Can gather and patrol and examine mileage, location effective to defect.
Description
Technical field
The invention belongs to railway track defect dynamic test and detection technique field, relate to a kind of trigger-type drainage pattern
Direct current Magnetic Flux Leakage Testing System and method thereof.
Background technology
Along with high speed and the great development of heavy haul railway, online military service rail is squeezed and punching press degree becomes big, damages
The probability of wound also increases.The damage of rail in high speed railway is mainly caused with rail contact fatigue by Railway wheelset, and weighs
Carrying railway track damage and be mostly derived from plastic deformation and the abrasion of rail, this brings grave danger and sternness to train traffic safety
Challenge.At present, the detection of domestic and international railway track main use based on conventional ultrasound detection technique and eddy detection technology big
The mode that type high speed inspection car and low speed hand propelled inspection car combine, wherein conventional Ultrasound detection technique is that main employing is wheeled
Probe contacts with rail, and the highest polling rate, up to 80km/h, can detect rail internal flaw, needs couplant, Detection results
Affected by Rail Surface geometry, roughness and cleannes, when Rail Surface out-of-flatness, easily pricked during detection
Wheel, can affect testing result.There is surface and near surface check frequency in the ultrasonic detecting technology for steel rail defect detection.Eddy current
Detection technique major advantage need not couplant, adapts to adverse circumstances, ferrimagnet defects detection under high-speed condition, so
And, this detection technique is disturbed many factors, it is difficult to judge the size of defect, shape and kind, simultaneously need to special signal
Treatment technology goes to process output signal, is unsuitable for the high speed of rail defects and failures defect, visual inspection.
Direct current Magnetic Flux Leakage Inspecting technology is because its sensor construction is simple, detection sensitivity is high, can realize non-contact detection, existing
It is widely used in Non-Destructive Testing and the assessment of structural member defect.In conjunction with the electromagnetic property of the ferromagnetic materials such as rail, and rail top
Surface crack testing requirement, Magnetic Flux Leakage Inspecting technology is suitable for rail top surface crackle high speed detection.Direct current Magnetic Flux Leakage Inspecting technology
Magnetizing field penetration power strong.In addition to detecting ferrimagnet Surface-breaking defect, moreover it is possible to relatively significantly detect ferromagnetic
Property material internal defect, its detection degree of depth can reach distance material surface 7 millimeters at.
Chinese patent application (application publication number: 104764799.A) discloses that " a kind of AC and DC leakage field technology is tied mutually
The detecting system closed and method thereof ", proposition direct current leakage field goes to overcome direct current with exchanging the method that Magnetic Flux Leakage Inspecting technology combines
Or the problem that the single flux-leakage detection method of exchange can not cover whole velocity interval.But there is following defect in this application: 1. should
Application is in DC detecting system, and capture card uses continuous mode, in such a mode, owing to capture card is carried out with polling mode
, between its adjacent twice poll, there is certain intervals in collecting work, so there is the problem losing data, and obtained inspection
Survey and in packet, there are many data unrelated with defect, cause packet to be unfavorable for the most greatly processing.2. detecting system can not be right
Defect carries out the monitoring function positioning .3. without probe with rail distance.
Summary of the invention
It is an object of the invention to provide a kind of direct current Magnetic Flux Leakage Testing System and the method thereof of trigger-type drainage pattern, it is possible to
Realize the inspection car Magnetic Flux Leakage Inspecting to railway steel rail surface defect under the conditions of different polling rates, be difficult to lose data;Permissible
Railway track is patrolled and examined mileage be acquired, and be mapped with the Magnetic Flux Leakage Inspecting data of corresponding railway division, defect is had
Effect location;It is capable of the lift-off value between sensor array and tested Rail Surface is measured.
