RU2442152C1 - Echoscopic method for ultrasonic quality control of the product across the entire section - Google Patents

Abstract

FIELD: ultrasonic quality control.

SUBSTANCE: multiple piezoelectric transducers are installed on the surface of the tested product, these transducers alternate between coupled and separate modes of ultrasonic oscillations transmitting and receiving after finishing the ultrasonic oscillation cycles with various acceptance angles ranging from 0 to 90 degrees, the angular orientation of the piezoelectric plates along the longitudinal axis of the tested product ranges from 0 to 90 degrees. All transducers are moved along the longitudinal axis of the tested product and the echo signals reflected from standard and non-standard reflectors (defects) are detected across the whole section of the tested product by the piezoelectric plates with various echo signal acceptance angles ranging from 0 to 90 and with angular orientation of a piezoelectric plate in relation to the longitudinal section of the tested product ranging from 0 to 90. The plates also alternate between coupled and separate modes of ultrasonic oscillations transmitting and receiving after finishing the ultrasonic oscillation cycles regardless of the oscillations position and distance from the piezoelectric plate which transmits the ultrasonic oscillations. Afterwards the piezotronic plates working modes are alternated to detect the echo signal from any reflectors and all detected signals are united into one united information field. Furthermore, the piezoelectric transducers work in cyclic mode of ultrasonic oscillations and after the cycle is finished they alternate between coupled and separate modes of ultrasonic oscillations transmitting and receiving, but in respect to the rule “one transmits, many receive”.

EFFECT: increased control accuracy and reliability.

2 cl, 1 tbl, 15 dwg

Description

The invention relates to non-destructive testing of materials and can be used both for ultrasonic flaw detection of rails, and in other industries.

Due to the dynamic effect of the rolling stock wheels on railway rails, deviations from the rail production technology, insufficient metallurgical quality of the rail steel, violation of the instructions for the current track maintenance, processing technology of the ends and bolt and plug holes of the rails, mechanical effects on the rail (impact of tools, rail about rail, etc.), shortcomings and violations of rail welding technology and processing of welded joints of the rail, shortcomings and violations of technology rail tracks, deficiencies and violations of the technology of rail surfacing or welding of rail connectors, corrosion of the rail and other causes of the rail over its entire cross section undergoes maximum loads. In this regard, a large number of various defects occur in the rail over its entire section, provided for by NTD / CP-1-93 “Classification of rail defects” (Ministry of Railways of the Russian Federation. Publishing House Transport. Moscow, 1993).

