CN214895027U - Quality inspection device for steel rail welding joint - Google Patents
Quality inspection device for steel rail welding joint Download PDFInfo
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- CN214895027U CN214895027U CN202022058998.4U CN202022058998U CN214895027U CN 214895027 U CN214895027 U CN 214895027U CN 202022058998 U CN202022058998 U CN 202022058998U CN 214895027 U CN214895027 U CN 214895027U
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 105
- 239000010959 steel Substances 0.000 title claims abstract description 105
- 238000007689 inspection Methods 0.000 title claims abstract description 56
- 238000003466 welding Methods 0.000 title claims description 43
- 238000001514 detection method Methods 0.000 claims abstract description 194
- 230000007246 mechanism Effects 0.000 claims abstract description 51
- 238000005259 measurement Methods 0.000 claims abstract description 8
- 239000000523 sample Substances 0.000 claims description 47
- 230000008878 coupling Effects 0.000 claims description 22
- 238000010168 coupling process Methods 0.000 claims description 22
- 238000005859 coupling reaction Methods 0.000 claims description 22
- 239000007788 liquid Substances 0.000 claims description 15
- 238000003825 pressing Methods 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 8
- 238000000034 method Methods 0.000 description 13
- 238000012372 quality testing Methods 0.000 description 12
- 230000008569 process Effects 0.000 description 10
- 238000012360 testing method Methods 0.000 description 7
- 239000012530 fluid Substances 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 238000005452 bending Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 230000033764 rhythmic process Effects 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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Abstract
本实用新型提供一种钢轨焊接接头质检装置，包括：移动轨道车；探伤工作台，所述探伤工作台设置在移动轨道车上并设置有两个探伤单元；外观检测平台，所述外观检测平台设置在移动轨道车上且沿着钢轨的长度方向延伸，并且位于探伤工作台的上方且设置有平直度检测单元和外观检测单元；钢轨定位机构，所述钢轨定位机构设置在移动轨道车的机架上以定位并压紧钢轨；和控制单元，所述控制单元分别与两个探伤单元、平直度检测单元、外观检测单元和钢轨定位机构相连接，并且控制单元包括电控系统和上位机。根据本实用新型的钢轨焊接接头质检装置的检测精度高、可靠性强、可实现质量追溯，从而可以有效提高工厂生产效率，降低人为因素导致的测量结果不准确。
The utility model provides a quality inspection device for steel rail welded joints, comprising: a mobile rail car; a flaw detection workbench, wherein the flaw detection workbench is arranged on the mobile rail car and is provided with two flaw detection units; The platform is arranged on the mobile rail car and extends along the length direction of the rail, and is located above the flaw detection workbench and is provided with a flatness detection unit and an appearance detection unit; a rail positioning mechanism, the rail positioning mechanism is arranged on the mobile rail car. on the frame to locate and press the rail; and a control unit, the control unit is respectively connected with two flaw detection units, a flatness detection unit, an appearance detection unit and a rail positioning mechanism, and the control unit includes an electric control system and host computer. The rail welded joint quality inspection device according to the utility model has high detection accuracy, strong reliability, and can realize quality traceability, thereby effectively improving factory production efficiency and reducing inaccurate measurement results caused by human factors.
Description
Technical Field
The utility model relates to a quality testing field, more specifically relates to a rail welded joint quality testing device.
Background
When long railway steel rails are produced on a rail welding base, the final process of the production line is to carry out quality detection on steel rail welding joints, and the main contents are as follows: flatness detection, surface quality inspection and flaw detection.
The existing quality detection method for the steel rail welding joint comprises the following steps: (1) the straightness detects, and the straightness that establishes in the workshop detects the station, and operating personnel will hand the straightness detector and stabilize at the rail top surface, and another person operates handheld terminal and opens and stop the straightness detector. During inspection, an operator is required to manually change the orientation of the flatness detector; (2) flaw detection, namely performing ultrasonic flaw detection on a welded joint of a steel rail by using a single probe to scan the steel rail or matching with a small flaw detection frame in cooperation of a plurality of persons at a flaw detection station arranged in a workshop; (3) and (4) checking the surface quality, and observing the full section of the steel rail welding joint by an operator with naked eyes.
