CN102230915A - Device and method for flaw detection of small crawler-type rails based on three-way ultrasonic diffraction - Google Patents
Device and method for flaw detection of small crawler-type rails based on three-way ultrasonic diffraction Download PDFInfo
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Abstract
The invention provides a device and a method for flaw detection of small crawler-type rails based on three-way ultrasonic diffraction. The device provided by the invention comprises a three-way crawler-type travel system, an ultrasonic detection master control system and a plurality of three-way ultrasonic diffraction detection sub-systems, wherein, all the three-way ultrasonic diffraction detection sub-systems and the ultrasonic detection master control system are configured on the three-way crawler-type travel system, and the three-way detector of each three-way ultrasonic diffraction detection sub-system is embedded in the crawler of the three-way crawler-type travel system. The method provided by the invention comprises the following steps: by means of the operations of all the three-way ultrasonic diffraction detection sub-systems and the ultrasonic detection master control system, carrying out crawler-type flaw detection, thus largely increasing the data sampling time in an area of the rail at the same detection speed; and simultaneously based on the three-way structure, carrying out flaw estimation by means of the propagation sound path of diffracted waves so as to be not sensitive to the energy and amplitude of received echo pulses, thereby still ensuring accurate work in the detection condition with large energy attenuation.
Description
Technical field
The invention belongs to the rail technical field of nondestructive testing, be specifically related to a kind of rail examination apparatus and method of utilizing ultrasonic diffraction and three-dimensional crawler type to roll into.
Background technology
Along with the high speed development of railway traffic transportation, rail transportation circuit is more and more busier, and vehicle density also increases thereupon.And the rail on the transportation route is in the process of bearing heavy transport task, because train causes friction, extruding, bending and percussive action to rail, rail can produce various damages inevitably, for observable outer damage such as corrosion, crushing of rail head, peel off fast, side grinding etc. and can in time handle; Hinder and then can't discern by naked eyes for the residual nuclear that causes with white point that is mingled with that rail inside exists, these internal injuries retain in serious traffic safety hidden danger such as the transversal crack that will cause rail in the rail of day and night operation, rail head fracture for a long time.These invisible internal injuries have only by rail flaw detector and could find, according to result of detection rail are carried out respective handling in time then.
Technical, acoustic characteristic that ultrasound wave is good and recent two decades come the tremendous development of computing machine and Digital Electronic Technique to bring faster, more accurate, more humane application for the rail Non-Destructive Testing.And traditional pulse echo method has been widely used in the rail examination field as the main flow of Ultrasonic NDT.It utilizes ultrasonic probe to being examined workpiece emission ultrasonic pulse, and according to the energy size that reflects by workpiece, defect and phase information as the foundation of judging defective.Pulse echo method since prolonged application in the rail examination field, thereby it is ripe relatively technically.Yet, it relies on the energy size of reflection wave on principle, belong to detection method to energy-sensitive, in actual applications, because the echo amplitude sensitivity characteristic of pulse echo method, often performance is not good aspect detection by quantitative to make it, and this also is to utilize classic method to carry out one of reason that the omission risk of rail examination can not more effective control.On the other hand, in rail examination, often very big with the harmfulness of the crack defect of rail Surface Vertical, and for this orientation defective vertical with detection faces, conventional pulse echo detection method is usually because be difficult to accomplish that incident acoustic wave is vertical with the reflecting surface of defective, the difficulty that causes defective to detect, during quantitative information such as the position of this class defective, length, conventional supersonic testing method is powerless usually if desired.
The technology of utilizing the ultrasonic diffraction principle to carry out Non-Destructive Testing has overcome many deficiencies of conventional pulse echo method, has wide application space, and has brought new opportunity for modern rail examination technology.Its physical basis is the Huygens' principle that was proposed in 1690 by Dutch physicist Huygens.This principle is pointed out, the each point that the fluctuation in the medium is passed to can be regarded the new wave source of launching sound wave as, wave front later on constantly, and the enveloping surface of the wavelet wavefront that can be sent by these new wave sources is made.Ultrasound wave is launched ultrasound wave from probe to examined object, when ultrasound wave runs into such as linear discontinuities such as crackles, can produce diffraction at the most advanced and sophisticated position of defective, according to Huygens' principle, the edge of each defective can be regarded hyperacoustic signal source as, and outwards launches the ultrasonic diffraction ripple.Utilizing the ultrasonic diffraction principle to detect a flaw is exactly to note these diffracted wave signals, as the foundation of judging damage.At the beginning of 21 century, the ultrasonic diffraction time difference method that is proposed by Britain country Non-Destructive Testing center imports China into, and this method progressively is applied in China Non-Destructive Testing field.Yet it has but brought some other defectives when remedying traditional pulse echo method deficiency.For example, poor to the transverse defect detectability, in the defect map of ultrasonic diffraction time difference method, easily the transverse defect erroneous judgement is point defect; Owing to straight-through ripple and near surface flaw diffracted wave are obscured easily and are caused such defective to detect inferior positions such as poor effect.
