CN113804755A - Automatic steel rail welding seam identification system and method - Google Patents
Automatic steel rail welding seam identification system and method Download PDFInfo
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- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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Abstract
Provided is a rail weld automatic recognition system, including: an acoustic wave sensor configured to transmit acoustic waves to the rail and receive echoes from the rail; a coupling medium; the acoustic wave sensor is fixedly arranged in the rubber wheel, the coupling medium is filled in the rubber wheel, and the rubber wheel can be connected to the tread of the steel rail in a rolling and pressing mode to form an acoustic wave transmission channel among the acoustic wave sensor, the coupling medium, the rubber wheel and the steel rail; the welding seam identification unit is used for processing the echo received by the acoustic wave sensor to identify the welding seam; the positioning unit is used for determining the coordinate position of the identified welding seam on the steel rail; a storage unit for storing the correction data; and the correction unit is used for correcting the identified welding seam data according to the correction data. Also provides a steel rail welding seam automatic identification method and a steel rail defect detection system.
Description
Technical Field
The invention relates to a system and a method for automatically identifying a steel rail welding seam, which can be applied to steel rail flaw detection equipment and belong to the technical field of steel rail flaw detection.
Background
Chinese patent CN201811503525 proposes a method for identifying a weld joint by using a rail surface image identification method. The method disclosed by the patent can be used for shooting the surface image of the steel rail in real time, the data volume is large, and a large amount of information redundancy is caused in the area without the welding seam of the steel rail. Meanwhile, the image identification calculation and marking process of the patent has large time delay, and errors are easily generated at the position of a welding seam mark. Meanwhile, the difference of the image gray values is used for distinguishing the welding line and the normal steel rail, the difference needs to be established on the extraction and training of massive standard welding line photos, the implementation conditions and the difficulty are high, the road condition state is complex in actual flaw detection, and the identification accuracy is difficult to guarantee.
In addition, the detection of the welding seam data and the rail defects relates to the safety of railway operation, and the rapid and effective detection of the welding seams is beneficial to improving the safety of the railway operation and is a problem to be solved for a long time.
Therefore, there is a need to develop an automatic rail weld recognition system and method thereof to solve the above-mentioned problems.
Disclosure of Invention
Research shows that a large number of welding seams existing in the existing steel rail in China have certain interference on detection results when the defects or the damages of the steel rail are detected by adopting sound waves. Specifically, the weld bead emergence wave of the weld is very similar to the rail head nuclear damage emergence wave of the steel rail base metal, so that the weld or the damage is not easy to distinguish when flaw detection data analysis is carried out. That is, for example, when a rail flaw detection vehicle is used to detect a rail flaw, although the operation speed is fast, the later data analysis personnel cannot distinguish a weld bead wave from a rail head nuclear damage, and thus misjudgment or missed judgment is easily caused. The misjudgment of the damage can cause the unnecessary on-site retest of the staff, which wastes time and labor, and the missed judgment of the nuclear injury can easily cause serious accidents such as rail break and the like.
Based on the above research findings, the present invention provides an automatic rail weld joint identification system for solving one or more technical problems in the prior art, which is characterized by comprising:
an acoustic wave sensor configured to transmit acoustic waves to the rail and receive echoes from the rail;
a coupling medium;
the acoustic wave sensor is fixedly arranged in the rubber wheel, the coupling medium is filled in the rubber wheel, and the rubber wheel can be connected to the tread of the steel rail in a rolling and pressing mode to form an acoustic wave transmission channel among the acoustic wave sensor, the coupling medium, the rubber wheel and the steel rail;
the welding seam identification unit is used for processing the echo received by the acoustic wave sensor to identify the welding seam;
the positioning unit is used for determining the coordinate position of the identified welding seam on the steel rail;
a storage unit for storing the correction data;
and the correction unit is used for correcting the identified welding seam data according to the correction data.
According to another aspect of the present invention, the correction data may include data of the weld seam and its corresponding coordinate position after field confirmation from the railway maintenance department, or may include related data of the weld seam after multiple identifications by the weld seam identification unit, or a combination thereof.
