A fully automatic weld scan frame and a weld scan method

Abstract

The application provides a full-automatic weld scanning frame and a weld scanning method. The full-automatic weld scanning frame comprises an instrument scanning frame body, a handle, a stretching rod, a track wheel mechanism, a steel rail locking device, a laser positioning device, a collection box, a main sliding block unit and a vice sliding block unit. The steel rail locking device is used for achieving stable clamping and fixing between the instrument scanning frame body and the steel rail when the instrument scanning frame body moves to a target weld scanning area. The main sliding block unit and the vice sliding block unit are arranged in the interior of the instrument scanning frame body and are used for detecting the target weld. The full-automatic weld scanning frame and the weld scanning method change the traditional manual weld flaw detection mode, replace manual flaw detection, realize the automation of flaw detection, reduce the labor intensity of flaw detection personnel and improve the precision and efficiency of weld flaw detection.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of rail weld detection, and particularly relates to a full-automatic weld scanning frame and a weld scanning method. BACKGROUND

[0002] Rail transportation is one of the most important transportation modes in China. With the development of the railway industry, the total mileage of railways is more than 140,000 kilometers. The longer the railway line is, the more potential hazards it has, thereby putting forward higher requirements for the daily maintenance and care of the railway line. The application of rail flaw detection technology can timely understand the potential safety problems of the railway and avoid the occurrence of traffic accidents. In particular, for the rail weld, the ultrasonic nondestructive detection technology has important promoting significance for the development of the railway industry due to its accurate positioning and quantification of defects, high detection sensitivity, and the like. The ultrasonic nondestructive detection technology has been widely applied in the current rail flaw detection work.

[0003] The existing rail flaw detector has the following defects: the existing weld flaw detection technology generally relies on pure manual operation, and various probes are used to detect each part of the weld by using a scanning frame. These operations need to be manually positioned multiple times, and the requirements for the operator are high. The detection of each weld consumes a long time and has low efficiency. SUMMARY

[0004] In view of the defects in the prior art, the present application provides a full-automatic weld scanning frame and a weld scanning method, which can effectively solve the above problems.

[0005] The technical scheme adopted by the present application is as follows:

[0006] The present application provides a full-automatic weld scanning frame, which comprises an instrument scanning frame body (1), a handle (2), a stretching rod (3), a track wheel mechanism (4), a rail locking device (5), a laser positioning device (6), an acquisition box (7), a main sliding block unit (8), and a vice sliding block unit (9).

[0007] The instrument scanning frame body (1) is erected above a rail (10).

[0008] The handle (2) is fixedly installed at the top of the instrument scanning frame body (1) to provide a gripping position for an operator to open and close the instrument and to move up and down the track.

[0009] The stretching rod (3) is hingedly connected to the top of the instrument scanning frame body (1) and is used to drag the instrument scanning frame body (1) to move longitudinally along the rail (10).

[0010] The track wheel mechanism (4) is symmetrically hinged and installed at the front and rear of the instrument scanning frame (1), and has two states: unfolded and retracted. In the unfolded state, it supports the instrument scanning frame (1) above the rail (10) and provides a guiding movement function for longitudinal movement along the rail (10). In the retracted state, it causes the instrument scanning frame (1) to fall and clamp on the left and right sides of the rail (10).

[0011] The rail locking device (5) is used to achieve stable clamping and fixing between the instrument scanning frame (1) and the rail (10) when the instrument scanning frame (1) moves to the target weld scanning area.

[0012] The laser positioning device (6) is fixedly installed at the top center of the instrument scanning frame (1) and is used to emit a horizontal laser line in the start state so that the horizontal laser line is aligned with the center face of the target weld, thereby realizing the positioning of the instrument scanning frame (1) in the longitudinal direction of the rail (10).

[0013] The acquisition box (7) is fixedly installed on the top of the instrument scanning frame (1) and is used to connect with the main slider unit (8) and the auxiliary slider unit (9) to acquire and store the detection results of the target weld.

[0014] The main slider unit (8) and the secondary slider unit (9) are both located inside the instrument scanning frame (1) and are used to detect the target weld.

[0015] Preferably, the instrument scanning frame (1) includes an instrument guard plate (11) and a main support plate (12) fixed to both ends of the instrument guard plate (11); scales (13) are provided on the left and right sides of the instrument guard plate (11) along the longitudinal direction to assist in adjusting the longitudinal position of the instrument scanning frame (1) on the rail (10); an alignment baseline (14) is provided at the top center of the instrument guard plate (11) to align with the center face of the target weld, thereby realizing the positioning of the instrument scanning frame (1) in the longitudinal direction of the rail (10).

[0016] Preferably, the track wheel mechanism (4) includes a track wheel (41), a left wheel leg (42), a right wheel leg (43), a free hinge (44), and a folding hinge (45).

[0017] The shape of the track wheel (41) matches the top shape of the rail (10) and is used to slide longitudinally along the top of the rail (10); the left side of the track wheel (41) is hinged to one end of the left wheel leg (42), the other end of the left wheel leg (42) is fixed to the bottom of the free hinge (44), and the side of the free hinge (44) is fixed to the main support plate (12); the right side of the track wheel (41) is hinged to one end of the right wheel leg (43), the other end of the right wheel leg (43) is fixed to the bottom of the folding hinge (45), and the side of the folding hinge (45) is fixed to the main support plate (12);

[0018] The bottom of the free hinge (44) can be folded or unfolded freely relative to the side of the free hinge (44); the bottom of the folding hinge (45) can be folded or unfolded under the action of external force relative to the side of the folding hinge (45).

[0019] Preferably, the rail locking device (5) includes a top positioning block (51), a main side clamping block (52), a main side limiting rod (53), a main side spring (54), a secondary side clamping block (55), a secondary side limiting rod (56), a secondary side spring (57), and a quick clamp (58).

[0020] The top positioning block (51) is fixedly installed on the side of the main support plate (12), and the bottom shape of the top positioning block (51) matches the top shape of the rail (10). On the left and right sides of the top positioning block (51), the secondary side limiting rod (56) and the main side limiting rod (53) are fixedly installed along the width direction of the rail (10). The secondary side clamping block (55) is installed on the outer surface of the secondary side limiting rod (56), and the secondary side spring (57) is installed on the inner side of the secondary side clamping block (55). The main side clamping block (52) is installed on the outer surface of the main side limiting rod (53), and the main side spring (54) is installed on the inner side of the main side clamping block (52). The quick clamp (58) is installed on the top of the main side clamping block (52).

[0021] When the instrument scanning frame (1) is in a drag state, under the elastic force of the secondary side spring (57) and the main side spring (54), the secondary side clamping block (55) slides to the outermost side along the secondary side limiting rod (56), and the main side clamping block (52) slides to the outermost side along the main side limiting rod (53);

[0022] When the instrument scanning frame (1) is lowered and in working condition, the secondary side clamping block (55) and the primary side clamping block (52) move to the innermost side and are fixed together by the quick clamp (58). At this time, the bottom of the top positioning block (51) is attached to the top of the rail (10). The secondary side clamping block (55) and the primary side clamping block (52) are respectively clamped on the left and right sides of the bottom of the rail top of the rail (10). At this time, the left and right sides of the instrument scanning frame (1) are clamped on the left and right sides of the bottom of the rail (10), thereby realizing the multi-point positioning and fixing between the instrument scanning frame (1) and the rail (10).

[0023] Preferably, the instrument scans the interior of the frame (1), and the main slider unit (8) and the auxiliary slider unit (9) are installed on the left and right sides of the rail (10), respectively; wherein the longitudinal direction of the rail (10) is the X direction, the width direction of the rail (10) is the Y direction, and the height direction of the rail (10) is the Z direction;

[0024] The main slider unit (8) includes a main slider X-axis drive mechanism (81), a main slider X-axis optical axis (82), and a main slider module (83); the secondary slider unit (9) includes a secondary slider X-axis drive mechanism (91), a secondary slider X-axis optical axis (92), and a secondary slider module (93).

[0025] The main slider X-axis (82) and the auxiliary slider X-axis (92) are fixedly installed on the left and right sides inside the instrument scanning frame (1), respectively; the main slider module (83) is slidably connected to the main slider X-axis (82), and under the drive of the main slider X-axis driving mechanism (81), the main slider module (83) moves in the X direction along the main slider X-axis (82);

[0026] The secondary slider module (93) is slidably connected to the X-axis (92) of the secondary slider. Under the drive of the X-axis driving mechanism (91) of the secondary slider, the secondary slider module (93) moves in the X direction along the X-axis (92) of the secondary slider.

[0027] Preferably, the main slider X-axis drive mechanism (81) and the auxiliary slider X-axis drive mechanism (91) are both stepper motors, each connected to a synchronous belt (A1); the main slider module (83) and the auxiliary slider module (93) are respectively fixed to the fixing point of their respective synchronous belts (A1) through synchronous belt clamping blocks (A2).

[0028] Preferably, the main slider module (83) includes a main slider support plate (831), a main slider rail top surface detection component (832), a main slider rail top side surface K1 detection component (833), a main slider rail bottom inclined surface K2.5 detection component (834), and a main slider rail bottom side surface K1 detection component (835).

[0029] The main slider rail top surface detection component (832) includes a rail top surface Y-axis drive motor (8321), a rail top surface Y-axis optical axis (8322), a rail top surface probe slider seat (8323), a rail top surface K1 probe (8324), a rail top surface K0.8 probe (8325), a rail top surface 0 degree probe (8326), a rail top surface K2.5 probe (8327), and a rail top surface K2.5 probe drive servo motor (8328).

[0030] The main slider support plate (831) is fixedly mounted on the upper part of the rail top surface Y-axis (8322); the rail top surface probe slider seat (8323) is sleeved on the outside of the rail top surface Y-axis (8322), and slides in the Y direction along the rail top surface Y-axis (8322) under the drive of the rail top surface Y-axis drive motor (8321);

[0031] The bottom of the rail top surface probe slider seat (8323) is fixedly installed with the rail top surface K1 probe (8324), the rail top surface K0.8 probe (8325), and the rail top surface 0 degree probe (8326). The rail top surface K1 probe (8324), the rail top surface 0 degree probe (8326), and the rail top surface K0.8 probe (8325) are arranged sequentially along the Y direction. Under the drive of the rail top surface Y direction drive motor (8321), the rail top surface K1 probe (8324), the rail top surface 0 degree probe (8326), and the rail top surface K0.8 probe (8325) are moved sequentially to the center position of the rail top surface Y direction to perform target weld flaw detection work.

