JP2015010950A - Rail flaw detection device and rail flaw detection method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent erroneous determination with contact failure of a probe to a rail.SOLUTION: A rail flaw detection device which includes a flaw detection transmission probe for transmitting an ultrasonic wave along a flow detection virtual transmission plane obliquely intersecting with an upper surface of a rail, a flaw detection reception probe for receiving an echo incident along a flaw detection virtual reception plane having substantially the same angle as the inclination angle of the flaw detection virtual transmission plane, a coupling check transmission probe for transmitting the ultrasonic wave along a coupling check virtual transmission and reception plane intersecting with at least one of the flaw detection virtual transmission plane and the flaw detection virtual reception plane, and a coupling check reception probe arranged at the position of receiving an echo reflected on the surface of a head part, executes flaw detection processing subsequent to coupling check, and determines a flaw detection result at an opportunity at which contact failure of the probe is determined from the flaw detection result by comparing the flaw detection processing result and the result of coupling check.

Description

  The present invention relates to an apparatus and method for flaw detection on rails using echoes of ultrasonic pulses.

A rail that supports a load such as a railway vehicle may have scratches (cracks or transverse cracks) in the head of the rail as the vehicle travels.
In addition, in this specification, a rail shows what has a bottom part, the abdominal part which stands up from a bottom part, and the head provided in the upper end of an abdominal part.
Such a scratch on the rail head not only adversely affects the running of the vehicle, but can also cause serious accidents such as rail rupture, so it must be detected as soon as possible and appropriate measures required. .

The present applicant has disclosed Japanese Patent Application Laid-Open No. 2013-036770 (Patent Document 1) as a rail flaw detection apparatus and a rail flaw detection method for efficiently and reliably inspecting rail flaws.
In Patent Document 1, an ultrasonic wave is transmitted obliquely upward from the lower surface of the head.
When the rail is not damaged, the transmitted ultrasonic echo does not return to the direction of the ultrasonic transmission source.

For this reason, it is possible to identify a flaw (crack, lateral fissure) by receiving an ultrasonic echo that returns in the direction of the ultrasonic transmission source and analyzing the received information of the echo.
As described above, in Patent Document 1, when an ultrasonic echo is received, it is determined that there is a flaw in the transmission direction of the ultrasonic wave. Therefore, when no echo is received, the transmission direction of the ultrasonic wave is determined. It is determined that there is no scratch in the area.

However, for example, when a transmission probe or a reception probe that transmits / receives ultrasonic waves is not in contact with the rail, the reception probe does not receive an echo regardless of whether or not an echo is generated. This flaw detection process is in a state of flaw detection where substantially no flaw detection is performed.
Such a situation occurs, for example, when foreign matter is attached to the contact surface of the probe on the rail surface or is not properly in contact with the rail surface.
In the case of such a flaw detection defect, even if there is a flaw in the ultrasonic transmission direction area, the determination result is processed as no echo, and the flaw detection result is the same as when there is no flaw. Therefore, there is a problem that the occurrence of scratches may be overlooked.

JP2013-036770

  The present invention has been made to solve the above-described problem, and prevents erroneous determination that occurs when a probe for transmitting and receiving ultrasonic waves for rail flaw detection is not properly in contact with the rail surface. It is an object of the present invention to provide a rail flaw detector and a rail flaw detection method that can be performed.

In order to achieve the above object, a rail flaw detector according to the first invention of the present invention comprises:
A bottom part, an abdomen extending upward from the bottom part, and a head that is provided at the upper end of the abdomen and receives a wheel on the upper surface, and along the rail in which the upper neck part is formed on the continuous surface of the abdomen and the head, A rail flaw detector that detects damage caused by running of a wheel while moving a probe that transmits and receives sound waves,
Virtual transmission for flaw detection arranged in contact with at least one of the lower surface of the head of the rail and the upper neck, passing through the contact surface, and obliquely intersecting the upper surface of the rail at a predetermined inclination angle with respect to the upper surface of the rail A flaw detection transmitter that transmits ultrasonic waves along a plane;
A flaw detection virtual that is in contact with at least one of the lower surface of the head of the rail and the upper neck, and is arranged in proximity to the flaw detection transmission probe and has substantially the same angle as the inclination angle of the flaw detection virtual transmission plane. A receiving probe for flaw detection for receiving echoes incident along the receiving plane;
It is in contact with at least one of the lower surface of the head of the rail and at least one of the upper neck, and is superlong along a virtual transmission plane for coupling check that intersects at least one of the virtual transmission plane for flaw detection and the virtual reception plane for flaw detection. A transmission probe for coupling check that transmits sound waves;
A cup that contacts at least one of the lower surface of the head of the rail and the upper neck, is reflected at the surface of the head, and is disposed at a position for receiving echoes incident along the virtual transmission / reception plane for coupling check. A ring check receiving probe;
Coupling check transmission probe transmission processing, coupling check reception probe reception processing, flaw detection transmission probe transmission processing, and flaw detection reception probe reception processing A transmission / reception control means to be executed;
In response to the ultrasonic transmission of the flaw detection transmission probe, when the ultrasonic echo is received by the flaw detection reception probe, the transmission range of the flaw detection transmission probe when the transmission was executed A processing means for determining a "existing" flaw detection result indicating that damage has occurred in the test object, and determining a flaw detection result of "no" when no other ultrasonic echo is received;
It is determined whether or not the ultrasonic echo transmitted from the coupling check transmission probe is received by the coupling check reception probe, and the coupling check reception probe does not receive the echo. If there is no reception, at least one of the transmission check probe for coupling check and the reception probe for coupling check is not properly in contact with the rail. A coupling check processing means for determining;
The flaw detection result is compared with the flaw detection result determined as “defective” in the coupling check result corresponding to the flaw detection time of the flaw detection result. From the flaw detection result, the coupling check result is determined as “defective”. Comprehensive determination means for determining a comprehensive determination result for associating information on “response required” with the flaw detection result is provided.

The rail flaw detector according to the second invention is the first invention,
The flaw detection transmission probe transmits ultrasonic waves obliquely toward the moving direction.