According to another aspect of the invention, the idler wheel is arranged on rail flaw detection equipment capable of moving along a rail, and rolls on a rail tread along with the movement of the flaw detection equipment on the rail so as to realize continuous identification of a rail welding seam.
According to another aspect of the invention, the acoustic wave sensor is arranged so that the distance between the incident point of the acoustic wave emitted by the acoustic wave sensor on the rail tread and the center line of the rail tread is 0.14-0.4L, a refraction angle of 35-50 degrees is formed on the rail tread, and an included angle of 8-15 degrees is formed with the longitudinal section of the rail, wherein L is the distance between the side surface of the rail and the center line of the rail tread.
According to another aspect of the present invention, the acoustic sensor includes a first acoustic sensor and a second acoustic sensor disposed on both an inner side and an outer side of a rail, and the first acoustic sensor and the second acoustic sensor detect a weld at the same position of the rail and identify the weld as the weld.
According to another aspect of the present invention, the weld recognition unit may include first and second weld recognition units corresponding to the first and second sonic sensors, respectively, for processing to independently recognize the weld based on echoes received by the first and second sonic sensors, respectively.
According to another aspect of the invention, the automatic steel rail weld joint recognition system further comprises an encoder unit, which is used for sending a trigger signal to the acoustic wave sensor to trigger the acoustic wave sensor to work periodically, and the encoder unit synchronously follows the wheel rotation of the flaw detection equipment to determine the coordinate position of the detected weld joint on the steel rail.
According to another aspect of the invention, the echo includes dihedral reflections from the railhead jaw ribbing at the weld.
According to another aspect of the present invention, the weld identifying unit further includes an echo time gain compensating unit in which a corresponding coefficient table of acoustic wave transmission time and gain values is stored.
According to another aspect of the present invention, when one of the first acoustic wave sensor and the second acoustic wave sensor disposed at the same position of the rail detects a weld and the other does not detect a weld, it is determined that the rail is cracked, and preferably, a maintenance person may be notified to confirm.
According to another aspect of the present invention, the correction data is generated based on the confirmation result and stored in the storage unit.
According to another aspect of the present invention, the correction unit performs the correction process when one of the first acoustic wave sensor and the second acoustic wave sensor provided at the same position of the rail detects the weld and the other does not detect the weld, determines that the rail is cracked if the correction process is not successful, and preferably notifies a maintenance worker to confirm.
According to another aspect of the invention, the invention further provides a rail welding seam automatic identification method, which is characterized in that the rail welding seam is identified by adopting the rail welding seam automatic identification system.
According to another aspect of the invention, the invention further provides a rail defect detection system, which is characterized in that the rail defect detection result is corrected by adopting the rail welding seam automatic identification system.
Compared with the prior art, the invention has the following technical effects: 1) the real-time and automatic identification and/or marking of the welding line are realized, the monitoring and data analysis of flaw detection personnel are greatly facilitated, and the efficiency of industrial fault detection is improved; 2) the welding seam recognition result can be corrected, and the accuracy and the efficiency are improved; 3) the safety of railway operation is improved.
Drawings
Fig. 1 is a schematic structural view of a rail welding seam automatic recognition system according to a preferred embodiment of the present invention;
FIG. 2 is a schematic diagram of a sonic reflectometry process for weld identification in accordance with a preferred embodiment of the present invention;
fig. 3 is a schematic diagram of the operation flow of the echo time gain compensation unit based on the FPGA and the programmable gain amplifier according to the preferred embodiment of the present invention.
Detailed Description
The best mode for carrying out the present invention will be described in detail with reference to the accompanying drawings, wherein the detailed description is for the purpose of illustrating the invention in detail, and is not to be construed as limiting the invention, as various changes and modifications can be made therein without departing from the spirit and scope thereof, which are intended to be encompassed within the appended claims.
