CN202404068U - Crawler type wireless ultrasonic probe assembly for detecting flaws of steel rail - Google Patents
Crawler type wireless ultrasonic probe assembly for detecting flaws of steel rail Download PDFInfo
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- CN202404068U CN202404068U CN2011205565664U CN201120556566U CN202404068U CN 202404068 U CN202404068 U CN 202404068U CN 2011205565664 U CN2011205565664 U CN 2011205565664U CN 201120556566 U CN201120556566 U CN 201120556566U CN 202404068 U CN202404068 U CN 202404068U
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Abstract
The utility model discloses a crawler type wireless ultrasonic probe assembly for detecting flaws of a steel rail. Each grouser in the assembly comprises a grouser base, an ultrasonic probe array, a battery, a pressure sensor, an ultrasonic transceiving circuit, a converter and an ultra wide band (UWB) communication module, wherein the ultrasonic probe array, the battery, the pressure sensor, the ultrasonic transceiving circuit, the converter and the UWB communication module are embedded in the grouser base, and the battery is connected with the ultrasonic transceiving circuit, the converter and the UWB communication module; the ultrasonic transceiving circuit, the UWB communication module and the pressure sensor are connected with the converter respectively; and the ultrasonic transceiving circuit is connected with the ultrasonic probe array. When ultrasonic waves encounter damages such as oval flaws, horizontal cracks, longitudinal cracks in the steel rail in a transmission direction, damaged portions can generate reflection and scattering effects to the ultrasonic waves. According to the crawler type wireless ultrasonic probe assembly for detecting flaws of the steel rail, a track rolling mode is used for replacing the traditional wheel rolling mode, the relative rest between the ultrasonic probe and the steel rail is achieved, the time for data sampling is greatly prolonged, simultaneously the detection flexibility can be improved, and the detection cost can be reduced.
Description
Technical field
The utility model relates to ultrasound wave lossless detection technology and wireless communication technology, is specifically related to the ultrasonic probe assembly of crawler type rail examination.
Background technology
China Railway is busy, and Train Interval has only tens minutes, simultaneously, nearly 80,000 kilometers of operating line, line conditions is relatively poor, and extended active duty rail quantity is very big, causes the rail failure incidence high.For guarantee railway safety, need regularly circuit to be checked, and the rail that damages is changed.The major equipment that detects the rail inherent vice at present is the small-sized steel rail ultra-sonic defect detector, carries out rail examination by the method that manual work is carried out.Be atraumatic generation and deterioration, every circuit need detect and need refer to that frequency is more than ten times every year on average, always detects the nearly gigameter of mileage.There are nearly ten thousand full-time rail examination personnel to be responsible for the detection of rail internal injury completely.Along with the further speed-raising of Chinese Railway, urgent to the increasing demand that can accomplish rail high speed defect-detecting equipment, the device of research and development high speed rail examination, significant to railway transportation.
Ultrasound wave is meant that frequency surpasses the sound wave of 20kHz; UT (Ultrasonic Testing) has utilized its three characteristics: the one, and reflection characteristic; When ultrasound wave gets into another kind of medium by a kind of medium, can reflect, when Media density differed greatly, sound wave almost completely was reflected; The 2nd, attenuation characteristic, in communication process, owing to receive the obstruction of medium or impurity, intensity can produce decay; The 3rd, acoustic-velocity characteristic, under similarity condition, its velocity of propagation in same medium is a constant.To the rail ultimate principle of detecting a flaw is to utilize the propagation characteristic of sound wave in different medium; The sound wave that is higher than 2MHz with frequency is injected in the rail; When running into rail failure; The ultrasonic signal that reflects can differ from the regular reflection ripple, therefore can judge the size and location of scar according to the detection of reflected ripple.Usually, the ultrasonic probe of different angles is installed on the defectoscope, checks the damage of different parts respectively.Be used for finding nuclear wound or the transverse fissure in the rail head like 65 ° ~ 75 ° pitch angle ultrasonic probes; 35 ° ~ 45 ° pitch angle ultrasonic probes are used for surveying the damage at the web of the rail and bolt hole place, and vertical ultrasonic probe then is used for visiting horizontal crackle, the longitudinal crack of rail head, the web of the rail and the flange of rail.