Moreover, the rail flaw detector according to the third invention is the first invention or the second invention,
Transmission / reception processing of transmission probe for coupling check and reception probe for coupling check, determination of coupling check result, transmission / reception processing of transmission probe for flaw detection and reception probe for flaw detection, determination of flaw detection result, It is characterized in that the determination of the comprehensive determination result based on the comparison between the flaw detection result and the coupling check result is continuously executed, and the above-described processing and determination continuous steps are repeated during the rail flaw detection.

Moreover, the rail flaw detector according to the fourth invention is any one of the first invention to the third invention,
Coupling check transmission / reception including transmission / reception processing of at least a coupling check transmission probe and coupling check reception probe, and flaw detection transmission / reception including at least transmission / reception processing of the flaw detection transmission probe and flaw detection reception probe Are executed on the same machine.

Moreover, the rail flaw detector according to the fifth invention is any one of the first invention to the fourth invention,
In one area on the lower surface side of the rail head, with the abdomen as the boundary, it is in contact with at least one of the lower surface of the rail head and the upper neck and is movable along the longitudinal direction of the rail. A first moving block to be
In the other area of the lower surface side of the rail head, with the abdomen as the boundary, it is in contact with at least one of the lower surface of the rail head and the upper neck, and is held movable along the longitudinal direction of the rail. A second moving block,
A transmission probe for flaw detection is provided in the first moving block;
A receiving probe for flaw detection is provided on the second moving block,
A transmission probe for coupling check is provided on one of the first moving block and the second moving block,
A reception probe for coupling check is provided on the other of the first moving block and the second moving block.

Moreover, the rail flaw detector according to the sixth aspect of the invention is any one of the first to fourth aspects of the invention,
One area of the lower surface of the rail head, with the abdomen as the boundary, is in contact with at least one of the lower surface of the rail head and the upper neck, and is held movably along the longitudinal direction of the rail. A moving block
A flaw detection transmission probe, a flaw detection reception probe, a coupling check transmission probe, and a coupling check reception probe are provided.

In order to achieve the above object, the rail flaw detection method according to the seventh invention
A bottom part, an abdomen extending upward from the bottom part, and a head that is provided at the upper end of the abdomen and receives a wheel on the upper surface, and along the rail in which the upper neck part is formed on the continuous surface of the abdomen and the head, A rail flaw detection method for flaw detection caused by traveling of a wheel while moving a probe that transmits and receives sound waves,
A coupling check transmission step for transmitting an ultrasonic wave toward the surface of the head from a coupling check transmission probe that contacts at least one of the lower surface of the head of the rail and the upper neck; and
For coupling check that receives at least one of the lower surface of the head of the rail and the upper neck, and receives the echo of the ultrasonic wave transmitted from the transmission probe for coupling check reflected on the surface of the head. Receiving step;
Determining whether the receiving probe for coupling check has received an echo; and
On the upper surface of the rail across the transmission axis of ultrasonic waves transmitted from the transmission probe for flaw detection from the lower surface of the rail head and at least one of the upper neck and the flaw detection transmission probe A flaw detection transmission step of transmitting ultrasonic waves along a flaw detection virtual transmission plane that obliquely intersects the upper surface of the rail at a predetermined inclination angle;
A flaw detection receiving probe that contacts at least one of the lower surface of the head of the rail and at least one of the upper neck portions, and is transmitted along the flaw detection virtual receiving plane having substantially the same angle as the flaw detecting virtual transmission plane. A flaw detection receiving step for receiving an ultrasonic echo transmitted from the probe;
When an ultrasonic echo transmitted from the flaw detection transmission probe is received by the flaw detection reception probe, damage has occurred in the transmission range of the flaw detection transmission probe that performed the transmission. A damage determination step for determining;
If the reception probe for coupling check does not receive the ultrasonic echo transmitted from the transmission probe for coupling check, the transmission of the ultrasonic wave by the transmission probe for coupling check is continued. And an error determination step of determining that the damage determination result using the ultrasonic wave transmitted from the flaw detection transmission probe is “necessary to handle”.

The rail flaw detection method according to the eighth invention is the seventh invention,
At least a coupling check transmission / reception step including a coupling check transmission step and a coupling check reception step and a flaw detection transmission / reception step including a flaw detection transmission step and a flaw detection reception step are executed simultaneously. To do.

  According to the first invention, the coupling check transmission probe and the coupling check reception probe intersect at least one of the flaw detection virtual transmission plane and the flaw detection virtual reception plane. Since the probe has a transmission / reception plane, these probes are close to at least one of the flaw detection transmission probe and the flaw detection reception probe, so from the reception status of the coupling check reception probe, It becomes possible to check the contact status of the flaw detection transmission probe and the flaw detection reception probe with respect to the rail as needed.

  If at least one of the flaw detection transmission probe and the flaw detection reception probe is not in contact with the rail, even if the ultrasonic transmission area is damaged, the ultrasonic transmission may be transmitted. As a result, the echo from the damage cannot be received, and as a result, it is misjudged as non-detection of the damage. However, in the above invention, the flaw detection transmission probe and the flaw detection reception probe are detected. If at least one of the children is inadequate contact with the rail, the judgment result at the transmission / reception position will be judged as an error and can be distinguished from the judgment result without damage. This makes it possible to prevent oversight of damage caused by.

  According to the second invention, in addition to the effects of the first invention, the transmission probe for coupling check and the reception probe for coupling check are the transmission probe for flaw detection and the reception probe for flaw detection. Since the probe travels along the rail before the child, the probe contact with the rail in the area where the transmission probe for flaw detection and the reception probe for flaw detection perform transmission / reception of ultrasonic waves The operation status of the transmission probe for coupling check and the reception probe for coupling check can be confirmed, and the contact status of the transmission probe for flaw detection and the reception probe for flaw detection can be confirmed. Can be estimated more reliably, and erroneous determination can be further prevented.

  According to the third invention, in addition to the effects of the first invention and the second invention, the unit unit in which the flaw detection process is executed subsequent to the coupling check process is repeated, so that the echo In addition to preventing erroneous detection, it is possible to effectively transmit and receive ultrasonic waves for flaw detection, minimizing uninspected areas and suppressing the occurrence of uninspected areas.

