Intelligent water spraying device and method for double-track flaw detection vehicle

Abstract

The application discloses a double-track flaw detection vehicle intelligent water spraying device, which comprises a water tank, a constant pressure pump, three flow meters, three electromagnetic valves, three spray heads, connecting pipelines and a controller. The water tank is connected with the constant pressure pump, the constant pressure pump is connected with the three spray heads through the connecting pipelines, one flow meter and one electromagnetic valve are arranged on the pipeline of each of the three spray heads. The constant pressure pump provides constant water pressure, and the controller controls the opening and closing of each electromagnetic valve to control water spraying or stopping. The first spray head among the three spray heads is perpendicular to the surface of the steel rail and plays a role of pre-wetting the steel rail. The second spray head is opposite to the surface of the wheel type probe and plays a role of wetting the wheel type probe. The third spray head is opposite to the joint surface of the steel rail and the wheel type probe and directly fills the small gap between the steel rail and the wheel type probe. The application has reasonable structure layout and good coupling effect.

Description

Technical Field

[0001] This invention relates to a water spraying device for a flaw detection vehicle installed on a track to detect rail damage, specifically an intelligent water spraying device and method for a dual-track flaw detection vehicle. Background Technology

[0002] Flaw detection devices are widely used for inspecting rails used in existing conventional railways, high-speed railways, urban subways, or light rail systems. Currently, the most widely used flaw detection vehicle is the ultrasonic flaw detection vehicle. The principle of ultrasonic testing is that when the ultrasonic probe (piezoelectric crystal) in the probe is excited by the ultrasonic emission signal (i.e., "high-voltage pulse") emitted by the system, it will vibrate according to its own inherent vibration frequency. The ultrasound propagates in the rail, and when it encounters cracks, defects, or voids in the rail, some of the ultrasonic energy will be reflected back. The reflected energy is received by the crystal and becomes the echo. The echoes obtained by various ultrasonic probes are converted into electrical signals in the ultrasonic transducer, and then processed through analog processing, digital processing, spatial conversion, and damage identification. Finally, the signals are displayed as images on the display and control computer, completing the detection process of different parts and different shapes of damage to the rail.

[0003] Dual-track rail flaw detectors use ultrasonic waves to detect internal rail damage. Because they use high-frequency ultrasound, the waves attenuate significantly in air. Therefore, a liquid is needed to fill the gap between the probe and the rail, a process known as coupling. Typically, a special coupling fluid is filled inside the wheel, while water is sprayed outside to improve the coupling effect. Currently, most dual-track rail flaw detectors on the market use ordinary fan-shaped nozzles that spray water at a point in front of the wheel probe. The water jet is a single line, resulting in large pressure fluctuations, high water consumption, and a tendency to clog, leading to poor coupling. Summary of the Invention

[0004] This invention addresses the problems of large pressure fluctuations, high water consumption, easy clogging, and poor coupling effect in current dual-rail ultrasonic flaw detection vehicle water spraying devices. It proposes an intelligent water spraying device and method for dual-rail flaw detection vehicles. The key features are a water spraying device based on three nozzles and a three-phase variable duty cycle switch water spraying control method. The specific technical solution of this invention is as follows:

[0005] This invention first discloses an intelligent water spraying device for a dual-rail flaw detection vehicle, comprising a constant pressure pump, three solenoid valves, three nozzles, and a controller. The constant pressure pump provides a constant water pressure, and the controller controls the opening and closing of each solenoid valve to control water spraying or stopping the spraying. Of the three nozzles, the first nozzle is perpendicular to the surface of the rail, serving to pre-wet the rail; the second nozzle faces the surface of the wheel probe, serving to wet the wheel probe; and the third nozzle faces the joint surface between the rail and the wheel probe, directly filling the small gap between the rail and the wheel probe.

[0006] The inlet of the constant pressure pump pipeline is placed in the water tank. The outlet of the constant pressure pump pipeline is connected to the inlet of three flow meters. The outlet of each flow meter pipeline is connected to the inlet of the corresponding solenoid valve pipeline. The outlet of each solenoid valve pipeline is connected to the corresponding nozzle.

[0007] The controller signal input terminal is connected to the flow meter signal output terminal to detect the flow rate of each water spray pipe. The controller signal output terminal is connected to the signal input terminal of the constant pressure pump and the signal input terminal of the solenoid valve to control the water spray volume of each water spray pipe.

