CN111983025B - Method for analyzing defects of rail head and rail web of steel rail - Google Patents

Method for analyzing defects of rail head and rail web of steel rail Download PDF

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CN111983025B
CN111983025B CN202010893170.2A CN202010893170A CN111983025B CN 111983025 B CN111983025 B CN 111983025B CN 202010893170 A CN202010893170 A CN 202010893170A CN 111983025 B CN111983025 B CN 111983025B
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CN111983025A (en
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杨永杰
张兴家
任婉婷
朱林钰
盛明华
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Nantong University
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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    • G01N29/44Processing the detected response signal, e.g. electronic circuits specially adapted therefor
    • G01N29/4409Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison
    • G01N29/4418Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison with a model, e.g. best-fit, regression analysis
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/44Processing the detected response signal, e.g. electronic circuits specially adapted therefor
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    • G01MEASURING; TESTING
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    • GPHYSICS
    • G01MEASURING; TESTING
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Abstract

The invention discloses a method for analyzing defects of a rail head and a rail web of a steel rail, which comprises the following steps: s1, establishing a steel rail 3D model; s2, solving an ultrasonic sound beam incident point; s3, calculating a linear equation of the ultrasonic primary wave; s4, solving a reflection point; s5, solving a normal equation of the ultrasonic beam; s6, solving a linear equation of the secondary wave, namely the reflection line; s7, solving the intersection point of the reflection line, namely the secondary wave, and the surface of the steel rail; s8, coordinate conversion of defect points: the defect analysis method for the rail head and the rail web of the steel rail can conveniently distinguish the positions of the defects, can obtain the coordinates of the defects in the steel rail by the defect analysis method, and can draw the coordinates of the defects to describe the approximate forms of the defects; is beneficial to making reasonable and scientific judgment on the steel rail.

Description

Rail head and rail web defect analysis method for steel rail
Technical Field
The invention belongs to the technical field of flaw detection, particularly relates to the field of steel rail flaw detection, and particularly relates to a method for analyzing defects of a rail head and a rail web of a steel rail.
Background
The steel rail may be damaged during welding, installation and use, which cannot be observed by naked eyes. The damage condition becomes increasingly serious with the use of time. When the damage reaches a certain degree, serious safety accidents are likely to happen. At present, the rail damage is displayed by adopting a plane fan shape to display whether damage exists, when the damage exists, different colors are displayed at the corresponding sound path of the fan shape, and color spots are utilized to distinguish whether a damaged area exists.
There are also significant limitations to the damage management methods described above. The ultrasonic beam emitted by the probe is regarded as a sector, when only the primary wave is adopted for flaw detection, the approximate form of the flaw can be detected very conveniently by the flaw detection method, however, when the secondary wave and the above-mentioned wave are adopted for flaw detection, the flaw detection method only can reflect whether the flaw exists qualitatively, and the position of the flaw and one form of the flaw cannot be detected accurately. However, multiple waves are often used for flaw detection in production practice, and the coverage rate of ultrasonic waves on the steel rail is improved. That is to say, the traditional flaw detection display method cannot effectively track and study the evolution of the flaw, and is not beneficial to the knowledge of the cause of the flaw. Further, the current flaw detection method is highly demanding on the flaw detector, and requires a great amount of flaw detection experience to be able to roughly estimate the location of the flaw.
Disclosure of Invention
The invention aims to provide a method for analyzing the defects of a rail head and a rail web of a steel rail, which can improve the detection quality of the defects of the steel rail, can accurately detect the defects in the rail head and the rail web of the steel rail, and can shield the occurrence of misjudgment and missed judgment caused by subjective reasons such as experience of flaw detection personnel so as to solve the defects or problems in the background technology.
In order to achieve the above object, an embodiment of the present invention provides a method for analyzing defects of a rail head and a rail web of a steel rail, which is based on detection of a phased ultrasonic flaw detection device, wherein the phased ultrasonic flaw detection device includes an ultrasonic phased array probe, an ultrasonic control board card and an encoder; the ultrasonic phased array probe is contacted with a workpiece to be detected through a coupling agent, the ultrasonic control board card is electrically connected with the ultrasonic phased array probe and used for generating ultrasonic signals, processing the received return signals through an encoder to generate a series of digital signals and establishing a steel rail 3D model in a space rectangular coordinate system; the encoder is used for calculating a path equation of primary wave and secondary wave of the ultrasonic beam by combining the position information of the ultrasonic phased array probe and the beam parameters, and then converting the acquired digital signals into three-dimensional coordinates; the method for analyzing the defects of the rail head and the rail web of the steel rail is characterized by comprising the following steps of:
s1, establishing a steel rail 3D model: selecting the bottom surface of the steel rail as an xoy surface of a three-dimensional coordinate axis, wherein the transverse direction of the steel rail is the y-axis direction, the longitudinal direction of the steel rail is the x-axis direction, converting the position of the probe on the steel rail into a coordinate value of the probe on a steel rail model, and enabling the ultrasonic phased array probe to be positioned on a steel rail head tread and to rotate and move on a slope;