  According to the fourth invention, in addition to the effects of the first to third inventions, there is no need to strictly manage such as delaying the relative timing of each process, so the processing load necessary for control is reduced, Maintenance can be facilitated, the design can be simplified, manufacturing costs and operation costs can be reduced, and flaw detection intervals can be narrowed, and flaw detection can be performed with extremely short pulses.

  According to the fifth invention, in addition to the effects of the first to fourth inventions, the flaw detection transmission probe and the flaw detection reception probe are respectively distributed in the first block and the second block, and In addition, the transmission probes for coupling check and the reception probes for coupling check are arranged in a distributed manner, and the movement of each block is integrally controlled, so that the flaw detection probe provided in the same block is provided. It is possible to homogenize the contact state of the probe and the probe for coupling check with the rail, and the contact state via the probe for coupling check depends on the contact state of the probe for flaw detection. It becomes possible to reflect accurately, and it becomes possible to specify the occurrence of damage more accurately.

  According to the sixth invention, in addition to the effects of the first to fourth inventions, all the probes are provided in one block, so that the apparatus itself can be made compact and each probe can be made compact. Since the contact area of the child can be limited to a very narrow area, and the contact situation via the probe for coupling check can be more accurately reflected by the contact situation of the probe for flaw detection, The occurrence of damage can be identified more accurately.

  According to the seventh aspect, as in the first aspect, when at least one of the flaw detection transmission probe and the flaw detection reception probe is not in contact with the rail, the ultrasonic transmission region is damaged. Even if there is, since it is not possible to transmit ultrasonic waves to the damage or receive echoes from the damage, it will be erroneously determined as non-detection of damage, but in the above invention, When at least one of the flaw detection transmitting probe and the flaw detection receiving probe is in inappropriate contact with the rail, the determination result at the transmission / reception position is determined as an error, and the determination result without damage Therefore, it is possible to prevent oversight of damage caused by non-contact of the probe.

  According to the seventh invention, similarly to the fourth invention, in addition to the effects of the seventh invention, it is not necessary to strictly manage such as delaying the relative timing of each process, so the processing load necessary for the control is reduced. It can be reduced, maintenance can be facilitated, design can be simplified, manufacturing cost and operation cost can be suppressed, and flaw detection intervals can be narrowed, and flaw detection can be performed with pulses having a very short cycle.

FIG. 1 is a conceptual front view of a main part of a rail flaw detector according to a first embodiment of the present invention. FIG. 2 is a conceptual front view showing the installation state of each moving block shown in FIG. FIG. 3 is a conceptual side view of the main part viewed from the direction of the AA line in FIG. FIG. 4 is a conceptual side view of the main part viewed from the direction of the line BB in FIG. FIG. 5 is a conceptual plan view of the rail contact surface of the first moving block shown in FIG. FIG. 6 is a conceptual plan view of the rail contact surface of the second moving block shown in FIG. FIG. 7 is a timing chart showing the timing of the coupling check and flaw detection processing of the first embodiment shown in FIG. FIG. 8 is a block diagram illustrating the basic configuration of the first embodiment. FIG. 9 is a flowchart illustrating the processing and operation of the first embodiment. FIG. 10 is a conceptual front view of a main part of a second embodiment of the rail flaw detector according to the present invention. FIG. 11 is a conceptual side view of the main part as viewed from the direction of line CC in FIG. FIG. 12 is a timing chart showing the timing of the coupling check and the flaw detection processing of the rail flaw detector according to the third embodiment of the present invention.

The present invention provides ultrasonic waves through a transmitting / receiving probe for flaw detection that is in contact with at least one of the lower surface of a rail head, such as a railway, and the upper neck, as disclosed in Japanese Patent Application Laid-Open No. 2013-036770. It is used for a flaw detection device that detects flaws (cracks / transverse cracks) generated on the rail head using a pulse, and whether the transmitting / receiving probe for flaw detection is in proper contact with the rail. This is monitored by a coupling check to prevent flaw detection leakage due to poor contact.
Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.

  FIG. 1 is a conceptual front view of a main part of a rail flaw detector according to a first embodiment of the present invention, FIG. 2 is a conceptual front view showing an installation state of each moving block shown in FIG. 1, and FIG. 4 is a conceptual side view of the main part viewed from the line direction, FIG. 4 is a conceptual side view of the main part viewed from the BB line direction of FIG. 1, and FIG. 5 is a conceptual view of the rail contact surface of the first moving block shown in FIG. FIG. 6 is a conceptual plan view of a rail contact surface of the second moving block shown in FIG. 1. FIG. 7 is a timing chart showing the timing of the coupling check and flaw detection processing of the first embodiment shown in FIG. FIG. 8 is a block diagram showing the basic configuration of the first embodiment shown in FIG. 1, and FIG. 9 is a flowchart showing the processing and operation of the first embodiment.

First, FIGS. 1 to 6 will be described.
In the figure, 1 is a rail used for a railroad track, 1a is the bottom of the rail 1, 1b is an abdomen extending upward from the bottom 1a, 1c is a head provided at the upper end of the abdomen and receives wheels on the upper surface, 1d is an abdomen 1b The upper neck 10 formed between the head 1c and the head 1c are scratches formed on the upper surface of the rail 1.
In addition, the name of each said part is a name prevailing widely with respect to a flat bottom rail.

The rail flaw detector according to the present embodiment has a first moving block, a second moving block, and a slider as main components as follows.
2 is the first moving block, 20 is the flaw detection transmission probe provided in the first movement block 2, 20a is the ultrasonic wave transmitted from the flaw detection transmission probe 20, and 21 is provided in the first movement block 2. A transmission probe for coupling check, 21a is a transmission range of ultrasonic waves transmitted from the transmission probe for coupling check 21, 21b is ultrasonic waves transmitted from the transmission probe for coupling check 21, 22 is A contact medium discharge hole provided in the first block 2, a contact medium supply line for supplying the contact medium to the contact medium discharge hole 22, and a slide shoe provided in a contact area with the rail of the first moving block.

  3 is a second moving block, 30 is a receiving probe for flaw detection provided in the second moving block 3, 31 is a receiving probe for coupling check provided in the second moving block 3, and 32 is in the second block 3. A contact medium discharge hole 33, a contact medium supply line 33 for supplying the contact medium to the contact medium discharge hole 32, and a slide shoe 34 are provided in a contact area with the rail of the second moving block.

