CN209911291U - Hand-held flaw detector - Google Patents
Hand-held flaw detector Download PDFInfo
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- CN209911291U CN209911291U CN201920638894.5U CN201920638894U CN209911291U CN 209911291 U CN209911291 U CN 209911291U CN 201920638894 U CN201920638894 U CN 201920638894U CN 209911291 U CN209911291 U CN 209911291U
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Abstract
The utility model provides a hand-held type appearance of detecting a flaw, including hand-held type's detection terminal and the signal processing terminal who is connected through data line and hand-held type detection terminal. The handheld detection terminal comprises a shell, two orthogonal U-shaped iron cores positioned in the shell, two groups of coils wound on the iron cores and an electromagnetic sensor array, wherein the coils are excited by two sine wave signals with the phase difference of 90 degrees to generate a rotating eddy current; the electromagnetic sensor array is formed by arranging and combining a plurality of magnetic sensors and is used for receiving a feedback signal of eddy current detection; the signal processing terminal comprises a box body, and a display screen, a key panel, a data input interface and a data export and charging interface which are arranged on the box body. The signal processing circuit arranged in the signal processing terminal comprises a signal conditioning circuit, an AD acquisition circuit and an image reconstruction circuit which are sequentially and electrically connected. The utility model discloses a hand-held type appearance of detecting a flaw can realize hindering comprehensive surveying to the rail to it is high to detect the precision, can improve detection efficiency.
Description
Technical Field
The utility model relates to an eddy current testing technical field particularly relates to hand-held type appearance of detecting a flaw.
Background
The current rail detection method mainly comprises manual identification, ultrasonic flaw detection, a CCD scanning camera and point eddy current flaw detection, but the methods have advantages and disadvantages.
The manual identification mode has the advantages of low detection speed, poor precision and extremely high requirement on the work literacy of detection personnel.
The ultrasonic flaw detection is suitable for detecting the inside of a rail and is extremely easy to be influenced by environmental factors.
The CCD line scanning camera has high detection precision, is suitable for rail surface detection and is easily influenced by impurities on the rail surface.
The traditional eddy current flaw detection is suitable for detecting the surface and the subsurface of a rail, can accurately judge the position of a flaw, but still cannot realize the quantitative evaluation of the shape, the size and the damage degree of the rail flaw.
The eddy current generated by the probe design of the common eddy current rail flaw detection can only finish measuring the cracks of a certain type of defects, such as transverse cracks, and is difficult to measure for other types of cracks, such as longitudinal cracks. This directly leads to the possibility of missed detections and does not allow assessment of quantitative visualizations.
SUMMERY OF THE UTILITY MODEL
The utility model aims at providing a hand-held type appearance of detecting a flaw, including hand-held type's detection terminal and the signal processing terminal who is connected with hand-held type detection terminal through the data line, wherein:
the handheld detection terminal comprises a shell, two orthogonal U-shaped iron cores positioned in the shell, two groups of coils wound on the iron cores and an electromagnetic sensor array, wherein the coils are excited by two sine wave signals with the phase difference of 90 degrees to generate a rotating eddy current surrounding a measuring surface or a sub-surface;
the shell comprises an upper shell and a lower shell, the lower shell is detachably clamped and fixed with the upper shell, and the iron core, the coil and the electromagnetic sensor array which are distributed orthogonally are arranged in the lower shell;
the upper part of the shell is also fixed with a holding part through a sealing ring, and the top of the holding part is provided with a data wire leading-out interface which is connected to a signal processing terminal through a data wire;
the electromagnetic sensor array is formed by arranging a plurality of magnetic sensors to form an M-N combination and is used for receiving a feedback signal of eddy current detection, wherein M and N are positive integers which are more than or equal to 1, and the lower surface of the electromagnetic sensor array and the free end of the side part of the U-shaped iron core which is orthogonally distributed are positioned on the same plane;
the signal processing terminal comprises a box body, and a display screen, a key panel, a data input interface and a data exporting and charging interface which are arranged on the box body, wherein the display screen, the key panel, the data input interface and the data exporting and charging interface are all electrically connected with an internal signal processing circuit, and the display screen is used for displaying a signal processing result; the key panel is used for adjusting and controlling working conditions and working parameters;
the signal processing circuit arranged in the signal processing terminal comprises a signal conditioning circuit, an AD acquisition circuit and an image reconstruction circuit which are electrically connected in sequence, wherein the signal conditioning circuit receives signals output by the electromagnetic sensor array, performs phase discrimination, amplification and shaping processing and outputs the signals to the AD acquisition circuit; the AD acquisition circuit converts the analog quantity into digital quantity; the image reconstruction circuit carries out image reconstruction based on digital quantity obtained by detecting magnetic field detection signals of relevant positions by the array type magnetic sensor to obtain a defect graph.