[0032] The bottom of the rail top surface probe slider seat (8323) is equipped with the rail top surface K2.5 probe drive servo motor (8328), and the bottom of the rail top surface K2.5 probe drive servo motor (8328) is equipped with the rail top surface K2.5 probe (8327). Driven by the rail top surface K2.5 probe drive servo motor (8328), the rail top surface K2.5 probe (8327) is rotated by a certain angle to realize flaw detection at different positions on the rail top surface. At the same time, after the main slider module (83) crosses the target weld, the rail top surface K2.5 probe drive servo motor (8328) drives the rail top surface K2.5 probe (8327) to rotate 180° to perform flaw detection work on the other side of the target weld.

[0033] The main slider rail top side K1 detection component (833) includes a rail top side motor (8331), a rail top side connecting rod (8332), a rail top side slide rail (8333), a rail top side main compartment (8334), a rail top side slide compartment (8335), and a main slider rail top side K1 probe (8336).

[0034] The rail top side connecting rod (8332) is fixedly installed on the side of the main slider support plate (831), and the rail top side connecting rod (8332) is inclined at a certain angle to the Z-axis; the rail top side slide rail (8333) is arranged in the same direction as the rail top side connecting rod (8332) and is fixed to the rail top side connecting rod (8332); the rail top side main compartment (8334) slides along the rail top side connecting rod (8332) and inside the rail top side slide rail (8333) under the drive of the rail top side motor (8331); the rail top side slide compartment (8335) arranged along the Y direction is installed at the bottom of the rail top side main compartment (8334), and the main slider rail top side K1 probe (8336) arranged along the Y direction is installed on the end face of the rail top side slide compartment (8335).

[0035] Driven by the side motor (8331) on the rail top, the main compartment (8334) on the rail top moves along the inner wall of the side slide (8333) in the YZ direction, thereby driving the side slide (8335) on the rail top to move in the YZ direction. A compression spring is installed between the main compartment (8334) on the rail top and the side slide (8335) on the rail top, thereby ensuring that the main slider side K1 probe (8336) on the rail top is in contact with the side of the rail top and moves in the Z-axis direction, thereby realizing full-range scanning of different heights on the side of the rail top.

[0036] The main slider rail bottom slope K2.5 detection component (834) includes a rail bottom slope Y-direction drive motor (8341), a rail bottom slope Y-direction lead screw (8342), a rail bottom slope Y-direction optical axis (8343), a rail bottom slope Y-direction slider (8344), a rail bottom slope Z-direction optical axis (8345), a rail bottom slope servo base (8346), a rail bottom slope servo (8347), a bottom slope probe swing frame (8348), a bottom slope probe limiting plate (8349), and a main slider rail bottom slope K2.5 probe (83410).

[0037] The bottom of the main slider support plate (831) is parallel to the bottom of the rail bottom inclined surface Y-axis screw (8342) and the rail bottom inclined surface Y-axis optical shaft (8343); the guide hole of the rail bottom inclined surface Y-axis slider (8344) is fitted outside the rail bottom inclined surface Y-axis optical shaft (8343), and the rail bottom inclined surface Y-axis slider (8344) and the rail bottom inclined surface Y-axis screw (8342) are threadedly engaged; the rail bottom inclined surface Y-axis drive motor (8341) drives the rail bottom inclined surface Y-axis screw (8342). When rotated, the Y-axis slider (8344) on the inclined surface of the rail base slides along the Y-axis optical axis (8343) of the inclined surface of the rail base in the Y direction; the bottom of the Y-axis slider (8344) on the inclined surface of the rail base is fixedly installed with the Z-axis optical axis (8345) of the inclined surface of the rail base; the servo mount (8346) on the inclined surface of the rail base is sleeved on the outside of the Z-axis optical axis (8345) of the inclined surface of the rail base, and can move in the Z direction along the Z-axis optical axis (8345) of the inclined surface of the rail base; and the outer sleeve of the Z-axis optical axis (8345) of the inclined surface of the rail base is... A compression spring is installed, which applies downward pressure to the rail-bottom inclined surface servo mount (8346), thereby causing the main slider rail-bottom inclined surface K2.5 probe (83410) to conform to the rail-bottom inclined surface and adapt to the height difference of the rail-bottom inclined surface; the rail-bottom inclined surface servo mount (8346) is installed at the bottom of the Z-axis optical axis (8345) of the rail-bottom inclined surface, the rail-bottom inclined surface servo (8347) is assembled inside the rail-bottom inclined surface servo mount (8346), and the bottom surface of the rail-bottom inclined surface servo (8347) is mounted with... The bottom-angle probe swing frame (8348) is used to drive the bottom-angle probe swing frame (8348) to rotate around the X-axis. The bottom-angle probe swing frame (8348) houses the main slider rail bottom-angle surface K2.5 probe (83410) arranged along the Z-axis. The bottom-angle probe limiting plate (8349) is installed on the outside of the bottom-angle probe swing frame (8348). The bottom-angle probe limiting plate (8349) is used to prevent the main slider rail bottom-angle surface K2.5 probe (83410) from rotating along the Y-axis. When moving in the axial direction, the slide rail bottom inclined surface servo motor (8347) drives the main slide rail bottom inclined surface K2.5 probe (83410) to rotate around the X-axis direction through the bottom inclined probe swing frame (8348), and adjusts the deflection angle of the main slide rail bottom inclined surface K2.5 probe (83410). At the same time, when the main slide module (83) passes the target weld, the main slide rail bottom inclined surface K2.5 probe (83410) rotates 180° to achieve detection on the other side of the target weld.

[0038] The main slider rail bottom side K1 detection component (835) includes a rail bottom side slide platform (8351), a rail bottom side Z-axis drive motor (8352), a rail bottom side Z-axis lead screw (8353), a rail bottom side Z-axis optical axis (8354), a rail bottom side probe frame (8355), a Y-axis electromagnetic push-pull rod (8356), a main slider rail bottom side K1 probe (8357), and a lifting baffle (8358); the bottom of the main slider support plate (831) is fixedly installed with... The rail bottom side slide platform (8351) is described above; a rail bottom side Z-axis lead screw (8353) and a rail bottom side Z-axis optical axis (8354) are slidably installed on each side of the rail bottom side slide platform (8351) along the Z-direction; the tops of the rail bottom side Z-axis lead screw (8353) and the rail bottom side Z-axis optical axis (8354) can slide upward along the Z-direction; the bottom of the rail bottom side Z-axis lead screw (8353) is threadedly fitted with the rail bottom side probe frame (8355). Furthermore, the bottom of the rail bottom side probe frame (8355) is fixed to the bottom of the rail bottom side Z-axis optical axis (8354); when the rail bottom side Z-axis drive motor (8352) drives the rail bottom side Z-axis lead screw (8353) to rotate, it drives the rail bottom side probe frame (8355) to perform Z-axis lifting and lowering motion; the bottom of the rail bottom side probe frame (8355) is equipped with the Y-axis electromagnetic push-pull rod (8356), and the bottom of the Y-axis electromagnetic push-pull rod (8356) is... The K1 probe (8357) on the bottom side of the main slider rail is installed along the Y direction; the lifting baffles (8358) are fixedly installed on both sides of the K1 probe (8357) on the bottom side of the main slider rail, so as to drive the K2.5 probe (834) on the bottom slope of the main slider rail to be lifted synchronously when the K1 detection component (835) on the bottom side of the main slider rail is lifted to a certain height, so as to avoid collision with the weld protrusion when the main slider module (83) passes the weld.

[0039] Preferably, the secondary slider module (93) includes a secondary slider support plate (931), a secondary slider rail top surface detection component (932), a secondary slider rail top side surface K1 detection component (933), a secondary slider rail bottom inclined surface K2.5 detection component (934), and a secondary slider rail bottom side surface K1 detection component (935).

[0040] The auxiliary slider rail top surface detection component (932) is different from the main slider rail top surface detection component (832); the auxiliary slider rail top surface detection component (932) includes an auxiliary slider rail top surface probe bracket (9321) and an auxiliary slider rail top surface K0.8 probe (9322); the auxiliary slider rail top surface probe bracket (9321) is fixed to the auxiliary slider support plate (931); the auxiliary slider rail top surface K0.8 probe (9322) is fixedly installed at the end of the auxiliary slider rail top surface probe bracket (9321), so that when the fully automatic weld seam scanning frame is in working condition, the auxiliary slider rail top surface K0.8 probe (9322) is pressed tightly against the center position of the Y direction of the rail top surface;

[0041] The structures of the auxiliary slider rail top side K1 detection component (933), the auxiliary slider rail bottom inclined surface K2.5 detection component (934), and the auxiliary slider rail bottom side K1 detection component (935) are the same as those of the main slider module (83) main slider rail top side K1 detection component (833), main slider rail bottom inclined surface K2.5 detection component (834), and main slider rail bottom side K1 detection component (835);

[0042] in:

[0043] The auxiliary slider rail top side K1 detection component (933) includes the auxiliary slider rail top side K1 probe (9336).

[0044] The detection component (934) of the inclined surface K2.5 of the auxiliary slider rail includes the probe (93410) of the inclined surface K2.5 of the auxiliary slider rail.

[0045] The K1 detection component (935) on the bottom side of the auxiliary slider rail includes the K1 probe (9357) on the bottom side of the auxiliary slider rail.

[0046] The present invention also provides a weld inspection method for a fully automatic weld inspection frame, comprising the following steps:

[0047] Step 1: The fully automatic weld seam scanning frame has both a drag state and a working state;

[0048] In the drag state, first operate the track wheel mechanism (4), lift the handle (2) with one hand and press the track wheel (41) with the other hand to unfold the track wheel mechanism (4). At this time, the track wheel (41) slides in contact with the surface of the rail (10), and the support instrument scanning frame (1) is higher than the top surface of the rail (10). Then, hold the tension rod (3) and drag the fully automatic weld seam scanning frame along the rail (10). When the horizontal line emitted by the laser positioning device (6) coincides with the target weld seam, it indicates that the target position has been reached.

[0049] Then, press the folding hinge (45) to retract the track wheel mechanism (4) and lower the instrument scanning frame (1). After the instrument scanning frame (1) is lowered into place, lock the rail locking device (5). Through the joint support and positioning effect of the instrument scanning frame (1) and the rail locking device (5), the instrument scanning frame (1) is stably fixed in the target position, and the fully automatic weld seam scanning frame is put into working state.

[0050] Step 2: After the fully automatic weld seam scanning frame is put into working state, the main slider unit (8) and the auxiliary slider unit (9) are controlled to realize a comprehensive scan of the target weld seam and the rail area where it is located, and the scan results are transmitted to the acquisition box (7).