  Reference numeral 4 denotes a slider that is detachably attached to the upper portion of the rail 1, 40 denotes a roller that has a rotation axis orthogonal to the longitudinal direction of the rail 1 and can roll on the upper surface of the rail 1, and 41 denotes the rail 1 via the roller 40. A main body disposed along the rail 1 at the top, 420 is an arm extending downward from one side edge of the main body 41 through one side of the head 1c of the rail 1, and 421 is the other side of the main body 41. Arms 430 extending downward from the side edges through the other side of the head 1c of the rail 1 are attached to the arms 420, and guide rollers 431 are pressed against the lower corners of the head 1c of the rail 1. A guide roller attached to the arm 421 and pressed against the lower corner of the head 1c of the rail 1.

The rail 1 is a kind of general-purpose flat bottom rail.
The rail 1 includes a bottom 1a, an abdomen 1b extending upward from the bottom 1a, and a head 1c that is provided at the upper end of the abdomen 1b and receives wheels such as a train (not shown) on the upper surface. Has an upper neck 1d on the continuous outer surface.

As shown in FIG. 2, the first moving block 2 and the second moving block 3 are attached to the lower ends of the arms 420 and 421 of the slider 4, respectively.
The arms 420 and 421 can be widened by an opening / closing mechanism (not shown), and the slider 4 is attached to and detached from the rail 1 with the wide opening.

  In addition, the first moving block 2 and the second moving block 3 are configured such that, when the slider 4 is mounted on the rail 1, the contact surfaces described later are moved to the rail with a required pressure by the action of an elastic body (not shown). 1 is pressed against the lower surface of the head 1c and at least a part of the upper neck 1d.

  In addition, the structure of the slider 4 is detachable with respect to the rail 1, is movable along the rail 1 via the roller 40, and the first moving block 2 and the second moving block. 3 may be any structure as long as it can be pressed against a required position of the rail 1, for example, disclosed in Japanese Patent Application Laid-Open No. 2013-036770 filed by the applicant of the present invention. Mechanism.

Next, the first moving block 2 and the second moving block 3 will be described with reference to FIGS. 1 and 3 to 6.
The first moving block 2 has a substantially rectangular parallelepiped shape, and a slide shoe 24 having an outer surface shape that can be brought into close contact with a required position of the rail 1 is provided on one surface serving as a contact surface with the rail 1.

The flaw detection transmission probe 20, the coupling check transmission probe 21, and the contact medium protruding hole 22 are respectively connected to the surface of the slide shoe 24 of the first moving block 2 by the coupling check transmission probe 21. It is sequentially arranged between them.
The flaw detection transmission probe 20 is, for example, a conventionally known flaw detection probe shown as a conventional technique, and transmits ultrasonic waves in a predetermined pattern in the upper surface direction of the rail 1. is there.

In the present embodiment, the flaw detection transmission probe 20 contacts the rail 1 when the slide shoe 24 of the first moving block 2 is in contact with a predetermined position of the rail 1 and pressed.
The flaw detection transmission probe 20 passes through the contact surface, obliquely intersects the upper surface of the rail 1 at a predetermined inclination angle with respect to the upper surface of the rail 1, and a transmission probe for coupling check described later. Ultrasound is transmitted in a predetermined pattern along the flaw detection virtual transmission plane that intersects the coupling check virtual transmission / reception plane of the child 21.

The transmission probe 21 for coupling check transmits an ultrasonic wave for coupling check toward a predetermined transmission range 21a.
In addition, since the automatic ultrasonic flaw detector itself by the coupling check method is conventionally known based on the echo obtained according to the coupling check, the state of the test material such as a steel plate is conventionally known. The description will focus on parts related to the features of the invention.

The transmission probe 21 for coupling check in the present embodiment contacts the rail 1 when the slide shoe 24 of the first moving block 2 is in contact with a predetermined position of the rail 1 and pressed.
The coupling check transmission probe 21 transmits ultrasonic waves in a predetermined pattern along the coupling check virtual transmission / reception plane intersecting the flaw detection virtual transmission plane.

In this embodiment, the virtual transmission / reception plane for coupling check is perpendicular to the upper surface of the rail 1.
The contact medium discharge hole 22 supplies the contact medium supplied from the outside via the contact medium supply line 23 between the rail 1 and the slide shoe 24.
Examples of the contact medium include glycerin paste and water.

The second moving block 3 has a substantially rectangular parallelepiped shape, and a slide shoe 34 having an outer surface shape that can be brought into close contact with a required position of the rail 1 is provided on one surface serving as a contact surface with the rail 1.
The second moving block 3 is held at an adjacent position across the first moving block 2 and the abdomen 1b of the rail 1.

The flaw detection receiving probe 30, the coupling check receiving probe 31, and the contact medium protruding hole 32 are respectively connected to the surface of the slide shoe 34 of the second moving block 3. It is sequentially arranged between them.
The flaw detection receiving probe 30 is a conventionally known flaw detection probe shown as the prior art, for example, and receives an ultrasonic echo transmitted from the flaw detection transmission probe 20.

In the present embodiment, the flaw detection receiving probe 30 contacts the rail 1 when the slide shoe 34 of the second moving block 3 is in contact with a predetermined position of the rail 1 and pressed.
In this embodiment, the ultrasonic wave that returns as an echo is incident along the flaw detection virtual reception plane having the same or substantially the same inclination angle as the flaw detection virtual transmission plane. The receiving probe 30 is provided so as to receive an echo along the flaw detection virtual receiving plane.

The coupling check reception probe 31 is arranged at a position where an echo along the coupling check virtual transmission / reception plane can be received.
The coupling check receiving probe 31 in this embodiment contacts the rail 1 when the slide shoe 34 of the second moving block 3 is in contact with a predetermined position of the rail 1 and pressed.

Then, the coupling check reception probe 31 receives the ultrasonic wave that returns as an echo along the coupling check virtual transmission / reception plane.
In this embodiment, the coupling check virtual transmission / reception plane is set to be perpendicular to the upper plane of the rail 1 and orthogonal to the longitudinal direction of the rail 1. Then, the coupling check receiving probe 31 is juxtaposed with the abdomen 1b of the rail 1 in between.
The contact medium discharge hole 32 supplies the contact medium supplied from the outside via the contact medium supply line 33 between the rail 1 and the slide shoe 34.