s2, solving the incidence point of the ultrasonic sound beam: according to the requirements of flaw detection, when the rail head and the rail web are subjected to ultrasonic flaw detection, the probe is fixed on the rail head tread of the steel rail by using the clamping device and moves back and forth and rotates left and right,realizing ultrasonic coverage of railhead and rail web areas; recording the distance l from the rotation original point of the probe to the outermost edge of the steel rail and the transverse included angle beta of the probe and the steel rail; when moving flaw detection is carried out, according to the position of the rotation origin of the probe and the rotation angle; the coordinate value after rotation, that is, the coordinate (x) of the incident point of the ultrasonic wave obtained can be calculated from the relationship between the rotation origin and the rotation angle r ,y r ,z r );
S3, calculating a linear equation of the ultrasonic primary wave: according to the incident point coordinates (x) of the ultrasonic beam solved in step S2 r ,y r ,z r ) Solving for the coordinates (x) of the point of incidence when not rotated i ,y i ,z i ) Determining the corresponding coordinate (x) of the incident point on the xoy surface under the action of the incident angle theta z ,y z ,z z ) (ii) a Determining a straight line by using two points, and solving an equation of the straight line of the ultrasonic primary wave according to the two points;
s4, solving a reflection point: the equation of the line where the ultrasonic primary wave is located is obtained through the solution of the step S3, and the intersection point, namely the coordinate (x) of the reflection point of the primary wave is solved through simultaneous solution by using the equation and the piecewise function of the steel rail surface c1 ,y c1 ,z c1 ) Simultaneously solving an equation set;
s5, solving a normal equation of the ultrasonic beam: by utilizing the principle of specular reflection, when an incident ray and a normal are known, a reflected ray is solved; using the reflection point, solving the normal vector at the point according to the situation, and writing a normal equation;
s6, solving a linear equation of the secondary wave, namely the reflection line: according to the mirror reflection principle, randomly selecting a point on an incident line, and solving the symmetric point coordinate of the point relative to the normal; selecting an incidence point (x) r ,y r ,z r ) Solving for the point of symmetry (x) of the point about the normal t ,y t ,z t ) Because the normal line at any position is vertical to the y axis due to the structural characteristics of the steel rail and the establishment mode of the coordinate system, the distance from the incident point to the normal line is equal to the distance from the reflection point of the incident point to the normal line; solving the values of two components of x and z of the incidence point about the normal line symmetry point; writing out the reflection lineThe equation of the straight line;
s7, solving the intersection point of the reflection line, namely the secondary wave, and the surface of the steel rail: the equation of the line where the ultrasonic secondary wave is located is obtained through the solving of the steps, and the equation and the piecewise function of the surface of the steel rail are used for simultaneous solving to obtain an intersection point, namely the reflection point coordinate (x) of the secondary wave c2 ,y c2 ,z c2 );
S8, defect point coordinate transformation: using the three points solved above: incident Point (x) r ,y r ,z r ) Primary reflection point coordinates (x) c1 ,y c1 ,z c1 ) Coordinates (x) of reflection point of secondary wave c2 ,y c2 ,z c2 ) The primary wave length S and the secondary wave length F can be calculated; the ultrasonic flaw detection device returns a series of discrete data points, the returned data represents ultrasonic return information at equal intervals according to the number of sampling points in a sound path set by ultrasonic beams, and the numerical value of each data point is used for judging whether damage exists or not; determining the distance S from a data point to an incident point by using the position of the point in the data sequence, determining whether the point is positioned on the primary wave by using the ratio of S/S, if S/S is less than 1, on the primary wave, and then substituting t-S/S into the obtained primary wave linear equation to calculate the coordinate of the point; on the contrary, if S/S is greater than 1, the secondary wave is substituted with t ═ S/F into the above-obtained linear equation of the secondary wave, and the coordinates of the defect point can be calculated.
In a further embodiment of the present invention, in step S2, the method specifically includes the following steps: the tread of the rail head of the steel rail can be regarded as a plane parallel to the bottom surface of the steel rail, namely, the included angle between the tread and the xoy plane is 0 degree;
suppose the rotation origin coordinate of the probe is (x) 0 ,y 0 ,z 0 ) When the probe is not rotated, the direction of the probe is parallel to the transverse direction of the steel rail, and the coordinate of the incident point of a certain sound beam is (x) i ,y i ,z i ) The rotation angle of the probe is beta, and the corresponding incidence point of the probe after the rotation is (x) r ,y r ,z r ) Due to rotation of front and rear incident points to the origin of rotationThe distance is constant and is always y i -y 0 Only the x and y components will change after rotation:
Δx=(y i -y 0 )*sinβ;
Δy=(y i -y 0 )*cosβ;
the obtained incident points are:
x r =x 0 +Δx;
y r =y 0 +Δy。
in a further embodiment of the present invention, in step S3, the calculation process of the linear equation of the ultrasonic primary wave is as follows:
when the rotation angle β is 0 °, the incident angle is θ, and the coordinates (x) of the corresponding point on the xoy plane d ,y d ,z d ) Comprises the following steps:
x d =x r
y d =z r *tanθ+y r
z d =0;
since the steel rail tread and the xoy surface can be considered as a parallel interface, when the incident point coordinate (x) of the probe is i ,y i ,z i ) Around the origin of rotation (x) 0 ,y 0 ,z 0 ) Coordinate (x) when rotated on the tread by an angle beta z ,y z ,z z ) Equivalent to a point (x) d ,y d ,z d ) Around a point (x) on the xoy plane 0 ,y 0 ,z 0 ) By rotating the angle β, one can obtain:
x z =(y d -y 0 )*cosβ+x 0
y z =(y d -y 0 )*sinβ+y 0
