CN111024805B - Steel rail surface damage magnetic flux leakage detection device and method - Google Patents
Steel rail surface damage magnetic flux leakage detection device and method Download PDFInfo
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- 230000005291 magnetic effect Effects 0.000 title claims abstract description 167
- 230000006378 damage Effects 0.000 title claims abstract description 48
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 22
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- 230000004907 flux Effects 0.000 title claims abstract description 13
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- 238000007689 inspection Methods 0.000 claims abstract description 16
- 230000003750 conditioning effect Effects 0.000 claims abstract description 9
- 238000005259 measurement Methods 0.000 claims description 6
- 230000005284 excitation Effects 0.000 claims description 5
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- 239000003302 ferromagnetic material Substances 0.000 description 3
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- 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
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- 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
- B61K9/10—Measuring installations for surveying permanent way for detecting cracks in rails or welds thereof
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Abstract
The invention discloses a steel rail surface damage magnetic flux leakage detection device and a method, comprising a U-shaped magnetic yoke, magnetic sensors, a conditioning circuit and an acquisition circuit, wherein a main magnetic sensor is arranged in the middle below the magnetic yoke, and auxiliary magnetic sensors are arranged on two sides of the main magnetic sensor; when in detection, firstly, a magnetic leakage detection probe is adopted to convert a rail surface damage magnetic leakage signal into an analog voltage signal, then the analog voltage signal is converted into a digital signal through a conditioning circuit and an acquisition circuit, then the digital signal is processed, and finally, whether surface damage exists is judged according to the magnitude relation of output signals of a main magnetic sensor and an auxiliary magnetic sensor. The invention can inhibit the influence of lifting interference, effectively detect surface damage and is suitable for magnetic flux leakage inspection of the surface damage of the steel rail.
Description
Technical Field
The invention relates to a nondestructive testing technology, in particular to a device and a method for testing the surface damage and the magnetic flux leakage of a steel rail.
Background
Nondestructive testing is a new discipline for evaluating structural abnormalities and damage, that is, detecting the presence or absence of damage such as cracks or inclusions in the internal structure, physical properties, or state of a workpiece or material to be tested, without damaging the workpiece or material, by using changes in the response to heat, sound, electricity, light, magnetism, or the like, caused by the presence of the abnormalities and damage in the internal structure of the material.
The magnetic flux leakage nondestructive detection method can detect the surface and internal damage of a ferromagnetic material workpiece, has the advantages of high detection sensitivity, high speed, low requirement on the surface cleanliness of the workpiece, low cost, simple operation and the like, and is widely applied to nondestructive detection of ferromagnetic materials, such as steel rails, steel pipes and other equipment.
The vertical distance between the magnetic sensor and the measured workpiece is called lift-off, and the distribution of leakage magnetic fields is different under different lift-off conditions. When the probe is used for circular detection on the surface of a workpiece, the lift-off is changed under the influence of factors such as vibration and the like, so that the output change of the magnetic sensor is called lift-off interference. During high-speed inspection, lifting-off interference and random interference are superposed on a detection signal, so that a damage signal is difficult to distinguish, and the measurement of the damage is not facilitated. In order to increase the detection rate of damage and reduce the false alarm rate, it is necessary to suppress the influence of various disturbances.
Disclosure of Invention
The purpose of the invention is as follows: aiming at the problems, the invention provides a device and a method for detecting the surface damage and the magnetic leakage of the steel rail, which can effectively inhibit the extraction interference and the random interference of magnetic leakage signals, improve the detection rate of the damage and reduce the false alarm rate.
The technical scheme is as follows: in order to realize the purpose of the invention, the technical scheme adopted by the invention is as follows: the utility model provides a rail surface damage magnetic leakage detection device, includes magnetic leakage test probe, modulate circuit and acquisition circuit, magnetic leakage test probe is analog voltage signal with rail surface damage magnetic leakage signal conversion to by the modulate circuit filtering, convert digital signal into through acquisition circuit again, send and handle for the computer.
Furthermore, the magnetic flux leakage detection probe comprises a U-shaped magnetic yoke, an excitation coil, a main magnetic sensor and four auxiliary magnetic sensors, wherein the excitation coil is wound on the U-shaped magnetic yoke, the main magnetic sensor is arranged in the middle of the lower part of the U-shaped magnetic yoke, and the auxiliary magnetic sensors are arranged on two sides of the main magnetic sensor.