[0008] Each nozzle is an elliptical outlet atomizing nozzle, its structure comprising four parts: nozzle body; pressure element; side filter; and filter fixing element. The pressure element is screwed into the nozzle body via threads, and the side filter is mounted on the filter fixing element, which is also screwed into the nozzle body via threads. Using a side filter instead of a straight filter provides a larger filtration area and reduces clogging.

[0009] This invention also discloses an intelligent water spraying method for a dual-track flaw detection vehicle, employing constant pressure, three-phase complementarity, variable period, variable duty cycle, and pulse water spraying control. A water tank, constant pressure pump, three flow meters, three solenoid valves, and three nozzles are connected by a water spraying pipeline, where the constant pressure pump ensures constant water pressure. The three-phase complementarity refers to a single water spraying process comprising two parallel spraying cycles T. The first and second nozzles have a spraying cycle of T / 2, occupying the first and second halves of a single spraying cycle T. The third nozzle occupies a single spraying cycle T, synchronized with the start time of the first nozzle. The duty cycles of the first, second, and third nozzles are different, and each nozzle switches on and off according to its respective duty cycle. The magnitude of T is inversely proportional to the speed of the flaw detection vehicle; the faster the vehicle travels, the smaller T becomes. Specifically, the spraying cycle T is expressed as:

[0010] T = T0 + k / V m Where: T0 is the minimum switching period to avoid high-frequency oscillation of the electromagnetic valve, k is the proportional coefficient of the solenoid valve switching period, and V m To measure the speed of the flaw detection vehicle.

[0011] The intelligent water spraying method of this dual-rail flaw detection vehicle uses a solenoid valve with variable duty cycle, and includes the following steps:

[0012] 1) Calculate the actual spray ratio Where: V an To measure the outlet flow velocity corresponding to the nth flow meter, where n = 1, 2, 3; V m To correspond to the actual measured speed of the flaw detection vehicle;

[0013] 2) The controller obtains the given spray ratio and the actual spray ratio of the nth spray pipe, performs digital calculations based on the PID algorithm, and obtains the time duty cycle ρ of the control solenoid valve of the nth spray pipe. n :

[0014]

[0015] Where: e i e j K represents the deviation between a given ratio and the actual ratio. p For the controller proportional parameter; T i The integral time parameter of the controller; T d is the differential time parameter of the controller; Tc is the control cycle of the controller; n is the solenoid valve of the nth water spray pipe, n=1,2,3;

[0016] 3) The opening time of the nth solenoid valve is T. kn =T*ρ n The closing time is T. gn =T*(1-ρ n ); n = 1, 2, 3. Where: T is the solenoid valve switching cycle. Then the expression for the control quantity output by the controller for the nth water spray pipe is as follows:

[0017]

[0018] 4)M n When the output value is 1, the nth solenoid valve is open; when the controller output value is 0, the nth solenoid valve is closed.

[0019] The beneficial effects of this invention are:

[0020] 1) The device is equipped with three nozzles. The first nozzle pre-wets the rail, the second nozzle pre-wets the probe, and the third nozzle is directly facing the joint surface of the rail and the probe, filling the small gap between the rail and the probe. The structure is reasonable and the coupling effect is good.

[0021] 2) The nozzle structure has been changed to change from spraying water to spraying mist, resulting in more uniform spraying; the filter screen is designed with a large filtration area, making it less prone to clogging;

[0022] 3) A constant pressure pump is used to provide power to the water spraying pipeline. Regardless of whether the three water spraying pipelines are open or closed, they can ensure constant pressure water spraying in each pipeline. The water spraying pipelines do not interfere with each other and have strong independence.

[0023] 4) Control Method: Constant pressure water spraying achieves uniform spray effect; the first and second nozzles each have a spray cycle of T / 2, occupying a total of one spray cycle; the third nozzle occupies a dedicated spray cycle T. This three-phase complementary spraying is beneficial for stabilizing the flow rate in the main water supply circuit; the spray cycle T can be automatically adjusted according to the speed of the flaw detection vehicle. The faster the vehicle travels, the smaller T becomes, and the more frequent the spraying. Variable duty cycle and pulse spraying control achieve zero static error between the setpoint and the actual spray ratio. Attached Figure Description

[0024] Figure 1 This is a diagram showing the connection relationship of the components of the water spraying device of the present invention.

[0025] Figure 2 This is a distribution diagram of the elliptical outlet atomizing nozzles of the present invention.

[0026] Figure 3 This is a schematic diagram of the elliptical outlet atomizing nozzle of the present invention.

