A track plate temperature crack simulation device and implementation method thereof

Abstract

The present invention relates to a track plate temperature crack simulation device and an implementation method thereof, the device comprising: a track plate model, a rail support platform model and a plurality of pre-cracked false seams are provided on the surface thereof, a steel mesh frame is provided inside thereof, and a through-type preset temperature crack is provided at a first preset distance from a central section; a temperature acquisition unit, comprising a temperature sensor, the temperature sensor being arranged at a set distance from the side edge of the through-type preset temperature crack; a temperature heating unit, arranged inside the track plate model; an environmental element simulation acquisition unit, comprising a heating lamp, a straight air blower, a solar radiation measuring instrument and an anemometer arranged around the track plate model. Compared with the prior art, the present invention simulates the track plate temperature crack and realizes non-contact detection, and the temperature, radiation and wind speed parameters can be continuously changed through the environmental element simulation acquisition unit, so that the track plate temperature crack simulation under different working conditions can be realized, and the simulation accuracy is high and the cost is low.

Description

Technical Field

[0001] The invention relates to the technical field of railway engineering, and in particular to a track plate temperature crack simulation device and an implementation method thereof. Background Art

[0002] With the development of high-speed railways in my country, CRTSⅡ ballastless track structures have been widely used. Due to long-term exposure to the natural environment in the wild, and the continuous effects of environmental factors and train loads, the engineering department has found more and more diseases on the CRTSⅡ track slabs, among which crack disease is one of the most common diseases. The inspection and maintenance work of the engineering department is carried out at night, and the crack diseases are often very small. Generally, the width of the cracks is only about 0.1mm. In addition, the lighting conditions at night are poor and the maintenance time is short. It is often impossible to effectively detect crack diseases in time, which buries hidden dangers for the safe operation of high-speed railways. Therefore, in order to better and more timely detect crack diseases, it is urgent to conduct experimental research on crack detection. Therefore, a convenient, effective and accurate simulation effect track slab crack simulation device is needed. Summary of the invention

[0003] The purpose of the present invention is to provide a track plate temperature crack simulation device and an implementation method thereof in order to overcome the defects of the above-mentioned prior art.

[0004] The purpose of the present invention can be achieved by the following technical solutions:

[0005] A track plate temperature crack simulation device, comprising:

[0006] A track plate model, the surface of which is provided with a rail support model and a plurality of pre-cracked false seams, the interior of which is provided with a steel mesh frame, and a through-type preset temperature crack is provided at a first preset distance from the central section;

[0007] A temperature acquisition unit, comprising a temperature sensor, wherein the temperature sensor is arranged at a set distance from a side edge of the through-type preset temperature crack;

[0008] A temperature heating unit is arranged inside the track plate model;

[0009] The environmental element simulation collection unit includes a heating lamp, a straight fan, a solar radiation meter and an anemometer arranged around the track plate model.

[0010] Preferably, the track plate model is provided with a non-contact temperature crack detection device.

[0011] Preferably, the non-contact temperature crack detection device comprises a PC terminal and an infrared thermal imager arranged on a movable height-adjustable bracket.

[0012] Preferably, the movable height-adjustable bracket includes a fixed slide rail base, a sliding platform, and a thermal imager support bracket which are arranged in sequence from bottom to top.

[0013] Preferably, the temperature sensor comprises a thin rod and a plurality of temperature sensors arranged on the thin rod at a certain interval.

[0014] Preferably, two sets of temperature sensors are provided, which are respectively buried at a first set distance and a second set distance from the edge of the through-type pre-cracking false seam.

[0015] Preferably, the temperature heating unit comprises an adjustable double-sided aluminum foil heating pad.

[0016] Preferably, the length and width of the track plate model are 1 / 5 of the actual track plate, and the height is 3 / 4 of the actual track plate.

[0017] Preferably, the pre-cracked false seam is obtained by embedding an L-shaped aluminum profile on the surface of the track slab model when the casting of the track slab model is about to be completed, and the through-type preset temperature crack is obtained by embedding a thin iron wire into the surface of the track slab model.

