JP6121513B2 - Rail head wound continuous inspection method and apparatus - Google Patents

Description

  The present invention relates to a method and apparatus for flaw detection using an echo of an ultrasonic pulse, and more particularly to a rail flaw detection method and apparatus capable of accurately inspecting a flaw on a rail head.

The rail is a strip-shaped steel product that supports the load of the railway vehicle and guides the railway vehicle in the traveling direction, and has a special cross-sectional shape.
FIG. 16 is a conceptual longitudinal cross-sectional view of a railcar and a rail that supports the railcar.
As shown in FIG. 16, the rail 100 includes a head 100a. The head 100a includes a tread surface 100b and two side surfaces 100e continuous to the tread surface 100b. The wheel 200 of the railway vehicle is in direct contact with the one side surface 100e and the tread surface 100b.
The rail 100 includes an abdomen 100d that supports the head 100a. The abdomen 100d has a width that is narrower than the width (rail width) between the two side surfaces 100e.
Moreover, the rail 100 is provided with the upper neck part 100c which connects the head part 100a and the abdominal part 100d. This connection connects each side surface 100e or the lower surface of the head portion 100a and the abdomen portion 100d. The upper neck portion 100c has a curved surface 101 in which the surface of the rail 100 is recessed in a round shape.

Since the head 100a of the rail 100 supports the load of the wheel 200 of the railway vehicle, the head 100a may be damaged (cracked).
FIG. 17A to FIG. 17C are views showing the state of scratches (cracks) occurring on the rail.
17A is a conceptual perspective view of the rail, FIG. 17B is a conceptual side view of the rail in FIG. 17A, and FIG. 17C is a conceptual front view of the rail in FIG. 17A. FIG.
As shown by the broken lines in FIGS. 17A to 17C, the scratches generated on the rail 100 are scratches (simply “substantially parallel”) that proceed substantially parallel to the tread surface 100b from the starting point F1 of the tread surface 100b of the head 100a. There are F2 and a flaw that progresses in the head 100a in an obliquely downward direction in the vertical direction (simply referred to as “scratch that proceeds in an obliquely downward direction”) F3. Among these, the flaw F3 progressing in the diagonally downward direction is derived from the flaw F2 progressing substantially in parallel or occurs from the starting point F1. Further, both the flaw F2 traveling substantially parallel and the flaw F3 traveling obliquely downward occur so as to extend in the traveling direction A of the wheel 200 of the railway vehicle.
In FIGS. 17A to 17C, the same parts as those in FIG. 16 are denoted by the same reference numerals.

The flaw F2 traveling substantially in parallel can be detected visually because the upper tread surface 100b is darkened. In order to accurately measure the depth (the depth from the tread surface 100b) of the front end of the flaw F2 traveling substantially in parallel, an ultrasonic flaw detector irradiates the rail 100 with an ultrasonic wave, and the inside of the rail 100 is detected from the echo. The tip of the wound F2 that runs substantially in parallel is found.
For example, in this ultrasonic flaw detector, the probe is applied to the tread surface 100b, the ultrasonic wave is irradiated obliquely toward the inside of the head 100a, and the echo is detected via the probe. There are types (see, for example, Patent Document 1).

In the conventional rail flaw detection method and apparatus, an ultrasonic wave is obliquely applied to the surface of the wound to detect an echo at the tip (end) of the wound, and the beam path when the maximum value of this echo is obtained In many cases, an edge echo method is used in which the depth of a flaw is measured from the refraction angle (such as the irradiation angle of ultrasonic waves) of a probe.
Since this end echo method specifies the depth (position) from the propagation time of ultrasonic waves to the tip of the wound, the measurement of the depth of the wound requires identification of the scanned portion as the tip of the wound. is necessary.
For that purpose, the continuity (or relevance) of echoes from the surface of the wound is important.
On the other hand, if the echo from the surface of the scratch becomes dominant during scanning, the echo at the tip may be buried in this and may be difficult to catch.

In the conventional ultrasonic flaw detection method and apparatus of the type in which an ultrasonic probe is applied to the tread surface 100b, the ultrasonic wave is reflected by the cross section of the flaw F2 that travels substantially in parallel, and reaches the flaw F3 that proceeds in the diagonally downward direction. Therefore, the depth of the flaw F3 proceeding obliquely downward could not be measured.
In addition, since the rail 100 may break when the depth from the tread surface 100b of the front end portion of the flaw F3 progressing obliquely downward reaches about 30 mm, the depth of the front end portion of the flaw F3 proceeding diagonally downward is likely. It is important to measure the accuracy accurately.

Further, in the conventional ultrasonic flaw detection method and apparatus of the type in which the probe is brought into contact with the tread surface 100b, the tread surface 100b is always in contact with the wheel 200 of the railway vehicle as shown in FIG. To do. In particular, the curve portion is worn obliquely.
As wear on the tread 100b progresses, the probe position shifts in one probe method in which measurement is performed using one probe, and two probes in which measurement is performed using two probes. In this method, the positional relationship between the probe for transmitting ultrasound and the probe for receiving ultrasound is shifted. Therefore, regardless of the one-probe method or the two-probe method, accurate measurement of the depth of the tip of each of the flaws F2 traveling in substantially parallel, the flaws proceeding diagonally downward 3 and other flaws. I could not.

  Therefore, conventionally, an ultrasonic transmission probe is applied to one of the two side surfaces 100e (FIG. 16) of the head 100a, and an ultrasonic reception probe is applied to the other of the two side surfaces 100e. A rail flaw detection method and apparatus for irradiating a probe and detecting the echo with a probe for ultrasonic reception has been proposed (see, for example, Patent Document 2).

  Conventionally, in order to accurately detect the depth of the flaw F3 in the obliquely downward direction, an ultrasonic transmission probe and an ultrasonic reception probe are applied to the upper neck portion 100c of the rail 100 and ultrasonic transmission is performed. A rail flaw detection method and apparatus for irradiating ultrasonic waves from a trusted probe toward the tread surface 100b has also been proposed (see Patent Document 3).

In this conventional rail flaw detector, a slider that can move in the length direction of the rail 100, a biasing mechanism that biases the slider in an upward direction, and the slider pivots about the lengthwise axis of the rail 100. A pair of arms provided in a possible manner, and an ultrasonic transmission probe and an ultrasonic reception probe attached to the tips of the arms so as to be movable in the length direction of the rail 100, respectively. And a rail engaging portion that is provided at the tip of each arm and engages with the upper neck portion 100c.
When each arm is rotated toward the rail 100 side and the rail engaging portion is engaged with the upper neck portion 100c, the ultrasonic transmission probe and the ultrasonic reception probe are respectively attached to the upper neck portion 100c. At this time, the ultrasonic wave is irradiated from the ultrasonic transmission probe toward the tread surface 100b, and the rail 100 is flawed from the echo.

According to this conventional rail flaw detection method and apparatus, since the ultrasonic wave is irradiated from the upper neck portion 100c of the rail 100 toward the tread surface 100b, the ultrasonic wave is reflected by the cross section of the flaw F2 that travels substantially parallel and proceeds in a diagonally downward direction. The possibility of not reaching the wound F3 is prevented as much as possible. Therefore, it is possible to irradiate the wound F3 traveling diagonally downward with ultrasonic waves, and by measuring the echo, the depth of the scratch F3 traveling diagonally downward can be measured.
Furthermore, since the upper neck portion 100c does not wear due to contact with the wheels 200 of the railway vehicle, it is possible to accurately measure the depth of the flaw F2 that advances substantially parallel, the flaw 3 that advances obliquely downward, and other flaws. In particular, it is suitable as a reference plane for measuring the depth of the tip of the flaw F3 that progresses diagonally downward, which is the most important factor for determining the rail strength and necessity of replacement.

In this conventional rail flaw detector, since the upper neck portion 100c has the curved surface 101, the transmission angle of the ultrasonic transmission probe and the ultrasonic reception flaw detector can rotate along the curved surface 101, respectively. As described above, a probe rotating mechanism is provided which supports the curved surface 101 so as to be rotatable about the center of the radius.
For this reason, in this conventional rail flaw detector, a probe rotation mechanism connected to the ultrasonic transmission probe and a probe rotation mechanism connected to the ultrasonic reception probe are provided. There is a problem that the number of parts increases and the structure becomes complicated.
Further, for flaw detection at a certain position in the length direction of the rail 100, it is necessary to set the transmission angle of the ultrasonic transmission probe and the reception angle of the ultrasonic reception flaw detector, respectively. In the conventional rail flaw detection method and apparatus, in order to set the transmission angle of the ultrasonic transmission probe, the probe rotating mechanism connected to the probe is manually operated, and the ultrasonic reception probe is further operated. In order to set the receiving angle of the probe, the probe rotating mechanism connected to the probe is manually operated.
For this reason, the conventional rail flaw detection method and apparatus have a problem that the rail flaw detection work is complicated, and that it takes a long time to measure the depth of the front end of the flaw F3 that progresses in an obliquely downward direction.

