RU2360240C2 - Method for ultrasonic control of rail transport wheels and device for its realisation - Google Patents

Abstract

FIELD: transportation.

SUBSTANCE: elastic waves are transmitted from transducer to controlled wheel via immersion medium, and specified areas of wheel are rung out along trajectories in the form of concentric circumferences, at that prior to ultrasonic tests thickness is measured in wheel rim, with account of rim thickness acoustic block is installed in initial position with piezoelectric transducers, tested wheelset is installed in supports so that wheels are immersed into liquid medium of immersion bath at least at thickness of rim, then rotation of wheelset is executed, rim is rung out as well as near-rim part of wheel disc in all dangerous areas, and signals exceeding are registered in zones of control higher than threshold value, which is not permissible for defect.

EFFECT: increased efficiency of flaw detection and operational reliability of device.

4 cl, 2 dwg

Description

The invention relates to methods and means of testing products with ultrasound and can be used to detect wheel defects in the repair and manufacture of rolling stock of railway transport.

A known method of ultrasonic monitoring of rims of wheels of a rail vehicle [1], which consists in the fact that contact liquid is applied to a controlled part of the side surface of the rim, the piezoelectric transducer is manually moved along a predetermined path first in the search sensitivity mode, the signal recording locations from the alleged defects are noted, and then In the rejection sensitivity mode, unacceptable defects are detected. The disadvantage of this method is the low performance of the control.

Closest to the proposed method is the technological process of ultrasonic flaw detection of wagon wheels, described in [2] and that the piezoelectric transducers are directed on the contact surfaces of the test wheel along concentric circles using a scanning device USK-4, which is mounted on the rim of the test wheel, contact liquid is applied to the wheel sector to be controlled with a brush, then search control is carried out by manually moving the scanning devices and in the search sensitivity mode, and note the zones of the appearance of signals within the controlled sector. Then the wheelset is rotated by the rotation mechanism and in the same way search monitoring of the following sectors is performed, and then the marked zones are re-checked in the rejection sensitivity mode to detect unacceptable defects.

The disadvantage of this method is the low productivity and reliability of the control.

A device for ultrasonic testing of cylindrical products [3] is known, comprising a base, an acoustic unit, including ultrasonic piezoelectric transducers and a local immersion bath with a seal associated with the base, orientation and fixation mechanisms of the acoustic unit, the acoustic unit being pressed by means of a spring-lever system with tracking rollers pressed to the object of control.

The disadvantage of this device is the structural limitations for the implementation of ultrasonic testing of bodies of revolution with complex curved surfaces, such as wheel sets of rail rolling stock.

The closest to the claimed invention in purpose and design features is a stand for ultrasonic testing of wheel pairs of rail rolling stock [4], containing a fixed base with supports for axle boxes of the tested pair of wheels, a drive with a friction roller located with the possibility of interaction with the side surface of the wheels of the tested wheeled pairs, two immersion baths, a lifting and turning device for lifting and turning the wheelset, and immersion baths are placed in vertical ur vnyu below the axis of rotation of the test wheel pair and below the supports for the axle-boxes.

The disadvantage of this device is the low efficiency of detecting defects in the transition zone of the wheel rim in the disk, as well as the complexity of the settings and maintenance.

The objective of the present invention is to increase the efficiency of defect detection and operational reliability of the device.

The technical result is achieved by a method consisting in the transmission of elastic waves from the transducer to the controlled wheel through an immersion medium and the sounding of the specified areas of the wheel along the paths in the form of concentric circles, in which, according to the invention, the thickness of the wheel rim is measured before ultrasound testing, taking into account the thickness of the rim in the required initial position, the acoustic unit with piezoelectric transducers, the checked pair of wheels placed on the supports in such a way that Wheel plunged into the liquid medium immersion bath is not less than the rim thickness, then the rotation is performed wheelset prozvuchivayut priobodnuyu rim and of the wheel disc, record signals in excess of the control zones is above a threshold, for unacceptable defect.