The existing method for detecting the quality of the steel rail welding joint has the following defects: (1) the occupied stations are more, and at least two stations with the distance of about 100 meters are needed; (2) the quality detection result cannot be automatically or efficiently recorded, and the quality tracing of the service steel rail in the future is influenced; (3) the measurement result is greatly influenced by human factors, and the repeatability is high.
SUMMERY OF THE UTILITY MODEL
In order to solve the problem, the utility model provides a rail welded joint quality testing device, include:
moving the rail car;
a flaw detection table provided on the moving rail car and provided with two flaw detection units disposed on both sides of the rail opposite to each other in a lateral direction of the rail and movable relative to each other in the lateral direction;
the appearance detection platform is arranged on the movable rail car and extends along the length direction of the steel rail, the appearance detection platform is positioned above the flaw detection workbench, and a flatness detection unit and an appearance detection unit are respectively arranged at two ends of the appearance detection platform in the length direction;
the steel rail positioning mechanism is arranged on a rack of the movable rail car so as to position and press the steel rail; and
and the control unit is respectively connected with the two flaw detection units, the flatness detection unit, the appearance detection unit and the steel rail positioning mechanism and comprises an electric control system and an upper computer.
According to one embodiment, the quality inspection device for the steel rail welding joint further comprises a longitudinal moving mechanism which is arranged on the flaw detection workbench and can move along the length direction, and the two flaw detection units are arranged on the longitudinal moving mechanism.
Further, according to an exemplary embodiment, each of the two inspection units may include: a flaw detection support which is provided on the longitudinal moving mechanism and is movable in a lateral direction; and the probe scanning system is arranged on the flaw detection bracket, comprises a plurality of scanning probes for scanning flaw detection of the steel rail welding joint from different angles and transmits the obtained flaw detection scanning data to the control unit.
Preferably, the steel rail welding joint quality inspection device further comprises a coupling liquid circulating device which is arranged on the upper side of the longitudinal moving mechanism and is connected to the probe scanning system, so that the coupling liquid which is coupled with the steel rail by the auxiliary probe scanning system is supplied to the steel rail during flaw detection, and the coupling liquid is recovered.
Alternatively, the plurality of scanning probes may comprise a plurality of top rail probes, a plurality of web probes and a plurality of bottom rail probes located at the top, web and bottom of the rail, respectively, during flaw detection.
According to one example, the flaw detection carriage may be connected with a servo motor to move in the lateral direction on the longitudinal movement mechanism under the driving of the servo motor, and the servo motor is connected with the electronic control system.
Alternatively, the longitudinal moving mechanism can be connected with a variable frequency motor to move along the length direction under the driving of the variable frequency motor, and the variable frequency motor is connected with the electronic control system.
According to another embodiment, the rail positioning mechanism may comprise: the rollers are arranged on a frame of the mobile rail car side by side to form a roller plane for supporting the steel rail; the pressing wheels are arranged above the rollers at intervals so as to press the steel rails on the roller planes; and the hydraulic system is respectively connected with each of the plurality of press wheels and the upper computer so as to drive the plurality of press wheels to move under the control of the upper computer.
Alternatively, the rail positioning mechanism may comprise eight rollers.
Alternatively, the rail positioning mechanism may include two pinch rollers.
According to still another embodiment, the flatness detecting unit may include: the straightness moving measuring frame is arranged on the appearance detection platform and can move along the length direction; the scanning frame is connected with a lead screw module arranged on the straightness movement measuring frame so as to move under the driving of the lead screw module; and the straightness detection device is arranged on the scanning frame to detect the straightness of the steel rail.
Preferably, the scanning gantry may have a recess for receiving a rail.
Further, the straightness detection device may include a plurality of non-contact eddy current distance measuring sensors, which are respectively connected to the upper computer.
Optionally, the straightness movement measuring rack may be connected to a servo motor disposed on the appearance detecting platform through a gear belt to move along the length direction under the driving of the servo motor, and the servo motor is connected to the electric control system.
According to another embodiment, the appearance detection unit may include: the camera shooting mobile measuring frame is arranged on the appearance detection platform and can move along the length direction; a camera bracket connected to the camera moving measuring stand so as to be movable in a length direction together with the camera moving measuring stand; and the plurality of camera devices are respectively arranged at different positions of the camera bracket so as to shoot the steel rail welding joint by 360 degrees, and are respectively connected with the upper computer so as to transmit the shot pictures to the upper computer.