Further, the first auxiliary magnetic sensor and the second auxiliary magnetic sensor are at a distance of the main magnetic sensor
The third auxiliary magnetic sensor and the fourth auxiliary magnetic sensor are at a distance of the main magnetic sensor
Wherein 2a is the minimum flaw width to be detected, b is the minimum flaw depth to be detected, and z0And lifting away the expected value for the preset inspection.
Further, the main magnetic sensor is used for detecting magnetic fields in x and z directions, the first auxiliary magnetic sensor and the second auxiliary magnetic sensor are used for detecting magnetic fields in the x direction, and the third auxiliary magnetic sensor and the fourth auxiliary magnetic sensor are used for detecting magnetic fields in the z direction.
A method for detecting the surface damage and magnetic flux leakage of a steel rail comprises the following steps:
(1) placing the magnetic leakage detection probe on the surface of the steel rail, and adjusting the lift-off to be z0Starting to inspect;
(2) a magneto-dependent sensor in the magnetic leakage detection probe converts a rail surface damage magnetic leakage signal into an analog voltage signal, the analog voltage signal is filtered through a conditioning circuit, and the analog signal is converted into a digital signal through an acquisition circuit;
(3) sending the processed digital signal to a computer for processing;
(4) the computer respectively performs curve fitting on the data in the x direction and the z direction obtained by the measurement of the main magnetic sensor to obtain Hx(l)、Hz(l) (ii) a Respectively carrying out curve fitting on the data in the x direction measured by the first auxiliary magnetic-sensing sensor and the second auxiliary magnetic-sensing sensor to obtain Hx1(l)、Hx2(l) (ii) a Respectively carrying out curve fitting on the data in the z direction measured by the third auxiliary magnetic-sensing sensor and the fourth auxiliary magnetic-sensing sensor to obtain Hz3(l)、Hz4(l) (ii) a Wherein l is the inspection mileage;
(5) judging; if the signal of each magnetic sensor is at0When conditions 1 and 3 are satisfied simultaneously or conditions 2 and 3 are satisfied simultaneously, it is considered that0There is a lesion; otherwise, consider as being in0No damage is caused;
condition 1: hz(l0)＝0；
Condition 2: hx(l0) Is a maximum;
condition 3; hx(l0)>Hx1(l0-l1)，Hx(l0)>Hx2(l0+l1)，Hz(l0)<Hz3(l0-l2)，Hz(l0)>Hz4(l0+l2) At least 3 of the 4 equations are true, wherein,
has the advantages that: the device and the method for detecting the surface damage and the magnetic leakage of the steel rail can effectively inhibit the magnetic leakage signal lift-off interference and random interference, improve the detection rate of the damage, reduce the false alarm rate, and are suitable for the itinerant detection of the surface or near-surface damage of ferromagnetic materials such as the steel rail, a steel pipe and the like.
Drawings
FIG. 1 is a schematic view of a rail surface flaw and flux leakage detection apparatus according to the present invention;
FIG. 2 is a cross-sectional view taken in the x-z plane near a rail flaw;
fig. 3(a) is a schematic view of the magnetic field intensity distribution at the flaw in the x direction, and fig. 3(b) is a schematic view of the magnetic field intensity distribution at the flaw in the z direction.
Detailed Description
The technical solution of the present invention is further described below with reference to the accompanying drawings and examples.
As shown in fig. 1, the steel rail surface damage and leakage detection device of the present invention includes a leakage detection probe, a conditioning circuit and an acquisition circuit, wherein the leakage detection probe is firstly adopted to convert a steel rail surface damage and leakage signal into an analog voltage signal, then the conditioning circuit is used to process the voltage signal output by the sensor of the leakage detection probe, primarily filter interference, and finally the acquisition circuit is used to convert the analog signal after the primarily filtering interference is lifted off into a digital signal, and the digital signal is sent to a computer for processing.
The magnetic leakage detection probe comprises a U-shaped magnetic yoke, an excitation coil, a main magnetic sensor and four auxiliary magnetic sensors, wherein the first auxiliary magnetic sensor, the second auxiliary magnetic sensor, the third auxiliary magnetic sensor and the fourth auxiliary magnetic sensor are wound on the U-shaped magnetic yoke, the main magnetic sensor is arranged in the middle of the lower part of the U-shaped magnetic yoke, and the auxiliary magnetic sensors are arranged on two sides of the main magnetic sensor.