z z =0;
thus, two point coordinates on the primary wave are obtained, and a parametric equation of the spatial straight line is written:
x=(x r -x z )*t+x z
y=(y r -y z )*t+y z
z=(z r -z z )*t+z z
in a further embodiment of the present invention, in the steps S4 and S7, the coordinates (x) of the reflection point of the primary wave are solved c1 ,y c1 ,z c1 ) Coordinates (x) of reflection point of secondary wave c2 ,y c2 ,z c2 ) The method can be obtained according to the specific situation of a plane section or a circular arc section by the following steps:
(1) simultaneous solution of the equation of the steel rail plane section: the steel rail can be regarded as a cylinder, and the solving process is simplified when the solution is carried out; regarding the steel rail surface plane section as a function of x and z;
setting: the equation of a certain section of plane of the steel rail is z ═ kx + b; wherein k is the slope and b is the intercept of the z-axis, both of which are known quantities;
the parameter equation of the space linear equation is as follows:
x=(x1-x0)*t+x0;
y=(y1-y0)*t+y0;
z=(z1-z0)*t+z0;
and the equation of a straight line where z is kx + b and the secondary wave are combined to obtain:
x=(x1-x0)*t+x0;
kx+b=-((z1-z0)*t+z0);
the above equation is a linear equation of two in relation to x and t; the values of x and t can be calculated by LU decomposition method, the value of t is brought back to the parameter equation, the values of y and z can be calculated, and the obtained solution is the intersection point of the continuous equation, namely (x) c ,y c ,z c );
(2) Simultaneous solving of steel rail arc segment equations:
if the circle center coordinate of the arc segment is (m, n) and the radius is r, the equation of the circle is as follows:
(x-m) 2 +(z-n) 2 =r 2
to simplify the solution, let the spatial linear equation be:
x=at+b;
y=et+f;
z=ct+d;
the equation that brings x, z of the straight line equation into a circle can be:
(a 2 +c 2 )t 2 +2*[a*(b-m)+c*(d-n)]*t+(b-m) 2 +(d-n) 2 -r 2 =0;
converting the equation into a quadratic equation with respect to t, solving the value of t, removing an invalid solution by using a constraint condition for two possible solutions to the quadratic equation with respect to t, bringing the value of t back to the parameter equation, and solving the values of x, y and z, namely the solved intersection point (x) c ,y c ,z c )。
In a further embodiment of the present invention, in the step S5, the solving is performed according to a specific situation that the reflection point falls on the plane segment or the circular arc segment, and the solving of the normal equation specifically includes the following processes:
(1) if the reflection point falls on the plane, the obtained normal lines are collinear at any position on the plane, at the moment, any three non-collinear coordinate points on the plane can be selected to form two vectors in the plane, at the moment, the two vectors are subjected to cross multiplication operation, and the obtained structure is the normal vector of the plane
Figure GDA0003712601020000051
(2) If the reflection point falls on the arc surface, the partial derivative at the point needs to be solved. Assuming that the coordinates of the circle center of the arc surface are (m, n) and the radius is r; the equation for the circle is then: (x-m) 2 +(z-n) 2 =r 2 The equation for the circle can be rewritten as:
F(x,y,z)=(x-m) 2 +(z-n) 2 -r 2
respectively solving partial derivatives of x, y and z for the F (x, y and z) function;
then, F' x =2*(x-m);
F′ y =0;
F′ z =2*(z-m);
The coordinates of the point are substituted to obtain the normal vector of the point
Figure GDA0003712601020000061
At this point, the normal equation can be written:
x=x v *t+x c1
y=0*t+y c1
z=z v *t+z c1
in a further embodiment of the present invention, in step S6, the values of the two components x and z of the incident point about the normal symmetry point are solved; the calculation steps are as follows: to make the reasoning process simpler, the normal equation is rewritten as a truncated form for x, z, where k is the slope and b is the intercept on the z-axis: z is kx + b;
according to the characteristics of the symmetrical points, the midpoint of the point A and the point B satisfies the normal equation, and the product of the slope of the straight line AB and the slope of the normal is-1; based on these two constraints, two equations can be written to solve for x t And z t
Figure GDA0003712601020000062
Figure GDA0003712601020000063
The difference between the y value of the incident point to the reflection point is y c -y r It can be seen that the difference between the symmetric point and the reflection point is also y c1 -y r Can find y t =2*y c1 -y r
Thus, the equation of the line on which the reflection line lies can be written:
x=(x c1 -x t )*t+x t
y=(y c1 -y t )*t+y t
z=(z c1 -z t )*t+z t
the technical scheme of the invention has the following beneficial effects: the method for analyzing the defects of the rail head and the rail web of the steel rail can be used for conveniently distinguishing the positions of the defects by establishing a 3D model of the steel rail, solving the incident point of an ultrasonic sound beam, calculating a linear equation of a primary ultrasonic wave, solving a reflection point, solving a normal equation of the ultrasonic wave, solving a linear equation of a secondary wave, namely a reflection line, solving the coordinate transformation process of the reflection line, namely the intersection point of the secondary wave and the surface of the steel rail and the defect point, and drawing the defect coordinates, so that the approximate form of the defects can be described; the method is favorable for making reasonable and scientific judgment on the steel rail; by using the visual display method, the dependence on the working experience of the flaw detector and the misjudgment and misjudgment caused by the subjective factors of the flaw detector are reduced.
Drawings
FIG. 1 is a block diagram of a 60kg version of the invention.
FIG. 2 is a front view of an ultrasonic probe of the present invention in relation to a defect;
FIG. 3 is a diagram illustrating the distribution of defect coordinates when the rotation angle β is 0 ° in the present invention;
fig. 4 is a defect coordinate distribution when the rotation angle β is 10 ° in the present invention.
Detailed Description
In order to make the technical problems, technical solutions and advantages of the present invention more apparent, the following detailed description is given with reference to the accompanying drawings and specific embodiments.
