CN202305483U - Real-time online nondestructive inspection detecting device for rails by means of ultrasonic guided waves - Google Patents
Real-time online nondestructive inspection detecting device for rails by means of ultrasonic guided waves Download PDFInfo
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- CN202305483U CN202305483U CN201120421193XU CN201120421193U CN202305483U CN 202305483 U CN202305483 U CN 202305483U CN 201120421193X U CN201120421193X U CN 201120421193XU CN 201120421193 U CN201120421193 U CN 201120421193U CN 202305483 U CN202305483 U CN 202305483U
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Abstract
The utility model relates to a real-time online nondestructive inspection detecting device for rails by means of ultrasonic guided waves, which comprises a guided wave sensor array, ultrasonic exciting/receiving and AD (analog-digital) converting equipment, wireless data transmission equipment and terminal data receiving and detecting equipment, wherein output signals of the guided wave sensor array is connected with the ultrasonic exciting/receiving and AD converting equipment, and the wireless data transmission equipment is used for transmitting data of the ultrasonic exciting/receiving and AD converting equipment to a data receiver. By means of the guided waves for flat plates or bent plates, pipes, pipelines, composite layer structures or other natural materials, long-distance detection on a single probe is completed, the detecting distance can reach 500 meters, and comprehensive and good defect inspection and estimation effect can be achieved.
Description
Technical field
The utility model relates to a kind of nondestructive examination detection technique, a kind of specifically supersonic guide-wave rail real time on-line nondestructive carrying out flaw detection device.
Background technology
Guided wave can be used for three kinds of status detection: short distance＜1m; Moderate distance pact≤5m; Remote pact≤100m.
Remote ultrasonic guided wave detecting can have been saved traditional ultrasound wave or eddy current method consumed time that scanning requires from the position probing of a separated sensor to structural member on a large scale.Sensor transmits guided wave along structural member, receives the echo that returns and handles, and demonstrates the further feature of defective or structural member.
The process of manual formula rail examination operation is through nearly more than 20 years use, comparative maturity, and the recall rate of hurt is higher, and reliability is better, is guaranteeing to bring into play vital role aspect the safety of railway traffic.But along with the direction of railway to high-speed overload develops, be main with hand propelled flaw detection dolly, large-scale inspection car is that the situation of assisting exposes weak point significantly:
1) the artificial flaw detection of hand propelled dolly flaw detection operating efficiency is low.Its detection speed is generally 2-3 kilometer/hour, and the workload of every day is an interval (being generally the 7-10 kilometer).This hand propelled flaw detection dolly inspection speed is low, can not adapt to the new requirement in speed-raising back significantly.
2) manual rail examination operating type need drop into great amount of manpower, does not meet the policy that the Ministry of Railways cuts payroll to improve efficiency.If use the flaw detection mode of real-time online instead, required personnel are less than one of percentage of manual flaw detection personnel.
3) 13 the most effective large-scale rail-defect detector car highest detection speed that adopt on the railway at present are 40 kilometers/hour, and operating type is the dwell type operation, promptly find hurt after; Inspection car need stop; Continue after checking with small-sized defectoscope to detect, the road occupying time is long again, the difficult arrangement of transportation tissue.
4) to hinder recall rate low for the nuclear of large-scale inspection car, and False Rate is high, yet along with the raising of train speed, nuclear is hindered becomes the great hidden that influence transportation safety, and detecting of nuclear wound become even more important.
At present, the technology that China is used for the rail flaw detection is main, traditional ultrasonic technology with the ultrasonic beam detection mainly, and the sensor that adopts 0-70 degree pulse echo pattern is in the operation of railway center line surface.Common angle probe can be confirmed the degree of depth of rail, also can detect slag inclusion, horizontal crackle etc.Because the sensing range of measured device nondestructive examination directly receives the restriction of sensor institute overlay area, guided wave rail detection system is surveyed in the instance rail, and length comprises the defective of various manual works from 5-20 rice.Use the speed of conventional ultrasonic wave beam technique detection large-sized structural parts slow,, just need carry out the pointwise scanning if detect the total part.Therefore, the nondestructive examination system of development and application real-time online, just need seek a kind of new detection technique that is suitable for the rail operating mode.
