JP2816662B2 - Portable rail flaw detector - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention can display the results of ultrasonic flaw detection on a rail in real time as an image adapted to the shape of the rail, record data on a recording medium such as an IC card or a floppy desk, and use an AC power supply. The present invention relates to a portable rail flaw detector that is not required and is portable.

[0002]

2. Description of the Related Art Conventionally, rail flaw detection is carried out by a method in which a flaw detector equipped with a probe that generates ultrasonic waves is run and scanned, or a method in which a required portion is manually flaw-detected. It was done. In the former method of driving a flaw detection car, usually, as many flaw detectors as the number of probes attached are provided, and the data of ultrasonic flaw detection performed from the top of the rail head is continuously captured. After being processed by a computer, it is displayed on a CRT or recorded on a recording device. Therefore, the scale of the apparatus becomes large, and the apparatus cannot be operated unless it is loaded on a flaw detection vehicle. It has been a precondition that flaw detection is performed on the already laid rail. In addition, the latter manual inspection method is used in places where inspection vehicles cannot be used, for example, inspection after welding a rail at a welding base, or when replacing a new rail, transport it to the side of the track and then use it as a long rail. It is mainly applied to a case where a connection is made, or a case where a flaw is detected between trains in the daytime. To judge the flaw detection result, observe the A scope image of the ultrasonic flaw detector, record the height and distance of the echo that seems to be a defect, and then input this data to a computer to calculate the defect position taking into account the rail shape And so on.

[0003]

As described above, when a new rail is replaced, it is transported beside the track and then connected as a long rail, or when a flaw is detected between trains. Required a manual flaw detection method. However, in this flaw detection method, when a defect is detected while looking at the A scope, the distance from the reference point of the probe at that time is measured with a ruler, and once this is written on a recording sheet or the like, the rail is further moved. It was necessary to calculate the defect position in consideration of the shape. For example, when a defect echo P as shown in FIG. 14 is detected,
In addition to reading the beam path w and the echo height V from the A-scope screen, it was necessary to measure the distance y from the reference point to the probe in the rail length direction and the distance x in the rail width direction. In addition, the A scope only displays ultrasonic echoes, regardless of the type of rail or the welding location, so if you are not a fairly skilled person, immediately estimate the actual defect position from the A scope. Was impossible. In view of the difficulty in securing flaw detection workers, there has been no prospect of performing sufficient flaw detection inspection in the future. The present invention has been made in view of the above-mentioned conventional inconvenience, and simply by moving a probe by hand, flaw detection data is automatically taken in, calculation is performed along a rail shape, and a state of a defect is performed. It is an object of the present invention to provide a portable rail flaw detector capable of observing an image as an image and recording flaw detection data on an IC card or the like.

[0004]