Preferably, the holding portion is cylindrical and fixed with the upper housing.
Preferably, the winding of the coil adopts any one of the following modes:
1) respectively winding the slot parts of the two orthogonal iron cores at the mutually overlapped positions, and respectively forming a coil on each of the two iron cores;
2) and the coils are respectively wound at the opposite end positions of each iron core, and a pair of coils wound on each iron core form a group of coils.
Preferably, a PCB board is further fixed inside the lower housing on a side away from the upper housing, and the electromagnetic sensor array is disposed on the PCB board.
Preferably, a signal generating circuit is arranged in the signal processing terminal, and two sine wave signals with a phase difference of 90 degrees for exciting the coil are generated by adjusting the type of the output signal, the phase of the signal, the peak value of the amplitude of the signal and the frequency of the signal, wherein the peak value of the amplitude of the sine wave signal is 5V, and the frequency of the sine wave signal is 1 KHz.
Preferably, the signal conditioning circuit comprises a phase detection circuit, an amplifying circuit and a shaping circuit, wherein the phase detection circuit is used for detecting the phase of a circuit signal and judging whether the phase changes; the amplifying circuit is used for amplifying the signal and outputting an amplified voltage signal; the shaping circuit is used for shaping the voltage signal output by the amplifying circuit, correcting the output waveform and outputting the corrected output waveform to the AD acquisition circuit.
Preferably, the magnetic sensor is a three-axis electromagnetic sensor of AMI 306R.
Preferably, a gap is left between the two orthogonal U-shaped iron cores.
Preferably, the box body of the signal processing terminal and the shell of the detection terminal are both made of ferrous materials.
It should be understood that all combinations of the foregoing concepts and additional concepts described in greater detail below can be considered as part of the inventive subject matter of the present disclosure unless such concepts are mutually inconsistent. In addition, all combinations of claimed subject matter are considered a part of the inventive subject matter of this disclosure.
The foregoing and other aspects, embodiments and features of the present teachings can be more fully understood from the following description taken in conjunction with the accompanying drawings. Additional aspects of the present invention, such as features and/or advantages of exemplary embodiments, will be apparent from the description which follows, or may be learned by practice of the specific embodiments in accordance with the teachings of the present invention.
Drawings
The drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. Embodiments of various aspects of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
fig. 1 is a schematic view of a detection terminal of the handheld flaw detector of the present invention.
Fig. 2 is a schematic diagram of a signal processing terminal of the hand-held flaw detector of the present invention.
Fig. 3 is a schematic structural diagram of the detection terminal of the hand-held flaw detector of the present invention.
Fig. 4 is a schematic coil diagram of the detection terminal of the hand-held flaw detector of the present invention.
Fig. 5 is a coil diagram of another example of the inspection terminal of the hand-held flaw detector of the present invention.
Fig. 6 is a schematic circuit diagram of the signal processing terminal of the hand-held flaw detector of the present invention.
Detailed Description
For a better understanding of the technical content of the present invention, specific embodiments are described below in conjunction with the accompanying drawings.