A rail head and rail web defect analysis method of a steel rail is based on the detection of a phased ultrasonic flaw detection device for analysis, wherein the phased ultrasonic flaw detection device comprises an ultrasonic phased array probe, an ultrasonic control board card and an encoder; the ultrasonic phased array probe is contacted with a workpiece to be detected through a coupling agent, the ultrasonic control board card is electrically connected with the ultrasonic phased array probe and used for generating ultrasonic signals, processing the received return signals through an encoder to generate a series of digital signals and establishing a steel rail 3D model in a space rectangular coordinate system; the encoder is used for calculating a path equation of primary wave and secondary wave of the ultrasonic beam by combining the position information of the ultrasonic phased array probe and the beam parameters, and then converting the acquired digital signals into three-dimensional coordinates; the method for analyzing the defects of the rail head and the rail web of the steel rail comprises the following steps:
s1, establishing a steel rail 3D model: the bottom surface of the steel rail is selected as an xoy surface of a three-dimensional coordinate axis, the transverse direction of the steel rail is a y-axis direction, the longitudinal direction of the steel rail is an x-axis direction, the position of the probe on the steel rail is converted into a coordinate value of the probe on a steel rail model, and the ultrasonic phased array probe is positioned on a steel rail head tread and can rotate and move on a slope surface.
S2, solving the incidence point of the ultrasonic sound beam: according to the requirements of flaw detection, when ultrasonic flaw detection is carried out on a railhead and a railweb, a probe is fixed on a tread of the railhead of a steel rail by using a clamping device, and the ultrasonic coverage of the railhead and the railweb area is realized through back-and-forth movement and left-and-right rotation; recording the distance l from the rotation origin of the probe to the outermost edge of the steel rail and the transverse included angle beta of the probe and the steel rail; when moving flaw detection is carried out, the position of the rotation origin of the probe and the rotation angle are determined; the coordinate value after rotation, that is, the coordinate (x) of the incident point of the ultrasonic wave obtained can be calculated from the relationship between the rotation origin and the rotation angle r ,y r ,z r ) (ii) a Specifically, the ultrasonic sound beam incident point specifically includes the following calculation processes: the tread of the rail head can be considered as a plane parallel to the bottom surface of the rail, i.e. at an angle of 0 ° to the xoy plane.
Suppose the rotation origin coordinate of the probe is (x) 0 ,y 0 ,z 0 ) When the probe is not rotated, the direction of the probe is parallel to the transverse direction of the steel rail, and the coordinate of the incident point of a certain sound beam is (x) i ,y i ,z i ) The rotation angle of the probe is beta, and the corresponding incidence point after the probe rotates is (x) r ,y r ,z r ) Since the distance from the incident point to the rotation origin is constant, it is always y i -y 0 Only the x and y directional components will change after rotation:
Δx=(y i -y 0 )*sinβ;
Δy=(y i -y 0 )*cosβ;
the obtained incidence points are:
x r =x 0 +Δx;
y r =y 0 +Δy。
s3, calculating a linear equation of the ultrasonic primary wave: according to the incident point coordinates (x) of the ultrasonic beam solved in step S2 r ,y r ,z r ) Solving for the coordinates (x) of the point of incidence when not rotated i ,y i ,z i ) Determining the corresponding coordinate (x) of the incident point on the xoy surface under the action of the incident angle theta z ,y z ,z z ) (ii) a And (3) determining an idea of a straight line by using two points, and solving an equation of the straight line of the ultrasonic primary wave according to the two points.
Specifically, the calculation process of the linear equation of the ultrasonic primary wave is as follows:
when the rotation angle β is 0 °, the angle of incidence θ, at which the coordinate (x) of the corresponding point on the xoy plane d ,y d ,z d ) Comprises the following steps:
x d =x r
y d =z r *tanθ+y r
z d =0;
since the rail tread and xoy plane can be considered as parallel interfaces, when the probe is around the rotation origin (x) 0 ,y 0 ,z 0 ) Coordinate (x) when rotated on the tread by an angle beta z ,y z ,z z ) Equivalent to a point (x) d ,y d ,z d ) Around a point (x) on the xoy plane 0 ,y 0 ,z 0 ) By rotating the angle β, one can obtain:
x z =(y d -y 0 )*cosβ+x 0
y z =(y d -y 0 )*sinβ+y 0
z z =0;
thus, two point coordinates on the primary wave are obtained, and a parametric equation of the spatial straight line is written:
x=(x r -x z )*t+x z
y=(y r -y z )*t+y z
z=(z r -z z )*t+z z
s4, solving a reflection point: the equation of the line where the ultrasonic primary wave is located is obtained through the solution of the step S3, and the intersection point, namely the coordinate (x) of the reflection point of the primary wave is solved through simultaneous solution by using the equation and the piecewise function of the steel rail surface c1 ,y c1 ,z c1 ) The system of equations is solved concurrently.