[0051] Preferably, step 2 specifically includes:

[0052] Step 2.1, the working process of the K2.5 probe (8327) on the top surface of the main slider module (83):

[0053] The scanning range and scanning method are determined as follows: taking the target weld as the reference, the scanning range is extended by a distance L1 to both ends along the X direction to form a scanning range; within the scanning range, the K2.5 probe (8327) on the top surface of the drive rail is driven to perform a set number of scans with different deflection angles. When the K2.5 probe (8327) on the top surface of the rail is performing scanning detection, the emission direction is continuously aligned with the center of the target weld; the deflection angles include 0°, a left deflection set angle, and a right deflection set angle.

[0054] The specific process of a single round-trip scan is as follows:

[0055] Start the X-direction drive mechanism (81) of the main slider, drive the main slider module (83) to move along the X direction, and move the K2.5 probe (8327) on the top surface of the rail to the initial detection position at one end of the scanning range;

[0056] The Y-axis drive motor (8321) on the top surface of the rail is started, which drives the K2.5 probe (8327) on the top surface of the rail to move along the Y-axis to the center position of the top surface of the rail along the Y-axis; and, since the K2.5 probe (8327) on the top surface of the rail is equipped with a pressure spring, the K2.5 probe (8327) on the top surface of the rail is pressed tightly against the top surface of the rail.

[0057] Start the X-direction drive mechanism (81) of the main slider, and drive the K2.5 probe (8327) on the top surface of the rail to move along the X direction, from the initial detection position at one end of the scanning range to the target weld position, and complete the forward single-pass scanning of one side of the target weld;

[0058] The drive servo motor (8328) drives the K2.5 probe on the top surface of the drive rail to rotate the K2.5 probe (8327) on the Z-axis until it forms a set angle with the center of the top surface of the drive rail; then the X-axis drive mechanism (81) of the main slider is activated to drive the K2.5 probe (8327) on the top surface of the drive rail to move along the X-axis from the target weld position to the initial detection position, thus completing the reverse one-way scan of one side of the target weld.

[0059] When the flaw detection work on one side of the target weld is completed, drive the main slider module (83) to move to the other side of the target weld, and drive the servo motor (8328) of the rail top surface K2.5 probe to adjust the rail top surface K2.5 probe (8327) to rotate. Repeat the above steps to complete the flaw detection work on the other side of the target weld.

[0060] Step 2.2, the working process of the 0-degree probe (8326) on the rail top surface:

[0061] When the 0-degree probe (8326) on the top surface of the rail is used to detect the weld, it is necessary to monitor the bottom wave and identify the reflected wave. Taking the target weld as the reference, the probe extends a distance L2 to both ends along the X direction to form a scanning range. Within the scanning range, the 0-degree probe (8326) on the top surface of the rail is moved longitudinally at a constant speed according to the set number of round trips. When the 0-degree probe (8326) on the top surface of the rail is scanned above the target weld, the probe (8326) on the top surface of the rail is moved laterally within the width of the rail head to detect horizontal cracks in the weld bead.

[0062] The specific process of a single round-trip scan is as follows:

[0063] Start the X-direction drive mechanism (81) of the main slider, drive the main slider module (83) to move along the X direction, and move the 0-degree probe (8326) on the top surface of the rail to the initial detection position at one end of the scanning range;

[0064] The Y-axis drive motor (8321) on the top surface of the rail is started, which drives the 0-degree probe (8326) on the top surface of the rail to move along the Y-axis to the detection position on the top surface of the rail along the Y-axis; and, since the 0-degree probe (8326) on the top surface of the rail is equipped with a pressure spring, the 0-degree probe (8326) on the top surface of the rail is pressed tightly against the top surface of the rail.

[0065] Start the main slider X-axis drive mechanism (81) to drive the rail top surface 0 degree probe (8326) to move along the X-axis from one end of the scanning range to the other end, and complete a single flaw detection scan; after completing the scan of one path, the rail top surface 0 degree probe (8326) moves a certain distance along the Y-axis to continue the detection of the next area of ​​the rail top surface, and so on until the entire area is scanned;

[0066] Step 2.3, the working process of the K0.8 probe (9322) on the top surface of the auxiliary slider rail and the K0.8 probe (8325) on the top surface of the main slider rail:

[0067] The detection process on one side of the target weld: On one side of the target weld, the K0.8 probe (9322) on the top surface of the auxiliary slider rail and the K0.8 probe (8325) on the top surface of the main slider rail are both located at the center position in the Y direction of the top surface of the rail, but at different positions in the X direction. Then, the K0.8 probe (9322) on the top surface of the auxiliary slider rail and the K0.8 probe (8325) on the top surface of the main slider rail are driven to move relative to each other in the X direction to realize the serial scanning of K0.8. During the movement, the K0.8 probe (8325) on the top surface of the main slider rail emits detection waves to different depth positions of the target weld along the Z direction, and the K0.8 probe (9322) on the top surface of the auxiliary slider rail receives the reflected waves, thus completing the detection of the entire depth of the target weld and completing the detection process on one side of the target weld.

[0068] After the top surface K0.8 probe (9322) of the auxiliary slider rail and the top surface K0.8 probe (8325) of the main slider rail have completed the scanning of one side of the target weld, the positions of the top surface K0.8 probe (9322) of the auxiliary slider rail and the top surface K0.8 probe (8325) of the main slider rail are reversed, and then moved along the X direction to the other side of the target weld, repeating the detection process on one side of the target weld.

[0069] Specifically: When swapping the front and rear positions, the position of the K0.8 probe (9322) on the top surface of the auxiliary slider rail remains unchanged, while the K0.8 probe (8325) on the top surface of the main slider rail moves along the X direction. When it is close to the K0.8 probe (9322) on the top surface of the auxiliary slider rail and needs to pass, the K0.8 probe (8325) on the top surface of the main slider rail moves along the Y direction to the inside of the main slider to avoid the K0.8 probe (9322) on the top surface of the auxiliary slider rail. Then, the K0.8 probe (8325) on the top surface of the main slider rail moves along the X direction to the other side of the K0.8 probe (9322) on the top surface of the auxiliary slider rail, thus completing the swapping of the front and rear positions of the main and auxiliary sliders.

[0070] Step 2.4, the working process of the K1 probe (8324) on the rail top surface:

[0071] The scanning range and scanning method are determined as follows: taking the target weld as the reference, the scanning range is extended to both ends along the X direction by a distance L3 to form a scanning range; within the scanning range, the K1 probe (8324) on the top surface of the drive rail is driven to perform a set number of scans back and forth. When the K1 probe (8324) on the top surface of the rail is performing scanning and detection, the emission direction is continuously aimed at the center of the target weld.

[0072] Start the X-axis drive mechanism (81) of the main slider, and drive the K1 probe (8324) on the top surface of the drive rail to move along the X-axis to one end of the scanning range;

[0073] Start the Y-axis drive motor (8321) on the top surface of the rail, and drive the K1 probe (8324) on the top surface of the rail to move along the Y-axis to the center position of the top surface of the rail along the Y-axis;

[0074] Start the main slider X-direction drive mechanism (81) to drive the K1 probe (8324) on the top surface of the rail to move along the X direction, from one end of the scanning range to the other end, and complete a single scan;

[0075] After completing the scan of one path, the K1 probe (8324) on the top rail surface moves a certain distance along the Y-axis and continues to detect the next area on the top rail surface. This cycle continues until the entire area is scanned.

[0076] Step 2.5, the working process of the K1 probe (8336) on the top side of the main slider rail and the K1 probe (9336) on the top side of the auxiliary slider rail:

[0077] The main slider rail top side K1 probe (8336) and the auxiliary slider rail top side K1 probe (9336) serve as the transmitting probe and the receiving probe, respectively. They are placed on both sides of the target weld rail head, with the transmitting probe and the receiving probe close to the upper height surface of the rail top side. At this upper height position, the transmitting and receiving directions of the probes are aligned with the center of the target weld. First, one probe is fixed, and then the other probe is moved along the X direction within a set range for scanning. Then, the fixed probe is moved forward a set distance, and the scanning process is repeated. This process is repeated to complete the set number of scans.

[0078] Then adjust the height of the transmitting and receiving probes on the side of the top of the rail to the height of the lower layer, and repeat the scan.

[0079] Step 2.6, the working process of the K2.5 probe (83410) on the bottom inclined surface of the main slider rail and the K2.5 probe (93410) on the bottom inclined surface of the auxiliary slider rail:

[0080] The main sliding block rail bottom slope K2.5 probe (83410) and the auxiliary sliding block rail bottom slope K2.5 probe (93410) are located on the rail bottom slopes on both sides of the rail, and each probe independently detects the rail bottom slope on the corresponding side, and the detection methods are the same.

[0081] The working process of the K2.5 probe (83410) on the inclined surface of the main slide rail is as follows:

[0082] When the K2.5 probe (83410) on the bottom slope of the main slide rail is used for detection, its emission direction is aligned with the center of the target weld. It scans multiple times from the outside to the inside starting from the edge of the bottom corner of the rail to ensure full coverage of the bottom of the rail. Each probe scan should cover a certain width of the previous scan. Then, it checks once in reverse along the edge of the bottom corner of the rail. In addition, the probe is deflected outward at a certain angle during each check.

[0083] The specific work process is as follows:

[0084] When the K2.5 probe (83410) on the bottom slope of the main slide rail moves to the set position along the X direction, the Y-direction drive motor (8341) on the bottom slope of the rail drives the K2.5 probe (83410) on the bottom slope of the main slide rail to move along the Y-axis, so that the K2.5 probe (83410) on the bottom slope of the main slide rail reaches the set position in the Y direction of the bottom slope of the rail.

[0085] Drive the K2.5 probe (83410) on the inclined surface of the main slide rail to perform a straight-line scan of the inclined surface of the rail bottom along the X direction;

[0086] When the probe needs to move at an angle for scanning, the rail bottom inclined surface servo motor (8347) causes the main slider rail bottom inclined surface K2.5 probe (83410) to rotate a certain angle along the Z axis and then scan along the X direction;

[0087] When performing a fan-shaped scanning action, the rail bottom inclined surface servo motor (8347) is activated, driving the main slider rail bottom inclined surface K2.5 probe (83410) to rotate left and right to achieve fan-shaped scanning;

[0088] When the K2.5 probe (83410) on the bottom slope of the main slide rail crosses the weld and reaches the other side, the rail bottom slope servo motor (8347) drives the K2.5 probe (83410) on the bottom slope of the main slide rail to rotate 180°, adjust the orientation of the wedge block, and perform the scanning work on the other side of the weld.