JP 9-304364 A JP2000-9698 JP2009-236808

  The present invention has been made in view of the above problems, and can accurately measure the depth of scratches on the head, has a small number of parts, has a simple structure, and has a simple rail flaw detection operation. An object of the present invention is to provide a rail flaw detector capable of reducing time. It is another object of the present invention to provide a rail flaw detection method and apparatus that can accurately measure the depth of flaws on the head, can easily perform rail flaw detection work, and can shorten the flaw detection time.

In the rail flaw detector according to the first aspect of the present invention, a plurality of first ultrasonic transducers are arranged, and a plurality of phased array probes for transmission for irradiating ultrasonic waves and a plurality of second ultrasonic transducers are arranged. A receiving phased array probe for receiving an echo of the ultrasonic wave applied to the rail from the transmitting phased array probe, the transmitting phased array probe, and the receiving The phased array probe is arranged with the abdomen of the rail sandwiched between each other, and both are placed against the upper neck portion of the rail where the curved surface is formed or the lower surface of the head portion of the rail, Ultrasonic wave is irradiated from the phased array probe for transmission toward the tread of the rail, the echo is received by the phased array probe for reception, and the position of the tip of the flaw of the rail from the echo And measuring.
In the rail flaw detector according to the first aspect of the present invention, measurement information is obtained by performing sector scanning with the transmission phased array probe and the receiving phased array probe. And a measurement means for measuring the position of the tip of the wound by an end echo method based on the measurement information.
The invention of claim 3 of the present application is the rail flaw detector of the invention of claim 2 of the present application, in which the transmitting phased array probe and the receiving phased array probe are fixed, and the slider is fixed. Drive means for moving in the length direction of the rail is provided, and the drive means moves the slider in the length direction of the rail when the sector scanning is performed.
The invention of claim 4 of the present application is the rail flaw detector according to claim 2 or claim 3 of the present application, and a slider for fixing the phased array probe for transmission and the phased array probe for reception. Drive means for moving the slider in the length direction of the rail, and the sector scanning is performed in synchronization with the movement of the slider by the drive means.
The invention of claim 5 of the present application is the rail flaw detector according to claim 2 or claim 3, wherein the transmitting phased array probe and the receiving phased array probe are fixed, Drive means for moving the slider in the length direction of the rail is provided, and movement of the slider by the drive means is performed independently of the sector scanning.
The invention of claim 6 of the present application is the rail flaw detector according to claim 2 of the present application, wherein the transmitting phased array probe and the slider for fixing the receiving phased array probe are fixed to the rail. Driving means for moving the slider in the length direction, and the driving means moves the slider based on the end information of the sector scan.
The invention of claim 7 of the present application is the rail flaw detector according to any one of claims 1 to 6, wherein the phased array probe for transmission and the phased array probe for reception are It is characterized by being arranged on the same side with respect to the traveling direction of the wound.
The invention of claim 8 of the present application is the rail flaw detector according to any one of claims 1 to 7, wherein the transmitting phased array probe and the receiving phased array probe are both It arrange | positions behind the advancing direction of the said damage | wound, It is characterized by the above-mentioned.
The invention of claim 9 of the present application is the rail flaw detector according to any one of claims 1 to 7, wherein the transmitting phased array probe and the receiving phased array probe are both It is arrange | positioned ahead of the advancing direction of the said wound.

According to the rail flaw detection method of the invention of claim 10 of the present application, a rail is irradiated with ultrasonic waves from a transmission phased array probe in which a plurality of first ultrasonic transducers are arranged, A method of detecting a rail by receiving with a phased array probe for reception in which a plurality of ultrasonic transducers are arranged, wherein the phased array probe for transmission and the phased array probe for reception include And an arrangement step of placing the rail against the upper neck of the rail or the lower surface of the head of the rail, both of which are arranged with the abdomen of the rail interposed therebetween, and after the arrangement An irradiating step in which the transmitting phased array probe emits ultrasonic waves toward the tread surface of the rail; and a receiving step in which the receiving phased array probe receives echoes of the ultrasonic waves. It characterized in that it comprises the flop, and a measurement step of measuring the position of the distal end portion of the wound of the rail on the basis of the received information.
The rail flaw detection method according to claim 11 of the present application is the rail flaw detection method according to claim 10, wherein in the irradiation step and the reception step, the transmission phased array probe and the reception phased array, respectively. Sector scanning is performed by a probe, thereby obtaining measurement information, and in the measurement step, the position of the tip of the rail flaw is measured by an end echo method based on the measurement information. To do.
The rail flaw detection method according to claim 12 of the present application is the rail flaw detection method according to claim 11, wherein the transmitting phased array probe and the receiving phased array are used when the sector scan is performed. The probe moves in the length direction of the rail.
A rail flaw detection method according to a thirteenth aspect of the present invention is the rail flaw detection method according to the eleventh or twelfth aspect of the present invention, wherein the transmission phased array probe and the reception phased array probe are fixed. The sector scan is performed in synchronization with the movement of the slider.
A rail flaw detection method according to a fourteenth aspect of the present invention is the rail flaw detection method according to claim 11 or 12, wherein the transmission phased array probe and the reception phased array probe are fixed. The slider is moved independently of the sector scanning.
A rail flaw detection method according to a fifteenth aspect of the present invention is the rail flaw detection method according to the eleventh aspect of the present invention, in which the transmission phased array probe and the reception phased array probe are moved to the end of the sector scan. It is characterized in that it is moved in the length direction of the rail based on the information.
The rail flaw detection method according to the present invention of claim 16 is the rail flaw detection method according to any one of claims 10 to 15, wherein, in the placement step, the transmission phased array probe and the reception flaw detection method are used. The phased array probe is arranged on the same side with respect to the traveling direction of the scratch.
The rail flaw detection method according to claim 17 of the present application is the rail flaw detection method according to any one of claims 10 to 16, wherein in the placement step, the transmission phased array probe and the reception flaw detection method are used. All of the phased array probes are arranged behind the wound in the traveling direction.
The rail flaw detection method of the present invention of claim 18 is the transmission flawed array probe and the reception phased in the arrangement step of the rail flaw detection method according to any one of claims 10 to 16. All of the array probes are arranged in front of the wound in the traveling direction.

In the rail flaw detection method and apparatus of the present invention, a phased array probe for transmission and a phased array probe for reception are applied to the curved surface of the upper neck of the rail or the lower surface of the head, and the phased array probe for transmission is transmitted. Since ultrasonic waves are irradiated from the child toward the tread, ultrasonic waves can be applied to wounds that travel in a substantially parallel manner, scratches that progress in a diagonally downward direction, and other scratches. Can be measured.
Furthermore, since the lower surface or upper neck of the head of the rail does not wear due to friction with the wheels of the railway vehicle, it accurately measures the depth of scratches traveling in parallel, scratches traveling downward in the diagonal direction, and other scratches. In particular, it is suitable as a reference plane for measuring the depth of the tip of a flaw that progresses obliquely downward, which is the most important factor in determining the strength of rails and whether or not replacement is necessary.
In the rail flaw detector according to the present invention, as in the prior art, a probe rotation mechanism connected to the phased array probe for transmission and a probe rotation mechanism connected to the phased array probe for reception are provided. As a result, the number of parts is reduced and the structure is simplified.
Further, in the rail flaw detection method and apparatus according to the present invention, a probe rotating mechanism connected to the transmission phased array probe is not required. Therefore, when flaw detection is performed at a point on the rail, the phased array probe for transmission is used. Manual operation to set the transmitter's transmission angle is not required, and a probe rotation mechanism connected to the phased array probe for reception is also unnecessary, so that flaw detection at a point with a rail is not necessary. At this time, a manual operation for setting the reception angle of the phased array probe for reception is also unnecessary. Therefore, in this rail flaw detection method and apparatus, the flaw detection work of the rail is easy, and the depth measurement (flaw detection time) of the front end of a flaw such as a flaw that progresses in a diagonally downward direction can be performed in a shorter time than before. That is, the flaw detection time can be shortened.
In the rail flaw detection method and apparatus according to the present invention, the two-probe V scanning method and the rear flaw detection are suitable.
The two-probe V-scanning method is suitable because the noise echo is low and the discrimination of the echo of the scratch is high. In addition, the back flaw detection is suitable because the continuity of the echo from the surface of the wound traveling diagonally downward and the echo at the tip of the wound can be seen, and the depth (position) of the tip of the wound. This is because it is easy to accurately identify. In addition, when the echo from the surface of the wound progressing in the diagonally downward direction becomes dominant and the echo at the tip of the wound is buried in this and is difficult to catch, it is preferable to perform forward flaw detection.

