A full-section ultrasonic imaging liquid immersion array probe ultrasonic flaw detection device

Abstract

This invention relates to a full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device, comprising a coupling chamber, within which are a tread detection component and a side detection component. The tread detection component includes a support base mounted on the bottom wall of the coupling chamber, a direct ultrasonic probe mounted on the support base, and oblique ultrasonic probes symmetrically positioned on either side of the direct ultrasonic probe. The ultrasonic beam emitted from the direct ultrasonic probe propagates radially along the rim to be inspected, while the ultrasonic beam emitted from the oblique ultrasonic probes intersects the radial direction of the rim to be inspected at an angle. The side detection component includes a connecting seat mounted on the side wall of the coupling chamber and a side detection ultrasonic probe mounted on the connecting seat. This invention's full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device achieves full-section inspection of the rim through the tread and side detection components, resulting in higher inspection efficiency and reliability, smaller size, and easier installation, use, and maintenance.

Description

Technical Field

[0001] This invention relates to an ultrasonic flaw detection device, and more particularly to a full-section ultrasonic imaging liquid immersion array probe ultrasonic flaw detection device. Background Technology

[0002] Currently, the inspection of railway wheel rims mainly includes two methods: manual single-probe inspection and automated inspection.

[0003] The manual single-probe inspection method relies on the A-type pulse echo method for inspection. It uses a single probe to manually scan the wheel rim tread surface to inspect the area. However, the inspection speed is slow, the inspection efficiency is low, the workload of front-line inspectors is heavy, and the inspection results are greatly affected by human factors, resulting in poor consistency and reliability.

[0004] Automated inspection methods employ fixed water tank or water spray scanning inspection to automatically inspect the inspection area. Compared to manual inspection, this method offers a certain improvement in inspection efficiency. However, existing automated inspection methods using fixed water tanks are significantly limited by site and environmental factors. For example, the inspection workshop must provide dedicated workstations and spaces, and the probe and coupling immersion device are independent components requiring dedicated water supply and drainage systems. These methods are bulky, cannot be used for mobile inspection, and have high maintenance and modification costs. On the other hand, automated inspection methods using water spray coupling are often affected by water pressure, water flow, and the spray coverage area, often resulting in poor or unstable coupling between the probe and the workpiece, which greatly affects the quality and effectiveness of ultrasonic flaw detection.

[0005] Meanwhile, existing wheel rim inspection equipment lacks an array probe device for full-section ultrasonic testing, making it impossible to achieve one-time ultrasonic imaging inspection of the wheel rim cross-section. Summary of the Invention

[0006] To address the aforementioned technical problems, the present invention aims to provide a full-section ultrasonic imaging liquid immersion array probe ultrasonic flaw detection device that is small in size, easy to install, use and maintain, and has high detection efficiency and reliability.

[0007] The present invention relates to a full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device, comprising a coupling chamber, wherein a tread detection component and a side detection component are provided within the coupling chamber. The tread detection component includes a support base disposed on the bottom wall of the coupling chamber, a direct ultrasonic probe disposed on the support base, and oblique ultrasonic probes symmetrically disposed on both sides of the direct ultrasonic probe. The ultrasonic beam emitted by the direct ultrasonic probe is transmitted radially along the rim to be tested, and the ultrasonic beam emitted by the oblique ultrasonic probe intersects the radial direction of the rim to be tested at an angle. The side detection component includes a connecting base disposed on the side wall of the coupling chamber and a side detection ultrasonic probe disposed on the connecting base.

[0008] The advantages of this full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device lie in its ability to detect the tread and sides of the wheel rim respectively through tread detection and side detection components installed within the coupling chamber. The tread detection component includes a direct ultrasonic probe and two symmetrically arranged oblique ultrasonic probes. The ultrasonic beams emitted by the direct and oblique probes can be focused onto the same detection surface of the wheel rim as required. Because the ultrasonic beam emitted by the oblique probe intersects the radial angle of the wheel rim, it, along with the ultrasonic beam emitted by the direct probe, achieves full-section detection of the wheel rim, thus improving the reliability of the detection results. The side detection ultrasonic probes enable the detection of side defects on the wheel rim, achieving full coverage of the wheel rim and improving detection efficiency. Furthermore, compared to existing fixed water tank-type automatic inspection devices, this ultrasonic inspection device is smaller in size, facilitating installation, use, and maintenance. It also has less environmental impact compared to spray-type automatic inspection devices.

[0009] In summary, the full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device of the present invention is small in size, easy to install, use and maintain, and has high detection efficiency and reliability.

[0010] Furthermore, in the full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device of the present invention, the support base includes a base, the surface of the base is provided with a mounting groove, a support plate is provided above the base, and the bottom end of the support plate is fixed in the mounting groove.