Traditional pulse echo method has been widely used in the rail examination field as the main flow of Ultrasonic Nondestructive.It utilizes ultrasonic probe to be launched ultrasonic pulse to examining workpiece, and judges that according to the energy size and the phase information of reflection wave rail has zero defect.Pulse echo method since prolonged application in the rail examination field, thereby it is ripe relatively technically.What indicate current leading technology is the RTS serial large-scale rail-defect detector car by U.S. Sprry manufactured.This serial large-scale rail-defect detector car is made up of mechanical subsystem and background process subsystem two large divisions.Wherein mechanical subsystem is by being used to arrange that the flaw detection dolly of ultrasonic probe assembly and mechanisms such as hydraulic system, air system, water system and Mk system form; The background process subsystem mainly is made up of external units such as principal computer, A/D and D/A converter, remote amplifier, display and System printers.Can detect a flaw to railway track with F-Zero 80km/h in the real work.Current, the ultrasonic probe that is used for rail examination has two kinds of forms: wheel seach unit and skid shoe type probe.Wheel seach unit is made up of probe bracket and spy wheel adventitia, and probe bracket is installed in and is used for fixing ultrasonic probe on the wheel shaft, visits the wheel adventitia and is made the entrant sound coupling liquid that is used to wrap up whole inner chamber by the entrant sound resin material.Five ultrasonic probes of general installation on the probe bracket are to the ultrasound wave of three kinds of different directions of rail emission and different frequency.During flaw detection, visit the wheel adventitia with the car motion and roll forward, and ultrasonic probe wherein is motionless, hyperacoustic to transmit and receive direction constant to keep.The skid shoe type probe is then combined by ultrasonic probe and skid plate, and a plurality of ultrasonic probes embed in the skid plate by different angles, and during flaw detection, ultrasonic probe slides along the rail orbital plane with skid plate.Early stage because wheel seach unit design and manufacturing technology are relatively backward, bad adaptability, the skid shoe type probe was once got the upper hand.Recently the more than ten years, the wheel seach unit quality obviously improves, so wheel seach unit has become main flow again gradually.Yet wheel seach unit relies on the energy size of reflection wave on principle, belong to the detection method to energy-sensitive, and detection by quantitative aspect performance is not good.This also is one of reason that loss can not effectively be controlled when in practical application, utilizing classic method to carry out rail examination.Sum up the characteristics of the current wheeled ultrasonic probe assembly that generally uses, have following shortcoming and defect:
(1) in the rail examination process; Ultrasonic probe and rail are in the relative motion state all the time; Sampling time has only several milliseconds of zero points, adds the not high a series of problems of Doppler effect, detection sensitivity, makes that detection efficiency is low, speed of detection can't improve.
(2) because sound wave usually only forms reflection at vertical, smooth blemish surface, so examine when injuring weld seam surveying the rail head vertical, can't receive flaw echo basically with the rail orbital plane based on pulse echo method, false dismissal probability is bigger.
(3) the consumable accessory consumption is big, and maintenance cost is high.The thousands of units of spy wheel each unit price of adventitia that existing entrant sound resin material is made, and because need a large amount of coupling liquids of parcel, just need to change so small damage appears in tire tread.The China railways main line has 30,000 kilometers (are multiple line, do not comprise each city underground, light rail and nearly 50,000 kilometers branch line), detects if all use large-scale inspection car instead, and annual test is by minimum 6 times.Rail-defect detector car uses 4 to visit wheel simultaneously, visits wheel 100km operating limit by each and calculates, and only visits the wheel adventitia and consumes annual just up to up to ten million units.
(4) trafficability characteristic is relatively poor, operation is complicated.Tens millimeters at least of idle spaces in the rail track switch, more than 100 millimeter at most.For the wheel seach unit of main flow, because surface of contact is little, can directly be absorbed in the idle space of track switch when crossing track switch, ultrasonic probe is caused very big impact, damage ultrasonic probe easily.In order to be unlikely to take place the incident that this type of damages ultrasonic probe, each when crossing track switch all the very important person cause very big inconvenience to the inspection car operator, and can not stop the generation of this type incident fully for ultrasonic probe is mentioned.
The utility model content
To exist in the steel rail ultrasonic flaw detecting technical field at present some such as inspection speed be difficult to improve, loss is high, cost is high and deficiency such as complicated operation; The utility model is intended to propose the wireless ultrasonic probe assembly of crawler type rail examination; Utilize ultra broadband (Ultra Wide-Band; UWB) method of wireless communication directly reaches the ultrasonic probe in the shoe sheet base with the continuous multifrequency Modulated Ultrasonic ripple signal that the background process subsystem sends; Through measuring the reflection wave signal of this continuous multifrequency Modulated Ultrasonic ripple signal, realize Non-Destructive Testing to rail.The utility model adopts crawler belt to roll into mode to replace traditional wheel rolling mode, has realized between ultrasonic probe and the rail staticly relatively, makes the data sampling time increase greatly; Adopt the UWB technology to be used for the short-distance wireless communication between background process subsystem and the ultrasonic probe assembly simultaneously, background process subsystem and ultrasonic probe assemblies physical are separated, greatly improved the dirigibility of surveying; In addition, adopt the transmitting-receiving separate mode to replace traditional transmit-receive sharing mode, can increase substantially the signal to noise ratio (S/N ratio) that receives signal ultrasonic signal.The described background process subsystem of the utility model is structurally similar with the background process subsystem of existing large-scale rail-defect detector car; Difference is to have installed additional a UWB communication module, replaces the wired connection between existing background process subsystem and the ultrasonic probe assembly with the mode of UWB radio communication.The utility model is realized through following technical scheme.
