CN212622416U - Steel rail crack monitoring system and sensor - Google Patents
Steel rail crack monitoring system and sensor Download PDFInfo
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- CN212622416U CN212622416U CN202020464754.3U CN202020464754U CN212622416U CN 212622416 U CN212622416 U CN 212622416U CN 202020464754 U CN202020464754 U CN 202020464754U CN 212622416 U CN212622416 U CN 212622416U
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Abstract
The utility model discloses a rail crack monitoring system, which comprises a data processing device fixed beside a track, an antenna electrically connected with the data processing device, a cable with one end electrically connected with the data processing device, and a plurality of data acquisition devices which are electrically connected with the other end of the cable, hung on the railway track and used for acquiring the health information of the railway track; any one of the data acquisition devices comprises a clamping and fixing component clamped and buckled below a railway track, an installation base arranged on the clamping and fixing component, a protective shell buckled on the installation base, a PCB insulating plate fixed in the protective shell, and a track acceleration sensor, an ultrasonic position sensor and a track temperature sensor which are arranged in the protective shell; the data processing device comprises a protective case base, a protective case upper cover, a sensor connector and an antenna connector which are arranged on the protective case base, and a signal processing circuit board, a wireless transmission module and a battery which are arranged on the protective case base and arranged in the protective case upper cover.
Description
Technical Field
The utility model belongs to the technical field of equipment health diagnosis, track crack detects technique and specifically relates to a rail crack monitoring system and sensor.
Background
When a train runs on the track, the train can generate large mechanical excitation on the track, and if the track has microscopic defects, cracks can be expanded and even broken at the later stage. The train is used as a large-scale transportation means, the traffic safety is particularly important, the train operation must be matched with the rail, so the rail maintenance detection is particularly important, the existing detection and early warning modes are mainly tested regularly according to manpower, the mode obviously has the defects of consuming a large amount of manpower, bringing huge labor cost, often being incapable of accurately predicting due to large detection errors and threatening the railway safety. Secondly, the inability of manual detection to monitor in real time also presents a significant risk to safe operation.
Therefore, there is a need for a track health diagnosis and detection system that facilitates signal acquisition, real-time transmission, and accurate and diverse acquired data.
SUMMERY OF THE UTILITY MODEL
To the above problem, an object of the utility model is to provide a rail crack monitoring system and sensor, the utility model discloses a technical scheme as follows:
a steel rail crack monitoring system comprises a data processing device fixed beside a track, an antenna electrically connected with the data processing device, a cable with one end electrically connected with the data processing device, and a plurality of data acquisition devices which are electrically connected with the other end of the cable, hung and buckled on a railway track and used for acquiring health information of the railway track;
any one of the data acquisition devices comprises a clamping fixing component clamped below a railway track, an installation base arranged on the clamping fixing component, a protective shell buckled on the installation base, a PCB insulation board fixed on the installation base and arranged in the protective shell, a track acceleration sensor fixed on the PCB insulation board, arranged in the protective shell and connected with a cable, an ultrasonic position sensor and a track temperature sensor fixed at the top of the protective shell, arranged in the protective shell and connected with the cable;
the data processing device comprises a protective case base, a protective case upper cover buckled on the protective case base, a sensor connector and an antenna connector which are arranged on the protective case base and connected with a cable, and a signal processing circuit board, a wireless transmission module and a battery which are arranged on the protective case base and arranged in the protective case upper cover.
Furthermore, the clamping and fixing assembly comprises a main track fastener and an auxiliary track fastener, wherein the main track fastener and the auxiliary track fastener are oppositely buckled on the railway track through openings, and a fastener bolt is connected between the main track fastener and the auxiliary track fastener and used for tightly buckling the main track fastener and the auxiliary track fastener on the railway track.
Furthermore, an ultrasonic position sensor sealing cover is arranged at the top of the ultrasonic position sensor.
Furthermore, a rubber insulating pad is arranged between the rail main clamp buckle and the mounting base.
And the device further comprises a data processing device base which is fixed beside the track and used for installing a data processing device and an antenna, and a metal bracket which is arranged in the protective case base and used for installing a signal processing circuit board and a battery.