In this disclosure, aspects of the present invention are described with reference to the accompanying drawings, in which a number of illustrative embodiments are shown. Embodiments of the present disclosure are not necessarily intended to include all aspects of the invention. It should be appreciated that the various concepts and embodiments described above, as well as those described in greater detail below, may be implemented in any of numerous ways, as the disclosed concepts and embodiments are not limited to any implementation. Additionally, some aspects of the present disclosure may be used alone or in any suitable combination with other aspects of the present disclosure.
With reference to fig. 1-6, the present invention provides a hand-held flaw detector, which includes a hand-held detection terminal and a signal processing terminal connected to the hand-held detection terminal through a data line. The handheld terminal adopts an orthogonal eddy current detection head which comprises two orthogonal U-shaped iron cores and two groups of coils wound on the iron cores, and the coils are excited by two sine wave signals with the phase difference of 90 degrees to generate rotary eddy current surrounding a measurement surface or a subsurface so as to achieve the purpose of comprehensive detection.
With reference to the illustrated example, the handheld inspection terminal of the handheld inspection apparatus of the preferred example of the present invention includes a housing 10, and orthogonally distributed iron cores (1a, 1b) disposed in the housing, an electromagnetic sensor array, and coils (3a, 3b) wound on the iron cores, as described above, by applying two sine wave excitation signals with a phase difference of 90 degrees to the two groups of coils, the excitation current causes the coils to generate rotating eddy currents.
As shown in connection with fig. 1, the housing 10 includes an upper case 10a and a lower case 10 b.
The upper portion of the housing 10 also secures a grip portion 20, preferably having an ergonomic configuration, such as the cylindrical shape illustrated to facilitate gripping, by a sealing ring 30. The top of the terminal is provided with a data line leading-out interface 40 which is connected to a data input interface of the signal processing terminal 50 through a data line.
The lower case 10b is detachably engaged with the upper case 10a, and is, for example, an engaging structure with a stopper in the drawing.
Referring to fig. 1, the orthogonally distributed cores include two identical U-shaped cores, a first core 1a and a second core 1b, which are orthogonally fixed in the housing, particularly, inside the lower case 10b, respectively.
The first core 1a and the second core 1b are distributed in an orthogonal position with a gap left therebetween.
A group of coils 3a and another group of coils 3b are correspondingly and respectively arranged on the first iron core 1a and the second iron core 1b, and corresponding coils (namely two groups of coils) on different iron cores are used as eddy current generating devices.
The two groups of coils form independent circuits through respective coil wires, are led out of the shell and are connected with an excitation circuit, namely an alternating current excitation circuit.
With reference to the coil winding method shown in fig. 4 and 5, the flaw detector of the present invention forms a wound coil by using one of the following two types:
referring to fig. 4, the slot portions of the first iron core 1a and the second iron core 1b are respectively wound at the positions overlapped with each other, and a coil 3a and a coil 3b are respectively formed on the two iron cores and respectively excited;
referring to fig. 5, the coils are wound around the opposite end portions of each of the irons 1a and 1b, a pair of coils wound around each iron core forms a group of coils, and 2 groups of coils are correspondingly formed on the two iron cores to apply excitation respectively.
With reference to fig. 1 and 6, the ac excitation circuit has a signal generating circuit, the signal generating circuit has a signal generator and a phase detector, the signal generator is used for generating a 50-100KHz signal, and the phase detector is used for phase-detecting two sine wave excitation signals with a phase difference of 90 degrees and outputting the two sine wave excitation signals to the two corresponding sets of coils.
Optionally, the signal generating circuit generates two sine wave signals with a phase difference of 90 degrees by adjusting the type of the output signal, the phase of the signal, the peak amplitude value of the signal and the frequency of the signal, wherein the peak amplitude value is 5V and the frequency is 1 KHz.
Preferably, a buffer is further provided between the phase detector and the coil.
The electromagnetic sensor array is formed by arranging a plurality of magnetic sensors 2 in an M x N combination, namely in a combination of M rows and N columns, and receives a feedback signal of eddy current detection. M and N are positive integers greater than or equal to 1. The lower surface of the electromagnetic sensor array and the free end of the side part of the U-shaped iron core which is orthogonally distributed are positioned on the same plane.