[0027] Figure 4 This is a cross-sectional view of the nozzle body of the present invention.

[0028] Figure 5 This is a front view of the nozzle of the present invention.

[0029] Figure 6 This is a detailed drawing of the pressure core of the present invention.

[0030] Figure 7 This is an installation diagram of the side filter screen of the present invention.

[0031] Figure 8 This is an assembly diagram of the elliptical outlet atomizing nozzle of the present invention.

[0032] Figure 9 This is a side view of the installation environment in which the present invention is implemented.

[0033] Figure 10 This is a bottom view of the installation environment for implementing the present invention.

[0034] Figure 11 This is a diagram showing the relationship between the water spraying cycle and timing of the present invention.

[0035] Figure 12 This is a graph showing the relationship between the controller output and time in this invention. Detailed Implementation

[0036] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0037] like Figure 1 As shown, the present invention includes a water tank 11, a constant pressure pump 12, three flow meters 13, three solenoid valves 14, three nozzles, connecting pipes 15, and a controller; the water tank 11 is connected to the constant pressure pump 12, and the constant pressure pump 12 is connected to the three nozzles through the connecting pipes 15. Each of the three nozzles is equipped with a flow meter and a solenoid valve on its respective pipe; the constant pressure pump provides constant water pressure, and the controller controls the opening or closing of each solenoid valve to control water spraying or stopping spraying;

[0038] like Figure 2As shown, of the three nozzles, the first nozzle 16 is perpendicular to the surface of the rail 9 and serves to pre-wet the rail 9; the second nozzle 17 is directly opposite the surface of the wheel probe 3 and serves to wet the wheel probe 3; the third nozzle 18 is directly opposite the joint surface of the rail 9 and the wheel probe 3 and directly fills the small gap between the rail 9 and the wheel probe 3.

[0039] like Figure 3 As shown, each nozzle of the present invention is an elliptical outlet atomizing nozzle, the structure of which includes a nozzle body 1-1, a pressure core 1-2, a side filter 1-3, and a filter fixing core 1-4. The pressure core 1-2 is screwed into the nozzle body 1-1 by threads, the filter fixing core 1-4 is screwed into the nozzle body 1-1 by threads, and the side filter 1-3 is installed on the filter fixing core 1-4. The side filter 1-3 replaces the straight filter, resulting in a larger filtration area and less clogging.

[0040] like Figure 4-8 As shown, the specific structure of the elliptical outlet atomizing nozzle of the present invention is given, specifically:

[0041] like Figure 4 As shown, 1-1 of the present invention is the nozzle body, and 1-1-1 is the water outlet inside the nozzle.

[0042] like Figure 5 As shown, the elliptical water outlet of the nozzle body 1-1 of the present invention has a width of 0.1 mm and a length of 0.2 mm. The coupling fluid exits from the elliptical water outlet through the water outlet 1-1-1 inside the nozzle.

[0043] like Figure 6 As shown, in this invention, 1-2 is a pressure core, and 1-2-1 is a ejector pin. The taper of the ejector pin 1-2-1 is slightly smaller than that of the inner water outlet 1-1-1, pressing against the inner water outlet 1-1-1 to provide a certain atomization pressure for the water, making the spray more uniform. 1-2-2 is a water channel through which the liquid flows. 1-2-3 is a screwdriver slot for tightening the screws on the pressure core 1-2.

[0044] like Figure 7 As shown, the side filter screen of the present invention is installed on the filter screen fixing core 1-4. Compared with the straight filter screen, the side filter screen has a larger filtration area and is less prone to clogging.

[0045] like Figure 8 As shown in the diagram, the elliptical outlet atomizing nozzle of the present invention is assembled with the pressure core 1-2 screwed into the nozzle body 1-1 by threads. The side filter screen 1-3 is installed on the filter screen fixing core 1-4, which is also screwed into the nozzle body 1-1 by threads. 1-2-1 is a pin with a taper slightly smaller than that of the inner water outlet 1-1-1, pressing against the inner water outlet 1-1-1 to provide a certain atomization pressure for the water. The coupling fluid exits from the elliptical water outlet through the inner water outlet 1-1-1 of the nozzle.

[0046] like Figure 9-10 As shown, the installation environment for implementing this invention is a dual-rail rail flaw detection vehicle.

[0047] The aforementioned intelligent refueling control method:

[0048] like Figure 1 , 11 As shown in Figures 1 and 12, the present invention includes a connection diagram of the water spraying device, a diagram of the water spraying cycle and timing, and a diagram of the controller output and time.