Specifically, the coordinates (x) of the reflection point of the primary wave are solved c1 ,y c1 ,z c1 ) The method can be obtained according to the specific situation of a plane section or a circular arc section by the following steps:
(1) simultaneous solution of the equation of the steel rail plane section: the steel rail can be regarded as a cylinder, and the solving process is simplified during solving; regarding the steel rail surface plane section as a function of x and z;
setting: the equation of a certain section of plane of the steel rail is z ═ kx + b; wherein k is the slope and b is the intercept of the z-axis, both of which are known quantities;
the parameter equation of the space linear equation is as follows:
x=(x1-x0)*t+x0;
y=(y1-y0)*t+y0;
z=(z1-z0)*t+z0;
and the equation of a straight line where z is kx + b and the secondary wave are combined to obtain:
x=(x1-x0)*t+x0;
kx+b=-((z1-z0)*t+z0);
the above equation is a linear equation of two in relation to x and t; the values of x and t can be calculated by LU decomposition method, the value of t is brought back to the parameter equation, the values of y and z can be calculated, and the obtained solution is the intersection point of the continuous equation, namely (x) c1 ,y c1 ,z c1 );
(2) Simultaneous solving of steel rail arc segment equations:
if the circle center coordinate of the arc segment is (m, n) and the radius is r, the equation of the circle is as follows:
(x-m) 2 +(z-n) 2 =r 2
to simplify the solution, let the spatial linear equation be:
x=at+b;
y=et+f;
z=ct+d;
the equation that brings x, z of the straight line equation into a circle can be given:
(a 2 +c 2 )t 2 +2*[a*(b-m)+c*(d-n)]*t+(b-m) 2 +(d-n) 2 -r 2 =0;
converting the equation into a unitary quadratic equation about t, solving for a t value, removing an invalid solution by using a constraint condition for two possible solutions of the unitary quadratic equation, bringing the t value back to the parameter equation, and solving for x, y and z values, namely the solved intersection point (x) c1 ,y c1 ,z c1 )。
S5, solving a normal equation of the ultrasonic beam: by utilizing the principle of specular reflection, when an incident ray and a normal are known, a reflected ray is solved; and (4) solving the normal vector at the point in different situations by using the reflection point, and writing a normal equation.
Specifically, solving is performed according to the specific situation that the reflection point falls on the plane segment or the circular arc segment, and solving the normal equation specifically includes the following processes:
(1) if the reflection point falls on the plane, the obtained normal lines are collinear at any position on the plane, at the moment, any three non-collinear coordinate points on the plane can be selected to form two vectors in the plane, at the moment, the two vectors are subjected to cross multiplication operation, and the obtained structure is the normal vector of the plane
Figure GDA0003712601020000101
(2) If the reflection point falls on the arc surface, the partial derivative at the point needs to be solved. Assuming that the coordinates of the circle center of the arc surface are (m, n) and the radius is r; the equation for the circle is then: (x-m) 2 +(z-n) 2 =r 2 The equation for the circle can be rewritten as:
F(x,y,z)=(x-m) 2 +(z-n) 2 -r 2
respectively solving partial derivatives of x, y and z for the F (x, y and z) function;
then, F' x =2*(x-m);
F′ y =0;
F′ z =2*(z-m);
The coordinates of the point are substituted to obtain the normal vector of the point
Figure GDA0003712601020000111
At this point, the normal equation can be written:
x=x v *t+x c1
y=0*t+y c1
z=z v *t+z c1
s6, solving a linear equation of the secondary wave, namely the reflection line: according to the mirror reflection principle, randomly selecting a point on an incident line, and solving the symmetric point coordinate of the point relative to the normal; selecting an incident point (x) r ,y r ,z r ) Recording the point on the primary wave as A, and recording the point as B (x) by solving the symmetry point of the point with respect to the normal line t ,y t ,z t ) Because the normal line at any position is vertical to the y axis due to the structural characteristics of the steel rail and the establishment mode of the coordinate system, the distance from the incident point to the normal line is equal to the distance from the reflection point of the incident point to the normal line; solving the values of two components of x and z of the incidence point relative to the normal symmetry point; and writing an equation of a straight line where the reflection line is located.
Specifically, solving the values of two components of x and z of an incidence point about a normal symmetry point; the calculation steps are as follows: to make the reasoning process simpler, the normal equation is rewritten as a truncated form for x, z, where k is the slope and b is the intercept on the z-axis: z is kx + b;
according to the characteristics of the symmetrical points, the midpoint of the point A and the point B satisfies the normal equation, and the product of the slope of the straight line AB and the slope of the normal is-1; according to the two constraint conditions, two equations can be written, and x is solved t And z t
Figure GDA0003712601020000112
Figure GDA0003712601020000113
The difference between the y value of the incident point to the reflection point is y c -y r It can be seen that the difference between the symmetric point and the reflection point is also y c 1-y r Can find y t =2*y c1 -y r
Thus, the equation of the line on which the reflection line lies can be written:
x=(x c1 -x t )*t+x t
y=(y c1 -y t )*t+y t
z=(z c1 -z t )*t+z t
s7, solving the intersection point of the reflection line, namely the secondary wave, and the surface of the steel rail: the equation of the line where the ultrasonic secondary wave is located is obtained through the solving of the steps, and the intersection point, namely the coordinate (x) of the reflection point of the secondary wave is solved through simultaneous solving of the equation and the piecewise function of the surface of the steel rail c2 ,y c2 ,z c2 );
Specifically, the coordinates (x) of the reflection point of the secondary wave are solved c2 ,y c2 ,z c2 ) The method can be obtained according to the specific situation of a plane section or a circular arc section by the following steps:
