CN110672718A - Electromagnetic ultrasonic point focusing/diverging surface wave method and device for steel rail tread detection - Google Patents
Electromagnetic ultrasonic point focusing/diverging surface wave method and device for steel rail tread detection Download PDFInfo
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Abstract
An electromagnetic ultrasonic point focusing/diverging surface wave device for rapid online detection of a rail tread, comprising: the device comprises an electromagnetic ultrasonic point focusing/diverging surface wave probe, an impedance matching network, a pulse power amplifier, a signal generator, a preamplifier, a secondary filtering and amplifying circuit, a data acquisition card, a LabVIEW software detection interface, a motion controller and a mechanical walking/rotating device. The method can realize accurate quantitative detection of micro defects including inclined cracks and effective detection of crack inclination angles while realizing on-line automatic detection.
Description
Technical Field
The invention belongs to the technical field of non-contact ultrasonic detection, and can realize on-line rapid detection of micro defects of a steel rail tread and inclined cracks on two sides of the tread.
Background
Railway transportation occupies an important position in the transportation system of China. The steel rail is used as a key part in railway transportation, and the actual contact area with each wheel of a train is only more than 100mm2But bearing and transmitting loads weighing tens of tons; in addition, in recent years, the damage of the steel rail is increasingly serious due to the increase of the speed of the train and the frequent and heavy loading of freight. Rail tread cracking due to wheel rail rolling contact fatigue is a common manifestation of rail failure. Oblique cracks are the most common form of cracks on the rail tread, and further propagation thereof will lead to sudden breakage of the rail, with consequent loss of life and economic loss being enormous.
The railway departments at home and abroad usually adopt the conventional ultrasonic surface wave technology to realize the automatic detection of the rail tread cracks, the good coupling between a probe and a detected part can be realized only by a coupling agent (water and glycerol), and the requirement on the surface quality of the detected part is higher, so the method is difficult to be used for the online rapid detection of the rail. The electromagnetic ultrasonic transducer realizes the excitation and the reception of ultrasonic waves by utilizing the principle of electromagnetic induction, has the characteristics of non-contact and no need of a coupling agent, and can be used for the rapid online detection of the tread of the steel rail.
The electromagnetic ultrasonic technology is used for on-line detection of the steel rail at present; however, accurate quantification/analysis of micro-defects and oblique cracks on two sides of the tread by generating surface wave acoustic beams with different pointing angles by adopting an electromagnetic ultrasonic point focusing/diverging surface wave technology and combining a stepping motor driving rotation mode has not been reported yet. The main patents on the electromagnetic ultrasonic detection technology of the steel rail are summarized as follows:
the application number 201110436682.7 is named as a multi-probe electromagnetic ultrasonic detection device for detecting the wheel tread defect of the high-speed train and a detection method thereof. The patent realizes the detection of different defects of the wheel tread of the high-speed train by combining a plurality of probes, but the patent does not relate to the online detection of the rail tread.
Application No. 200320111599.3 entitled "railway locomotive, vehicle wheel tread on-line automatic flaw detection device". The patent realizes on-line detection of the tread of the train wheel by arranging a plurality of electromagnetic ultrasonic probes on the outer side of the tread, but the patent does not relate to the on-line detection of the tread of the steel rail.
Application No. 200810137486.8 entitled "method and apparatus for rapidly scanning rail tread defect". The method uses a zigzag coil electromagnetic ultrasonic probe to generate surface waves on a tread, and has high precision for defect quantification by a mode of combining a pulse reflection method and a transmission method through a one-shot two-shot probe mode; it does not relate to a point focused/divergent electromagnetic surface acoustic wave technology that can be rotated.
Application No. 201310258586.7 entitled "an electromagnetic ultrasonic transducer for detecting rail head tread defects". The patent adopts an electromagnetic ultrasonic surface wave probe formed by combining a magnetizer and a zigzag coil, realizes the defect detection of a steel rail tread, but does not relate to a rotatable point focusing/diverging electromagnetic ultrasonic surface wave technology.
Application No. 201620295730.3 entitled "electromagnetic ultrasonic rail flaw detector". The patent detects the steel rail by arranging four channel ultrasonic probes below the base, but does not mention the combination form of the ultrasonic probes.
The application number 201711375553.5 is named as 'steel rail web electromagnetic ultrasonic detection probe and electromagnetic ultrasonic detection device'. The defect detection of the rail web is realized by adopting an electromagnetic ultrasonic direct incidence body wave/oblique incidence body wave/surface wave technology.
