A data processing system and method for rail flaw detection

Abstract

The present invention discloses a data processing system and method for rail flaw detection, including: a data acquisition unit for collecting ultrasonic flaw detection data; a data processing unit for receiving the ultrasonic flaw detection data and generating defect characteristic data; a communication unit for transmitting the defect characteristic data to a host computer unit. The present invention realizes the collection, filtering and flaw judgment of ultrasonic flaw detection data in a hardware circuit manner by setting a programmable data processing unit at the front end, and because the hardware circuit can be triggered based on the same clock signal, it ensures the synchronization of multiple collected data at each moment, realizes the processing and compression of a large amount of data at the front end, effectively improves the real-time and accuracy of the data processing system, and reduces the computing power load of the back-end host computer, solving the problems of high back-end computing power load and poor real-time performance in the traditional rail flaw detection data processing system.

Description

Technical Field

[0001] The present invention relates to the technical field of rail vehicle detection, and in particular to a data processing system and method for rail flaw detection. Background Art

[0002] Train tracks are important components used to guide trains. When the train is running, the tracks will rub against the wheels of the train, vibrate, and collide with the gravel on the roadbed. Therefore, after the train tracks have been in use for a long time, they will suffer fatigue damage or wear damage, and the tracks will be damaged to varying degrees, such as wear, pits, cracks, loose screw holes, corrugation defects, etc.

[0003] At present, the conventional flaw detection method for train tracks is to use large rail flaw detection vehicles. In the high-speed flaw detection process, large rail flaw detection vehicles have gradually become the main detection method in the field of railway flaw detection due to their fast detection speed, strong line adaptability, and high degree of equipment automation. However, due to the large amount of detection data and the large number of channels of large rail flaw detection vehicles, in order to meet the requirements of real-time detection of defect size, type, and defect location, the real-time requirements of the system are relatively high. The technology commonly used in the flaw detection vehicle system is front-end acquisition and back-end processing. This processing method makes the computing power load of the back-end computer higher, reduces the real-time detection of the system, and increases the complexity of the system. At the same time, the number of channels in the current flaw detection vehicle system is relatively small, and the redundancy requirements of the channels are also difficult to adapt to changes in complex defects.

[0004] In summary, the traditional data processing system for rail flaw detection has problems such as high back-end computing load and poor real-time performance. Summary of the invention

[0005] In view of this, the present invention provides a data processing system and method for rail flaw detection, which solves the problems of high back-end computing load and poor real-time performance in traditional data processing systems for rail flaw detection.

[0006] To solve the above problems, the technical solution of the present invention is to adopt a data processing system for rail flaw detection, including: a data acquisition unit for collecting ultrasonic flaw detection data; a data processing unit for receiving the ultrasonic flaw detection data and generating defect feature data; and a communication unit for transmitting the defect feature data to a host computer unit.

[0007] Optionally, the data processing unit includes a filtering module and a single-channel flaw judgment module, wherein the filtering module eliminates the ultrasonic flaw detection data with a voltage value lower than a first threshold, and eliminates the ultrasonic flaw detection data with discontinuous voltage values ​​higher than the first threshold, to generate the filtered ultrasonic flaw detection data; the single-channel flaw judgment module generates defect level data and defect depth data based on the voltage value of the filtered ultrasonic flaw detection data and the position data corresponding to the ultrasonic flaw detection data, and then generates the defect feature data based on the defect level data and the defect depth data.

[0008] Optionally, the data processing unit also includes a multi-channel flaw judgment module, wherein, when the ultrasonic flaw detection data is multi-channel, the single-channel flaw judgment module generates a plurality of defect feature data based on the ultrasonic flaw detection data after multi-channel filtering, and then the multi-channel flaw judgment module performs joint flaw judgment based on the plurality of defect feature data and generates defect type data, and the communication unit packages the plurality of ultrasonic flaw detection data, the plurality of defect feature data and the defect type data and sends them to the host computer unit.

[0009] Optionally, the data processing system also includes a positioning unit triggered synchronously with the data acquisition unit, for collecting the position data corresponding to the ultrasonic flaw detection data, wherein the positioning unit is composed of one or more modules of a GPS signal module, an encoder module and a mileage synchronization module.

