CN113092577B - Rail defect detection system based on multifrequency excitation vortex and detection method thereof - Google Patents

Rail defect detection system based on multifrequency excitation vortex and detection method thereof Download PDF

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CN113092577B
CN113092577B CN202110313519.5A CN202110313519A CN113092577B CN 113092577 B CN113092577 B CN 113092577B CN 202110313519 A CN202110313519 A CN 202110313519A CN 113092577 B CN113092577 B CN 113092577B
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CN113092577A (en
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许�鹏
曾泓茗
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Nanjing University of Aeronautics and Astronautics
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N27/00Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
    • G01N27/72Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
    • G01N27/82Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
    • G01N27/90Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents
    • G01N27/9006Details, e.g. in the structure or functioning of sensors
    • 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B61RAILWAYS
    • B61LGUIDING RAILWAY TRAFFIC; ENSURING THE SAFETY OF RAILWAY TRAFFIC
    • B61L23/00Control, warning, or like safety means along the route or between vehicles or vehicle trains
    • B61L23/04Control, warning, or like safety means along the route or between vehicles or vehicle trains for monitoring the mechanical state of the route
    • B61L23/042Track changes detection
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N27/00Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
    • G01N27/72Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
    • G01N27/82Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
    • G01N27/90Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents
    • G01N27/9046Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents by analysing electrical signals
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E30/00Energy generation of nuclear origin
    • Y02E30/30Nuclear fission reactors

Abstract

The invention provides a track defect detection system and a detection method based on multi-frequency excitation vortex, wherein the system comprises a multi-frequency excitation signal generation module, an vortex sensor module, a signal processing module and a defect evaluation module, wherein the multi-frequency excitation signal generation module is used for generating multi-frequency excitation signals; the vortex sensor module is used for receiving the multi-frequency excitation signal, forming a vortex field on the surface of the track according to the multi-frequency excitation signal, detecting the change of the vortex field on the surface of the track due to the track defect, and converting the change into a measurement signal; the signal processing module is used for receiving and processing the measurement signals and extracting defect signals; the defect evaluation module is used for evaluating the defect signal to obtain depth information of the track defect. According to the multi-frequency eddy current detection technology, more defect information can be extracted under the condition that the sensor structure is not complicated, and the signal comparison among the frequencies is used for comprehensive evaluation, so that interference can be restrained, and the detection reliability is improved.

Description

Rail defect detection system based on multifrequency excitation vortex and detection method thereof
Technical Field
The invention belongs to online detection of a high-speed running track, and particularly relates to a track defect detection system and a track defect detection method based on multi-frequency excitation vortex.
Background
The on-line detection of high-speed running track is a technology for on-line detection and health monitoring of defect and damage of rail in service state by adopting nondestructive detection method in order to prevent rail fault of high-speed railway. The current on-line detection technology of the high-speed running rail commonly used at home and abroad mainly comprises ultrasonic detection, eddy current detection, magnetic leakage detection, visual detection and the like.
The eddy current detection is a nondestructive detection method based on an electromagnetic induction principle, has the advantages of rapidness and low cost, and is mainly used for detecting defects on the surface and near surface of a steel rail in the online detection of a high-speed running rail. As a non-contact detection technique, eddy current detection can realize high-speed and automatic online detection. However, the defect information acquired in the conventional single-frequency eddy current inspection is single and is easily interfered by noise.
Disclosure of Invention
In order to solve the problems, the invention provides a track defect detection system and a detection method based on multi-frequency excitation vortex.
In order to achieve the above purpose, the technical scheme of the invention is as follows:
an orbital defect detection system based on multi-frequency excitation eddy currents, comprising:
the multi-frequency excitation signal generation module is used for generating a multi-frequency excitation signal;
the vortex sensor module is used for receiving the multi-frequency excitation signal, forming a vortex field on the surface of the track according to the multi-frequency excitation signal, and detecting the change of the vortex field on the surface of the track to convert the change into a measurement signal;
the signal processing module is used for receiving and processing the measurement signals and extracting defect signals;
the defect evaluation module is used for evaluating the defect signals to obtain depth information of the track defects;
wherein the multi-frequency excitation signal generation module has:
the user setting module is used for receiving the parameter value input by the user;
the control module outputs a first control instruction according to the parameter value;
the signal generation module outputs sine wave signals with various frequencies according to the first control instruction;
the signal amplifying module amplifies and combines the sine wave signals to form a multi-frequency excitation signal;
the amplitude detection module is used for detecting the amplitude of the multi-frequency excitation signal and outputting a second control instruction to the control module so as to adjust the amplitude of the multi-frequency excitation signal
Further, the user setting module comprises a touch screen and a matrix keyboard.