For the timely detection of defects indicated in NTD / CP-1-93, the following methods of ultrasonic rail monitoring are used. The echo method of ultrasonic control, based on the emission of short probe pulses into the controlled product and registration of the echo signal reflected from the defect by a piezoelectric transducer operating in the combined radiation-reception mode of ultrasonic vibrations from the surface of the rail head. A sign of defect detection is the appearance of an echo reflected from the surface of the defect (Figure 1). The shadow method of ultrasonic testing, based on the emission of short probe pulses into the controlled product from the tread surface of the rail head and registration of the echo signal on the opposite (parallel) surface, the input surface of ultrasonic vibrations. To implement the shadow method of ultrasonic testing, a direct piezoelectric transducer is used, operating in a separate radiation-receiving mode of ultrasonic vibrations. A sign of defect detection is a weakening of the signal amplitude (Figure 2). The mirror-shadow method of ultrasonic control is based on the emission of short probe pulses into the controlled product and registration of the echo signal reflected from the opposite (parallel) surface, the surface of the input of ultrasonic vibrations. To implement the mirror-shadow method of ultrasonic testing, a direct piezoelectric transducer is used, operating in separate, separately-combined, combined modes of radiation-reception of ultrasonic vibrations. A sign of defect detection is a weakening of the amplitude of the signal reflected from the opposite (parallel) surface, the surface of the input of ultrasonic vibrations (Figure 3). The mirror method of ultrasonic testing is based on the emission of short probe pulses into the controlled product and registration of an echo signal that is mirrored from the surface of the defect having a mirror surface, which, in turn, is also mirrored from the opposite (parallel) surface having a mirror surface input ultrasonic vibrations. To implement the mirror method of ultrasonic testing, inclined piezoelectric transducers are used, operating in a separate radiation-receiving mode of ultrasonic vibrations at a certain distance from each other. The distance between the two piezoelectric transducers is selected based on the conditions for the best sounding of the zone of probable defect formation. The mirror method of ultrasonic testing is implemented only if all surfaces from which ultrasonic vibrations are reflected have a mirror surface. A sign of defect detection is the registration of the echo signal by a piezoelectric transducer operating in the reception mode (Figure 4). The echo-mirror method of ultrasonic control is based on the emission of short probe pulses into the controlled product by an inclined piezoelectric transducer operating both in separate and in separately combined modes of radiation-reception of ultrasonic vibrations, having two piezoelectric plates deployed relative to the longitudinal axis of the rail at identical angles reversal of the ultrasonic beam on both sides of the rail head and with the same angles of input of the ultrasonic beam in one direction along the movement of the piezoelectric transducer, and recording the echo signal three times mirrored from the standard reflector (standard reflectors are any surfaces on the rail that are a structural feature of the geometry of the rail during its manufacture - the rolling surface of the rail head, subhead faces of the rail head, the interface of the rail head with the neck, the pairing of the neck with the sole, the sole and surfaces made in the process of preparing the rail for operation on the go in accordance with it standards - butt-bolted and plug hole) of one verge podgolovochnoy railhead, optional reflector (flaw) and standard reflector - podgolovochnoy other faces of the rail head. The movement of the ultrasound beam along its path forms a “rhombus” shape - to one of the head head faces of the rail, from it to the surface of the defect, from the face of the defect to another head side of the rail head and then to the piezoelectric plate, which is the receiver in the same piezoelectric transducer.

The echo-mirror method of ultrasonic testing is implemented only if all surfaces from which ultrasonic vibrations are reflected have a mirror surface. A sign of defect detection is the registration of the echo signal by a piezoelectric plate operating in the reception mode (Figure 5). The ultrasonic control delta method is based on the emission of short probe pulses into the controlled product and registration of the echo signal reflected by the diffraction phenomenon from the defect on the rolling surface of the rail head. To implement the delta method of ultrasonic testing, an inclined piezoelectric transducer and a direct piezoelectric transducer are used, operating in a separate radiation-receiving mode of ultrasonic vibrations at a certain distance from each other. The distance between the two piezoelectric transducers is selected based on the conditions for the best sounding of the zone of probable defect formation. A sign of defect detection is the registration of the echo signal by a piezoelectric transducer operating in the receiving mode (Figure 6).

The echo method of ultrasonic testing, the mirror-shadow method of ultrasonic testing, the shadow method of ultrasonic testing, the mirror method of ultrasonic testing, the echo-mirror method of ultrasonic testing, the delta method of ultrasonic testing are based on sending short probe pulses emitted by a piezoelectric plate with angles to the controlled product input ultrasonic vibrations from 0, 38, 40, 41, 42, 45, 49, 50, 55, 58, 60, 65, 70 degrees and the rotation angles of the piezoelectric plate relative to the longitudinal axis of the rail 34, 10, 12 degrees and the reception of echo signals reflected either from standard reflectors and non-standard reflectors (defects), strictly along a certain path of the acoustic beam using the same piezoelectric plate installed in a piezoelectric transducer operating in a combined radiation mode - receiving ultrasonic vibrations (echo method of ultrasonic testing), or using a piezoelectric plate working to receive an echo signal installed in a piezoelectric transducer operating in a separate radiation-receiving mode of ultrasonic vibrations for receiving an echo signal (mirror ultrasonic testing method, ultrasonic testing delta method, ultrasonic testing mirror-shadow method, ultrasonic shadow monitoring method) or in a piezoelectric transducer operating in a combined ultrasonic radiation-receiving mode oscillations (echo-mirror method of ultrasonic testing) with the same angles of input of ultrasonic vibrations, installed strictly at a certain distance based on the condition the best sounding of the zone of probable defect formation and on the longitudinal axis of the rail, on the surface of the controlled product or on the opposite surface relative to the piezoelectric plate emitting ultrasonic vibrations installed in the piezoelectric transducer, to identify defects of a certain code provided by NTD / CP-1-93 “Classification of defects rails ”, Ministry of Railways of the Russian Federation, Transport Publishing House, Moscow, 1993.