A kind of wireless ultrasonic probe assembly of crawler type rail examination; It comprises several shoes, and each shoe comprises shoe sheet base and is embedded in array ultrasonic probe, battery, pressure transducer, ultrasonic transmission/reception circuit, converter and the UWB communication module in the shoe sheet base; Said battery is connected with ultrasonic transmission/reception circuit, converter and UWB communication module; Ultrasonic transmission/reception circuit, UWB communication module, pressure transducer are connected with converter respectively, and the ultrasonic transmission/reception circuit also is connected with array ultrasonic probe; Pressure transducer is responsible for detecting the pressure state of shoe; The ultrasonic transmission/reception circuit is given corresponding ultrasonic probe with continuous multifrequency Modulated Ultrasonic ripple signal forwarding, and the ultrasonic transmission/reception circuit is the reflection wave signal that receives of each ultrasonic probe of buffer memory and reach converter also; Converter comprises A/D and D/A converter, is responsible for the conversion between simulating signal and the digital signal; The UWB communication module is sent to the ultrasonic transmission/reception circuit with the continuous multifrequency Modulated Ultrasonic ripple signal that the background process subsystem produces, and the reflection wave signal that simultaneously each ultrasonic probe is received and the signal of pressure transducer send the background process subsystem to and handle.
As the prioritization scheme of the wireless ultrasonic probe assembly of above-mentioned crawler type rail examination, row is arranged in parallel with row in the said array ultrasonic probe, and row are arranged with column alignment; The both sides ultrasonic probe parallel with the rail length direction adopts 60 ° ~ 80 ° pitch angle to arrange in the array ultrasonic probe, and the nuclear that is used for surveying in the rail head is hindered and transverse fissure; The some ultrasonic probes that are positioned at the array middle part in the array ultrasonic probe adopt 0 ° of pitch angle to arrange, are used for surveying the horizontal crackle and the longitudinal crack of rail head, the web of the rail and the flange of rail; The ultrasonic probe that is positioned at beyond said both sides and the middle part adopts 30 ° ~ 50 ° pitch angle to arrange, is used for surveying the damage of the web of the rail and bolt hole; Said pitch angle is the angle of ultrasonic probe transmit direction and rail xsect.
As the prioritization scheme of the wireless ultrasonic probe assembly of above-mentioned crawler type rail examination, the pitch angle is that the ultrasonic frequency of 60 ° ~ 80 ° ultrasonic probe is 4 ~ 5MHz, and its beams reflected face is positioned at the rail head bottom surface; The pitch angle is that the ultrasonic frequency of 0 ° of ultrasonic probe is 3 ~ 4MHz, and its beams reflected face is positioned at flange of rail bottom surface; The pitch angle is that the ultrasonic frequency of 30 ° ~ 50 ° ultrasonic probe is 2 ~ 3MHz, and its beams reflected face is positioned at flange of rail bottom surface equally.
As the prioritization scheme of the wireless ultrasonic probe assembly of above-mentioned crawler type rail examination, said pressure transducer is arranged in the middle part of shoe sheet base.
Prioritization scheme as the wireless ultrasonic probe assembly of above-mentioned crawler type rail examination; Said battery adopts minicell, minicell with resilient material in said ultrasonic transmission/reception circuit, A/D converter and UWB communication module are fixed on shoe sheet base.
As the prioritization scheme of the wireless ultrasonic probe assembly of above-mentioned crawler type rail examination, shoe sheet base adopts elastomeric material, and shoe sheet primary surface installs the entrant sound adventitia additional, and fill with the entrant sound coupling liquid in the slit between shoe sheet base and the entrant sound adventitia.
The method of detection of above-mentioned wireless ultrasonic probe assembly comprises the steps:
(1) behind the shoe contact rail, the pressure transducer in the shoe sheet base is experienced pressure, produces the contact trigger pip and after A/D converter carries out analog to digital conversion, reaches the background process subsystem through the UWB communication module;
(2) this shoe of control was in running order after the background process subsystem received the contact trigger pip; The duty of the ultrasonic probe in the shoe comprises to be sent and receives; If at a time the background process subsystem judges that certain ultrasonic probe A should be emission state, then produce continuous multifrequency Modulated Ultrasonic ripple signal UWB communication module through the background process subsystem after analog to digital conversion and reach this shoe with the form of UWB signal;
(3) the UWB communication module on the shoe receives the background process subsystem and transmits the UWB signal, after D/A converter carries out digital-to-analog conversion, is reduced into continuous multifrequency Modulated Ultrasonic ripple signal and transfers to the ultrasonic transmission/reception circuit; The ultrasonic transmission/reception circuit carries out rail examination according to the ultrasound beamformer that the said ultrasonic probe A of continuous multifrequency Modulated Ultrasonic ripple signal controlling that transmits sends corresponding frequencies;
(4) direction that reflects through rail of the ultrasound beamformer that sends of said ultrasonic probe A has a ultrasonic probe B, and then the background process subsystem judges that ultrasonic probe B is an accepting state; Ultrasonic probe B receives the ultrasonic signal that sends and return through the rail internal reflection from ultrasonic probe A, after the A/D converter analog to digital conversion, reaches the background process subsystem through the UWB communication module in the shoe with the form of UWB signal;
(5) the background process subsystem carries out analyzing and processing to signal after receiving the signal that said ultrasonic probe B sends back, judges that ultrasound beamformer sends from probe A that rail has not damaged in rail reflexes to the path of ultrasonic probe B;
(6) when shoe breaks away from rail, the pressure transducer in the shoe sheet base is experienced pressure and is disappeared, and produces the disengaging trigger pip and after the A/D converter analog to digital conversion, reaches the background process subsystem through the UWB communication module in the shoe; The background process subsystem judges that this shoe breaks away from rail after receiving and breaking away from trigger pip, so stop the transmitting-receiving of this shoe ultrasonic signal, then this shoe is in waiting status, until next one circulation beginning.