In order to achieve the above-mentioned object, a portable rail flaw detector according to the present invention holds an ultrasonic probe movably in two axial directions by a slide mechanism and performs the above-mentioned probe operation. A measuring unit for measuring the biaxial movement amount of the probe, and a probe position detector having a fixed unit that can be fixed to the rail and that can hold the measuring unit on the rail head upper surface or the rail head side surface, Based on an ultrasonic echo signal obtained from the probe and a biaxial movement amount obtained from the measurement unit,
A defect position and a defect level can be automatically calculated, and the ultrasonic echo signal can be displayed on an A-scope image. When the defect level exceeds a predetermined value, the defect position is displayed on a B-scope image or a C-scope image. A digital ultrasonic flaw detector capable of displaying a scope image in real time, the digital ultrasonic flaw detector displaying an A-scope image and a C-scope image in real time, and then responding to an artificial operation to a B-scope image. And a C-scope image, and stores information on the defect position and defect level in response to a subsequent operation. Here, the A-scope image is an ultrasonic echo signal (flaw detection waveform) displayed by plotting the magnitude of the ultrasonic echo on the vertical axis and the propagation time (distance) of the ultrasonic wave on the horizontal axis. If present, the level of the ultrasonic echo will be high. In addition, the C scope image displays an internal defect when the measurement target is viewed from directly above, and allows the user to know the planar position of the defect. The B-scope image is an image in which an internal defect to be measured is displayed in a cross-sectional view, so that the depth position of the defect can be known. Since this portable rail flaw detector can be operated with a small battery and can be reduced in size and weight, it can be easily carried anywhere, for example,
As long as there is an interval between trains, flaw detection can be performed during the day. Further, the upper surface of the rail head, the side surface of the rail head, and the rail base surface can be individually inspected, and the inspection results can be combined and displayed as a B-scope image of a cross section of the rail and a C-scope image from above.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in more detail with reference to embodiments. FIG. 1 shows a configuration diagram of a portable rail flaw detector 1 according to one embodiment of the present invention. The portable rail flaw detector 1 includes a digital ultrasonic flaw detector 2, a probe position detector 3, a remote controller 4, a printer 5, and a card drive unit 6.
It is composed of The digital ultrasonic flaw detector 2 is a computer-incorporated flaw detector that appropriately processes high-precision digitized flaw detection data and displays ultrasonic echoes and the like on the liquid crystal screen 7 in color. It can be used. A switch panel 8 having an ESC key 8a, an ENTER key 8b and the like is provided on the right side of the liquid crystal screen 7, and two operation knobs 9a and 9b for rotating operation are provided on the lower side of the liquid crystal screen 7. Is provided. The operation of the ultrasonic flaw detector 2 can be performed to a considerable extent only with the operation knobs 9a and 9b. For example, when the operation knob 9a is turned clockwise, a series of flaw detection operations can be performed. Conversely, turning to the left can return to the original inspection work. Also, the operation knob 9b
Is a knob mainly used for moving the cursor on the liquid crystal screen 7, and is used, for example, when selecting a necessary operation item from the window screen of the liquid crystal screen 7.

The remote controller 4 allows the main operation of the ultrasonic flaw detector 2 to be performed near the probe position detector 3, and includes four operation units 4a ₁ , 4a ₂ , 4
b ₁ and 4b ₂ are provided. Typically, the operation unit 4
a ₁ and 4a ₂ are the ENTER key 8b of the switch panel 8 and
It corresponds to the ESC key 8a, and the operation units 4b ₁ , 4
b ₂ is used to move the cursor on the LCD screen 7 vertically and horizontally. The printer 5 is a device that outputs flaw detection data taken into the ultrasonic flaw detector 2 in a book, and the card drive unit 6 transfers management data registered in an IC card to the ultrasonic flaw detector 2, This is a device for registering measured flaw detection data in an IC card. However, the printer 5 and the card drive unit 6 do not necessarily need to be brought to the flaw detection work site, and may be used by connecting to the ultrasonic flaw detector 2 as needed. The probe position detector 3 includes an oblique flaw detection detector 3A and a tandem flaw detection detector 3B, and one of them is used as necessary. The bevel flaw detector 3A has a rail top surface,
The side face of the head and the surface of the base are flaw-detected by an oblique probe. On the other hand, the detector 3B for tandem flaw detection uses two oblique probes for the top face of the rail and the side face of the head. It is intended for tandem flaw detection.

As shown in the schematic diagram of FIG. 2, the bevel flaw detector 3A includes, for example, a bevel probe 10 that emits ultrasonic waves toward a welding portion WELD of a rail, and a bevel probe 10 A probe holder 11 that movably holds the probe holder 11 in the Z direction, a measurement unit 12 that holds the probe holder 11 movably in the XY direction, and measures each amount of movement. It is composed of a fixing bracket 13 to be magnetically attached. The oblique probe 10 is, for example, 7
A probe that emits an ultrasonic signal to the rail RAIL at an angle of 0 ° and receives reflected waves from defects etc.
0a is connected to the ultrasonic flaw detector 2 (FIG. 1). The length direction of the rail is defined as a Y direction, the width direction of the rail is defined as an X direction, and the height direction of the rail is defined as a Z direction. The measuring unit 12 includes an X-direction encoder 12 _X and a Y-direction encoder 1
It incorporates a 2 _Y, measuring their X-direction moving amount x by X-direction encoder 12 _X, Y-direction encoder 1
It measures the Y-direction movement amount y of the slide shaft 12a by 2 _Y. Then, these measured quantities x and y are transmitted to the ultrasonic flaw detector 2 via the cable 10b.