The echo-location method of ultrasonic rail monitoring is based on sending short probing pulses to the controlled product with a piezoelectric plate (Figure 7), operating in the combined radiation-receiving mode of ultrasonic vibrations, and registering echo signals with the same piezoelectric plate and many piezoelectric plates operating in separate modes of radiation-reception of ultrasonic vibrations that implement the alternate change in the combined and separate modes of radiation-reception of the piezoelectric lastin (figure 8). A sign of defect detection is the registration of the echo signal by piezoelectric plates operating both in the combined radiation-receiving mode of ultrasonic vibrations and in the separate radiation-receiving mode of ultrasonic vibrations. The result is achieved due to the fact that on the rolling surface of the rail head, on its longitudinal axis, a block of resonators is installed with piezoelectric plates operating in combined and separate radiation-receiving modes of ultrasonic vibrations with different angles of input of ultrasonic vibrations, the ultrasonic rays of which are directed in the same direction with the direction of movement of this block of resonators, while one of the piezoelectric plates of this block of resonators operates in a combined mode of radiation-reception of ultra sonic vibrations, and the rest of the piezoelectric plates operate in a separate radiation-receiving mode of ultrasonic vibrations, and the piezoelectric plate operating in a combined radiation-receiving mode of ultrasonic vibrations is an emitter of ultrasonic vibrations for all piezoelectric plates operating in a separate radiation-receiving mode of ultrasonic vibrations echo reception. In front of a block of resonators with piezoelectric plates operating in combined and separate radiation-receiving modes of ultrasonic vibrations on the rolling surface of the rail head, another block of resonators with piezoelectric plates operating in a separate radiation-receiving mode of ultrasonic vibrations operating to receive an echo is mounted on the longitudinal axis of the rail -signal also with different angles of reception of ultrasonic vibrations, the ultrasonic rays of which are also directed in one direction, but in the opposite the other side of the motion of the block of resonators with piezoelectric plates operating in combined and separate modes of radiation-reception of ultrasonic vibrations. At the end of the cycle of ultrasonic vibrations, the operation modes of the piezoelectric plates in the resonator block alternately change with the piezoelectric plates operating in combined and separate radiation-receiving modes of ultrasonic vibrations. The cycle of ultrasonic vibrations is the time interval from the moment of introducing ultrasonic vibrations by a piezoelectric plate with a certain angle of ultrasonic vibrations and the angle of rotation of the piezoelectric plate relative to the longitudinal axis of the rail into the product to be monitored until the echo signal is received by many piezoelectric plates with different echo reception angles and angles the rotation of the piezoelectric plates relative to the longitudinal axis of the rail. Moreover, the number and location of the piezoelectric plates operating in a separate radiation-receiving mode of ultrasonic vibrations as an echo signal receiver with respect to the piezoelectric plate operating in a combined radiation-receiving mode of ultrasonic vibrations is not limited. This ability can be limited only by technical reasons - the lack of special equipment. Due to the scattering phenomenon, the propagation of ultrasonic vibrations in the rail from the interface between two media, including standard reflectors, occurs in a radius of 360 degrees in all coordinate planes. The ability of piezoelectric plates receiving ultrasonic vibrations to receive echo signals, regardless of the strictly defined direction of propagation of ultrasonic waves, is directly proportional to the registration of echo signals from any reflectors, regardless of their orientation, configuration and size, which are in the controlled product, which is fundamental element of the echo-location method of ultrasonic testing and, as a result, allows you to register echo signals from a standard reflector and non-standard reflectors, defects that are in the controlled product and, in particular, in the rail over the entire section in accordance with NTD / CP-1-93 “Classification of rail defects”, Ministry of Railways of the Russian Federation, Transport Publishing House, Moscow, 1993, except in feathers of the rail sole, if ultrasonic vibrations are input and echo signals are received from the rolling surface of the rail head.