On the other hand, improving with raising speed significantly of China railways net had higher requirement to rail examination speed and efficient.Its speed per hour of military wide high ferro passenger traffic the Shinkansen that mileage is the longest in the world, overall trip speed is the highest that China in 2009 builds up has reached 350 kilometers.Yet the speed per hour of existing large-scale rail-defect detector car but still rests on tens kilometers, and small-sized hand propelled inspection car speed per hour only has only several kilometers, the needs that this can not satisfy busy day by day, railway transportation efficiently far away and safeguard.Unlikely echo is lost to guarantee ultrasonic probe that the enough data sampling time is arranged to be to control the inspection car road speed for the main cause that limits current motor-driven inspection car speed per hour.Yet current motor-driven inspection car generally can not satisfy the needs of flaw detection at a high speed because the duration of contact of its probe and a certain fixed position of rail is too short when high-speed cruising.
In disclosed Chinese invention patent application CN1225453A on August 11st, 1999, proposed a kind ofly to change the conventional liquid couplant and adopt solid-state couplant to carry out the method for rail examination, this method utilizes ultrasonic beam directly to be coupled in the rail by solid-state slide plate, reduced the hysteresis that when using coupling liquid, occurs, it can reduce echo to a certain extent and lose, yet still there are some shortcomings and deficiencies in this method: at first, adopt the solid-state couplant can not be from increasing the time of probe data sampling in fact, actual inspection speed can not increase substantially, and solid-state couplant influences the flaw detection performance and changes complicated after wearing and tearing; The second, adopt traditional pulse echo method to carry out defects detection, be difficult to detect running into the orientation defective vertical with detection faces, and can not accurately quantitatively detect the size of defective.
Summary of the invention
At exist in ultrasonic rail examination technical field at present some such as inspection speed be difficult to improve, inefficiency, deficiency such as the defective recall rate vertical with detection faces is low and the detection by quantitative performance is not good, the present invention proposes a kind of small-sized caterpillar belt formula rail examination apparatus and method based on the three-dimensional ultrasonic diffraction.The present invention adopts crawler type to roll into the traditional wheel drive inspection car walking of replacement, and the data sampling time to a certain zone of rail increases greatly under the identical inspection speed thereby make.On the other hand, the track structure of this failure detector driving system is a three-dimensional, and utilizes the structure of described device to realize a kind of more accurate method of detection.
For reaching the desired purpose of the present invention, will adopt following technical scheme:
Should comprise three-dimensional crawler type driving system, several three-dimensional ultrasonic diffraction detection subsystem and Ultrasonic Detection master control system based on the small-sized caterpillar belt formula rail examination device of three-dimensional ultrasonic diffraction.Wherein, all three-dimensional ultrasonic diffraction detection subsystem and Ultrasonic Detection master control system are installed on the three-dimensional crawler type driving system, drive described small-sized caterpillar belt formula rail examination device based on the three-dimensional ultrasonic diffraction by three-dimensional crawler type driving system and advance; The three-dimensional of embedded each three-dimensional ultrasonic diffraction detection subsystem probe on the crawler belt of described three-dimensional crawler type driving system; All three-dimensional ultrasonic diffraction detection subsystem all are connected with the Ultrasonic Detection master control system is parallel; And the Ultrasonic Detection master control system manages each three-dimensional ultrasonic diffraction detection subsystem of concurrent working.
Three-dimensional crawler type driving system of the present invention comprises 3 groups of crawler belts, and the crawler belt that wherein is positioned at the rail top is main crawler belt, and the crawler belt of the left and right sides is auxilliary crawler belt, is responsible for driving the flaw detection dolly by main crawler belt and advances.3 groups of crawler belts are along all embedded some ultrasonic probes on the direction of rail trend, be close to respectively during detection rail directly over and the left and right sides.Along the length of rail trend the crawler belt of embedded ultrasonic probe is divided into plurality of detection subarea (being assumed to be N) according to crawler belt, wherein each side crawler belt all carries 1 ultrasonic probe in each subarea, because have 3 groups of crawler belts, so 3 ultrasonic probes are carried in each subarea of dividing altogether on three directions.On a certain section perpendicular to the rail trend, these 3 ultrasonic probes that carry in the subarea promptly are 1 group of three-dimensional probes of three-dimensional ultrasonic diffraction detection subsystem; With the different frequency concurrent working, and each detects subarea and is responsible for detection by a corresponding three-dimensional ultrasonic diffraction detection subsystem all three-dimensional probes of being close to rail when detecting.Because this track structure, when failure detector was advanced, the time that every group of three-dimensional probe rests on a certain fixed test zone of rail increased greatly than classic method, thereby has the longer data sampling time.