The electromagnetic sensor array is led out of the shell through the lead-out wires and is electrically connected with the signal processing terminal.
In the foregoing embodiment, the winding base of the coil is provided by the orthogonal U-shaped iron core, so as to perform a magnetic gathering function, prevent excessive leakage of the magnetic field, and reduce energy loss.
The utility model discloses the preferred triaxial electromagnetic sensor who adopts AMI306R detects out its interfering signal as the magnetic sensor that the feedback detected to confirm the situation of defect.
With reference to fig. 1, the weight of the iron core, the coil and the magnetic sensor which are distributed orthogonally is light, which is beneficial to the miniaturization design of the whole equipment. The core and the PCB board are both fixed to the housing using an adhesive.
Preferably, the shell is made of a ferrous material so as to carry out electromagnetic shielding and avoid the influence of an external magnetic field on the flaw detection equipment.
Referring to fig. 1, preferably, the lead-out wires corresponding to the magnetic sensor 2 and the coil wires corresponding to the coil are collected in the grip 20 and then connected to the data line lead-out interface 40. In the figure, the lead-out wires are collectively denoted by reference numeral 11.
As shown in fig. 1, a PCB board 5 is further fixed inside the lower casing 10b on a side away from the upper casing, and the electromagnetic sensor array is disposed on the PCB board to realize fixed installation of the sensor array.
Referring to fig. 2, the signal processing terminal 50 has a housing 51, which is made of iron material for electromagnetic shielding. The front face of the box body is provided with a display screen 52 occupying 60% for displaying the signal processing result, and the display screen 52 is electrically connected with the internal signal processing circuit.
As shown in fig. 2, the front of the box 51 is further provided with a key panel 55 for controlling and operating the signal processing terminal and a knob type adjusting switch 56 connected to the internal signal processing circuit for adjusting and controlling the display content and the excitation and other working conditions and working parameters.
The side of the box 51 is also provided with a data input interface 53 and a data export and charging interface 54. Preferably, the internal signal processing circuit is powered by a storage battery to facilitate portable detection operations, such as detection of an industrial site and a rail, and the storage battery can be charged through the charging interface. The data input interface 53 is in data connection with the data line leading-out interface 40 of the detection terminal through a data line, so that data interaction is realized.
The signal processing circuit inside the exemplary signal processing terminal of fig. 5 includes a signal conditioning circuit, an AD acquisition circuit, and an image reconstruction circuit that are electrically connected in sequence.
The signal conditioning circuit receives the multi-channel output signals output by the electromagnetic sensor array, performs phase discrimination, amplification and shaping processing, and outputs the signals to the AD acquisition circuit.
The AD acquisition circuit converts the analog quantity into a digital quantity.
The image reconstruction circuit carries out image reconstruction based on digital quantity obtained by detecting magnetic field detection signals of relevant positions by the array type magnetic sensor to obtain a defect graph.
With reference to fig. 1, when the coil is energized with a pulse signal, the winding coil will generate a magnetic field, and the present invention applies two sine wave excitations with a phase difference of 90 degrees, so that the coil generates an eddy current that is applied to the surface to be detected (e.g., rail) and the subsurface to form a rotation, and if the detected rail has a defect, the detection result of the probe will change (i.e., form an interference signal).
With reference to fig. 1 and 6, two sinusoidal signals with a phase difference of 90 degrees generated by the signal generator are applied to the coil to form a rotating eddy current on the surface or subsurface to be detected, when a defective place is encountered, because the defective part has a blocking effect on the rotating eddy current, a feedback magnetic field generated by the rotating eddy current will be different from a feedback signal generated when the defect is not detected, and the feedback signal is detected by using a three-axis electromagnetic sensor with the model of AMI 306R.
In a specific embodiment, the signal conditioning circuit includes a phase detection circuit, an amplification circuit, and a shaping circuit.
The phase discrimination circuit is used for detecting the phase of a circuit signal and judging whether the phase is changed or not, the input of the phase discrimination circuit is from the signal generator and is input in a sine wave form, and the output signal is two paths of sine wave signals with the phase difference of 90 degrees.