1 (a) to 1 (d) are conceptual perspective views showing a main part of a rail flaw detector and a rail flaw detection method according to a first embodiment of the present invention. It is a figure which shows the mode of the rail flaw detection apparatus in a flaw detection, and the rail flaw detection method. FIG. 2 is a conceptual front view of a main part of the rail flaw detector shown in FIG. FIGS. 3A and 3B are views showing the arrangement relationship between the rail and the rail flaw detector in the rail flaw detector and the rail flaw detection method of FIG. FIG. 4 is an enlarged view of a main part of FIG. FIG. 5 is a conceptual diagram showing a configuration (hardware) of the rail flaw detector shown in FIG. 6 is a functional block diagram of the rail flaw detector shown in FIG. FIG. 7 is a conceptual enlarged perspective view of the slider of FIG. FIG. 8 is a conceptual perspective view of the main part of the slider showing a state in which the slider of FIG. 7 is partially disassembled. FIG. 9 is a conceptual cross-sectional view of a main part of the rail flaw detector shown in FIG. FIGS. 10A and 10B are conceptual diagrams showing the sector scanning process in the information acquisition means. FIG. 11 is an enlarged view of the main part of FIG. 2 and shows the transmission range of ultrasonic waves and the reception range of echoes (reflected ultrasonic waves) in sector scanning. FIG. 12 (a) shows the slider moving distance (horizontal axis) and slider moving speed (vertical axis) in each rail flaw detection method and apparatus of the first embodiment, the second embodiment, and the fourth embodiment. FIG. 12 (b) shows the relationship between the first and second embodiments, and FIG. 12 (c) shows the rail flaw detection method and apparatus of the fourth embodiment, using the slider shown in FIG. 3 (a). It is a conceptual top view of a rail which shows a mode that the sector scan was performed with respect to the rail. FIGS. 13A to 13D are conceptual perspective views showing a main part of the rail flaw detector and the rail flaw detection method according to the second embodiment, particularly in the two probe V scanning method and in the front flaw detection. It is a figure which shows the mode of a rail flaw detector and a rail flaw detection method. FIGS. 14A and 14B are views showing the arrangement relationship between the rail and the rail flaw detector in the rail flaw detector and the rail flaw detection method of the second embodiment. FIG. 15A is a diagram showing the relationship between the slider moving distance (horizontal axis) and the slider moving speed (vertical axis) in the rail flaw detection method and apparatus according to the third embodiment. ) Is a conceptual plan view of a rail showing a state in which sector scanning is performed on the rail using the slider of FIG. FIG. 16 is a conceptual cross-sectional view of a railcar and a rail that supports the railcar. FIGS. 17A to 17C are views showing the state of scratches (cracks) generated on the rail.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

1 (a) to 1 (d) are conceptual perspective views showing a main part of a rail flaw detection method and apparatus according to a first embodiment of the present invention, and particularly a two-probe V scanning method and a rear flaw detection. It is a figure which shows the mode of the rail flaw detection method and apparatus in FIG. Among these, FIG. 1A is a diagram showing a state of the rail 100 before flaw detection.
As shown in FIG. 1A, the rail flaw detector 1 includes a phased array probe 50T for transmission and a phased array probe 50R for reception. 1A to 1D show a state from the front side of the rail 100. FIG.

FIG. 2 is a conceptual front view of a main part of the rail flaw detector shown in FIG.
As shown in FIG. 2, the transmitting phased array probe 50T and the receiving phased array probe 50R are arranged with the abdomen 100d of the rail 100 interposed therebetween, and both are curved surfaces of the upper neck 100c. 101 or the lower surface of the head 100a. 2 to 15A and 15B, the same parts as those in FIGS. 1, 16 and 17A to 17C are indicated by the same reference numerals.

FIGS. 3A and 3B are views showing the arrangement relationship between the rail and the rail flaw detector in the rail flaw detector and the rail flaw detection method of FIG. 3A shows a conceptual plan view of the rail and rail flaw detector (left part of the figure) and a conceptual rear view thereof (right part of the figure), and FIG. 3B shows a conceptual right side of the rail and rail flaw detector. A plane view (left part of the figure) and a conceptual front view (right part of the figure) are shown.
In the rail flaw detector 1, the transmitting phased array probe 50T and the receiving phased array probe 50R have a flaw F2 that advances substantially in parallel, or a flaw F3 that advances diagonally downward (hereinafter referred to as “scratch”). It is arranged on the same side with respect to the direction of travel.
In the rail flaw detector 1 as an example, as shown in FIGS. 3A and 3B, both the transmission phased array probe 50T and the receiving phased array probe 50R are obliquely downward. It is arranged behind the forward direction of F3.

The transmitting phased array probe 50T and the receiving phased array probe 50R are arranged in the rearward direction of the wound as described below, and as will be described later, the rearward direction of the wound in the forward direction of the wound. A method for flaw detection / scanning toward the tread surface 100b obliquely upward toward the back is referred to as rear flaw detection.
In addition, the transmitting phased array probe 50T and the receiving phased array probe 50R are arranged with the abdomen 100d of the rail 100 sandwiched between each other, and both are arranged on the same side with respect to the traveling direction of the wound. The scanning method is called a double probe V scanning method.

  In this rail flaw detector 1, ultrasonic waves are irradiated (transmitted) from the transmitting phased array probe 50T toward the tread surface 100b of the rail 100, and the echo is received by the receiving phased array probe 50R. The rail 100 is flawed from the echo and the position of the front end Fa of the flaw is measured. This measured position includes the depth M from the tread 100b of the front end portion Fa of the wound.

FIG. 4 is a conceptual diagram of a main part of FIG.
As shown in FIG. 4, the phased array probe 50T for transmission is a probe in which a plurality of first ultrasonic transducers Tn are arranged. Note that n is an arbitrary natural number of 2 or more.
The receiving phased array probe 50R is a probe in which a plurality of second ultrasonic transducers Rn are arranged. Note that n is an arbitrary natural number of 2 or more.
Each first ultrasonic transducer Tn (T-1, T-2, ..., Tn-1, Tn) and each second ultrasonic transducer Rn (R-1, T) -2, ..., Rn-1, Rn) have the same structure, and a pulser receiver (not shown) is connected to each ultrasonic transducer Tn, Rn. Yes.

As shown in FIG. 4, the transmission phased array probe 50T and the reception phased array probe 50R are both a casing 51 and a flaw detection shoe 52 provided on the rail 100 side of the casing 51. It has.
The casing 51 of the phased array probe 50T for transmission accommodates each first ultrasonic transducer T-n, and the casing 51 of the phased array probe 50R for reception has each second ultrasonic vibration. The child RN is accommodated.
Further, the flaw detection shoe 52 has a portion along the curvature radius of the curved surface 101 formed on the upper neck portion 100c of the rail 100, a portion formed with a curvature radius slightly smaller than the curvature radius, or a portion along the lower surface of the head. It is a convex member. The flaw detection shoe 52 is made of a material having an ultrasonic wave propagation speed.
The flaw detection shoe 52 of the transmission phased array probe 50T and the flaw detection shoe 52 of the reception phased array probe 50R are both the curved surface 101 of the upper neck portion 100c or the lower surface of the head portion 100a and glycerin or water. Contact through a medium such as

FIG. 5 is a conceptual diagram showing a configuration (hardware) of the rail flaw detector shown in FIG.
FIG. 6 is a functional block diagram of the rail flaw detector shown in FIG.
As shown in FIG. 5, in the rail flaw detector 1, in addition to the transmission ultrasonic array probe 50T and the reception ultrasonic array probe 50R described above, a slider 10 and an encoder (slider position detection means) are provided. 35, a motion control drive unit 110, a computer 120, an ultrasonic flaw detector 130, and a detector (not shown).

  Among these, as shown in FIG. 6, the slider 10 functions as a moving means for allowing the transmitting phased array probe 50 </ b> T and the receiving phased array probe 50 </ b> R to move in the length direction of the rail 100. . As shown in FIG. 2, the slider 10 includes a roller 12 disposed on the tread surface 100 b of the rail 100.

7 is a conceptual enlarged perspective view of the slider of FIG. 2, and FIG. 8 is a conceptual perspective view of a main part of the slider showing a state in which the slider of FIG. 7 is partially disassembled.
As shown in FIGS. 7 and 8, the slider 10 further includes a roller support member 13 that makes the roller 12 rotatable, and a slider body 14 that moves in the length direction of the rail 100 together with the roller support member 13. It is.
Among these, the roller support member 13 is a frame-like member provided with a shaft 13a for rotatably supporting the roller 12, as shown in FIG. The shaft 13a is provided with a pulley 13b, and a motor (not shown) is connected to the pulley 13b. The roller support member 13 is provided with a guide shaft 13 c that protrudes toward the slider body 14.

  Further, as shown in FIG. 2, the slider main body 14 is a frame that supports the roller support member 13 so as to be movable with respect to the slider main body 14 in a direction perpendicular to the tread surface 100b, in other words, in a vertical direction. The slider body 14 is provided with a guide groove 14a for guiding the guide shaft 13c (FIG. 8) of the roller support member 13 and two shafts 14b (FIG. 8) protruding toward the roller support member 13.