[0018] A method for implementing the above-mentioned track plate temperature crack simulation device comprises:

[0019] S1. Make a mold, a steel grid, a temperature sensor, and a temperature heating unit according to the size of the track slab model to be cast;

[0020] S2. Cast the track slab model with concrete according to the actual track slab ratio. When the depth reaches the first depth, lay the temperature heating unit flat in the mold. When the depth reaches the second depth, put in the steel grid and continue to cast concrete until the designed depth.

[0021] S3. On the basis of smoothing the concrete surface, multiple L-shaped aluminum profiles pre-coated with vaseline are embedded into the surface of the track plate model at a second preset distance to achieve the production of pre-cracked false seams, and thin iron wires pre-coated with vaseline are lightly embedded into the concrete surface at a first preset distance from the central section to achieve the production of through-type preset temperature cracks;

[0022] S4, burying the temperature sensors at a set distance from the side edge of the preset temperature crack;

[0023] S5. Cast the rail support platform model on the surface of the track slab model at equal intervals according to the actual ratio;

[0024] S6. Build environmental element simulation and collection units around the track slab model and connect all electrical components.

[0025] Compared with the prior art, the present invention has the following advantages:

[0026] 1. Simulate the temperature cracks of the track plate and perform non-contact detection. The environmental factor simulation acquisition unit can continuously change the temperature, radiation and wind speed parameters, and can simulate the temperature cracks of the track plate under different working conditions. The simulation has high accuracy and low cost, and has strong promotion and use value.

[0027] 2. The length and width of the track plate model are 1 / 5 of the actual track plate, and the height is 3 / 4 of the actual track plate. The depth dimension can be appropriately expanded to eliminate the temperature effect of the bottom structure boundary of the track plate. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic structural diagram of a track plate temperature crack simulation device of the present invention;

[0029] Figure 2 It is a structural schematic diagram of the track plate model in the present invention;

[0030] Figure 3 It is a structural schematic diagram of the non-contact temperature crack detection device of the present invention;

[0031] Figure 4 It is a structural schematic diagram of the embedded temperature acquisition unit in the present invention;

[0032] Figure 5 It is a flow chart of the implementation method of the track plate temperature crack simulation device of the present invention.

[0033] Markings in the figure: 1. Track plate model, 2. Track support platform model, 3. Pre-cracked false seam, 4. Wire, 5. Fixed slide rail base, 6. Sliding platform, 7. Aluminum tube, 8. Square tube, 9. Fastening rod, 10. Thermal imager grid, 11. Thin rod, 12. Thermocouple sensor, 13. Digital thermometer. DETAILED DESCRIPTION

[0034] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0035] Example

[0036] like Figure 1As shown, the present application proposes a track plate temperature crack simulation device, which is used to simulate track plate crack diseases under different working conditions, including: a track plate model 1, a rail support platform model 2 and a plurality of pre-cracked false seams 3 are provided on its surface, a steel mesh frame is provided inside, and a through-type preset temperature crack is provided at a first preset distance from the central section; a temperature acquisition unit, including a temperature sensor, and the temperature sensor is arranged at a set distance from the side edge of the through-type preset temperature crack; a temperature heating unit, which is arranged inside the track plate model 1; an environmental factor simulation and acquisition unit, including a power-adjustable halogen heating lamp, a wind speed-adjustable straight wind machine, a high-sensitivity solar radiation measuring instrument and a high-sensitivity anemometer, which are arranged around the track plate model 1 to simulate solar radiation.