As shown in fig. 2, which is a cross-sectional view of an x-z plane near a rail damage, the direction in which the inspection vehicle advances along the rail is taken as the x direction, the direction perpendicular to the direction in which the inspection vehicle advances on the surface of the rail is taken as the y direction, and the normal direction of the surface of the rail is taken as the z direction. Because the x direction and the y direction are both parallel to the surface of the steel rail, the characteristics of the leakage magnetic field in the x direction and the y direction are very similar, and only the characteristics of the leakage magnetic field in the x direction and the z direction are analyzed; wherein the width of the damage is 2a and the depth is b.
The main magnetic sensor is used for detecting magnetic fields in the x and z directions and is arranged in the middle of the lower part of the U-shaped magnetic yoke; the auxiliary magnetic sensor can detect a magnetic field in a single direction and is arranged on two sides of the main magnetic sensor. The main magnetic sensor is used for detecting magnetic fields in the x and z directions, the first auxiliary magnetic sensor and the second auxiliary magnetic sensor are used for detecting the magnetic field in the x direction, and the third auxiliary magnetic sensor and the fourth auxiliary magnetic sensor are used for detecting the magnetic field in the z direction.
The distribution of the leakage magnetic field is different under different lift-off. During high-speed inspection, lifting-off interference and random interference are superposed on a detection signal, so that a damage signal is difficult to distinguish, and the detection of the damage is adversely affected. The leakage magnetic field intensity of a certain point P (x, z) above the damage is H (x, z), wherein, the component in the x direction is Hx(x, z) with a z-direction component of Hz(x, z) can be obtained from the formulae (1) and (2), respectively.
Wherein, mu0Denotes the permeability, σ, of airmsThe surface magnetic charge density of the damaged side surface can be calculated by equation (3).
Where μ is the permeability of the material and H is the applied magnetic field strength.
The same damage has different amplitudes of output signals of the magnetic sensors under different lift-off conditions. In inspection, when the amplitude of the output signal of the magnetic sensor changes, it is difficult to distinguish whether the change is caused by damage or lift-off. Because the inspection is also interfered immediately, the judgment difficulty is further increased.
If the lift-off z of the probe is 1mm, a is 1mm, b is 1mm, σmsWhen/2 pi is 1, the magnetic field distribution in the x and z directions of the damage is as shown in fig. 3(a) and (b). Can prove Hx(0, z) is maximum and Hz(0, z) is 0, namely when the main magnetic sensor is right above the injury, the output of the x direction is larger than the output of the first auxiliary magnetic sensor and the second auxiliary magnetic sensor no matter the lifting-off size; the output in the z direction is smaller than the output of the third auxiliary magnetic sensor and larger than the output of the fourth auxiliary magnetic sensor. Whether damage exists can be judged by comparing the relative magnitude of the output signal amplitudes of the main magnetic sensor and the auxiliary magnetic sensor. Since the judgment is not based on the signal amplitude, but on the relative amplitude of different magnetic-sensing sensor signals, the influence of the lift-off change is small.
Because random interference exists during routing inspection, in order to reduce misjudgment, the position of the auxiliary magnetic sensor needs to be reasonably set, so that the output difference value of the auxiliary magnetic sensor and the main magnetic sensor is as large as possible. The first auxiliary magnetic-sensing sensor and the second auxiliary magnetic-sensing sensor are arranged at Hx(x,z0) At the minimum value of; the third auxiliary magnetic-sensing sensor is arranged at Hz(x,z0) At the maximum of; the fourth auxiliary magnetic-sensing sensor is arranged at Hz(x,z0) At the minimum value of (c).
Due to Qx(x,z0) Point of minimum value of (A) and (H)x(x,z0) The minimum point position at the negative half axis of x is close, for convenience of calculation, with Qx(x,z0) The value of x at the minimum of (a) is the position of the first auxiliary magnetic sensor.
Because the distance between the magnetic sensors is small and the lifting distance is the same, the z is equal to the z0Deriving x with constant value, and let G'x(x,z0) Is equal to 0, to obtain
Can obtain the product
Time QX(x,z0) The absolute value is taken as a minimum value, and the distance from the first auxiliary magnetic sensor to the main magnetic sensor is obtained
Wherein 2a is the minimum flaw width to be detected, b is the minimum flaw depth to be detected, and z0And lifting away the expected value for the preset inspection.
Due to Gx(x,z0) Point of minimum value of (A) and (H)x(x,z0) The position of the minimum value point on the positive half axis of x is close to G for convenient calculationx(x,z0) The value of x at the minimum of (a) is the position of the second auxiliary magnetic sensor.