Next, transmission / reception of ultrasonic waves of the flaw detection transmission probe 20 and the flaw detection reception probe 30 will be described with reference to FIGS.
3 and 4, the slider 4 is omitted for convenience.
The flaw detection transmission probe 20 transmits the ultrasonic wave 20a obliquely upward (FIG. 3) along the traveling direction m of the slider 4 (not shown).

The transmitted ultrasonic wave travels in a direction away from the first moving block 2 when the rail 1 is not damaged.
On the other hand, when the flaw 10 exists on the rail 1, the ultrasonic wave 20a hitting the lower end position of the flaw 10 is echoed as a reception for flaw detection (not shown) of the second moving block 3 as shown in FIG. Proceed toward the probe 30.

3 and 4, cracks generated from the upper right to the lower left of the figure are shown as the position of the wound 10, but the form and direction of the wound are other than those shown, for example, from the upper left of the figure. Even cracks generated in the lower right, scratches (cracks, lateral fissures), and partial defects generated in the vertical direction are detected as in FIGS.
The received echo is analyzed by a conventional technique as disclosed in the prior art document, the presence or absence of a flaw is determined, and the position thereof is specified.

Next, transmission / reception of ultrasonic waves of the transmission probe 21 for coupling check and the reception probe 31 for coupling check will be described based on FIG. 1, FIG. 3, and FIG.
In FIG. 1, FIG. 3 and FIG. 4, the slider 4 is omitted for convenience.
The transmission probe 21 for coupling check transmits an ultrasonic wave to a region sandwiched by the transmission range 21a. In this embodiment, the ultrasonic wave 21b that has advanced toward the center of the upper plane of the rail 1 is used. Is received by the coupling check reception probe 31 provided in the second moving block 3, and the coupling check reception probe 31 is adjusted.

Next, determination of reception results of echoes of the ultrasonic waves 20a and 21b will be described.
When the ultrasonic wave 21b is transmitted from the coupling check transmission probe 21, when the coupling check reception probe 31 does not receive the echo of the ultrasonic wave 21b, at the time of transmission, the first Whether at least one of the moving block 2, the transmission probe 21 for coupling check, the second moving block 3, and the receiving probe 31 for coupling check is not properly arranged with respect to the rail 1, It is determined that there is an abnormality such as a scratch at the transmission destination of the sound wave 21b.

  In this case, at least one of the flaw detection transmission probe 20 adjacent to the coupling check transmission probe 21 and the flaw detection reception probe 30 adjacent to the coupling check reception probe 31 is also included. The possibility that the rail 1 is not properly adhered is estimated.

  Therefore, when the coupling check receiving probe 31 does not properly receive the echo of the ultrasonic wave 21b, the flaw detection receiving probe 30 formed before and after the ultrasonic wave 21b generates the ultrasonic wave 20a. Even if not received, whether the rail 1 is normal, or even if the rail 1 is damaged, whether the ultrasonic transmission 20a could not be transmitted properly due to poor contact of the flaw detection transmission probe 20 with the rail 1, It cannot be determined whether or not the echo that should be originally received by the ultrasonic wave 20a from the scratch on the rail 1 could not be properly received due to poor contact of the flaw detection receiving probe 30 with the rail 1.

  For this reason, the reception probe 31 for the coupling check corresponds to a time when the echo of the ultrasonic wave 21b is not properly received, specifically, immediately before or immediately after the coupling check, preferably immediately after. Information indicating measurement failure is added to the flaw detection result via the flaw detection receiving probe 30 so that the possibility that an abnormality has occurred in the rail 1 at that point can be recognized.

Next, the timing of the coupling check and the flaw detection process will be described with reference to FIG.
In this embodiment, as shown in FIG. 2, the slider 4 is mounted on the rail 1, the first moving block 2 and the second moving block 3 are brought into contact with the required positions of the rail 1, and then the slider 4 is moved to FIG. The following processing is executed while moving in the traveling direction m of FIG.

First, the ultrasonic wave 21b is transmitted from the transmission probe 21 for coupling check, and is received by the reception probe 31 for coupling check.
Next, it is determined from the reception result of the coupling check reception probe 31 that “normal” is received if the echo of the ultrasonic wave 21 b is properly received, and “error” if the echo is not received properly. Execute the process.

Next, an ultrasonic wave 20 a is transmitted from the flaw detection transmission probe 20, and the presence or absence of the flaw 10 is determined from the reception result of the echo of the ultrasonic wave 20 a via the flaw detection reception probe 30, and the flaw 10 A process for determining the position is executed.
The above processing results are linked with positioning information obtained through a positioning system (not shown), and the processing result information and the measurement position information are stored in a storage area (not shown) so as to be able to correspond. It is recommended to leave

  By performing each processing in the above order, the flaw detection transmission probe 20 and the flaw detection reception probe are located in the vicinity of the range in which the coupling check is performed or the vicinity thereof by the movement of the slider 4. When the child 30 moves, the ultrasonic wave 20a is transmitted and received, and the flaw detection process is performed in the range where the coupling check is performed or in the vicinity thereof. The result of the coupling check more accurately corresponds to the contact state of the flaw detection transmission probe 20 and the flaw detection reception probe 30 with respect to the rail 1.

Next, the basic configuration of the first embodiment will be specifically described with reference to FIG.
In addition, the same number as the above is attached | subjected to the structure same as description in FIGS.
In the figure, 50 is a control means for controlling the execution of the present embodiment, 51 is an input panel for inputting operations necessary for control, 52 is a flaw detection result processing means for judging and judging the result of flaw detection processing, and 53 is a coupling check. Coupling check result processing means 54 for judging the processing result, 54 is a comprehensive judgment means for reflecting the processing result of the coupling check means 53 on the processing result of the flaw detection processing means 52, and executing a final judgment, 55 It is a display means for displaying information necessary for the operation of the embodiment and various determination results.

The control means 50 transmits signals necessary for processing to each component, receives the results and information obtained by the processing, and controls the operation of this embodiment.
The control means 50 operates the flaw detection transmission probe 20 and the flaw detection reception probe 30 according to a predetermined program, acquires the flaw detection result, and sends the flaw detection result to a flaw detection result processing means 52 described later.