Preferably, the upper cover and the base of the protection case are made of ABS (acrylonitrile-butadiene-styrene) insulating plastics; the mounting base is made of the same material as the railway track; the battery is a high and low temperature resistant lithium battery.
The utility model provides a track health diagnosis sensor for gather railway rails's health information, including the fixed subassembly of centre gripping of clip under railway rails, the setting is the installation base on the fixed subassembly of centre gripping, the protective housing of lock on the installation base, fix on the installation base, and arrange the PCB insulation board in the protective housing in, fix on the PCB insulation board, arrange in the protective housing, and with cable junction's track acceleration sensor, fix at the protective housing top, arrange in the protective housing, and with cable junction's ultrasonic wave position sensor and rail temperature sensor.
Furthermore, the clamping and fixing assembly comprises a main track fastener and an auxiliary track fastener, wherein the main track fastener and the auxiliary track fastener are oppositely buckled on the railway track through openings, and a fastener bolt is connected between the main track fastener and the auxiliary track fastener and used for tightly buckling the main track fastener and the auxiliary track fastener on the railway track.
Furthermore, an ultrasonic position sensor sealing cover is arranged at the top of the ultrasonic position sensor.
Furthermore, a rubber insulating pad is arranged between the rail main clamp buckle and the mounting base.
Compared with the prior art, the utility model discloses following beneficial effect has:
(1) the utility model is skillfully provided with the upper cover and the base of the protective case, a rubber sealing gasket is added between the upper cover and the base of the protective case, ABS insulating plastic is selected for use, the upper cover and the base of the protective case are sealed, the whole data processing system is protected, and the protective case has the functions of water resistance, dust resistance and insulation, and simultaneously has large applicable temperature span and good mechanical property;
(2) the utility model is skillfully provided with the metal bracket, which is convenient for the installation of the battery and the signal processing circuit board, and simultaneously, the circuit board installed inside the metal bracket has electromagnetic shielding external interference and is convenient for the wiring of signal lines;
(3) the utility model skillfully arranges two battery mounting positions, thereby ensuring the sufficient power utilization of the equipment;
(4) the utility model skillfully selects the lithium battery, so that the energy storage of the battery is high, and the application range of the battery to the temperature is wide;
(5) the utility model skillfully uses the signal processing circuit board for processing and sending the data transmitted by a plurality of sensor systems, and adopts the integrated circuit to be beneficial to reducing the size of the equipment;
(6) the utility model discloses ingenious wireless transmission module that has set up, strengthened the transmission and the real-time observation of data, can select for use 2G/3G/4H/433 modules etc. according to the difference of data volume, the difference of on-the-spot communication condition, the module needs to have the low-power consumption mode, when not having the signal, sleeps, reduces the consumption, has both satisfied the communication propagation to the data, has also greatly reduced the artificial number of times of detecting on the spot;
(7) the utility model is skillfully provided with the sensor connector and the antenna connector, so that the data transmission is stable, and the connection is firm, waterproof, dustproof and convenient to disassemble;
(8) the utility model is skillfully provided with the protective shell, plays a role in protecting the whole sensor system and has the functions of water prevention and dust prevention;
(9) the utility model is skillfully provided with the rubber insulating pad, which plays a role of buffering between the PCB insulating board and the rail main clip;
(10) the utility model is skillfully provided with the PCB insulating board, thereby ensuring that the sensor is prevented from being interfered in the detection process;
(11) the utility model is skillfully provided with the antenna, which is beneficial to the transmission of data;
(12) the utility model skillfully designs the mounting base and the rail as the same material, which is beneficial to reducing the error collected by the rail acceleration sensor;
(13) the utility model skillfully installs the ultrasonic position sensor and the rail temperature sensor on the protective shell, which is beneficial to improving the precision of the signals collected by the ultrasonic position sensor and the rail temperature sensor;
(14) the utility model skillfully designs the main track clip, the auxiliary track clip and the clip bolt, which is convenient for the installation and the disassembly of the data acquisition device, and simultaneously, the main track clip and the auxiliary track clip are suitable for the rails with various specifications through tightening the bolt;
(15) the utility model skillfully designs a system integrating collection and calculation, namely, data collection and analysis are integrated, the output effective data volume is small, the data transmission cost is greatly reduced, and the algorithm is simple, easy to operate and easy to realize;
(16) the utility model discloses ingenious design only when the acceleration reaches the default, just start-up system is comprehensive to be worked, and other time only a small amount of device work, the lowering system consumption.