Described three-dimensional ultrasonic diffraction detection subsystem comprises control module, pressure transducer, couplant preparation device, ultrasonic emitting and reception switching channel, one group of three-dimensional probe, waveform acquisition module, DSP module, data memory module and breakdown diagnosis module.Wherein control module links to each other respectively with reception switching channel and one group of three-dimensional probe with pressure transducer, couplant preparation device, ultrasonic emitting; Three-dimensional probe removes with control module links to each other, and still is connected with reception switching channel and waveform acquisition module with ultrasonic emitting; The waveform acquisition module links to each other with the DSP module; Data memory module and breakdown diagnosis module are connected to each other, and all are connected with the DSP module.Wherein, control module is responsible for receiving the response signal of pressure transducer and is sent order to control their work to the couplant preparation device that is attached thereto, ultrasonic emitting and reception switching channel and one group of three-dimensional probe; Pressure transducer is installed on three-dimensional ultrasonic diffraction detection subsystem and is responsible for detecting on the crawler belt in subarea, and it is responsible for the crawler belt pressure in this detection subarea of lasting monitoring and whether breaks through a certain preset threshold value; The couplant preparation device is responsible for the preparation of couplant before detecting beginning; Ultrasonic emitting is used for switching ultrasonic emission and the reception of each son probe of this group three-dimensional probe with the reception switching channel; One group of three-dimensional probe is responsible for emission and reception ultrasonic signal when detecting; The waveform acquisition module is responsible for the waveform signal that acquisition testing arrives; The signal that the DSP module is responsible for gathering carries out denoising and hiding signal extraction is handled; The breakdown diagnosis module is responsible for the signal after the DSP resume module is analyzed to obtain the rail failure information of being examined; Data memory module is used for signal and the breakdown diagnosis result after the buffer memory DSP resume module.
Described Ultrasonic Detection master control system comprises computing machine main control module, mileage Displaying Meter, alarm module and display module.Mileage Displaying Meter, alarm module and display module are connected with the computing machine main control module successively, and all three-dimensional ultrasonic diffraction detection subsystem are connected with the computing machine main control module is parallel.The data of each three-dimensional ultrasonic diffraction detection subsystem collection all will be incorporated the computing machine main control module into and gather and in time handle it.The computing machine main control module is responsible for monitoring the duty of all three-dimensional ultrasonic diffraction detection subsystem, if certain subsystem is in state of activation and has finished current breakdown diagnosis and data archiving work, then all the data archiving information with it send it back the computing machine main control module, and control this subsystem and enter dormant state; The mileage Displaying Meter is responsible for showing the total kilometrage number of this device flaw detection and is worked as time mileage number of flaw detection; Alarm module is responsible for to point out current certain rail to be examined the zone damage being arranged according to the order that the computing machine main control module the is sent alarm of ringing; Display module is responsible for showing current result of detection.
In the method for detection of this small-sized caterpillar belt formula rail examination device, the work of three-dimensional ultrasonic diffraction detection subsystem comprises following concrete steps:
Step 6, the probe B that draws from step 5 receive that the diffracted wave sound path of waveform is
, the probe C receive that the diffracted wave sound path of waveform is for the 1st time
And probe C receives that the diffracted wave sound path of waveform is for the 2nd time
, known again velocity of wave is
, the defect point of establishing the generation diffraction is respectively apart from the position of probe A, B, C
,
,
, following system of equations is then arranged:
Section in the vertical rail trend of being examined the zone of this three-dimensional ultrasonic diffraction detection subsystem sets up plane right-angle coordinate, solves according to above-mentioned
,
,
The fixed position of value and probe A, B, C, then can in the coordinate system of being set up, determine the particular location of this defective, simultaneously according to each probe receive the phase information of waveform can judge fault location that diffraction takes place such as bubble, be mingled with, the specific nature of crackle upper prong, crackle lower prong etc.If examined the fault location that there are a plurality of generation diffraction in the zone, then in step 5, can draw the repeatedly diffracted wave data that each probe receives, list a plurality of system of equations according to many groups sound path data with said method, can try to achieve each defective locations that diffraction takes place, if defective is a crack defect, can also calculate the length information of crackle according to the particular location of crackle upper prong and crackle lower prong.
The work of the Ultrasonic Detection master control system of described small-sized caterpillar belt formula rail examination device comprises following concrete steps:
Whether step 2, computing machine main control module monitor certain subsystem is in state of activation and has finished breakdown diagnosis and data storage work, is then to jump to next step, continues monitoring otherwise jump to step 1; Of particular note, no matter whether monitor the subsystem that satisfies above-mentioned condition, the computing machine main control module all continues uninterruptedly to carry out to the monitoring of each three-dimensional ultrasonic diffraction detection subsystem.
By the above-mentioned technical scheme of setting forth as can be known, the present invention has creatively adopted the three-dimensional crawler type driving system of being close to left and right, last three sides of rail to replace traditional wheel drive inspection car walking; Simultaneously, based on this three-dimensional structure a kind of method of detection that utilizes ultrasonic diffraction has been proposed; On the other hand, whole crawler type rail examination device is divided into a plurality of subsystem parallel detections, and all subsystems are by the master control system unified management.Compare with technology with existing rail examination device, it has following concrete advantage:
1, because the characteristic of track structure, keep the relative position between the rail zone of crawler belt certain and the inspection of this place to remain unchanged in one period relative long period that it can be when driving, when inspection car is walked at a high speed, pop one's head in too short and defective that cause echo to be lost rail certain sampling time so overcome.Thereby under the prerequisite in identical sampling time of needs, compare with classic method, this device can be with road speed operation more at a high speed.
2, the track structure of this device is a three-dimensional.Compare with traditional pulse echo method based on the method for detection that utilizes ultrasonic diffraction that this three-dimensional structure proposes, it is to utilize diffraction wave propagation sound path to carry out defective to estimate, thereby its butt joint regains energy, amplitude big or small insensitive of wave impulse, still can accurately work in the bigger testing environment of energy attenuation.
