CN112406949A - Wheeled probe ultrasonic wave automatic centering system - Google Patents

Wheeled probe ultrasonic wave automatic centering system Download PDF

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Publication number
CN112406949A
CN112406949A CN202010083143.9A CN202010083143A CN112406949A CN 112406949 A CN112406949 A CN 112406949A CN 202010083143 A CN202010083143 A CN 202010083143A CN 112406949 A CN112406949 A CN 112406949A
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China
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centering
ultrasonic
rail
probe
signal
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CN202010083143.9A
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Chinese (zh)
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姜易斋
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Individual
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Individual
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Priority to CN202010083143.9A priority Critical patent/CN112406949A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B61RAILWAYS
    • B61KAUXILIARY EQUIPMENT SPECIALLY ADAPTED FOR RAILWAYS, NOT OTHERWISE PROVIDED FOR
    • B61K9/00Railway 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
    • B61K9/08Measuring installations for surveying permanent way
    • B61K9/10Measuring installations for surveying permanent way for detecting cracks in rails or welds thereof
    • 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
    • G01N29/22Details, e.g. general constructional or apparatus details
    • G01N29/26Arrangements for orientation or scanning by relative movement of the head and the sensor
    • G01N29/265Arrangements for orientation or scanning by relative movement of the head and the sensor by moving the sensor relative to a stationary material
    • 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
    • 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
    • G01N29/48Processing the detected response signal, e.g. electronic circuits specially adapted therefor by amplitude comparison

Abstract

A wheel type probe ultrasonic automatic centering system uses 3 parallel 0-degree wafers to collect steel rail bottom echo as a detection signal of a sensor, and is slightly influenced by the appearance of a steel rail, so that the detection is easy. The middle wafer transmits ultrasonic waves, the left wafer and the right wafer receive the ultrasonic waves, and automatic centering control is realized through distinguishing the amplitudes of pulse signals on the two sides, so that the speed is high, and the precision is high. The centering device can meet the requirements of centering effect and adjustment speed in common rail sections and special places such as turnouts, small-radius curves, temperature regulators and the like, the maximum allowable centering deviation is less than +/-2 mm, and the correction distance in each centering is 1 mm. The detection and adjustment intervals are synchronous with the scanning intervals of in-service flaw detection equipment, the scanning intervals of the double-rail type steel rail ultrasonic flaw detector are 3mm, and the scanning intervals of the large ultrasonic steel rail flaw detection vehicle are 1.6-6.4 mm. The invention can carry out normal flaw detection in the scanning interval, and can improve the detection quality and the adjustment speed of special places such as turnouts, small-radius curves, temperature regulators and the like, and reduce the flaw detection and the omission detection.