(1) simultaneous solution of the equation of the steel rail plane section: the steel rail can be regarded as a cylinder, and the solving process is simplified when the solution is carried out; regarding the steel rail surface plane section as a function of x and z;
setting: the equation of a certain section of plane of the steel rail is z ═ kx + b; wherein k is the slope and b is the intercept of the z-axis, both of which are known quantities;
the parametric equation of the spatial straight line equation is:
x=(x1-x0)*t+x0;
y=(y1-y0)*t+y0;
z=(z1-z0)*t+z0;
the equation of a straight line where the secondary wave is located is combined with z kx + b to obtain:
x=(x1-x0)*t+x0;
kx+b=-((z1-z0)*t+z0);
the above equation is a linear equation of two in relation to x and t; the values of x and t can be calculated by LU decomposition method, the value of t is brought back to the parameter equation, the values of y and z can be calculated, and the obtained solution is the intersection point of the continuous equation, namely (x) c2 ,y c2 ,z c2 );
(2) Simultaneous solving of steel rail arc segment equations:
if the circle center coordinate of the arc segment is (m, n) and the radius is r, the equation of the circle is as follows:
(x-m) 2 +(z-n) 2 =r 2
to simplify the solution, let the spatial linear equation be:
x=at+b;
y=et+f;
z=ct+d;
the equation that brings x, z of the straight line equation into a circle can be given:
(a 2 +c 2 )t 2 +2*[a*(b-m)+c*(d-n)]*t+(b-m) 2 +(d-n) 2 -r 2 =0;
converting the equation into a quadratic equation with respect to t, solving the value of t, removing an invalid solution by using a constraint condition for two possible solutions to the quadratic equation with respect to t, bringing the value of t back to the parameter equation, and solving the values of x, y and z, namely the solved intersection point (x) c2 ,y c2 ,z c2 )。
S8, defect point coordinate transformation: using the three points solved above: incident Point (x) r ,y r ,z r ) Coordinates (x) of the reflection point of the primary wave c1 ,y c1 ,z c1 ) Coordinates (x) of reflection point of secondary wave c2 ,y c2 ,z c2 ) The primary wave length S and the secondary wave length F can be calculated; the ultrasonic flaw detection device returns a series of discrete data points, the returned data represents ultrasonic return information at equal intervals according to the number of sampling points in a sound path set by ultrasonic beams, and the numerical value of each data point is used for judging whether damage exists or not; the position of the point in the data sequence can be used to determine the incident point of the data pointIf S/S is less than 1, then on the primary wave, and then let t be S/S to be substituted into the primary wave linear equation obtained above, so as to calculate the coordinates of the point; on the other hand, if S/S is greater than 1, the secondary wave is substituted with t ═ S/F into the above-obtained linear equation of the secondary wave, and the coordinates of the point can be calculated.
The flaw detection example verification is carried out by utilizing the rail head and web defect analysis method of the steel rail of the invention:
FIG. 1 shows a 60KG/m steel rail test block, in which an artificial defect A, B exists in the rail web part of the steel rail. The position of the defect A is measured by hand as follows: the distance between the steel rail and the bottom edge of the steel rail is 65mm and 106 mm; the position of the defect B is as follows: the distance from the edge of the rail bottom is 64mm, and the distance from the edge of the rail bottom is 39 mm; the horizontal distance between the defects A, B was 20mm, and the artificial defect aperture was 3.8 mm.
When flaw detection is carried out on the rail head and the rail web of the steel rail, the ultrasonic probe is placed on the tread of the rail head of the steel rail. The coverage of the flaw detection area is realized by moving back and forth and rotating left and right. Two cases were chosen in the case to scan for defect A, B.
The position relation between the probe and the defect is shown in figure 2 when the probe is placed at a position away from the center axis of the steel rail tread, the horizontal distance from the front edge of the probe to the defect A is 25m, and the position of the probe is converted into a coordinate position, namely the coordinate position of the center axis of the front edge of the probe is (0, 176).
The first scheme comprises the following steps:
the ultrasonic incident angle is 30-70 degrees, the sound path is set to be 200mm, the rotation angle is 0 degree, the test block is processed at the moment, the result of coding the returned ultrasonic data is sent into an algorithm for calculation, normal data are filtered out, the spatial position of an abnormal data point is converted into a right-angle coordinate point, and the result is shown in fig. 3. The coordinate values of the defect a and the defect B with respect to the probe position can be scanned in the conversion result.
Scheme two is as follows:
the ultrasonic incident angle is 30-70 degrees, the sound path is set to be 200mm, the rotation angle is 10 degrees, the test block is detected at the moment, the result of coding returned ultrasonic data is sent into an algorithm for calculation, normal data is filtered out, the spatial position of an abnormal data point is converted into a rectangular coordinate point, and the result is shown in fig. 4. The coordinate values of the defect a and the defect B with respect to the probe position can be scanned in the conversion result.
The defect analysis method for the rail head and the rail web of the steel rail can be used for conveniently distinguishing the positions of the defects, can be used for obtaining the coordinates of the defects in the steel rail, and can be used for drawing the coordinates of the defects to draw the approximate forms of the defects. Is beneficial to making reasonable and scientific judgment on the steel rail. By using the visual display method, the dependence on the working experience of the flaw detection personnel and misjudgment caused by subjective factors of the flaw detection personnel are reduced.
While the foregoing is directed to the preferred embodiment of the present invention, it will be appreciated by those skilled in the art that various changes and modifications may be made therein without departing from the principles of the invention as set forth in the appended claims.