3, traditional pulse echo detection method is when the defective that detects with the rail Surface Vertical, because be difficult to usually accomplish that incident wave is vertical with the defect reflection face and cause omission; And three-dimensional ultrasonic diffraction detection method proposed by the invention utilizes the principle of ultrasonic diffraction and do not require for whether incident wave and defect reflection face be vertical, thereby for this defective, these apparatus and method can be brought into play bigger advantage and accurately detect; Simultaneously, still has the advantage that traditional pulse echo method is had when detecting transverse defect.
4, the three-dimensional ultrasonic diffraction detection method of the present invention's proposition, because it is based on a plurality of direction image data, so have accurate testing result equally for transverse defect and near surface flaw, and that these advantages are based on the ultrasonic diffraction time difference method of single direction is not available.
5, one of each subsystem group of probe is made up of the probe that is positioned at 3 of rail, and it can carry out hyperacoustic emission and reception on the different directions by ultrasonic emitting and reception switching channel more neatly, gathers multi-group data; And estimate the position of steel rail defect according to the multi-group data of gathering, and the crack defect of especially helpless and rail Surface Vertical for traditional pulse echo method, it and can calculate the length information of this orientation crackle except detecting this defective.
6, whole small-sized caterpillar belt formula rail examination device is being divided into a plurality of subsystems along subregion on the direction of rail trend, the concurrent working when detecting of all subsystems, and by the main system managed together.This parallel schema has further improved flaw detection efficient.
7, the present invention sets up database to all management of flaw detection uniform data and storage, convenient big zone, unremitting efficient flaw detection in the Ultrasonic Detection master control system.Utilize this method after all scheduled plan zone flaw detections are finished, to utilize the data in the database to finish various subsequent treatment and report analysis, also can ring and do instant processing according to instant alarm device.In efficient flaw detection, have dirigibility concurrently.
Description of drawings
Fig. 1 is a three-dimensional crawler type driving system structural representation among the present invention;
Fig. 2 is the structured flowchart that the present invention realizes three-dimensional ultrasonic diffraction detection subsystem;
Fig. 3 is the structured flowchart that the present invention realizes the Ultrasonic Detection master control system
Fig. 4 is the detection method process flow diagram of three-dimensional ultrasonic diffraction detection subsystem among the present invention;
Fig. 5 is the detection method process flow diagram of Ultrasonic Detection master control system among the present invention;
Fig. 6 is the ultrasonic wave diffraction schematic diagram;
Fig. 7 is that the present invention realizes the schematic diagram that the three-dimensional ultrasonic diffraction detects;
The synoptic diagram of three-dimensional Ultrasonic Detection when wherein Fig. 7 a is the rail not damaged;
Fig. 7 b is the rail synoptic diagram that the three-dimensional ultrasonic diffraction detects when crack defect is arranged;
The waveform legend that probe B received when Fig. 7 c1 was based on defective shown in Fig. 7 b;
The waveform legend that probe C received for the first time when Fig. 7 c2 was based on defective shown in Fig. 7 b;
Fig. 7 c3 is based on the waveform legend that the probe C of defective shown in Fig. 7 b receives for the second time.
Embodiment
Below in conjunction with embodiment and accompanying drawing the present invention is done further detailed elaboration, but embodiments of the present invention are not limited thereto.
Embodiment
As shown in Figure 1, three-dimensional crawler type driving system of the present invention is made of 3 groups of crawler belts, and the crawler belt that wherein is positioned at rail 3 tops is main crawler belt 1, and the crawler belt of the left and right sides is auxilliary crawler belt 2, is responsible for driving the flaw detection dolly by main crawler belt 1 and advances.3 groups of crawler belts are along all embedded some ultrasonic probes on the direction of rail trend, be close to respectively during detection rail 3 directly over and the left and right sides.Along the length of rail trend the crawler belt of embedded ultrasonic probe is divided into plurality of detection subarea (being assumed to be N) according to crawler belt, wherein each side crawler belt all carries 1 ultrasonic probe in each subarea, because have 3 groups of crawler belts, so 3 ultrasonic probes are carried in each subarea of dividing altogether on three directions.On a certain section perpendicular to the rail trend, these 3 ultrasonic probes that carry in the subarea promptly are 1 group of three-dimensional probes of three-dimensional ultrasonic diffraction detection subsystem; With the different frequency concurrent working, and each detects subarea and is responsible for detection by a corresponding three-dimensional ultrasonic diffraction detection subsystem all three-dimensional probes of being close to rail 3 when detecting.Because this track structure, when failure detector was advanced, the time that every group of three-dimensional probe rests on a certain fixed test zone of rail increased greatly than classic method, thereby has the longer data sampling time.