The above patents all describe methods and apparatus for rail/wheel inspection using electromagnetic ultrasound, but none relate to the use of a rotatable point focused/divergent electromagnetic surface acoustic wave technique.
SUMMARY OF THE PATENT FOR INVENTION
The invention can realize the accurate quantitative detection of the tiny defects including the inclined cracks and the effective detection of the inclination angle of the cracks while realizing the on-line automatic detection. The specific technical scheme is as follows:
an electromagnetic ultrasonic point focusing/diverging surface wave device for rapid online detection of a rail tread, comprising: the device comprises an electromagnetic ultrasonic point focusing/diverging surface wave probe, an impedance matching network, a pulse power amplifier, a signal generator, a preamplifier, a secondary filtering and amplifying circuit, a data acquisition card, a LabVIEW software detection interface, a motion controller and a mechanical walking/rotating device.
Furthermore, the electromagnetic ultrasonic point focusing/diverging surface wave probe adopts a mode of combining the arc zigzag coil and the vertically magnetized permanent magnet, and not only can generate a focused surface wave, but also can generate a diverging surface wave.
Furthermore, the motion controller and the mechanical walking/rotating device can realize the automatic walking of the electromagnetic ultrasonic point focusing/diverging surface wave probe on the steel rail tread on one hand; on the other hand, the circular arc-shaped zigzag coil of the electromagnetic ultrasonic point focusing/diverging surface wave probe can rotate along the center in the detection process, and the rotation angle information is fed back to a LabVIEW software detection interface in real time.
Furthermore, the pulse power amplifier and the signal generator are matched for use, can provide radio frequency current with transient power reaching 5KW-15KW for the electromagnetic ultrasonic probe, drive an exciting coil in the electromagnetic ultrasonic point focusing/diverging surface wave probe and excite point focusing/diverging surface wave in the steel rail tread; and/or the presence of a gas in the gas,
the preamplifier, the secondary filter amplifying circuit and the data acquisition card are matched for use, so that a weak electric signal captured by a receiving coil in the electromagnetic ultrasonic point focusing/diverging surface wave probe can be subjected to multistage filter amplification, converted into a digital signal through an analog-to-digital converter and sent into a LabVIEW software detection interface; and/or
The impedance matching network is used for realizing impedance matching between an exciting coil and the output impedance of the pulse power amplifier in the electromagnetic ultrasonic surface wave probe and transferring the exciting power to the exciting coil to the maximum extent; on the other hand, the impedance difference problem between the input impedance of the receiving coil and the input impedance of the preamplifier in the electromagnetic ultrasonic point focusing/diverging surface wave probe can be solved, the weak induced power captured by the receiving coil can be transferred to the preamplifier to the maximum extent, and the energy conversion efficiency of the electromagnetic ultrasonic surface wave probe is improved finally.
Further, the main functions of the LabVIEW software detection interface include: 1) adjusting electromagnetic ultrasonic excitation parameters, wherein the electromagnetic ultrasonic excitation parameters comprise current amplitude, frequency, duration and trigger interval; 2) adjusting electromagnetic ultrasonic receiving parameters, wherein the adjustment of the electromagnetic ultrasonic receiving parameters comprises gain multiples, filtering parameters and average times; 3) the walking and rotating actions of the electromagnetic ultrasonic probe; 4) recording and analyzing ultrasonic echo data, and quantifying and positioning and analyzing defects.
Furthermore, in the LabVIEW detection interface, a signal generator is controlled to generate a sine pulse string with adjustable duration and periodicity through an RS232 serial port bus, an amplified large-amplitude pulse excitation current can be generated through a pulse power amplifier, and the amplified large-amplitude pulse excitation current is sent to an excitation coil in an electromagnetic ultrasonic surface wave probe through an impedance matching network; exciting a point focusing/diverging surface wave on a steel rail tread by an exciting part of the electromagnetic ultrasonic point focusing/diverging surface wave probe under the combined action of Lorentz force and magnetostrictive effect, and propagating along the length direction of the steel rail; when a tiny defect or a crack is encountered, a defect echo is obtained through reflection; when the defect echo reaches the position under a receiving coil of the electromagnetic ultrasonic surface wave probe, a weak induced voltage signal is induced at a receiving part of the electromagnetic ultrasonic point focusing/diverging surface wave probe according to the inverse Lorentz force and the inverse magnetostrictive effect; the induced voltage signal is filtered and amplified by the preamplifier and the secondary filtering and amplifying circuit to obtain a voltage signal with high signal-to-noise ratio within the range of the data acquisition card, and then the voltage signal is converted into a digital signal by the analog-to-digital conversion function of the data acquisition card and sent into a LabVIEW software interface for signal analysis and processing through NET or PCI-E transmission bus.