The fixing bracket 13 is provided with slide shafts 13b, 13c and 13d on its upper surface and on the left and right side surfaces.
Each slide shaft 13b, 13c, 13d has a holder 14
b, 14c and 14d are slidably mounted (FIG. 3). The holder 14 holds the measuring unit 12 in a detachable manner.
Holding 2. FIG. 3 is a schematic front view of the rail RAIL viewed in the length direction.
The measurement unit 12 is held at the left and right holders 14c,
14d shows a state where the measurement unit 12 is not held. That is, FIG. 3 illustrates a state in which the rail top surface (A portion) is measured, and the side surface of the head (B1 portion, B portion) is measured.
2), the measuring unit 12 is attached to the holder 14b.
Needs to be replaced with the holders 14c and 14d. FIG. 4 shows a plan view (a) and a side view (b) of the detector for oblique flaw detection 3A. Angle probe 10, probe holder 11, slide shaft 12a, X-direction encoder 1
_2X , Y-direction encoder _12Y , detachable switch 13a,
The slide shaft 13b and the holder 14d are shown in some detail. Incidentally, the fixing bracket 13 has teeth 13e of the encoder 12 _X is provided on its upper surface and left and right sides, allowing the measurement of the amount of movement x of the measuring part 12.

As described above, the top surface and the side surface of the rail are measured by the oblique flaw detector 3A shown in FIGS. 2 to 4. In the case where the base surface (C portion, D portion) of the rail is measured. In this case, an inverted U-shaped probe holder 16 shown in FIG. 5 is used. The probe holder 16 has a proximal end 16a connected to the slide shaft 12a of the measuring section 12, a distal end 16b for detachably holding the probe 10, and a proximal end 16a and a distal end 16b. And a central portion 16c. Then, the oblique probe 10 is inserted into the mounting hole 17 provided in the tip portion 16b.
Is mounted, and the connecting rod 18 is provided at the center portion 16c so as to be vertically movable, so that the probe 10 can measure the base surface. FIG. 5 illustrates a state at the time of flaw detection at the D portion, and the amount of movement of the probe 10 in the rail length direction (Y direction) and the rail width direction (X direction) is determined via the slide shaft 12a. To the encoders 12 _X and 12 _Y of the measuring unit 12.

Next, a description will be given of a method of use and operation of the portable rail flaw detector 1 having the above configuration. [ Preparation work and the like ] First, it is necessary to input management data on the measurement point to the ultrasonic flaw detector 2. Although the specific contents of the management data are determined as appropriate, an example is shown in FIG. Here, the route name and the kilometer from the starting point are data for specifying a measurement point, and whether the rail is an up / down / single line at the specified measurement point, or which rail is left or right. Is specifically specified. Also, a rail type, a welding type, and the like are specified.
60K, 37K, 50PS, etc., and the welding types include gas welding, enclosed arc welding, and gold summit. In addition, the management data may include flaw detection conditions, measurement dates, and the like. All of these management data may be manually input at the flaw detection site.
The data of the head office computer may be transferred via a C card. In any case, at the start of measurement,
Since the type of the rail at the measurement point is specified, the ultrasonic flaw detector 2 can specify the shape of the corresponding rail based on data as shown in FIG.

Next, the probe position detector 3 is attached at the measurement point in the vicinity of the welding point WELD of the rail RAIL. If the oblique flaw detector 3A is used, for example, after setting the detector 3A in the state of FIG. 2, the detachable switch 13a is rotated to magnetically attach the fixing bracket 13 to the rail. In the case where foreign matter is attached to the rail, the foreign matter is removed with a rag or the like, and the rail is cleaned with a wire brush or cloth. Thereafter, a glycerin aqueous solution having a concentration of 75% or more is used as a couplant. Rail RAIL for fixing bracket 13
When the magnetic attachment is completed, the ultrasonic flaw detector 2 stores the origin position in a state where the probe 10 is set at the reference position. Although the origin position is not particularly limited, for example, the end of the rail welding portion WELD is determined as the origin set position. FIG. 8 is a drawing in which the end point of the rail is viewed from the start point of the rail.
Part) measurement, head left side (B1 part) measurement, head right side (B
2), the origin positions of the base left surface (C portion) measurement and the base right surface (D portion) measurement are indicated by circles. In the following description, measurement is first performed on the top of the rail (A section).