[0049] Water tank 11, constant pressure pump 12, flow meter 13, solenoid valve 14, first nozzle 16, second nozzle 17, and third nozzle 18 are connected by pipe 15 to form a water spray pipeline, where the constant pressure pump 12 ensures constant water pressure. The three-phase complementary design means that one spraying process includes two parallel spraying cycles T. The spraying cycles of the first nozzle 16 and the second nozzle 17 are T / 2, each occupying the first and second halves of a spraying cycle T. The third nozzle 18 occupies a single spraying cycle T, synchronized with the start time of the first nozzle 16. The duty cycles of the first nozzle 16, the second nozzle 17, and the third nozzle 18 are different, and each nozzle switches according to its own duty cycle. The value of T is inversely proportional to the speed of the flaw detection vehicle; the faster the flaw detection vehicle travels, the smaller T is, and the more frequent the spraying. Variable duty cycle and pulse spraying control achieve zero static error between the given spraying ratio and the actual spraying ratio. The specific spraying cycle T is expressed as:

[0050] T = T0 + k / V m Where: T0 is the minimum switching period to avoid high-frequency oscillation of the solenoid valve, k is the proportional coefficient of the solenoid valve switching period, and V m To measure the speed of the flaw detection vehicle.

[0051] The intelligent water spraying method of this dual-rail flaw detection vehicle adopts electromagnetic valve variable duty cycle and pulse water spray control, including the following steps:

[0052] 1) Calculate the actual spray ratio Where: V an To measure the outlet flow velocity corresponding to the nth flow meter 13, where n = 1, 2, 3; V m To correspond to the actual measured speed of the flaw detection vehicle;

[0053] 2) The controller obtains the given spray ratio and the actual spray ratio of the nth spray pipe, performs digital calculations based on the PID algorithm, and obtains the time duty cycle ρ of the control solenoid valve 14 of the nth spray pipe. n :

[0054]

[0055] Where: e i e jK represents the deviation between a given ratio and the actual ratio. p For the controller proportional parameter; T i The integral time parameter of the controller; T d Tc is the differential time parameter of the controller; Tc is the control cycle of the controller; n is the solenoid valve 14 of the nth water spray pipe, n = 1, 2, 3;

[0056] 3) The opening time of the nth solenoid valve 14 is T. kn =T*ρ n The closing time is T. gn =T*(1-ρ n ); n = 1, 2, 3. Where: T is the switching cycle of solenoid valve 14. Then the expression for the control quantity output by the controller for the nth water spray pipe is as follows:

[0057]

[0058] 4)M n When the output value is 1, the nth solenoid valve 14 is open; when the controller output value is 0, the nth solenoid valve 14 is closed.

[0059] The control method proposed in this invention employs constant pressure water spraying to achieve a uniform spray effect; the first and second nozzles each have a spray cycle of T / 2, sharing one spray cycle; the third nozzle occupies a dedicated spray cycle T, with three-phase complementary spraying, which is beneficial for stabilizing the flow rate in the main water supply circuit; the spray cycle T can be automatically adjusted according to the speed of the flaw detection vehicle, with a smaller T and more frequent spraying as the vehicle speed increases. Variable duty cycle and pulse spraying control achieve zero static error between the given spray ratio and the actual spray ratio.

Claims

1. A dual-rail flaw detection vehicle intelligent water spray device, characterized in that: It includes a water tank (11), a constant pressure pump (12), three flow meters (13), three solenoid valves (14), three nozzles, connecting pipes (15), and a controller; the water tank (11) is connected to the constant pressure pump (12), and the constant pressure pump (12) is connected to the three nozzles through the connecting pipes (15). Each of the three nozzles is equipped with a flow meter and a solenoid valve on its respective pipe; the constant pressure pump (12) provides constant water pressure, and the controller controls the opening or closing of each solenoid valve to control water spraying or stopping spraying; Of the three nozzles, the first nozzle (16) is perpendicular to the surface of the rail (9) and serves to pre-wet the rail (9); the second nozzle (17) faces the surface of the wheel probe (3) and serves to wet the wheel probe (3); the third nozzle (18) faces the joint surface of the rail (9) and the wheel probe (3) and directly fills the small gap between the rail (9) and the wheel probe (3); each nozzle is an elliptical outlet atomizing nozzle, the structure of which includes a nozzle body (1-1), a pressure core (1-2), a side filter (1-3), and a filter fixing core (1-4). The pressure core (1-2) is screwed into the nozzle body (1-1) by threads, the filter fixing core (1-4) is screwed into the nozzle body (1-1) by threads, and the side filter (1-3) is installed on the filter fixing core (1-4).