When ultrasound is introduced through the wheel’s rolling surface, the emitter and receiver are placed on a common base symmetrically with respect to the vertical drawn through the axis of rotation of the controlled wheel, they are turned on in a separate scheme, search sensitivity is set, then by moving the common base in a direction parallel to the axis of rotation of the wheelset , choose a position with a minimum level of interference from structural reflectors in the control zone, carry out control by rotating the wheelset at least one full th turn, then is switched to the combined mode of reception and emission, each of converters alternately repeated by each transducer monitoring wheelset by rotating at least one full turn. To implement the proposed method, a device for ultrasonic testing of wheel pairs of a rail rolling stock is proposed, comprising a fixed base with supports for the test wheelset, a drive with a friction roller located to interact with the side surface of the wheels of the tested wheelset, a lifting and transport mechanism for lifting, transporting and installation of a wheelset, two immersion baths placed at a vertical level below the axis of rotation of the tested wheelset, characterized in that in the immersion baths there are acoustic blocks associated with separate movement mechanisms in the vertical and horizontal directions, the acoustic axes of the piezoelectric transducers are oriented at an angle from 0 to 25 degrees to the normal at the point of ultrasound input into the surface of the controlled wheel, and the transducers directed to the rolling surface of the wheel, placed on pairwise parallel axes with the possibility of rotation in a common plane for both converters.

The specified sequence and features of the operations along with the design parameters of the device allow the most complete identification of defects such as discontinuities throughout the cross section of the rim and the outer zone of the wheel disc.

Figure 1 presents a General view of the device, figure 2 is a diagram of the orientation of the converters directed to the surface of the wheel.

The device comprises a fixed base 1 with supports 2 for the test pair of wheels 3, two immersion baths 4, placed at a vertical level below the axis of rotation of the tested pair of wheels, acoustic blocks 5, each connected by a movement mechanism in the vertical direction 6 and a movement mechanism in the horizontal direction 7, piezoelectric transducers 8.

The acoustic axis of the piezoelectric transducers 8 are oriented at an angle α to the normal at the point of introduction of ultrasound into the surface, which can take values from 0 to 25 degrees. Converters directed to the wheel rolling surface are placed on pairwise parallel axes 9 with the possibility of rotation in a plane common to both converters.

The proposed method is implemented as follows. Initially, the thickness of the rims of the tested wheels of the wheelset 3 is measured, taking into account the measured thicknesses, the acoustic blocks 5 are installed in each bath in the required height position by means of vertical movement mechanisms 6.

The test pair of wheels 3 is placed on the supports 2 so that the wheels are immersed in the liquid medium of the immersion bath 4 not less than the thickness of the rim, then the wheelset is rotated, the rim and the adjacent part of the wheel rim in all dangerous sections are sounded by switching the converters, this is recorded the excess of signals in the control zones above a threshold value that is unacceptable for the defect.

When ultrasound is introduced through the wheel’s rolling surface (Fig. 2), the piezoelectric transducers 8 are placed on a common base 10 symmetrically with respect to the vertical drawn through the axis of rotation of the controlled wheel, they are turned on in a separate circuit, search sensitivity is set, then by moving the acoustic unit 5 into in the horizontal direction, select a position with a minimum level of interference from structural reflectors in the control zone, monitor by rotating a wheel pair of at least one floor each revolution, then switch to the combined mode of reception and radiation each of the converters in turn and repeat the control by each converter by rotating the wheelset at least one full revolution.

The method is implemented on a prototype device for ultrasonic testing of wagon wheel pairs of 1520 mm gauge. The UD2-12 electronic unit was used as a flaw detector; piezoelectric transducers are made on the basis of piezoelectric elements with a resonant frequency of 2.5 MHz and a diameter of 12 mm. Piezo transducers were switched by a special channel commutator. Industrial water was used as an immersion medium.

On the technological rail track, the rim thickness of the tested pair of wheels was measured, which was 34 mm for the right wheel and 33 mm for the left wheel. Taking into account the measured thicknesses, acoustic blocks by means of vertical movement mechanisms were installed in each bath in the required height position.

The test wheelset was placed on the supports in such a way that the wheels were immersed in the immersion bath to the thickness of the rim. The electronic unit of the ultrasonic flaw detector UD2-12 was turned on, piezoelectric transducers directed to the skating surface of the right wheel were connected in a separate operating mode of the emitter and receiver.