As shown in Figure 2, described three-dimensional ultrasonic diffraction detection subsystem comprises control module, pressure transducer, couplant preparation device, ultrasonic emitting and reception switching channel, one group of three-dimensional probe, waveform acquisition module, DSP module, data memory module and breakdown diagnosis module.Wherein control module links to each other respectively with reception switching channel and one group of three-dimensional probe with pressure transducer, couplant preparation device, ultrasonic emitting; Three-dimensional probe removes with control module links to each other, and still is connected with reception switching channel and waveform acquisition module with ultrasonic emitting; The waveform acquisition module links to each other with the DSP module; Data memory module and breakdown diagnosis module are connected to each other, and all are connected with the DSP module.Wherein, control module is responsible for receiving the response signal of pressure transducer and is sent order to control their work to the couplant preparation device that is attached thereto, ultrasonic emitting and reception switching channel and one group of three-dimensional probe; Pressure transducer is installed on three-dimensional ultrasonic diffraction detection subsystem and is responsible for detecting on the crawler belt in subarea, and it is responsible for the crawler belt pressure in this detection subarea of lasting monitoring and whether breaks through a certain preset threshold value; The couplant preparation device is responsible for the preparation of couplant before detecting beginning; Ultrasonic emitting is used for switching ultrasonic emission and the reception of each son probe of this group three-dimensional probe with the reception switching channel; One group of three-dimensional probe is responsible for emission and reception ultrasonic signal when detecting; The waveform acquisition module is responsible for the waveform signal that acquisition testing arrives; The signal that the DSP module is responsible for gathering carries out denoising and hiding signal extraction is handled; The breakdown diagnosis module is responsible for the signal after the DSP resume module is analyzed to obtain the rail failure information of being examined; Data memory module is used for signal and the breakdown diagnosis result after the buffer memory DSP resume module.This failure detector is in traveling process, certain crawler belt zone, place of detecting the subarea will at a time begin to be close to rail, the detected pressure of pressure transducer this moment will reach a certain threshold value that sets in advance, it will trigger the three-dimensional ultrasonic diffraction detection subsystem of being responsible for this detection subarea and enter state of activation, control module produces control signal, start the couplant preparation device, and the work of control three-dimensional probe; Send into the DSP module through the Wave data of waveform acquisition module collection and carry out denoising and hiding signal extraction; Signal after the processing is used for carrying out the rail failure analysis on the one hand, its storage is prepared against called from now on the other hand; And last breakdown diagnosis result also sends into data memory module.Finish behind time all working of detection, the flaw detection information in the data memory module will be sent into the Ultrasonic Detection master control system and carry out subsequent treatment under the computing machine master control module controls of Ultrasonic Detection master control system.
As shown in Figure 3, described Ultrasonic Detection master control system comprises computing machine main control module, mileage Displaying Meter, alarm module and display module.Mileage Displaying Meter, alarm module and display module are connected with the computing machine main control module successively, and all three-dimensional ultrasonic diffraction detection subsystem are connected with the computing machine main control module is parallel.The data of each three-dimensional ultrasonic diffraction detection subsystem collection all will be incorporated the computing machine main control module into and gather and in time handle it.The computing machine main control module is responsible for monitoring the duty of all three-dimensional ultrasonic diffraction detection subsystem, if certain subsystem is in state of activation and has finished current breakdown diagnosis and data archiving work, then all the data archiving information with it send it back the computing machine main control module, and control this subsystem and enter dormant state; The mileage Displaying Meter is responsible for showing the total kilometrage number of this device flaw detection and is worked as time mileage number of flaw detection; Alarm module is responsible for to point out current certain rail to be examined the zone damage being arranged according to the order that the computing machine main control module the is sent alarm of ringing; Display module is responsible for showing current result of detection.
As shown in Figure 4, the workflow of three-dimensional ultrasonic diffraction detection subsystem may further comprise the steps among the present invention:
Step 6, the probe B that draws from step 5 receive that the diffracted wave sound path of waveform is
, the probe C receive that the diffracted wave sound path of waveform is for the 1st time
And probe C receives that the diffracted wave sound path of waveform is for the 2nd time
, known again velocity of wave is
, the defect point of establishing the generation diffraction is respectively apart from the position of probe A, B, C
,
,
, following system of equations is then arranged:
Section in the vertical rail trend of being examined the zone of this three-dimensional ultrasonic diffraction detection subsystem sets up plane right-angle coordinate, solves according to above-mentioned
,
,
The fixed position of value and probe A, B, C, then can in the coordinate system of being set up, determine the particular location of this defective, simultaneously according to each probe receive the phase information of waveform can judge fault location that diffraction takes place such as bubble, be mingled with, the specific nature of crackle upper prong, crackle lower prong etc.If examined the fault location that there are a plurality of generation diffraction in the zone, then in step 5, can draw the repeatedly diffracted wave data that each probe receives, list a plurality of system of equations according to many groups sound path data with said method, can try to achieve each defective locations that diffraction takes place, if defective is a crack defect, can also calculate the length information of crackle according to the particular location of crackle upper prong and crackle lower prong.
As shown in Figure 5, the workflow of Ultrasonic Detection master control system may further comprise the steps among the present invention:
Whether step 2, computing machine main control module monitor certain subsystem is in state of activation and has finished breakdown diagnosis and data storage work, is then to jump to next step, continues monitoring otherwise jump to step 1; Of particular note, no matter whether monitor the subsystem that satisfies above-mentioned condition, the computing machine main control module all continues uninterruptedly to carry out to the monitoring of each three-dimensional ultrasonic diffraction detection subsystem.