[0089] Step 2.7, the working process of the K1 probe (8357) on the bottom side of the main slider rail and the K1 probe (9357) on the bottom side of the auxiliary slider rail:

[0090] The K1 probe (8357) on the bottom side of the main slider rail and the K1 probe (9357) on the bottom side of the auxiliary slider rail are used as transmitting probes and receiving probes, respectively. They are placed on both sides of the bottom of the target weld rail, with the transmitting and receiving directions of the probes aligned with the center of the target weld and the incident point set at a distance from the center of the weld.

[0091] First, fix one probe, then move the other probe within the set range to scan; then move the fixed probe forward 15mm and repeat the scan, and so on, for a total of the set number of scans; both sides of the weld need to be scanned during the detection.

[0092] The motion trajectories of the K1 probe (8357) on the bottom side of the main slide rail and the K1 probe (9357) on the bottom side of the auxiliary slide rail are the same on the target weld side; for the K1 probe (8357) on the bottom side of the main slide rail, its motion trajectory is as follows:

[0093] The K1 probe (8357) on the bottom side of the main slider rail descends along the Z-axis to the bottom side of the rail. The Y-axis electromagnetic push-pull rod (8356) is de-energized, and the K1 probe (8357) on the bottom side of the main slider rail adheres to the bottom side of the rail under the action of the compression spring. Then, the K1 probe (8357) on the bottom side of the main slider rail is driven to move linearly along the X-axis to realize the flaw detection work of the K1 probe (8357) on the bottom side of the rail.

[0094] The fully automatic weld seam scanning frame and weld seam scanning method provided by this invention have the following advantages:

[0095] The present invention provides a fully automatic weld inspection frame and weld inspection method, which changes the traditional manual operation mode of weld flaw detection, replaces manual flaw detection, realizes the automation of flaw detection, reduces the labor intensity of flaw detection personnel, and improves the accuracy and efficiency of weld flaw detection. Attached Figure Description

[0096] Figure 1 A perspective view of the fully automatic weld seam scanning frame provided by the present invention in its working state;

[0097] Figure 2 A 3D view of the fully automatic weld seam scanning frame in drag mode;

[0098] Figure 3 A side view of the fully automatic weld seam scanning frame in drag mode;

[0099] Figure 4 This is a three-dimensional view of the track wheel mechanism 4;

[0100] Figure 5 This is a schematic diagram of the rail locking device 5 in the locked state.

[0101] Figure 6 This is a schematic diagram of the rail locking device 5 in the released state.

[0102] Figure 7 A diagram showing the positional relationship between the main slider unit 8 and the auxiliary slider unit 9 inside the instrument scanning frame 1;

[0103] Figure 8 A 3D view of the main slider module 83;

[0104] Figure 9 A three-dimensional view of the top surface detection component 832 of the main slider rail;

[0105] Figure 10 A schematic diagram showing the K1 probe 8324 moving to the center of the Y-axis on the top surface of the rail;

[0106] Figure 11 A schematic diagram showing the 0-degree probe 8326 moving to the center of the Y-axis on the top surface of the rail.

[0107] Figure 12 This is a schematic diagram showing the K0.8 probe 8325 moving to the center of the Y-axis on the top surface of the rail.

[0108] Figure 13 This is a schematic diagram showing the K2.5 probe 8327 moving to the center of the Y-axis on the top surface of the rail.

[0109] Figure 14 A three-dimensional view of the K1 detection component 833 on the top side of the main slider rail;

[0110] Figure 15 A schematic diagram of the K1 probe 8336 on the side of the main slider rail top detecting the height of the upper layer on the side of the rail top;

[0111] Figure 16 A schematic diagram of the K1 probe 8336 on the side of the main slider rail top detecting the height of the lower layer on the side of the rail top;

[0112] Figure 17 A three-dimensional view of the detection component 834 on the inclined surface K2.5 of the main slider rail bottom;

[0113] Figure 18 A three-dimensional view of the K1 detection component 835 on the side of the main slider rail bottom;

[0114] Figure 19 A schematic diagram of the detection component 834 on the inclined surface K2.5 of the main sliding rail bottom and the detection component 835 on the side surface K1 of the main sliding rail bottom at the rail detection position;

[0115] Figure 20 A 3D view of the secondary slider module 93;

[0116] Figure 21 An elevation view of the detection principle of the K2.5 probe 8327 on the top surface of the main slider module 83;

[0117] Figure 22 This is a schematic diagram of the detection principle of the 8326 0-degree probe on the top surface of the rail;

[0118] Figure 23 This is a schematic diagram of the detection principle of the K0.8 probe 9322 on the top surface of the auxiliary slider rail and the K0.8 probe 8325 on the top surface of the main slider rail on the weld side;

[0119] Figure 24The diagram shows the front-to-back positional relationship between the K0.8 probe 9322 on the top surface of the auxiliary slider rail and the K0.8 probe 8325 on the top surface of the main slider rail, when they are located on both sides of the weld.

[0120] Figure 25 Schematic diagram of the working principle of K1 probe 8324 on the top surface of the rail;

[0121] Figure 26 Top view of the main slider rail top side K1 probe 8336 and the auxiliary slider rail top side K1 probe 9336 located on the side of the target weld.

[0122] Figure 27 This is a schematic diagram of the detection principle of the K2.5 probe on the inclined plane at the bottom of the rail. Detailed Implementation

[0123] To make the technical problems solved, the technical solutions, and the beneficial effects of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the invention.

[0124] See Figure 1 The present invention provides a fully automatic weld seam scanning frame, comprising: an instrument scanning frame body 1, a handle 2, a tension rod 3, a track wheel mechanism 4, a rail locking device 5, a laser positioning device 6, a data acquisition box 7, a main slider unit 8, and a secondary slider unit 9.

[0125] The instrument scanning frame 1 is erected above the steel rail 10;

[0126] Handle 2 is fixedly installed on the top of the instrument scanning frame 1, providing a gripping position for the operator to open and close the instrument and move it up and down the track;

[0127] The tension rod 3 is hinged to the top of the instrument scanning frame 1 and is used to drag the instrument scanning frame 1 to move longitudinally along the rail 10. Specifically, this device is used to provide a grip for the hand when moving the instrument on the rail. The tension rod 3 is made of aviation trolley case rod, which can be adjusted in three sections. The indexing hinge can position the rod at multiple angles, providing a suitable grip angle and position for operators of different heights.

[0128] The track wheel mechanism 4 is symmetrically hinged and installed at the front and rear of the instrument scanning frame 1, and has two states: unfolded and retracted. In the unfolded state, it supports the instrument scanning frame 1 above the rail 10 and provides a guiding movement function for longitudinal movement along the rail 10. In the retracted state, it causes the instrument scanning frame 1 to fall and clamp on the left and right sides of the rail 10.

[0129] The rail locking device 5 is used to achieve stable clamping and fixing between the instrument scanning frame 1 and the rail 10 when the instrument scanning frame 1 moves to the target weld scanning area.

[0130] The laser positioning device 6 is fixedly installed at the top center of the instrument scanning frame 1. It is used to emit a horizontal laser line when the instrument is activated, so that the horizontal laser line is aligned with the center face of the target weld, thereby achieving the positioning of the instrument scanning frame 1 in the longitudinal direction of the rail 10.

[0131] The data acquisition box 7 is fixedly installed on the top of the instrument scanning frame 1 and is used to connect with the main slider unit 8 and the auxiliary slider unit 9 to acquire and store the detection results of the target weld.

[0132] The main slider unit 8 and the auxiliary slider unit 9 are both located inside the instrument scanning frame 1 and are used to detect the target weld.

[0133] This invention provides a fully automatic weld seam scanning frame, including a drag state and a working state; such as Figure 1 The image shown is a 3D view of the fully automatic weld seam scanning frame in operation; as shown... Figure 2 The image shown is a 3D view of the fully automatic weld seam scanning frame in drag mode; as shown... Figure 3 The image shown is a side view of the fully automatic weld seam scanning frame in drag mode.

[0134] The following is a detailed introduction to each major component:

[0135] (a) Instrument scanning frame 1

[0136] The instrument scanning frame 1 includes an instrument guard plate 11 and a main support plate 12 fixed to both ends of the instrument guard plate 11. Scales 13 are set longitudinally on the left and right sides of the instrument guard plate 11 to assist in adjusting the longitudinal position of the instrument scanning frame 1 on the rail 10. An alignment baseline 14 is set at the top center of the instrument guard plate 11 to align with the center face of the target weld, thereby achieving the longitudinal positioning of the instrument scanning frame 1 on the rail 10.

[0137] Specifically, the instrument guard plate 11 provides overall support and waterproofing for the instrument, and has five observation windows. These windows are fitted with highly transparent PC panels, which are resistant to aging and offer excellent performance for outdoor use. The scale 13 is used to assist in adjusting the instrument's longitudinal position on the rail. The alignment baseline serves the same purpose as the laser positioning device 6, facilitating overhead alignment of the instrument.

[0138] (ii) Rail-mounted wheel mechanism 4:

[0139] Due to the high degree of automation and large overall size of the instrument, it is not suitable for long-distance manual transport. The track wheel mechanism 4 can provide the instrument with the function of being dragged on the rail.

[0140] The track-mounted wheel mechanism 4 includes a track-mounted wheel 41, a left wheel leg 42, a right wheel leg 43, a free hinge 44, and a folding hinge 45; as shown Figure 4 The figure shown is a three-dimensional view of the track wheel mechanism 4.

[0141] The shape of the track wheel 41 matches the top shape of the rail 10 and is used to slide longitudinally along the top of the rail 10; the left side of the track wheel 41 is hinged to one end of the left wheel leg 42, the other end of the left wheel leg 42 is fixed to the bottom of the free hinge 44, and the side of the free hinge 44 is fixed to the main support plate 12; the right side of the track wheel 41 is hinged to one end of the right wheel leg 43, the other end of the right wheel leg 43 is fixed to the bottom of the folding hinge 45, and the side of the folding hinge 45 is fixed to the main support plate 12.

[0142] The bottom of the free hinge 44 can be folded or unfolded freely relative to the side of the free hinge 44; the bottom of the folding hinge 45 can be folded or unfolded under the action of external force relative to the side of the folding hinge 45.

[0143] (iii) Rail locking device 5:

[0144] When the instrument is inspecting welds at various locations, it needs to have a relatively stable and consistent fixed position. The rail locking device 5 provides positioning for the instrument in the lateral direction and locks the entire instrument at the same time, ensuring that the probe is in contact with the rail when the instrument is in operation, and ensuring that the instrument will not move with the rail, and will not cause problems such as tipping over or derailment.