[0037] In this embodiment, the casting length and width of the track slab model 1 are 1 / 5 of the actual CRTSⅡ track slab, and the height is 3 / 4 of the actual CRTSⅡ track slab. Figure 2 As shown, 9 pre-cracked false seams 3 are preset at equal intervals on the surface of the track slab model 1, and a through-type preset temperature crack is set at 2 cm from the central section. 10 rail support platform models 2 of 1 / 5 of the original size are laid at equal intervals on both sides of the surface of the track slab model 1, and scaled rails are set on the rail support platform model 2. A steel mesh is arranged at a depth of 5 cm inside the track slab model 1. The track slab model 1 is cast with the same concrete material ratio as the actual CRTSⅡ track slab. In order to eliminate the boundary temperature effect of the bottom structure of the track slab, the depth size is appropriately expanded. After comprehensive consideration, its size is determined to be 1290 mm long, 510 mm wide, and 150 mm high. The pre-cracked false seams 3 are made of L-shaped aluminum profiles with a side length of 10 mm and a length of 510 mm. When the casting is about to be completed, the L-shaped aluminum profiles pre-coated with vaseline are buried in the model surface every 128 mm. The rail support platform model 2 is cast with the same concrete material ratio as the track plate, and its dimensions are 60mm long, 30mm wide, and 15mm high, and are laid on both sides of the track plate model 1 at equal intervals. The scaled rail is an I-beam, and its dimensions are 34mm wide at the bottom, 18mm wide at the top, and 60mm high. The steel mesh is made of stainless steel round bars with a diameter of 10mm. Six 100mm and six 48mm stainless steel bars are tied with cable ties. On the basis of ensuring that it is stable and not loose, it is placed in the concrete when the track plate is cast to a depth of 10 cm. The through-type preset temperature crack is made of thin iron wire with a diameter of 1mm and a length of 510mm. On the basis of smoothing the concrete surface, the thin iron wire pre-coated with vaseline is lightly buried in the surface to complete the crack production.

[0038] In this embodiment, the temperature acquisition unit includes 2 sets of temperature sensors and 4 sets of digital thermometers 13. Figure 4As shown, the temperature sensor includes a thin rod 11 and 8 thermocouple sensors 12 arranged on the thin rod 11 at a certain interval. There are two sets of temperature sensors, and the two sets of temperature sensors are buried at 0 cm and 5 cm from the side edge of the through-type preset temperature crack. The production process is as follows: select a thin wooden stick with a length of 80 mm, and bond the thermocouples 12 at 0 mm, 5 mm, 10 mm, 15 mm, 20 mm, 40 mm, 60 mm, and 80 mm from its top, respectively, and fix the wires of each thermocouple sensor 12 along the surface of the thin wooden stick from top to bottom, and close and bundle them at the bottom of the thin wooden stick. During pouring, on the basis that the preset temperature crack has been set, the two sets of temperature sensors are buried at 0 mm and 50 mm from the edge of the temperature crack, and the bundled wires are buried at a depth of 80 mm to eliminate the influence of the wires on the heat transfer of the collection area. Finally, the wire 4 is led out close to the side of the mold to complete the burying work. The digital thermometer 13 can collect temperature data of all 16 thermocouple sensors 12 at the same time. After the burial is completed, the temperature sensors and the digital thermometer 13 are connected to perform test detection to ensure the effectiveness of all temperature sensors.

[0039] The temperature heating unit includes a temperature-adjustable double-sided aluminum foil heating pad with a size of nine-tenths of the track plate model 1, and is pre-buried at a depth of 10 cm inside the track plate model 1. In this embodiment, the temperature heating unit is 1161 mm long and 459 mm wide. The inside of the aluminum foil is covered with heating wires to ensure its heating uniformity. At the same time, the temperature adjustable function ensures that it can be heated at a constant temperature between 20 and 100°C, with an adjustment step of 10°C. During pouring, when the concrete reaches 50mm, it is paved and placed in it to continue pouring. At the same time, the wire 4 is passed through the side of the mold close to complete the embedding.

[0040] In the environmental element simulation acquisition unit, the power-adjustable halogen heating lamp can be used to simulate solar radiation. The power adjustment range is between 100 and 1000W. The irradiation is stable and uniform and can last for a long time. The wind speed-adjustable straight fan is used to simulate environmental wind conditions. The wind speed can be adjusted in the range of 1 to 10m / s, and the air supply is stable and uniform. The high-sensitivity solar radiation measuring instrument has a sensitivity of 0.01W / ㎡ and a measurement range of 0 to 2000W / ㎡, which can fully meet the simulation needs. At the same time, it can automatically record the measurement results for subsequent search and analysis. The high-sensitivity anemometer can simultaneously measure two meteorological parameters, wind speed and wind direction. The wind speed measurement sensitivity is 0.1m / s and the measurement range is 0 to 20m / s, which fully meets the needs of simulation tests.