In order to solve above-mentioned problem of the prior art, the present invention adopts the following technical scheme that
The direct current Magnetic Flux Leakage Testing System of a kind of trigger-type drainage pattern of the present invention, including industrial computer, capture card, filtered electrical
Road, amplifying circuit, sensor array magnetizator, DC source of energization;
Described sensor array, including 48 road Hall elements, the radial direction at every rail patrols and examines BX direction, steel respectively
Rail horizontal BY direction, it is perpendicular to Rail Surface BZ direction 16 tunnels are respectively set;
Described magnetizator is installed at directly over described sensor array, is used for providing excited signal;
Described DC source of energization adds driving source to magnetizator, produces magnetizing field, tested ferromagnetic workpiece is carried out magnetic
Change, when tested ferromagnetic workpiece surface is defective, output stray field, utilize sensor array can get 48 road leakage field letters
Number and be converted to 48 tunnel detectable voltage signals;
It is characterized in that:
Described system also includes:
Trigger circuit, be serially connected between described capture card and filter circuit;Described triggering circuit utilizes window to compare
48 described tunnel detectable voltage signals are carried out threshold decision process by device principle;The described threshold value triggering circuit is by one
Single-chip Controlling digital regulation resistance is configured;
Block isolating circuit, is serially connected between described amplifying circuit and sensor array, for 48 described tunnel detection electricity
Pressure signal is removed DC component treatment in signal;
Displacement transducer, connects with the outfan of described DC source of energization, is used for measuring sensor array and tested steel
Lift-off value between track surface;
Mileage coder, described single-chip microcomputer reads the output of mileage coder, thus obtains patrolling of tested railway track
Inspection mileage;
Described capture card is set to trigger-type drainage pattern, and it triggers signal and is provided by described triggering circuit;
Described sensor array, block isolating circuit, amplifying circuit, filter circuit, triggering circuit, capture card, industrial computer depend on
Secondary connected in series, displacement transducer, mileage coder, triggering circuit are the most connected in series.
Further, described block isolating circuit uses the mode of AC coupled, enters 48 described tunnel detectable voltage signals
Row removes DC component treatment in signal.
Further, described DC source of energization is provided by accumulator, and voltage magnitude is 48V.
Further, described displacement transducer uses BZF-II type electric vortex type displacement sensor.
A kind of direct current flux-leakage detection method of the trigger-type drainage pattern of the present invention, it is characterised in that: when 48 described tunnels
When in detectable voltage signals, the voltage magnitude of all signals is within the threshold range set, described triggering circuit does not produce tactile
Signaling, therefore described capture card will not carry out detectable voltage signals collection;When in 48 described tunnel detectable voltage signals extremely
When the voltage magnitude of a few road signal is outside the threshold range set, triggering circuit and produce triggering signal, capture card then starts
Carry out detectable voltage signals collection;Then, the detection signal that capture card is collected by described industrial computer is analyzed processing, and carries
Take out the feature of defect.
The inventive method, when described detection signal analysis and processing, uses Wavelet Denoising Method and high pass filter signal processing
The technology combined;Detection signal data after process carries out multichannel leakage field imaging and shows.
The inventive method uses the mode of the network binary stream transmission of asynchronous TCP communication, enters described detection data
Transmit between row network.
Compared with prior art, the present invention has the following advantages and beneficial effect:
1. the present invention uses trigger-type drainage pattern, can effectively detect Rail Surface crack defect, it is ensured that detection
The integrity of signal data, moreover it is possible to patrol and examine data real-time stabilization process, show, store and network transmission, improve industrial computer
Utilization rate;Analyzing the frequecy characteristic of body oscillating interference signal, the data using Wavelet Denoising Method and high-pass filtering to combine process
Method, can effective filter out in Analysis of Magnetic Flux Leakage Testing Signals body oscillating interference signal, contribute to railway track trauma defect analysis and
Identify, and the detection signal data after processing is carried out multichannel leakage field imaging shows, rail table can be reflected quickly and intuitively
The distribution of facial cleft stricture of vagina and feature;The present invention is provided with triggering circuit, and being configured to trigger-type drainage pattern for capture card provides hardware
Condition.
2. the present invention has merged the advantage of direct current Magnetic Flux Leakage Inspecting technology, and block isolating circuit can eliminate direct current in detection signal
Component, can retract zero position by the detection signal criterion line of all passages, not affect signal amplitude and reasonably fluctuate, contribute to
Patrol and examine judgement and the analysis of result.
3. the present invention uses the lift-off between electric vortex type displacement sensor measurement sensor array and tested Rail Surface
Value, it is ensured that design inspection car patrols and examines safety;Due to the distance of probe and the rail impact on testing result in direct current Magnetic Flux Leakage Inspecting
Very big, therefore select the distance of current vortex sensor monitoring probe and rail.
4., for not positioning function to defect in the detecting system of prior art, the present invention is provided with mileage coding
Device, reads mileage coder umber of pulse with single-chip microcomputer, thus records mileage.
5. the present invention uses the network binary stream of asynchronous TCP communication to transmit, and improves the transmission speed of raw sensor data
Rate.