[0010] Optionally, the data processing system further includes the host computer unit, and the host computer unit is used to receive the defect feature data and configure the first threshold.

[0011] Optionally, the data processing system further comprises a data storage unit for storing the ultrasonic flaw detection data, the defect feature data, the defect type data, the position data and the first threshold value.

[0012] Accordingly, the present invention provides a data processing method for rail flaw detection, comprising: S1: collecting ultrasonic flaw detection data; S2: generating defect feature data based on the ultrasonic flaw detection data; S3: transmitting the defect feature data to a host computer unit.

[0013] Optionally, S2 includes: eliminating the ultrasonic flaw detection data with voltage values ​​lower than a first threshold, and eliminating the ultrasonic flaw detection data with discontinuous voltage values ​​higher than the first threshold, to generate filtered ultrasonic flaw detection data; generating defect level data and defect depth data based on the voltage value of the filtered ultrasonic flaw detection data and the position data corresponding to the ultrasonic flaw detection data; generating the defect feature data based on the defect level data and the defect depth data.

[0014] Optionally, S2 also includes: when the ultrasonic flaw detection data is multi-channel, the single-channel flaw judgment module generates a plurality of the defect feature data based on the ultrasonic flaw detection data after multi-channel filtering, and the multi-channel flaw judgment module performs joint flaw judgment based on the plurality of the defect feature data and generates defect type data, and the communication unit packages the plurality of the ultrasonic flaw detection data, the plurality of the defect feature data and the defect type data and sends them to the host computer unit.

[0015] Optionally, the S1 further includes: collecting the position data corresponding to the ultrasonic flaw detection data.

[0016] The primary improvement of the present invention is the data processing system for rail flaw detection. By setting a programmable data processing unit at the front end, the collection, filtering and flaw judgment of ultrasonic flaw detection data are realized in the form of hardware circuits. Moreover, since the hardware circuit can be triggered based on the same clock signal, the synchronization of multiple collected data at each moment is guaranteed, and the processing and compression of a large amount of data are completed at the front end, which effectively improves the real-time and accuracy of the data processing system, reduces the computing power load of the back-end host computer, and solves the problems of high back-end computing power load and poor real-time performance existing in the traditional data processing system for rail flaw detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a simplified module connection diagram of the data processing system for rail flaw detection of the present invention;

[0018] Figure 2 is a schematic diagram of ultrasonic flaw detection data of the present invention;

[0019] Figure 3 is a schematic diagram of the filtered ultrasonic flaw detection data of the present invention; and

[0020] Figure 4 It is a simplified flow chart of the data processing method for rail flaw detection of the present invention. DETAILED DESCRIPTION

[0021] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0022] like Figure 1As shown, a data processing system for rail flaw detection includes: a data acquisition unit for collecting ultrasonic flaw detection data; a data processing unit for receiving the ultrasonic flaw detection data and generating defect characteristic data; and a communication unit for transmitting the defect characteristic data to a host computer unit. The data acquisition unit may be an ultrasonic sensor; the data processing unit may be a programmable logic device, and the present invention does not limit the specific device type and model; the communication unit may be composed of a TCP / IP communication module and an RS232 / RS485 / RS422 module, which is used to establish a communication connection between the data processing unit and the host computer and other external modules.

[0023] Furthermore, the data processing unit includes a filtering module and a single-channel flaw judgment module, wherein the filtering module eliminates the ultrasonic flaw detection data with a voltage value lower than a first threshold, and eliminates the ultrasonic flaw detection data with discontinuous voltage values ​​higher than the first threshold, to generate the filtered ultrasonic flaw detection data; the single-channel flaw judgment module generates defect level data and defect depth data based on the voltage value of the filtered ultrasonic flaw detection data and the position data corresponding to the ultrasonic flaw detection data, and then generates the defect characteristic data based on the defect level data and the defect depth data.

