CN210862514U - Automatic detection system for wave-shaped abrasion of steel rail - Google Patents
Automatic detection system for wave-shaped abrasion of steel rail Download PDFInfo
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- CN210862514U CN210862514U CN201921367374.1U CN201921367374U CN210862514U CN 210862514 U CN210862514 U CN 210862514U CN 201921367374 U CN201921367374 U CN 201921367374U CN 210862514 U CN210862514 U CN 210862514U
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Abstract
The utility model relates to an automatic detecting system of rail wave type wearing and tearing, including portable testing platform, include a plurality of non-contact displacement sensor's rail detection device, for the rail detection device power supply and receive rail detected signal's host computer, and information output device, this system adopts non-contact displacement sensor and cooperation vertical follower mechanism, the distance of response detection to the rail can lead to the displacement change with the wave loss apart from signal feedback to the host computer realization quick automatic rail wave wearing and tearing that detect, alleviate track work maintainer work greatly, improve circuit maintenance efficiency, realize reducing operation unit cost, improve the purpose of operation security.
Description
Technical Field
The invention relates to the technical field of rail transit safety guarantee, in particular to a steel rail wave-shaped wear automatic detection system.
Background
In track traffic, the long-term contact friction between vehicle wheel and the rail can cause the wave type wearing and tearing of rail, and when rail wave type wearing and tearing were more serious, effort and track vibration can greatly increased between the wheel rail, not only causes the violent vibrations of vehicle and track system, increases wheel rail noise, leads to the fatigue destruction of vehicle and track spare part moreover, also increases to orbital destructiveness, can threaten driving safety when serious.
So far, the detection of the wave wear of the steel rail still mainly adopts a manual detection method. The rail abrasion condition judgment highly depends on the experience of personnel, lacks accurate and scientific standards, cannot provide accurate guidance basis for the maintenance and replacement period of the rail, and has the problems of low efficiency, low precision and serious dependence on the manual experience.
Disclosure of Invention
In order to solve the defects of the prior art, the invention provides a steel rail wave-shaped abrasion automatic detection system, which adopts a non-contact displacement sensor and is matched with a vertical follow-up mechanism, and the distance from the non-contact displacement sensor to a steel rail is sensed and detected, so that a distance signal of displacement change caused by wave loss can be fed back to a host to realize rapid automatic detection of the steel rail wave abrasion, thereby greatly lightening the work of rail maintenance staff, improving the line maintenance efficiency, and achieving the purposes of reducing the cost of an operation unit and improving the operation safety.
In order to achieve the above purpose, the technical scheme adopted by the invention comprises the following steps:
a steel rail wave-shaped abrasion automatic detection system is characterized by comprising a movable detection platform, a steel rail detection device, a host and an information output device, wherein the steel rail detection device comprises a plurality of non-contact displacement sensors;
the movable detection platform is a four-wheel moving platform which is used for moving along a steel rail to be detected, the host and the information output device are fixedly arranged on the front side of the platform, and the steel rail detection device is arranged on the back side of the platform in a hanging mode along two side edges of the extending direction of the steel rail;
the steel rail detection devices are two symmetrical groups which respectively correspond to the detection of two steel rails, each non-contact displacement sensor of each group of steel rail detection devices is arranged between two wheels on the same side, and a sensor probe faces the steel rail to be detected in a downward non-contact manner; the steel rail detection device also comprises a vertical follow-up mechanism which enables the relative distance between the non-contact displacement sensor and the steel rail to be detected to be kept within a set range, and the vertical follow-up mechanism comprises a limiting wheel which is in direct contact with the steel rail and a limiting connection device which is connected with the movable detection platform and can move vertically and freely;
the host comprises a signal analyzer and a power supply; the host is connected with the non-contact displacement sensor on the steel rail detection device, supplies power to the non-contact displacement sensor through a power line and a signal line and receives a steel rail detection distance signal; the signal analyzer in the host computer calculates and processes the steel rail detection distance signal based on a chord measuring method to obtain steel rail wave-shaped wear information, and the host computer sends the steel rail wave-shaped wear information to the information output device through a signal wire;
and the information output device receives the wave-shaped wear information of the steel rail and displays the information in real time.
Furthermore, the non-contact displacement sensor is an eddy current sensor, the eddy current sensor utilizes electromagnetic eddy current induction to place the steel rail to be measured in a changing magnetic field or generate eddy current-shaped induction current when the steel rail moves to cut magnetic lines of force in the magnetic field, then the eddy current sensor outputs absolute code signals containing the length and the depth of the steel rail to a host, and the host performs fitting calculation processing on the signals sent by the eddy current sensors to obtain steel rail wave-shaped wear information.