As an indicator of the effective performance of the sonar method of ultrasonic testing, a comparative table has been compiled for identifying artificially made defects in the rail using code 21.1 (Figure 10), 30 g. 1 (Figure 11), 52.1 (Figure 12), 53.1 (Figure 13), 55.1 (Figure 14), 69 (Figure 15) according to NTD / CP-1-93 “Classification of rail defects”, Ministry of Railways of the Russian Federation, Transport Publishing House, Moscow, 1993 and registration of echo signals from the defect-free end of the rail with bolt holes (figure 9).

Comparison table No. 1 detection of artificially made defects by the echo method of ultrasonic testing and the echo-location method of ultrasonic testing along the longitudinal axis of the rail and over the entire section of the rail. Defect code PEP ultrasound echo method40 degrees echo method of ultrasonic inspection of the probe 42 degrees echo method of ultrasonic inspection of PEP45 degrees echo-location method of ultrasonic testing of probes 40, 45, 55, 58, 70 degrees Figure 10.1. defect code 21.1: X - 75.0 mm, L - 2.0 mm, H1 - 3.0 mm, H2 - 0.0 mm, H - 3.0 mm, angle 7 degrees. - - - + Figure 10.2. defect code 21.1: X - 30.0 mm, L - 5.0 mm, H1 - 6.0 mm, H2 - 0.0 mm, conditional H - 6.0 mm, angle 0 degrees, cut R - 50 mm. - - - + Figure 10.3. defect code 21.1: X - 75.0 mm, L - 14.0 mm, H1 - 17.0 mm, H2 - 0.0 mm, conditional H - 17.0 mm, angle 45 degrees. - - - + Figure 10.4. defect code 21.1: X - 60.0 mm, L - 8.0 mm, H1 - 12.0 mm, H2 - 0.0 mm, conditional H - 12.0 mm, angle 15 degrees. - - - + Figure 11 defect code 30g.1: X - 30.0 mm, L - 150.0 mm, H1 - 17 mm, H2 - 27 mm, conditional H - 10 mm, angle 5 degrees. Drank deep into R - 50 mm. - - - + Figure 12 defect code 52.1: X - 12.0 mm. L - 10.0 mm, H1 - 42.0 mm, Н2 - 40.0 mm, nominal Н - 2.0 mm, angle 0 degrees. + + + + Figure 13.1 defect code 53.1: X - 4.5 mm, L - 16.0 mm, H1 - 72 mm, H2 - 82 mm, conditional H - 10 mm, angle 28 degrees (up “for 1 hour”). - - - + Figure 13.2 defect code 53.1: X - 6.0 mm, L - 18.0 mm, H1 - 115 mm, H2 - 107 mm, conditional H - 8 mm, angle 60 degrees (down “for 4 hours”). - - - + Figure 13.3 defect code 53.1: X - 4.0 mm, L - 14.0 mm, H1 - 109 mm, H2 - 114.0 mm, conditional H - 5.0 mm, angle 50 degrees (down “at 7 o’clock”). + + + + Figure 13.4 defect code 53.1: X - 4.0 mm, L - 12.0 mm, H1 - 84.0 mm, H2 - 70.0 mm, conditional H - 14.0 mm, angle 25 degrees (up “for 1 hour”). + + + + Figure 14.1 defect code 55.1: X - 6.0 mm, L - 55.0 mm, H1 - 62.0 mm, H2 - 60.0 mm, conditional H - 2.0 mm, angle 0 degrees. - - - + Figure 14.2 defect code 55.1: X - 8.0 mm, L - 35.0 mm, H1 - 114 mm, H2 - 72 mm, conditional H - 42 mm, angle 35 degrees. - + - + Figure 15 defect code 69.1: X - 45.0 mm. L - 4.0 mm, H1 - 180.0 mm, Н2 - 176.0 mm, conditional Н - 4.0 mm, angle 0 degrees. + + + + Defect detection in% 30.77% 38.46% 30.77% one hundred%