[0145] like Figure 5 The diagram shown is a schematic of the rail locking device 5 in the locked state; as shown... Figure 6 The diagram shown is a schematic of the rail locking device 5 in the released state; the rail locking device 5 includes a top positioning block 51, a main side clamping block 52, a main side limiting rod 53, a main side spring 54, a secondary side clamping block 55, a secondary side limiting rod 56, a secondary side spring 57, and a quick clamp 58.

[0146] The top positioning block 51 is fixedly installed on the side of the main support plate 12, and the bottom shape of the top positioning block 51 matches the top shape of the rail 10. On the left and right sides of the top positioning block 51, a secondary side limiting rod 56 and a main side limiting rod 53 are fixedly installed along the width direction of the rail 10. A secondary side clamping block 55 is installed on the outer surface of the secondary side limiting rod 56, and a secondary side spring 57 is installed on the inner side of the secondary side clamping block 55. A main side clamping block 52 is installed on the outer surface of the main side limiting rod 53, and a main side spring 54 is installed on the inner side of the main side clamping block 52. A quick clamp 58 is installed on the top of the main side clamping block 52.

[0147] When the instrument scanning frame 1 is in a dragging state, under the elastic force of the secondary side spring 57 and the main side spring 54, the secondary side clamping block 55 slides to the outermost side along the secondary side limiting rod 56, and the main side clamping block 52 slides to the outermost side along the main side limiting rod 53.

[0148] When the instrument scanning frame 1 is lowered and in working condition, the secondary side clamping block 55 and the primary side clamping block 52 move to the innermost side and are fixed to the top positioning block 51 by the quick clamp 58. At this time, the bottom of the top positioning block 51 is in contact with the top of the rail 10; the secondary side clamping block 55 and the primary side clamping block 52 are respectively clamped on the left and right sides of the bottom of the rail top of the rail 10; at this time, the left and right sides of the instrument scanning frame 1 are clamped on the left and right sides of the bottom of the rail 10, thus realizing the multi-point positioning and fixing between the instrument scanning frame 1 and the rail 10. Specifically, the top positioning block 51, the primary side clamping block 52, the secondary side clamping block 55, and the reinforcing feet on the left and right sides of the instrument scanning frame 1 form a positioning support of 5 points. Among them, the rail jaw and the rail bottom are positions that are not prone to wear and deformation, thus providing a relatively stable positioning reference for the instrument.

[0149] (iv) Main slider unit 8 and secondary slider unit 9

[0150] All probes of the automated weld seam scanning rack are deployed on the main slider unit 8 and the auxiliary slider unit 9. These two slider units are driven by two 57 stepper motors respectively. Under the guidance of the optical axis and the traction of the synchronous belt, they can move along the rail in the X direction to achieve the scanning effect of the probe.

[0151] like Figure 7 The diagram shows the positional relationship between the main slider unit 8 and the auxiliary slider unit 9 inside the instrument scanning frame 1. Inside the instrument scanning frame 1, on the left and right sides of the rail 10, the main slider unit 8 and the auxiliary slider unit 9 are installed respectively. The longitudinal direction of the rail 10 is the X direction, the width direction of the rail 10 (i.e., the transverse direction) is the Y direction, and the height direction of the rail 10 is the Z direction.

[0152] The main slider unit 8 includes a main slider X-axis drive mechanism 81, a main slider X-axis optical axis 82, and a main slider module 83; the auxiliary slider unit 9 includes an auxiliary slider X-axis drive mechanism 91, an auxiliary slider X-axis optical axis 92, and an auxiliary slider module 93.

[0153] Inside the instrument scanning frame 1, the main slider X-axis 82 and the auxiliary slider X-axis 92 are fixedly installed on the left and right sides respectively; the main slider module 83 is slidably connected to the main slider X-axis 82, and under the drive of the main slider X-axis drive mechanism 81, the main slider module 83 moves along the main slider X-axis 82 in the X direction.

[0154] The secondary slider module 93 is slidably connected to the X-axis optical axis 92 of the secondary slider. Under the drive of the X-axis driving mechanism 91 of the secondary slider, the secondary slider module 93 moves in the X direction along the X-axis optical axis 92 of the secondary slider.

[0155] Both the main slider X-axis drive mechanism 81 and the auxiliary slider X-axis drive mechanism 91 are stepper motors, each connected to a synchronous belt A1. The main slider module 83 and the auxiliary slider module 93 are fixed to their respective fixed points on the synchronous belt A1 via synchronous belt clamping blocks A2. Therefore, when the stepper motor starts, the synchronous belt pulls the slider to the position that the probe needs to detect.

[0156] (4.1) Main slider module 83

[0157] like Figure 8 The figure shown is a perspective view of the main slider module 83; the main slider module 83 includes a main slider support plate 831, a main slider rail top surface detection component 832, a main slider rail top side surface K1 detection component 833, a main slider rail bottom inclined surface K2.5 detection component 834, and a main slider rail bottom side surface K1 detection component 835.

[0158] (4.1.1) Main slider rail top surface detection component 832

[0159] like Figure 9 The image shown is a perspective view of the main slider rail top surface detection component 832. The main slider rail top surface detection component 832 includes a rail top surface Y-axis drive motor 8321, a rail top surface Y-axis optical axis 8322, a rail top surface probe slider seat 8323, a rail top surface K1 probe 8324, a rail top surface K0.8 probe 8325, a rail top surface 0 degree probe 8326, a rail top surface K2.5 probe 8327, and a rail top surface K2.5 probe drive servo motor 8328.

[0160] The main slider support plate 831 serves to provide support and installation connection for the entire slider component. The upper part of the main slider support plate 831 is fixedly mounted with the Y-axis optical axis 8322 of the rail top surface; the rail top surface probe slider seat 8323 is sleeved on the outside of the rail top surface Y-axis optical axis 8322 and slides along the rail top surface Y-axis optical axis 8322 under the drive of the rail top surface Y-axis drive motor 8321.

[0161] The bottom of the rail top surface probe slider seat 8323 is fixedly equipped with the rail top surface K1 probe 8324, the rail top surface K0.8 probe 8325, and the rail top surface 0 degree probe 8326, and these probes are arranged sequentially along the Y direction. Driven by the rail top surface Y-direction drive motor 8321, the rail top surface K1 probe 8324, the rail top surface 0 degree probe 8326, and the rail top surface K0.8 probe 8325 are moved sequentially to the center position of the rail top surface in the Y direction to perform target weld flaw detection.Figure 10 The diagram shown illustrates the movement of probe K1 8324 on the rail top surface to the center of the rail top surface in the Y direction. Figure 11 The diagram shown illustrates the movement of the 0-degree probe 8326 on the rail top surface to the center of the rail top surface in the Y direction. Figure 12 The diagram shown is a schematic of the K0.8 probe 8325 moving to the center of the Y direction on the top surface of the rail.

[0162] A rail top surface K2.5 probe drive servo motor 8328 is installed at the bottom of the rail top surface probe slider seat 8323, and a rail top surface K2.5 probe 8327 is installed at the bottom of the rail top surface K2.5 probe drive servo motor 8328. Driven by the rail top surface K2.5 probe drive servo motor 8328, the rail top surface K2.5 probe 8327 rotates at a certain angle to achieve flaw detection at different positions on the rail top surface. Simultaneously, after the main slider module 83 crosses the target weld, the rail top surface K2.5 probe drive servo motor 8328 drives the rail top surface K2.5 probe 8327 to rotate 180° to perform flaw detection on the other side of the target weld. Figure 13 The diagram shown is a schematic of the K2.5 probe 8327 moving to the center of the Y direction on the top surface of the rail.

[0163] Therefore, the main slider rail top surface detection component 832 integrates the rail top surface K1 probe 8324, rail top surface K0.8 probe 8325, rail top surface 0 degree probe 8326, and rail top surface K2.5 probe 8327. The entire component is driven by the rail top surface Y-axis drive motor 8321 to move along the Y-axis, thereby adjusting the position of each probe on the rail top surface in the Y-axis direction. Simultaneously, the rail top surface K2.5 probe 8327 also has the function of adjusting the deflection angle via a servo motor 8328 driven by the rail top surface K2.5 probe. The servo motor can rotate the rail top surface K2.5 probe 8327 by a certain angle to achieve flaw detection at certain locations on the rail. Furthermore, after the main slider of the instrument crosses the weld, the servo motor can drive the rail top surface K2.5 probe 8327 to rotate 180°, allowing it to perform flaw detection work on the other side of the weld.

[0164] (4.1.2) Main slider rail top side K1 detection component 833

[0165] like Figure 14 The figure shown is a perspective view of the K1 detection component 833 on the top side of the main slider rail; the K1 detection component 833 on the top side of the main slider rail includes a rail top side motor 8331, a rail top side connecting rod 8332, a rail top side slide rail 8333, a rail top side main compartment 8334, a rail top side slide compartment 8335, and a K1 probe 8336 on the top side of the main slider rail.

[0166] A rail top side connecting rod 8332 is fixedly installed on the side of the main slider support plate 831. The rail top side connecting rod 8332 is inclined at a certain angle to the Z-axis. The rail top side slide rail 8333 is arranged in the same direction as the rail top side connecting rod 8332 and is fixed to the rail top side connecting rod 8332. The rail top side main compartment 8334 slides along the rail top side connecting rod 8332 and inside the rail top side slide rail 8333 under the drive of the rail top side motor 8331. The bottom of the rail top side main compartment 8334 is equipped with a rail top side slide compartment 8335 arranged along the Y direction. The end face of the rail top side slide compartment 8335 is equipped with a main slider rail top side K1 probe 8336 arranged along the Y direction.

[0167] Driven by the side motor 8331 on the rail top, the main compartment 8334 on the rail top moves along the inner wall of the side slide rail 8333 in the YZ direction, thereby driving the side slide rail 8335 to move in the YZ direction. A compression spring is installed between the main compartment 8334 and the side slide rail 8335, ensuring that the main slide rail top K1 probe 8336 is in contact with the side rail top and moves in the Z-axis direction, thus achieving full-range scanning of different heights on the side rail top; achieving full-range scanning of the side rail top. Figure 15 The diagram shows the height detection of the upper layer on the side of the main slider rail top by probe K1 8336; as shown. Figure 16 The diagram shown is a schematic of the K1 probe 8336 on the side of the main slider rail top detecting the height of the lower layer on the side of the rail top.

[0168] (4.1.3) Main slider rail bottom inclined surface K2.5 detection component 834

[0169] like Figure 17 The image shown is a perspective view of the main slider rail bottom slope K2.5 detection component 834. The main slider rail bottom slope K2.5 detection component 834 includes a rail bottom slope Y-direction drive motor 8341, a rail bottom slope Y-direction lead screw 8342, a rail bottom slope Y-direction optical axis 8343, a rail bottom slope Y-direction slider 8344, a rail bottom slope Z-direction optical axis 8345, a rail bottom slope servo base 8346, a rail bottom slope servo 8347, a bottom slope probe swing frame 8348, a bottom slope probe limiting plate 8349, and a main slider rail bottom slope K2.5 probe 83410.