Furthermore, the non-contact displacement sensor is an ultrasonic sensor, the ultrasonic sensor receives ultrasonic waves generated by vibration of the steel rail to be detected and converts the ultrasonic waves into electric signals containing the length and the depth of the steel rail to be output to the host, and the host performs fitting calculation processing on the signals sent by the ultrasonic sensors to obtain wave-shaped wear information of the steel rail.
Furthermore, the steel rail detection device is provided with a cross beam made of non-metal materials and extending along the steel rail, each non-contact displacement sensor is fixedly arranged on the cross beam, and the cross beam covers and protects the probe of each non-contact displacement sensor from the upper side.
Further, the relative distance between the non-contact displacement sensor and the steel rail to be measured is 3-5 mm.
Furthermore, the steel rail detection device also comprises a rail profile detection sensor which is directly or indirectly fixedly arranged on the back of the movable detection platform and is connected with the signal analyzer through a signal line so as to send a rail profile detection signal to the signal analyzer; and the signal analyzer calculates the rail profile information of the steel rail through the rail profile detection signal.
Further, the signal analyzer calculates the horizontal distance and the depth information of the steel rail by using the steel rail distance detection signal.
Further, the host also comprises an information storage circuit; the information storage circuit stores the signal obtained by the steel rail detection device and the information obtained by the signal analyzer.
Further, the movable detection platform comprises a power device; and the power device drives the movable detection platform to move back and forth along the steel rail.
Furthermore, the front face of the movable detection platform is also provided with an operation position for accommodating an operator, the information output device, the operation position and the host are sequentially arranged from front to back, and the information output device is arranged facing the operation position.
The invention has the beneficial effects that:
the steel rail wave-shaped wear automatic detection system adopts the movable detection platform, the steel rail detection device, the host and the information output device, the steel rail detection device is arranged on the back of the movable detection platform, comprises a plurality of non-contact displacement sensors and is matched with the vertical follow-up mechanism, so that the relative distance between the non-contact displacement sensors and the steel rail to be detected is kept in a set range, a detection probe of the non-contact displacement sensors does not need to contact the steel rail to be detected, a coupling agent is not needed, and the steel rail is easy to detect automatically at high speed and high efficiency; the detection sensitivity to the defects on the surface and near surface of the steel rail is very high; the detection can also be carried out at high temperature, or the detection can be carried out at the deep and far positions which can be reached by probes such as narrow areas and deep hole walls of the steel rail, the non-contact displacement sensor preferably adopts an eddy current sensor, an ultrasonic sensor and the like, the distance from the induction detection to the steel rail can feed back distance signals of displacement change caused by wave loss to the host to realize the rapid automatic detection of the wave abrasion of the steel rail, the work of rail work maintenance personnel is greatly reduced, and the line maintenance efficiency is improved. Each device component of the system can be made of light materials, so that the system is convenient to transport, assemble and use on site, can meet the requirement of quick assembly and disassembly of the system in the process of detecting the steel rail line and is convenient for different on-line requirements; non-contact displacement sensors such as an eddy current sensor and an ultrasonic sensor do not need to contact a steel rail in a working state, do not damage the steel rail in a detection process, and have the advantages of high detection sensitivity and adaptability to high-temperature and low-temperature detection environments; the steel rail detection device has a follow-up effect, when the steel rail detection device has an external force, the external force can be released through the vertical follow-up mechanism, and the vertical follow-up mechanism is adopted to ensure that the relative distance between the eddy current sensor and the steel rail to be detected is always kept at the optimal detection distance of 3-5 mm, so that the detection effect is stable; the signal analyzer in the host computer calculates and processes the steel rail detection distance signal to obtain the steel rail wave-shaped abrasion information based on a chord measuring method, the signal analyzer can adopt different signal processing circuits to inhibit interference and extract different eddy current influence factors, eddy current detection can be used for measuring the horizontal thickness of the track, and the steel rail detection distance signal obtained by the non-contact displacement sensor is an electric signal, the detection signal can be digitally processed according to any requirement, and then the electric signal is stored, reproduced and subjected to data processing and comparison, and the detection data can be checked through an information output device such as a display in real time; the structure of the system can be additionally provided with other monitoring instruments aiming at the steel rail, such as a rail profile detection sensor and the like, and various related data are obtained through one-time detection, so that the automatic comprehensive detection of the steel rail is realized. By adopting the automatic detection system for the wave-shaped abrasion of the steel rail, the wave abrasion of the steel rail can be quickly and automatically detected, the work of rail maintenance staff is greatly reduced, the line maintenance efficiency is improved, the trend analysis of the wave abrasion of the steel rail can be realized through the management of the collected detection data, the line maintenance is guided, the maintenance is advanced, and the purposes of reducing the cost of an operation unit and improving the operation safety are achieved.