Further, by adjusting the distance d between adjacent wires of the zigzag coil, point focusing/diverging surface waves with different frequencies f can be excited, wherein d and f need to satisfy: d is c _ s/2f, wherein c _ s represents the surface wave sound velocity of the rail tread; and/or the presence of a gas in the gas,
the sound pressure distribution of the point focusing/diverging surface wave can be changed by adjusting the arc angle alpha of the exciting coil of the electromagnetic ultrasonic point focusing/diverging surface wave probe, the arc angle beta of the receiving coil and the radius of the arc zigzag coil thereof.
Furthermore, the arc-shaped zigzag coil rotates along the central shaft, and ultrasonic beams in different directions are generated on the tread of the steel rail, so that the detection of micro defects and cracks in different directions in different areas can be realized; the same circular arc zigzag coil EMAT can generate point focusing surface waves to realize the detection of micro defects and can also generate divergent surface waves to realize the detection of straight cracks/inclined cracks on two sides of a tread; and determining the inclination angle of the crack according to the rotation angle of the electromagnetic ultrasonic probe corresponding to the maximum echo amplitude of the inclined crack on the tread.
Further, the electromagnetic ultrasonic point focusing/diverging surface wave probe comprises the following structure: the stainless steel shell is mainly used for protecting structures such as a permanent magnet and a zigzag coil in the probe and shielding electromagnetic interference signals of the external environment; the stepping motor is connected with the arc zigzag coil through a rotating rod and an elastic retaining plate, and a flexible supporting structure is arranged above the arc zigzag coil and used for applying certain pressure to ensure that the arc zigzag coil is mutually attached to the complex tread of the steel rail; a flexible wear-resistant layer is arranged below the circular arc-shaped zigzag coil; and a rolling bearing is arranged in the electromagnetic ultrasonic point focusing/diverging surface wave probe and is used for ensuring that the probe and the steel rail tread are lifted off by 0.5-1 mm.
A detection method adopting the device comprises the following steps:
the method comprises the following steps: LabVIEW software detects the sine pulse train with adjustable frequency/periodicity/repetition frequency generated by an interface control signal generator, and obtains high-power radio-frequency pulse current through the amplification effect of a pulse power amplifier;
step two: under the action of high-power radio frequency pulse current, an excitation coil in the electromagnetic ultrasonic point focusing/diverging surface wave probe generates point focusing/diverging surface waves on the surface of the steel rail according to Lorentz force and magnetostrictive effect;
step three: point focusing/diverging surface wave is transmitted in the steel rail tread, when a tiny defect or cracks on two sides of the tread are met, a defect echo is generated and is obtained by a receiving coil in an electromagnetic ultrasonic point focusing/diverging surface wave probe and converted into an induced voltage signal; controlling gain multiples and filter parameters of a preamplifier and a secondary amplifying circuit through a LabVIEW software detection interface, filtering and amplifying weak induced voltage signals, performing analog-to-digital conversion through a data acquisition card, and sending the signals into the LabVIEW software detection interface;
step four: the LabVIEW software detection interface sends a motion instruction, the mechanical rotating device is driven by the motion controller to drive the circular arc zigzag coil in the electromagnetic ultrasonic point focusing/diverging surface wave probe to rotate along the central shaft, and corresponding ultrasonic echo signals at different rotation angles are recorded in real time;
step five: performing positioning analysis on the flight time t of the defect echo corresponding to the maximum ultrasonic echo amplitude, and calculating the distance L from the defect to the surface of the sample according to a formula L (c _ s) t/2, wherein c _ s is the sound velocity of the surface wave of the steel rail; positioning and analyzing the defect echo amplitude corresponding to the maximum ultrasonic echo amplitude, comparing the defect echo amplitude with a previously-known round hole or crack to determine the equivalent size of the defect;
step six: and the LabVIEW software detection interface sends a motion instruction, the mechanical walking device is driven by the motion controller to drive the electromagnetic ultrasonic point focusing/diverging surface wave probe to move to a preset position along the length direction of the steel rail, and the steps from the first step to the fifth step are repeated until the detection of all the steel rail treads is completed.
The technical effect produced by the invention patent.
The main reflecting surface of a micro defect or cracks on two sides of a tread is determined according to the characteristic that the corresponding ultrasonic echo amplitude is the highest when the main reflecting surface of the defect is detected. The technology can realize accurate quantitative detection of tiny defects including inclined cracks and effective detection of crack inclination angles while realizing on-line automatic detection.