The utility model content
To traditional ultrasonic technology rail is carried out carrying out flaw detection and exist sensing range directly to receive weak points such as restriction, the detection speed of sensor institute overlay area be slow, the technical matters that the utility model will solve provides a kind ofly can accomplish long distance detecting and detection speed supersonic guide-wave rail real time on-line nondestructive carrying out flaw detection device soon and accurately.
For solving the problems of the technologies described above, the technical scheme that the utility model adopts is:
The utility model supersonic guide-wave rail real time on-line nondestructive carrying out flaw detection device has guided wave sensor array, ultrasonic excitation/reception and AD conversion equipment, data wireless transmission equipment and terminal data and receives and checkout equipment; Wherein the output signal of guided wave sensor array is connected with ultrasonic excitation/reception and AD conversion equipment, and the data of ultrasonic excitation/reception and AD conversion equipment are delivered to data receiver through wireless data transmission device.
Said guided wave sensor array is classified many groups as, and per four groups of sensor arraies are equipped with a cover ultrasonic excitation/reception and an AD conversion equipment, and four rails in same place comprise up and downgoing line is respectively respectively installed one group of guided wave sensor array on two rails.
The parallel four every interval of rail predetermined distances that are provided with are a check point; Said predetermined distance is 450～500 meters; The guided wave sensor array be arranged in rail head below, the web of the rail and the flange of rail above, every component three row, every row are at a distance of quarter-wave, each guided wave sensor is pressed on the corresponding site of rail.
The utlity model has following beneficial effect and advantage:
Compare with traditional ultrasound beamformer inspection technique, guided wave detects has following advantage:
1. the utility model is accomplished long distance detection for flat board or bent plate, pipe, pipeline, lamination layer structure or other natural guided wave from single probe positions, detects distance and can reach 500 meters.
2. the utility model is set up suitable acoustic resonance, through suitable wave mode and frequency selection or tuning, reaches good comprehensively defects detection and estimation effect.
3. the remolding sensitivity standard normal ultrasound beamformer obtained of the utility model detects or that other NDT method is obtained is highly sensitive, can reach 0.2mm.
4. the utility model has highly sensitive detection performance in water, coating or heat-insulation layer, lamination layer structure or xoncrete structure detect.
5. sensor installation array on the track of high-speed railway through controlled in wireless, emission, reception technique, can be realized the no people detection of high speed rail; Because simplification and rapidity that guided wave detects can reach the higher cost benefit, be equivalent to 10% of standard normal ultrasonic beam and the required expense of other NDT technology for detection usually, detection efficiency is high, and personnel cost is low.
6. large-scale detection is convenient in the configuration of guided wave sensor; Can solve every group of sensor array and be equipped with the problem that a cover detects main frame; Save the expensive main frame expense of three covers, but resultant be the reduction that detects frequency, but still can realize per minute detection speed once.
Description of drawings
Fig. 1 is the utility model detection system electrical structure synoptic diagram;
Fig. 2 arranges synoptic diagram for the utility model detection system;
Fig. 3 is that the signal waveform data in ultrasonic excitation/reception and the AD conversion equipment produces the part-structure synoptic diagram;
Fig. 4 is that four groups of guided wave sensor arraies are arranged synoptic diagram in the utility model;
Fig. 5 is listed in the layout synoptic diagram on the rail for every group of guided wave sensor array in the utility model;
Fig. 6 is every group of guided wave transducer arrangements figure in the utility model.
Embodiment
Below in conjunction with Figure of description the utility model is done further to set forth.
Like Fig. 1, shown in 2; The utility model supersonic guide-wave rail real time on-line nondestructive carrying out flaw detection device has guided wave sensor array 1, ultrasonic excitation/reception and AD conversion equipment 2, data wireless transmission equipment 3 and data receiver 4; Wherein the output signal of guided wave sensor array 1 is connected with ultrasonic excitation/reception and AD conversion equipment 2, and the data of ultrasonic excitation/reception and AD conversion equipment 2 are delivered to data receiver 4 through wireless data transmission device 3.