Drawings
Fig. 1 is a schematic structural diagram of an embodiment of the automatic detection system for wave-shaped wear of a steel rail according to the present invention.
Fig. 2A is a schematic diagram of the operation of the vertical follower mechanism of the present invention.
Fig. 2B is another schematic diagram of the operation of the vertical follower mechanism of the present invention.
Fig. 3 is a schematic structural diagram of another embodiment of the steel rail detection device.
Description of the figure numbering: the device comprises a movable detection platform 1, a wheel 11, a steel rail detection device 2, an eddy current sensor 21, a limiting wheel 221, a limiting connecting device 222, a rail profile detection sensor 23, a host computer 3, a signal analyzer 31, a power supply 32, an information storage circuit 33, an information output device 4, a power device 5 and a steel rail to be detected 6.
Detailed Description
For a clearer understanding of the contents of the present invention, reference will be made to the accompanying drawings and examples.
The wave-shaped wear automatic detection system for the steel rail adopts a non-contact induction principle, if an eddy current sensor adopts a Faraday electric sensing induction principle, when metal (the steel rail to be detected) is placed in a changing magnetic field or moves for cutting magnetic lines of force in the magnetic field, eddy current-shaped induction current is generated in a conductor (a head coil of the eddy current sensor, namely a sensor probe), and non-contact nondestructive flaw detection can be realized by collecting and analyzing the eddy current-shaped induction current.
Fig. 1 is a schematic structural diagram of an embodiment of the automatic detection system for wave-shaped wear of a steel rail according to the present invention, which includes a movable detection platform 1 made of all aluminum or other light materials, a set of symmetrical steel rail detection devices 2 including a plurality of non-contact displacement sensors and suspended on the back of the movable detection platform 1 along two sides of the extension direction of the steel rail, a host 3 and an information output device 4 fixedly disposed on the front of the movable detection platform 1, and preferably a power device 5 for driving the movable detection platform 1 to move back and forth along the steel rail. The movable detection platform 1 is arranged on the steel rail 6 to be detected through 4 wheels 11 and can move back and forth along the steel rail 6 to be detected; the non-contact displacement sensor preferably employs an eddy current sensor 21; the host 3 comprises a signal analyzer 31, a power supply 32 and an information storage circuit 33, the host 3 is connected with the eddy current sensor 21, supplies power to the eddy current sensor through a power line and a signal line and receives a steel rail detection distance signal, and the host is connected with the information output device through the signal line and sends steel rail wave-shaped wear information to the information output device; the rail detection device 2 is provided with a plurality of eddy current sensors 21, and a vertical follow-up mechanism which is composed of a limiting wheel 221 directly contacted with the rail and a limiting connection device 222 which is connected with the rail detection device and the movable detection platform and can move vertically and freely. In the moving process of the whole system on the steel rail, the relative distance between the platform and the steel rail may be changed due to the fact that the surface of the steel rail is concave-convex or the stress of the movable detection platform 1 is changed, but in the measuring process of the eddy current sensor, a relatively stable reference measuring distance needs to be kept, namely, a fixed 3-5 mm gap is kept between the eddy current sensor and the steel rail, otherwise, the measuring result is adversely affected. In order to eliminate the influence as much as possible, the invention adopts a vertical follow-up mechanism to connect the movable detection platform 1 and the steel rail detection device 2, so that the relative distance between the eddy current sensor 21 and the steel rail to be detected does not change along with the change of the vertical position of the movable detection platform 1, namely, the steel rail detection device 2 and the movable detection platform 1 are freely movable in the vertical direction, and the relative distance between the eddy current sensor 21 and the steel rail to be detected is kept unchanged through the contact between the limiting wheel 221 and the surface of the steel rail. Fig. 2A and 2B are schematic diagrams illustrating the operation of the vertical follower mechanism, wherein fig. 2A is a schematic diagram illustrating that when the system of the present invention encounters an uneven surface of a steel rail during the process of detecting a steel rail, for example, when a protrusion with a vertical height h appears on the surface of the steel rail, if the system does not have the vertical follower mechanism, the relative distance between the eddy current sensor 21 and the steel rail to be detected is reduced from original a to a-h, thereby affecting the process of detecting the steel rail 6 by the eddy current sensor 21; when a vertical follow-up mechanism is used, the limiting wheel 221 is always in contact with the steel rail 6, when the limiting wheel 221 meets the protrusion h on the surface of the steel rail, the limiting wheel moves along with the protrusion and enables the whole steel rail detection device 2 to vertically move upwards by a distance