As shown in Figure 6, wherein dash area is a crack-like defect of being examined the zone, and ultrasound wave is emitted to by probe and is subjected to the inspection zone, as runs into suchlike linear discontinuities, and incident wave will be at the most advanced and sophisticated diffraction phenomena that produces of defective.According to Huygens' principle, the edge of each defective can be regarded hyperacoustic another signal source as, outwards launches diffracted wave.In the figure, after incident wave 1 entered and examined the zone, because the defect area shown in the dash area differs greatly with the undamaged inspection district's acoustic impedance that is subjected to, so incident wave 1 will be launched formation reflection wave 2 on their acoustic interface; Simultaneously, some energy will pass defect area and form transmitted wave 3; Because the diffraction phenomena at the defective tip at the upper prong formation diffracted wave 4 of defective, and forms diffracted wave 5 at the lower prong of defective.Utilize the method for ultrasonic diffraction to detect a flaw, main rely on the diffracted wave information that receives and they are noted, as the foundation of defects detection.
When as shown in Figure 7, wherein Fig. 7 a and Fig. 7 b are the rail not damaged respectively and the synoptic diagram that detects of the three-dimensional ultrasonic diffraction of rail when crack defect is arranged.Shown in Fig. 7 a, Fig. 7 b, ultrasonic probe A is positioned at perpendicular to directly over the cross-section of the rail that moves towards direction along rail, and ultrasonic probe B, C lay respectively at the both sides of this cross-section of the rail; Set up plane right-angle coordinate as shown in the figure, wherein probe A is positioned at the mid point of its place line segment, and line segment length is
, probe B apart from the length of the initial point of foundation coordinate system is
Shown in Fig. 7 a, under the undamaged situation of rail, at first by probe A emission ultrasound wave, probe B, the received direction that only has of C are respectively
With
Direct wave; Afterwards, probe B emission ultrasound wave, the direction of still having only that probe C receives is
Direct wave.Owing to except direct wave, detect less than any diffracted wave, so decidable this examined regional zero defect.Shown in Fig. 7 b, wherein dash area is a crack defect, and of particular note, this figure is clear in order to explain, and omission marks
With
The direct wave of direction.At first, by probe A emission ultrasound wave, probe B, C receive ultrasound wave, and this incident wave will diffraction phenomena take place at the upper prong U and the lower prong L place of defective, and the upper prong U of defective and lower prong L can regard the sound source of an emission diffracted wave as.Thereby in this process, probe B is except receiving
Outside the direction direct wave, also priority is received diffracted wave
With
In like manner, probe C also is like this.Shown in Fig. 7 c1, what probe B at first received is
The direction direct wave,
Constantly receive the upper prong diffracted wave
,
Constantly receive the lower prong diffracted wave
Wherein, direct wave is opposite with the phase place of upper prong diffracted wave, and the upper prong diffracted wave also is opposite with the phase place of lower prong diffracted wave, therefore, is easy to they are distinguished on phase place.Shown in Fig. 7 c2, what probe C at first received is
The direction direct wave,
Constantly receive the upper prong diffracted wave
,
Constantly receive the lower prong diffracted wave
Subsequently, we switch probe B emission ultrasound wave, and probe C receives ultrasound wave, and the probe A break-off.Shown in Fig. 7 c3, this moment is because the through path between probe B, the C has been blocked in the existence of defective, transmitted wave will arrive at probe C but the ultrasound wave of some energy will penetrate defective formation, but because the transmitted wave energy is too small relatively, and it can be ignored, here, more clear for making diagram, also omit and indicate this transmitted wave.Therefore, probe C exists
Constantly receive the upper prong diffracted wave
,
Constantly receive the lower prong diffracted wave
Thus, suppose ultrasonic in being examined rail velocity of wave be
, establish defective upper prong U and be respectively apart from the distance of probe A, B, C
,
,
Defective lower prong L is respectively apart from the distance of probe A, B, C
,
,
Find the solution the upper prong position earlier, formula 1 arranged,
Separate it, try to achieve formula 2,
In the plane right-angle coordinate of being set up before, the coordinate of establishing the defective upper prong is
, the coordinate of defective lower prong is
, can release formula 3,
(formula 3)
In formula 2 substitution formula 3, the group of solving an equation can be tried to achieve the position coordinates of defective upper prong
In like manner,, formula 4 is arranged still for the defective lower prong,
In the coordinate system of being set up, can get formula 5,
In formula 4 substitution formula 5, the group of solving an equation can be tried to achieve the position coordinates of defective lower prong
Thus, obtain being examined in the zone position coordinates of lower prong on the defective, simultaneously by the diffracted wave phase information that receives as the foundation of judging defect property.For most of crack defect, this method is easy to draw the quantitative information of defective.
The present invention utilizes the three-dimensional track structure and carries out rail examination based on the three-dimensional ultrasonic diffraction detection method that this structure proposes, overcome traditional rail failure detector and defectives such as method efficient is low, speed is slow, loss is high, detection by quantitative poor performance, energy amplitude sensitivity, in modern rail examination is used, had bigger advantage.In three-dimensional system of coordinate, estimate defective locations if desired more accurately, can be by in each three-dimensional ultrasonic diffraction detection subsystem, increasing many group three-dimensional probes, so that in detection,, set up three-dimensional system of coordinate simultaneously with accurate estimation defective locations to the sampling of Z axis data.
The foregoing description is a preferred implementation of the present invention; but embodiments of the present invention are not restricted to the described embodiments; other any do not deviate from change, the modification done under spirit of the present invention and the principle, substitutes, combination, simplify; all should be the substitute mode of equivalence, be included within protection scope of the present invention.