A fixing member 17 is fixed to the slider body 14. The fixing members 17 are arranged on both sides of the head 100a of the rail 100.
Each fixing member 17 includes a fixing portion 17a fixed to the slider body 14, a probe fixing portion 17b fixed to the fixing portion 17a, and an engaging roller support portion 17c.
Among these, the fixing portion 17a is fixed to the slider main body 14 by a screw 20 that is screwed into a hole 19 (FIG. 8) of the fixing portion 17a and a hole (not shown) of the slider main body 14.
Further, the phased array probe 50T for transmission is fixed to the probe fixing portion 17b of one fixing member 17 among the fixing members 17, and the probe fixing portion 17b of the other fixing member 17 is fixed to the probe fixing portion 17b of the other fixing member 17. The phased array probe 50R for reception is fixed.
Further, the engagement roller support portions 17c are arranged on both sides in the length direction of the rail 100 with respect to each probe fixing portion 17b. Each engagement roller support portion 17c is a shaft that rotatably supports the engagement roller 18, and the engagement roller 18 rotates about this shaft. The engaging roller 18 has two surfaces 18a that form a recess.

  Further, as shown in FIG. 8, the slide main body 14 is urged upward by the urging means 15 away from the tread surface 100b. The urging means 15 has a plate spring connected to the guide shaft 13c of the roller support portion 13 at its substantially center, and both ends of the plate spring are connected to the shafts 14b of the slide main body 14, respectively.

  When the slider 10 from which the fixing member 17 is fixed to the slide body 14 is prepared, the roller 12 of the slider 10 is arranged on the tread surface 100b, and each fixing member 17 is fixed to the slide body 14, FIG. The slider 10 can be attached to the rail 100 as shown.

In the slider 10 attached to the rail 100, as shown in FIG. 2, each of the transmitting phased array probe 50T and the receiving phased array probe 50R has its flaw detection shoe 52 above the medium. Engage with the curved surface 101 of the neck 100c or the lower surface of the head 100a.
Further, when this engagement is performed, the transmitting phased array probe 50T and the receiving phased array probe 50R are urged upward by the urging means 15 (FIG. 8).
FIG. 9 is a conceptual cross-sectional view of a main part of the rail flaw detector shown in FIG. In addition, in FIG. 9, the diagonal line which shows the cross section of a rail and a rail flaw detector is abbreviate | omitted.
In the slider attached to the rail 100, as shown in FIG. 9, one of the two surfaces 18a of the engagement roller 18 contacts the lower portion of the side surface 101e of the rail 100, and the other is a curved surface of the upper neck portion 100c. 101 or the lower surface of the head 100a.
When this contact is made, the engagement roller 18 is urged upward by the urging means 15 (FIG. 8).

In the slider 10 attached to the rail 100, when the roller 12 rotates through the shaft 13a by driving a motor (not shown), the slider body 14 moves along the length direction of the rail 100 together with the roller support portion 13, thereby The transmitting phased array probe 50T and the receiving phased array probe 50R move along the length direction of the rail 100.
As the slider 10 moves, the engaging roller 18 rotates. Even when the engagement roller 18 is rotating, one of the two surfaces 18a contacts the lower part of the side surface 101e of the rail 100 by the urging force of the urging means 15 (FIG. 8), and the other is The state of contacting the curved surface 101 of the upper neck portion 100c or the lower surface of the head portion 100a is maintained. Therefore, the slider 10 is guided by the engagement roller 18 along the longitudinal direction of the rail as much as possible.

  Further, since the curved surface 101 of the upper neck portion 100c or the lower surface of the head portion 100a with which the engagement roller 18 contacts does not wear due to contact with the wheel 200 of the railway vehicle, the slider main body 14 passes through the engagement roller 18 and the rail 100. Therefore, the positional relationship between the phased array probe 50T and the receiving phased array probe 50R is not shifted, and accurate measurement of the depth of the front end Fa of the wound is not hindered.

When the unused rail 100 (initial state) is used and the tread surface 100b is worn, the roller 12 and the roller support portion 13 move downward from their initial state positions, while the fixing member 17 and the slide body 14 are The initial position is held by the urging force of the urging means 15. Therefore, the state where the transmitting phased array probe 50T and the receiving phased array probe 50R are engaged with the lower surface of the upper neck 100c or the head 100a is maintained, and the two surfaces 18a of the engaging roller 18a are maintained. However, the state which contacted the lower part of the side surface 101e of the rail 100, the curved surface 101 of the upper neck part 100c, or the lower surface of the head part 100a is maintained.
The detector (not shown) is a means for detecting the movement distance from the initial position of the roller support member 13 to the position where the roller support member 14 is moved in the vertical direction with respect to the slide body 14. The detected moving distance is the amount of wear of the rail 100. When the depth (position) of the front end Fa of the wound is measured, if this amount of wear is further added to the depth M (described later) of the front end Fa of the wound from the tread 100b, the tread 100b of the rail 100 in the initial state is added. It is possible to measure the depth of scratches from the surface more accurately.

  The encoder 35 (FIGS. 5 and 6) is a slider position detecting unit that is connected to the slider 10 and detects the position of the slider 10. The position information of the slider 10 detected by the encoder 35 is transmitted to the moving distance measuring unit 121 of the computer 120. In addition, the reference | standard of the position (movement distance K) of the slider 10 is the front D of the rail 100 (refer Fig.3 (a)).

  In the rail flaw detector 1 of the present invention, the transmitting phased array probe 50T and the receiving phased array probe 50R are rotated about the axis so as to follow the radius of the curved surface 101 of the upper neck portion 100c. A probe rotation mechanism (see Prior Art Document 3) is not provided.

Further, the motion control drive unit 110 in FIG. 5 is a device that controls transmission and reception of ultrasonic waves.
As shown in FIG. 6, the motion control drive unit 110 performs sector scanning (fan-shaped scanning) by the phased array probe 50T for transmission and the phased array probe 50R for reception, and the echo is detected with respect to the scratches. Measurement information acquisition means 111 for obtaining measurement information is provided.

  The measurement information acquisition unit 111 includes a delay time control unit 112a, an applied voltage generation unit 112b, a reception signal processing unit 113a, and a reception signal synthesis unit 113b.

FIG. 10A is a conceptual diagram showing the sector scanning process in the information acquisition means. In particular, the time delay in the delay time control means in the sector scan (lower part of the figure), the voltage generation in the applied voltage generation means (see FIG. Middle stage) and the state of the ultrasonic wave St (the upper stage in the figure) obtained by synthesizing the ultrasonic waves of the respective transducers generated by this voltage.
As shown in FIG. 10A, the delay time control means 112a applies a voltage to each of the first ultrasonic transducers T-1, T-2, ..., Tn-1, Tn. The drive signal St-n to be performed is transmitted to the applied voltage means 112b, and the delay control is performed for the transmission of each drive signal T-n. For example, the delay control is performed sequentially from the first ultrasonic transducer T-1 disposed at one end of the first ultrasonic transducers T-1, T-2, ..., Tn-1, Tn. The transmission of each drive signal T-n is delayed.
The applied voltage generation means 112b that has received the drive signal St-n applies a voltage to each of the first ultrasonic transducers of the phased array probe 50T for transmission in the order in which the drive signal St-n is received. Generate a form of ultrasound.
When pulse-type ultrasonic waves are generated from the first ultrasonic transducers T-1, T-2,..., Tn-1, Tn in this way, the phased array probe 50T for transmission uses By combining the ultrasonic waves of the respective pulse formats, there is an inclination with respect to the arrangement surface of the first ultrasonic transducers T-1, T-2, ..., Tn-1, Tn. The ultrasonic wave St is irradiated.
In addition, the first ultrasonic transducers T-1, T-2,... The angle of inclination with respect to the surfaces of the ultrasonic transducers T-1, T-2,..., Tn-1, and Tn is changed, and thereby, a fan-shaped scanning (sector scanning) irradiation operation is performed.

FIG. 10B is a conceptual diagram showing the sector scanning process in the information acquisition means. In particular, the state of the echo Sr received in the sector scanning (the upper part of the figure) and the echo Sr in the received signal processing means are shown in the second graph. The figure shows the division of the received wave of the ultrasonic transducer (middle of the figure) and the correction for the time delay in the received signal processing means (lower of the figure).
As shown in FIG. 10 (b), the reception signal processing means 113a is configured to receive the ultrasonic wave reflected from the scratch or the like, that is, the echo Sr (FIG. 10 (b)) from the reception phased array probe 50R. )).
The echo Sr is a reception signal in which reception signals to be received by the second ultrasonic transducers are synthesized. The echo Sr is an echo of the ultrasonic wave St that is time-delayed by the delay time control unit 112a.
Therefore, the reception signal processing means 113a divides the echo Sr into ultrasonic waves of each pulse format by the second ultrasonic transducers R-1, R-2,..., Rn-1, Rn. At the same time, each ultrasonic wave Pr-n is corrected by using the correction signal Sr-n to eliminate the time delay. Each ultrasonic wave (reception signal) of the corrected second ultrasonic transducer is transmitted to the reception signal synthesis unit 113b.
The reception signal synthesizing unit 113b (FIG. 6) receives the corrected ultrasonic wave Pr-n (reception signal) of each second ultrasonic transducer and synthesizes each reception signal. This synthesized signal is measurement information regarding the position where the echo is generated. The reception signal combining unit 113b acquires this measurement information, and the acquired measurement information is transmitted to the measurement unit 122 of the computer 120 via the storage unit 123.