Example 1
Referring to fig. 1-2, the present invention provides an automatic rail weld recognition system, which is characterized by comprising:
an acoustic wave sensor 2 configured to transmit an acoustic wave to the steel rail and receive an echo from the steel rail;
a coupling medium;
the acoustic sensor 2 is fixedly arranged in the rubber wheel 1, the coupling medium is filled in the rubber wheel, and the rubber wheel can be in rolling press connection with the steel rail tread 3 to form an acoustic transmission channel among the acoustic sensor, the coupling medium, the rubber wheel and the steel rail;
the welding seam identification unit is used for processing the echo received by the acoustic wave sensor to identify the welding seam;
the positioning unit is used for determining the coordinate position of the identified welding seam on the steel rail;
a storage unit for storing the correction data;
and the correction unit is used for correcting the identified welding seam data according to the correction data.
It can be understood that the pulley 1 can roll on the rail tread, and the acoustic wave sensor 2 does not roll along with the rolling of the pulley 1, and the distance and angle of the pulley relative to the rail tread and the incident point position of the acoustic wave on the rail tread are relatively fixed. That is, during rolling of the pulley 1, the acoustic sensor 2 is simply moved forward parallel to the rail tread, and the position relative to the rail tread 3 during operation preferably remains substantially fixed. It will be appreciated that the parallel movement of the acoustic sensor 2 is for the purpose of continuously identifying defects at different locations in the rail. The acoustic wave may be, for example, an ultrasonic wave.
Further, the correction data may include data of the weld seam and the corresponding coordinate position after field confirmation from the railway maintenance department, or may include related data that the weld seam is identified by the weld seam identification unit for multiple times (for example, more than 10 times), or a combination thereof. It is understood that abundant correction data can be obtained through long-term accumulation and machine learning.
Preferably, the pulley 1 is arranged on a rail flaw detection device movable along a rail and rolls on a rail tread 3 along with the movement of the flaw detection device on the rail, so as to realize continuous identification of a rail weld 4.
Preferably, the acoustic wave sensor 2 is arranged so that the distance between the incident point of the acoustic wave emitted by the acoustic wave sensor on the rail tread and the center line of the rail tread is 0.14-0.4L, a refraction angle of 35-50 degrees is formed at the rail tread, and an included angle of 8-15 degrees is formed between the acoustic wave sensor and the longitudinal section of the rail, wherein L is the distance between the side surface of the rail and the center line of the rail tread. Research finds that reliable identification of the rail weld can be achieved through specific arrangement of the relative positions of the acoustic wave sensors 2.
Preferably, the sound wave sensor comprises a first sound wave sensor and a second sound wave sensor which are respectively arranged at the inner side and the outer side of one steel rail, and the first sound wave sensor and the second sound wave sensor determine the existence of the welding seam when the welding seam is detected at the same coordinate position (the same position of the steel rail). It can be understood that the interference is eliminated by two sets of acoustic sensors for detecting the rail weld, for example, the acoustic sensors are respectively arranged on the inner side and the outer side of one rail to detect the rail weld. Therefore, when one sound wave sensor is in fault or is subjected to false detection, potential crack defects are taken as welding seams to be excluded without later maintenance, and the running safety of the train can be guaranteed to the greatest extent.
Preferably, the weld joint recognition unit may include a first weld joint recognition unit and a second weld joint recognition unit corresponding to the first sonic sensor and the second sonic sensor, respectively, and configured to process echoes received by the first sonic sensor and the second sonic sensor, respectively, to independently recognize the weld joint.
Preferably, the automatic steel rail weld joint recognition system further comprises an encoder unit, which is used for sending a trigger signal to the acoustic wave sensor 2 to trigger the acoustic wave sensor 2 to periodically work, and the acoustic wave sensor 2 synchronously rotates along with wheels of the steel rail flaw detection equipment to determine the coordinate position of the detected weld joint 4 on the steel rail.
Preferably, the echo comprises dihedral reflections from the railhead jaw band-hump at the weld. Advantageously, reliable detection of the weld can be achieved efficiently by this detection of the dihedral angle. It will be appreciated that the invention is not so limited and that reflection of the sound waves by other parts of the weld may also be chosen, for example, although its detection may not be optimal.