The utility model discloses simple structure, safe and reliable, efficient have very high practical value and spreading value in equipment health diagnosis and track crack detection technology field.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention, and therefore should not be considered as a limitation of the scope of protection, and for those skilled in the art, other related drawings may be obtained from these drawings without inventive effort.
Fig. 1 is a schematic structural diagram of the present invention.
Fig. 2 is an overall schematic diagram of the data processing apparatus of the present invention.
Fig. 3 is a schematic diagram of the internal structure of the data processing apparatus of the present invention.
Fig. 4 is the overall schematic diagram of the data acquisition device of the present invention.
Fig. 5 is a schematic view of the rail clip structure of the present invention.
Fig. 6 is a schematic diagram (a) of the internal structure of the data acquisition device of the present invention.
Fig. 7 is the internal structure diagram (ii) of the data acquisition device of the present invention.
Fig. 8 is the internal structure diagram (iii) of the data acquisition device of the present invention.
Fig. 9 is a flowchart of the operation of the present invention.
In the drawings, the names of the parts corresponding to the reference numerals are as follows:
1-data processing device base, 2-data processing device, 3-antenna, 4-cable, 5-rail, 6-data acquisition device, 21-protective case upper cover, 22-protective case base, 23-sensor connector, 24-antenna connector, 25-metal support, 26-signal processing circuit board, 27-wireless transmission module, 28-battery, 611-track main clamp, 612-track auxiliary clamp, 613-clamp bolt, 62-mounting base, 63-protective shell, 64-ultrasonic position sensor cover, 65-ultrasonic position sensor, 66-track acceleration sensor, 67-rail temperature sensor, 68-PCB insulation board, 69-rubber insulation pad.
Detailed Description
To make the objectives, technical solutions and advantages of the present application more clear, the present invention will be further described with reference to the accompanying drawings and examples, and embodiments of the present invention include, but are not limited to, the following examples. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
Examples
As shown in fig. 1 to 9, in the present embodiment, a rail crack monitoring system is provided, and it should be noted that, in the present embodiment, the terms of "first", "second", and the like are only used for distinguishing similar components, and cannot be understood as a specific limitation to the protection range. In the present embodiment, the terms of orientation such as "bottom", "top", "peripheral edge", "center", and the like are explained based on the drawings.
As shown in fig. 1, the steel rail crack monitoring system comprises a data processing device 2 fixed beside a track, an antenna 3 electrically connected with the data processing device 2, a cable 4 electrically connected with the data processing device 2 at one end, and a plurality of data acquisition devices 6 electrically connected with the other end of the cable 4, hung and buckled on a railway track and used for acquiring health information of the railway track;
as shown in fig. 4 to 8, any of the data acquisition devices 6 includes a clamping fixing component clamped below the railway track, a mounting base 62 arranged on the clamping fixing component, a protective housing 63 fastened on the mounting base 62, a PCB insulation board 68 fixed on the mounting base 62 and disposed in the protective housing 63, a track acceleration sensor 66 fixed on the PCB insulation board 68, disposed in the protective housing 63 and connected to the cable 4, an ultrasonic position sensor 65 and a rail temperature sensor 67 fixed on the top of the protective housing 63, disposed in the protective housing 63 and connected to the cable 4;
as shown in fig. 2 to 3, the data processing device 2 includes a protection chassis base 22, a protection chassis upper cover 21 fastened to the protection chassis base 22, a sensor connector 23 and an antenna connector 24 both disposed on the protection chassis base 22 and connected to the cable 4, and a signal processing circuit board 26, a wireless transmission module 27 and a battery 28 both disposed on the protection chassis base 22 and disposed in the protection chassis upper cover 21.