The invention relates to an electromagnetic ultrasonic point focusing/diverging surface wave method and device for rapid online detection of a steel rail tread, which can be used for rapid online detection of the steel rail tread, generate point focusing/diverging surface waves in a non-contact and coupling-free manner by adopting an arc-shaped zigzag coil, realize real-time adjustment of the acoustic beam axis direction of the surface waves in the detection process by adopting a digital signal processing technology and an automatic control technology, find a main reflecting surface of a tiny defect or crack, and can be used for accurately measuring the equivalent size and the position of cracks with different inclination angles on the steel rail tread.
Drawings
FIG. 1 is a hardware schematic block diagram of the present invention.
Fig. 2 illustrates the transduction principle of electromagnetic ultrasonic surface waves based on lorentz force.
Fig. 3 shows the transduction principle of an electromagnetic ultrasonic surface wave based on the magnetostrictive effect.
Fig. 4 is a schematic view of a meander coil shaped as a circular arc.
FIG. 5 is a schematic diagram of a point focusing surface wave generated by an electromagnetic ultrasonic probe with a curved coil for detecting a tiny defect on a steel rail tread.
FIG. 6 is a schematic diagram of detecting straight cracks and inclined cracks on two sides of a steel rail tread by using divergent surface waves generated by an electromagnetic ultrasonic probe with a circular arc-shaped zigzag coil.
FIG. 7 is a schematic diagram of an electromagnetic ultrasonic probe with a circular arc zigzag coil rotating along the center and detecting different oriented cracks.
Fig. 8 is a waveform diagram of the electromagnetic ultrasonic probe when detecting a defect.
Fig. 9 is a schematic structural diagram of an electromagnetic ultrasonic probe.
Detailed Description
The invention is further illustrated by the following examples in conjunction with the accompanying drawings:
as shown in figure 1, the steel rail defect detection device of the invention consists of a non-contact electromagnetic super surface acoustic wave probe, a signal generator, a pulse power amplifier, a preamplifier, a two-stage filter amplifying circuit, a data acquisition card, a central processing system provided with an electromagnetic ultrasonic detection interface, a mechanical walking/rotating device and a motion controller.
In a LabVIEW detection interface, a signal generator is controlled to generate a sine pulse string with adjustable duration and periodicity through an RS232 serial port bus, amplified large-amplitude pulse excitation current can be generated through a pulse power amplifier, and the amplified large-amplitude pulse excitation current is sent to an excitation coil in an electromagnetic ultrasonic surface wave probe through an impedance matching network. Under the combined action of Lorentz force and magnetostriction effect, the exciting part of the electromagnetic ultrasonic surface wave probe excites point focusing/diverging surface waves on the steel rail tread and propagates along the length direction of the steel rail. When a tiny defect or crack is encountered, a defect echo will be reflected. When the defect echo reaches the position right below a receiving coil of the electromagnetic ultrasonic surface wave probe, a weak induced voltage signal is induced at a receiving part of the electromagnetic ultrasonic surface wave according to the inverse Lorentz force and the inverse magnetostriction effect. The induced voltage signal is filtered and amplified by the preamplifier and the secondary filtering and amplifying circuit to obtain a voltage signal with high signal-to-noise ratio within the range of the data acquisition card, and then the voltage signal is converted into a digital signal by the analog-to-digital conversion function of the data acquisition card and sent into a LabVIEW software interface for signal analysis and processing through NET or PCI-E transmission bus.
As shown in fig. 4, by adjusting the spacing d between adjacent wires of the meander coil, point-focused/divergent surface waves of different frequencies f can be excited, where d and f need to satisfy: d is c _ s/2f, wherein c _ s represents the surface wave sound velocity of the rail tread. When the sound velocity of the surface wave on the steel rail tread is 2900m/s, the coil wire spacing d corresponding to the 0.5MHz surface wave is 2.9mm, and the coil spacing d corresponding to the 0.3MHz surface wave is about 4.83 mm. The arc-shaped zigzag coil is mainly manufactured by adopting flexible FPC technology, the thickness of the substrate can be 0.1-0.3mm, and the height of the lead is 1-2 ounces. The sound pressure distribution of the point focusing/diverging surface wave can be changed by adjusting the arc angle alpha of the exciting coil, the arc angle beta of the receiving coil and the radius of the arc zigzag coil. Typically, the angle β is slightly greater than the angle α by 1-2 °.