Claims (7)
1. small-sized caterpillar belt formula rail examination device based on the three-dimensional ultrasonic diffraction, it is characterized in that comprising three-dimensional crawler type driving system, Ultrasonic Detection master control system and several three-dimensional ultrasonic diffraction detection subsystem, wherein, all three-dimensional ultrasonic diffraction detection subsystem and Ultrasonic Detection master control system are installed on the three-dimensional crawler type driving system, drive described small-sized caterpillar belt formula rail examination device based on the three-dimensional ultrasonic diffraction by three-dimensional crawler type driving system and advance; The three-dimensional of embedded each three-dimensional ultrasonic diffraction detection subsystem probe on the crawler belt of described three-dimensional crawler type driving system; All three-dimensional ultrasonic diffraction detection subsystem all are connected with the Ultrasonic Detection master control system is parallel; And the Ultrasonic Detection master control system is controlled each three-dimensional ultrasonic diffraction detection subsystem of concurrent working.
2. the small-sized caterpillar belt formula rail examination device based on the three-dimensional ultrasonic diffraction according to claim 1, it is characterized in that described three-dimensional crawler type driving system comprises three groups of crawler belts, the crawler belt that wherein is positioned at the rail top is main crawler belt, the crawler belt of the left and right sides is auxilliary crawler belt, is responsible for driving the flaw detection dolly by main crawler belt and advances; 3 groups of crawler belts are along all embedded some ultrasonic probes on the direction of rail trend, be close to respectively during detection rail directly over and the left and right sides; Along the length of rail trend the crawler belt of embedded ultrasonic probe is divided into the plurality of detection subarea according to crawler belt, wherein each side crawler belt all carries a ultrasonic probe in each subarea, each subarea of division directly over and carry three ultrasonic probes altogether on three directions in the left and right sides; On a certain section perpendicular to the rail trend, three ultrasonic probes that carry in described subarea promptly are one group of three-dimensional probes in the described three-dimensional ultrasonic diffraction detection subsystem; With the different frequency concurrent working, and each detects subarea and is responsible for detection by a corresponding three-dimensional ultrasonic diffraction detection subsystem all three-dimensional probes of being close to rail when detecting.
3. the small-sized caterpillar belt formula rail examination device based on the three-dimensional ultrasonic diffraction according to claim 1, it is characterized in that described three-dimensional ultrasonic diffraction detection subsystem comprises control module, pressure transducer, couplant preparation device, ultrasonic emitting and reception switching channel, one group of three-dimensional probe, waveform acquisition module, DSP module, data memory module and breakdown diagnosis module, wherein control module links to each other respectively with reception switching channel and one group of three-dimensional probe with pressure transducer, couplant preparation device, ultrasonic emitting; Three-dimensional probe removes with control module links to each other, and still is connected with reception switching channel and waveform acquisition module with ultrasonic emitting; The waveform acquisition module links to each other with the DSP module; Data memory module and breakdown diagnosis module are connected to each other, and all are connected with the DSP module; Wherein, control module is responsible for receiving the response signal of pressure transducer and is sent order to control their work to the couplant preparation device that is attached thereto, ultrasonic emitting and reception switching channel and one group of three-dimensional probe; Pressure transducer is installed on three-dimensional ultrasonic diffraction detection subsystem and is responsible for detecting on the crawler belt in subarea, and it is responsible for the crawler belt pressure in this detection subarea of lasting monitoring and whether breaks through preset threshold value; The couplant preparation device is responsible for the preparation of couplant before detecting beginning; Ultrasonic emitting is used for switching ultrasonic emission and the reception of each son probe of this group three-dimensional probe with the reception switching channel; One group of three-dimensional probe is responsible for emission and reception ultrasonic signal when detecting; The waveform acquisition module is responsible for the waveform signal that acquisition testing arrives; The signal that the DSP module is responsible for gathering carries out denoising and hiding signal extraction is handled; The breakdown diagnosis module is responsible for the signal after the DSP resume module is analyzed to obtain the rail failure information of being examined; Data memory module is used for signal and the breakdown diagnosis result after the buffer memory DSP resume module.
4. the small-sized caterpillar belt formula rail examination device based on the three-dimensional ultrasonic diffraction according to claim 1, it is characterized in that described Ultrasonic Detection master control system comprises computing machine main control module, mileage Displaying Meter, alarm module and display module, mileage Displaying Meter, alarm module and display module are connected with the computing machine main control module successively, and all three-dimensional ultrasonic diffraction detection subsystem are connected with the computing machine main control module is parallel; The data of each three-dimensional ultrasonic diffraction detection subsystem collection incorporate all that the computing machine main control module gathers into and and handle; The computing machine main control module is responsible for monitoring the duty of all three-dimensional ultrasonic diffraction detection subsystem, if certain subsystem is in state of activation and has finished current breakdown diagnosis and data archiving work, then all the data archiving information with it send it back the computing machine main control module, and control this subsystem and enter dormant state; The mileage Displaying Meter is responsible for showing the total kilometrage number of this device flaw detection and is worked as time mileage number of flaw detection; Alarm module is responsible for to point out current certain rail to be examined the zone damage being arranged according to the order that the computing machine main control module the is sent alarm of ringing; Display module is responsible for showing current result of detection.