Description

Wheeled probe ultrasonic wave automatic centering system
Technical Field
The invention belongs to the field of ultrasonic flaw detection of steel rails, and particularly relates to a wheel type probe ultrasonic automatic centering system.
Background
The high-speed flaw detection equipment for the steel rails in service in China mainly comprises a double-rail type steel rail ultrasonic flaw detector and a large ultrasonic steel rail flaw detection vehicle, and both the double-rail type steel rail ultrasonic flaw detector and the large ultrasonic steel rail flaw detection vehicle use wheel type ultrasonic probes for flaw detection.
The alignment of the detection center line of the wheel type ultrasonic probe and the longitudinal center line of the steel rail is called centering, and the alignment degree and the alignment adjustment speed directly influence the detection quality of the damage of the steel rail.
The double-rail ultrasonic steel rail flaw detector realizes probe centering adjustment by means of manual or mechanical limiting, a centering result is confirmed by visually observing the echo amplitude of the bottom surface of a channel with 0 degree, the centering degree is difficult to control and maintain, the adjusting speed is slow, and damage and leakage detection are easily caused; the large ultrasonic steel rail flaw detection vehicle uses the laser automatic centering system at present, realizes automatic centering by using a shape comparison technology, has better effect in a long rail section, has poor centering effect in a common rail section, a turnout, a small-radius curve, a temperature regulator and other special places, has slower tracking and adjusting speed, and is easy to cause damage and leak detection.
Disclosure of Invention
The invention provides an ultrasonic automatic centering system of a wheel type probe, which can improve the centering precision and the centering adjustment speed of the wheel type probe and can meet the requirements of special places such as a common rail section, a turnout, a small-radius curve, a temperature regulator and the like on the centering effect and the tracking adjustment speed.
The system comprises the following components: the device comprises a wheel type probe sensor, ultrasonic left receiving, ultrasonic transmitting, ultrasonic right receiving, ultrasonic processing, a 0-degree channel synchronous signal, a rail type conversion signal, logic judgment automatic control, manual centering control, manual/automatic centering conversion, automatic centering driving and a wheel type probe centering execution device.
The invention uses the steel rail bottom surface reflection echo as a monitoring signal, the signal comes from the inside of the steel rail, the detection is easy, the judgment is simple, the adjusting speed is high, the influence by the steel rail appearance is small, the automatic centering control speed is high, the precision is high, the functional block diagram is shown in figure 1, and the specific principle is as follows:
the invention uses 3 parallel 0 degree wafers to collect the echo of the bottom surface of the steel rail as the monitoring signal of the wheel probe sensor.
The middle wafer is an ultrasonic transmitting wafer, and the left and right wafers are ultrasonic receiving wafers.
And (3) synchronous signal acquisition: in order to synchronize the detection signal and the centering control with the flaw detection equipment, the synchronous signal of the invention is acquired from a 0-degree channel synchronous signal of the flaw detection equipment and is used as an input signal of an ultrasonic processing circuit.
Under the control of the synchronous pulse sent by the ultrasonic processing circuit, the ultrasonic transmitting circuit transmits ultrasonic waves from the top surface of the steel rail to the bottom surface of the steel rail through the middle wafer; the wafers on the two sides receive the ultrasonic waves reflected from the bottom surface of the steel rail, and echo signals of the ultrasonic waves are amplified by the ultrasonic wave left receiving circuit and the ultrasonic wave right receiving circuit and then sent to the ultrasonic processing circuit for processing.
The ultrasonic processing circuit respectively performs wave detection, shaping and other processing on the bottom echo signals sent by the ultrasonic left receiving circuit and the ultrasonic right receiving circuit into pulse signals which are easy to distinguish according to the rail type switching signals, and the pulse signals are supplied to the logic distinguishing automatic control circuit for distinguishing.
The logic discrimination automatic control circuit firstly compares the amplitudes of the two input pulse signals, and then carries out logic discrimination and outputs corresponding control signals for automatic control according to the comparison result of the amplitudes of different amplitudes and the amplitude of the reference signal.
Setting the amplitude of the reference signal: in order to keep the sensitivity and stability of the logic discrimination automatic control circuit, the amplitude of the reference signal is lower than the trigger threshold and is set to be 1dB lower than the trigger threshold, and the allowable variation range is +/-0.5 dB.