In the above-mentioned method of detection; Each bundle ultrasound beamformer is propagated definite path of time correspondence in rail: the ultrasound beamformer that sends for the ultrasonic probe that certain pitch angle is arranged; The path that this ultrasound beamformer is confirmed is exactly a symmetrical broken line, if damage appears in the rail head of rail or the web of the rail, this damage meeting influences through the incident wave beam of this position and the reflection wave behind rail head bottom surface or flange of rail bottom reflection simultaneously; The intersection point of this two bundles ultrasound beamformer is exactly the position of damage; Simultaneously, for the damage of same place, have multi beam incident wave and reflection wave and intersect a plurality of intersection points of formation in this position; According to the distribution of these a plurality of intersection points, can accurately depict the shape and the size of rail failure; And for vertically arranged ultrasonic probe; Every bundle ultrasound beamformer and reflected beam thereof are only passed through some tangent planes of rail; If horizontal crackle or longitudinal crack appear in rail head, the web of the rail and the flange of rail that certain tangent plane of rail is corresponding, time, energy and the waveform that returns according to reflection wave just can directly be confirmed position, the shape of crackle.
The principle of the method for detection in the utility model is following: when rail was intact, ultrasound wave only formed direct reflection at smooth rail head and flange of rail bottom surface, and the ultrasound wave that receives changes very little on waveform and energy.And when ultrasound wave ran into nuclear wound, horizontal crackle and longitudinal crack equivalent damage in the direction of propagation, damage location can produce reflection and scattering effect to ultrasound wave.The ultrasound wave that continuation is propagated along beam direction all has bigger variation on waveform and energy, just can detect and locate damaging in the rail according to the variation of this waveform and energy.
Compare with existing wheeled ultrasonic probe assembly, the utlity model has following advantage:
(1) adopt a plurality of shoes to roll into the mode of detection, each shoe when work and rail be close to, and be static relatively, the time that contacts with rail can increase considerably.To have overcome when inspection car is walked at a high speed ultrasonic probe too short and to cause that echo is lost etc. not enough to rail certain sampling time, avoided Doppler effect, the sensitivity a series of problems that occur because of relative motion such as low simultaneously.
(2) shoe contacts rail with planar structure, and the time of contact rail is long, and has guaranteed that a plurality of ultrasonic probes survey same position, and the rail detection information amount of obtaining is big.Therefore can avoid omission, improve detection accuracy simultaneously, and can support higher road speed.
(3) adopt the UWB signal to be used for the short-distance wireless communication between background process subsystem and the ultrasonic probe assembly; Background process subsystem and array ultrasonic probe physics are separated; Replace existing with the ultrasonic probe support with the fixing wired ways of connecting of ultrasonic probe and background process subsystem, greatly improved the dirigibility of surveying.
(4) mode of the continuous Modulated Ultrasonic wave-wave of employing multifrequency is sent the modulated continuous wave that 2 ~ 5Mz does not wait respectively to a plurality of ultrasonic probes on the shoe, replaces traditional pulsating wave, can reduce detecting voltage greatly, improves detection accuracy.
(5) adopt transmitting-receiving to separate the mode that combines with transmitting-receiving simultaneously and replace the mode that traditional simple transmitting-receiving combines; By each ultrasonic probe wave beam direction of arrival received ultrasonic signal; Can not form repeatedly boundary reflection at shoe adventitia place disturbs; Can significantly improve signal to noise ratio (S/N ratio), overcome existing method the nuclear in the rail head is hindered the low shortcoming of detection efficiency.
(6) adopt the design of crawler belt chip good through performance.More than 100 millimeter at least of the idle space that is used for the track switch of rail conversion station track, hundreds of at most millimeters.For traditional little surface of contact wheel seach unit, can directly be absorbed in the idle space of track switch when crossing track switch, ultrasonic probe is caused very big impact, to such an extent as to damage ultrasonic probe.And the design of crawler belt chip improves surface of contact greatly, has avoided the generation of this type situation.