[0011] The base is designed to mount the support plate, and the mounting grooves on its surface allow for the positioning of the support plate. The support plate, in turn, enables the mounting and support of both direct and oblique ultrasonic probes.

[0012] Furthermore, in the full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device of the present invention, the top surface of the support plate includes a planar portion for mounting the direct ultrasonic probe and two symmetrically arranged inclined portions, and a spacer for positioning and spacing is also provided between the planar portion and the inclined portions.

[0013] This design meets the requirements for the installation angles of both direct and oblique ultrasonic probes. The spacer serves both for positioning and to separate the two types of probes.

[0014] Furthermore, in the full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device of the present invention, a coupling fluid replenishment chamber is provided outside the coupling chamber, and a circulation pump is provided inside the coupling fluid replenishment chamber. The input port and output port of the circulation pump are respectively connected to the coupling chamber and the coupling fluid replenishment chamber.

[0015] The coupling fluid replenishment tank and circulation pump enable automatic replenishment of the coupling fluid.

[0016] Furthermore, the full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device of the present invention includes a housing, and a partition is provided inside the housing to divide the inner cavity of the housing into the coupling chamber and the coupling fluid replenishment chamber.

[0017] The design of the housing and partitions integrates the coupling chamber and coupling fluid replenishment chamber, thereby reducing the overall volume and facilitating installation and transportation.

[0018] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the following describes the embodiments of the present invention in detail. Attached Figure Description

[0019] Figure 1 This is a three-dimensional view of the full-section ultrasonic imaging liquid immersion array probe ultrasonic flaw detection device in Embodiment 1;

[0020] Figure 2 This is a layout diagram of the side detection component and the tread detection component in the coupling chamber in Embodiment 1;

[0021] Figure 3 This is a 3D view of the tread detection component;

[0022] Figure 4 This is the main view of the tread detection component;

[0023] Figure 5 It is a 3D view of the support base;

[0024] Figure 6 This is a 3D view of the side detection component;

[0025] Figure 7 This is a 3D view of the connector;

[0026] Figure 8 This is a schematic diagram of the transmission of the ultrasonic beam emitted from a direct ultrasonic probe and an oblique ultrasonic probe.

[0027] Figure 9 This is the front view of the wheel rim;

[0028] Figure 10 This is a perspective view of the full-section ultrasonic imaging liquid immersion array probe ultrasonic flaw detection device in Embodiment 2;

[0029] Figure 11 This is a schematic diagram of the ultrasonic flaw detection device for full-section ultrasonic imaging liquid immersion array probe in Example 2;

[0030] Figure 12 This is a front view of the full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device in Embodiment 3, where the coupling chamber is not shown.

[0031] In the figure, coupling chamber 1, support base 2, direct ultrasonic probe 3, oblique ultrasonic probe 4, detection rim 5, connecting seat 6, side detection ultrasonic probe 7, base 8, mounting groove 9, support plate 10, partition block 11, backrest 12, coupling fluid replenishment chamber 13, box body 14, partition plate 15, circulation pump 16. Detailed Implementation

[0032] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0033] Example 1:

[0034] See Figures 1 to 9 The full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device of this embodiment includes a coupling chamber 1, which is equipped with a tread detection component and a side detection component. The tread detection component includes a support base 2 on the bottom wall of the coupling chamber, a direct ultrasonic probe 3 on the support base, and oblique ultrasonic probes 4 symmetrically arranged on both sides of the direct ultrasonic probe. The ultrasonic beam emitted by the direct ultrasonic probe is transmitted radially along the rim 5 to be tested, and the ultrasonic beam emitted by the oblique ultrasonic probe intersects the radial direction of the rim to be tested at an angle. The side detection component includes a connecting base 6 on the side wall of the coupling chamber and a side detection ultrasonic probe 7 on the connecting base.

[0035] The full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device of the present invention achieves the detection of the tread and side surfaces of the wheel rim by means of a tread detection component and a side surface detection component arranged in a coupling chamber. The tread detection component includes a direct ultrasonic probe and two symmetrically arranged oblique ultrasonic probes. The ultrasonic beams emitted by the direct and oblique ultrasonic probes can be focused onto the same detection surface of the wheel rim to be inspected as required. Because the ultrasonic beam emitted by the oblique ultrasonic probe intersects the radial angle of the wheel rim to be inspected, it, along with the ultrasonic beam emitted by the direct ultrasonic probe, achieves full-section detection of the wheel rim to be inspected, thereby improving the reliability of the detection results. The side surface detection ultrasonic probes enable the detection of side defects of the wheel rim to be inspected, thus achieving full coverage of the wheel rim inspection and improving the inspection efficiency. Furthermore, compared with existing fixed water tank type automatic inspection devices, this ultrasonic inspection device is smaller in size, making it easier to install, use, and maintain. At the same time, compared with spray-type automatic inspection devices, its environmental impact is also smaller.