When the amplitudes of the two echo pulse signals exceed the allowable variation range of the amplitude of the reference signal and do not exceed the trigger threshold, the logic judgment automatic control circuit outputs two gain adjustment signals to the ultrasonic wave left and right receiving circuits respectively, so as to increase or decrease the gain, and the amplitudes of the two echo pulse signals are stabilized within the allowable variation range of the amplitude of the reference signal, as shown in fig. 1.
The logic discrimination automatic control circuit can determine that the wheel type probe is in a state of deviating from the right, centering or deviating from the left through amplitude comparison results of three echo pulse signals of high left, high same height and high right.
When the wheel type probe deviates to the right, the amplitude of the left echo pulse signal is higher than that of the right echo pulse signal, and is higher than that of the reference signal and exceeds the trigger threshold, the wheel type probe centering execution device is driven by the manual/automatic centering conversion circuit and the automatic centering driving circuit to adjust the wheel type probe leftwards, and the wheel type probe returns to the centering state, as shown in fig. 2.
When the wheel probe is centered, the amplitudes of the two echo pulse signals are simultaneously lower than the trigger threshold, the logic judgment is that the wheel probe is in a centered state, and the control circuit does not output a centering adjustment signal, as shown in fig. 3.
When the wheel type probe deviates to the left, the amplitude of the echo pulse signal on the right side is higher than that on the left side, and is higher than that of the reference signal and exceeds the trigger threshold, the wheel type probe centering execution device is driven by the manual/automatic centering conversion circuit and the automatic centering driving circuit to adjust the wheel type probe rightwards, and the wheel type probe returns to the centering state, as shown in fig. 4.
When the amplitudes of the two echo pulse signals disappear simultaneously, the logic judgment automatic control circuit does not output an adjusting instruction.
The centering sensitivity of the wheel type probe is set to be +/-1 mm, and when the offset exceeds 1mm, the pulse signal amplitude of the due side reaches or exceeds a trigger threshold value.
The maximum allowable deviation of the wheel type probe centering is less than +/-2 mm, namely before the deviation amount reaches 2mm, the wheel type probe centering execution device adjusts the wheel type probe to be in a centering state, and the correction distance is 1mm in each centering.
When the logic discrimination automatic control circuit monitors that the continuous leftward or rightward adjustment distance of the wheel type probe reaches 15mm, the wheel type probe centering execution device adjusts the wheel type probe in the opposite direction for 30mm or receives an echo pulse signal, and then the logic discrimination automatic control circuit adjusts and keeps the wheel type probe in a centering state.
The detection and adjustment intervals of the invention are synchronous with the scanning intervals of the in-service flaw detection equipment; the detection speed of the double-track steel rail ultrasonic flaw detector is 15km/h, and the scanning interval is 3 mm; when the detection speed of the large ultrasonic steel rail flaw detection vehicle is 12km/h, the scanning interval is 1.6mm, and when the detection speed is more than 72km/h, the scanning interval is 6.4 mm.
The invention can carry out normal flaw detection on long-rail sections, common-rail sections and small-radius curves within the scanning interval; meanwhile, the detection quality and the adjustment speed of special places such as turnouts, temperature regulators and the like can be improved, and the damage and the omission are reduced.
The speed detection and adjustment method can meet the detection requirement of TB/T2340-2012 on the rail damage.
Drawings
Fig. 1 is a schematic block diagram of the circuit of the present invention.
Fig. 2 is a schematic diagram showing the reflection characteristics of ultrasonic waves when the wheel probe is tilted to the right.
Fig. 3 is a schematic view showing the ultrasonic reflection characteristics in the centering state of the wheel probe.
Fig. 4 is a schematic diagram showing the ultrasonic reflection characteristics when the wheel probe is shifted to the left.
Detailed Description
The wheel type probe detection signal sensor is composed of 3 parallel 0-degree wafers, the middle wafer is an ultrasonic wave transmitting wafer, and the left and right wafers are ultrasonic wave receiving wafers.
The wheel type probe ultrasonic automatic centering system is as shown in figure 1, and comprises the following components from bottom to top and from left to right in sequence: the device comprises an ultrasonic left receiving device, an ultrasonic transmitting device, an ultrasonic right receiving device, an ultrasonic processing device, a 0-degree channel synchronous signal, a rail type switching signal, a logic discrimination automatic control device, a manual centering control device, a manual/automatic centering switching device, an automatic centering driving device and a wheel type probe centering executing device.