The control means 50 operates the coupling check transmission probe 21 and the coupling check reception probe 31 according to a predetermined program, acquires the coupling check result, and outputs the coupling check result to be described later. The result is sent to the coupling check result processing means 53.
The input panel 51 is an input means for making various inputs necessary for the operation of the present embodiment to the control means 50.

The flaw detection processing means 52 receives the flaw detection result from the control means 50, analyzes the received flaw detection result, and determines the flaw detection result.
Specifically, when the echo of the ultrasonic wave 20a is received by the flaw detection receiving probe 30 in response to the transmission of the flaw detection transmission probe 20, there is an abnormality such as a flaw 10 in the transmission range of the ultrasonic wave 20a. As a certain thing, it judges "existence" with respect to the flaw detection result, and specifies the position of a flaw.

On the contrary, when there is no reception of the ultrasonic wave 20a, the determination of “no” is performed.
The flaw detection processing means 52 associates the determination result “Yes” or “No” corresponding to each flaw detection result and the information on the specific position in the case of “Yes” with each flaw detection result, and then sends it to the control means 50. Output.

The coupling check processing unit 53 receives the coupling check result from the control unit 50, analyzes the received coupling check result, and determines whether the coupling check state is “normal” or “bad” for each coupling check result. Determine.
Specifically, when the echo of the ultrasonic wave 21b is not received by the coupling check reception probe 31 for the transmission of the transmission probe 21 for the coupling check, the position where the coupling check is executed, In the vicinity thereof, it is determined that the transmission and reception of the ultrasonic wave 20a by the flaw detection transmission probe 20 and the flaw detection reception probe 21 were not properly performed, and the state of the coupling check is “bad”. Is determined.

On the other hand, when the echo of the ultrasonic wave 21b is received, “normal” is determined.
The coupling check processing means 53 outputs the “normal” and “bad” determination results corresponding to each coupling check result to the control means 50 after associating the results with each coupling check result.

  The comprehensive judgment unit 54 receives at least information including “no” of the flaw for each flaw detection result and information including “bad” of the coupling check result from the control unit 50, and the flaw is “no” in the flaw detection result. By excluding flaw detection results associated with “bad” in the coupling check result from those determined to be, there is a possibility that there is a flaw from those determined as flawless in the flaw detection result. Make a decision to exclude something.

Specifically, in the present embodiment, each flaw detection result is associated with a coupling check result acquired immediately before or immediately after, preferably immediately before, respectively. A comprehensive judgment is performed between the ring check results.
By this comprehensive determination, it is possible to exclude from the flaw detection results those that have been flawed and those in which the flaw detection process itself is defective.

That is, in this embodiment, the flaw detection results are classified into three categories: “Flaw detection result present”, “No flaw detection result + Flaw detection flaw”, and “No flaw detection result + Flaw detection normal”. A flaw detection processing area corresponding to a flaw detection result other than “normal” is a target for the abnormality check of the rail 1 and a target for a precise inspection of the rail 1.
Then, the comprehensive determination means 54 associates “correspondence not required” information with the flaw detection result “no flaw detection result + normal flaw detection”, and “correspondence required” information with the other flaw detection results.

The acquired information, various results, and analysis results thereof are displayed on the display device 55.
This display device 55 is connected to the slider 4 by wire or wirelessly, and displays the obtained information such as the analysis result as needed in parallel with the flaw detection work, but stores various information in a storage area (not shown), You may display after completion | finish of a flaw detection work, and you may extract and display the location which needs a close inspection.

Next, processing and operation of the first embodiment will be described with reference to FIG.
First, the rail flaw detector according to the first embodiment is attached to the rail 1, and the first moving block 2 and the second moving block 3 are brought into contact with and brought into close contact with the required position of the rail 1 (step S101).
Next, the rail flaw detector is activated, and after various settings, operation is started (step S102).

With the start of the operation of the rail flaw detector, the supply of the contact medium to the first moving block 2 and the second moving block 3 is started, respectively, and between the first moving block 2 and the second moving block 3 and the rail 1 A contact medium is supplied (step S103).
The ultrasonic wave 21b is transmitted from the coupling check transmission probe 21, and the echo is received by the coupling check reception probe 31, thereby obtaining the coupling check result (step S104).

The coupling check result processing means 53 analyzes the coupling check result and determines whether the coupling check has been executed normally or has failed (step S105).
Then, the ultrasonic wave 20a is transmitted from the flaw detection transmission probe 20, and the echo is received by the flaw detection reception probe 30, thereby obtaining a flaw detection result (step S106).
The flaw detection result processing means 52 analyzes the flaw detection result, and determines and specifies the presence / absence of a flaw and the position of the flaw (step S107).

  Then, the comprehensive judgment means 54 excludes the result of the flaw detection determined as “no flaw detection” from the flaw detection result determined as “poor flaw detection” by the determination of the coupling check result, There is no need for re-inspection, ie, “no flaw detection + normal flaw detection” that requires no response, and close inspection or re-inspection is required, ie “require flaw detection”, and “require flawless inspection + flaw detection”. The determination classified into the three categories is executed, and information on the necessity of handling is attached to the flaw detection results classified other than “no flaw detection + normal flaw detection” that does not require handling (step S108).

  Then, it is determined whether or not the operation stop of the rail flaw detector is input (step S109). When the operation stop of the rail flaw detector is not input, the process returns to the acquisition of the coupling check result in step S104, and the stop is input. Sometimes, the operation is stopped, the operation of the apparatus is stopped (step S110), and the operation and the process are finished.

In the above step, the rail flaw detector moves in the traveling direction m after the contact medium is supplied (step S103), and this movement is stopped before the operation stop input (Y in S109). To do.
The flaw detection processing is executed when the flaw detection transmission probe and the flaw detection reception probe approach or approach the region where the coupling check is performed by the above movement.

  In the above embodiment, the contact state of the flaw detection transmission probe and the flaw detection reception probe with respect to the rail can be accurately determined from the coupling check result. Can be prevented very effectively, and maintenance of the rail can be performed appropriately.