[ Measurement of Rail Top] After instructing the ultrasonic flaw detector 2 to perform the measurement at the part A, the flaw detection operator presses the flaw detector at a pressure of about 1 to ² kg / cm ² while performing the flaw detection. The tentacle 10 is moved away from the origin position, and then is moved closer to the origin position (hereinafter, referred to as zigzag scanning). Then, the echo data from the probe 10 and the distance data from the encoders 12 _X and 12 _Y are continuously transmitted to the ultrasonic flaw detector 2 through the cables 10 a and 10 b, respectively. Display of A-Scope Image Then, the ultrasonic flaw detector 2 displays an A-scope image on the upper half of the liquid crystal screen 7 based on the echo intensity V and the transmission / reception time difference of the ultrasonic echo input from the cable 10a. . Specifically, as shown in FIG. 10A, an ultrasonic echo is displayed together with the dividing line L, the dividing line M, and the dividing line H. Note that an echo portion exceeding the L division line is displayed in red.

Identification of Defect Area The ultrasonic flaw detector 2 also calculates deviations x and y of the probe 10 from the origin based on distance data from the encoders 12 _X and 12 _Y. Further, the beam path w is calculated based on the time difference until the ultrasonic echo is received, and the distances y _F and Z in the Y direction from the defect to the probe 10 are calculated based on the following equation.
The direction depth d is calculated (see FIG. 9). _{y F = w × SIN (α} ), d = w × COS (α) Consequently, in the state of FIG. 9, the position coordinates of the defect, (x,
y−y _F , d). On the other hand, the probe 10
Of the echo intensity V and the beam path w with the zigzag scanning of
Since changes sequentially, ultrasonic flaw detector 2, the coordinates of the defect echo exceeding L divided lines _{(x, y-y F,} d) and by successively determining the echo intensity V, the start point coordinates (x
_{s, ys-y F, ds} ) and ending point coordinates (xe, YE
y _F , de). Also extracts the maximum value Vm of the defect echo, the coordinate position _{(xc, yc-y F,} dc) a. X direction decoder 12 in the X direction obtained from _X start point xs and the end point xe, determined from the Y-direction decoder 12 _Y Y
If calculated based on the start point ys and end point ye of the direction and the start point ws and end point we of the beam path obtained from the propagation time of the ultrasonic signal, the spread of the defect echo on the XY plane is
(Xs, ys-y _F) and (xe, ye-y _F) believed to be an end point. The spread on the ZY plane is
(Ys-y _F, ds) is believed to be (ye-y _F, de) and the end point. Note that ys−y _F = ys−ws × SIN (α), ds = ws ×
COS (α) ye−y _F = ye−we × SIN (α), de = we ×
COS (α).

Display of C Scope Image The ultrasonic flaw detector 2 extracts the spread of the defect echo on the XY plane by the above-described procedure, and displays the defect echo on the C scope image of the liquid crystal screen 7 in real time (FIG. 10
(A)). In the state of FIG. 10A, the C scope image is an image of the top of the rail (part A) viewed from directly above, but as shown, (xs, ys-y _F ) and (xe, y)
rectangular shape appears to e-y _F) of the endpoints, the rectangular shape is colored in a color corresponding to the maximum value Vm of the defect echo. Note that the dashed line at the center of the C-scope image in FIG. 10A is the welding location (reference origin).
A broken line near the reference origin is a reference line indicating a range in which a defect is likely to occur, and is drawn based on information on the rail type and the welding type specified at the start of the operation. As described above, according to the present invention, the defect position can be visually confirmed on the XY plane only by causing the probe 10 to perform zigzag scanning on the rail, and furthermore, the positional relationship with the welding portion of the rail and the echo intensity. Since the level is also indicated, the flaw detection operation can be performed without skill. For example, when the probe 10 is roughly scanned on the rail, an A-scope image or C
If an anxious echo appears on the scope image,
Once again, the probe 10 may be finely scanned to perform a precise flaw detection operation.