Setting the amplitude of the reference signal: placing a manual/automatic change-over switch at a manual position, changing the rail shape to be consistent with the rail shape of the detected steel rail, and manually adjusting the probe wheel to be in a centering state; and respectively adjusting the sensitivity of the ultrasonic left and right receiving circuits to ensure that the amplitude of the echo pulse signal on the bottom surface of the steel rail reaches a trigger threshold and then is reduced by 1dB to serve as the amplitude of a reference signal.
After the amplitude of the reference signal is set, the wheel type probe ultrasonic automatic centering system stores the data, and the data does not need to be reset under the condition of no damage.
Flaw detection of steel rails: firstly, a manual/automatic change-over switch is placed at a manual position, the position of a wheel type probe is manually adjusted to be in a centering state, then the manual/automatic change-over switch is placed at an automatic position, and flaw detection is carried out on the line steel rail.
Detecting the material difference and the coupling state of the steel rails: when the amplitude of the echo pulse signal of the bottom surface of the steel rail is reduced due to the large attenuation of the material of the steel rail and the poor thermit welding joint or coupling state in the detection process, the logic judgment automatic control circuit can automatically increase the gains of the ultrasonic left and right receiving circuits, so that the amplitude of the echo pulse signal of the bottom surface of the steel rail is increased to be within the allowable variation range of the amplitude of the reference signal; if the attenuation of materials is small or the coupling state is good, so that the amplitude of the echo pulse signal of the bottom surface of the steel rail is increased, the logic judgment automatic control circuit can automatically reduce the gains of the ultrasonic left and right receiving circuits, and the amplitude of the echo pulse signal of the bottom surface of the steel rail is reduced to be within the allowable variation range of the amplitude of the reference signal.
The small radius curve, the large abrasion of the side surface of the steel rail, the fat edge generated by the crushing of the rail head and the like are detected: the wheel probe can deviate from the longitudinal center line of the steel rail, so that one side of the amplitude of the echo pulse signal on the bottom surface of the steel rail is increased, the other side of the amplitude is reduced or disappears, the logic discrimination automatic control circuit drives the wheel probe centering execution device to move the wheel probe to the deviated opposite direction, and the centering state is kept.
When the joint bolt hole, the wire guide hole or the damage and the like are detected, the received echo pulse signal of the bottom surface of the steel rail disappears simultaneously; after passing through the position, echo pulse signals of the bottom surfaces of the steel rails on the two sides appear at the same time, and the logic judgment automatic control circuit does not output an adjusting instruction at the moment.
The common switch rail and the temperature regulator have similar structures and the detection method is the same, and here, the left switch rail is taken as an example:
when the switch rail is forwardly entered, the wheel type probe gradually moves rightwards along the inner side of the planning part of the head of the switch rail from the tip of the switch rail, the transition from the stock rail to the switch rail is started, the amplitude of a pulse signal on the left side is higher than that of a reference signal, and when the amplitude exceeds a trigger threshold value, the wheel type probe is corrected leftwards, 1mm is corrected each time, and a centering state is kept; when the continuous leftward correction distance reaches 15mm, the wheel type probe automatically adjusts 30mm in the reverse direction or receives a pulse signal, and the wheel type probe is transited to the switch rail and is adjusted by a logic judgment automatic control circuit and kept in a centering state.
When the probe reversely enters the switch rail, the wheeled probe enters the planing part on the inner side of the head of the switch rail from the heel end of the switch rail and gradually moves rightwards, the amplitude of the left pulse signal is higher than the amplitude of the reference signal, and when the amplitude exceeds a trigger threshold value, the wheeled probe is corrected leftwards, each time the pulse signal is corrected by 1mm, and the centering state is kept; when the continuous leftward correction distance reaches 15mm, the wheel type probe automatically adjusts 30mm in the reverse direction or receives a pulse signal, and the wheel type probe is transited to the switch rail and is adjusted by a logic judgment automatic control circuit and kept in a centering state.
The right side switch rail detection method is the same as the left side switch rail, and the adjustment direction is opposite.
The grain thickness of the cast frog is thicker, the attenuation is larger, the amplitude of two paths of pulse signals disappears simultaneously, the logic discrimination automatic control circuit does not output an adjusting instruction, and the wheel type probe keeps a centering state.
The assembled frog and the movable point frog comprise movable point rail detection, and the detection method is the same as that of steel rail flaw detection.