(7) shoe is simple in structure, volume is little, price is low.When crawler belt damaged, the single shoe that only need will damage was changed and is got final product, and does not more need the lot of consumption coupling liquid.So compare with wheeled ultrasonic probe assembly, later maintenance cost significantly reduces.
Description of drawings
Fig. 1 is the wireless ultrasonic probe assembly work synoptic diagram of crawler type rail examination.
Fig. 2 is single shoe inner structure block diagram.
Fig. 3 a is a shoe outside floor map.
Fig. 3 b is a shoe inner side plane synoptic diagram.
Fig. 4 is a UWB communication module inner structure block diagram.
Fig. 5 is single shoe single workflow diagram.
Fig. 6 is the ultrasonic probe assembly flaw detection process synoptic diagram of crawler type rail examination.
Fig. 7 a is 70 ° of pitch angle ultrasonic probe signal transmitting and receiving synoptic diagram.
Fig. 7 b is 38 ° of pitch angle ultrasonic probe signal transmitting and receiving synoptic diagram.
Fig. 7 c is vertical ultrasonic probe signal transmitting and receiving synoptic diagram.
Fig. 8 a is that wave beam is hindered the synoptic diagram that detects to rail head nuclear.
Fig. 8 b is the synoptic diagram that wave beam detects web of the rail crackle.
Fig. 8 c is the synoptic diagram that wave beam detects flange of rail longitudinal crack.
Embodiment
Be described further below in conjunction with the embodiment of accompanying drawing, but the enforcement of the utility model is not limited thereto the utility model.
As shown in Figure 1, be the work synoptic diagram of the ultrasonic probe assembly 101 of the said crawler type rail examination of the utility model.The ultrasonic probe assembly 101 of the said crawler type rail examination of the utility model; Self unpowered device; The ultrasonic probe assembly 101 of 4 groups of crawler type rail examinations is connected on the flaw detection dolly support 103 through the wheel shaft of the expansion tightening wheel in the crawler belt 102 jointly; Constitute a flaw detection dolly, and then be connected with the chassis of high speed rail-defect detector car.The ultrasonic probe assembly 101 of the rail examination of crawler type shown in the figure adopts 4 expansion tightening wheels 102 to be made into a secondary crawler belt.The number of the ultrasonic probe assembly 101 of the number of expansion tightening wheel 102 and crawler type rail examination can be adjusted according to the needs of concrete acquisition environment.When crawler belt when rail raceway surface 104 rolls forward, each shoe from press to through the expansion tightening wheel of head rail to expansion tightening wheel from afterbody break away from rail during this period of time in and rail be close to the maintenance transfixion.During this period of time, the array ultrasonic probe in the shoe sheet base sends (or reception) 2 ~ 5MH by the control of background process subsystem
ZThe continuous Modulated Ultrasonic ripple that does not wait.Suppose that the total length that crawler belt contacts with rail is 1m, the speed that rolls forward is 100km/h.Through simple computation, can get the time that each shoe contacts with rail is 36ms.Compare with existing highest detectable speed 80 km/h, sampling time 0.3 ms, can significantly prolong the sampling time, reduce loss.
As shown in Figure 2, be the said single shoe inner structure block diagram of the utility model.Shoe is formed by shoe sheet base and embedded array ultrasonic probe, minicell, pressure transducer, ultrasonic transmission/reception circuit, converter and the combination of UWB communication module.
Above-mentioned minicell is fixed together with ultrasonic transmission/reception circuit, converter and the UWB communication module in resilient material and the shoe sheet base, and to these equipment power supply is provided; Pressure transducer is arranged in the middle part of shoe sheet base, is responsible for detecting the pressure state of shoe; Ultrasonic transmission/reception circuit one end is connected with ultrasonic probe; The other end is connected with the UWB communication module through converter; Being responsible for the transmission and the reception of ultrasonic signal, promptly is to give the reflection wave signal that corresponding ultrasonic probe and each ultrasonic probe of buffer memory receive multifrequency Modulated Ultrasonic ripple signal forwarding continuously and reach converter; Converter is made up of A/D converter and D/A converter two parts, and an end is connected with ultrasonic transmission/reception circuit and pressure transducer, and the other end is connected with the UWB communication module, is responsible for the conversion between simulating signal and the digital signal; The UWB communication module is connected with ultrasonic transmission/reception circuit and pressure transducer through converter; Be responsible for the signal transmission between ultrasonic transmission/reception circuit and pressure transducer and the background process subsystem; Promptly be to be sent to the ultrasonic transmission/reception circuit to the continuous multifrequency Modulated Ultrasonic ripple signal that the background process subsystem produces, the reflection wave signal and the pressure sensor signal that receive each ultrasonic probe send the background process subsystem to.The background process subsystem adopts corresponding UWB module to receive and send the UWB signal.