Further, the signal generating module comprises a plurality of DDS chips, and the model of the DDS chips is AD9833.
Further, the signal amplifying module comprises a DAC chip and a plurality of voltage-controlled amplifiers, the model of the DAC chip is MCP4728, and the model of the voltage-controlled amplifiers is AD603.
Further, the parameter values include the frequency and amplitude of the multi-frequency excitation signal.
Further, the eddy current sensor module is provided with a differential eddy current probe, the differential eddy current probe comprises a first coil and a second coil which are wound in opposite directions, and the first coil and the second coil are arranged in front and back along the moving direction of the differential eddy current probe.
Further, the signal processing module comprises a plurality of band-pass filters and a phase-locked amplifier, wherein the band-pass filters are used for carrying out frequency band separation on the measurement signals and transmitting the measurement signals to the phase-locked amplifier, and the phase-locked amplifier is used for carrying out IQ demodulation on the measurement signals subjected to frequency band separation to obtain defect signals of each frequency band and real part signals I and imaginary part signals Q of the defect signals.
A detection method of an orbit defect detection system based on multi-frequency excitation vortex comprises the following steps:
step 1: outputting a first control instruction according to a parameter value set by a user;
step 2: outputting sine wave signals with various frequencies according to a first control instruction, amplifying the sine wave signals to form sine wave excitation signals, and synthesizing the sine wave excitation signals into multi-frequency excitation signals;
step 3: detecting the amplitude of the multi-frequency excitation signal, and outputting a second control instruction to adjust the amplitude of the multi-frequency excitation signal;
step 4: forming a vortex field on the surface of the track according to the multi-frequency excitation signal, detecting the change of the vortex field on the surface of the track, and converting the change into a measurement signal;
step 5: receiving and processing the measurement signals, and extracting defect signals;
step 6: and evaluating the defect signal to obtain depth information of the track defect.
Further, the step 4 includes: and receiving the multifrequency excitation signals, forming a vortex field on the surface of the track according to the multifrequency excitation signals, detecting the change of an alternating magnetic field generated by the vortex field, and outputting a measuring signal.
Still further, the step 5 includes: and performing frequency band separation on the measurement signals, and performing IQ demodulation on the measurement signals subjected to frequency band separation to obtain defect signals of each frequency band and real part signals I and imaginary part signals Q of the defect signals.
Compared with the prior art, the invention has the beneficial effects that:
the invention provides a track defect detection system and a track defect detection method based on multi-frequency excitation vortex, which can realize inspection of a track under the condition of high-speed operation, extract more defect information, and improve the stability of track defect detection through multi-frequency comprehensive evaluation based on root mean square. Compared with the conventional eddy current detection with single frequency excitation, the multi-frequency eddy current detection technology can extract more defect information under the condition that the sensor structure is not complicated, and can inhibit interference and improve the detection reliability through comprehensively evaluating signal comparison among the frequencies.
Drawings
FIG. 1 is a schematic diagram of a track defect detection system according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a multi-frequency excitation signal generation module according to an embodiment of the invention;
FIG. 3 is a schematic diagram of the principle of the vortex skin effect;
FIG. 4 is a schematic diagram of an eddy current sensor module;
FIG. 5 is a schematic diagram of a signal processing module;
FIG. 6 is a graph of the amplitude-frequency of a band pass filter;
FIG. 7 is a graph of a multi-frequency excitation signal spectrum;
FIG. 8 is a schematic diagram of the characteristics of the I-path measurement signal;
FIG. 9 is a schematic diagram of Q-channel measurement signal characteristics;
FIG. 10 is a graph of the effect of multi-frequency integrated assessment.
Detailed Description
The following describes in further detail the embodiments of the present invention with reference to the drawings and examples. The following examples are illustrative of the invention and are not intended to limit the scope of the invention.