Claims (15)

1. A wheel type probe ultrasonic wave automatic centering system is characterized by comprising 12 parts of a wheel type probe sensor, ultrasonic wave left receiving, ultrasonic wave transmitting, ultrasonic wave right receiving, ultrasonic wave processing, a 0-degree channel synchronous signal, a rail type conversion signal, logic judgment automatic control, manual centering control, manual/automatic centering conversion, automatic centering driving and a wheel type probe centering execution device circuit; the system utilizes the reflected echo of the bottom surface of the steel rail as a monitoring signal, is easy to detect, simple to distinguish, high in adjusting speed, small in influence of the appearance of the steel rail, and high in automatic centering control speed and precision.
2. The wheel probe sensor of claim 1, wherein 3 parallel 0 ° wafers are used to collect the rail bottom echo as the monitor signal, the middle is the ultrasonic transmitting wafer, and the left and right are the ultrasonic receiving wafers.
3. The 0 ° channel synchronizing signal circuit according to claim 1, the acquired synchronizing signal is from a synchronizing signal of a 0 ° channel of the flaw detection apparatus as an input signal of the ultrasonic processing circuit.
4. The ultrasonic processing circuit of claim 1, wherein the synchronous pulse emitted from the ultrasonic emitting circuit controls the ultrasonic emitting circuit to emit ultrasonic waves from the top surface of the steel rail to the bottom surface of the steel rail through the intermediate wafer; the wafers on the two sides receive the ultrasonic waves reflected from the bottom surface of the steel rail, and echo signals of the ultrasonic waves are amplified by the ultrasonic wave left receiving circuit and the ultrasonic wave right receiving circuit and then sent to the ultrasonic processing circuit for processing.
5. According to claim 4, the ultrasonic processing circuit detects and shapes the bottom echo signals from the ultrasonic left and right receiving circuits respectively into pulse signals that can be easily distinguished according to the rail type switching signal, and supplies the pulse signals to the logic distinguishing automatic control circuit for distinguishing.
6. According to claim 5, the logic discrimination automatic control circuit firstly compares the amplitudes of the two input pulse signals, and then performs logic discrimination and outputs a corresponding control signal for automatic control according to the comparison result of the amplitudes of the different amplitude conditions and the reference signal;
in order to maintain the sensitivity and stability of the logic judgment automatic control circuit, the amplitude of a reference signal needs to be set, the amplitude of the reference signal is lower than a trigger threshold value, the amplitude of the reference signal is set to be 1dB lower than the trigger threshold value, and the allowable variation range is +/-0.5 dB.
7. According to claim 6, when the amplitudes of the two echo pulse signals exceed the allowable variation range of the amplitude of the reference signal and do not exceed the trigger threshold, the logic discrimination automatic control circuit outputs two gain adjustment signals to the ultrasonic wave left and right receiving circuits, respectively, to increase or decrease the gain, so that the amplitudes of the two echo pulse signals are stabilized within the allowable variation range of the amplitude of the reference signal.
8. According to claim 6, the logic discrimination automatic control circuit can determine whether the wheel type probe is in a state of right deviation, centering or left deviation through the amplitude comparison results of three echo pulse signals of left high, same high and right high.
9. According to the claim 8, when the wheel probe is inclined to the right, the amplitude of the left echo pulse signal is higher than that of the right echo pulse signal, and is higher than that of the reference signal and exceeds the triggering threshold, the wheel probe centering execution device is driven by the manual/automatic centering conversion circuit and the automatic centering driving circuit to adjust the wheel probe to the left, so that the wheel probe returns to the centering state.
10. According to claim 8, when the wheel probe is centered, the amplitudes of the two echo pulse signals are simultaneously lower than a trigger threshold, the logical judgment is that the wheel probe is in a centered state, and the control circuit does not output a centering adjustment signal; when the amplitudes of the two echo pulse signals disappear simultaneously, the logic judgment automatic control circuit does not output an adjusting instruction.
11. According to claim 8, when the wheel probe is deviated to the left, the amplitude of the right echo pulse signal is higher than that of the left echo pulse signal, and is higher than that of the reference signal and exceeds the triggering threshold, the wheel probe centering execution device is driven by the manual/automatic centering conversion circuit and the automatic centering driving circuit to adjust the wheel probe to the right, so that the wheel probe returns to the centering state.
12. The wheel probe centering sensitivity is set to be +/-1 mm according to claim 1, and when the offset exceeds 1mm, the pulse signal amplitude of one side reaches or exceeds a trigger threshold value; the maximum allowable deviation of the wheel type probe centering adjustment is less than +/-2 mm, namely before the deviation amount reaches 2mm, the wheel type probe centering execution device adjusts the wheel type probe to a centering state, and the correction distance is 1mm in each centering.
13. According to claim 12, when the automatic logic discrimination control circuit monitors that the distance of the wheel probe continuously adjusted leftwards or rightwards reaches 15mm, the wheel probe centering execution device adjusts the wheel probe in the opposite direction for 30mm or the automatic logic discrimination control circuit adjusts and maintains the wheel probe in the centering state after receiving the echo pulse signal.
14. According to claim 1, the detection and adjustment interval of the invention is synchronized with the scanning interval of the in-service flaw detection equipment: when the ultrasonic flaw detector is applied to a double-rail type steel rail ultrasonic flaw detector, the detection and adjustment interval is 3 mm; when the ultrasonic steel rail flaw detection vehicle is applied to large ultrasonic steel rail flaw detection vehicles, the detection and adjustment interval is 1.6 mm-6.4 mm.
15. According to the invention, the normal flaw detection can be carried out on long-rail sections, common-rail sections and small-radius curves within the scanning interval of in-service flaw detection equipment; meanwhile, the detection quality and the adjustment speed of the common switch rail, the AT switch rail, the cast frog, the assembled frog, the movable frog, the long point rail, the short point rail and the temperature regulator can be improved, the damage missing detection is reduced, and the damage detection requirement of TB/T2340-2012 is met.
CN202010083143.9A 2020-02-08 2020-02-08 Wheeled probe ultrasonic wave automatic centering system Pending CN112406949A (en)