Said guided wave sensor array 1 is many groups, and per four groups of sensor arraies are equipped with a cover ultrasonic excitation/reception and an AD conversion equipment 2, and four rails in same place comprise up and downgoing line is respectively respectively installed one group of guided wave sensor array 1 on two rails; The parallel four every interval of rail predetermined distances that are provided with are a check point; The afore mentioned rules distance is 450～500 meters.
Guided wave sensor array 1 be arranged in rail head T below, web of the rail Y and flange of rail D above, every component three row, every row adopt mechanical hook-up that each guided wave sensor 101 is compressed, like Fig. 5, shown in 6 at a distance of quarter-wave.
For realizing the optimality price ratio of the utility model; The mode that the equipment of rail nondestructive examination system is installed and adopted per four groups of sensor arraies outfit, one cover detection main frame is ultrasonic excitation/reception and AD conversion equipment 2 is carried out; As shown in Figure 4; On four rails (up and each two rail of downgoing line) in same place, one group of guided wave sensor array 1 is installed respectively; By detecting main frame four groups of sensor arraies 1 are patrolled and examined, and through the data wireless transmission equipment detection signal to be transferred to the office terminal be data receiver.Take this scheme, can solve every group of sensor array 1 and be equipped with the problem that a cover detects main frame, save the expensive main frame expense of three covers, but resultant be the reduction that detects frequency, but still can realize per minute detection speed once.
In the present embodiment, per 450～500 meters four rails are a check point, and required microcomputer of terminal management apparatus and unit equipment are equipped with by the user voluntarily on request, and the detection of pitching for the road is equally applicable to this mount scheme.
Ultrasonic excitation/reception and A/D conversion equipment (model that present embodiment adopts is U2000) comprise that signal waveform data produces, data transmission is stored and 3 parts of conversion output.The generation of signal waveform realizes on computers, produces various needed positive and negative square-wave waveforms through programming, and signal is carried out time frequency analysis and visualization processing.
The data transmission storage is exactly the digital waveform that adopts software to produce with on the computing machine, and utilization USB2.0 technology adopts fpga chip control to produce the transmission time sequence logic, data transmission is stored into the sram chip of D/A conversion and control plate.
12 D/A conversion chip AD568 output of fpga chip control analog signals is adopted in the output of signal waveform, and the amplification through integrated transporting discharging produces various high-frequency signals.The amplitude of output simulating signal is 5.12 volts of scholars, and highest frequency is the 10M hertz, main frequency of operation 35K hertz.
It is as shown in Figure 3 that signal waveform data produces part.Be the subscriber interface module programming on computers, produce various waveforms, and on subscriber interface module realize visual through the waveform display module above all waveforms through waveform generation module; By data analysis module the various waveforms that waveform generation module produces are made Fourier transform, obtain the frequency domain characteristic curve of various waveforms; According to curvilinear characteristic dot generation amplitude envelope line, and with on its frequency domain characteristic curve that is added to; Frequency curve after the stack is made inversefouriertransform, obtains frequency conversion, luffing ripple, and realizes that it is visual; Behind above waveform sampling, through format conversion, be converted into D/A converter ability recognition data, row shows when passing through the waveform display module by subscriber interface module again. Line access when the external data access module is the Wave data that waveform generation module is produced supplies data analysis module and waveform display module to read at random and calls.
Realize data communication function, data rate reaches 480Mb/s.Select the single-chip microcomputer with intelligent USB interface for use, with SIE, USB2.0 communication interface standard, Peripheral Interface able to programme are incorporated in the single-chip microcomputer integrated circuit.Integrated USB transceiver module links to each other with D one pin with the D ten of usb bus.Powerful SIE (SIE) is realized the usb communication interface protocol, is carried out serial data decoding and error correction with hardware mode; And the desired signal level operation of other USB etc., send data byte at last and receive data to USB port or from USB port.The data rate that it is realized has two kinds: full speed 12Mb/s, high speed 480Mb/s.
Owing to be the high-speed a/d collection, obtain performance as well as possible in order to make total system, in circuit and wires design, adopted following measure:
1. for fear of crosstalking and guarantee the integrality of signal between each signal; Adopted multilayer board in the PCB design,, made between signal wire and ground or the power plane and form a tight coupling layer, thereby reduced crosstalking between the signal wire through using large-area power circuit and ground plane.