Claims (6)

1. A rail head and rail web defect analysis method of a steel rail is based on the detection of a phased ultrasonic flaw detection device for analysis, wherein the phased ultrasonic flaw detection device comprises an ultrasonic phased array probe, an ultrasonic control board card and an encoder; the ultrasonic phased array probe is contacted with a workpiece to be detected through a coupling agent, the ultrasonic control board card is electrically connected with the ultrasonic phased array probe and used for generating ultrasonic signals, processing the received return signals through an encoder to generate a series of digital signals and establishing a steel rail 3D model in a space rectangular coordinate system; the encoder is used for calculating a path equation of primary wave and secondary wave of the ultrasonic beam by combining the position information of the ultrasonic phased array probe and the beam parameters, and then converting the acquired digital signals into three-dimensional coordinates; the method for analyzing the defects of the rail head and the rail web of the steel rail is characterized by comprising the following steps of:
s1, establishing a steel rail 3D model: selecting the bottom surface of the steel rail as an xoy surface of a three-dimensional coordinate axis, wherein the transverse direction of the steel rail is the y-axis direction, the longitudinal direction of the steel rail is the x-axis direction, converting the position of the probe on the steel rail into a coordinate value of the probe on a steel rail model, and performing rotary movement on a slope by positioning the ultrasonic phased array probe on a tread of a rail head of the steel rail;
s2, solving the incident point of the ultrasonic sound beam: according to the requirements of flaw detection, when ultrasonic flaw detection is carried out on a railhead and a railweb, a probe is fixed on a tread of the railhead of a steel rail by using a clamping device, and the ultrasonic coverage of the railhead and the railweb area is realized through back-and-forth movement and left-and-right rotation; recording the distance l from the rotation original point of the probe to the outermost edge of the steel rail and the transverse included angle beta of the probe and the steel rail; when performing mobile flaw detection, the coordinates (x) of the position of the rotation origin of the probe are determined 0 ,y 0 ,z 0 ) Coordinate (x) of incident point when not rotated i ,y i ,z i ) And a rotation angle β; the coordinate value after rotation, i.e. the coordinate (x) of the incidence point of the ultrasonic wave obtained, is calculated by the relationship between the rotation origin and the rotation angle r ,y r ,z r );
S3, calculating a linear equation of the ultrasonic primary wave: according to the incident point coordinates (x) of the ultrasonic beam solved in step S2 r ,y r ,z r ) Solving for the coordinates (x) of the point of incidence when not rotated i ,y i ,z i ) The corresponding coordinate (x) of the incident point on the xoy surface is obtained under the action of the incident angle theta z ,y z ,z z ) (ii) a Determining a straight line by using two points, and solving an equation of the straight line of the ultrasonic primary wave according to the two points;
s4, solving a reflection point: the equation of the line where the ultrasonic primary wave is located is obtained through the solution of the step S3, and the intersection point, namely the coordinate (x) of the reflection point of the primary wave is solved through simultaneous solution by using the equation and the piecewise function of the steel rail surface c1 ,y c1 ,z c1 ) Simultaneously solving an equation set;
s5, solving a normal equation of the ultrasonic beam: by utilizing the principle of specular reflection, when an incident ray and a normal are known, a reflected ray is solved; using the reflection point, solving the normal vector at the point according to the situation, and writing a normal equation;
s6, solving a linear equation of the secondary wave, namely the reflection line: according to the mirror reflection principle, randomly selecting a point on an incident line, and solving the symmetric point coordinate of the point relative to the normal; selecting an incident point (x) r ,y r ,z r ) Solving for the incident point (x) r ,y r ,z r ) Point of symmetry about normal (x) t ,y t ,z t ) Because the normal line at any position is vertical to the y axis due to the structural characteristics of the steel rail and the establishment mode of the coordinate system, the distance from the incident point to the normal line is equal to the distance from the reflection point of the incident point to the normal line; solving the values of two components of x and z of the incidence point relative to the normal symmetry point; writing an equation of a straight line where the reflection line is located;
s7, solving the intersection point of the reflection line, namely the secondary wave, and the surface of the steel rail: the equation of the line where the ultrasonic secondary wave is located is obtained through the solving of the steps, and the equation and the piecewise function of the surface of the steel rail are used for simultaneous solving to obtain an intersection point, namely the reflection point coordinate (x) of the secondary wave c2 ,y c2 ,z c2 );
S8, defect point coordinate transformation: using the three points solved above: incident point (x) r ,y r ,z r ) Coordinates (x) of the reflection point of the primary wave c1 ,y c1 ,z c1 ) Coordinates (x) of reflection point of secondary wave c2 ,y c2 ,z c2 ) Calculating the primary wave length S and the secondary wave length F; the ultrasonic flaw detection device returns a series of discrete data points, the returned data represents ultrasonic return information at equal intervals according to the number of sampling points in a sound path set by ultrasonic beams, and the numerical value of each data point is used for judging whether damage exists or not; determining the distance S from a data point to an incident point by using the position of the point in the data sequence, determining whether the point is positioned on the primary wave or not by using the ratio of S/S, if S/S is less than 1, on the primary wave, and then substituting t-S/S into the obtained primary wave linear equation to calculate the coordinate of the point; if S/S is larger than 1, on the secondary wave, let t equal to (S-S)/F, and take it into the above-mentioned quadratic wave linear equation to calculate the coordinates of the defect point.