Next, Example 2 will be described.
Since the main configuration and operation of the second embodiment are the same as those of the first embodiment, a redundant description will be omitted, and differences will be mainly described.
10 is a conceptual front view of a main part of a rail flaw detector according to a second embodiment of the present invention, and FIG. 11 is a conceptual side view of the main part when viewed from the CC line direction of FIG.

  In the figure, 1 is a rail, 10 is a scratch on rail 1, 6 is a moving block, 60a is an ultrasonic wave transmitted from a flaw detection transmission probe (not shown), 61b is transmitted from a transmission probe for coupling check (not shown). Is ultrasound.

In the second embodiment, a flaw detection transmission probe, a flaw detection reception probe, a coupling check transmission probe, and a coupling check reception probe (not shown) are provided in the same moving block. .
A flaw detection reception probe (not shown) is provided at a position close to or adjacent to a flaw detection transmission probe (not shown) and capable of receiving an echo of the ultrasonic wave 60a.

  A coupling check reception probe (not shown) is provided in a position close to or adjacent to a coupling check transmission probe (not shown) and capable of receiving the echo of the ultrasonic wave 61b.

At this time, the reflection point of the ultrasonic wave 61b is set to a curved surface at a diagonal position of the head of the rail 1 with respect to the position where the moving block is arranged, and the ultrasonic wave 61b is set to cross the center of the head diagonally. It is desirable to do.
In this second embodiment, in addition to the operational effects of the first embodiment, all the probes can be provided in one moving block, so that the apparatus can be made compact, and the manufacturing cost and Operation costs can be reduced, and various types of rails can be targeted for flaw detection.

Next, a third embodiment will be described.
Since the basic configuration of the third embodiment is the same as that of the first embodiment, the description of the overlapping configuration is omitted, and the description will focus on the differences.
In the first embodiment, the coupling check transmission / reception, the coupling check result processing, and the flaw detection processing are sequentially performed sequentially. In this third embodiment, the coupling check transmission / reception and the flaw detection transmission / reception are performed simultaneously. Executed.
Then, the coupling check result process is executed after the coupling check transmission / reception based on the result of the coupling check transmission / reception, and the flaw detection process is performed after the coupling check result process, and the result of the flaw detection transmission / reception and the coupling check result. It is executed based on the determination information of the coupling state based on the process.
In this embodiment, since the timing of coupling check transmission / reception and flaw detection transmission / reception can be set at the same time, there is no need to set the relative timing of each transmission / reception according to the working conditions, and setting work and operation management can be performed. It becomes easy.

  In the first to third embodiments, the transmission / reception of coupling check ultrasonic waves and the transmission / reception of ultrasonic waves for flaw detection are continuously switched so as not to leave a gap. It is recommended that the transmission / reception be performed during transmission / reception of ultrasonic waves in the next step. However, each transmission / reception may be switched at a predetermined interval.

In addition, if the probe for coupling check is arranged so that the ultrasonic wave for coupling check crosses at least one of the virtual transmission surface for flaw detection or the virtual reception surface for flaw detection, its relative position, The transmission direction is not limited to the above embodiment.
Further, the positions of the first moving block and the second moving block do not need to be arranged in parallel with the rail interposed therebetween as long as transmission and reception can be appropriately performed.

Further, the relative positions of the probes may be any arrangement as long as the relative relationship between the virtual transmission plane and the virtual reception plane can be maintained.
Also, the dotted lines extending upward from the vicinity of both ends of each moving block in FIGS. 1 and 10 indicate the transmission range of the ultrasonic waves, and the ultrasonic waves are transmitted in a fan shape as indicated by the dotted lines. You may make it transmit in a required pattern toward several predetermined required points.

  In the first embodiment, the flaw detection transmission probe and the coupling check transmission probe are provided in one moving block. However, the flaw detection transmission probe and A coupling check reception probe may be provided, and the other moving block may be provided with a flaw detection reception probe and a coupling check transmission probe.

Further, in the above embodiment, each slide shoe is configured such that almost the entire surface thereof is in contact with the surface of the rail, but depending on the shape of the rail, in the range where there is no hindrance to transmission and reception of ultrasonic waves and their echoes, Only a part of the rail may contact the surface of the rail.
Furthermore, the present invention can be freely modified within the scope of the present invention, and is not limited to the above embodiments.

  In the present invention, the coupling check makes it possible to accurately grasp the contact state of the probe for flaw detection with respect to the rail. Therefore, for conventional rail flaw detection using transmission of ultrasonic waves and reception of ultrasonic echoes. It is possible to prevent flaw detection leakage caused by a poor contact of the probe with the rail, which occurs in the apparatus and method, and the applicability is high in that the maintenance of the rail can be performed extremely accurately and efficiently.

DESCRIPTION OF SYMBOLS 1 Rail 1a Bottom part 1b Abdominal part 1c Head 1d Upper neck part 10 Wound 2 1st movement block 20 Transmission probe 20a for flaw detection Ultrasonic 21 Transmission probe 21a for coupling check Transmission range 21b Ultrasonic wave 22 Contact medium discharge hole 23 Contact medium supply line 24 Slide shoe 3 Second moving block 30 Flaw detection reception probe 31 Coupling check reception probe 32 Contact medium discharge hole 33 Contact medium supply line 34 Slide shoe 4 Slider 40 Roller 41 Body 420 Arm 421 Arm 430 Guide roller 431 Guide roller 50 Control means 51 Input panel 52 Flaw detection result processing means 53 Coupling check result processing means 54 Overall judgment means 55 Display means 6 Moving block 60a Ultrasonic wave 61b Ultrasonic wave

Claims (8)