2. The intelligent water spray device for the dual-rail flaw detection vehicle according to claim 1, characterized in that it maintains constant pressure. The pipeline inlet of pump (12) is placed in water tank (11). The pipeline outlet of constant pressure pump (12) is connected to the pipeline inlet of three flow meters (13). The pipeline outlet of each flow meter (13) is connected to the pipeline inlet of the corresponding solenoid valve (14). The pipeline outlet of each solenoid valve (14) is connected to the corresponding nozzle.

3. The intelligent water spray device for the dual-rail flaw detection vehicle according to claim 1, characterized in that: The signal input terminal of the controller is connected to the signal output terminal of the flow meter (13) to detect the flow rate of each water spraying pipeline. The signal output terminal of the controller is connected to the signal input terminal of the constant pressure pump (12) and the signal input terminal of the solenoid valve (14) to control the water spray volume of each water spraying pipeline.

4. The intelligent water spray device for the dual-rail flaw detection vehicle according to claim 1, characterized in that: The nozzle body (1-1) has an internal water outlet (1-1-1) located from the top of the nozzle body to the cavity. The top of the pressure core (1-2) is a pin (1-2-1) structure. The taper of the pin (1-2-1) is smaller than that of the inner water outlet (1-1-1) and it is pressed against the tail of the inner water outlet (1-1-1), providing a certain atomization pressure to the water and making the spray more uniform.

5. The intelligent water spray device for the dual-rail flaw detection vehicle according to claim 1, characterized in that: The end of the pressure core (1-2) is provided with a screwdriver groove (1-2-3) for tightening the screws on the pressure core (1-2).

6. The intelligent water spray device for the dual-rail flaw detection vehicle according to claim 1, characterized in that: Water channels (1-2-2) are provided on the outer surface of the middle part of the pressure core (1-2).

7. A smart water spraying method for a dual-track flaw detection vehicle, based on the device described in any one of claims 1-6, characterized in that constant pressure is maintained therein. The pump ensures constant water pressure; one spraying process consists of two parallel spraying cycles T. The spraying cycles of the first and second nozzles are T / 2, each occupying the first and second halves of a spraying cycle T; the third nozzle occupies a single spraying cycle T, synchronized with the start time of the first nozzle. The duty cycles of the first, second, and third nozzles are different, and each nozzle switches on and off according to its own duty cycle; the size of T is inversely proportional to the speed of the flaw detection vehicle. The faster the flaw detection vehicle travels, the smaller T is, and the more frequently water is sprayed. By employing variable duty cycle and pulse spray control, zero static error is achieved between the given spray ratio and the actual spray ratio. The variable duty cycle, pulse water jet control method includes the following steps: 1) Calculate the actual spray ratio Where: V an To measure the outlet flow velocity corresponding to the nth flow meter, where n = 1, 2, 3; V m To correspond to the actual measured speed of the flaw detection vehicle; 2) The controller obtains the given spray ratio and the actual spray ratio of the nth spray pipe, performs digital calculations based on the PID algorithm, and obtains the time duty cycle ρ of the control solenoid valve of the nth spray pipe. n : Where: e i e j K represents the deviation between a given ratio and the actual ratio. p For the controller proportional parameter; T i T is the integral time parameter of the controller. d is the differential time parameter of the controller; Tc is the control cycle of the controller; n is the solenoid valve of the nth water spray pipe, n=1,2,3; 3) The opening time of the nth solenoid valve is T. kn =T*ρ n The closing time is T. gn =T*(1-ρ n ); n = 1, 2, 3; where: T is the solenoid valve switching cycle; then the control quantity expression of the controller output for the nth water spray pipe is as follows: 4)M n When the output value is 1, the nth solenoid valve is open; when the controller output value is 0, the nth solenoid valve is closed.

8. The intelligent water spraying method for a dual-track flaw detection vehicle according to claim 7, characterized in that: The specific water spray cycle T is expressed as: T = T0 + k / V m Where: T0 is the minimum switching period to avoid high-frequency oscillation of the electromagnetic valve, k is the proportional coefficient of the solenoid valve switching period, and V m To measure the speed of the flaw detection vehicle.

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