h, meanwhile, due to the existence of the limiting connection device 222, the vertical displacement of the steel rail detection device 2 cannot affect the movable detection platform 1, the movable detection platform 1 is always kept at the same horizontal position and moves forwards along the steel rail, and the relative distance between the eddy current sensor 21 and the surface of the steel rail 6 to be detected is always kept unchanged as a. Fig. 2B shows a situation that when the system of the present invention encounters a force variation of the movable inspection platform 1 during rail inspection, for example, when the movable inspection platform 1 experiences an additional vertical downward external force F (for example, an operator stands on the movable inspection platform 1 during inspection), if the system does not have a vertical follower mechanism, the relative distance between the eddy current sensor 21 and the rail to be inspected may be reduced from original a to a-B, thereby affecting the inspection process of the eddy current sensor 21 on the rail 6; when the vertical follow-up mechanism is used, the limiting wheel 221 is always in contact with the steel rail 6, the movable detection platform 1 vertically moves downwards for a distance b under the action of an external force F, due to the existence of the limiting connecting device 222, the steel rail detection device 2 is not influenced by the vertical displacement of the movable detection platform 1, any vertical displacement does not occur, and the relative distance between the eddy current sensor 21 and the surface of the steel rail 6 to be detected is always kept as a. The rail detection device 2 is provided with an up-down follow-up system under the action of the vertical follow-up mechanism, and the bottom of the rail detection device is in contact with the rail surface by using the limiting wheel 221, so that the gap between the eddy current sensor 21 and the rail surface cannot be changed under any condition.
Referring to fig. 3, a schematic structural diagram of another embodiment of the steel rail detection apparatus according to the present invention is shown, in which the steel rail detection apparatus 2 further includes a track profile detection sensor 23, and the track profile detection sensor 23 is directly or indirectly fixedly disposed on the back of the movable detection platform and connected to the host computer 3 through a signal line and transmits a track profile detection signal to the host computer 3. In use, the track profile detection sensor 23 and the eddy current sensor 21 work independently without influencing each other, so that synchronous detection of the wave grinding track profile is realized, and the two sensors cannot interfere with each other.
The invention relates to a steel rail wave-shaped abrasion automatic detection system which adopts an eddy current sensor and utilizes the electromagnetic induction principle, in particular to a steel rail to be detected which is placed in a changing magnetic field or generates eddy current-shaped induction current when the magnetic line of force is cut in the magnetic field by utilizing the electromagnetic eddy current induction, then the eddy current sensor outputs absolute code signals containing the length and the depth of the steel rail to a host computer, the host computer fits the signals sent by each eddy current sensor, the detected transfer function defines the range of the system function according to the wavelength by a chord measuring method, the steel rail wave-shaped abrasion information is obtained by calculation processing, certain performances or defects of conductive materials and workpieces thereof are evaluated without damage by measuring the change of the induced eddy current in the detected workpieces, the waveform within 3 meters can be detected, a steel rail detection device 2 utilizes a vertical follow-up hoisting mechanism to ensure that the gap between the eddy current sensor and the rail surface can not change under any condition on a movable detection platform 1, the high-speed and high-efficiency automatic detection of short waves, medium waves and long waves of the steel rail is realized; the detection can also be carried out at high temperature, or the detection can be carried out at the deep distance which can be reached by probes such as narrow areas, deep hole walls and the like of workpieces. Compared with manual detection, the method can save a large amount of time, improve the precision and have high detection sensitivity on the defects of the surface and the near surface of the workpiece. Meanwhile, because the electric eddy current sensor obtains an electric signal by detection, the detection result can be digitally processed and then stored, reproduced, processed and compared; different signal processing circuits are adopted to suppress interference, different eddy current influence factors are extracted, and the eddy current sensor can also be used for measuring the horizontal thickness of the track.
It should be further noted that the non-contact displacement sensor adopted in the present invention may also adopt other displacement sensors, such as an ultrasonic sensor, the ultrasonic sensor and the steel rail are also in non-contact, the ultrasonic sensor receives ultrasonic waves generated by vibration of the steel rail to be measured and converts the ultrasonic waves into an electrical signal containing the length and depth of the steel rail, and the electrical signal is output to the host, and the host performs fitting calculation processing on the signal sent by each ultrasonic sensor to obtain the steel rail wave-shaped wear information.