[0170] The bottom of the main slider support plate 831 is parallel to the Y-axis lead screw 8342 and the Y-axis optical shaft 8343 of the rail bottom inclined surface; the guide hole of the Y-axis slider 8344 of the rail bottom inclined surface is fitted outside the Y-axis optical shaft 8343 of the rail bottom inclined surface, and the Y-axis slider 8344 and the Y-axis lead screw 8342 of the rail bottom inclined surface are threadedly engaged; when the Y-axis drive motor 8341 of the rail bottom inclined surface drives the Y-axis lead screw 8342 of the rail bottom inclined surface to rotate... The Y-axis slider 8344 on the inclined surface of the rail base slides along the Y-axis optical axis 8343 of the inclined surface of the rail base in the Y direction; the bottom of the Y-axis slider 8344 is fixedly installed with the Z-axis optical axis 8345 of the inclined surface of the rail base; the servo mount 8346 on the inclined surface of the rail base is sleeved on the outside of the Z-axis optical axis 8345 of the inclined surface of the rail base, and can move along the Z-axis optical axis 8345 of the inclined surface of the rail base; and the Z-axis optical axis 8345 of the inclined surface of the rail base is sleeved on the outside of the servo mount. A compression spring applies downward pressure to the rail bottom inclined surface servo mount 8346, thereby causing the main slider rail bottom inclined surface K2.5 probe 83410 to conform to the rail bottom inclined surface, adapting to the height difference of the rail bottom inclined surface. The rail bottom inclined surface servo mount 8346 is installed at the bottom of the Z-axis optical axis 8345 of the rail bottom inclined surface. A rail bottom inclined surface servo 8347 is installed inside the rail bottom inclined surface servo mount 8346. A bottom inclined probe swing frame 8348 is installed on the bottom surface of the rail bottom inclined surface servo 8347 to drive the bottom inclined probe swing frame 8348 to rotate around the X-axis. The main slider rail bottom inclined surface K2.5 probe 83410, which is set along the Z-axis, is installed inside the bottom inclined probe swing frame 8348. A bottom inclined probe limiting plate 8349 is installed outside the bottom inclined probe swing frame 8348. The bottom inclined probe limiting plate 8349 is used to prevent the main slider rail bottom inclined surface K2.5 probe 83410 from rotating along the Y-axis. When moving in the axial direction, it flips over; when the rail bottom inclined surface servo motor 8347 drives the main slider rail bottom inclined surface K2.5 probe 83410 to rotate around the X-axis direction through the bottom inclined probe swing frame 8348, it adjusts the deflection angle of the main slider rail bottom inclined surface K2.5 probe 83410. At the same time, when the main slider module 83 passes the target weld, it realizes the 180° rotation of the main slider rail bottom inclined surface K2.5 probe 83410, so as to achieve detection on the other side of the target weld.

[0171] Therefore, the functions of each component of the detection unit 834 on the inclined surface K2.5 of the main slider rail are as follows:

[0172] The Y-axis drive motor 8341 on the inclined surface of the rail bottom is used to adjust the Y-axis position of the probe 83410 on the K2.5 probe of the inclined surface of the main slider rail bottom.

[0173] The Z-axis optical axis 8345 on the inclined surface of the rail base serves as a guide for lifting the servo mount 8346 on the inclined surface of the rail base. The compression spring installed on it continuously provides pressure to the servo mount 8346 on the inclined surface of the rail base, ensuring the coupling of the probe and adapting to the height difference of the inclined surface of the rail base.

[0174] The rail-bottom inclined plane servo motor 8347 rotates to adjust the deflection angle of the K2.5 probe 83410 on the main slider rail-bottom inclined plane. Simultaneously, after the instrument slider passes the weld, it can achieve a 180° rotation of the probe to achieve detection on the other side of the weld.

[0175] The bottom-angle probe swing frame 8348 enables the probe to rotate along the X-axis and conform to the bottom slope of the rail under pressure.

[0176] The bottom-angle probe limiting plate 8349 prevents the probe from flipping over when moving along the Y-axis.

[0177] (4.1.4) Main slider rail bottom side K1 detection component 835

[0178] The design of this component is primarily aimed at enabling the K1 probe on the side of the rail to avoid sleeper fixing bolts or other obstacles. The electromagnetic push-pull rod provides the force for the probe to retract and extend.

[0179] like Figure 18 The image shown is a perspective view of the K1 detection component 835 on the bottom side of the main slider rail. The K1 detection component 835 includes a rail bottom side slide platform 8351, a rail bottom side Z-axis drive motor 8352, a rail bottom side Z-axis lead screw 8353, a rail bottom side Z-axis optical axis 8354, a rail bottom side probe frame 8355, a Y-axis electromagnetic push-pull rod 8356, a main slider rail bottom side K1 probe 8357, and a lifting baffle 8358. The rail bottom side slide platform 8351 is fixedly mounted on the bottom of the main slider support plate 831. The rail bottom side Z-axis lead screw 8353 and the rail bottom side Z-axis optical axis 8354 are slidably mounted on both sides of the rail bottom side slide platform 8351 along the Z-axis. The tops of the rail bottom side Z-axis lead screw 8353 and the rail bottom side Z-axis optical axis 8354 can slide upwards along the Z-axis. The bottom of the rail bottom side Z-axis lead screw 8353 is threaded. The rail bottom side probe frame 8355 is installed, and the rail bottom side probe frame 8355 is fixed to the bottom of the rail bottom side Z-axis optical axis 8354. When the rail bottom side Z-axis drive motor 8352 drives the rail bottom side Z-axis lead screw 8353 to rotate, it drives the rail bottom side probe frame 8355 to perform Z-axis lifting and lowering movement. A Y-axis electromagnetic push-pull rod 8356 is installed at the bottom of the rail bottom side probe frame 8355, and the main slider rail bottom side K1 probe 8357 is installed along the Y-axis at the bottom of the Y-axis electromagnetic push-pull rod 8356. Lifting baffles 8358 are fixedly installed on both sides of the main slider rail bottom side K1 probe 8357. When the main slider rail bottom side K1 probe 8357 is lifted upward to a certain height, it drives the main slider rail bottom inclined surface K2.5 probe 834 to lift upward synchronously. This is to prevent collision with the weld protrusion when the main slider module 83 crosses the weld. Figure 19The diagram shows the detection components 834 on the inclined surface K2.5 of the main sliding rail bottom and K1 on the side surface of the main sliding rail bottom at the rail detection position.

[0180] One of its working methods is as follows:

[0181] Under normal conditions, the K1 probe 8357 on the bottom side of the main slider rail is located on the bottom side of the rail and is pressed against the bottom side of the rail by the pressure provided by the Y-axis electromagnetic push-pull rod 8356.

[0182] When avoiding obstacles, the Z-axis drive motor 8352 on the side of the rail base starts, and the K1 probe 8357 on the side of the main slider rail base rises.

[0183] When the K1 probe 8357 on the bottom side of the main slide rail drops down again, the Y-axis electromagnetic push-pull rod 8356 is activated, and the K1 probe 8357 on the bottom side of the main slide rail retracts to avoid collision with the rail.

[0184] When the K1 probe 8357 on the bottom side of the main slider rail reaches the position, the Y-axis electromagnetic push-pull rod 8356 closes, and the K1 probe 8357 on the bottom side of the main slider rail is pressed against the bottom side of the rail.

[0185] (4.2) Sub-slider module 93

[0186] like Figure 20 The figure shown is a perspective view of the secondary slider module 93; the secondary slider module 93 includes a secondary slider support plate 931, a secondary slider rail top surface detection component 932, a secondary slider rail top side surface K1 detection component 933, a secondary slider rail bottom inclined surface K2.5 detection component 934, and a secondary slider rail bottom side surface K1 detection component 935;

[0187] (4.2.1) Detection component 932 on the top surface of the auxiliary slider rail

[0188] The auxiliary slider rail top surface detection component 932 is different from the main slider rail top surface detection component 832. The auxiliary slider rail top surface detection component 932 includes an auxiliary slider rail top surface probe bracket 9321 and an auxiliary slider rail top surface K0.8 probe 9322. The auxiliary slider rail top surface probe bracket 9321 is fixed to the auxiliary slider support plate 931. The auxiliary slider rail top surface K0.8 probe 9322 is fixedly installed at the end of the auxiliary slider rail top surface probe bracket 9321, so that when the fully automatic weld seam scanning frame is in working condition, the auxiliary slider rail top surface K0.8 probe 9322 is pressed tightly against the center position of the rail top surface in the Y direction. Therefore, the auxiliary slider rail top surface K0.8 probe 9322 does not have a Y direction adjustment function.

[0189] (4.2.2) K1 detection component 933 on the top side of the auxiliary slider rail, K2.5 detection component 934 on the bottom inclined surface of the auxiliary slider rail, and K1 detection component 935 on the bottom side of the auxiliary slider rail.

[0190] The structures of the auxiliary slider rail top side K1 detection component 933, the auxiliary slider rail bottom inclined surface K2.5 detection component 934, and the auxiliary slider rail bottom side K1 detection component 935 are the same as those of the main slider module 83;

[0191] in:

[0192] The K1 detection component 933 on the top side of the auxiliary slider rail includes the K1 probe 9336 on the top side of the auxiliary slider rail;

[0193] The detection component 934 for the inclined surface K2.5 of the auxiliary slider rail includes the probe 93410 for the inclined surface K2.5 of the auxiliary slider rail.

[0194] The K1 detection component 935 on the bottom side of the auxiliary slider rail includes the K1 probe 9357 on the bottom side of the auxiliary slider rail.

[0195] To ensure proper contact between the probe and the rail, in this invention, all probes of the main and auxiliary sliders are equipped with compression springs, and the pressure can be adjusted according to the wire diameter of the compression springs.

[0196] This invention also provides a weld inspection method for a fully automatic weld inspection frame, comprising the following steps:

[0197] Step 1: The fully automatic weld seam scanning frame has both a drag state and a working state;

[0198] In drag mode, first manipulate the track wheel mechanism 4, lift the handle 2 with one hand and press the track wheel 41 with the other hand to unfold the track wheel mechanism 4. At this time, the track wheel 41 slides in contact with the surface of the rail 10, and the support instrument scanning frame 1 is higher than the top surface of the rail 10; Figure 2 and Figure 3 The diagram shows the dragging state. Then, hold the tension rod 3 and drag the fully automatic weld seam scanning frame along the rail 10. When the horizontal line emitted by the laser positioning device 6 coincides with the target weld seam, it indicates that the target position has been reached.