Alternatively, the camera shooting moving measurement frame can be connected with a servo motor arranged on the appearance detection platform through a gear belt so as to move along the length direction under the driving of the servo motor, and the servo motor is connected with the electric control system.
According to one embodiment, the upper computer may include: the control device is respectively connected with the two flaw detection units, the steel rail positioning mechanism, the flatness detection unit and the appearance detection unit; and the display device is connected with the control device to display the detection data of the two flaw detection units, the steel rail positioning mechanism, the straightness detection unit and the appearance detection unit and provide control options for an operator.
According to the utility model discloses a rail welded joint quality testing device's detection precision is high, the good reliability, can realize that the quality traces back, is applicable to the production line operation of fast rhythm mass to can effectively improve mill production efficiency, reduce the personnel selection cost, reduce the measuring result that the human factor leads to inaccurate.
Drawings
The above and other aspects and features of the present invention will become apparent from the following description of the embodiments, taken in conjunction with the accompanying drawings, in which:
fig. 1 is a front view of a steel rail welded joint quality inspection device according to an embodiment of the present invention;
FIG. 2 is a schematic view showing the construction of two flaw detection units of the rail weld joint quality inspection apparatus shown in FIG. 1;
FIG. 3 is a top view of the rail weld joint quality inspection apparatus shown in FIG. 1;
FIG. 4 is a side view of the rail weld joint quality inspection apparatus shown in FIG. 1; and
fig. 5 is a schematic structural view of a flatness detecting unit and an appearance detecting unit of the rail weld joint quality inspection apparatus shown in fig. 1.
Detailed Description
Illustrative, non-limiting embodiments of the present invention are described in detail below with reference to the accompanying drawings, which further illustrate the rail weld joint quality inspection device according to the present invention.
According to the utility model discloses a rail welded joint quality testing device is including removing railcar 1, the workstation 2 of detecting a flaw, outward appearance testing platform 3, rail positioning mechanism 4 and the control unit, and wherein the workstation 2 of detecting a flaw and outward appearance testing platform 3 all set up on removing railcar 1, and rail positioning mechanism 4 sets up in the frame of removing railcar 1, as shown in fig. 1. The flaw detection workbench 2 is provided with two flaw detection units, the appearance detection platform 3 is provided with a flatness detection unit and an appearance detection unit, and the control unit is respectively connected with the two flaw detection units, the flatness detection unit, the appearance detection unit and the steel rail positioning mechanism. The control unit further comprises an electric control system 5 and an upper computer 6, wherein the electric control system 5 is used for controlling the electric equipment of the quality inspection device, and the upper computer 6 is used for sending control commands to the two flaw detection units, the steel rail positioning mechanism, the flatness detection unit and the appearance detection unit and receiving corresponding detection data from the two flaw detection units, the steel rail positioning mechanism, the flatness detection unit and the appearance detection unit.
Specifically, the mobile rail car 1 is a carrying tool of the quality inspection device for transporting the quality inspection device to an inspection site. The movable rail car 1 is of a two-layer structure, the first layer is a flaw detection workbench 2, and the second layer is an appearance detection platform 3. The inspection work table 2 is provided with two inspection units (shown in fig. 2) which are disposed on both sides of the steel rail opposite to each other in the lateral direction of the steel rail and are movable relative to each other in the lateral direction so as to inspect the steel rail. The appearance inspection platform 3 extends on the moving railcar 1 along the longitudinal direction of the rail perpendicular to the transverse direction. Appearance testing platform 3 is located the top of workstation 2 of detecting a flaw, and length direction's both ends are provided with straightness detecting element 7 and outward appearance detecting element 8 respectively to detect the straightness and the outward appearance of rail 9 respectively. The steel rail positioning mechanism 4 is arranged on a rack of the movable rail car 1 to position, compress and straighten the steel rail, so that the steel rail 9 is positioned on the central lines of the two flaw detection units, and the detection error in the flatness detection process is further reduced.
According to the quality inspection device for the steel rail welding joint, all items of quality inspection of the steel rail welding joint can be finished at one station, so that the occupied area of inspection equipment is reduced; in the detection process, a steel rail positioning mechanism is used for straightening the steel rail, so that the steel rail is positioned on the central line of the two flaw detection units, and the accuracy of flatness detection is improved; the automation degree is high, the manual investment can be greatly reduced, and the problem of inaccurate measurement result caused by human factors is solved; the steel rail welded joint quality inspection device has the function of one-key operation, automatically completes the operations of detecting the straightness of the welded joint, carrying out full-section ultrasonic flaw detection on the joint, recording the surface quality of the joint and the like, and can adapt to the production takt of high frequency and large workload of a welded rail base.