FIG. 11 is an enlarged view of the main part of FIG. 2, showing the irradiation range (transmission range) W1 of the phased array probe for transmission in sector scanning and the reception range W2 of the phased array probe for reception in sector scanning. Show.
As shown in FIG. 11, when the transmitting phased array probe 50T and the receiving phased array probe 50R are arranged on the curved surface 101 of the upper neck 100c or the lower surface of the head 100a, the ultrasonic irradiation range W1 A range where the reception range W2 overlaps with each other and a range where the ultrasonic irradiation range W1 and the reception range W2 do not overlap are formed. The overlapping range is the echo detection range.
If one phased array probe serving both for transmission and reception is arranged on the curved surface 101 of the upper neck 100c or the lower surface of the head 100a and sector scanning is performed on the rail 100, one conventional ultrasonic wave is used. Compared to scanning with a probe made of a vibration element, a large amount of measurement information can be obtained, so that the position of the front end Fa of the flaw may be more accurately detected.
However, since enormous amount of measurement information can be obtained, it takes time to measure the depth (position) of the front end Fa of the wound.
In contrast, in the rail flaw detection method and apparatus 1 according to the embodiment of the present invention, the transmitting phased array probe 50T and the receiving phased array probe 50R are arranged with the abdomen 100d of the rail 100 interposed therebetween. In addition, both are disposed so as to contact the curved surface 101 of the upper neck portion 100c or the lower surface of the head portion 100a. For this reason, the detection range of the echo is narrower than that in the case of performing sector scanning using one phased array probe that serves both for transmission and reception, and the scratches generated on the rail 100 are hardly affected by this echo. Since it occurs within the detection range, a flaw that normally exists within the detection range of the echo can be reliably detected in a short time.
Note that scars on the rail 100 hardly occur in the range where the irradiation range W1 and the reception range W2 in the rail 100 do not overlap each other.
In addition, the code | symbol Oa of FIG. 11 conceptually illustrated the reference point of the irradiation range W1, and the code | symbol Ob conceptually illustrated the reference point of the receiving range.

  The computer 120 shown in FIG. 6 includes a moving distance measuring unit 121, a measuring unit 122, a storage unit 123, a scanning instruction unit 124, and a driving unit 125.

Among these, the movement distance measuring means 121 receives the position information of the slider 10 from the encoder 35 and continuously calculates the movement distance K from the initial position of the slider 10.
This reception and calculation are continuously performed after the slider 10 starts moving in the length direction of the rail 100 until the moving distance K reaches the rail length L (0 ≦ K ≦ L). Further, the moving distance measuring means 121 measures the elapsed time after the slider 10 starts moving in the length direction of the rail 100, and this measurement is performed until the moving distance K of the slider 10 reaches the rail length L. It is done continuously.

The measurement means 122 measures the measurement information related to the echo generation position measured by the reception signal synthesis means 113b, the measurement conditions (for example, the irradiation angle (transmission angle) α1, the reception angle α2) input from the ultrasonic flaw detector 130, and the like. The information stored in the storage unit 123 is received.
The measurement information related to the echo generation position is specifically information related to the irradiated ultrasonic wave or each beam path of the echo, and more specifically, a phased array probe for transmission. These are the irradiation time (transmission time) of ultrasonic waves at 50T, the reception time of echoes, the reception time of echoes by the phased array probe 50R for reception, and the like.
The measuring means 122 determines the depth of the tip of the wound by the end echo method from the measurement information on the echo occurrence position and the measurement conditions (for example, transmission angle α1, reception angle α2) input from the ultrasonic flaw detector 130. Find (position) M. The end echo method is a conventional technique.

The storage unit 123 stores an arithmetic expression of the end echo method and the like.
The storage means 123 also includes a drive signal (slider drive instruction signal, slider stop instruction signal, and scan instruction signal of the drive means 125) sent from an input means 131 (described later) of the ultrasonic flaw detector 130, and an ultrasonic transmission angle α1. The reception angle α2, the echo of the received ultrasonic wave, etc. are recorded (stored).
In addition, the storage unit 123 receives the measurement information on the echo generation position from the reception signal synthesis unit 113b, the depth M of the rail 100 (M ≧ 0) measured by the measurement unit 122, and the movement information measurement unit 121. The transmitted movement distance information of the slider 10 is stored.
Further, the information stored in the storage unit 123 is appropriately read by a request signal from the measurement unit 122, the scanning instruction unit 124, the driving unit 125, the ultrasonic flaw detector 130, the motion control drive unit 110, or the like.

The scanning instruction means 124 performs sector scanning by the phased array probe 50T and the receiving phased array probe 50R based on a scanning instruction signal sent from the input means 131 (described later) of the ultrasonic flaw detector 130. Make it.
More specifically, when the scanning instruction unit 124 receives the scanning instruction signal from the input signal 131 via the storage unit 123, the scanning instruction unit 124 issues an ultrasonic irradiation instruction (transmission instruction) by the transmission phased array probe 50T. At the same time, an echo reception instruction is transmitted by the phased array probe 50R for reception.
The transmission instruction is transmitted to the delay time control unit 112a via the storage unit 123. The reception instruction is transmitted to the reception signal processing unit 113a via the storage unit 123.
The phased array probe 50T for transmission irradiates the ultrasonic wave by the delay time control unit 112a that has received the ultrasonic transmission instruction, and the reception signal processing unit 113a that has received the echo reception instruction receives the ultrasonic wave. The phased array probe 50R receives the echo and thereby performs the sector scan described above.

The driving unit 125 is a unit that moves the slider 10 in the length direction of the rail 100.
FIG. 12 (a) shows the slider moving distance (horizontal axis) and slider moving speed (vertical axis) in each rail flaw detection method and apparatus of the first embodiment, the second embodiment, and the fourth embodiment. It is a figure which shows a relationship.
The driving means 125 transmits a slider drive instruction signal to the motor of the slider 10, and the motor that has received the slider drive instruction signal reaches the slider 10 at a certain speed as shown in FIG. Accelerate to. After the state where the slider 10 reaches a certain speed continues for a certain time, the driving means 125 sends a slider stop instruction signal. Upon receiving this slider stop signal, the motor of the slider 10 decelerates and finally stops.

FIG. 12B is a rail diagram showing a state in which sector scanning is performed on the rail 100 using the slider 10 of FIG. 3A in the rail flaw detection method and apparatus of the first and second embodiments. It is a conceptual top view.
As shown by the scanning line B (broken line) of sector scanning in FIGS. 12A and 12B, the driving unit 125 performs sector scanning by ultrasonic wave irradiation (transmission) and echo reception. When moving, the slider 10 is moved in the length direction of the rail 100.

Further, as shown in FIGS. 12A and 12B, sector scanning is continuously performed until the moving distance K of the slider 10 reaches the rail length L from the initial position (moving distance K = 0). .
The sector scan is performed in synchronization with the movement of the slider 10 by the driving means 125.
For example, as shown by scanning line B in FIGS. 12A and 12B, in sector scanning, the moving distance K of the slider 10 reaches a certain fixed distance regardless of the moving speed of the slider 10. Each time, sector scanning is performed once in the width direction of the rail 100. Thus, sector scanning is performed as uniformly as possible in the length direction of the rail 100 with respect to the rail 100.
The scanning instruction unit 124 receives the movement distance information of the movement distance K of the slider 10 from the movement distance measurement unit 121 via the storage unit 123.
When sector scanning is not performed, the driving unit 125 transmits a slider stop instruction signal to a motor (not shown), thereby stopping the movement of the slider 10 in the length direction of the rail 100.

Further, the ultrasonic flaw detector 120 of FIG. 6 includes an input unit 131 and a display unit 132.
Among these, the input means 131 receives the slider drive instruction signal and slider stop instruction signal of the drive means 125, the scanning instruction signal, the ultrasonic irradiation angle α1, the echo reception angle α2, the received ultrasonic echo, and the like. The
The display unit 132 also includes information read from the storage unit 123, for example, measurement information of the depth M measured from the measurement unit 122, position information of the slider 10 from the movement information measurement unit 121, and scanning instruction unit 124. The driving information of the is displayed. The display means 132 may be provided in the computer 120 instead of the ultrasonic flaw detector 130.

  Next, in this rail flaw detector 1, a method for flaw detection on the rail will be described, and a detailed structure of the rail flaw detector 1 will also be described.

  First, the lower surface or upper neck portion 100c of the head 100a of the rail 100 to be inspected shown in FIGS. 1 (a), 3 (a), and 3 (b) is cleaned, and mud or oil adhered thereto. Remove rust.