[0024] Furthermore, the data processing unit also includes a multi-channel flaw judgment module, wherein, when the ultrasonic flaw detection data is multi-channel, after the single-channel flaw judgment module generates a plurality of the defect feature data based on the ultrasonic flaw detection data after filtering of the multi-channel, the multi-channel flaw judgment module performs joint flaw judgment based on the plurality of the defect feature data and generates defect type data, and the communication unit packages the plurality of the ultrasonic flaw detection data, the plurality of the defect feature data and the defect type data and sends them to the host computer unit. Specifically, the flaw judgment working principle of the multi-channel data module is: based on the defect level data and defect depth data contained in the defect feature data of any channel generated by the single-channel flaw judgment module, it is judged whether the defect feature data values ​​of other channels are included in the level and depth range; if the other defect feature data values ​​are included in the level and depth range, it is judged as a type of defect, and if the feature data values ​​of other channels are not included in the level and depth range, the flaw judgment is not established. Furthermore, the implementation principle is to extract the defect level data and defect depth data contained in the defect feature data of any channel, and expand the range on this basis (range expansion refers to adding or subtracting a numerical value (such as 50) for the horizontal front and back, and adding or subtracting a data (such as 20) for the depth up and down) as the basis for multi-channel data damage judgment. If the level and depth data of all defect feature data values ​​of other channels are included in the previous defect expansion range, the damage judgment is established. The multi-channel damage judgment module compares the defect feature data values ​​of all channels according to the defect feature data values ​​of all channels, extracts the maximum and minimum values ​​of the defect level, and the maximum and minimum values ​​of the depth, as the new defect feature data for combined damage judgment and uploads them to the host computer for defect drawing to complete the defect type judgment; if the level and depth data of the defect feature value of any channel of other channels are not included in the previous defect expansion range, the damage judgment is not established and the damage judgment ends.

[0025] In order to facilitate understanding of the working mode of the data processing unit of the present invention, the ultrasonic flaw detection data collected by the data acquisition unit is as follows: Figure 2 As shown in FIG. 1 (the voltage value actually output by the data acquisition unit is a digital signal, which is represented by an analog value for ease of understanding), when the first threshold is 3V and the continuous threshold is 2, the filtering module removes the ultrasonic flaw detection data whose voltage value is lower than the first threshold, and removes the ultrasonic flaw detection data whose voltage value is lower than the continuous threshold and higher than the first threshold, and generates the following: Figure 3 After the ultrasonic flaw detection data is filtered, the single-channel flaw judgment module generates defect level data and defect depth data based on the voltage value of the ultrasonic flaw detection data after filtering and the position data corresponding to the ultrasonic flaw detection data, and the data processing unit generates the defect feature data based on the defect level data and the defect depth data. Specifically, Figure 3As shown, the data processing unit can generate multiple defect level values ​​and defect depth values ​​based on multiple voltage values ​​of the filtered ultrasonic flaw detection data, and the data processing unit can extract the first non-zero voltage value as the defect starting point and the last non-zero voltage value as the defect end point according to the time sequence relationship, and generate defect level data by calculating the difference between the defect level value at the defect end point and the defect level value at the defect starting point, and generate defect depth data by calculating the difference between the defect depth value at the defect end point and the defect depth value at the defect starting point, wherein the calculation formula can be: X v =S+L+(b n *V+a n ) and Y v =d n *V+c n , where X v is the defect level value, Y v is the defect depth value, V is the voltage value of the ultrasonic flaw detection data, S is the mileage value of the data collection point, L is the distance from the horizontal zero point at the beginning of the data collection unit, a n ,b n ,c n ,d n is the correction factor.

[0026] Furthermore, the data processing system also includes a positioning unit that is triggered synchronously with the data acquisition unit, and is used to collect the position data corresponding to the ultrasonic flaw detection data, wherein the positioning unit is composed of one or more modules selected from the group consisting of a GPS signal module, an encoder module, and a mileage synchronization module. Specifically, when the GPS signal module is used, the GPS signal acquisition module built into the rail flaw detection vehicle can be used to locate the defect position and the train position without externally connecting additional equipment, so as to facilitate the accurate positioning of defects during track maintenance and improve maintenance efficiency; when the encoder module is used, the encoder signal can be converted into the train speed and the train mileage, and the same clock signal can be used as a synchronous trigger signal for encoder acquisition and ultrasonic detector acquisition, so that the actual position of the damage defect can be located according to the encoder signal, which is convenient for track maintenance; when the mileage synchronization module is used, the defect position and the train position can be located based on the wireless communication module built into the rail flaw detection vehicle; when a plurality of the modules are used to form the positioning unit, the positioning accuracy can be further improved by taking the average of a plurality of position data.