According to the utility model discloses an embodiment, rail welded joint quality testing device still includes longitudinal movement mechanism 10, and wherein two flaw detection units set up on longitudinal movement mechanism 10. The longitudinal moving mechanism 10 is arranged on the flaw detection workbench 2 and can move along the length direction of the steel rail, so that the flaw detection unit is driven to move along the length direction of the steel rail to complete flaw detection scanning of the welded joint. According to a preferred embodiment, the longitudinal moving mechanism 10 can be connected to, for example, a variable frequency motor to move along the length of the rail under the drive of the variable frequency motor, and the variable frequency motor is connected to the electronic control system 5.
Further, according to an exemplary embodiment of the present invention, each of the two inspection units comprises an inspection rack 11 and a probe scanning system 12, as shown in fig. 2 and 3. The flaw detection carriage 11 is provided on the longitudinal movement mechanism 10 and is movable in the lateral direction of the rail. Preferably, the flaw detection brackets 11 can be connected with a servo motor, and the servo motor is connected with the electronic control system 5 to move on the longitudinal moving mechanism 10 along the transverse direction of the steel rail under the driving of the servo motor, so that the two flaw detection brackets 11 synchronously move in opposite directions and are kept stable, and the flaw detection scanning operation on the welding joint is completed. The probe scanning system 12 is provided on the flaw detection support 11, and includes a plurality of scanning probes for scanning flaw detection of a welded joint of a steel rail from different angles and transmits obtained flaw detection scanning data to the control unit. Preferably, the plurality of scanning probes may comprise a plurality of rail-top probes, a plurality of rail-web probes and a plurality of rail-bottom probes respectively located at the rail top, rail web and rail bottom of the steel rail during flaw detection. In the quality detection process of the steel rail welding joint, a plurality of rail top probes, a plurality of rail waist probes and a plurality of rail bottom probes are automatically and respectively arranged at the rail top, the rail waist and the rail bottom of the steel rail 9. Meanwhile, the upper computer 6 can correspondingly store the probe position and the probe flaw detection scanning graph, and further realizes tracing of flaw detection data.
According to another exemplary embodiment of the present invention, the rail welding joint quality inspection apparatus may further include a coupling liquid circulating device 13 disposed at an upper side of the longitudinal moving mechanism 10 and connected to the probe scanning system 12, as shown in fig. 2. In order to couple the probe with the steel rail well, a coupling liquid needs to be sprayed on the steel rail to assist the coupling. During the flaw detection scanning of the welding joint by the probe scanning system 12, the coupling liquid circulating device 13 sprays the coupling liquid to the steel rail and recovers the redundant coupling liquid for recycling. For example, the coupling fluid may be water, oil, and other coupling fluids commonly used in the art, and is not particularly limited herein.
According to one embodiment, the rail positioning mechanism 4 of the present invention may include a plurality of rollers 41, a plurality of pinch rollers 42, and a hydraulic system 43, as shown in fig. 1 and 4. A plurality of rollers 41 are arranged side by side on the frame of the mobile trolley 1 to form a roller plane for supporting the rails. A plurality of press wheels 42 are arranged spaced apart from each other above the rollers 41 to press the rails 9 on the roller plane. Hydraulic system 43 is connected to each of the plurality of pressure wheels 42 and to upper machine 6, respectively, to drive the movement of the plurality of pressure wheels 42 under the control of upper machine 6. Like this, when using straightness detecting element to detect the straightness of rail 9, convey rail 9 to the roller plane that a plurality of rollers 41 formed on, then use a plurality of pinch rollers 42 to compress tightly rail 9 and straighten to guarantee the straightness testing result accuracy. Preferably, the rail positioning mechanism may comprise eight rollers. In addition, the rail positioning mechanism may preferably include two pinch rollers. Those skilled in the art will understand that the number of rollers and press wheels is not limited thereto, and can be arbitrarily selected according to actual needs.