[0036] The full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device of the present invention is small in size, easy to install, use and maintain, and has high detection efficiency and reliability.

[0037] The support base is used to install direct ultrasound probes and oblique ultrasound probes. In this embodiment, the support base includes two sets, front and rear. Each set of support bases includes a base 8, the surface of which is provided with a mounting groove 9, and a support plate 10 is provided above the base. The bottom end of the support plate is fixed in the mounting groove.

[0038] The top surface of the support plate includes a flat portion for mounting a direct ultrasound probe and two symmetrically arranged inclined portions. A spacer 11 for positioning and spacing is also provided between the flat portion and the inclined portions.

[0039] Direct-firing ultrasonic probes, oblique-firing ultrasonic probes, and side-firing ultrasonic probes are all array-type ultrasonic probes. They can be single probes containing multiple crystals, or arrays of probes composed of multiple single-crystal probes. The number of crystals in an array-type ultrasonic probe ranges from 8 to 128, with the specific number determined by the required detection accuracy.

[0040] In this embodiment, the direct ultrasonic probe, the oblique ultrasonic probe, and the side-mounted ultrasonic probe can all be self-generating and self-receiving longitudinal wave probes. The ultrasonic beam emitted by the direct ultrasonic probe propagates radially along the rim to be tested. The ultrasonic beams emitted by the two oblique ultrasonic probes intersect the radial direction of the rim to be tested at an angle between 20 and 30 degrees, depending on the testing requirements. In this embodiment, this angle is 26 degrees. Correspondingly, the angle between the inclined portion used to mount the oblique ultrasonic probe and the flat portion is also 26 degrees.

[0041] The connecting seat is used to install the side detection ultrasonic probe. A connecting seat can be set at each end of a single side detection ultrasonic probe. In this embodiment, the connecting seat is an L-shaped seat. The vertical plate of the L-shaped seat is fixed to the side wall of the coupling chamber. The end of the horizontal plate of the L-shaped seat is also provided with a backing plate 12. One end of the side detection ultrasonic probe is installed on the horizontal plate of the L-shaped seat and positioned by the backing plate.

[0042] During inspection, the wheel rim is positioned at a predetermined height above the tread inspection assembly, with the side inspection assembly located on one side of the rim. After the rim is installed in the predetermined position, the operator injects a predetermined amount of coupling fluid into the coupling chamber until the fluid completely covers the inspected portion of the rim. The operator then automatically rotates the rim using existing workstations on the production line. During rotation, the tread inspection assembly below and the side inspection assembly to its side perform ultrasonic inspections until the rim completes one full rotation, thus completing a full-section scan of the rim.

[0043] Because each probe is immersed in the coupling fluid during testing, its coupling effect is better than that of the spray type. Combined with full-section scanning flaw detection, its detection reliability is also higher.

[0044] Meanwhile, the coupling chamber facilitates installation and transportation, thereby improving the efficiency of rim inspection.

[0045] Example 2:

[0046] See Figures 10 to 11 The full-section ultrasonic imaging liquid immersion array probe ultrasonic flaw detection device of this embodiment adds the following technical contents based on the full-section ultrasonic imaging liquid immersion array probe ultrasonic flaw detection device of Embodiment 1.

[0047] Specifically, in this embodiment of the full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device, a coupling fluid replenishment tank 13 is provided outside the coupling chamber. The coupling fluid replenishment tank can be fixed to the outer wall of the coupling chamber, stacked below the coupling chamber, or hung on the outside of the coupling chamber and connected through a pipe.

[0048] In this embodiment, the coupling chamber and the coupling fluid replenishment chamber are integrated, consisting of a housing 14 and an internal partition 15. The partition divides the housing into a coupling chamber for detecting the wheel rim and a coupling fluid replenishment chamber for replenishing the coupling fluid.

[0049] A circulation pump 16 is installed in the coupling fluid replenishment tank. When the coupling fluid level in the coupling tank is too low, the circulation pump pumps the coupling fluid in the coupling fluid replenishment tank into the coupling tank, thereby replenishing the coupling fluid.

[0050] During batch testing of wheel rims, the coupling fluid decreases due to continuous workpiece replacement. The coupling fluid replenishment tank ensures that the coupling fluid level remains optimal to meet testing requirements.

[0051] The structure, size, shape, and volume of the coupling chamber and coupling fluid replenishment chamber can be determined according to the size of the workpiece, the number of probes, the installation method of the probes, the detection process, and the conditions of the coupling fluid. Under the condition of meeting the detection process, the coupling chamber and coupling fluid replenishment chamber should be designed to be as small and light as possible to facilitate installation and maintenance.