[0027] Furthermore, the data processing system further includes a host computer unit for receiving the defect feature data and configuring the first threshold value and a data storage unit for storing the ultrasonic flaw detection data, the defect feature data, the defect type data, the position data and the first threshold value. The host computer unit may be a PC, etc., and the data storage unit may be a random access memory (RAM), a memory, a read-only memory (ROM), an electrically programmable ROM, an electrically erasable programmable ROM, a register, a hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the technical field.

[0028] The present invention realizes the collection, filtering and flaw judgment of ultrasonic flaw detection data in the form of hardware circuit by arranging a programmable data processing unit at the front end. Moreover, since the hardware circuit can be triggered based on the same clock signal, the synchronization of multiple collected data at each moment is guaranteed, and the processing and compression of a large amount of data are completed at the front end, which effectively improves the real-time and accuracy of the data processing system, reduces the computing power load of the back-end host computer, and solves the problems of high back-end computing power load and poor real-time performance existing in the traditional data processing system for rail flaw detection.

[0029] Accordingly, the present invention provides, Figure 4 As shown, a data processing method for rail flaw detection includes: S1: collecting ultrasonic flaw detection data; S2: generating defect feature data based on the ultrasonic flaw detection data; S3: transmitting the defect feature data to a host computer unit. Wherein, S1 also includes: collecting the position data corresponding to the ultrasonic flaw detection data.

[0030] Furthermore, S2 includes: eliminating the ultrasonic flaw detection data with voltage values ​​lower than a first threshold, and eliminating the ultrasonic flaw detection data with discontinuous voltage values ​​higher than the first threshold, to generate filtered ultrasonic flaw detection data; generating defect level data and defect depth data based on the voltage value of the filtered ultrasonic flaw detection data and the position data corresponding to the ultrasonic flaw detection data; generating the defect characteristic data based on the defect level data and the defect depth data.

[0031] Furthermore, S2 also includes: when the ultrasonic flaw detection data is multi-channel, the single-channel flaw judgment module generates a plurality of the defect feature data based on the ultrasonic flaw detection data after multi-channel filtering, and the multi-channel flaw judgment module performs joint flaw judgment based on the plurality of the defect feature data and generates defect type data, and the communication unit packages the plurality of the ultrasonic flaw detection data, the plurality of the defect feature data and the defect type data and sends them to the host computer unit.

[0032] The data processing system and method for rail flaw detection provided by the embodiments of the present invention are introduced in detail above. The various embodiments in the specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same and similar parts between the various embodiments can be referred to each other. For the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the method part description. It should be pointed out that for ordinary technicians in this technical field, without departing from the principle of the present invention, several improvements and modifications can be made to the present invention, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

[0033] Professionals may further appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of the two. In order to clearly illustrate the interchangeability of hardware and software, the composition and steps of each example have been generally described in the above description according to function. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professionals and technicians may use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of the present invention.

[0034] The steps of the method or algorithm described in conjunction with the embodiments disclosed herein may be implemented directly using hardware, a software module executed by a processor, or a combination of the two. The software module may be placed in a random access memory (RAM), a memory, a read-only memory (ROM), an electrically programmable ROM, an electrically erasable programmable ROM, a register, a hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art.