[0041] The track plate model 1 is provided with a non-contact temperature crack detection device. The non-contact temperature crack detection device includes a PC terminal and an infrared thermal imager arranged on a movable height-adjustable bracket. Figure 3As shown, the movable height adjustable bracket includes a fixed slide rail base 5, a sliding platform 6, and a thermal imager support frame arranged in sequence from bottom to top. In this embodiment, the fixed slide rail base 5 is made of aluminum profile, 1400mm long, 8mm wide on the upper bottom surface, and 24mm wide on the lower bottom surface. The slide rail thereon is an inverted T-shaped structure design with a height of 10mm and a base height of 5mm, one on each side, and a design width of 300mm. The bottom structure of the sliding platform 6 is concave, with a length of 100mm and a width of 16mm on the left and right sides. There is a slide groove with a width of 8mm and a depth of 10mm inside to cooperate with the slide rail structure of the fixed base to achieve forward and backward movement. The middle part of the left and right slide grooves is welded by an aluminum tube 7 to form a whole. The length of the aluminum tube 7 is determined according to the design width of the fixed base slide rail. The square tube 8 with a welding height of 1000mm in the middle of the aluminum tube 7 has an inner diameter of 16mm and an outer diameter of 20mm. Three threaded holes with a diameter of 6mm are opened in sequence at a height of 500mm in the middle to cooperate with the fastening bolts and the thermal imager support rod. The thermal imager support rod consists of a fastening rod 9 and a thermal imager grid 10. The fastening rod 9 is a round tube with a diameter of 15mm and a height of 1000mm. The top is welded to the thermal imager grid 10 to form a whole. The thermal imager grid 10 is welded by a rectangular steel ring with a length of 120mm and a width of 80mm and a circular steel ring with a diameter of 35mm. The size of the rectangular steel ring and the size of the circular steel ring are respectively matched with the size of the thermal imager. The infrared thermal imager integrates shooting and storage functions, and the temperature sensitivity can reach 0.01℃, which can realize rapid detection and identification. It can be connected to the PC terminal through USB, and the collected data and images can be comprehensively analyzed with temperature data and environmental parameter data.

[0042] like Figure 5 As shown, the implementation method of the track plate temperature crack simulation device includes:

[0043] S1. Make a mold according to the size of the track slab model 1 to be cast: customize a detachable stainless steel mold with a length of 1290 mm, a width of 510 mm, and a height of 150 mm, and evenly apply vaseline on the inner wall of the mold to facilitate demoulding;

[0044] Making steel mesh: Select stainless steel bars with a diameter of 10mm, and cut out 6 spare bars with a length of 1000mm and 6 spare bars with a length of 480mm according to the design requirements. Use cable ties to tie the spare bars in a 6*6 manner to complete the making of the steel mesh;

[0045] Make a temperature sensor: prepare 2 80mm long slender wooden sticks and 16 thermocouple 12 temperature sensors with a temperature measurement range of -20 to 70°C. Starting from one end of the wooden stick, glue the thermocouple sensor 12 sensing contacts to the wooden stick in order at distances of 0mm, 5mm, 10mm, 15mm, 20mm, 40mm, 60mm, and 80mm. Fix and bundle the wires from top to bottom, and mark the relevant depth at the end of each thermocouple sensor 12 connector.

[0046] Temperature heating unit: Cut the aluminum foil heating pad to a size of 1161 mm long and 459 mm wide, and glue the cut area to prevent the internal heating wire from being exposed;

[0047] S2. Use C55 concrete to cast the track slab model 1 according to the actual track slab mix ratio. When the depth reaches the first depth of 50 mm, lay the aluminum foil heating pad flat in the mold, and place the wire close to the side of the mold and lead it out; when the depth reaches the second depth of 100 mm, put in the steel grid and continue to cast concrete until the designed depth;

[0048] S3, select L-shaped aluminum profiles with a side length of 10 mm and a length of 510 mm to make the track plate surface pre-crack false seams 3, on the basis of smoothing the surface, bury the L-shaped aluminum profiles pre-coated with vaseline into the model surface at a second preset distance of 128 mm;