Then, by the mechanisms of horizontal movement, the acoustic blocks were installed at a distance determined by the position of the wheels on the axis and the position of the axis of the pair of wheels on the roller bearings. When ultrasound was introduced through the wheel’s rolling surface (Fig. 2), the piezoelectric transducers 8 were placed on a common base 9 symmetrically with respect to the vertical drawn through the axis of rotation of the controlled wheel, turned on in a separate circuit, search sensitivity was established, then by moving the acoustic unit in the horizontal direction the position with the minimum level of interference in the control zone was chosen, so that on the flaw detector in the strobe area of the automatic alarm about defects, respectively the current control depth in the wheel steel from 10 to 120 mm, there were no signals from structural reflectors. By rotating the wheel pair, the rim and the adjacent part of the wheel disk were sounded, registering the excess of signals in the control zones above a threshold value that is unacceptable for the defect. Thus, defects whose reflective surface is parallel to the surface of the wheel are detected most effectively. The control was carried out by turning the wheelset two full turns.

Then they switched to the combined mode of reception and radiation, each of the converters in turn. Thus, volume defects and defects whose reflective surface is oriented at an angle of 40 ° ... 50 ° to the skating surface were most effectively detected. The control was repeated by each converter by rotating the wheelset two full turns. The left wheel was checked in the same way.

The duration of the control of one wheel pair by the described method and device was 12 minutes, which is 3-4 times less than the time spent in the control of the prototype method.

Literature

1. Ilyin V.A. Flaw detection of parts of rolling stock of railways and subways. M., “Transport”, 1983, p. 292-295.

2. Guidelines for comprehensive ultrasonic testing of wagon wheelsets. RD 07.09-97. Approved by the Council on Rail Transport of the Member States of the Commonwealth on 05/08/1998, p.153-154.

3. A.S. USSR No. 1083106 A, IPC G01N 29/04, published in the Bulletin of Inventions of the USSR No. 12, 03/30/1984

4. Dubina A.V., Bychek I.S., Komarovsky I.S. The application of RB No. a20000607 for the invention “Stand for ultrasonic testing of wheel pairs of rail rolling stock”, IPC ⁷ G01M 17/08, 17/10, G01N 29/04. Published in the Bulletin of Inventions of the Republic of Belarus No. 4 for 2001

Claims (4)

1. The method of ultrasonic control of wheels of rail vehicles, which consists in transmitting elastic waves from the transducer to the controlled wheel through an immersion medium and sounding the specified areas of the wheel along the paths in the form of concentric circles, characterized in that before the start of ultrasonic testing, measure the thickness of the wheel rim, taking into account the thickness the rim is installed in the required initial position, the acoustic unit with piezoelectric transducers, the checked wheel pair is placed on supports in this way so that the wheels are immersed in the liquid medium of the immersion bath at least by the thickness of the rim, then the wheelset rotates, the rim and the outer part of the wheel rim are heard in all dangerous areas and the signals in the control zones are exceeded above a threshold value that is unacceptable for the defect. 2. The method according to claim 1, characterized in that the emitter and the receiver, oriented on the tread surface of the controlled wheel, are placed on a common basis symmetrically with respect to the vertical drawn through the axis of rotation of the controlled wheel, include them in a separate scheme, set the search sensitivity, then, by moving the common base in a direction parallel to the axis of rotation of the wheelset, select a position with a minimum level of interference from structural reflectors in the control zone, control the path m rotation of the wheelset at least one revolution, then switch to a combined mode of reception and radiation each of the converters in turn and repeat the control by each converter by rotating the wheelset at least one full revolution. 3. Device for ultrasonic testing, containing a fixed base with supports for the test wheelset, a drive with a friction roller located with the possibility of interaction with the side surface of the wheels of the tested wheelset, a lifting and transport mechanism for lifting, transporting and installing the wheelset, two immersion baths placed at a vertical level below the axis of rotation of the test wheelset, characterized in that in the immersion baths there are acoustic blocks associated with the mechanisms displacements in the vertical and horizontal directions, and the piezoelectric transducers are oriented at an angle from 0 to 25 ° to the normal at the point of ultrasound entry into the surface of the controlled wheel. 4. The device according to claim 3, characterized in that the transducers oriented on the surface of the wheel are placed on parallel axes with the possibility of rotation in a plane common to both transducers.

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