As shown in fig. 4 to 5, the clamping and fixing assembly includes a rail main clip 611 and a rail sub clip 612 which are oppositely buckled on the railway rail, and a clip bolt 613 which is connected between the rail main clip 611 and the rail sub clip 612 and is used for buckling and clasping the rail main clip 611 and the rail sub clip 612 on the railway rail.
An ultrasonic position sensor cover 64 is provided on top of the ultrasonic position sensor 65 as shown in fig. 6.
As shown in fig. 7, a rubber insulating pad 69 is disposed between the rail main clip 611 and the mounting base 62.
As shown in fig. 1 to 3, the device further includes a data processing device base 1 fixed beside the track for installing the data processing device 2 and the antenna 3, and a metal bracket 25 disposed in the protective casing base 22 for installing a signal processing circuit board 26 and a battery 28.
Specifically, the protective case upper cover 21 and the protective case base 22 are made of ABS insulating plastic; the mounting base 62 is made of the same material as the railway track; the battery 28 is a high and low temperature resistant lithium battery.
As shown in fig. 4 to 8, a rail health diagnosis sensor for collecting health information of a railway rail comprises a clamping fixing component clamped below the railway rail, an installation base 62 arranged on the clamping fixing component, a protection shell 63 fastened on the installation base 62, a PCB insulation board 68 fixed on the installation base 62 and arranged in the protection shell 63, a rail acceleration sensor 66 fixed on the PCB insulation board 68 and arranged in the protection shell 63 and connected with a cable 4, an ultrasonic position sensor 65 fixed on the top of the protection shell 63 and arranged in the protection shell 63 and connected with the cable 4, and a rail temperature sensor 67.
As shown in fig. 4 to 5, the clamping and fixing assembly includes a rail main clip 611 and a rail sub clip 612 which are oppositely buckled on the railway rail, and a clip bolt 613 which is connected between the rail main clip 611 and the rail sub clip 612 and is used for buckling and clasping the rail main clip 611 and the rail sub clip 612 on the railway rail.
As shown in fig. 6, an ultrasonic position sensor cover 64 is provided on top of the ultrasonic position sensor 65.
As shown in fig. 7, a rubber insulating pad 69 is disposed between the rail main clip 611 and the mounting base 62.
During operation, the installation is carried out according to the following procedures:
the first step is as follows: fixing the data acquisition device 6, sheathing a rail main clip 611 on the inner side of the bottom of a rail 5, sheathing a rail auxiliary clip 612 on the outer side of the bottom of the rail corresponding to the rail main clip 611, using two clip screws 613 to bolt the rail main clip 611 and the rail auxiliary clip 612 and then screwing and fixing the rail main clip and the rail auxiliary clip, fixing a rubber insulating pad 69, a PCB insulating plate 68 and a mounting base 62 on the top of the rail main clip 611 in sequence through bolts, fixing a rail acceleration sensor 66 on the mounting base 62 through the bolts at the moment, taking out a protective shell 63, installing a rail temperature sensor 67 and an ultrasonic position sensor 65 on the top of the protective shell 63, adding corresponding rubber gaskets to ensure sealing during installation and fixing, installing an ultrasonic position sensor cover 64 on the top of the ultrasonic position sensor 65, installing a sensor connector 23 on the side surface of the protective shell 63, and placing corresponding rubber sealing rings during installation, sealing is achieved, the ultrasonic position sensor 65, the track acceleration sensor 66, the track temperature sensor 67 and the sensor connector 23 are electrically connected, finally the installed protective shell 63 is fixed above the installation base 62 through bolts, so that the installation of one data acquisition device 6 is completed, and in the same way, one data acquisition device 6 is installed on the same rail 5 after a certain distance is formed;
the second step is that: fixing the data processing device 2, fixing four corners of a protective case base 22 on the data processing device base 1 through bolts, installing a plurality of sensor connectors 23 and antenna connectors 24 at the bottom of the protective case base 22, installing a metal support 25 in the protective case base 22, installing a signal processing circuit board 26 for installing a wireless transmission module 27 in the metal support 25, installing and fixing batteries 28 at two sides of the outside of the metal support 25, electrically connecting the batteries 28, the wireless transmission module 27, the signal processing circuit board 26, the sensor connectors 23 and the antenna connectors 24, and completing the installation of the data processing device 1;