Next, an ultrasonic wave is irradiated (transmitted) to the rail 100 from the phased array probe 50T for transmission, and the echo of the ultrasonic wave is received by the phased array probe 50R for reception to detect the rail 100.
Specifically, first, a phased array probe for transmission 50T and a phased array probe for reception 50R are arranged (arrangement step).
In this arrangement, the slider 10 is attached to the rail 100. This attachment method is as described above.
Further, in this arrangement, the transmitting phased array probe 50T and the receiving phased array probe 50R are arranged with the abdomen 100d of the rail 100 sandwiched between them, both of which are the curved surface 101 or the head of the upper neck 100c. It is arranged so as to contact the lower surface of 100a.
Then, as shown in FIG. 2, in the phased array probe 50T for transmission and the phased array probe 50R for reception, each flaw detection shoe 52 has the curved surface 101 or head of the upper neck portion 100c through the medium. As shown in FIG. 9, one of the two surfaces 18a of the engagement roller 18 is in contact with the lower portion of the side surface 101e of the rail 100, and the other is the curved surface 101 of the upper neck portion 100c. It contacts the lower surface of the head 100a.

  Further, in this arrangement step, the transmitting phased array probe 50T and the receiving phased array probe 50R are traveling in the direction of the flaw F3 traveling in the diagonally downward direction (the traveling direction of the railway vehicle along the rail length direction). Are arranged on the same side. As the arrangement, for example, as shown in FIG. 1A, FIG. 3A, and FIG. 3B, a transmitting phased array probe 50T and a receiving phased array probe 50R are Is also arranged behind the wound F3 traveling in the diagonally downward direction.

  After the transmission phased array probe 50T and the transmission phased array probe 50R are arranged, the drive unit 125 is controlled by the slider drive instruction signal from the input unit 131 of the ultrasonic flaw detector 130. Is the reference plane of the rail 100 (FIG. 3A), that is, from the initial position (K = 0) until the moving distance K reaches the length L of the rail 100, the slider 10 The motor is driven.

  Further, after the transmission phased array probe 50T and the transmission phased array probe 50R are arranged, the scanning instruction signal transmitted simultaneously with the slider drive instruction signal from the input means 131 is used as shown in FIG. ), The transmitting phased array probe 50T faces the tread 100b of the rail 100 obliquely upward from the rear in the traveling direction of the flaw F3 traveling in the diagonally downward direction to the front in the traveling direction. Then, the ultrasonic wave is irradiated (irradiation step), and the reception phased array probe 50R receives the ultrasonic echo U2 irradiated to the rail 100 from the transmission phased array probe 50T (reception step). Based on the received information or the like, the tip position (depth M) of the flaw F3 traveling in the diagonally downward direction is measured (measurement step).

In the irradiation step and the reception step described above, ultrasonic waves are transmitted by the transmitting phased array probe 50T toward the tread surface 100b obliquely upward from the rear in the traveling direction of the wound F3 traveling in the diagonally downward direction toward the front in the traveling direction. Irradiate diagonally up.
In this case, as indicated by the ultrasonic wave U1 in FIG. 1B, a portion where the surface of the wound F3 where the ultrasonic wave is traveling obliquely downward and the tread surface 110b intersect with the phased array probe 50T for transmission ( When the light is applied to the corner portion, a very high echo is detected by the receiving phased array probe 50R as indicated by the echo U2.

  Further, as shown in FIG. 1 (c), the driving means 125 moves the transmitting phased array probe 50T and the receiving phased array probe 50R to move the flaw F3 traveling in the diagonally downward direction. The ultrasonic wave U3 irradiated toward the tread 100b obliquely upward from the rear in the traveling direction of the flaw F3 traveling in the diagonally downward direction is moved forward by the phased array probe 50T for transmission. When the surface of the flaw F3 is irradiated, as shown by an echo U4, a very high echo is detected by the receiving phased array probe 50R on the surface of the flaw F3 traveling in a diagonally downward direction.

  Further, as shown in FIG. 1D, when the driving means 125 moves the transmitting phased array probe 50T and the receiving phased array probe 50R forward in the direction of travel of the flaw F3, By the trusted phased array probe 50T, the ultrasonic wave U5 irradiated toward the tread surface 100b obliquely upward from the rear to the front in the traveling direction of the wound F3 traveling in the diagonally downward direction is the front end portion Fa of the surface of the scratch F3. A high echo (see echo U6) is detected by the receiving phased array probe 50R until it is irradiated in the vicinity.

Further, the transmission phased array probe 50T and the receiving phased array probe 50R are further advanced by the driving means 125, and the flaw F3 traveling in the diagonally downward direction by the transmitting phased array probe 50T. When the ultrasonic wave irradiated toward the tread surface 100b obliquely upward from the rear in the traveling direction reaches the front end Fa of the scratch F3 that progresses in the diagonally downward direction, the echo on the surface of the scratch F3 that progresses in the diagonally downward direction decreases. As a result, as shown in FIGS. 3A and 3B, the end echo U (FIG. 11) is detected.
Further, when the end echo method is used by detecting this end echo, the position (depth M) of the front end portion Fa of the flaw F3 traveling in the diagonally downward direction can be measured.

  In the irradiation step and the reception step described above, sector scanning is executed by the transmission phased array probe 50T and the reception phased array probe 50R, respectively, thereby obtaining measurement information relating to the echo generation position. In the measurement step, the position (depth M) of the front end portion Fa of the wound is measured by the end echo method based on the measurement information on the position where the echo is generated, as described above.

Further, the movement of the slider 10 in the length direction of the rail 100 by the driving unit 125 is performed when sector scanning is performed by irradiation (transmission) of ultrasonic waves and reception of echoes.
The sector scanning is continuously performed until the moving distance K of the slider 10 reaches the rail length L from the initial position (moving distance K = 0).
The sector scan is performed in synchronization with the movement of the slider 10 by the driving means 125. For example, every time the moving distance K of the slider 10 reaches a certain distance, sector scanning is performed once in the width direction of the rail. This sector scanning is repeatedly performed in synchronization with the movement of the slider 10, whereby the scanning in the length direction of the rail 100 can be performed as uniformly as possible on the rail 100.
Further, as described above, the driving unit 125 continuously moves the slider 10 in the length direction of the rail 100 when performing sector scanning by irradiation of ultrasonic waves and reception of echoes. Scanning in the length direction can be performed in a short time.

  Further, the above-described backward flaw detection method has an advantage (continuity or relevance) that it is easy to capture both the surface and the echo of the flaw F3 and the echo of the front end portion Fa of the flaw F3.

  In the case of the flaw F3 traveling in the diagonally downward direction, the echo for the tip Fa is mixed with the echo of the surface of the scratch F3 traveling in the diagonally downward direction depending on the direction of the surface of the scratch, and it is difficult to extract the echo of the distal end Fa. May perform forward flaw detection. The forward flaw detection means that the transmitting phased array probe 50T and the receiving phased array probe 50R are disposed in front of the flaw F3 traveling in the diagonally downward direction, and the flaw F3 traveling in the diagonally downward direction proceeds. This is a method of flaw detection / scanning for a flaw F3 that progresses in a diagonally downward direction toward the tread surface 100b obliquely upward from the front in the direction toward the rear in the traveling direction.

13 (a) to 13 (d) are conceptual perspective views showing a main part of the rail flaw detector and the rail flaw detection method of the second embodiment, particularly the two-probe V scanning method and the front flaw detection. It is a figure which shows the mode of the rail flaw detection apparatus and rail flaw detection method.
FIG. 14A and FIG. 14B are diagrams showing the arrangement relationship between the rail and the rail flaw detection apparatus in the rail flaw detection method and apparatus according to the second embodiment. 14A shows a conceptual plan view (left part of the figure) and a conceptual rear view (right part of the figure) of the rail and the rail flaw detector, and FIG. 14B shows a conceptual right side view (left part of the figure). Part) and a conceptual front view (right part of the figure).

  As shown in FIGS. 13 (a) to 13 (d), 14 (a) and 14 (b), in the rail flaw detection method and apparatus 201 placement step of this embodiment, a phased array probe for transmission is used. As an example in which the child 50T and the receiving phased array probe 50R are arranged on the same side with respect to the traveling direction of the wound F3, the transmitting phased array probe 50T and the receiving phased array probe 50R are used. 50R is disposed in front of the flaw F3 traveling in the diagonally downward direction (arrangement step in front flaw detection). FIGS. 13A to 13D are perspective views showing the rail flaw detection apparatus and the rail flaw detection method as seen from the back side of the rail 100. FIG.