5. the method for detection of each described small-sized caterpillar belt formula rail examination device of claim 1 ~ 4 comprises the course of work of Ultrasonic Detection master control system and three-dimensional ultrasonic diffraction detection subsystem it is characterized in that the work of Ultrasonic Detection master control system comprises the steps:
Step 1, the computing machine main control module continuous firing of Ultrasonic Detection master control system, it monitors the duty of each three-dimensional ultrasonic diffraction detection subsystem: dormant state and state of activation; Further, its monitoring is in the detection progress and the data processing progress of the three-dimensional ultrasonic diffraction detection subsystem of state of activation;
Whether step 2, computing machine main control module monitor certain three-dimensional ultrasonic diffraction detection subsystem is in state of activation and has finished breakdown diagnosis and data storage work, is then to jump to next step, continues monitoring otherwise jump to step 1; Of particular note, no matter whether monitor the subsystem that satisfies above-mentioned condition, the computing machine main control module all continues uninterruptedly to carry out to the monitoring of each three-dimensional ultrasonic diffraction detection subsystem;
Step 3, the breakdown diagnosis data that this that monitors are in state of activation and finished the three-dimensional ultrasonic diffraction detection subsystem of relevant work deposit the database of computing machine main control module in, simultaneously, switch this three-dimensional ultrasonic diffraction detection subsystem and enter dormant state; Even subsystem is in dormant state, the pressure transducer of this subsystem is still in running order;
Step 4, the computing machine main control module judges once more for the current detection information that deposits database in whether it belongs to rail damage information is arranged; If rail has wound, display module demonstrates the current damage information that deposits database in, the alarm device of ringing simultaneously, and the failure detector mileage information of counting that current appearance is damaged deposits database in;
Step 5 is selected whether to continue each three-dimensional ultrasonic diffraction detection subsystem of monitoring, is then still to continue monitoring; Otherwise finish, close whole failure detector.
6. method of detection according to claim 5 is characterized in that the work of described three-dimensional ultrasonic diffraction detection subsystem comprises the steps:
Step 1, in failure detector was advanced, pressure transducer continued to be in the duty of detected pressures; Roll into when closely contacting with rail when the crawler belt zone that certain three-dimensional ultrasonic diffraction detection subsystem is responsible for detecting, the detected pressure of pressure transducer will be broken through a certain threshold value, and at this moment, this three-dimensional ultrasonic diffraction detection subsystem enters state of activation;
Step 2, control module control ultrasonic emitting and the work of reception switching channel make the probe (A) of rail top launch ultrasound wave, and the ultrasonic probe of rail both sides (B, C) receive ultrasound wave, subsequently, note the waveform that the ultrasonic probe (B, C) of rail both sides receives;
Step 3, control module control ultrasonic emitting and the work of reception switching channel, make ultrasonic probe (B) the emission ultrasound wave of rail one side, be positioned at probe (A) break-off of rail top, and the ultrasonic probe (C) that is positioned at the rail opposite side receives ultrasound wave, subsequently, note the waveform that the ultrasonic probe (C) of this opposite side receives;
Step 4, judge all waveforms that this group three-dimensional ultrasonic probe (A, B, C) in this three-dimensional ultrasonic diffraction detection subsystem receives remove outside the direct wave whether still have diffracted wave, if there is not diffracted wave, then the detection subarea not damaged be responsible for of this subsystem does not carry out following steps; If detect diffracted wave, then enter next step;
Step 5, the detected waveform of ultrasonic probe (C) that makes opposite side described in ultrasonic probe (B, C) the detected waveform of rail both sides in the step 2 and the step 3 by the DSP module denoising and hide signal extraction and handle sound path, the phase information that draws the diffracted wave that they receive;
Step 6, the ultrasonic probe (B) of rail one side that draws from step 5 receives that the diffracted wave sound path of waveform is
, described opposite side ultrasonic probe (C) receive that the diffracted wave sound path of waveform is for the 1st time
And the 2nd time received that the diffracted wave sound path of waveform is
, known velocity of wave is
, the defect point of establishing the generation diffraction is respectively apart from the position of the three-dimensional ultrasonic probe (A, B, C) in this three-dimensional ultrasonic diffraction detection subsystem
,
,
, following system of equations is then arranged:
Section in the regional vertical rail trend of being examined of this three-dimensional ultrasonic diffraction detection subsystem is set up plane right-angle coordinate, solves
,
,
The particular location of this defective then can be determined in the value and the fixed position of a three-dimensional ultrasonic probe (A, B, C) in the coordinate system of being set up, the while receives that according to each probe the phase information of waveform can judge the specific nature of the fault location of generation diffraction.
7. method of detection according to claim 6, the specific nature that it is characterized in that described fault location comprises bubble, is mingled with, crackle upper prong or crackle lower prong, if examined the fault location that there are a plurality of generation diffraction in the zone, then in step 5, draw the repeatedly diffracted wave data that each probe receives, list a plurality of system of equations according to many groups diffracted wave sound path data, can try to achieve each defective locations that diffraction takes place; If defective is a crack defect, can also calculate the length information of crackle according to the particular location of crackle upper prong and crackle lower prong.
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| CN102565198A (en) * | 2011-12-27 | 2012-07-11 | 华南理工大学 | Wireless ultrasonic probe assembly for flaw detection of crawler-type steel rail and flaw detection method of wireless ultrasonic probe assembly |
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