the third step: electrically connecting the antenna 3 with an antenna connector 24 of the data processing device 2 through a cable 4, and vertically fixing the antenna on the top of the data processing device base 1; the sensor connectors 23 on the data processing device 2 are respectively and electrically connected with the sensor connectors 23 on the two data acquisition devices 6 through cables 4, so that the connection between the data processing device 2 and the two data acquisition devices 6 is completed, and the whole device is connected;
in this embodiment, the signal processing circuit board 26, the wireless transmission module 27, the battery 28, the ultrasonic position sensor 65, the track acceleration sensor 66, the track temperature sensor 67, and the like are purchased, and the software program used in the present embodiment is a combination of conventional program segments, which is not repeated herein, and the detection process during operation is briefly described below:
the first step is as follows: and judging whether the train runs or not, and ensuring that the acquired information is in the running process of the train. In real-time detection, the system is always in low-power-consumption operation, only a few devices (such as the track acceleration sensor 66, the ultrasonic position sensor 65, the track temperature sensor 67, the signal processing circuit board 26 and the like) continuously work, the power consumption of the system is reduced, when the acceleration peak value is detected to be larger than 0.2g (g is gravity acceleration), the system is judged to have a coming vehicle, the overall working state of the system is started, and the power consumption is instantly maximized.
The second step is that: after the system is started, the acceleration signals acquired by the track acceleration sensor 66 are subjected to filtering acquisition, FFT analysis, amplitude analysis to judge abnormal data and eliminate abnormal data.
And (3) checking the analyzed data by using a Grubbs test method, and when the distance between the sample and the average value is more than 3 delta (3 times of standard deviation), judging the sample as abnormal data and rejecting the abnormal data.
The third step: performing filtering collection, FFT analysis and amplitude analysis on an acceleration signal collected by a track acceleration sensor 66, removing abnormal data from an amplitude analysis result, extracting an acceleration characteristic value, and performing filtering collection on an ultrasonic position signal collected by an ultrasonic position sensor 65, and extracting the acceleration characteristic value, wherein the characteristic value comprises a peak value and main frequency information of the acceleration signal, the number of events of the ultrasonic position signal, the number of rings, the duration of the events and the emissivity of the ultrasonic position signal;
the fourth step: if the peak value, the main frequency information, the event number, the ringing number, the event duration and the ultrasonic position emissivity meet preset conditions:
the peak value range of the acceleration signal is more than 0.2, the dominant frequency range is 200 Hz-10000 Hz, the number of ultrasonic position events is more than 2, the ringing number is more than 50, the event duration is more than 10ms, and the ultrasonic position emissivity is more than 5000 (the determination method of the event duration and the number of the events is that after the envelope detection is carried out on the acoustic emission signal, the waveform exceeds the preset threshold voltage (the range is 10mV-10V) and maintains the preset time, a rectangular pulse is formed and is called an event, the duration time of one event is the event duration, the number of events generated in the running process of one train is called the event number, and one event can generate one ringing number);
it is determined that a crack is generated, the characteristic values are stored and transmitted for subsequent analysis and study, and the raw data generated by the track acceleration sensor 66 and the ultrasonic position sensor 65 in the current train traveling is deleted. The above data are not intended as specific limitations on the preset conditions of the present invention, but are rather the best values or value ranges obtained by a number of tests in practice.
The above-mentioned embodiments are merely preferred embodiments of the present invention, and are not limitations on the protection scope of the present invention, but all the changes made by adopting the design principle of the present invention and performing non-creative work on this basis shall fall within the protection scope of the present invention.