Accompanying drawing explanation
Fig. 1 is the system architecture diagram of one embodiment of the present of invention.Wherein, 1 is industrial computer, and 2 is capture card, and 3 is tactile
Power Generation Road, 4 filter circuits, 5 is amplifying circuit, and 6 is block isolating circuit, and 7 is sensor array, and 8 is magnetizator, and 9 is continuous current excitation
Source, 10 is displacement transducer, and 11 is mileage coder.
Fig. 2 is the sensor array schematic diagram of one embodiment of the present of invention.Wherein, Fig. 2 a is that sensor plank is overlooked
Figure, Fig. 2 b is detection direction schematic diagram.
Fig. 3 is the single channel schematic diagram of the block isolating circuit of one embodiment of the present of invention.
Fig. 4 is the single channel schematic diagram triggering circuit of one embodiment of the present of invention, and Fig. 4 a is to trigger circuit theory signal
Figure, Fig. 4 b is to trigger signal schematic representation.
Detailed description of the invention
With embodiment, the present invention is described in further details below in conjunction with the accompanying drawings.
As it is shown in figure 1, be the system architecture diagram of one embodiment of the present of invention.The system of embodiments of the invention, bag
Include industrial computer 1, capture card 2, filter circuit 4, amplifying circuit 5, sensor array 7, magnetizator 8, DC source of energization 9.
Fig. 2 is the sensor array schematic diagram of one embodiment of the present of invention.As in figure 2 it is shown, every rail is provided with 48
Road Hall element, is divided into BX direction (rail radially, i.e. patrols and examines direction), BY direction (rail is horizontal), BZ direction (to be perpendicular to steel
Track surface) each 16 road Hall elements, a length of 70mm, it is possible to achieve the whole horizontal covering detection of rail.Interface is 50 cores,
I.e. 48 road holding wires and two-way earth signal line.
Described magnetizator 8 is installed at directly over described sensor array 7, is used for providing excited signal.
Described DC source of energization 9 adds driving source to magnetizator 8, produces magnetizing field, to tested ferromagnetic workpiece such as steel
Rail magnetizes, when tested ferromagnetic workpiece surface is defective, and output stray field, utilize sensor array 7 to get
48 tunnel magnetic leakage signal are also converted to 48 tunnel detectable voltage signals.Described DC source of energization 9 is provided by accumulator, and voltage magnitude is
48V。
Described system also includes: trigger circuit 3, block isolating circuit 6, displacement transducer 10, mileage coder 11.
Described triggering circuit 3, is serially connected between described capture card 2 and filter circuit 4;Described triggering circuit 3 profit
Use window comparator principle, 48 described tunnel detectable voltage signals are carried out threshold decision process;The described threshold triggering circuit 3
Value is configured by a Single-chip Controlling digital regulation resistance.
Fig. 4 is the single channel schematic diagram triggering circuit of one embodiment of the present of invention.As shown in Figure 4, U is worked asInAt UAWith UB
Between (UA>UB) time, UOut_trgIt is output as high level UOH, work as UIAt UAWith UBOutside (UA>UB) time, UOut_trgIt is output as low level
UOL。UIIt is a wherein road output signal of 48 road hall sensing arrays, threshold voltage UAWith UBIt is controllable voltage, STM32 can be passed through
Control digital regulation resistance regulation, meet difference and detect the adjustment of the threshold voltage under environment.UOut_sampWith capture card AI_CH pin
Being connected, the signal of AI_CH pin can be acquired by capture card.This circuit uses window comparator chip LM393 to realize, threshold
Threshold voltage passes through digital regulation resistance AD7376 programming Control.
Threshold formula:Wherein, V is threshold value, and scope is 0~5v, and D is the byte life that potentiometer able to programme receives
Order.The process that sets of threshold value is as: host computer and single-chip microcomputer by RS232 interface communication, and during adjustment, host computer is downward frame ordering
Issuing single-chip microcomputer, single-chip microcomputer issues potentiometer able to programme byte after receiving complete order.
Described block isolating circuit 6, is serially connected between described amplifying circuit 5 and sensor array 7, for described 48
Road detectable voltage signals is removed DC component treatment in signal;Described block isolating circuit 6 uses the mode of AC coupled, right
48 described tunnel detectable voltage signals are removed DC component treatment in signal.
Described displacement transducer 10, connects with the outfan of described DC source of energization 9, is used for measuring sensor array
Lift-off value between 7 and tested Rail Surface.This displacement transducer 10 uses BZF-II type electric vortex type displacement sensor.