The invention adopts two groups of steel rail detection devices, each group of steel rail detection devices adopts a plurality of non-contact displacement sensors, as shown in the embodiment of figure 1, each group of steel rail detection devices adopts 4 non-contact displacement sensors (such as eddy current sensors), in order to ensure that the 4 eddy current sensors are positioned on the same horizontal reference surface, the steel rail detection devices can be provided with a cross beam made of non-metal materials along the extending direction of the steel rail, each eddy current sensor is fixedly arranged on the cross beam, the cross beam covers and protects the probe of each eddy current sensor from the upper part, the cross beam plays the role of a positioning rod, and a positioning rod can also be additionally arranged to be connected with the cross beam. The embodiment shown in fig. 1 detects and collects the wave abrasion of the steel rail through the electromagnetic induction of 4 eddy current sensors at the same level, has higher precision, adopts a non-contact structure, and detects the steel rail without contact and damage. The 4 eddy current sensors input the acquired steel rail detection distance signals into the host, and a signal analyzer in the host receives the four paths of signals and performs fitting calculation processing on the four paths of steel rail detection distance signals based on a four-chord measuring method to obtain steel rail wave-shaped wear information.
The front face of the movable detection platform 1 can be further provided with an operation position (only the position is reserved without drawing in the figure) for accommodating an operator, the information output device 4, the operation position and the host 3 are sequentially arranged from front to back, the information output device 4 receives steel rail wave-shaped wear information and displays the information in real time, the steel rail wear condition can be checked in real time through the information output device 4, and the record analysis is carried out. The information output device 4 may be set up facing the operation site so that the operator can visually see the wave-shaped wear information of the steel rail when driving the movable detection platform 1.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (9)
1. A steel rail wave-shaped abrasion automatic detection system is characterized by comprising a movable detection platform, a steel rail detection device, a host and an information output device, wherein the steel rail detection device comprises a plurality of non-contact displacement sensors;
the movable detection platform is a four-wheel moving platform moving along a steel rail to be detected, the host and the information output device are fixedly arranged on the front side of the platform, and the steel rail detection device is suspended on the back side of the platform along two side edges of the steel rail extending direction;
the steel rail detection devices are two symmetrical groups which respectively correspond to the detection of two steel rails, each non-contact displacement sensor of each group of steel rail detection devices is arranged between two wheels on the same side, and a sensor probe faces the steel rail to be detected in a downward non-contact manner; the steel rail detection device also comprises a vertical follow-up mechanism, wherein the vertical follow-up mechanism comprises a limiting wheel which is in direct contact with the steel rail and a limiting and connecting device which is connected with the movable detection platform and can move vertically and freely;
the host comprises a signal analyzer and a power supply; the host is connected with a non-contact displacement sensor on the steel rail detection device through a power line and a signal line; the host computer is connected with the information output device through a signal line.
2. The system of claim 1, wherein the non-contact displacement sensor is an eddy current sensor.
3. The system of claim 1, wherein the non-contact displacement sensor is an ultrasonic sensor.
4. The system according to any one of claims 1 to 3, wherein the rail detection device has a beam made of a non-metallic material extending along the rail, each non-contact displacement sensor is fixedly arranged on the beam, and the beam covers and protects the probe of each non-contact displacement sensor from above.
5. The system of claim 4, wherein the relative distance between the non-contact displacement sensor and the rail to be measured is 3 to 5 mm.
6. The system of claim 4, wherein the rail detection device further comprises a rail profile detection sensor, and the rail profile detection sensor is directly or indirectly fixedly arranged on the back of the movable detection platform and is connected with the signal analyzer through a signal line.
7. A system according to any one of claims 1 to 3, wherein the host further comprises information storage circuitry.
8. A system according to any one of claims 1 to 3, wherein the movable detection platform comprises a powered device.
9. The system of any one of claims 1 to 3, wherein the front face of the movable detection platform is further provided with an operation position for accommodating an operator, the information output device, the operation position and the host computer are sequentially arranged from front to back, and the information output device is arranged facing the operation position.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201921367374.1U CN210862514U (en) | 2019-08-21 | 2019-08-21 | Automatic detection system for wave-shaped abrasion of steel rail |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
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| CN201921367374.1U CN210862514U (en) | 2019-08-21 | 2019-08-21 | Automatic detection system for wave-shaped abrasion of steel rail |
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| CN210862514U true CN210862514U (en) | 2020-06-26 |
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| CN201921367374.1U Active CN210862514U (en) | 2019-08-21 | 2019-08-21 | Automatic detection system for wave-shaped abrasion of steel rail |
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