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3978714A (en) * 1972-08-16 1976-09-07 Shraiber David S Method of ultrasonic echo flaw detection and device for effecting same
US4235112A (en) * 1979-08-06 1980-11-25 The United States Of America As Represented By The Secretary Of The Department Of Transportation Rail flaw detector position control
CN103954696A (en) * 2014-05-22 2014-07-30 株洲时代电子技术有限公司 Flaw detection simulated test method for steel rail
CN104359983A (en) * 2014-11-03 2015-02-18 中国铁道科学研究院 Centering system and method for steel rail flaw detection device
CN108519439A (en) * 2018-04-20 2018-09-11 株洲时代电子技术有限公司 A kind of automatic centering control system with wear compensation
CN110596253A (en) * 2019-07-22 2019-12-20 株洲时代电子技术有限公司 Steel rail flaw detection signal generation and processing device

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3978714A (en) * 1972-08-16 1976-09-07 Shraiber David S Method of ultrasonic echo flaw detection and device for effecting same
US4235112A (en) * 1979-08-06 1980-11-25 The United States Of America As Represented By The Secretary Of The Department Of Transportation Rail flaw detector position control
CN103954696A (en) * 2014-05-22 2014-07-30 株洲时代电子技术有限公司 Flaw detection simulated test method for steel rail
CN104359983A (en) * 2014-11-03 2015-02-18 中国铁道科学研究院 Centering system and method for steel rail flaw detection device
CN108519439A (en) * 2018-04-20 2018-09-11 株洲时代电子技术有限公司 A kind of automatic centering control system with wear compensation
CN110596253A (en) * 2019-07-22 2019-12-20 株洲时代电子技术有限公司 Steel rail flaw detection signal generation and processing device

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Application publication date: 20210226