Next, an ultrasonic wave is irradiated to the rail 100 from the transmission phased array probe 50T by the scanning instruction signal from the input means 131 (irradiation step), and the echo of the ultrasonic wave is received to the phased array probe 50R for reception. Are received (receiving step), and the rail 100 is detected (measuring step).
In the forward flaw detection, the transmitting phased array probe 50T and the receiving phased array probe 50R are positioned forward with respect to the traveling direction of the flaw F3, and the traveling direction of the flaw F3 that advances ultrasonic waves diagonally downward. Irradiation is performed toward the tread surface 100b irradiated from the front toward the tread surface 100b obliquely upward toward the rear in the traveling direction. In this case, as shown in FIG. 13B, the tip of the portion (corner portion) where the flaw F3 progressing in the diagonally downward direction and the tread surface 100b intersect is irradiated, and a very high end echo is detected.
Further, when the driving means 125 moves the transmitting phased array probe 50T and the receiving phased array probe 50R forward in the traveling direction of the flaw F3 traveling in the diagonally downward direction by the driving means 125, FIG. As shown in FIG. 13 (c), the ultrasonic wave irradiated toward the tread surface 100b obliquely upward from the front to the back in the traveling direction of the wound F3 traveling in the diagonally downward direction is reflected by the tread surface 100b and then substantially horizontally. It is difficult to reach the flaw F3 irradiated to the surface of the flaw F2 and proceeding in the diagonally downward direction, and the echo of the flaw F3 in the diagonally downward direction is difficult to detect.
Then, as shown in FIG. 13 (d), when the driving means 125 further advances the transmitting phased array probe 50T and the receiving phased array probe 50R by the driving means 125, a downward diagonal direction is obtained. The ultrasonic wave U7 irradiated to the tread surface 100b obliquely upward from the front to the rear in the direction of travel of the wound F3 traveling to the rear is reflected by the tread surface 100b and then irradiated to the surface of the wound F3 proceeding obliquely downward to the echo U8. As shown, a high echo is obtained (easy to detect).
In the irradiation step and the reception step, sector scanning is executed by the transmission phased array probe 50T and the reception phased array probe 50R, respectively, thereby obtaining measurement information relating to the echo generation position. Further, in the measurement step, the position (depth M) of the front end portion Fa of the flaw F3 proceeding diagonally downward of the rail 100 is measured by the end echo method based on measurement information on the echo generation position.
In the rail flaw detection method and apparatus 201 according to the second embodiment, the transmitting phased array probe 50T and the receiving phased array probe 50R are arranged in front of the traveling direction of the flaw F3 traveling in an obliquely downward direction, The first embodiment, except that a method of flaw detection / scanning (forward flaw detection) is performed for the flaw F3 traveling in the diagonally downward direction toward the tread surface obliquely upward from the front to the rear in the traveling direction of the flaw F3 traveling in the diagonally downward direction. The rail flaw detection method and the structure / configuration of the apparatus 1 are the same.

In the rail flaw detection method and apparatus 201 of the second embodiment, sector scanning is performed in synchronization with the movement of the slider by the driving means 125, as in the rail flaw detection method and apparatus 1 of the first embodiment. The scanning of the rail in the width direction is performed once every time the slider moving distance reaches a predetermined distance.
However, in the rail flaw detection method and apparatus of the present invention, the synchronization between the movement of the slider 10 and the sector scan is not limited to this, and the driving means 125 moves the slider 10 based on the end information of the sector scan. May be.

  FIG. 15A is a diagram showing the relationship between the slider moving distance (horizontal axis) and the slider moving speed (vertical axis) in the rail flaw detection method and apparatus according to the third embodiment. ) Is a conceptual plan view of a rail showing a state in which sector scanning is performed on the rail using the slider of FIG.

As shown by the scanning line B (broken line) of sector scanning in FIGS. 15A and 15B, the third rail flaw detector 301 in which the third rail flaw detection method is performed uses a phased array probe for transmission. A slider 10 (see FIG. 2) for fixing the touch element 50T and the receiving phased array probe 50R, and driving means 125 (see FIG. 6) for moving the slider 10 in the length direction of the rail 100 are provided. The means 125 makes the slider 10 in the rail length direction based on the sector scan end information.
The end information of the sector scan is information that detects that the scan in the width direction of the rail 100 has been completed once as indicated by the scan line B (broken line).
The end information of the sector scan is detected by the scanning instruction unit 124, and the detection signal is transmitted to the driving unit 125. The driving unit 125 that has received the detection signal of the sector scanning end information drives a motor (not shown) of the slider 10.
Note that while the scanning instruction unit 124 instructs execution of sector scanning, and while the sector scanning is being performed, the driving unit 125 stops driving a motor (not shown) of the slider 10.

  In each rail flaw detection method and apparatus 1, 201, 301 of the first to third embodiments, sector scanning is performed in synchronization with the movement of the slider 10 by the driving means 125. In the flaw detection method and apparatus, the movement of the slider 10 by the driving unit 125 may be performed independently of the sector scanning, that is, the sector scanning may be asynchronous with the movement of the slider 10.

FIG. 12C is a conceptual plan view of the rail showing a state in which sector scanning is performed on the rail using the slider of FIG. 12A in the rail flaw detection method and apparatus of the fourth embodiment.
As shown by the scanning line B (broken line) of sector scanning in FIGS. 12A and 12C, the fourth rail flaw detector 401 in which the fourth rail flaw detection method is performed has a phased array probe for transmission. A slider 10 (see FIG. 2) for fixing the touch element 50T and the receiving phased array probe 50R, and driving means 125 (see FIG. 6) for moving the slider 10 in the length direction of the rail 100 are provided. The movement of the slider 10 by the means 125 is performed independently of the sector scanning.
For example, as shown by the scanning line B (broken line) in FIGS. 12A and 12C, the sector scanning starts from the start of movement of the slider 100 in the rail length direction regardless of the movement distance K of the slider 10. It is executed every certain time.
In this way, when the moving speed of the slider 10 is less than a certain speed, the moving speed of the slider becomes the constant speed as the difference between the moving speed of the slider and the constant speed increases. Compared with the scanning density in sector scanning at this time, the scanning density in sector scanning becomes higher. Therefore, by adjusting the moving speed of the slider 10, the scanning density of sector scanning can be adjusted.
12A and 12C, when the sector scanning is performed by the irradiation (transmission) of ultrasonic waves and the reception of echoes, the driving unit 125 moves the slider 10 in the length direction of the rail 100. The state of the movement and the sector scanning are also shown from the time when the movement distance K of the slider 10 is at the initial position (movement distance K = 0) until the rail length L is reached.

  As described above, in the rail flaw detection methods 1, 201, 301, and 401 according to the above-described embodiments of the present invention, the probe rotation mechanism coupled to the transmission phased array probe 50T and the reception phased as in the prior art. Since the probe rotating mechanism connected to the array probe 50R is not provided, the number of parts is reduced and the structure is simplified.

  Further, in the rail flaw detection method and apparatus 1, 201, 301, 401 of the above-described embodiments of the present invention, a probe rotating mechanism connected to the transmission phased array probe 50T is not necessary. At the time of flaw detection at a certain point, since the transmission angle of the phased array probe 50T for transmission is set, manual operation (operation of the probe rotating mechanism) becomes unnecessary. Further, in the rail flaw detection methods and apparatuses 1, 201, 301, 401 of the above-described embodiments of the present invention, a probe rotating mechanism connected to the receiving phased array probe 50R is not required. When the flaw detection is performed at a certain point, the reception angle of the receiving phased array probe 50R is set, so that manual operation (operation of the probe rotation mechanism) is not required. Therefore, in the rail flaw detectors 1, 201, 301, 401 and the rail flaw detection method of each of the above-described embodiments, the rail flaw detection operation is simple, and the depth Fa of the flaw F3 progressing in the diagonally downward direction is measured. It can be performed in a shorter time than conventional.

In the rail flaw detection method and apparatus 1, 201, 301, 401 according to the above embodiments of the present invention, a phased array probe for transmission is formed on the curved surface 101 formed on the lower surface or upper neck portion 100c of the head 100a of the rail 100. Since the ultrasonic wave is irradiated from the transmitting phased array probe 50T toward the tread surface 100b by applying the child 50T and the receiving phased array probe 50R, the wound F2 progresses substantially in parallel, and proceeds downward in the diagonal direction. By applying ultrasonic waves to the wound F3 and other wounds and measuring the echoes thereof, the position (depth) of the tip of the wound can be measured.
In addition, since the ultrasonic wave is irradiated toward the tread surface 100b from the upper neck portion 100c of the rail 100, there is a possibility that the ultrasonic wave is reflected on the cross section of the flaw F2 that travels substantially in parallel and does not reach the flaw F3 that travels in the diagonally downward direction. It is prevented as much as possible. Therefore, as described above, it is possible to irradiate the wound F3 traveling in the diagonally downward direction with ultrasonic waves, and by measuring the echo, the position (depth) of the scratch F3 traveling in the diagonally downward direction can be measured.
Further, since the lower surface of the head 100a or the curved surface 101 of the upper neck portion 100c does not wear and does not wear with the wheels 200 (FIG. 16) of the railway vehicle, the scratch F2 progresses substantially in parallel, the scratch F3 progresses in the diagonally downward direction, and the like. The depth of each tip Fa of the wound can be accurately measured, and in particular, the depth measurement of the tip of the wound proceeding obliquely downward, which is the most important factor for determining the rail strength and necessity of replacement. Suitable as a reference plane.

  Therefore, the rail flaw detectors 1, 201, 301, 401 according to the above embodiments of the present invention accurately determine the depth of the flaws F2 generated in the head and proceeding substantially in parallel, the flaw F3 proceeding in a diagonally downward direction, and other flaws. It can be measured, has a small number of parts, has a simple structure, is easy for rail flaw detection work, and is suitable as a rail flaw detection device that can shorten the flaw detection time. Further, the rail flaw detection method according to each of the embodiments of the present invention can accurately measure the depth of flaws F2 generated in the head and proceeding substantially in parallel, flaws F3 proceeding in the diagonally downward direction, and other flaws. It is suitable as a rail flaw detection method that can work easily and shorten the flaw detection time.