In one aspect, an embodiment of the present invention provides a track defect detection system based on multi-frequency excitation eddy currents, as shown in fig. 1, including a multi-frequency excitation signal generating module, an eddy current sensor module, a signal processing module, and a defect evaluation module, where the multi-frequency excitation signal generating module is configured to generate a multi-frequency excitation signal; the vortex sensor module is used for receiving the multi-frequency excitation signal, forming a vortex field on the surface of the track according to the multi-frequency excitation signal, and detecting the change of the vortex field on the surface of the track due to the track defect to convert the change into a measurement signal; the signal processing module is used for receiving and processing the measurement signals and extracting defect signals; the defect evaluation module is used for evaluating defect signals to obtain depth information of the track defects;
as shown in fig. 2, the multi-frequency excitation signal generation module is provided with a user setting module, a control module, a signal generation module, a signal amplification module and an amplitude detection module; the method comprises the steps that a user inputs parameter values containing the frequency and the amplitude of a multi-frequency excitation signal through a touch screen and a matrix keyboard in a user setting module, a control module outputs a first control instruction to a signal generation module according to the parameter values, and the signal generation module outputs sine wave signals with various frequencies according to the first control instruction; the signal amplification module amplifies and combines the sine wave signals to form a multi-frequency excitation signal.
The amplitude detection module outputs a second control instruction to the control module according to the detected amplitude of the multi-frequency excitation signal so as to adjust the amplitude of the multi-frequency excitation signal.
In this embodiment, the signal generating module includes a plurality of DDS chips, and the model of the DDS chips is AD9833. The signal amplification module comprises a DAC chip and a plurality of voltage-controlled amplifiers, the model of the DAC chip is MCP4728, and the model of the voltage-controlled amplifier is AD603; the DAC chip and the voltage-controlled amplifier form a signal amplifier with controllable gain, the amplified signal is collected by the ADC chip in the amplitude detection module, and compared with the amplitude set by a user, the gain is changed, so that the actual signal amplitude is the same as the set value.
To further illustrate the relationship between the multifrequency excitation signal and the track defect in the present invention, the following description is made with reference to the accompanying drawings.
Fig. 3 is a schematic diagram of the principle of eddy current skin effect, in which eddy current is concentrated on the surface of a conductor due to skin effect, and the density of eddy current is increased as the eddy current is closer to the surface of the conductor, and the density of eddy current is reduced as the depth is increased, and the eddy current decays exponentially as e.
The eddy current density is typically specified to decay to a depth of penetration of 1/e of the surface expressed as:
Figure BDA0002990894460000041
wherein delta is penetration depth, f is excitation frequency, sigma is conductivity of the conductor, and mu is permeability of the conductor;
therefore, when setting the frequency, it is assumed that the depth to be detected is δ 1 The corresponding excitation frequency is f 1 =1/(δ 1 2 Pi sigma mu), setting n excitation frequencies (1.ltoreq.n.ltoreq.4), delta is determined when an average distribution over the spatial detection is desired 2 =(n-1)δ 1 /n,δ 3 =(n-2)δ 1 /n,……δ n =δ 1 N, the corresponding excitation frequency is f 2 =(n/n-1) 2 f 1 ,f 3 =(n/n-2) 2 f 1 ,……f n =n 2 f 1
Preferably, as shown in fig. 4, the eddy current sensor module has a differential eddy current probe including a first coil L1 and a second coil L2 wound in opposite directions, the first coil L1 and the second coil L2 being arranged in front and back along a moving direction of the differential eddy current probe; when the defect is detected, the first coil and the second coil pass through the track defect, the vortex field change caused by the track defect acts on the differential vortex detection probe through the magnetic field to cause the impedance of the two coils in the differential vortex detection probe to change successively, and the output measurement signal is a multi-frequency excitation signal with the amplitude and the phase changed when the track defect passes through.
Preferably, as shown in fig. 5, the signal processing module includes a plurality of band-pass filters and a lock-in amplifier, where the band-pass filters are used to perform band separation on the measurement signals and transmit the measurement signals to the lock-in amplifier, and the lock-in amplifier is used to perform IQ demodulation on the measurement signals subjected to band separation to obtain defect signals of each band and real part signals I and imaginary part signals Q thereof; the signal processing module receives the measurement signals sent by the eddy current sensor module, separates out measurement signals of different frequency bands, carries out IQ demodulation to obtain defect information of different frequency bands, and can carry out signal comparison among the frequency bands in the follow-up process, thereby being beneficial to providing guidance for the evaluation of the rail defect hazard level.