Because the distance between the magnetic sensors is small and the lifting distance is the same, the z is equal to the z0Taking derivative of x under the premise of constant value and letting Q'x(x,z0) Is equal to 0, to obtain
Can obtain the product
Time Gx(x,z0) The distance between the second auxiliary magnetic sensor and the main magnetic sensor is minimum
Because the damage or the crack is small, a magnetic dipole model of crack leakage magnetic field distribution can be introduced, and the formula (2) is simplified:
because the distance between the magnetic sensors is small and the lifting distance is the same, the z is equal to the z0Taking derivative of x under the premise of constant number, and letting H'z(x,z0) Is equal to 0, to obtain
Namely, it is
When Hz(x,z0) Is a maximum value of the number of pixels,
when Hz(x,z0) If the distance between the third auxiliary magnetic sensor and the main magnetic sensor is a minimum value, the distance between the third auxiliary magnetic sensor and the main magnetic sensor is
The invention discloses a method for detecting the surface damage and magnetic flux leakage of a steel rail, which comprises the following steps:
(1) placing the magnetic leakage detection probe on the surface of the steel rail, and adjusting the lift-off to be z0Starting to inspect;
(2) a magneto-dependent sensor in the magnetic leakage detection probe converts a rail surface damage magnetic leakage signal into an analog voltage signal, the analog voltage signal is filtered through a conditioning circuit, and the analog signal is converted into a digital signal through an acquisition circuit;
(3) sending the processed digital signal to a computer for processing;
(4) computer main magnetic sensorRespectively carrying out curve fitting on the measured data in the x and z directions to obtain Hx(l)、Hz(l) (ii) a Respectively carrying out curve fitting on the data in the x direction measured by the first auxiliary magnetic-sensing sensor and the second auxiliary magnetic-sensing sensor to obtain Hx1(l)、Hx2(l) (ii) a Respectively carrying out curve fitting on the data in the z direction measured by the third auxiliary magnetic-sensing sensor and the fourth auxiliary magnetic-sensing sensor to obtain Hz3(l)、Hz4(l) (ii) a Wherein l is the inspection mileage;
(5) judging; if l0A wound in the area, then Hz(l0)＝0、Hx(l0) Is a maximum value, Hx(l0)>Hx1(l0-l1)、Hx(l0)>Hx2(l0+l1)、Hz(l0)>Hz4(l0+l2)、Hz3(l0)>Hz(l0-l2). When in inspection, because of random interference, the output of each magnetic sensor at the damaged part is difficult to satisfy all conditions, if the signal of each magnetic sensor is in I0When conditions 1 and 3 are satisfied simultaneously or conditions 2 and 3 are satisfied simultaneously, it is considered that0There is a lesion; otherwise, consider as being in0There was no damage.
Condition 1: hz(l0)＝0；
Condition 2: hx(l0) Is a maximum;
condition 3; hx(l0)>Hx1(l0-l1)，Hx(l0)>Hx2(l0+l1)，Hz(l0)<Hz3(l0-l2)，Hz(l0)>Hz4(l0+l2) At least 3 of the 4 equations are true, wherein,
let a 1mm, b 1mm, z02mm, the distance from the first auxiliary magnetic sensor and the second auxiliary magnetic sensor to the main magnetic sensor is
The distance from the third auxiliary magnetic sensor and the fourth auxiliary magnetic sensor to the main magnetic sensor is
Respectively carrying out curve fitting on the data in the x direction and the z direction obtained by the measurement of the main magnetic sensor to obtain Hx(l)、Hz(l) And l is the mileage of the patrol. Respectively carrying out curve fitting on the data in the x direction obtained by the measurement of the first and second auxiliary magnetic sensors to obtain Hx1(l)、Hx2(l) (ii) a Respectively carrying out curve fitting on the data in the z direction obtained by the measurement of the third and fourth auxiliary magnetic sensors to obtain Hz3(l)、Hz4(l)。
If the signal of each magnetic sensor is at0If conditions 1 and 3 are satisfied simultaneously, or if conditions 2 and 3 are satisfied simultaneously, it is considered that l is0There is damage; otherwise, consider as being in0There was no damage.
Condition 1: hz(l0)＝0
Condition 2: hx(l0) Is a maximum value
Condition 3:
at least 3 of these 4 equations hold.