Preferably, the bead recognition unit further includes an echo time gain compensation unit in which a table of corresponding coefficients of acoustic wave transmission time and gain values is stored to improve sensitivity of the echo from the dihedral angle and suppress interference waves other than the echo.
Preferably, when one of the first acoustic wave sensor and the second acoustic wave sensor detects a weld and the other does not detect the weld at the same coordinate position (the same position of the rail), it is determined that the rail is cracked, and maintenance personnel is notified to confirm.
Preferably, for example, a maintenance person generates correction data based on the confirmation result and stores the correction data in the storage unit. For example, the correction data may be a weld and its coordinate position, or may be a non-weld and its coordinate position.
Preferably, when one of the first acoustic wave sensor and the second acoustic wave sensor detects a weld and the other does not detect a weld at the same coordinate position (the same position of the rail), correction processing is performed using the correction data, and if the correction processing is successful (that is, when correction data relating to the coordinate position does not exist in the correction data), it is determined that the rail is cracked, and maintenance personnel is notified to confirm the crack.
Preferably, the invention also provides a steel rail welding seam automatic identification method which is characterized in that the steel rail welding seam automatic identification system is adopted to identify the steel rail welding seam.
Preferably, the invention also provides a steel rail defect detection system, which is characterized in that the steel rail welding seam automatic identification system is adopted to correct the steel rail defect detection result.
Example 2
Preferably, the invention also provides a steel rail welding seam automatic identification system which comprises a welding seam monitoring probe and a welding seam identification unit.
Preferably, referring to fig. 2, the weld monitoring probe includes an acoustic sensor 2, a coupling medium, and a pulley 1. The acoustic wave sensor realizes transmission and reception of acoustic waves. The sound wave sensor emits sound waves under the trigger of the external encoder, the sound waves are reflected in the steel rail, and the reflected sound waves are received by the sound wave sensor. Preferably, the acoustic wave sensor 2 has a frequency of 2MHz to 5 MHz.
Preferably, the weld recognition unit processes the acoustic wave sensor echo information. Specifically, a gate (threshold value) is arranged in the time span of reflection at the weld joint of the steel rail jaw part of the unit, the weld joint exists when the echo of the monitoring sound wave sensor triggers the gate, and otherwise, the weld joint is the normal steel rail. The gating means that an amplitude threshold is set in a certain time period of the echo, and when the amplitude of the echo signal exceeds the threshold in the time period, the gating is triggered. And sending the result to an information summarizing unit after the welding seam is identified.
Preferably, the encoder adopts an incremental photoelectric encoder and follows the running wheels of the steel rail flaw detection equipment. The wheels of the flaw detection equipment run for one circle, and the encoder rotates 360 degrees. Every 360 degrees of rotation of the encoder, namely, a fixed number of pulse trigger signals are given outwards, and the pulse trigger signals serve as external triggers for starting transmission and receiving and information processing of the acoustic wave sensor. Because the encoder outputs the pulse signals evenly in the rotation, namely the pulse signals output by the unit distance or angle of rotation are fixed, the number of turns of the encoder is calculated through counting triggered outwards, and then the number of turns of the wheel and the running distance can be obtained. Therefore, when the encoder is triggered each time, the corresponding relation between the flaw detection data and/or the weld joint information and the position of the unique encoder can be known exactly.
Preferably, the encoder triggers the resolution, i.e. how far the inspection device is driven to perform an acoustic inspection. In order to meet different pulse triggering resolutions, each pulse can be triggered or triggered after receiving a plurality of continuous pulses. The encoder trigger unit realizes high-resolution stepping scanning, and the pulse emission interval of each acoustic wave sensor 2 is less than or equal to 3 mm.
Preferably, the position of each encoder can accurately acquire the information whether the welding seam exists, the welding seam identification and marking are not delayed, the real-time performance is high, and the marking position is ensured to be timely and accurate. .