Described mileage coder 11, described single-chip microcomputer reads the output of mileage coder, thus obtains tested railway
Rail patrol and examine mileage;
Described sensor array 7, block isolating circuit 6, amplifying circuit 5, filter circuit 4, trigger circuit 3, capture card 2, work
Control machine 1 is the most connected in series, and displacement transducer 10, mileage coder 11, triggering circuit 3 are the most connected in series.
Described capture card 2 is set to trigger-type drainage pattern, and it triggers signal and is provided by described triggering circuit 3.Adopt
When collection is stuck in the work of triggering collection pattern, capture card arranges it and triggers leads ends low level is effective triggering collection signal, touches
Power Generation Road 3 is set to suitable threshold voltage, when tested Rail Surface is defective, when road a certain in sensor array or certain
When several roads Hall element output voltage signal exceedes the threshold value of setting, triggering circuit 3 and be output as low level, triggering collection card is opened
Beginning acquisition testing signal.Analyze accordingly, 48 tunnels trigger circuit 3 output signal be designed as line and relation, when all 48 tunnels
When triggering circuit 3 applied signal voltage amplitude not less than threshold value, line is with rear for high level, and it is nothing that capture card triggers leg signal
Effect, will not gather data.When the applied signal voltage amplitude that an at least road in circuit 3 is triggered on 48 tunnels exceedes threshold value, line with
Being low level afterwards, it is effectively that capture card triggers leg signal, starts to gather data.
48 described tunnel detectable voltage signals sequentially pass through block isolating circuit 6, amplifying circuit 5, filter circuit 4, trigger circuit
3.When triggering circuit 3 and having triggering signal to produce, capture card 2 collects detection signal, and the industrial computer 1 signal to collecting is carried out
Analyzing and processing, extracts the feature of defect.
Fig. 3 is the single channel schematic diagram of the block isolating circuit of one embodiment of the present of invention.As it is shown on figure 3, block isolating circuit 6 uses
48 tunnel detection signals are removed DC component treatment in signal by the mode of AC coupled.Wherein cut-off frequency f-3dBCalculate
Formula is:
As R=1K Ω, C=10uF, f-3dB≈ 16Hz, can set different cut-off frequencies by regulation R, C.
The direct current flux-leakage detection method of the trigger-type drainage pattern of one embodiment of the present of invention, it is characterised in that: work as institute
When in the detectable voltage signals of Shu 48 tunnel, the voltage magnitude of all signals is within the threshold range set, described triggering circuit
3 do not produce triggering signal, and therefore described capture card 2 will not carry out detectable voltage signals collection;When 48 described tunnel detection electricity
When the voltage magnitude of at least one road signal is outside the threshold range set in pressure signal, triggers circuit 3 and produce triggering signal, adopt
Truck 2 then proceeds by detectable voltage signals collection;Then, the detection signal that capture card 2 is collected by described industrial computer 1 enters
Row analyzing and processing, extracts the feature of defect.
When described detection signal analysis and processing, use the skill that Wavelet Denoising Method and high pass filter signal processing combine
Art;Detection signal data after process carries out multichannel leakage field imaging and shows.
When raw sensor data network transmits, the network binary stream of asynchronous TCP communication is used to transmit.In 100,000,000 Netcoms
Under letter environmental condition, calling Socket transfer function Send () and Receive (), its stable network transmission speed upper limit is
800KB/s.The embodiment of the present invention uses the asynchronous TCP communication agreement that reliability is high, stable, and data transfer mode is selected
NetworkStream binary stream transmission, its binary stream transfer function BinaryReader.Read () with
BinaryWriter.Write () can directly transmit the data of double type, saves use Socket transfer function Send
The time that double data type conversion is Byte type in () and Receive (), improve message transmission rate and reservation
The precision of initial data.NetworkStream streaming test experiments result shows, this transmission means is at 100,000,000 Network Communication rings
Under the conditions of border, its transfer rate can reach more than 5MB/s.
In sum, the principle of the present invention is: detecting system uses sensor array, totally 48 road Hall element, every straight,
Amplification, filtering, gate circuit all use multichannel form, can realize showing the multichannel leakage field imaging of detection signal.This
Bright employing 48V DC source, as magnetizing field driving source, can produce the strongest magnetizing field, under the conditions of can realizing different polling rate
Detection to railway steel rail surface defect.The trigger-type drainage pattern of the present invention, when gate circuit has triggering signal to produce, adopts
Truck carries out data acquisition, including mileage value, lift-off value, and detection signal data.During to detection signal processing, use small echo
The technology that denoising and high pass filter signal processing combine, filters vibration interference signal and high-frequency noise interference signal, and right
Detection signal data after process carries out multichannel leakage field imaging and shows.When raw sensor data network transmits, use asynchronous
The network binary stream transmission of TCP communication, improves the network transmission speed of raw sensor data.