According to another exemplary embodiment, the straightness detecting unit may further include a straightness moving measuring stand 14, a scanning stand 15, and a straightness detecting device 16, as shown in fig. 5. The flatness movement measuring stand 14 is disposed on the appearance detecting platform 3 and can move along the length direction of the steel rail, and can be used as a supporting device of the flatness detecting unit. The scanning frame 15 is connected with a lead screw module 17 provided on the straightness-moving measuring frame 14 to move up and down by the drive of the lead screw module to adjust the height. The straightness detecting means 16 is mounted on the scanning frame 15 to detect the straightness of the rail. When the flatness detecting unit detects the flatness of the welded joint of the rail, the height of the scanning frame 15 is first adjusted so that the flatness detecting unit 16 is close to the rail 9. Then, the flatness detecting unit 16 is turned on to accommodate the rail 9 in a space formed by the detection surfaces of the flatness detecting unit 16, and the flatness moving measuring stand 14 is turned on to move the flatness detecting unit 16 along the length direction of the rail. The straightness detecting device 16 detects the straightness of the steel rail and transmits the obtained straightness data to the upper computer 6, and resets after the detection of a predetermined length is completed. Preferably, the scanning carriage 15 may have a recess for receiving the rail so that during inspection the rail passes through the recess and is retained therein with the flatness detection device 16 located below the lower surface of the rail for inspection.
Further, the flatness detecting device 16 may include a plurality of non-contact eddy current distance measuring sensors respectively connected to the upper computer 6. The non-contact eddy current distance measuring sensor detects the straightness of the welding joint, and the problem that the laser distance measuring sensor causes distortion of a measuring result due to reflection of light on a detection surface can be avoided. Meanwhile, a plurality of non-contact eddy current distance measuring sensors are respectively connected with the upper computer 6 to transmit the detection data to the upper computer. Preferably, the number of the plurality of non-contact eddy current distance measuring sensors is three, but is not limited to three. Therefore, in the detection process of detecting the straightness of the steel rail welding joint by using the steel rail welding joint quality detection device, the quality detection device does not need to be moved, namely, a fixed automatic detection device is adopted, so that the production takt of welding rail base with high frequency and large workload can be met.
Preferably, the straightness-moving measuring stand 14 is connected to a servo motor 18 provided on the appearance inspection platform 3 through a gear belt to move along the length direction of the steel rail under the driving of the servo motor, and the servo motor 18 is connected to the electronic control system 5.
According to another embodiment of the present invention, the appearance inspection unit of the quality inspection device for rail welded joints of the present invention may include a camera mobile measuring stand 19, a camera stand 20 and a plurality of cameras 21, as shown in fig. 5. The camera moving measurement frame 19 is arranged on the appearance detection platform 3 and can move along the length direction of the steel rail, so as to drive the camera bracket 20 and the camera device 21 to move along the length direction. The photographing bracket 20 is connected to the photographing movement measuring stand 19 to support a plurality of photographing devices, and can be moved along the length direction of the rail together with the photographing movement measuring stand 19, and also can be adjusted by adjusting the height and angle of the photographing device 20. The plurality of cameras 21 are respectively installed at different positions of the camera bracket 20 to shoot the steel rail welding joint for 360 degrees, and complete acquisition of appearance information of the welding joint is completed. In addition, a plurality of cameras 21 are respectively connected with the upper computer 6 to transmit the photographed pictures to the upper computer. Preferably, the camera moving measuring frame 19 may be connected to a servo motor 22 provided on the appearance inspection platform 3 through a gear belt to move along the length direction of the steel rail under the driving of the servo motor, and the servo motor is connected to the electronic control system 5.
According to another exemplary embodiment, the upper computer 6 may include a control device and a display device (not shown in the drawings). The control device is respectively connected with the two flaw detection units, the steel rail positioning mechanism, the flatness detection unit and the appearance detection unit so as to send control instructions to the two flaw detection units, the steel rail positioning mechanism, the flatness detection unit and the appearance detection unit and obtain corresponding detection data from the control instructions, so that the quality detection process of the welded joint is controlled. The display device is connected with the control device, and the high-resolution color touch screen is adopted, so that the actions of all parts of the whole machine can be visually controlled, the detection data of the two flaw detection units, the steel rail positioning mechanism, the flatness detection unit and the appearance detection unit are displayed, control options are provided for an operator, the quality detection device is conveniently and automatically controlled, and the functions of warning, fault elimination, formula parameter setting and the like are arranged.