Preferably, researches show that the steel rail welding seam generates belt-shaped bulges at the rail jaw and the rail waist, and the sound transmission characteristics of the steel rail welding seam are greatly different from those of the steel rail base material. Specifically, the device shown in fig. 2 is adopted to realize the weld monitoring by the acoustic reflection method. The acoustic sensor 2 is arranged in the leather wheel 1, the leather wheel 1 is tightly attached to the steel rail tread 3, and the leather wheel 1 is filled with liquid and used as a coupling medium for transmitting acoustic waves between the acoustic sensor 2 and the steel rail. 4 is a weld, and 5 is a dihedral angle formed by the weld at the jaw portion.
Preferably, the sound wave sensor 2 emits sound waves triggered by the encoder, and the sound waves are refracted into the steel rail on the tread and refracted. If the steel rail is positioned at the welding seam position, the refracted sound wave in the steel rail is reflected at the position of the dihedral angle 5 at the jaw part of the welding seam, and the reflected sound wave is received by the sound wave sensor 2 through the leather pulley and the coupling medium. A gate is provided according to the time of appearance of the reflected wave at the dihedral angle 5 at the weld jaw. The reflected sound waves will appear in the gate provided by the sound wave sensor 2 and will be detected by the weld recognition unit. If the weld is at the other rail jaw, the weld jaw dihedral angle reflected wave does not appear, and the weld recognition unit does not determine that the weld is present. The invention utilizes the dihedral angle reflection brought by the sound wave at the weld joint by the banded bulge at the railhead jaw to distinguish the normal steel rail from the weld joint, thereby realizing the weld joint monitoring.
Preferably, because the steel rail crystal grain at the welding seam is bigger, the clutter is many, and the reflection of sound wave at tread department is very strong simultaneously, causes the echo signal clutter that sound wave sensor 2 received to be many, and is obvious to welding seam hubei mian angle interference, and easily causes the gate to trigger by mistake. If the clutter amplitude is reduced by reducing the sensitivity setting, the weld joint jaw dihedral angle echo monitoring can be influenced, and the weld joint is missed to be judged. In order to solve the problems, the invention designs a Time Gain Compensation (TGC) method based on an FPGA and a programmable Gain amplifier, which can remarkably suppress interference waves nearby while improving the sensitivity of the dihedral angle echo of the weld jaw, thereby improving the accuracy of weld recognition.
Preferably, the logic design block diagram of the echo time gain compensation method of the present invention is shown in fig. 3. And issuing the two groups of coefficients with the sound wave transmission time and the gain value in one-to-one correspondence to the FPGA, wherein the FPGA adopts an on-chip cache unit for storage. The setting mode of the time-gain coefficient table is that the wave-emitting position of the two-surface angle of the jaw part of the welding seam is set with high gain, and the clutter position is set with low gain.
Preferably, the TGC function can be switched on or off. The TGC coefficients are a priori designed tables that set different gain values at different echo times, which can be obtained by research and empirical summarization. In an open state, when an encoder is triggered, the FPGA reads a group of distance D0 and a gain value G0 in a TGC coefficient, on the premise that sound velocity of sound waves in a steel rail is known (sound wave longitudinal waves are 5.92 mm/mu s, transverse waves are 3.23 mm/mu s), the FPGA calculates propagation distance D of the sound waves by recording sound wave transmission time, and when D is D0, the G0 is configured to the programmable gain amplifier by adopting a serial configuration interface. The FPGA will then read the second set of distance gain coefficients D1 and G1, and when D times out to D1, configure G0 to the programmable gain amplifier using the serial configuration interface until the FPGA has configured the last set of distance gain values. At which point the logic waits for the next encoder trigger to arrive.
Preferably, the operator may also modify the gain manually when the TGC function is off.
Preferably, the time gain compensation of the weld joint jaw dihedral angle echo is carried out by adopting the FPGA, the weld joint dihedral angle echo sensitivity and the monitoring accuracy are improved, the real-time performance is higher than that of data processing, the result is more accurate, meanwhile, the calculation pressure is reduced, and the system operation efficiency is improved.