As shown in fig. 7, the stepping motor is controlled to drive the circular arc zigzag coil to rotate along the central axis, and ultrasonic beams in different directions are generated on the tread of the steel rail, so that the detection of micro defects and cracks in different directions in different areas can be realized. The same circular arc zigzag coil EMAT can generate point focusing surface waves to realize the detection of micro defects (such as micro core damage/internal cracks on the shallow surface below the middle region of the tread) and can also generate divergent surface waves to realize the detection of straight cracks/inclined cracks on two sides of the tread. And determining the inclination angle of the crack according to the rotation angle of the electromagnetic ultrasonic probe corresponding to the maximum echo amplitude of the inclined crack on the tread.
As shown in fig. 8, if the rail tread surface has a defect, a defect echo appears before the rail end echo, and the position and size of the defect are determined from information such as the wave height and waveform of the echo.
As shown in fig. 9, the stainless steel casing is mainly used for protecting structures such as permanent magnets and meander coils inside the probe, and shielding electromagnetic interference signals of the external environment. The stepping motor is connected with the arc zigzag coil through a rotating rod and an elastic retaining plate, and a flexible supporting structure is arranged above the stepping motor and used for applying certain pressure to ensure that the arc zigzag coil is attached to the complex tread of the steel rail. A flexible wear-resistant layer with specific hardness is arranged below the circular arc-shaped zigzag coil, so that the zigzag coil is prevented from being rapidly worn due to direct contact friction with a steel rail tread, and early failure is caused. And a rolling bearing is arranged in the electromagnetic ultrasonic surface wave probe and used for ensuring that the probe and the steel rail tread are lifted off by 0.5-1 mm.
In the invention, the electromagnetic ultrasonic probe is mainly designed based on Lorentz force and a magnetostriction mechanism. The circular arc zigzag coil in the probe is manufactured by adopting a flexible FPC technology, and can be perfectly attached to a complex steel rail tread under the action of a small external force. The permanent magnet in the probe adopts a number N35-N52, and is magnetized in the vertical direction, the width is 60-80mm, the length is 80-100mm, and the height is 20-40 mm. Taking a 0.45MHz surface wave as an example, the radius corresponding to the shortest circular arc of the exciting coil is 74mm, and the circular arc angle is 20 degrees; the radius corresponding to the shortest circular arc of the receiving coil is 120mm, and the circular arc angle is 26 degrees. The number of turns of the exciting coil and the receiving coil is 10. And a copper plate is arranged right above the exciting coil and the receiving coil, and the thickness of the copper plate is 1-2 times of the skin depth of the copper material corresponding to 0.45 MHz. The area of the copper plate is enough to cover the whole exciting coil or receiving coil, and the copper plate is mainly used for avoiding noise caused by surface waves generated in the permanent magnet and improving the signal-to-noise ratio of surface wave signals in the tread of the steel rail.
The exciting part of the electromagnetic ultrasonic surface wave probe is excited by a sine pulse series excitation current with the frequency of 0.1MHz-0.5MHz, the periodicity of 5-10 and the amplitude of 10-100A. In ferromagnetic metal materials, the arc-shaped zigzag coil electromagnetic ultrasonic probe mainly has lorentz force and magnetostrictive effect. The steel rail tread surface particles generate high-frequency vibration under the action of Lorentz force and magnetostrictive strain and propagate along the steel rail surface in the form of surface waves. When the surface wave meets the tread defect, scattering and waveform conversion are generated between the surface wave and the defect, and the displacement, the size and the property of the defect can be determined by analyzing the amplitude and the flight time of the ultrasonic echo and the time-frequency characteristics such as the wave packet form and the quantity. The function can be realized by means of an algorithm in a LabVIEW software interface.
The same circular arc zigzag coil EMAT can generate point focusing surface waves to realize the detection of micro nuclear damage/internal cracks on the shallow surface below the middle region of the tread and can also generate diverging surface waves to realize the detection of straight cracks/inclined cracks on two sides of the tread.
The electromagnetic ultrasonic surface wave probe scans along the length direction of the steel rail tread, and in the process of traveling, the stepping motor is controlled to drive the circular arc-shaped zigzag coil to rotate along the central shaft, and ultrasonic sound beams in different directions are generated on the steel rail tread, so that the detection of micro defects and cracks in different directions in different areas can be realized. When the inclination angle of the crack is vertical to the central axis of the ultrasonic sound beam, the echo amplitude corresponding to the crack is maximum, so that the inclination angle of the crack can be determined according to the rotation angle of the electromagnetic ultrasonic probe corresponding to the maximum echo amplitude of the tread inclined crack.
Fig. 9 shows an arrangement of the rail tread surface electromagnetic surface acoustic wave probes.