Fig. 6 shows an amplitude-frequency characteristic curve of a band-pass filter used by the signal processing module, wherein the excitation frequency f in the band-pass filter is a center frequency, f±1000 is a pass-band frequency, f±2000 is a stop-band frequency, and the stop-band gain is-60 dB for filtering other frequency detection signals.
In another aspect, an embodiment of the present invention provides a method for detecting an orbital defect detection system based on a multi-frequency excitation vortex, including the steps of:
step 1: the user sets the parameter value of the multi-frequency excitation signal through the user setting module, the first control command is output according to the parameter value control module, the signal generating module outputs sine wave signals with various frequencies according to the first control command, and the signal amplifying module amplifies and combines the sine wave signals to form the multi-frequency excitation signal; meanwhile, the amplitude detection module detects the amplitude of the multi-frequency excitation signal and outputs a second control instruction to the control module so as to adjust the amplitude of the multi-frequency excitation signal;
step 2: the eddy current sensor module forms an eddy current field on the surface of the track through the first coil and the second coil according to the multi-frequency excitation signal, and the first coil and the second coil change differential output voltage due to the influence of the change of the eddy current field, so that a measurement signal is output;
step 3: the band-pass filter performs frequency band separation on the measurement signals, transmits the measurement signals to the lock-in amplifier, and performs IQ demodulation on the measurement signals subjected to frequency band separation by the lock-in amplifier to obtain defect signals of each frequency band and real part signals I and imaginary part signals Q of the defect signals;
step 4: the defect evaluation module evaluates the defect signal to obtain depth information of the track defect.
Example 1:
when the user selects three excitation frequencies (8 khz,18khz,72 khz), fig. 7 is a graph of the output signal spectrum of the multi-frequency excitation signal generation module.
Fig. 8 and 9 show waveforms of measurement signals on a steel rail test piece when three frequencies of 8khz,18khz and 72khz are adopted for excitation, after signal processing, signals of three paths of frequencies, I and Q, show different signal characteristics, and excitation signals of multiple frequencies can be obtained more than defect information detected by a single frequency, wherein the difference between a positive peak value and a negative peak value of one defect signal is called as a peak-to-peak value deltap.
Defects with the defect depths of 2mm, 4mm, 6mm and 8mm in the track test piece are researched, and the relation between the defect peak value delta P and the defect depth D is researched by using a fitting curve method, so that a linear function relation between the defect peak value delta P and the defect depth D can be obtained:
ΔP I =k 1 D+t 1
ΔP Q =k 2 D+t 2
wherein, k is determined when the detection speed v and the excitation frequency f are determined 1 、t 1 、k 2 、t 2 Is a parameter-free constant, deltaP I As the defect peak value of the I path, deltaP Q The Q-way defect peak value.
The measured peak value of the signal peak is carried into a fitting linear function, and three different defect depth evaluation values D of the frequency can be obtained I1 、D I2 、D I3 、D Q1 、D Q2 、D Q3 Through analysis, the evaluation effects of the I path and the Q path of the same frequency are similar, so that the defect evaluation values of the same frequency are combined by adopting a root mean square method as follows:
Figure BDA0002990894460000061
/>
obtaining depth evaluation value D of each frequency through operation f1 、D f2 、D f3
FIG. 10 is a graph of the effect of multi-frequency synthesis evaluation, which performs root mean square calculation synthesis evaluation on different frequency evaluation results relative to single frequency evaluation effect:
Figure BDA0002990894460000071
wherein D is s To comprehensively evaluate the defect depth values.
Comparing the comprehensive defect evaluation value with the evaluation value of each frequency to obtain respective absolute values of relative errors:
Figure BDA0002990894460000072
wherein, delta is the absolute value of the relative error, D' is the defect depth evaluation value, D 0 Is the actual depth of the defect.
In summary, it can be found that the accuracy and stability of the comprehensive evaluation effect are both stronger than that of the defect depth evaluation of the single frequency.