Compared with the prior art, the invention has the following technical effects: 1) the real-time and automatic identification and/or marking of the welding line are realized, the monitoring and data analysis of flaw detection personnel are greatly facilitated, and the efficiency of industrial fault detection is improved; 2) the welding seam recognition result can be corrected, and the accuracy and the efficiency are improved; 3) the safety of railway operation is improved.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (10)
1. A rail welding seam automatic identification system is characterized by comprising:
an acoustic wave sensor configured to transmit acoustic waves to the rail and receive echoes from the rail;
a coupling medium;
the acoustic wave sensor is fixedly arranged in the rubber wheel, the coupling medium is filled in the rubber wheel, and the rubber wheel can be connected to the tread of the steel rail in a rolling and pressing mode to form an acoustic wave transmission channel among the acoustic wave sensor, the coupling medium, the rubber wheel and the steel rail;
the welding seam identification unit is used for processing the echo received by the acoustic wave sensor to identify the welding seam;
the positioning unit is used for determining the coordinate position of the identified welding seam on the steel rail;
a storage unit for storing the correction data;
and the correction unit is used for correcting the identified welding seam data according to the correction data.
2. The automatic rail weld recognition system according to claim 1, wherein the pulleys are provided on a rail flaw detection device movable along a rail, and roll on a rail tread along with the movement of the flaw detection device on the rail, so as to realize continuous recognition of the rail weld.
3. A steel rail welding seam automatic identification system according to claim 1 or 2, characterized in that the sound wave sensor is arranged to enable the distance between the incident point of the steel rail tread and the center line of the steel rail tread to be 0.14-0.4L, a refraction angle of 35-50 degrees is formed at the steel rail tread, and an included angle of 8-15 degrees is formed with the longitudinal section of the steel rail, wherein L is the distance between the side surface of the steel rail and the center line of the steel rail tread.
4. The system of claim 1, wherein the sonic sensors include a first sonic sensor and a second sonic sensor respectively disposed on the inner and outer sides of a rail, and the first sonic sensor and the second sonic sensor detect the weld at the same coordinate position to determine the presence of the weld.
5. A rail weld seam automatic identification system as claimed in claim 1 further including an encoder unit for sending a trigger signal to the sonic sensor to trigger the sonic sensor to periodically operate and which synchronously follow the wheels of the vehicle to determine the coordinate position of the detected weld seam on the rail.
6. A rail weld seam automatic identification system as claimed in claim 3 wherein the echoes are from dihedral reflections from the proud at the railhead jaw at the weld seam.
7. A rail weld automatic identification system according to claim 6, characterized in that the weld identification unit further comprises an echo time gain compensation unit in which a table of corresponding coefficients of the transmission time and gain value of the acoustic wave is stored.
8. A rail weld seam automatic identification system according to claim 4, wherein when one of the first and second acoustic sensors at the same position of the rail detects a weld seam and the other does not detect a weld seam, it is determined that the rail is cracked, and maintenance personnel is notified of the determination.
9. The automatic rail weld joint recognition system according to claim 8, wherein correction data is generated based on the confirmation result and stored in the storage unit; preferably, the correction unit performs the correction processing when one of the first acoustic wave sensor and the second acoustic wave sensor detects the weld and the other does not detect the weld at the same position of the rail, and determines that the rail is cracked if the correction processing is successful, and notifies a maintenance person of confirmation.
10. A rail welding seam automatic identification method is characterized in that the rail welding seam automatic identification system of claims 1-9 is adopted to identify the rail welding seam; or
A rail defect detection system, characterized in that the rail weld automatic recognition system of claims 1-9 is used to correct the rail defect detection results.
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| CN202010530223.4A CN113804755B (en) | 2020-06-11 | 2020-06-11 | Automatic rail weld joint recognition system and method |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114561871A (en) * | 2022-03-31 | 2022-05-31 | 江苏润扬大桥发展有限责任公司 | Be used for steel bridge deck pavement deep level disease infrared detection equipment |
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