[0052] To detect the liquid level in the coupling fluid, liquid level sensors can be installed in both the coupling chamber and the coupling fluid replenishment chamber to monitor the liquid level and automatically replenish the coupling fluid. During operation, the external controller can automatically control the circulation pump through the liquid level signal sensed by the liquid level sensor, thereby achieving automatic replenishment of the coupling fluid.

[0053] When there is an excess of coupling fluid in the coupling chamber, the excess coupling fluid can overflow into the coupling fluid replenishment chamber through the overflow hole between the coupling chamber and the coupling fluid replenishment chamber, so as to keep the coupling fluid in the coupling chamber at the optimal liquid level.

[0054] When the level of coupling fluid in the coupling fluid replenishment tank is too low, the external controller can issue a corresponding alarm, such as an audible and visual alarm or a text message, to remind the operator to replenish the coupling fluid.

[0055] The specific connection protection and working principle of the external controller, liquid level sensor and circulating pump are conventional technologies and will not be described in detail here.

[0056] Example 3:

[0057] See Figure 12 The full-section ultrasonic imaging liquid immersion array probe ultrasonic flaw detection device of this embodiment adds the following technical content based on the full-section ultrasonic imaging liquid immersion array probe ultrasonic flaw detection device of Embodiment 1. Specifically, the full-section ultrasonic imaging liquid immersion array probe ultrasonic flaw detection device of this embodiment has two sets of side detection components, which are located on both sides of the tread detection component. One set of side detection components uses a side detection ultrasonic probe to emit an ultrasonic beam, and the other set of side detection components uses a side detection ultrasonic probe to receive the ultrasonic beam, thereby realizing penetrating detection of the wheel rim and improving the detection effect.

[0058] In summary, the cross-sectional ultrasonic imaging liquid immersion array probe ultrasonic flaw detection device of the present invention can perform full-section ultrasonic detection and achieve full-coverage imaging for railway wheel rims. This flaw detection device is suitable for full-section inspection of railway wheel rims. It adopts the optimal coupling method in ultrasonic testing, liquid immersion coupling, and can be equipped with its own coupling fluid, eliminating the need for an external coupling fluid supply system. It has no special requirements for the site or environment, is lightweight and reliable, and is easy to install and maintain. It saves workspace, promotes an environmentally friendly testing environment, and eliminates any on-site pollution, greatly improving testing efficiency and quality while significantly reducing the workload and costs for testing personnel.

[0059] The above are merely preferred embodiments of the present invention, used to assist those skilled in the art in implementing the corresponding technical solutions, and are not intended to limit the scope of protection of the present invention. The scope of protection of the present invention is defined by the appended claims. It should be noted that, for those skilled in the art, several equivalent improvements and modifications can be made based on the technical solutions of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention. Furthermore, it should be understood that although this specification describes the embodiments as described above, not every embodiment contains only one independent technical solution. This descriptive method is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions of each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device, comprising a coupling chamber (1), characterized in that: The coupling chamber is equipped with a tread detection component and a side detection component. The tread detection component includes a support base (2) on the bottom wall of the coupling chamber, a direct ultrasonic probe (3) on the support base, and oblique ultrasonic probes (4) symmetrically arranged on both sides of the direct ultrasonic probe. The ultrasonic beam emitted by the direct ultrasonic probe is transmitted radially along the rim (5) to be tested, and the ultrasonic beam emitted by the oblique ultrasonic probe intersects the radial direction of the rim to be tested. The side detection component includes a connecting base (6) on the side wall of the coupling chamber and a side detection ultrasonic probe (7) on the connecting base.

2. The full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device according to claim 1, characterized in that: The support base includes a base (8), the surface of which is provided with an installation groove (9), and a support plate (10) is provided above the base, with the bottom end of the support plate fixed in the installation groove.

3. The full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device according to claim 2, characterized in that: The top surface of the support plate includes a planar portion for mounting a direct ultrasound probe and two symmetrically arranged inclined portions. A spacer (11) for positioning and spacing is also provided between the planar portion and the inclined portions.

4. The full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device according to claim 1, characterized in that: A coupling fluid replenishment chamber (13) is provided outside the coupling chamber. A circulation pump is provided inside the coupling fluid replenishment chamber. The inlet and outlet of the circulation pump are connected to the coupling chamber and the coupling fluid replenishment chamber, respectively.

5. The full-section ultrasonic imaging immersion array probe ultrasonic flaw detection device according to claim 4, characterized in that: It includes a box body, and a partition is provided inside the box body, which divides the inner cavity of the box body into the coupling chamber and the coupling fluid replenishment chamber.

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