Claims (7)
1. a direct current Magnetic Flux Leakage Testing System for trigger-type drainage pattern, including industrial computer (1), capture card (2), filter circuit
(4), amplifying circuit (5), sensor array (7), magnetizator (8), DC source of energization (9);
Described sensor array (7), including 48 road Hall elements, the radial direction at every rail patrols and examines BX direction, steel respectively
Rail horizontal BY direction, it is perpendicular to Rail Surface BZ direction 16 tunnels are respectively set;
Described magnetizator (8) is installed at directly over described sensor array (7), is used for providing excited signal;
Described DC source of energization (9) adds driving source to magnetizator (8), produces magnetizing field, carries out tested ferromagnetic workpiece
Magnetization, when tested ferromagnetic workpiece surface is defective, output stray field, utilize sensor array (7) that 48 tunnels can be got
Magnetic leakage signal is also converted to 48 tunnel detectable voltage signals;
It is characterized in that:
Described system also includes:
Trigger circuit (3), be serially connected between described capture card (2) and filter circuit (4);Described triggering circuit (3) utilizes
48 described tunnel detectable voltage signals are carried out threshold decision process by window comparator principle;The threshold of described triggering circuit (3)
Value is configured by a Single-chip Controlling digital regulation resistance;
Block isolating circuit (6), is serially connected between described amplifying circuit (5) and sensor array (7), for 48 described tunnel inspections
Survey voltage signal and be removed DC component treatment in signal;
Displacement transducer (10), connects with the outfan of described DC source of energization (9), be used for measuring sensor array (7) with
Lift-off value between tested Rail Surface;
Mileage coder (11), described single-chip microcomputer reads the output of mileage coder, thus obtains patrolling of tested railway track
Inspection mileage;
Described capture card (2) is set to trigger-type drainage pattern, and it triggers signal and is provided by described triggering circuit (3);
Described sensor array (7), block isolating circuit (6), amplifying circuit (5), filter circuit (4), trigger circuit (3), gather
Card (2), industrial computer (1) are the most connected in series, displacement transducer (10), mileage coder (11), triggering circuit (3) serial successively
Connect.
The direct current Magnetic Flux Leakage Testing System of a kind of trigger-type drainage pattern the most according to claim 1, it is characterised in that: described
Block isolating circuit (6) use AC coupled mode, 48 described tunnel detectable voltage signals are removed direct current in signal and divide
Amount processes.
The direct current Magnetic Flux Leakage Testing System of a kind of trigger-type drainage pattern the most according to claim 1, it is characterised in that: described
DC source of energization (9) provided by accumulator, voltage magnitude is 48V.
The direct current Magnetic Flux Leakage Testing System of a kind of trigger-type drainage pattern the most according to claim 1, it is characterised in that: described
Displacement transducer (10) use BZF-II type electric vortex type displacement sensor.
5. use a direct current flux-leakage detection method for the trigger-type drainage pattern of system described in any one of Claims 1-4, its
It is characterised by: when in 48 described tunnel detectable voltage signals, the voltage magnitude of all signals is within the threshold range set,
Described triggering circuit (3) does not produce triggering signal, and therefore described capture card (2) will not carry out detectable voltage signals collection;
When the voltage magnitude of at least one road signal is outside the threshold range set in 48 described tunnel detectable voltage signals, trigger electricity
Road (3) produces triggers signal, and capture card (2) then proceeds by detectable voltage signals collection;Then, described industrial computer (1) is right
The detection signal that capture card (2) collects is analyzed processing, and extracts the feature of defect.
The direct current flux-leakage detection method of a kind of trigger-type drainage pattern the most according to claim 5, it is characterised in that: in institute
During the detection signal analysis and processing stated, use the technology that Wavelet Denoising Method and high pass filter signal processing combine;After process
Detection signal data carries out multichannel leakage field imaging and shows.
The direct current flux-leakage detection method of a kind of trigger-type drainage pattern the most according to claim 5, it is characterised in that: use
Described detection data are carried out transmitting between network by the mode of the network binary stream transmission of asynchronous TCP communication.
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