Claims (3)

1. A detection method of a track defect detection system based on multi-frequency excitation vortex, the track defect detection system comprises:
the multi-frequency excitation signal generation module is used for generating a multi-frequency excitation signal;
the vortex sensor module is used for receiving the multi-frequency excitation signal, forming a vortex field on the surface of the track according to the multi-frequency excitation signal, detecting the change of the vortex field on the surface of the track, and converting the change into a measurement signal;
the signal processing module is used for receiving and processing the measurement signals and extracting defect signals;
the defect evaluation module is used for evaluating the defect signals to obtain depth information of the track defects;
wherein the multi-frequency excitation signal generation module has:
the user setting module is used for receiving the parameter value input by the user;
the control module outputs a first control instruction according to the parameter value;
the signal generation module outputs sine wave signals with various frequencies according to the first control instruction;
the signal amplifying module amplifies and combines the sine wave signals to form a multi-frequency excitation signal;
the amplitude detection module is used for detecting the amplitude of the multi-frequency excitation signal and outputting a second control instruction to the control module so as to adjust the amplitude of the multi-frequency excitation signal;
the user setting module comprises a touch screen and a matrix keyboard;
the signal generation module comprises a plurality of DDS chips;
the signal amplification module comprises a DAC chip and a plurality of voltage-controlled amplifiers;
the parameter value comprises the frequency and the amplitude of the multi-frequency excitation signal;
the eddy current sensor module is provided with a differential eddy current detection probe, the differential eddy current detection probe comprises a first coil and a second coil which are wound in opposite directions, and the first coil and the second coil are arranged front and back along the moving direction of the differential eddy current detection probe;
the signal processing module comprises a plurality of band-pass filters and a phase-locked amplifier, wherein the band-pass filters are used for carrying out frequency band separation on the measurement signals and transmitting the measurement signals to the phase-locked amplifier, and the phase-locked amplifier is used for carrying out IQ demodulation on the measurement signals subjected to frequency band separation to obtain defect signals of each frequency band and real part signals I and imaginary part signals Q of the defect signals;
the method is characterized by comprising the following steps of:
step 1: outputting a first control instruction according to a parameter value set by a user;
step 2: outputting sine wave signals with various frequencies according to a first control instruction, amplifying the sine wave signals to form sine wave excitation signals, and synthesizing the sine wave excitation signals into multi-frequency excitation signals;
step 3: detecting the amplitude of the multi-frequency excitation signal, and outputting a second control instruction to adjust the amplitude of the multi-frequency excitation signal;
step 4: forming a vortex field on the surface of the track according to the multi-frequency excitation signal, detecting the change of the vortex field on the surface of the track, and converting the change into a measurement signal;
step 5: receiving and processing the measurement signals, and extracting defect signals;
step 6: according to the defect signal estimated by the defect estimating module, the depth information of the track defect is obtained, and the specific implementation process is as follows:
for excitation signals of multiple frequencies, the difference between the positive peak and the negative peak of one defect signal is referred to as peak-to-peak Δp;
and fitting the relation between the defect peak value delta P and the defect depth D by using a fitting curve method for defects with the defect depths of 2mm, 4mm, 6mm and 8mm in the track test piece to obtain a linear function relation between the defect peak value delta P and the defect depth D:
ΔP I =k 1 D+t 1
ΔP Q =k 2 D+t 2
wherein, k is determined when the detection speed v and the excitation frequency f are determined 1 、t 1 、k 2 、t 2 Is a parameter-free constant, deltaP I As the defect peak value of the I path, deltaP Q The Q path defect peak value;
the measured peak value of the signal peak is carried into a fitting linear function to obtain three frequency different defect depth evaluation values D I1 、D I2 、D I3 、D Q1 、D Q2 、D Q3 And combining defect evaluation values of the same frequency by adopting a root mean square method:
Figure FDA0004089628570000021
obtaining depth evaluation value D of each frequency through operation f1 、D f2 、D f3
Performing root mean square calculation on the evaluation results of different frequencies to obtain multi-frequency comprehensive evaluation:
Figure FDA0004089628570000022
wherein D is s To comprehensively evaluate the defect depth values.
2. The method for detecting an orbital defect detection system based on multi-frequency excitation eddy current according to claim 1, wherein: the step 4 comprises the following steps: and receiving the multifrequency excitation signals, forming a vortex field on the surface of the track according to the multifrequency excitation signals, detecting the change of an alternating magnetic field generated by the vortex field, and outputting a measuring signal.
3. The method for detecting an orbital defect detection system based on multi-frequency excitation eddy current according to claim 1, wherein the step 5 comprises: and performing frequency band separation on the measurement signals, and performing IQ demodulation on the measurement signals subjected to frequency band separation to obtain defect signals of each frequency band and real part signals I and imaginary part signals Q of the defect signals.
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