Shown in Fig. 3 a ~ b, be an embodiment synoptic diagram of inner each arrangements of cells of the said single shoe of the utility model.Wherein Fig. 3 a is the outer side plan view of shoe, and this surface contacts with the rail surface after installing the entrant sound adventitia additional.Shoe sheet base 301 selects for use elastomeric material to make, and the surface installs the entrant sound adventitia additional, and the micro gap between shoe sheet base and the entrant sound adventitia is filled with the entrant sound coupling liquid.Press embedded 9 ultrasonic probes of array in the shoe sheet base 301, with each 3 ultrasonic probe of every row of rail transverse cross-section parallel, totally 3 go, row is arranged in parallel with row, lists in column alignment and arranges.Be positioned at every capable both sides totally 6 layouts be 70 ° of pitch angle ultrasonic probes 302, the nuclears that are used for surveying in the rail head 105 are hindered and transverse fissure; Be positioned at middle line middle part 1 layout be 0 ° of pitch angle (vertically) ultrasonic probe 303, be used for surveying the horizontal crackle and the longitudinal crack of rail head 105, the web of the rail 106 and the flange of rail 107; Be positioned at 38 ° of pitch angle ultrasonic probes 304 of totally 2 layouts at the middle part of two row end to end, be used for surveying the damage of the web of the rail 106 and bolt hole.Fig. 3 b is shoe inner side plane figure, and this surface contacts with expansion tightening wheel 102 surfaces.Ultrasonic transmission/reception circuit 307 in minicell 305 usefulness resilient materials 306 and the shoe sheet base, converter 308, UWB communication module 309 etc. are fixed together.This part is stretched out rail one side and is not contacted with rail, the generation fault in order to avoid circuit is squeezed.Pressure transducer 310 is arranged in the middle part of this surperficial shoe sheet base 301, and its function is to detect the pressure state of shoe, when detecting pressure, produces the contact trigger pip, breaks away from trigger pip when detecting to produce when pressure solutions is removed.
As shown in Figure 4, be the UWB communication module inner structure block diagram among the embodiment.The composition of UWB communication module comprises pulse producer, pulse positon modulator, active crystal oscillator, power amplifier, low noise amplifier, radio-frequency filter, multiplier, low-pass filter, sampling/detecting device and UWB antenna.The production process of UWB signal is: active crystal oscillator produces the reference square wave signal, and the input pulse generator produces basic UWB signal.Basic UWB signal is transfused to pulse positon modulator; Simultaneously pulse positon modulator transmits according to ultrasonic transmission/reception circuit or pressure transducer; And the digital signal after analog to digital conversion; Basic UWB signal is carried out producing the modulating uwb signal after the pulse-position modulation, and the modulating uwb signal is transfused to power amplifier and amplifies after the UWB aerial radiation is gone out.The receiving course of UWB signal is: the UWB signal that the UWB communication module transmits in the background process subsystem is received by UWB antenna in the shoe, is transfused to low noise amplifier, radio-frequency filter and multiplier then successively.The basic UWB signal of simultaneous processing received pulse generator input; With importing low-pass filter behind two signal multiplications, filtered signal is transfused to sampling/detecting device and samples and obtain the continuous Modulated Ultrasonic ripple of digital signal input converter reduction multifrequency signal with detection and reach the ultrasonic transmission/reception circuit.
As shown in Figure 5: as to be single shoe single workflow diagram.It carries out lossless detection to rail and may further comprise the steps:
(1) shoe contacts with rail, and pressure transducer 310 detects pressure, then produces the contact trigger pip.
(2) after the contact trigger pip is carried out analog to digital conversion, pass to the backstage processing subsystem through the UWB communication module in the shoe 309, the background process subsystem specifies this shoe in running order after receiving trigger pip.And the ultrasonic probe in the shoe is carved with emission, receives two kinds of duties when difference, and concrete duty is controlled by the background process subsystem.
(3), then produce continuous multifrequency Modulated Ultrasonic ripple signal and reach this shoe with the form of UWB signal through the UWB communication module 309 of analog to digital conversion through the background process subsystem if at a time the background process subsystem judges that certain ultrasonic probe (being assumed to ultrasonic probe A) is an emission state.
(4) the UWB communication module 309 on the shoe receives the background process subsystem and transmits the UWB signal, after digital-to-analog conversion, is reduced into continuous multifrequency Modulated Ultrasonic ripple signal and transfers to ultrasonic transmission/reception circuit 307.Ultrasonic transmission/reception circuit 307 sends corresponding ultrasound beamformer according to the continuous multifrequency Modulated Ultrasonic ripple signal controlling ultrasonic probe A that transmits and carries out rail examination.
(5) at synchronization, the direction that the ultrasound beamformer that ultrasonic probe A sends reflects through rail has a ultrasonic probe (being assumed to ultrasonic probe B), and then the background process subsystem judges that this ultrasonic probe is an accepting state.Ultrasonic probe B receives and to send from ultrasonic probe A, and the ultrasonic signal of returning through the rail internal reflection, after converter 308 carries out analog to digital conversion, reaches the background process subsystem through the UWB communication module 309 in the shoe with the form of UWB signal.