The transduction mechanism of electromagnetic ultrasound point focused/divergent surface waves based on the lorentz force mechanism is shown in fig. 2. When an exciting coil in the electromagnetic ultrasonic probe is under the action of high-frequency and high-current, a pulse eddy current J is formed on the surface of the tread of the steel raileA vertical bias magnetic field B provided by a permanent magnetsUnder the action of (3), Lorentz force f is generatedL。
The transduction mechanism of electromagnetic ultrasound point focused/diverging surface waves based on the magnetostrictive mechanism is shown in fig. 3. Exciting coil with high frequency and large current is applied to form dynamic magnetic field H on the surface of sampledAnd in a static magnetic field H provided by the permanent magnetsUnder the combined action of the two components, periodic tensile and contraction deformation, namely magnetostriction strain epsilond. Surface waves are generated by mass points on the surface of the steel rail tread under the action of Lorentz force and magnetostrictive strain and are propagated along the surface of the steel rail. The surface wave is propagated along the tread of the steel rail, and after the surface wave meets a defect, the surface wave can be reflected to form a defect echo. According to the inverse Lorentz force or the inverse magnetostriction effect, the reflected ultrasonic waves vibrate on the steel rail tread to cause the change of the surrounding magnetic field, and a voltage signal is induced in the coil and received as an ultrasonic signal.
The main design parameters of the arc-shaped meander coil in the electromagnetic surface acoustic wave probe are shown in fig. 4. By adjusting the wire spacing d of the zigzag coil, surface waves of different frequencies can be excited by constructive interference of ultrasonic waves. By adopting the mode of separating the exciting coil and the receiving coil, on one hand, the influence of the self-electrified noise of the pulse power amplifier on the receiving coil can be reduced, on the other hand, the impedance of the exciting coil can be reduced, the impedance of the receiving coil can be improved, and the energy conversion efficiency of the electromagnetic ultrasonic probe can be enhanced as much as possible.
As shown in fig. 5 and 6, the arc meander coil can form a point focused surface wave on one side and a diverging surface wave on the other side. The sound pressure distribution characteristics of the point focusing surface wave and the divergent surface wave can be changed by adjusting the arc angle alpha of the exciting coil, the arc angle beta of the receiving coil and the radius of the arc zigzag coil. The effective detection range of the surface wave can be increased by reducing the arc angles of the exciting coil and the receiving coil and increasing the radius of the arc-shaped zigzag coil, but the detection sensitivity of the defects is reduced; increasing the arc angle of the exciting coil and the receiving coil and decreasing the radius of the arc zigzag coil can reduce the effective detection range of the surface wave, but can improve the detection sensitivity of the defect.
As shown in fig. 7, when the circular arc coil in the electromagnetic surface acoustic wave probe is rotated by the stepping motor, the principal axis of sound velocity of the point focusing/diverging surface wave will also be deflected, and when the center of the ultrasonic beam is perpendicular to the main reflection surface of the micro defect, or perpendicular to the main reflection surface of the oblique crack, the amplitude of the defect echo will reach the maximum. In ultrasonic detection, the maximum reflected wave amplitude of the defect is usually used as the basis for quantitative analysis of the defect. Therefore, the method can realize accurate quantitative detection of the tiny defects including the inclined cracks and effective detection of the inclination angle of the cracks during the linear automatic detection.
According to an inverse Lorentz force mechanism and an inverse magnetostriction mechanism, when a surface wave meets an end face or a tiny crack, an ultrasonic echo is returned, can be received by a receiving coil in an electromagnetic ultrasonic surface wave probe, is input into a computer through a data acquisition card after being amplified and filtered for several times, and a time difference t between a transmitting signal and a defect echo signal is acquired through a signal analysis processing module in LabVIEW software. The distance L between the defect in the tested sample and the upper surface is L ═ csT/2, thereby completing the localization analysis of the defect. And comparing the defect echo amplitude with defect echo amplitudes of different prefabricated defect comparison samples to finish the quantitative analysis of the defects.
The invention is not limited to the foregoing embodiments. The invention extends to any novel feature or any novel combination of features disclosed in this specification and any novel method or process steps or any novel combination of features disclosed. Therefore, the scope of the invention should not be limited by the description of the embodiments, but should be determined by the following claims.
Claims (10)
1. An electromagnetic ultrasonic point focusing/diverging surface wave device for rapid online detection of a steel rail tread, which is characterized by comprising: the device comprises an electromagnetic ultrasonic point focusing/diverging surface wave probe, an impedance matching network, a pulse power amplifier, a signal generator, a preamplifier, a secondary filtering and amplifying circuit, a data acquisition card, a LabVIEW software detection interface, a motion controller and a mechanical walking/rotating device.