Claims (3)
1. A steel rail surface damage and magnetic leakage detection device is characterized by comprising a magnetic leakage detection probe, a conditioning circuit and an acquisition circuit, wherein the magnetic leakage detection probe converts a steel rail surface damage and magnetic leakage signal into an analog voltage signal, the analog voltage signal is filtered by the conditioning circuit, the analog voltage signal is converted into a digital signal by the acquisition circuit, and the digital signal is sent to a computer for processing;
the magnetic flux leakage detection probe comprises a U-shaped magnetic yoke, an excitation coil, a main magnetic sensor and four auxiliary magnetic sensors, wherein the excitation coil is wound on the U-shaped magnetic yoke, the main magnetic sensor is arranged in the middle of the lower part of the U-shaped magnetic yoke, and the auxiliary magnetic sensors are arranged on two sides of the main magnetic sensor;
the first auxiliary magnetic sensor and the second auxiliary magnetic sensor are at a distance from the main magnetic sensor
The third auxiliary magnetic sensor and the fourth auxiliary magnetic sensor are at a distance of the main magnetic sensor
Wherein 2a is the minimum flaw width to be detected, b is the minimum flaw depth to be detected, and z0And lifting away the expected value for the preset inspection.
2. A rail surface flaw and flux leakage detection apparatus according to claim 1, wherein said main magnetic sensor is adapted to detect a magnetic field in x and z directions, said first and second auxiliary magnetic sensors are adapted to detect a magnetic field in x direction, and said third and fourth auxiliary magnetic sensors are adapted to detect a magnetic field in z direction.
3. A method for detecting the surface damage and magnetic flux leakage of a steel rail is characterized by comprising the following steps:
(1) placing the magnetic leakage detection probe on the surface of the steel rail, and adjusting the lift-off to be z0Starting to inspect;
(2) a magneto-dependent sensor in the magnetic leakage detection probe converts a rail surface damage magnetic leakage signal into an analog voltage signal, the analog voltage signal is filtered through a conditioning circuit, and the analog signal is converted into a digital signal through an acquisition circuit;
(3) sending the processed digital signal to a computer for processing;
(4) the computer respectively performs curve fitting on the data in the x direction and the z direction obtained by the measurement of the main magnetic sensor to obtain Hx(l)、Hz(l) (ii) a Respectively carrying out curve fitting on the data in the x direction measured by the first auxiliary magnetic-sensing sensor and the second auxiliary magnetic-sensing sensor to obtain Hx1(l)、Hx2(l) (ii) a Respectively carrying out curve fitting on the data in the z direction measured by the third auxiliary magnetic-sensing sensor and the fourth auxiliary magnetic-sensing sensor to obtain Hz3(l)、Hz4(l) (ii) a Wherein l is the inspection mileage;
(5) judging; if the signal of each magnetic sensor is at0When conditions 1 and 3 are satisfied simultaneously or conditions 2 and 3 are satisfied simultaneously, it is considered that0There is a lesion; otherwise, consider as being in0No damage is caused;
condition 1: hz(l0)＝0；
Condition 2: hx(l0) Is a maximum;
condition 3; hx(l0)>Hx1(l0-l1)，Hx(l0)>Hx2(l0+l1)，Hz(l0)<Hz3(l0-l2)，Hz(l0)>Hz4(l0+l2) At least 3 of the 4 equations are true, wherein,
wherein 2a is the minimum flaw width to be detected, b is the minimum flaw depth to be detected, and z0And lifting away the expected value for the preset inspection.
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| CN112083059B (en) * | 2020-08-28 | 2022-07-22 | 南京航空航天大学 | Method for filtering lifting interference of top surface of steel rail |
| CN112305063A (en) * | 2020-10-26 | 2021-02-02 | 西安热工研究院有限公司 | Method for judging magnetism of austenitic stainless steel matrix |
| CN112798682B (en) * | 2021-04-07 | 2021-07-02 | 山东大业股份有限公司 | Tire bead steel wire quality detection device |
| CN113264082B (en) * | 2021-04-08 | 2022-06-24 | 南京航空航天大学 | High-speed track array ACFM detection probe and detection method thereof |
| CN113671018B (en) * | 2021-08-10 | 2023-05-09 | 南京航空航天大学 | Filtering method for inhibiting lifting interference of steel rail magnetic flux leakage detection |
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| CN109060939A (en) * | 2018-08-31 | 2018-12-21 | 南京航空航天大学 | Steel rail defect checking method for width based on leakage magnetic detection device |
| CN109632941B (en) * | 2019-01-08 | 2022-06-10 | 南京航空航天大学 | Method for inhibiting magnetic leakage signal lift-off interference |
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| JP2018009867A (en) * | 2016-07-13 | 2018-01-18 | 株式会社Ihi | Leakage flux flaw detection device |
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| 双传感器差分峰值侦测的漏磁检测新方法;吴德会等;《仪器仪表学报》;20160630;第37卷(第6期);第1218-1225页 * |
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