2. comprehensively use filter capacitor, rational deployment and wiring etc. to reduce the disturbance of power unit, power supply is selected linear stabilized power supply for use.The output of the same power supply of A/D and front-end processing circuit ground reduces the influence that power-supply fluctuation is gathered data.
3. when wiring, adopt the arc corners wiring technique, reduce the radiation and the reflection of signal wire, reduction is crosstalked.
4. carefully solve the problem with grounding of unit and system, simulation separates with numeral publicly publicly, selects click-through to cross low value surface-mount resistor (1～2 Ω) or directly connection.
5. element adopts the surface encapsulation device as far as possible, reduces the distance of components and parts, reduces stray inductance and electric capacity.
Adjustable positive and negative square wave mode of excitation can fully satisfy the high-power requirement of ultrasound wave guided wave emission; Based on the high speed acquisition system of USB2.0 interface, can more convenient, high speed processing signal and secondary development more flexibly; In conjunction with UT-Scan processing, analysis software, the planar imaging and the stereo-picture that can carry out X axle, Y axle respectively are synthetic; The microminiature volume is convenient to on-the-spot the detection and is used; System works under windowsXP, stable performance, easy to use.
Wireless data transmission device (model that adopts in the present embodiment is DTU7500) adopts the mobile wireless data transmission card; The flaw detection data of main frame being received through the RS232 interface are linked in the data transmission unit; These data comprise identification number, detection time, flaw detection data of rail etc., and upload on the receiving trap of terminal.
Data receiver receives the terminal management that the classification authority can be set with pick-up unit (model that adopts in the present embodiment is DRU7800) as terminal data; Set different administration authorities by different management responsibilities, realize the difference supervision of concrete administrative authority, each upper management department.
The user management terminal receives various flaw detection data through wired or wireless network; The data and the graphical information that in the terminal management computing machine, show each location detection point; Can set up the position of checking on their own by the supvr, when on the track of monitoring, the hurt phenomenon occurring, computing machine proposes warning message; Orbital position, hurt phenomenon that prompting goes wrong supply the supvr in time to take measures to handle.
The detection system performance evaluation
1) detect distance and reach more than 250 meters, every group of sensor array detection range is 500 meters;
2) detection sensitivity and the ability of finding defective:
Because the needs of long distance detecting, the detection frequency that supersonic guide-wave adopts is lower, detection sensitivity keep previous level (ultrasound examination find the size of defective be about wavelength 1/2).
3) to the decision problem of defective:
Can adopt the automatic warning of setting gate or threshold line,, can reduce the phenomenon of reporting by mistake and failing to report and produce, also can in time judge the concrete phenomenon of hurt in conjunction with the mode of manual analysis.
The utility model technical parameter
Claims (5)
1. supersonic guide-wave rail real time on-line nondestructive carrying out flaw detection device; It is characterized in that: have guided wave sensor array, ultrasonic excitation/reception and AD conversion equipment, data wireless transmission equipment and terminal data and receive and checkout equipment; Wherein the output signal of guided wave sensor array is connected with ultrasonic excitation/reception and AD conversion equipment, and the data of ultrasonic excitation/reception and AD conversion equipment are delivered to data receiver through wireless data transmission device.
2. by the described supersonic guide-wave rail of claim 1 real time on-line nondestructive carrying out flaw detection device; It is characterized in that: said guided wave sensor array is classified many groups as; Per four groups of sensor arraies are equipped with a cover ultrasonic excitation/reception and an AD conversion equipment; Four rails in same place comprise up and downgoing line is respectively respectively installed one group of guided wave sensor array on two rails.
3. by the described supersonic guide-wave rail of claim 2 real time on-line nondestructive carrying out flaw detection device, it is characterized in that: the parallel four every interval of rail predetermined distances that are provided with are a check point.
4. by the described supersonic guide-wave rail of claim 3 real time on-line nondestructive carrying out flaw detection device, it is characterized in that: said predetermined distance is 450～500 meters.