[0199] Then, press the folding hinge 45 to retract the track wheel mechanism 4, causing the instrument scanning frame 1 to fall. After the instrument scanning frame 1 falls into place, lock the rail locking device 5. Through the joint support and positioning effect of the instrument scanning frame 1 and the rail locking device 5, the instrument scanning frame 1 is stably fixed in the target position, and the fully automatic weld seam scanning frame is put into working state; Figure 5The diagram shown is a reference diagram for the joint support and positioning of the instrument scanning frame 1 and the rail locking device 5.

[0200] Step 2: After the fully automatic weld seam scanning frame is put into working state, the main slider unit 8 and the auxiliary slider unit 9 are controlled to realize a comprehensive scan of the target weld seam and the rail area where it is located, and the scan results are transmitted to the acquisition box 7.

[0201] Step 2 is as follows:

[0202] Step 2.1, the working process of the K2.5 probe 8327 on the top surface of the main slider module 83:

[0203] The scanning range and scanning method are determined as follows: taking the target weld as the reference, the scanning range is extended by a distance L1 to both ends along the X direction to form a scanning range; within the scanning range, the K2.5 probe 8327 on the top surface of the drive rail is driven to perform a set number of scans with different deflection angles. When the K2.5 probe 8327 on the top surface of the rail is performing scanning and detection, the emission direction is continuously aligned with the center of the target weld; the deflection angles include 0°, a set left deflection angle, and a set right deflection angle, such as 0°, 20° left deflection, and 20° right deflection.

[0204] like Figure 21 The diagram shows an elevation view of the detection principle of the K2.5 probe 8327 on the rail top surface of the main slider module 83. It is a dual-crystal K2.5 (70°) channel probe on the rail top surface. One example of its operation is as follows: The probe is placed at the center of the weld rail head, with the emission direction aligned with the weld center. It is then subjected to four reciprocating scans at internal and external deflection angles of 12°–14° (75 kg / m) or 18°–20° (60 kg / m), and two straight reciprocating scans. The scanning range is at least 200 mm from the weld center outwards to both ends, and the weld rail head is scanned at least six times. The scanning speed is no greater than 100 mm / s, and the scanning time is no less than 1 minute.

[0205] The specific process of a single round-trip scan is as follows:

[0206] Start the main slider X-direction drive mechanism 81, drive the main slider module 83 to move along the X direction, and move the K2.5 probe 8327 on the top surface of the rail to the initial detection position at one end of the scanning range;

[0207] The Y-axis drive motor 8321 on the top surface of the starter rail drives the K2.5 probe 8327 on the top surface of the rail to move along the Y-axis to the center position of the top surface of the rail along the Y-axis; and, since the K2.5 probe 8327 on the top surface of the rail is equipped with a pressure spring, the K2.5 probe 8327 on the top surface of the rail keeps in close contact with the top surface of the rail in real time when it moves up and down in the Z-axis direction.

[0208] Start the main slider X-axis drive mechanism 81, which drives the K2.5 probe 8327 on the top surface of the rail to move along the X-axis from the initial detection position at one end of the scanning range to the target weld position, completing the forward single-pass scanning of one side of the target weld.

[0209] The drive servo motor 8328 drives the K2.5 probe on the top surface of the drive rail to rotate the K2.5 probe 8327 on the Z-axis until it forms a set angle with the center of the top surface of the drive rail; then the X-axis drive mechanism 81 of the main slider is activated to drive the K2.5 probe 8327 on the top surface of the drive rail to move along the X-axis from the target weld position to the initial detection position, completing the reverse one-way scan on one side of the target weld.

[0210] Once the flaw detection work on one side of the target weld is completed, drive the main slider module 83 to move to the other side of the target weld. The K2.5 probe on the rail top surface drives the servo motor 8328 to adjust the K2.5 probe 8327 on the rail top surface to rotate. Repeat the above steps to complete the flaw detection work on the other side of the target weld.

[0211] Step 2.2, the working process of the 0-degree probe 8326 on the rail top surface:

[0212] Acoustic transmission test of aluminothermic weld: Place the 0° probe above the aluminothermic weld to be inspected. If the coupling is good, the sensitivity is increased by 16dB based on the average acoustic transmission dB value, and the bottom echo is not less than 80% of the full amplitude, then the acoustic transmission test of the aluminothermic weld is considered qualified.

[0213] When the 0-degree probe 8326 on the top of the rail detects the weld, it must monitor the bottom wave and identify the reflected wave. Taking the target weld as the reference, it extends a distance L2 to both ends along the X direction to form a scanning range. Within the scanning range, the 0-degree probe 8326 on the top of the rail moves longitudinally at a constant speed according to the set number of round trips. When the 0-degree probe 8326 on the top of the rail reaches above the target weld, it moves laterally within the width of the rail head to detect horizontal cracks in the weld bead.

[0214] like Figure 22 The diagram shown is a schematic of the detection principle of the 8326 0-degree probe on the top surface of the rail.

[0215] As an example, when using a 0° probe to inspect welds, in addition to monitoring the bottom wave, it is also necessary to identify the reflected wave. The probe should be placed at the center of the rail surface, and the probe should be moved longitudinally at a uniform speed for scanning. The probe should be scanned back and forth once along the longitudinal direction of the rail, and the scanning range should be at least 110mm from the center of the weld to both ends. The scanning speed should not exceed 100mm / s, and the scanning time should not be less than 0.5 minutes. When the probe reaches above the weld, the 0° probe should be moved laterally (Y-axis) within the width of the rail head, which is beneficial for detecting horizontal cracks in the weld bead.

[0216] The specific process of a single round-trip scan is as follows:

[0217] Start the main slider X-direction drive mechanism 81 to drive the main slider module 83 to move along the X direction and move the 0-degree probe 8326 on the top surface of the rail to the initial detection position at one end of the scanning range;

[0218] The Y-axis drive motor 8321 on the top surface of the rail is started, which drives the 0-degree probe 8326 on the top surface of the rail to move along the Y-axis to the detection position on the top surface of the rail; and, since the 0-degree probe 8326 on the top surface of the rail is equipped with a pressure spring, the 0-degree probe 8326 on the top surface of the rail is pressed tightly against the top surface of the rail.

[0219] The main slider X-axis drive mechanism 81 is activated, which drives the rail top surface 0-degree probe 8326 to move along the X-axis from one end of the scanning range to the other end, completing a single flaw detection scan. After completing the scan of one path, the rail top surface 0-degree probe 8326 moves a certain distance along the Y-axis to continue the detection of the next area of ​​the rail top surface. This cycle continues until the entire area is scanned.

[0220] Step 2.3, the working process of the K0.8 probe 9322 on the top surface of the auxiliary slider rail and the K0.8 probe 8325 on the top surface of the main slider rail:

[0221] like Figure 23 The diagram shows the detection principle of the K0.8 probe 9322 on the top surface of the auxiliary slider rail and the K0.8 probe 8325 on the top surface of the main slider rail on one side of the weld. One operating method is as follows: the scanning frame is placed at the center of the rail head tread surface of the weld (parallel to the side of the rail head), and moves at a constant speed, performing one forward and one backward inspection, ensuring the probe moves at a constant speed, and scanning the weld at least three times. The scanning speed is no greater than 100 mm / s, and the scanning time is no less than 1 minute. Each of the main and auxiliary sliders carries a set of K0.8 probes, and the main and auxiliary sliders move relative to each other along the X-axis of the rail to achieve acoustic flaw detection.

[0222] The specific work process is as follows:

[0223] The detection process on one side of the target weld:

[0224] On one side of the target weld, the K0.8 probe 9322 on the top surface of the auxiliary slider rail and the K0.8 probe 8325 on the top surface of the main slider rail are both located at the center position in the Y direction of the top surface of the rail, but at different positions in the X direction. Then, the K0.8 probe 9322 on the top surface of the auxiliary slider rail and the K0.8 probe 8325 on the top surface of the main slider rail are driven to move relative to each other in the X direction to achieve tandem scanning of K0.8. During the movement, the K0.8 probe 8325 on the top surface of the main slider rail emits detection waves to different depth positions of the target weld along the Z direction, and the K0.8 probe 9322 on the top surface of the auxiliary slider rail receives the reflected waves, completing the detection of the entire depth of the target weld and completing the detection process on one side of the target weld.

[0225] After the top surface K0.8 probe 9322 of the auxiliary slider rail and the top surface K0.8 probe 8325 of the main slider rail have completed the scanning of one side of the target weld, the positions of the top surface K0.8 probe 9322 of the auxiliary slider rail and the top surface K0.8 probe 8325 of the main slider rail are reversed, and then moved along the X direction to the other side of the target weld, repeating the detection process on one side of the target weld.

[0226] Specifically: When swapping the front and rear positions, the position of the K0.8 probe 9322 on the top surface of the auxiliary slider rail remains unchanged, while the K0.8 probe 8325 on the top surface of the main slider rail moves along the X direction. When it approaches the K0.8 probe 9322 on the top surface of the auxiliary slider rail and needs to pass, the K0.8 probe 8325 on the top surface of the main slider rail moves along the Y direction to the inside of the main slider, avoiding the K0.8 probe 9322 on the top surface of the auxiliary slider rail. Then, the K0.8 probe 8325 on the top surface of the main slider rail moves along the X direction to the other side of the K0.8 probe 9322 on the top surface of the auxiliary slider rail, completing the front and rear position swap of the main and auxiliary sliders. Figure 24 The figure shows the front-to-back positional relationship between the K0.8 probe 9322 on the top surface of the auxiliary slider rail and the K0.8 probe 8325 on the top surface of the main slider rail when they are located on both sides of the weld.

[0227] Step 2.4, the working process of probe 8324 K1 on the rail top surface:

[0228] like Figure 25 The diagram shown illustrates the working principle of the K1 probe 8324 on the rail top surface. The scanning range and method are determined as follows: using the target weld as a reference, the probe extends a distance L3 along the X direction to both ends, forming the scanning range. Within the scanning range, the K1 probe 8324 on the rail top surface is driven to perform a set number of reciprocating scans. While the K1 probe 8324 is scanning, the emission direction remains continuously aligned with the center of the target weld.

[0229] One working method is as follows: Place the probe at the center of the welded rail head, align the emission direction with the center of the weld, and scan back and forth parallel to the longitudinal direction of the rail, for a total of no less than 2 scans of the welded rail head. The scanning range should be no less than 200mm from the center of the weld to both ends. The scanning speed should not exceed 100mm / s, and the scanning time should not be less than 0.5 minutes.