The amplifying circuit is used for amplifying the signal and outputting an amplified voltage signal.
The shaping circuit is used for shaping the voltage signal output by the amplifying circuit, correcting the output waveform and outputting the corrected output waveform to the AD acquisition circuit.
In the process of flaw detection, with reference to fig. 1, 2 and 6, the following briefly describes the implementation process:
1) two sine wave signals with the phase difference of 90 degrees are generated by adjusting the type, the phase, the peak amplitude value and the frequency of an output signal by a signal generator, wherein the peak amplitude value is 5V, and the frequency is 1 KHZ;
2) two sine wave signals with the phase difference of 90 degrees generated by the signal generator are transmitted on a coil of a sensor probe to form a rotating eddy current on a detected rail, when a defective part is met, because the defective part has a blocking effect on the rotating eddy current, a feedback magnetic field generated by the rotating eddy current is different from a feedback signal generated when the defect is not met, and the feedback signal is detected by a three-axis electromagnetic sensor of AMI 306R;
3) the signals output by the AMI306R triaxial electromagnetic sensor pass through a signal conditioning circuit (phase discrimination, amplification and shaping circuit) for AD conversion;
4) the DSP collects AD data signals (analog quantity is converted into digital quantity), and the AD data signals are analyzed and processed.
5) And outputting the processed data to an upper computer (such as an embedded host) to reconstruct the damage graph.
Use the utility model discloses an in-process of hand-held type flaw detector, measurement personnel only need hold the probe and mark on the rail surface, can see the shape size and the position of damage such as crackle on display screen (preferred liquid crystal display).
Compared with the prior art, the utility model discloses a hand-held type appearance of detecting a flaw, iron core and coil through two sets of orthorhombic are as eddy current generating device, make the probe can form a rotatory eddy current on rail surface and subsurface, if defect in the rail that detects, the testing result of probe will change (form interference signal promptly), detect out through the magnetic sensor array promptly, accomplish the detection of the different grade type defect on rail surface and subsurface, in order to do benefit to the later stage and can carry out visual, the categorised aassessment of quantification to the rail damage effectively.
The detection device designed by the device is beneficial to forming a rotary eddy current on a detected object, can detect the defects of different types on the surface of the rail, and can effectively avoid the influence of environmental variables on flaw detection methods such as ultrasonic waves, CCD line scanning cameras and the like. The device breaks through the problems that other rail flaw detection vehicles are single in function, low in detection speed, low in detection precision, greatly influenced by the environment and the like, innovatively applies a novel signal processing and damage reconstruction technology, and innovatively utilizes a rail surface and subsurface damage detection method (early detection) combining an eddy current flaw detection method and an MI sensor.
The equipment detection accuracy is as follows:
1. positioning the crack position: error is not more than 1mm
2. Crack shape reconstruction size: error less than 2mm
3. Surface damage position: error is not more than 2mm
4. Surface damage shape reconstruction size: error less than 2mm
5. Flaw detection depth of the rail surface: approximately equal to 2mm, can detect the surface crack and fatigue damage (early defect) of the rail and subsurface.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to limit the present invention. The present invention is intended to cover by those skilled in the art various modifications and adaptations of the invention without departing from the spirit and scope of the invention. Therefore, the protection scope of the present invention is subject to the claims.