A bottom part, an abdomen extending upward from the bottom part, and a head that is provided at the upper end of the abdomen and receives a wheel on the upper surface, and along the rail in which the upper neck part is formed on the continuous surface of the abdomen and the head, A rail flaw detector that detects damage caused by running of a wheel while moving a probe that transmits and receives sound waves,
Virtual transmission for flaw detection arranged in contact with at least one of the lower surface of the head of the rail and the upper neck, passing through the contact surface, and obliquely intersecting the upper surface of the rail at a predetermined inclination angle with respect to the upper surface of the rail A flaw detection transmitter that transmits ultrasonic waves along a plane;
A flaw detection virtual that is in contact with at least one of the lower surface of the head of the rail and the upper neck, and is arranged in proximity to the flaw detection transmission probe and has substantially the same angle as the inclination angle of the flaw detection virtual transmission plane. A receiving probe for flaw detection for receiving echoes incident along the receiving plane;
It is in contact with at least one of the lower surface of the head of the rail and at least one of the upper neck, and is superlong along a virtual transmission plane for coupling check that intersects at least one of the virtual transmission plane for flaw detection and the virtual reception plane for flaw detection. A transmission probe for coupling check that transmits sound waves;
A cup that contacts at least one of the lower surface of the head of the rail and the upper neck, is reflected at the surface of the head, and is disposed at a position for receiving echoes incident along the virtual transmission / reception plane for coupling check. A ring check receiving probe;
Coupling check transmission probe transmission processing, coupling check reception probe reception processing, flaw detection transmission probe transmission processing, and flaw detection reception probe reception processing A transmission / reception control means to be executed;
In response to the ultrasonic transmission of the flaw detection transmission probe, when the ultrasonic echo is received by the flaw detection reception probe, the transmission range of the flaw detection transmission probe when the transmission was executed A damage processing means for determining a “existing” flaw detection result indicating that damage has occurred on the surface, and for determining a flaw detection result of “no” when no other ultrasonic echo is received. ,
It is determined whether or not the ultrasonic echo transmitted from the coupling check transmission probe is received by the coupling check reception probe, and the coupling check reception probe does not receive the echo. If there is no reception, at least one of the transmission check probe for coupling check and the reception probe for coupling check is not properly in contact with the rail. And a coupling check result processing means for determining,
The flaw detection result is compared with the flaw detection result determined as “defective” in the coupling check result corresponding to the flaw detection time of the flaw detection result. From the flaw detection result, the coupling check result is determined as “defective”. The rail flaw detection apparatus as described above, comprising: comprehensive determination means for determining a comprehensive determination result for associating information on “response required” with the flaw detection result.   The rail flaw detector according to claim 1, wherein the flaw detection transmission probe transmits ultrasonic waves obliquely toward the moving direction.   Transmission / reception processing of transmission probe for coupling check and reception probe for coupling check, determination of coupling check result, transmission / reception processing of transmission probe for flaw detection and reception probe for flaw detection, determination of flaw detection result, The rail according to claim 1, wherein the determination of the overall determination result by contrasting the flaw detection result and the coupling check result is continuously performed, and the rails according to claim 1, including repeating the above-described processing and determination continuous steps during the rail flaw detection. Flaw detection equipment.   Coupling check transmission / reception processing including transmission / reception processing of at least a coupling check transmission probe and coupling check reception probe, and flaw detection including at least transmission / reception processing of a flaw detection transmission probe and flaw detection reception probe The rail flaw detector according to any one of claims 1 to 3, wherein the transmission / reception process is executed in a simultaneous machine. In one area on the lower surface side of the rail head, with the abdomen as the boundary, it is in contact with at least one of the lower surface of the rail head and the upper neck and is movable along the longitudinal direction of the rail. A first moving block to be
In the other area of the lower surface side of the rail head, with the abdomen as the boundary, it is in contact with at least one of the lower surface of the rail head and the upper neck, and is held movable along the longitudinal direction of the rail. A second moving block,
A transmission probe for flaw detection is provided in the first moving block;
A receiving probe for flaw detection is provided on the second moving block,
A transmission probe for coupling check is provided on one of the first moving block and the second moving block,
The rail flaw detector according to any one of claims 1 to 4, wherein the coupling check reception probe is provided on the other of the first moving block and the second moving block. One area of the lower surface of the rail head, with the abdomen as the boundary, is in contact with at least one of the lower surface of the rail head and the upper neck, and is held movably along the longitudinal direction of the rail. A moving block
The rail flaw detector according to any one of claims 1 to 4, wherein a flaw detection transmission probe, a flaw detection reception probe, a coupling check transmission probe, and a coupling check reception probe are provided. . A bottom part, an abdomen extending upward from the bottom part, and a head that is provided at the upper end of the abdomen and receives a wheel on the upper surface, and along the rail in which the upper neck part is formed on the continuous surface of the abdomen and the head, A rail flaw detection method for flaw detection caused by traveling of a wheel while moving a probe that transmits and receives sound waves,
A coupling check transmission step for transmitting an ultrasonic wave toward the surface of the head from a coupling check transmission probe that contacts at least one of the lower surface of the head of the rail and the upper neck; and
For coupling check that receives at least one of the lower surface of the head of the rail and the upper neck, and receives the echo of the ultrasonic wave transmitted from the transmission probe for coupling check reflected on the surface of the head. Receiving step;
Determining whether the receiving probe for coupling check has received an echo; and
On the upper surface of the rail across the transmission axis of ultrasonic waves transmitted from the transmission probe for flaw detection from the lower surface of the rail head and at least one of the upper neck and the flaw detection transmission probe A flaw detection transmission step of transmitting ultrasonic waves along a flaw detection virtual transmission plane that obliquely intersects the upper surface of the rail at a predetermined inclination angle;
A flaw detection receiving probe that contacts at least one of the lower surface of the head of the rail and at least one of the upper neck portions, and is transmitted along the flaw detection virtual receiving plane having substantially the same angle as the flaw detecting virtual transmission plane. A flaw detection receiving step for receiving an ultrasonic echo transmitted from the probe;
When an ultrasonic echo transmitted from the flaw detection transmission probe is received by the flaw detection reception probe, damage has occurred in the transmission range of the flaw detection transmission probe that performed the transmission. A damage determination step for determining;
If the reception probe for coupling check does not receive the ultrasonic echo transmitted from the transmission probe for coupling check, the transmission of the ultrasonic wave by the transmission probe for coupling check is continued. The rail flaw detection method as described above, further comprising: an error determination step of determining whether the determination result of damage using the ultrasonic wave transmitted from the flaw detection transmission probe is “response required”.   8. A coupling check transmission / reception step including at least a coupling check transmission step and a coupling check reception step, and a flaw detection transmission / reception step including at least a flaw detection transmission step and a flaw detection reception step are executed in the simultaneous machine. Rail flaw detection method described.

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