[0049] A thin iron wire with a diameter of 1 mm and a length of 510 mm was used to make a through-type preset temperature crack. On the basis of smoothing the surface, the thin iron wire pre-coated with vaseline was lightly buried into the surface at a first preset distance of 200 mm from the center section to complete the crack making;

[0050] S4. On the basis that the preset temperature crack has been set, two sets of temperature sensors are buried at 0mm and 50mm from the edge of the temperature crack respectively, and the bundled wires are buried at a depth of 80mm to eliminate the influence of the wires on the heat transfer of the collection area. Finally, the wires are led out close to the side of the mold, and the surface is smoothed to complete the burying work;

[0051] S5. When the maintenance of the main structure of the track slab is completed, C55 concrete is used to cast the scaled rail support platform model 2 with the dimensions of 60mm in length, 30mm in width and 15mm in height at equal intervals on the surface according to the actual mix ratio, with 10 rail support platform models 2 on each side, for a total of 20; after all concrete structures are cured, the scaled rails are placed on the surface. The scaled rails are simulated by I-beams with an upper bottom width of 18mm, a lower bottom width of 34mm and a height of 60mm to complete the construction of the model;

[0052] S6. Build environmental element simulation collection units around the track plate model 1 and connect all electrical components:

[0053] (1) On the basis of the pre-buried temperature sensor, the 16 lead wires 4 are connected to the 4 sets of digital thermometers 13 in sequence according to the numbers, each set of digital thermometers 13 is connected to the wires 4 of the 4 thermocouple sensors 12, and the depth and position information are marked in sequence to complete the construction of the embedded temperature acquisition unit;

[0054] (2) On the basis of the pre-buried aluminum foil heating pad, the lead wire 4 is connected to the temperature control switch to realize the adjustable temperature control of the heating pad. The temperature adjustment range is 20-100°C, and the adjustment step is 10°C, thus completing the construction of the temperature heating unit;

[0055] (3) On one side of the track plate model 1, a power-adjustable halogen heating lamp and a wind speed-adjustable direct air blower are installed, with adjustment ranges of 100-1000 W / ㎡ and 0-10 m / s, respectively. The wires of the two devices are connected to the same power switch to achieve simultaneous startup and shutdown. On the other side, i.e., the side where the temperature sensor and the heating pad wire 4 are led out, a high zero-sensitivity solar radiation meter and a high-sensitivity anemometer are installed, with sensitivities of 0.01 W / ㎡ and 0.1 m / s, respectively, to achieve synchronous collection of solar radiation and wind speed, completing the construction of the environmental element simulation collection unit;

[0056] (4) The thermal imager is installed on a mobile height-adjustable bracket to detect and shoot the track plate at different heights and positions to find the best detection point. The thermal imager and PC terminal are connected via USB to process and analyze the shooting data and images, thus completing the construction of a non-contact temperature crack detection device.

[0057] The track plate model 1, embedded temperature acquisition unit, temperature heating unit, environmental element simulation acquisition unit and non-contact temperature crack detection device are combined into a whole. The track plate experimental model is heated at a constant temperature of 40°C by an adjustable temperature aluminum foil heating pad. When the temperature of the track plate model 1 reaches a relatively stable state, the digital thermometer 13 is connected to record the temperature data of 16 thermocouple sensors 12 as the initial temperature data. Then, the halogen heating lamp is turned on and adjusted to 200W power for stable radiation irradiation. At the same time, the direct blower is turned on and adjusted to 1m / s wind speed for stable air supply. The relevant temperature, radiation and wind speed data are collected at a time interval of 30s, and the thermal imager is used for mobile shooting to observe the detection effect under different time domain conditions, and the shooting images and shooting data are stored, and the experimental data of 30min are collected cumulatively. In this way, the temperature, radiation and wind speed parameters are continuously changed to achieve simulation and detection of different working conditions. Finally, the data is imported into the PC terminal for comprehensive analysis and research.

[0058] The data are analyzed based on data processing and image processing methods. The specific steps are as follows:

[0059] ① Import the captured thermal images into the smart view professional analysis software and convert the visualized images into a temperature data csv table, where each cell corresponds to its corresponding pixel coordinate position.