2. The method for analyzing the defects of the head and the web of the steel rail according to claim 1, wherein in the step S2, the incident point of the ultrasonic beam specifically includes the following calculation processes: the steel rail head tread is regarded as a surface parallel to the bottom surface of the steel rail, namely, the included angle between the steel rail head tread and the xoy surface is 0 degree;
suppose the rotation origin coordinate of the probe is (x) 0 ,y 0 ,z 0 ) When the probe is not rotated, the direction of the probe is parallel to the transverse direction of the steel rail, and the coordinate of the incident point of a certain sound beam is (x) i ,y i ,z i ) The rotation angle of the probe is beta, and the incident point corresponding to the probe after the rotation is (x) r ,y r ,z r ) Since the distance from the incident point to the rotation origin is constant, it is always y i -y 0 Only the x and y components will change after rotation:
Δx=(y i -y 0 )*sinβ;
Δy=(y i -y 0 )*cosβ;
the obtained incident points are:
x r =x 0 +Δx;
y r =y 0 +Δy。
3. a rail head and web defect analysis method according to claim 1, wherein in step S3, the calculation process of the linear equation of the ultrasonic primary wave is as follows:
when the rotation angle β is 0 °, the incident angle is θ, and the coordinates (x) of the corresponding point on the xoy plane d ,y d ,z d ) Comprises the following steps:
x d =x r
y d =z r *tanθ+y r
z d =0;
since the rail tread and the xoy surface are considered as parallel interfaces, when the incident point coordinate (x) of the probe is measured i ,y i ,z i ) Around the origin of rotation (x) 0 ,y 0 ,z 0 ) When rotating on the tread by beta angle, sitLabel (x) z ,y z ,z z ) Equivalent to a point (x) d ,y d ,z d ) Around a point (x) on the xoy plane 0 ,y 0 ,z 0 ) Rotating the angle beta to obtain:
x z =(y d -y 0 )*cosβ+x 0
y z =(y d -y 0 )*sinβ+y 0
z z =0;
thus, two point coordinates on the primary wave are obtained, and a parametric equation of the spatial straight line is written:
x=(x r -x z )*t+x z
y=(y r -y z )*t+y z
z=(z r -z z )*t+z z
4. a rail head and web defect analysis method as claimed in claim 1, wherein in steps S4 and S7, the coordinates (x) of the reflection point of the primary wave are solved c1 ,y c1 ,z c1 ) Coordinates (x) of reflection point of secondary wave c2 ,y c2 ,z c2 ) According to the specific situation of the plane section or the circular arc section, the method comprises the following steps:
(1) simultaneous solution of the equation of the steel rail plane section: the steel rail is regarded as a cylinder, and when the solution is carried out, the solution process is simplified; regarding the steel rail surface plane section as a function of x and z;
setting: the equation of a certain section of plane of the steel rail is z ═ kx + b; wherein k is the slope and b is the intercept of the z-axis, both of which are known quantities;
the parametric equation of the spatial straight line equation is:
x=(x1-x0)*t+x0;
y=(y1-y0)*t+y0;
z=(z1-z0)*t+z0;
and (3) combining z-kx + b and a linear equation of a secondary wave:
x=(x1-x0)*t+x0;
kx+b=-((z1-z0)*t+z0);
the above formula is a linear equation of two elements with respect to x and t; calculating the values of x and t by LU decomposition, returning the value of t to the parameter equation, calculating the values of y and z, and calculating the intersection point of the two equations as (x) c ,y c ,z c );
(2) Simultaneous solving of steel rail arc segment equations:
if the circle center coordinate of the arc segment is (m, n) and the radius is r, the equation of the circle is as follows:
(x-m) 2 +(z-n) 2 =r 2
to simplify the solution, let the spatial linear equation be:
x=at+b;
y=et+f;
z=ct+d;
the equation that brings x, z of the straight line equation into a circle yields:
(a 2 +c 2 )t 2 +2*[a*(b-m)+c*(d-n)]*t+(b-m) 2 +(d-n) 2 -r 2 =0;
converting the equation into a quadratic equation of a unit related to t, solving the value of t, solving the quadratic equation of the unit to form two solutions, removing an invalid solution by using a constraint condition, bringing the value of t back to the parameter equation, and solving the values of x, y and z, namely the intersection point (x) to be solved c ,y c ,z c )。
5. The method for analyzing the defects of the head and the web of the steel rail according to claim 1, wherein in the step S5, the solution is performed according to the specific situation that the reflection point falls on the plane segment or the circular arc segment, and the solution of the normal equation specifically comprises the following processes:
(1) if the reflection point falls on the plane, the normal lines are collinear at any position on the plane, at the moment, any three non-collinear coordinate points on the plane are selected to form two vectors in the plane, at the moment, the two vectors are subjected to cross multiplication operation, and the obtained structure is the normal vector of the plane
Figure RE-FDA0003723668160000051
(2) If the reflection point falls on the arc surface, the partial derivative at the point needs to be solved; assuming that the coordinates of the circle center of the arc surface are (m, n) and the radius is r; the equation for this circle is then: (x-m) 2 +(z-n) 2 =r 2 The equation for the circle is rewritten as:
F(x,y,z)=(x-m) 2 +(z-n) 2 -r 2
respectively solving partial derivatives of x, y and z for the F (x, y and z) function;
then, F x ′=2*(x-m);
F y ′=0;
F z ′=2*(z-m);
Substituting the coordinates of the point to obtain the normal vector at the point
Figure RE-FDA0003723668160000052
At this point, the normal equation is written:
x=x v *t+x c1
y=0*t+y c1
z=z v *t+z c1
6. a method for analyzing defects of a rail head and a rail web of a steel rail according to claim 1, wherein in step S6, values of two components x and z of an incidence point about a normal symmetry point are solved; the calculation steps are as follows: to make the reasoning process simpler, the normal equation is rewritten as a truncated form for x, z, where k is the slope and b is the intercept on the z-axis: z is kx + b;
according to the characteristics of the symmetrical points, the midpoint of the point A and the point B satisfies the normal equation, and the product of the slope of the straight line AB and the slope of the normal is-1; according to the two constraint conditions, two equations are written, and x is solved t And z t
Figure RE-FDA0003723668160000053
Figure RE-FDA0003723668160000054
The difference between the y value of the incident point to the reflection point is y c -y r It can be seen that the difference between the symmetric point and the reflection point is also y c1 -y r Obtaining y t =2*y c1 -y r
Thus, the equation of the line on which the reflection line lies is written:
x=(x c1 -x t )*t+x t
y=(y c1 -y t )*t+y t
z=(z c1 -z t )*t+z t
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