Display of B-scope image After confirming the A-scope image and the C-scope image as shown in FIG. 10 (a), next, turn the operation knob 9a to the right or operate the remote controller 4 to display the liquid crystal screen. 7 can be changed to the state shown in FIG. FIG. 10 (b)
Shows a display state of the liquid crystal screen 7, in which a B-scope image is displayed on the left half and a C-scope image is displayed on the right half. The flaw detection operator could use this B scope image and C
The plane position and the depth position of the defect can be finally confirmed by the scope image. Note that the rail cross-sectional shape of the B-scope image is drawn based on the shape data in FIG.

Registration of Flaw Detection Data When the measurement of the portion A is completed as described above, the flaw detection operator operates the operation knob 9 (or the remote controller 4) to change the measured flaw detection data to the flaw detection result shown in FIG. Register in table TBL. In the example shown in the figure, two defects are detected in the measurement of the portion A. For example, xs = 30, xe
= 42, xc = 37, ds = 20, de = 25, dc =
At position 23, a defect at the level of “region 3” exists at a position yc = 13 from the origin position. Regions 2 to 5 indicate the level range of the echo intensity of the defect, “region 2” ranges from the L line to the M line, “region 3” ranges from the M line to the H line, 4 "is H line to + 6d
The range up to B, “region 5”, means that the defect has a higher echo intensity.

[ Measurement of Side of Rail Head ] Subsequently, measurement of the side of the head is performed.
b and replace it with the holder 14c or 14d. The subsequent operation is the same as the measurement for the top surface of the head (part A), and the oblique probe 10 is zigzag scanned on the side of the rail while viewing the A-scope image and the C-scope image.
When the processing is completed, a B-scope image and a C-scope image are drawn, and after confirming them, the measurement data is registered in the flaw detection result table TBL. In the example of FIG. 11, the measurement of the portion B2 is performed, and the coordinates of the defect are xs = 0, xe = 8, xc = 8, and ds = 1.
This means that a defect at the level of “region 5” exists at the position of 0, de = 17, dc = 17, yc = 1.

[ Measurement of Base Surface ] Next, when measuring the base surface of the rail, it is necessary to use the inverted U-shaped probe holder 16 shown in FIG. Then, for example, the probe 10 is mounted in the state shown in FIG. In the D section measurement, similarly to the measurement of the rail head, the deviation from the origin position of the probe 10 is determined by the decoder 1.
2 _X, 12 obtained from the _Y, but (see Figure 7) the shape of the base surface is different according to the type of rail, the ultrasonic flaw detector 2, the B-scope image and C scope images while performing appropriate correction I will draw. That is, the decoders 12 _X ,
_Assuming that the distance data from 12Y is x, y and the beam path is w, the depth of the defect is w × COS (α) when measured in a direction orthogonal to the base surface (FIG. 12).
(A)). Therefore, this is converted into a depth in the vertical direction, and is expressed as w × COS (α) × COS (θ) (FIG. 12).
(B)). Further, given the same manner, the X-direction deviation x _F from the origin position of the defect (base right end surface), x + w × C
OS (α) × SIN (θ).