  In the rail flaw detection method and apparatus 1, 201, 301, 401 according to the above embodiments of the present invention, the transmitting phased array probe 50T and the receiving phased array probe 50R are mutually connected to the abdomen of the rail 100. Both of them are placed on the curved surface 101 of the upper neck 100c or the lower surface of the head 100a, and sector scanning is performed by the phased array probe 50T for transmission and the phased array probe 50R for reception. To obtain measurement information, and based on the measurement information, the position of the tip of the wound is measured by the end echo method. Therefore, compared to the case where sector scanning is performed on the rail using a single phased array probe that serves both for transmission and reception, the flaw F2 that progresses substantially in parallel, the flaw F3 that progresses in an obliquely downward direction, and other flaws are shorter. Can be detected reliably in time.

  In the rail flaw detection methods and apparatuses 1, 201, and 301 of the first to third embodiments, the slider 10 is moved in the length direction of the rail 100 when ultrasonic wave irradiation (transmission) and echo reception are performed. Therefore, as compared with the conventional case where the driving unit 125 stops moving the slider 10 while performing ultrasonic irradiation and echo reception, scanning in the length direction of the rail 100 is performed in a short time. be able to.

  In the rail flaw detection methods and apparatuses 1, 201, and 301 according to the first to third embodiments, sector scanning is performed in synchronization with the movement of the slider 10 by the driving means 125. Therefore, the rail 100 is scanned in the length direction. This is performed as uniformly as possible on the rail 100.

  If the slider is moved independently of the sector scanning as in the rail flaw detection method and apparatus 401 of the fourth embodiment, the scanning density of the sector scanning is adjusted by adjusting the moving speed of the slider 10. Can be adjusted.

  In the rail flaw detection methods and apparatuses 1, 201, 301, and 401 of the first to fourth embodiments described above, it has been described that the scratch on the rail 100 is a scratch F3 that progresses in a diagonally downward direction. Needless to say, the rail flaw detection method and apparatus of the present invention are also applied to the case where the flaw is a flaw F2 progressing in a substantially horizontal direction.

  Further, in the rail flaw detectors 201, 301, and 401 of the second to fourth embodiments, like the rail flaw detector 101 of the first embodiment, the encoder 35, the motion control drive unit 110, the computer 120, and the ultrasonic flaw detector. Needless to say, 130 and a detector (not shown) are provided.

  The rail flaw detector of the present invention can accurately measure the depth of flaws generated in the head and proceeding in a substantially parallel and obliquely downward direction, with a small number of parts, a simple structure, and rail flaw detection work. It is simple and suitable as a rail flaw detector that can shorten the flaw detection time. In addition, the rail flaw detection method of the present invention can accurately measure the depth of flaws generated in the head and proceeding substantially in parallel and flaws traveling diagonally downward, and the rail flaw detection operation is simple and the flaw detection time can be shortened. Suitable for rail flaw detection.

1, 201, 301, 401 ... Rail flaw detector 10 ... Slider 50T ... Transmission phased array probe 50R ... Reception phased array probe 100 ... Rail 100a ... Head 100b ... Tread surface 100c ... Upper neck 101 ... Curved surface 111 ... Information acquisition means 122 ... Measuring means 125 ... Driving means F2, F3 ... Scratches F2 ... Scratches that proceed substantially in parallel F3 ... Scratches that proceed in a diagonally downward direction

Claims (19)

A plurality of first ultrasonic transducers, a phased array probe for transmission that emits ultrasonic waves;
A plurality of second ultrasonic transducers, and a receiving phased array probe for receiving an echo of the ultrasonic wave irradiated to the rail from the transmitting phased array probe,
The transmitting phased array probe and the receiving phased array probe are arranged with the abdomen of the rail between each other, and both of the upper neck portion of the rail on which the curved surface is formed or Arranged against the lower surface of the head of the rail,
Irradiating ultrasonic waves from the transmitting phased array probe toward the tread of the rail, receiving the echo by the receiving phased array probe, and the position of the tip of the rail flaw from the echo Is to measure
A slider main body that moves in the length direction of the rail, and a phased array probe for transmission and a phased array probe for reception that are disposed on both sides of the head of the rail and are fixed to the slider main body. A fixing member that fixes and supports the engagement member, and an engagement roller that is attached to each of the fixing members disposed on both sides of the head portion of the rail, and whose roller surface is in contact with at least a lower portion of the side surface of the rail; The slider body is biased upward away from the tread surface of the rail, and the transmitting phased array probe, the receiving phased array probe, and the engaging rollers are biased upward. A rail flaw detector comprising a slider including urging means. Measurement information acquisition means for obtaining measurement information by performing sector scanning with the phased array probe for transmission and the phased array probe for reception;
2. The rail flaw detector according to claim 1, further comprising a measuring means for measuring the position of the tip of the flaw by an end echo method based on the measurement information. Drive means for moving the slider in the length direction of the rail,
The rail flaw detector according to claim 2, wherein the driving means moves the slider in the length direction of the rail when the sector scanning is performed. Drive means for moving the slider in the length direction of the rail,
4. The rail flaw detector according to claim 2, wherein the sector scanning is performed in synchronization with the movement of the slider by the driving means. Drive means for moving the slider in the length direction of the rail,
The rail flaw detector according to claim 2 or 3, wherein the movement of the slider by the driving means is performed independently of the sector scanning. Drive means for moving the slider in the length direction of the rail,
3. The rail flaw detector according to claim 2, wherein the driving unit moves the slider based on end information of the sector scan.   7. The transmitting phased array probe and the receiving phased array probe are arranged on the same side with respect to the traveling direction of the flaw. The rail flaw detector according to claim 1.   8. The transmission phased array probe and the receiving phased array probe are both arranged behind the scratch in the advancing direction, according to claim 1. Rail flaw detector.   8. The transmission phased array probe and the receiving phased array probe are both arranged in front of the wound in the advancing direction, according to claim 1. Rail flaw detector. A transmission phased array probe in which a plurality of first ultrasonic transducers are arranged is irradiated with ultrasonic waves on a rail, and the ultrasonic echoes are received and phased for reception in which a plurality of second ultrasonic transducers are arranged. A method of detecting the rail by receiving with an array probe,
A slider main body that moves in the length direction of the rail, and a phased array probe for transmission and a phased array probe for reception that are disposed on both sides of the head of the rail and are fixed to the slider main body. A fixing member that fixes and supports the engagement member, and an engagement roller that is attached to each of the fixing members disposed on both sides of the head portion of the rail, and whose roller surface is in contact with at least a lower portion of the side surface of the rail; The slider body is biased upward away from the tread surface of the rail, and the transmitting phased array probe, the receiving phased array probe, and the engaging rollers are biased upward. The transmission phased array probe and the receiving phased array probe are arranged with the abdomen of the rail interposed therebetween, using a slider including an urging means. And an arrangement step in which both are placed against the upper neck of the rail on which the curved surface is formed or the lower surface of the head of the rail, and
After the arrangement, an irradiation step in which the phased array probe for transmission irradiates ultrasonic waves toward the tread surface of the rail;
A reception step in which the reception phased array probe receives the ultrasonic echo; and
A rail flaw detection method comprising: a measurement step of measuring a position of a tip portion of the rail flaw based on the received information. In the irradiation step and the reception step, sector scanning is performed by the phased array probe for transmission and the phased array probe for reception, respectively, thereby obtaining measurement information,
The rail flaw detection method according to claim 10, wherein in the measurement step, the position of the tip of the rail flaw is measured by an end echo method based on the measurement information.   12. The transmission phased array probe and the receiving phased array probe move in the length direction of the rail when the sector scan is performed. Rail flaw detection method.   13. The sector scan according to claim 11, wherein the sector scan is performed in synchronization with movement of a slider that fixes the phased array probe for transmission and the phased array probe for reception. Rail flaw detection method.   The movement of a slider that fixes the phased array probe for transmission and the phased array probe for reception is performed independently of the sector scanning. The described rail flaw detection method.   The phased array probe for transmission and the phased array probe for reception are moved in the length direction of the rail based on the end information of the sector scan. 11. The rail flaw detection method according to 11.   16. In the arranging step, the transmitting phased array probe and the receiving phased array probe are arranged on the same side with respect to the traveling direction of the flaw. The rail flaw detection method according to any one of the above.   17. In the arrangement step, the transmitting phased array probe and the receiving phased array probe are both arranged behind the wound in the traveling direction. The rail flaw detection method according to claim 1.   17. In the arrangement step, the transmitting phased array probe and the receiving phased array probe are both arranged in front of the wound in the traveling direction. The rail flaw detection method according to claim 1. Furthermore, a roller support member is provided as a frame-like member that rotatably supports a roller that contacts the rail tread surface, and the slider body is a frame body that supports the roller support member in a direction perpendicular to the rail tread surface. The rail flaw detector according to claim 1.

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