2. The electromagnetic ultrasonic point focusing/diverging surface wave device for rapid on-line inspection of rail treads according to claim 1, wherein the electromagnetic ultrasonic point focusing/diverging surface wave probe is capable of generating not only focused surface waves but also diverging surface waves by using a combination of a circular-arc meander coil and a vertically magnetized permanent magnet.
3. The electromagnetic ultrasonic point focusing/diverging surface wave device for the rapid online detection of the steel rail tread as claimed in claim 1 or 2, wherein the motion controller and the mechanical walking/rotating device can realize the automatic walking of the electromagnetic ultrasonic point focusing/diverging surface wave probe on the steel rail tread on one hand; on the other hand, the circular arc-shaped zigzag coil of the electromagnetic ultrasonic point focusing/diverging surface wave probe can rotate along the center in the detection process, and the rotation angle information is fed back to a LabVIEW software detection interface in real time.
4. The electromagnetic ultrasonic point focusing/diverging surface wave device for the rapid online detection of the rail tread as claimed in claim 1, wherein the pulse power amplifier and the signal generator are used together, and can provide the electromagnetic ultrasonic probe with the radio frequency current with the transient power of 5KW to 15KW, drive the exciting coil in the electromagnetic ultrasonic point focusing/diverging surface wave probe and excite the point focusing/diverging surface wave in the rail tread; and/or the presence of a gas in the gas,
the preamplifier, the secondary filter amplifying circuit and the data acquisition card are matched for use, so that a weak electric signal captured by a receiving coil in the electromagnetic ultrasonic point focusing/diverging surface wave probe can be subjected to multistage filter amplification, converted into a digital signal through an analog-to-digital converter and sent into a LabVIEW software detection interface; and/or
The impedance matching network is used for realizing impedance matching between an exciting coil and the output impedance of the pulse power amplifier in the electromagnetic ultrasonic surface wave probe and transferring the exciting power to the exciting coil to the maximum extent; on the other hand, the impedance difference problem between the input impedance of the receiving coil and the input impedance of the preamplifier in the electromagnetic ultrasonic point focusing/diverging surface wave probe can be solved, the weak induced power captured by the receiving coil can be transferred to the preamplifier to the maximum extent, and the energy conversion efficiency of the electromagnetic ultrasonic surface wave probe is improved finally.
5. The electromagnetic ultrasonic point focusing/diverging surface wave device for rapid on-line rail tread detection as claimed in claim 1, wherein the LabVIEW software detection interface comprises the main functions of: 1) adjusting electromagnetic ultrasonic excitation parameters, wherein the electromagnetic ultrasonic excitation parameters comprise current amplitude, frequency, duration and trigger interval; 2) adjusting electromagnetic ultrasonic receiving parameters, wherein the adjustment of the electromagnetic ultrasonic receiving parameters comprises gain multiples, filtering parameters and average times; 3) the walking and rotating actions of the electromagnetic ultrasonic probe; 4) recording and analyzing ultrasonic echo data, and quantifying and positioning and analyzing defects.
6. The electromagnetic ultrasonic point focusing/diverging surface wave device for the rapid on-line detection of the rail tread as claimed in claim 1, wherein in the LabVIEW detection interface, the signal generator is controlled to generate a sine pulse train with adjustable duration and cycle number through an RS232 serial port bus, and a large amplitude pulse excitation current after amplification can be generated through a pulse power amplifier and is sent to an excitation coil in the electromagnetic ultrasonic surface wave probe through an impedance matching network; exciting a point focusing/diverging surface wave on a steel rail tread by an exciting part of the electromagnetic ultrasonic point focusing/diverging surface wave probe under the combined action of Lorentz force and magnetostrictive effect, and propagating along the length direction of the steel rail; when a tiny defect or a crack is encountered, a defect echo is obtained through reflection; when the defect echo reaches the position under a receiving coil of the electromagnetic ultrasonic surface wave probe, a weak induced voltage signal is induced at a receiving part of the electromagnetic ultrasonic point focusing/diverging surface wave probe according to the inverse Lorentz force and the inverse magnetostrictive effect; the induced voltage signal is filtered and amplified by the preamplifier and the secondary filtering and amplifying circuit to obtain a voltage signal with high signal-to-noise ratio within the range of the data acquisition card, and then the voltage signal is converted into a digital signal by the analog-to-digital conversion function of the data acquisition card and sent into a LabVIEW software interface for signal analysis and processing through NET or PCI-E transmission bus.