The quality inspection process of the rail welded joint quality inspection apparatus according to the present invention will be described with reference to fig. 1 to 5.
When the quality inspection device for the steel rail welded joint detects the quality of the steel rail welded joint, the movable rail car 1 moves along the length direction of the steel rail 9, and the position of a welding seam of the steel rail 9 is searched for quality inspection. Therefore, each item for detecting the quality of the steel rail welding joint can be finished at one station in the steel rail welding assembly line operation, namely, the appearance detection and the flaw detection scanning of the welding joint are finished at the same station. The surface quality of the steel rail welding joint is shot through the appearance detection unit arranged on the appearance detection platform 3, the shot pictures are transmitted to the upper computer 6, and the pictures can be classified and stored by software in the upper computer 6 according to preset rules. Like this, acquire welded joint's surface quality and will shoot the picture automatic conveying to host computer 6 through the shooting mode, can reduce artifical range estimation in order to judge the great problem of error that surface quality exists to can record welded joint's surface quality condition, the playback in the later stage of being convenient for is traceed back. The steel rail is straightened by using the steel rail positioning mechanism before the steel rail 9 is subjected to flatness detection, so that the steel rail is ensured to be positioned on the central lines of the two flaw detection units so as to improve the accuracy of flatness detection. The straightness detection unit performs straightness detection on the welded joint and transmits the straightness data to the upper computer 6. The utility model discloses a straightness detecting element can accomplish rail welded joint's straightness automatically and detect, consequently has higher detection speed and detection accuracy. The two flaw detection units are coupled with the steel rail 9 from two sides of the welded joint, flaw detection scanning is carried out on the welded joint through the two flaw detection units, and detected flaw detection scanning data are transmitted to the upper computer 6. Flaw detection scanning data of the flaw detection unit is timely transmitted to the upper computer 6, so that the flaw detection data of the steel rail welding joint can be stored for later tracing. The upper computer 6 uses a program stored inside the upper computer to respectively process the picture, the straightness data and the detected flaw detection scanning data so as to output corresponding detection results. It should be noted that, according to the present invention, the quality testing steps in the quality testing process are not limited to the above sequence, as can be understood by those skilled in the art, wherein the sequence of the appearance testing, the straightness testing and the flaw detection scanning can be adjusted according to specific working conditions.
Further, the step of flaw detection scanning the welded joint by the two flaw detection units may include the following steps. Automatic flaw detection is started, and the flaw detection brackets 11 of each of the two flaw detection units are respectively close to the steel rail 9 from both sides thereof. Preferably, the flaw detection support 11 is driven by a servo motor to move along the length direction of the steel rail, and the servo motor is connected with the electronic control system 5 to control the movement direction and the movement speed of the flaw detection support 11 according to the instructions of the electronic control system 5. And spraying coupling liquid to the vicinity of the steel rail welding joint so as to enable the probe scanning system 12 to be in contact coupling with the steel rail, and starting the probe scanning system 12. And starting the flaw detection bracket 11 to drive the probe scanning system 12 to move reversely along the length direction of the steel rail 9 so as to perform flaw detection scanning on the steel rail welding joint and obtain flaw detection scanning data. The probe scanning system 12 synchronously transmits the flaw detection scanning data to the upper computer 6. After the flaw detection scanning is finished, the probe scanning system 12, the flaw detection support 11 and the longitudinal moving mechanism 10 are reset. Therefore, according to the utility model discloses, the scanning of detecting a flaw to welded joint is accomplished according to the procedure is automatic through electrical system 5 and host computer 6 completely, can satisfy the production beat requirement of welding rail base ground high frequency, big work load.
In the step of starting the probe scanning system 12, the probe scanning system 12 sequentially puts down a plurality of rail-top probes, a plurality of rail-web probes, and a plurality of rail-bottom probes according to a predetermined program. The flaw detection scanning data are transmitted to the upper computer 6 through the rail top probes, the rail waist probes and the rail bottom probes, and the flaw detection data are displayed in a graphical mode through software of the upper computer. Additionally, the step of contact coupling the probe scanning system 12 to the rail 9 includes the following steps. And opening the coupling liquid circulating device 13 to spray the coupling liquid to the steel rail welding joint and recover the coupling liquid, and coupling the probe scanning system 12 of each of the two flaw detection units with the steel rail welding joint.