(6) the background process subsystem just can carry out analyzing and processing to signal after receiving the signal that ultrasonic probe B sends back; Judge that rail is inner, send from ultrasonic probe A by ultrasound beamformer and reflex to through rail that rail has not damaged within this section of ultrasonic probe B path.
(7) when shoe breaks away from rail, the pressure transducer 310 in the shoe sheet base 301 is experienced pressure and is disappeared, and produces the disengaging trigger pip and after converter 308 analog to digital conversion, reaches the background process subsystem through the UWB communication module 309 in the shoe.
(8) the background process subsystem judges that this shoe breaks away from rail after receiving and breaking away from trigger pip, so stop the transmitting-receiving of this shoe ultrasonic signal, then this shoe is in waiting status, until next one circulation beginning.
As shown in Figure 6, be the wireless ultrasonic probe assembly 101 flaw detection process synoptic diagram of crawler type rail examination among the embodiment.Be positioned at 6 70 ° of pitch angle ultrasonic probes 302 of the every capable both sides of shoe, adopt mode that transmitting-receiving separates to proceeds posterolateral emission 4 ~ 5 MHz relative high frequency ultrasound waves or receive the transmitted wave in oblique the place ahead, the nuclears that are used for surveying in the rail head 105 are hindered and transverse fissure; Be positioned at shoe 2 38 ° of pitch angle ultrasonic probes 304 at middle part of two row end to end, adopt mode that transmitting-receiving separates to the proceeds posterolateral emission relative low-frequency ultrasonic waves of 2 ~ 3MHz or receive the reflection wave in oblique the place ahead equally, be used for surveying the damage of the web of the rail 106 and bolt hole; 0 ° of pitch angle (vertically) ultrasonic probe 303 that is positioned at the middle line middle part adopts the mode of transmitting-receiving combination, and transmission frequency is the medium and low frequency ultrasound wave of 3 ~ 4MHz vertically downward, is used to survey the horizontal crackle and the longitudinal crack of rail head 105, the web of the rail 106 and the flange of rail 107.
The 70kg/m heavy duty rail that mainly adopts with the current rail main line below is a detected object, adopts 4 expansion tightening wheels 102 to join a secondary crawler belt.Every secondary crawler belt is made up of 42 shoes, and wherein upper and lower surfaces are each 16, each 5 in former and later two expansion tightening wheel 102 outsides.When carrying out rail examination, each moment of confirming has 16 shoes and contacts with rail raceway surface 104.Here, the direction that rolls into by crawler belt shoe is compiled successively be 1,2,3 ... No. 16.Shown in Fig. 7 a, for 70 ° of pitch angle ultrasonic probes 302, by 9-16 shoe emission ultrasound wave, the 1-8 shoe receives ultrasound wave; Shown in Fig. 7 b, for 38 ° of pitch angle ultrasonic probes 304, by 13-16,5-8 shoe emission ultrasound wave, 9-12,1-4 shoe receive ultrasound wave.For vertical ultrasonic probe 303, the 1-16 shoe is all launched and is received ultrasound wave shown in Fig. 7 c.Along with crawler belt rolls forward along rail raceway surface 104; The background process subsystem is according to the trigger pip of shoe upward pressure sensor 310; Reiving/transmitting state to each ultrasonic probe carries out controlled in real-time and adjustment, thereby has realized the detection to each position of rail.
Shown in Fig. 8 a ~ c, be among the embodiment each angle ultrasonic probe to the detection synoptic diagram of rail internal injury.Corresponding definite path when each bundle ultrasound beamformer is propagated in rail; 3 wave beams that ultrasonic probe sends of a side (only illustrated among the figure in each shoe) for the ultrasound beamformer that 70 ° of pitch angle ultrasonic probes 302 send, its path of confirming is exactly a symmetrical broken line shown in Fig. 8 a.Nuclear occurs as if rail head of rail 105 and hinder (like the planar section of the encirclement of the outer smooth curve among the figure); This damage at first can influence the energy and the shape of reflection wave; Through the incident wave beam and the reflection wave behind the rail head bottom reflection of this position, the intersection point of this two bundles ultrasound beamformer can be confirmed the position damaged.Simultaneously, because the ultrasonic probe very dense on the shoe, and, have two groups of crawler belts successively to pass through for a side rail.So, have multi beam incident wave and reflection wave and intersect a plurality of intersection points of formation in this position for the damage of same place.To be distributed in outermost intersection point with dashed lines and couple together, can accurately depict the shape and the size (like the planar section of the dotted line of internal bend among the figure) of rail failure.Shown in Fig. 8 b (only illustrated among the figure each shoe in 1 wave beam that ultrasonic probe sends); Be the detection example schematic of 38 ° of pitch angle ultrasonic probes 304 for the web of the rail 106 crackles; It is just the same that its incident wave and reflection wave intersect principle and 70 ° of pitch angle ultrasonic probes 302 of forming intersection point; Difference is the damage (shown in thin curve among the figure) to this linearity; Incident wave and reflection wave intersect the intersection point indention that forms and distribute in (shown in rough sawn profile of tooth broken line among the figure), can judge position, length and the direction of crackle according to this serrate broken line.Shown in Fig. 8 c, be the detection example schematic of vertical ultrasonic probe 303 for flange of rail longitudinal crack.For vertical ultrasonic probe 303; Because adopt the mode of transmit-receive sharing; So every bundle ultrasound beamformer and reflected beam thereof are only passed through some tangent planes of rail; If horizontal crackle or longitudinal crack appear in rail head 105, the web of the rail 106 and the flange of rail 107 that certain tangent plane of rail is corresponding, time, energy, the waveform that returns according to reflection wave just can directly be confirmed the position and the shape of crackle.