Shape data corresponding to rail type (FIG. 7)
Is specified to the ultrasonic flaw detector 2 at the start of the work, the ultrasonic flaw detector 2 performs the above calculation corresponding to the rail type and displays the accurate defect position on the C scope image. . Therefore, the flaw detection operator can perform zigzag scanning while accurately grasping the defect position with the C-scope image, and thereafter can confirm the defect with the C-scope image and the B-scope image. In the B scope image, the defects detected by the A section measurement and the B section measurement are also displayed in an overlapping manner. After confirming the defect position and the defect level, the measurement data can be registered in the flaw detection result table TBL. In this way, if a series of flaw detection work is completed, flaw detection data may be registered in the IC card as necessary. Further, flaw detection data can be arranged and printed from a printer. FIG. 13 is a diagram showing a list of the results of the flaw detection. In the places where the defects are detected, the levels of the defects are classified and displayed in the range of regions 2 to 5. As mentioned above, although one Example of this invention was described, the specific apparatus structure and operation content shown in an Example do not limit this invention at all. For example, the method of extracting flaw detection data and the method of correction calculation in consideration of the rail shape are merely examples, and can be appropriately changed.

[0020]

As described above, according to the portable rail flaw detector according to the present invention, flaw detection data can be automatically acquired only by moving the probe by hand, and the ultrasonic echo signal can be obtained. Can be displayed on the A-scope image, and the defect position can be displayed on the C-scope image in real time. Further, the acquired flaw detection data can be subjected to a correction operation along the rail shape, and the defect position can be displayed on a B-scope image.

[Brief description of the drawings]

FIG. 1 is a configuration diagram of a portable rail flaw detector according to an embodiment of the present invention.

FIG. 2 illustrates a use state of the portable rail flaw detector of FIG. 1;

FIG. 3 is a front view of a probe position detector.

FIG. 4 is a plan view and a side view of a probe position detector.

FIG. 5 illustrates an inverted U-shaped probe holder.

FIG. 6 illustrates a part of management data.

FIG. 7 shows rail shape data for each rail type.

FIG. 8 illustrates a measurement origin position in ultrasonic testing.

FIG. 9 is a view for explaining internal calculation of the ultrasonic flaw detector.

FIG. 10 illustrates an A-scope image, a C-scope image, and a B-scope image displayed on a liquid crystal screen.

FIG. 11 illustrates an example of a data table for storing flaw detection data.

FIG. 12 is a diagram illustrating a correction operation in ultrasonic inspection of a base surface of a rail.

FIG. 13 illustrates an example of a book printed out from a printer.

FIG. 14 is an A-scope image for explaining a conventional technique.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Portable rail flaw detector 2 Digital ultrasonic flaw detector 3 Probe position detector 10 Ultrasonic probe 12 Measuring unit 13 Fixed part (fixed metal fitting)

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP 7-6959 (JP, B2) JP 6-43988 (JP, B2) (58) Fields surveyed (Int. Cl. ⁶ , DB name) G01N 29/00-29/28

Claims (3)

(57) [Claims] 1. An ultrasonic probe is moved by a slide mechanism.
A measurement unit that holds the probe so as to be movable in the axial direction and measures the amount of biaxial movement of the probe, and that can be fixed to a rail, and that the measurement unit can be held on a rail head upper surface or a rail head side surface. A probe position detector having a fixed portion, and a defect position and a defect level are automatically calculated based on an ultrasonic echo signal obtained from the probe and a biaxial movement amount obtained from the measuring portion. The ultrasonic echo signal can be displayed on an A-scope image, and when the defect level exceeds a predetermined value, the defect position is displayed on a B-scope image or C-scope image.
A digital ultrasonic flaw detector capable of displaying a scope image in real time, wherein the digital ultrasonic flaw detector displays an A-scope image and a C-scope image in real time, and then responds to an artificial operation to a B-scope image. And a C-scope image, and stores information on the defect position and defect level in response to a subsequent operation. 2. The digital ultrasonic flaw detector has means for specifying the type and shape of a rail as a measurement object, and a defect position calculated for each measurement object is
2. The portable rail flaw detector according to claim 1, wherein the device is displayed together with a rail graphic drawn on the C-scope image or the B-scope image. 3. 3. A holder which is slidable on each of the end faces is attached to a horizontal end face and a vertical end face of the fixing part, and by changing the measuring part to one of the holders, a rail head is provided. 3. The portable rail flaw detector according to claim 1 or 2, wherein flaw detection work on the upper surface, the rail head side surface, and the rail base surface is enabled.