Further, according to the utility model discloses a rail welded joint quality testing device uses the step of rail positioning mechanism alignment rail to include and drive a plurality of pinch rollers 42 through hydraulic system 43 and move down in order to straighten the roller surface that forms at a plurality of rollers 41 with rail 9. Thus, the problem of inaccurate detection results caused by bending of the steel rail 9 can be avoided.
In addition, the step of shooting the surface quality of the welded joint of the steel rail through the appearance detection unit and transmitting the shot picture to the upper computer comprises the following steps. The camera moving measuring frame 19 is driven by a servo motor to move along the length direction of the steel rail, so that the camera bracket 20 moves to the central position of the welded joint of the steel rail, and the camera device 21 arranged on the camera bracket 20 corresponds to the position of the welded joint. The welding joints are shot through the plurality of camera devices 21, so that multi-azimuth image acquisition on the surfaces of the welding joints is guaranteed, the shot pictures are transmitted to the upper computer 6 through the plurality of camera devices 21, and the shot pictures can be stored in the upper computer 6 according to preset rules in a classified mode through software. After the shooting of the plurality of cameras 21 is completed, the camera support 20 is driven to reset by the servo motor. According to the appearance acquisition method, according to the utility model discloses a rail welded joint quality testing device passes through camera device 21 automatic acquisition welded joint surface image to can avoid the subjective error that artifical observation caused, and can diversely take notes welded joint surface quality and save the picture of shooting, the inquiry in the later stage of being convenient for is traceed back.
Further, the step of performing flatness detection on the welded joint by the flatness detection unit and transmitting the flatness data to the upper computer includes the following steps. The height of the scanning frame 15 is adjusted so that the straightness detecting means 16 connected to the scanning frame 15 is close to the rail. In one embodiment, the straightness detection means 16 comprises a plurality of non-contact eddy current distance measuring sensors that detect the distance to the rail and transmit the distance data to the upper computer 6, which graphically displays the straightness curve of the joint by software computing the data. The flatness detecting unit 16 is opened to accommodate the rail 9 in a space formed by the detection surface of the flatness detecting unit 16. The flatness movement jig 14 is activated to move the flatness detecting unit 16 along the length of the rail. Preferably, the straightness-moving measuring stand 14 is driven to move along the length direction of the steel rail by a servo motor, and the servo motor is connected with the electronic control system 5 to control the straightness-moving measuring stand 14 to move according to the specified direction and speed according to the control command of the electronic control system 5. The straightness of the welded joint is detected using the straightness detection device 16 and the obtained straightness data is transmitted to the upper computer 6, and the upper computer 6 analyzes and stores the straightness data according to a predetermined program. The flatness detecting device 6 is reset after finishing the preset running length. Therefore, according to the utility model discloses a rail welded joint quality testing device need not to remove the quality testing device in the testing process of rail welded joint straightness, adopts fixed automatic checkout device promptly, can satisfy the production beat of welding rail base high frequency, big work load.
Although exemplary embodiments of the present invention have been described, it will be apparent to those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
Claims (15)
1. A rail welded joint quality inspection device, characterized in that rail welded joint quality inspection device includes:
moving the rail car;
a flaw detection table provided on the moving rail car and provided with two flaw detection units that are provided on both sides of a steel rail so as to be opposed to each other in a lateral direction of the steel rail and are movable relative to each other in the lateral direction;
the appearance detection platform is arranged on the movable rail car and extends along the length direction of the steel rail, the appearance detection platform is positioned above the flaw detection workbench, and a flatness detection unit and an appearance detection unit are respectively arranged at two ends of the appearance detection platform in the length direction;
the steel rail positioning mechanism is arranged on the rack of the movable rail car so as to position and press the steel rail; and
the control unit is respectively connected with the two flaw detection units, the straightness detection unit, the appearance detection unit and the steel rail positioning mechanism and comprises an electric control system and an upper computer;
the longitudinal moving mechanism is arranged on the flaw detection workbench and can move along the length direction, and the two flaw detection units are arranged on the longitudinal moving mechanism;
each of the two inspection units includes: a flaw detection support that is provided on the longitudinal movement mechanism and is movable in the lateral direction; and
the probe scanning system is arranged on the flaw detection bracket and comprises a plurality of scanning probes for carrying out flaw detection scanning on the steel rail welding joint from different angles, and the obtained flaw detection scanning data is transmitted to the control unit.