Claims (9)
1. The utility model provides a hand-held type appearance of detecting a flaw, its characterized in that, includes hand-held type's detection terminal and the signal processing terminal who is connected with hand-held type detection terminal through the data line, wherein:
the handheld detection terminal comprises a shell, two orthogonal U-shaped iron cores positioned in the shell, two groups of coils wound on the iron cores and an electromagnetic sensor array, wherein the coils are excited by two sine wave signals with the phase difference of 90 degrees to generate a rotating eddy current surrounding a measuring surface or a sub-surface;
the shell comprises an upper shell and a lower shell, the lower shell is detachably clamped and fixed with the upper shell, and the iron core, the coil and the electromagnetic sensor array which are distributed orthogonally are arranged in the lower shell;
the upper part of the shell is also fixed with a holding part through a sealing ring, and the top of the holding part is provided with a data wire leading-out interface which is connected to a signal processing terminal through a data wire;
the electromagnetic sensor array is formed by arranging a plurality of magnetic sensors to form an M-N combination and is used for receiving a feedback signal of eddy current detection, wherein M and N are positive integers which are more than or equal to 1, and the lower surface of the electromagnetic sensor array and the free end of the side part of the U-shaped iron core which is orthogonally distributed are positioned on the same plane;
the signal processing terminal comprises a box body, and a display screen, a key panel, a data input interface and a data exporting and charging interface which are arranged on the box body, wherein the display screen, the key panel, the data input interface and the data exporting and charging interface are all electrically connected with an internal signal processing circuit, and the display screen is used for displaying a signal processing result; the key panel is used for adjusting and controlling working conditions and working parameters;
the signal processing circuit arranged in the signal processing terminal comprises a signal conditioning circuit, an AD acquisition circuit and an image reconstruction circuit which are electrically connected in sequence, wherein the signal conditioning circuit receives signals output by the electromagnetic sensor array, performs phase discrimination, amplification and shaping processing and outputs the signals to the AD acquisition circuit; the AD acquisition circuit converts the analog quantity into digital quantity; the image reconstruction circuit carries out image reconstruction based on digital quantity obtained by detecting magnetic field detection signals of relevant positions by the array type magnetic sensor to obtain a defect graph.
2. The hand-held flaw detector of claim 1, wherein the grip portion is cylindrical in shape fixed to the upper housing.
3. The hand-held flaw detector of claim 1, wherein the coil is wound in any one of the following manners:
1) respectively winding the slot parts of the two orthogonal iron cores at the mutually overlapped positions, and respectively forming a coil on each of the two iron cores;
2) and the coils are respectively wound at the opposite end positions of each iron core, and a pair of coils wound on each iron core form a group of coils.
4. The hand-held flaw detector of claim 1, wherein a PCB board is further fixed to the inside of the lower housing on a side away from the upper housing, and the electromagnetic sensor array is disposed on the PCB board.
5. The hand-held flaw detector according to claim 1, wherein a signal generating circuit is provided in the signal processing terminal, and two sine wave signals having a phase difference of 90 degrees for exciting the coil are generated by adjusting the type of output signal, the phase of the signal, the peak amplitude value of the signal, and the frequency of the signal, and the peak amplitude value of the sine wave signal is 5V and the frequency is 1 KHz.
6. The hand-held flaw detector of claim 1, wherein the signal conditioning circuit comprises a phase detection circuit, an amplification circuit and a shaping circuit, wherein the phase detection circuit is used for detecting the phase of a circuit signal and judging whether the phase changes; the amplifying circuit is used for amplifying the signal and outputting an amplified voltage signal; the shaping circuit is used for shaping the voltage signal output by the amplifying circuit, correcting the output waveform and outputting the corrected output waveform to the AD acquisition circuit.
7. The hand-held flaw detector of claim 1, wherein the magnetic sensor is a three-axis electromagnetic sensor of AMI 306R.
8. The hand-held flaw detector of claim 1, wherein a gap is left between the two orthogonal U-shaped iron cores.
9. The hand-held flaw detector of claim 1, wherein the box body of the signal processing terminal and the shell of the detection terminal are both made of ferrous materials.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201920638894.5U CN209911291U (en) | 2019-05-07 | 2019-05-07 | Hand-held flaw detector |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201920638894.5U CN209911291U (en) | 2019-05-07 | 2019-05-07 | Hand-held flaw detector |
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| Publication Number | Publication Date |
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| CN209911291U true CN209911291U (en) | 2020-01-07 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN201920638894.5U Expired - Fee Related CN209911291U (en) | 2019-05-07 | 2019-05-07 | Hand-held flaw detector |
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| CN (1) | CN209911291U (en) |
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