7. The electromagnetic ultrasonic point focusing/diverging surface wave device for rapid on-line rail tread detection as claimed in claim 2, wherein point focusing/diverging surface waves of different frequencies f can be excited by adjusting the spacing d between adjacent wires of the meander coil, where d and f are satisfied: d ═ cs/2f, in the formula csRepresenting the surface wave sound velocity of the rail tread; and/or the presence of a gas in the gas,
the sound pressure distribution of the point focusing/diverging surface wave can be changed by adjusting the arc angle alpha of the exciting coil of the electromagnetic ultrasonic point focusing/diverging surface wave probe, the arc angle beta of the receiving coil and the radius of the arc zigzag coil thereof.
8. The electromagnetic ultrasonic point focusing/diverging surface wave device for the rapid online detection of the tread of the steel rail as claimed in claim 3, wherein the detection of the micro-defects and the cracks with different orientations in different areas can be realized by rotating the arc-shaped zigzag coil along the central axis and generating ultrasonic sound beams in different directions on the tread of the steel rail; the same circular arc zigzag coil EMAT can generate point focusing surface waves to realize the detection of micro defects and can also generate divergent surface waves to realize the detection of straight cracks/inclined cracks on two sides of a tread; and determining the inclination angle of the crack according to the rotation angle of the electromagnetic ultrasonic probe corresponding to the maximum echo amplitude of the inclined crack on the tread.
9. The electromagnetic ultrasonic point focusing/diverging surface wave device for rapid on-line inspection of rail treads according to claim 3, wherein the electromagnetic ultrasonic point focusing/diverging surface wave probe comprises the following structure: the stainless steel shell is mainly used for protecting structures such as a permanent magnet and a zigzag coil in the probe and shielding electromagnetic interference signals of the external environment; the stepping motor is connected with the arc zigzag coil through a rotating rod and an elastic retaining plate, and a flexible supporting structure is arranged above the arc zigzag coil and used for applying certain pressure to ensure that the arc zigzag coil is mutually attached to the complex tread of the steel rail; a flexible wear-resistant layer is arranged below the circular arc-shaped zigzag coil; and a rolling bearing is arranged in the electromagnetic ultrasonic point focusing/diverging surface wave probe and is used for ensuring that the probe and the steel rail tread are lifted off by 0.5-1 mm.
10. A method of testing using the apparatus of claims 1-9, comprising the steps of:
the method comprises the following steps: LabVIEW software detects the sine pulse train with adjustable frequency/periodicity/repetition frequency generated by an interface control signal generator, and obtains high-power radio-frequency pulse current through the amplification effect of a pulse power amplifier;
step two: under the action of high-power radio frequency pulse current, an excitation coil in the electromagnetic ultrasonic point focusing/diverging surface wave probe generates point focusing/diverging surface waves on the surface of the steel rail according to Lorentz force and magnetostrictive effect;
step three: point focusing/diverging surface wave is transmitted in the steel rail tread, when a tiny defect or cracks on two sides of the tread are met, a defect echo is generated and is obtained by a receiving coil in an electromagnetic ultrasonic point focusing/diverging surface wave probe and converted into an induced voltage signal; controlling gain multiples and filter parameters of a preamplifier and a secondary amplifying circuit through a LabVIEW software detection interface, filtering and amplifying weak induced voltage signals, performing analog-to-digital conversion through a data acquisition card, and sending the signals into the LabVIEW software detection interface;
step four: the LabVIEW software detection interface sends a motion instruction, the mechanical rotating device is driven by the motion controller to drive the circular arc zigzag coil in the electromagnetic ultrasonic point focusing/diverging surface wave probe to rotate along the central shaft, and corresponding ultrasonic echo signals at different rotation angles are recorded in real time;
step five: performing positioning analysis on the flight time t of the defect echo corresponding to the maximum ultrasonic echo amplitude, and calculating the distance L from the defect to the surface of the sample according to a formula L (c _ s) t/2, wherein c _ s is the sound velocity of the surface wave of the steel rail; positioning and analyzing the defect echo amplitude corresponding to the maximum ultrasonic echo amplitude, comparing the defect echo amplitude with a previously-known round hole or crack to determine the equivalent size of the defect;
step six: and the LabVIEW software detection interface sends a motion instruction, the mechanical walking device is driven by the motion controller to drive the electromagnetic ultrasonic point focusing/diverging surface wave probe to move to a preset position along the length direction of the steel rail, and the steps from the first step to the fifth step are repeated until the detection of all the steel rail treads is completed.
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| CN115881079A (en) * | 2023-02-16 | 2023-03-31 | 山东铁路投资控股集团有限公司 | Noise early warning method, system, equipment and storage medium in railway track construction |
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