2. The rail welding joint quality inspection device according to claim 1, further comprising a coupling liquid circulating device disposed at an upper side of the longitudinal moving mechanism and connected to the probe scanning system to supply the coupling liquid assisting the probe scanning system in coupling with the rail to the rail during the flaw detection and to recover the coupling liquid.
3. The apparatus of claim 2, wherein the plurality of scanning probes comprises a plurality of top probes, a plurality of web probes, and a plurality of bottom probes at the top, web, and bottom of the rail, respectively, during flaw detection.
4. The apparatus of claim 3, wherein the flaw detection bracket is connected to a servo motor to be driven by the servo motor to move on the longitudinal moving mechanism in the transverse direction, and the servo motor is connected to the electronic control system.
5. A rail weld joint quality inspection apparatus according to claim 4, wherein the longitudinal movement mechanism is connected to a variable frequency motor for movement along the length direction under the drive of the variable frequency motor, and the variable frequency motor is connected to the electronic control system.
6. The rail weld joint quality inspection apparatus according to claim 1, wherein the rail positioning mechanism includes:
the rollers are arranged on the frame of the mobile rail car side by side to form a roller plane for supporting the steel rail;
the pressing wheels are arranged above the rollers at intervals so as to press the steel rails on the roller planes; and
and the hydraulic system is respectively connected with each of the plurality of press wheels and the upper computer so as to drive the plurality of press wheels to move under the control of the upper computer.
7. A rail weld joint quality inspection apparatus according to claim 6, wherein the rail positioning means includes eight rollers.
8. The rail weld joint quality inspection device of claim 7, wherein the rail positioning mechanism includes two pinch rollers.
9. A rail weld joint quality inspection apparatus according to claim 1, wherein the flatness detection unit includes:
a flatness movement measuring stand disposed on the appearance inspection platform and movable along the length direction;
the scanning frame is connected with a lead screw module arranged on the straightness movement measuring frame so as to move under the driving of the lead screw module; and
and the straightness detection device is arranged on the scanning frame to detect the straightness of the steel rail.
10. The rail weld joint quality inspection device of claim 9, wherein the scanning rack has a recess for receiving a rail.
11. The steel rail welding joint quality inspection device of claim 10, wherein the flatness detection device comprises a plurality of non-contact eddy current distance measuring sensors, and the plurality of non-contact eddy current distance measuring sensors are respectively connected with the upper computer.
12. The steel rail welding joint quality inspection device according to claim 11, wherein the straightness moving measurement stand is connected to a servo motor provided on the appearance inspection platform through a gear belt to move in the length direction by being driven by the servo motor, and the servo motor is connected to the electronic control system.
13. The rail weld joint quality inspection apparatus according to claim 1, wherein the appearance detection unit includes:
the camera shooting mobile measuring frame is arranged on the appearance detection platform and can move along the length direction;
a camera carriage connected to the camera motion measurement rig so as to be movable along the length direction with the camera motion measurement rig; and
the plurality of camera devices are respectively installed at different positions of the camera bracket to shoot a steel rail welding joint for 360 degrees, and are respectively connected with the upper computer to transmit shot pictures to the upper computer.
14. The steel rail welding joint quality inspection device according to claim 13, wherein the camera-shooting mobile measuring frame is connected with a servo motor arranged on the appearance detection platform through a gear belt so as to move along the length direction under the driving of the servo motor, and the servo motor is connected with the electric control system.
15. The rail weld joint quality inspection device according to claim 1, wherein the upper computer includes:
the control device is respectively connected with the two flaw detection units, the steel rail positioning mechanism, the straightness detection unit and the appearance detection unit; and
and the display device is connected with the control device to display the detection data of the two flaw detection units, the steel rail positioning mechanism, the flatness detection unit and the appearance detection unit and provide control options for an operator.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202022058998.4U CN214895027U (en) | 2020-09-18 | 2020-09-18 | Quality inspection device for steel rail welding joint |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202022058998.4U CN214895027U (en) | 2020-09-18 | 2020-09-18 | Quality inspection device for steel rail welding joint |
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| CN214895027U true CN214895027U (en) | 2021-11-26 |
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| CN202022058998.4U Active CN214895027U (en) | 2020-09-18 | 2020-09-18 | Quality inspection device for steel rail welding joint |
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| CN (1) | CN214895027U (en) |
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