The echo-location method of ultrasonic testing is based on sending short probe pulses emitted by piezoelectric plates to the controlled product, alternating between combined and separate modes of radiation reception of ultrasonic vibrations at the end of ultrasonic vibrations cycles with different angles of ultrasonic vibrations input from 0 to 90 degrees, angles turning the piezoelectric plate relative to the longitudinal axis of the rail from 0 to 90 degrees, and receiving echo signals reflected from standard reflectors non-standard reflectors (defects), a variety of piezoelectric plates with different angles of reception of echo signals from 0 to 90 degrees and the rotation angles of the piezoelectric plate relative to the longitudinal axis of the rail from 0 to 90 degrees, alternating between combined and separate modes of radiation reception of ultrasonic vibrations at the end of the cycle of ultrasonic vibrations, located regardless of the distance and place on the surface of the controlled product relative to the piezoelectric plate emitting ultrasound oscillations, followed by a change in the operating modes of the piezoelectric plates at the end of the cycle of ultrasonic vibrations, to register the echo signal from any reflectors, regardless of their orientation, configuration and size, located in the controlled product, and bringing the recorded echo signals of all cycles of ultrasonic vibrations into a single information field.

The echo-location method of ultrasonic testing allows the following.

1. To constantly monitor the quality of each piezoelectric plate both in the area of the bolt joint and outside the area of the bolt joint.

2. To control the "dead" zone by piezoelectric transducers, working only on the reception of echo signals, and to monitor from the surface of the controlled product.

3. Receive echo signals from standard and non-standard reflectors located in the controlled product with different orientations, configurations and sizes, capable of reflecting the echo signal at the installation site of piezoelectric transducers receiving echo signals.

4. To receive duplicated echo signals from standard and non-standard reflectors received from the same point in the section of the controlled product with different angles of reception of echo signals and over the entire area of the controlled product.

5. Add the duplicated echo signals received from different zones of the reflector into a single section of information display.

6. Allows you to increase the information content by increasing the number of piezoelectric transducers operating in the radiation and reception mode.

7. Approach the creation of automatic decryption of the received information and the creation of the display of both standard and non-standard reflectors in three-dimensional measurement.

8. Identify defects in the controlled product, at different stages of its development, from its initial size to critical dimensions.

9. Predict the development of the defect.

10. Display the received echoes in the form of new information not previously used in the implementation of other methods.

11. Apply the echo-location method of ultrasonic testing in various sectors of the economy.

Claims (2)

1. The ultrasonic method of monitoring the product over the entire cross section, consisting in the fact that many piezoelectric transducers are installed on the surface of the controlled product, alternating the operation of combined and separate radiation-receiving modes of ultrasonic vibrations at the end of ultrasonic vibrations cycles with different angles of input of ultrasonic vibrations from 0 to 90 °, the rotation angles of the piezoelectric plate relative to the longitudinal axis of the controlled product from 0 to 90 °, and, moving all the transducers along along the single axis of the monitored product, echo signals reflected from standard reflectors and non-standard reflectors (defects) are recorded over the entire cross section of the monitored product, with the exception of the “Hidden” zone - the area of the monitored product that is unable to reflect echo signals at the installation site of the piezoelectric transducers receiving echo signals by a plurality of piezoelectric plates with different angles of reception of echo signals from 0 to 90 ° and rotation angles of the piezoelectric plate relative to the longitudinal axis a removable product from 0 to 90 °, also alternating between combined and separate modes of radiation-reception of ultrasonic vibrations at the end of a cycle of ultrasonic vibrations, placed regardless of the distance and location on the surface of the controlled product relative to the piezoelectric plate emitting ultrasonic vibrations, followed by a change in modes the work of piezoelectric plates for recording the echo signal from any reflectors, regardless of their orientation, configuration and dimensions, which are in control the manufactured product, and they perform the conversion of the registered echo signals of all cycles of ultrasonic vibrations into a single information field, characterized in that the piezoelectric transducers operate in a cyclic mode of ultrasonic vibrations and, at the end of the cycle, alternate the combined and separate modes of radiation-reception of ultrasonic vibrations, but with preservation The principle of one radiates and many accepts. 2. The ultrasonic method for monitoring the product over the entire cross section according to claim 1, characterized in that the radiation of ultrasonic vibrations into the controlled product is made by one piezoelectric plate, and the reception of echo signals by a plurality of piezoelectric plates with different angles of reception of echo signals from 0 to 90 ° and the rotation angles of the piezoelectric plate relative to the longitudinal axis of the controlled product from 0 to 90 ° in one cycle.

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