Claims

1. A data processing system for rail flaw detection, characterized in that: include: A data acquisition unit, used for collecting ultrasonic flaw detection data; A data processing unit is used to receive the ultrasonic flaw detection data and generate defect feature data, wherein the data processing unit includes a single-channel flaw judgment module and a multi-channel flaw judgment module. When the ultrasonic flaw detection data is multi-channel, the single-channel flaw judgment module generates a plurality of defect feature data based on the ultrasonic flaw detection data after multi-channel filtering, and then the multi-channel flaw judgment module performs joint flaw judgment based on the plurality of defect feature data and generates defect type data. The communication unit packages the plurality of ultrasonic flaw detection data, the plurality of defect feature data and the defect type data and sends them to the host computer unit. The flaw judgment working principle of the multi-channel data module is to extract the defect feature data packet of any channel. The defect level data and defect depth data contained in the multi-channel defect judgment module are compared according to the defect feature data values ​​of all channels, and the maximum and minimum values ​​of the defect level and the maximum and minimum values ​​of the depth are extracted as the new defect feature data for combined defect judgment and uploaded to the host computer for defect drawing to complete the defect type judgment. If the defect feature value level and depth data of any other channel are not included in the previous defect expansion range, the defect judgment is not established and the judgment ends. A communication unit is used to transmit the defect characteristic data to a host computer unit.

2. The data processing system according to claim 1, characterized in that The data processing unit includes a filtering module and a single-channel injury judgment module, wherein: The filtering module removes the ultrasonic flaw detection data whose voltage value is lower than a first threshold value, and removes the ultrasonic flaw detection data whose discontinuous voltage value is higher than the first threshold value, to generate the filtered ultrasonic flaw detection data; The single-channel flaw judgment module generates defect level data and defect depth data based on the voltage value of the filtered ultrasonic flaw detection data and the position data corresponding to the ultrasonic flaw detection data, and then generates the defect feature data based on the defect level data and the defect depth data.

3. The data processing system according to claim 2, characterized in that: The data processing system further includes a positioning unit that is triggered synchronously with the data acquisition unit and is used to acquire the position data corresponding to the ultrasonic flaw detection data, wherein: The positioning unit is composed of one or more modules selected from the group consisting of a GPS signal module, an encoder module and a mileage synchronization module.

4. The data processing system according to claim 2, characterized in that: The data processing system further comprises the host computer unit, which is used to receive the defect feature data and configure the first threshold.

5. The data processing system according to claim 2, characterized in that: The data processing system further includes a data storage unit for storing the ultrasonic flaw detection data, the defect feature data, the defect type data, the position data and the first threshold value.

6. A data processing method for rail flaw detection, characterized in that: include: S1: Collect ultrasonic flaw detection data; S2: Generate defect feature data based on the ultrasonic flaw detection data, wherein when the ultrasonic flaw detection data is multi-channel, after the single-channel flaw judgment module generates a plurality of the defect feature data based on the ultrasonic flaw detection data after multi-channel filtering, the multi-channel flaw judgment module performs joint flaw judgment based on the plurality of the defect feature data and generates defect type data, and the communication unit packages the plurality of the ultrasonic flaw detection data, the plurality of the defect feature data and the defect type data and sends them to the upper computer unit; the flaw judgment working principle of the multi-channel data module is to extract the defect level data and defect depth data contained in the defect feature data of any channel, and in the After the range is expanded on the basis, if the level and depth data of all defect feature data values ​​of other channels are included in the previous defect expansion range, the defect judgment is established. The multi-channel defect judgment module compares the defect feature data values ​​of all channels according to the defect feature data values ​​of all channels, extracts the maximum and minimum values ​​of the defect level, the maximum and minimum values ​​of the depth, as the new defect feature data for combined defect judgment and uploads them to the host computer for defect drawing to complete the defect type judgment. If the level and depth data of the defect feature value of any channel of other channels are not included in the previous defect expansion range, the defect judgment is not established and the defect judgment ends; S3: Transmit the defect feature data to the host computer unit.

7. The data processing method for rail flaw detection according to claim 6 is characterized in that: The S2 includes: Eliminating the ultrasonic flaw detection data whose voltage value is lower than a first threshold value, and eliminating the ultrasonic flaw detection data whose discontinuous voltage value is higher than the first threshold value, to generate the ultrasonic flaw detection data after filtering; Generate defect level data and defect depth data based on the voltage value of the filtered ultrasonic flaw detection data and the position data corresponding to the ultrasonic flaw detection data; The defect characteristic data is generated based on the defect level data and the defect depth data.

8. The data processing method for rail flaw detection according to claim 6 is characterized in that: The S1 also includes: collecting position data corresponding to the ultrasonic flaw detection data.

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