Claims (6)
1. the wireless ultrasonic probe assembly of a crawler type rail examination; It is characterized in that comprising several shoes, each shoe comprises shoe sheet base and is embedded in array ultrasonic probe, battery, pressure transducer, ultrasonic transmission/reception circuit, converter and the UWB communication module in the shoe sheet base; Said battery is connected with ultrasonic transmission/reception circuit, converter and UWB communication module; Ultrasonic transmission/reception circuit, UWB communication module, pressure transducer are connected with converter respectively, and the ultrasonic transmission/reception circuit also is connected with array ultrasonic probe.
2. the wireless ultrasonic probe assembly of crawler type rail examination according to claim 1 is characterized in that row is arranged in parallel with row in the said array ultrasonic probe, and row are arranged with column alignment; The both sides ultrasonic probe parallel with the rail length direction adopts 60 ° ~ 80 ° pitch angle to arrange in the array ultrasonic probe, and the nuclear that is used for surveying in the rail head is hindered and transverse fissure; The some ultrasonic probes that are positioned at the array middle part in the array ultrasonic probe adopt 0 ° of pitch angle to arrange, are used for surveying the horizontal crackle and the longitudinal crack of rail head, the web of the rail and the flange of rail; The ultrasonic probe that is positioned at beyond said both sides and the middle part adopts 30 ° ~ 50 ° pitch angle to arrange, is used for surveying the damage of the web of the rail and bolt hole; Said pitch angle is the angle of ultrasonic probe transmit direction and rail xsect.
3. the wireless ultrasonic probe assembly of crawler type rail examination according to claim 2; It is characterized in that the pitch angle is that the ultrasonic frequency of 60 ° ~ 80 ° ultrasonic probe is 4 ~ 5MHz; The pitch angle is that the ultrasonic frequency of 0 ° of ultrasonic probe is 3 ~ 4MHz, and the pitch angle is that the ultrasonic frequency of 30 ° ~ 50 ° ultrasonic probe is 2 ~ 3MHz.
4. the wireless ultrasonic probe assembly of crawler type rail examination according to claim 1 is characterized in that said pressure transducer is arranged in the middle part of shoe sheet base.
5. the wireless ultrasonic probe assembly of crawler type rail examination according to claim 1; It is characterized in that said battery adopts minicell, minicell with resilient material in said ultrasonic transmission/reception circuit, converter and UWB communication module are fixed on shoe sheet base.
6. according to the wireless ultrasonic probe assembly of each described crawler type rail examination of claim 1 ~ 5; It is characterized in that shoe sheet base adopts elastomeric material; Shoe sheet primary surface installs the entrant sound adventitia additional, and fill with the entrant sound coupling liquid in the slit between shoe sheet base and the entrant sound adventitia.
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| Application Number | Priority Date | Filing Date | Title |
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| CN2011205565664U CN202404068U (en) | 2011-12-27 | 2011-12-27 | Crawler type wireless ultrasonic probe assembly for detecting flaws of steel rail |
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| CN2011205565664U CN202404068U (en) | 2011-12-27 | 2011-12-27 | Crawler type wireless ultrasonic probe assembly for detecting flaws of steel rail |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103235100A (en) * | 2013-04-16 | 2013-08-07 | 内蒙古包钢钢联股份有限公司 | Longitudinal-transverse type core wound rail sampling and fracture analysis method |
| CN107782784A (en) * | 2017-09-01 | 2018-03-09 | 四川华铁电科信息技术有限公司 | Ultrasonic flaw detecting device |
-
2011
- 2011-12-27 CN CN2011205565664U patent/CN202404068U/en not_active Expired - Fee Related
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103235100A (en) * | 2013-04-16 | 2013-08-07 | 内蒙古包钢钢联股份有限公司 | Longitudinal-transverse type core wound rail sampling and fracture analysis method |
| CN103235100B (en) * | 2013-04-16 | 2016-04-20 | 内蒙古包钢钢联股份有限公司 | A kind of sampling of longitudinal-transverse type core wound rail and analysis method of fracture |
| CN107782784A (en) * | 2017-09-01 | 2018-03-09 | 四川华铁电科信息技术有限公司 | Ultrasonic flaw detecting device |
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