[0060] ②Extract the temperature data in each cell and establish a temperature data matrix. The elements of the matrix are expressed as follows:

[0061]

[0062] ③ Perform a subtraction operation on adjacent rows of the temperature data matrix once, and define the result as the adjacent pixel temperature difference matrix. The matrix elements are:

[0063] D ij =f i+1,j -f ij 1≤i≤480,1≤j≤640

[0064] ④ Set the critical value of temperature difference detected by the thermal imager as 0.2℃ as the threshold, define all elements in the adjacent pixel temperature difference matrix that are greater than or equal to 0.2℃ as 1, otherwise all are set to 0, then the matrix is ​​converted into a pixel grayscale matrix containing only 0,1 elements.

[0065] ⑤ According to the principle of thermal imaging detection, the crack area belongs to the high temperature area, and the temperature at the edge of the crack will be obviously different from that of the non-crack area, which is reflected in the pixel grayscale matrix as element 1. Therefore, by using image processing technology to perform image recognition on the converted thermal image, accurate detection of crack size and location information can be achieved.

Claims

1. A track plate temperature crack simulation device, characterized in that: include: A track plate model, the surface of which is provided with a rail support model and a plurality of pre-cracked false seams, the interior of which is provided with a steel mesh frame, and a through-type preset temperature crack is provided at a first preset distance from the central section; A temperature acquisition unit, comprising a temperature sensor, wherein the temperature sensor is arranged at a set distance from a side edge of the through-type preset temperature crack; A temperature heating unit is arranged inside the track plate model; Environmental element simulation collection unit, including heating lamps, direct blowers, solar radiation measuring instruments and anemometers set around the track plate model; The track plate model is provided with a non-contact temperature crack detection device; The non-contact temperature crack detection device comprises a PC terminal and an infrared thermal imager arranged on a movable height-adjustable bracket; The movable height-adjustable bracket includes a fixed slide rail base, a sliding platform, and a thermal imager support frame which are arranged in sequence from bottom to top; The length and width of the track plate model are 1 / 5 of the actual track plate, and the height is 3 / 4 of the actual track plate.

2. A track plate temperature crack simulation device according to claim 1, characterized in that: The temperature sensor includes a thin rod and a plurality of temperature sensors arranged on the thin rod at a certain interval.

3. A track plate temperature crack simulation device according to claim 2, characterized in that: The temperature sensors are provided with two sets, which are respectively buried at a first set distance and a second set distance from the edge of the through-type pre-cracking false seam.

4. A track slab temperature crack simulation device according to claim 1, characterized in that: The temperature heating unit includes an adjustable double-sided aluminum foil heating pad.

5. A track slab temperature crack simulation device according to claim 1, characterized in that: The pre-cracked false seam is obtained by embedding an L-shaped aluminum profile on the surface of the track slab model when the casting of the track slab model is about to be completed, and the through-type preset temperature crack is obtained by embedding a thin iron wire into the surface of the track slab model.

6. A method for implementing the track slab temperature crack simulation device according to any one of claims 1 to 5, characterized in that: include: S1. Make a mold, a steel grid, a temperature sensor, and a temperature heating unit according to the size of the track slab model to be cast; S2. Cast the track slab model with concrete according to the actual track slab ratio. When the depth reaches the first depth, lay the temperature heating unit flat in the mold. When the depth reaches the second depth, put in the steel grid and continue to cast concrete until the designed depth. S3. On the basis of smoothing the concrete surface, multiple L-shaped aluminum profiles pre-coated with vaseline are embedded into the surface of the track plate model at a second preset distance to achieve the production of pre-cracked false seams, and thin iron wires pre-coated with vaseline are lightly embedded into the concrete surface at a first preset distance from the central section to achieve the production of through-type preset temperature cracks; S4, burying the temperature sensors at a set distance from the side edge of the preset temperature crack; S5. Cast the rail support platform model on the surface of the track slab model at equal intervals according to the actual ratio; S6. Build environmental element simulation and collection units around the track slab model and connect all electrical components.

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