Claims (10)
1. A steel rail crack monitoring system is characterized by comprising a data processing device (2) fixed beside a track, an antenna (3) electrically connected with the data processing device (2), a cable (4) with one end electrically connected with the data processing device (2), and a plurality of data acquisition devices (6) which are electrically connected with the other end of the cable (4), hung and buckled on a railway track and used for acquiring health information of the railway track;
any data acquisition device (6) comprises a clamping fixing component clamped below a railway track, a mounting base (62) arranged on the clamping fixing component, a protective shell (63) buckled on the mounting base (62), a PCB insulating plate (68) fixed on the mounting base (62) and arranged in the protective shell (63), a track acceleration sensor (66) fixed on the PCB insulating plate (68), arranged in the protective shell (63) and connected with a cable (4), an ultrasonic position sensor (65) and a rail temperature sensor (67) fixed at the top of the protective shell (63), arranged in the protective shell (63) and connected with the cable (4);
the data processing device (2) comprises a protective case base (22), a protective case upper cover (21) buckled on the protective case base (22), a sensor connector (23) and an antenna connector (24) which are arranged on the protective case base (22) and connected with a cable (4), and a signal processing circuit board (26), a wireless transmission module (27) and a battery (28) which are arranged on the protective case base (22) and arranged in the protective case upper cover (21).
2. A rail crack monitoring system as claimed in claim 1, wherein the clamp fixing assembly comprises a rail main clamp (611) and a rail sub clamp (612) which are openly fastened to each other on the railway rail, and a clamp bolt (613) connected between the rail main clamp (611) and the rail sub clamp (612) for fastening the rail main clamp (611) and the rail sub clamp (612) on the railway rail.
3. A rail crack monitoring system according to claim 1, wherein an ultrasonic position sensor cover (64) is provided on top of the ultrasonic position sensor (65).
4. A rail crack monitoring system as claimed in claim 2 wherein a rubber insulating pad (69) is provided between the rail main clip (611) and the mounting base (62).
5. A rail crack monitoring system as claimed in claim 1, further comprising a data processing device base (1) fixed beside the track for mounting the data processing device (2) and the antenna (3), and a metal bracket (25) disposed in the protective housing base (22) for mounting the signal processing circuit board (26) and the battery (28).
6. A rail crack monitoring system according to claim 1, wherein the protective casing top cover (21) and the protective casing base (22) are made of ABS insulating plastic; the mounting base (62) is in accordance with a railway track manufacturing material; the battery (28) is a high and low temperature resistant lithium battery.
7. The utility model provides a track health diagnosis sensor, a health information for gathering railway rails, a serial communication port, including the fixed subassembly of centre gripping of clip under railway rails, install base (62) on the fixed subassembly of centre gripping, lock protective housing (63) on installation base (62), fix on installation base (62), and arrange PCB insulation board (68) in protective housing (63) in, fix on PCB insulation board (68), arrange in protective housing (63), and track acceleration sensor (66) of being connected with cable (4), fix at protective housing (63) top, arrange in protective housing (63), and ultrasonic wave position sensor (65) and rail temperature sensor (67) of being connected with cable (4).
8. The rail health diagnostic sensor of claim 7, wherein the clip fixing assembly comprises a rail primary clip (611) and a rail secondary clip (612) which are openly and oppositely fastened to the rail of the railway, and a clip bolt (613) connected between the rail primary clip (611) and the rail secondary clip (612) for fastening the rail primary clip (611) and the rail secondary clip (612) to the rail of the railway.
9. The rail health diagnostic sensor according to claim 7, wherein an ultrasonic position sensor cover (64) is provided on top of the ultrasonic position sensor (65).
10. The rail health diagnostic sensor of claim 8, wherein a rubber insulating pad (69) is disposed between the rail primary clip (611) and the mounting base (62).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202020464754.3U CN212622416U (en) | 2020-04-02 | 2020-04-02 | Steel rail crack monitoring system and sensor |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202020464754.3U CN212622416U (en) | 2020-04-02 | 2020-04-02 | Steel rail crack monitoring system and sensor |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN212622416U true CN212622416U (en) | 2021-02-26 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202020464754.3U Active CN212622416U (en) | 2020-04-02 | 2020-04-02 | Steel rail crack monitoring system and sensor |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN212622416U (en) |
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2020
- 2020-04-02 CN CN202020464754.3U patent/CN212622416U/en active Active
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