5. by the described supersonic guide-wave rail of claim 2 real time on-line nondestructive carrying out flaw detection device; It is characterized in that: the guided wave sensor array be arranged in rail head below, the web of the rail and the flange of rail above; Every component three row; Every row are at a distance of quarter-wave, and each guided wave sensor is pressed on the corresponding site of rail.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201120421193XU CN202305483U (en) | 2011-10-28 | 2011-10-28 | Real-time online nondestructive inspection detecting device for rails by means of ultrasonic guided waves |
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| CN201120421193XU CN202305483U (en) | 2011-10-28 | 2011-10-28 | Real-time online nondestructive inspection detecting device for rails by means of ultrasonic guided waves |
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102923164A (en) * | 2012-09-14 | 2013-02-13 | 上海交通大学 | High-speed rail health monitoring system based on ultrasonic guide wave and wireless network |
| CN103048386A (en) * | 2012-12-25 | 2013-04-17 | 中国石油天然气集团公司 | Wireless ultrasonic detection system for bent-pipe cracks |
| CN103217475A (en) * | 2013-03-18 | 2013-07-24 | 北京交通大学 | Detection device for continuously welded rails |
| CN104691575A (en) * | 2015-01-06 | 2015-06-10 | 上海电机学院 | Online rail fault diagnosis system and method |
| CN105564459A (en) * | 2015-12-14 | 2016-05-11 | 中国铁路总公司 | Seamless steel rail stress detection device and method based on ultrasonic guided waves and strain gauge |
| CN106596735A (en) * | 2016-12-09 | 2017-04-26 | 四川西南交大铁路发展股份有限公司 | Denoising and feature extraction method and system for acoustic emission signals of rail cracks |
| CN106768368A (en) * | 2017-02-23 | 2017-05-31 | 西南交通大学 | A kind of transmitting set detector of railway infrared journal temperature detection system |
| CN111551642A (en) * | 2020-04-02 | 2020-08-18 | 四川睿铁科技有限责任公司 | Steel rail crack monitoring system |
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2011
- 2011-10-28 CN CN201120421193XU patent/CN202305483U/en not_active Expired - Fee Related
Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102923164A (en) * | 2012-09-14 | 2013-02-13 | 上海交通大学 | High-speed rail health monitoring system based on ultrasonic guide wave and wireless network |
| CN102923164B (en) * | 2012-09-14 | 2015-03-11 | 上海交通大学 | High-speed rail health monitoring system based on ultrasonic guide wave and wireless network |
| CN103048386A (en) * | 2012-12-25 | 2013-04-17 | 中国石油天然气集团公司 | Wireless ultrasonic detection system for bent-pipe cracks |
| CN103217475A (en) * | 2013-03-18 | 2013-07-24 | 北京交通大学 | Detection device for continuously welded rails |
| CN103217475B (en) * | 2013-03-18 | 2015-12-02 | 北京交通大学 | A kind of pick-up unit of seamless track steel rail |
| CN104691575A (en) * | 2015-01-06 | 2015-06-10 | 上海电机学院 | Online rail fault diagnosis system and method |
| CN105564459A (en) * | 2015-12-14 | 2016-05-11 | 中国铁路总公司 | Seamless steel rail stress detection device and method based on ultrasonic guided waves and strain gauge |
| CN105564459B (en) * | 2015-12-14 | 2017-11-10 | 中国铁路总公司 | Gapless rail stress detection device and method based on supersonic guide-wave and foil gauge |
| CN106596735A (en) * | 2016-12-09 | 2017-04-26 | 四川西南交大铁路发展股份有限公司 | Denoising and feature extraction method and system for acoustic emission signals of rail cracks |
| CN106768368A (en) * | 2017-02-23 | 2017-05-31 | 西南交通大学 | A kind of transmitting set detector of railway infrared journal temperature detection system |
| CN106768368B (en) * | 2017-02-23 | 2018-12-25 | 西南交通大学 | A kind of wireless transmitter detector of railway infrared journal temperature detection system |
| CN111551642A (en) * | 2020-04-02 | 2020-08-18 | 四川睿铁科技有限责任公司 | Steel rail crack monitoring system |
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| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant | ||
| CF01 | Termination of patent right due to non-payment of annual fee |
Granted publication date: 20120704 Termination date: 20141028 |
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| EXPY | Termination of patent right or utility model |