[0230] Its specific working process is as follows:

[0231] Start the X-axis drive mechanism 81 of the main slider, and drive the probe 8324 on the top surface of the drive rail K1 to move along the X-axis to one end of the scanning range;

[0232] Start the Y-axis drive motor 8321 on the top surface of the starter rail, which drives the K1 probe 8324 on the top surface of the starter rail to move along the Y-axis to the center position of the top surface of the starter rail along the Y-axis.

[0233] Start the X-axis drive mechanism 81 of the main slider, which drives the K1 probe 8324 on the top surface of the rail to move along the X-axis from one end of the scanning range to the other end, thus completing a single scan.

[0234] After completing the scan of one path, the K1 probe 8324 on the top rail surface moves a certain distance along the Y-axis and continues to detect the next area on the top rail surface. This cycle continues until the entire area is scanned.

[0235] Step 2.5, the working process of the K1 probe 8336 on the top side of the main slider rail and the K1 probe 9336 on the top side of the auxiliary slider rail:

[0236] like Figure 26 The image shown is a top view of the main slider rail top side K1 probe 8336 and the auxiliary slider rail top side K1 probe 9336 located on the side of the target weld.

[0237] The main slider rail top side K1 probe 8336 and the auxiliary slider rail top side K1 probe 9336 serve as the transmitting probe and receiving probe, respectively. They are placed on both sides of the target weld rail head, with the transmitting and receiving probes close to the upper height surface of the rail top side. At this upper height position, the transmitting and receiving directions of the probes are aligned with the center of the target weld. First, one probe is fixed, and then the other probe is moved along the X direction within a set range for scanning. Then, the fixed probe is moved forward a set distance, and the scanning process is repeated. This process is repeated to complete a set number of scans. Then, the height of the transmitting and receiving probes on the rail top side is adjusted to the lower height position, and the scanning is repeated.

[0238] One specific operating method is as follows: Place the transmitting and receiving probes on both sides of the weld rail head, with the transmitting and receiving directions aligned with the center of the weld, and the incident point approximately 75mm from the center of the weld. First, fix one probe, then move the other probe within a 75mm range for scanning. Then move the fixed probe forward 15mm and repeat the scan, continuing in this manner for at least 5 scans. Due to the size limitations of the dual K1 probe chip used on-site, two layers of detection are required during on-site scanning, totaling at least 10 scans. Magnetic probes should be used during detection, and the coupling of the probes should be monitored at all times. The scanning speed should not exceed 100mm / s, and the scanning time should be at least 2 minutes.

[0239] Since the two rail-top side K1 probes are located on the main and auxiliary sliders respectively, the main and auxiliary sliders need to move alternately. The rail-top probe assembly slider on the main slider needs to move inward along the Y-axis to avoid interference with the auxiliary slider K0.8 probe bracket. Then, the main and auxiliary slider motors start, moving the K1 probe along the X-axis to the appropriate position on the rail. Under normal conditions, to protect the probe, the component carrying the rail-top side K1 probe will retract the probe, separating the K1 probe from the rail surface. When the K1 probe reaches the Y-axis position on the rail, the DC motor on the K1 probe component starts, pushing the K1 probe to the upper layer of the rail-top side to begin flaw detection. Finally, the main and auxiliary sliders move along the Y-axis to begin flaw detection work on the rail-top side K1 probe. After completing the upper layer inspection, the DC motor starts, continuing to move the probe close to the rail-top side to the lower layer.

[0240] Step 2.6, the working process of the main slider rail bottom inclined surface K2.5 probe 83410 and the auxiliary slider rail bottom inclined surface K2.5 probe 93410:

[0241] The main slider rail bottom slope K2.5 probe 83410 and the auxiliary slider rail bottom slope K2.5 probe 93410 are located on the rail bottom slopes on both sides of the rail, and each probe independently detects the rail bottom slope on the corresponding side, and the detection methods are the same.

[0242] like Figure 27 The diagram shown is a schematic of the detection principle of the K2.5 probe on the inclined plane at the bottom of the rail.

[0243] Taking the K2.5 probe 83410 on the inclined surface of the main slider rail as an example, its working process is as follows:

[0244] When the K2.5 probe 83410 on the bottom inclined surface of the main slide rail is used for detection, its emission direction is aligned with the center of the target weld, and multiple scans are performed from the outside to the inside starting from the edge of the bottom corner of the rail to ensure full coverage of the bottom of the rail; each probe scan trajectory should cover a certain width of the previous scan; then check in reverse along the edge of the bottom corner of the rail once; and the probe is deflected outward at a certain angle during each check.

[0245] For example, place the probe on the bottom slope of the rail weld, aiming the beam at the center of the weld. Starting from the edge of the rail bottom corner, perform six scans from the outside in, each scan covering 10% of the previous scan width. Then, check once in the reverse direction along the edge of the rail bottom corner. During the first, fourth, and fifth checks, the probe should be deflected outward at an angle (8°–10°). Seven scans are required for one rail bottom surface, totaling 28 scans for the four rail bottom surfaces on both sides of the weld. Finally, place the probe at the edge of the rail bottom corner, with the incident point of the 60kg / m rail approximately 125mm from the edge of the weld reinforcement on this side (approximately 160mm for the 75kg / m rail), aiming the beam at the arc of the weld waist and performing one fan-shaped scan. A total of four scans are performed for the four rail bottom surfaces on both sides of the weld. The scanning requirements stipulate that each rail bottom surface must be scanned 8 times, and the four rail bottom surfaces on both sides of the weld must be scanned a total of no less than 32 times to ensure complete coverage of the rail bottom area. The scanning range on each side should be no less than 200mm. The scanning speed should not exceed 100mm / s, and the scanning time should be no less than 2 minutes.

[0246] The specific work process is as follows:

[0247] When the main slider rail bottom inclined surface K2.5 probe 83410 moves to the set position along the X direction, the rail bottom inclined surface Y direction drive motor 8341 drives the main slider rail bottom inclined surface K2.5 probe 83410 to move along the Y axis, so that the main slider rail bottom inclined surface K2.5 probe 83410 reaches the set position of the rail bottom inclined surface Y direction.

[0248] The K2.5 probe 83410 drives the main slider to perform a linear scan of the inclined surface of the rail bottom along the X direction;

[0249] When the probe needs to move at an angle for scanning, the rail bottom inclined surface servo motor 8347 causes the main slider rail bottom inclined surface K2.5 probe 83410 to rotate a certain angle along the Z axis, and then scan along the X direction;

[0250] When performing a fan-shaped scanning action, the rail bottom inclined surface servo motor 8347 is activated, which drives the main slider rail bottom inclined surface K2.5 probe 83410 to rotate left and right to achieve fan-shaped scanning.

[0251] After the K2.5 probe 83410 on the bottom slope of the main slide rail crosses the weld and reaches the other side, the rail bottom slope servo motor 8347 drives the K2.5 probe 83410 on the bottom slope of the main slide rail to rotate 180°, adjust the orientation of the wedge block, and perform the scanning work on the other side of the weld.

[0252] When the K2.5 probe 83410 on the bottom inclined surface of the main slide rail crosses the weld, the horizontal slider of the bottom inclined probe needs to be moved to the innermost layer. This action is to allow the lifting baffle to function and to avoid interference with the weld bead of the French weld.

[0253] In this invention, the K2.5 probe on the rail bottom slope and the K1 probe on the rail bottom side of the main and auxiliary sliders need to avoid sleeper bolts and weld bead protrusions. When the K2.5 probe on the rail bottom slope is in the retracted state, the K2.5 probe does not contact the rail bottom slope. This state serves two purposes: first, it protects the probe from direct contact and impact with the rail during instrument loading; second, it prevents collisions with weld bead protrusions when the main and auxiliary sliders cross the rail weld. This function requires coordination with the movement of the K1 probe on the rail bottom side. The relevant component is a lifting baffle located on the K1 probe on the rail bottom side. The lifting baffle on the K1 probe on the rail bottom side can link the K2.5 probe on the rail bottom slope to achieve a lifting action. When crossing the weld or in the retracted state, the K1 probe on the rail bottom side rises, and the K2.5 probe on the rail bottom slope is lifted along with it by the lifting baffle.

[0254] Step 2.7, the working process of probe 8357 (K1) on the bottom side of the main slider rail and probe 9357 (K1) on the bottom side of the auxiliary slider rail:

[0255] like Figure 28 The image shown is a top view of the main slider rail bottom side K1 probe 8357 and the auxiliary slider rail bottom side K1 probe 9357 on the weld side.

[0256] The K1 probe 8357 on the bottom side of the main slider rail and the K1 probe 9357 on the bottom side of the auxiliary slider rail serve as the transmitting probe and the receiving probe, respectively. They are placed on both sides of the bottom of the target weld, with the transmitting and receiving directions of the probes aligned with the center of the target weld and the incident point at a set distance from the center of the weld. First, one probe is fixed, and then the other probe is moved within the set range for scanning. Then, the fixed probe is moved forward by 15mm, and the scanning is repeated. This process is repeated for a set number of scans. Both sides of the weld need to be scanned during the detection.

[0257] For example, place the transmitting and receiving probes on both sides of the weld seam rail base, with the transmitting and receiving directions aligned with the center of the weld seam, and the incident point approximately 150mm from the center of the weld seam. First, fix one probe, then move the other probe within a 150mm range to scan. Then move the fixed probe forward 15mm and repeat the scan, continuing this process for at least 10 scans. Scan each side of the weld seam once during the detection, constantly monitoring the probe coupling. The scanning speed should not exceed 100mm / s, and the scanning time should be at least 2 minutes. To achieve detection on both sides of the weld seam, the K1 probe on the rail base side uses a multi-wedge probe layout.

[0258] The motion trajectories of the main slide rail bottom side K1 probe 8357 and the auxiliary slide rail bottom side K1 probe 9357 are the same on the target weld side; for the main slide rail bottom side K1 probe 8357, its motion trajectory is as follows:

[0259] In the initial stage, the K1 probe 8357 on the bottom side of the main slide rail is in the retracted state. This state is used to prevent the probe from colliding with the bottom foot of the rail and damaging the probe when loading the instrument. At the same time, this state is also the state when crossing the weld to the other side of the rail.

[0260] When the K1 probe starts operating, the electromagnetic push-pull rod on the upper side of the K1 probe is activated, and the probe retracts inward.

[0261] Then, the K1 probe 8357 on the bottom side of the main slider rail descends along the Z-axis to the bottom side of the rail, the Y-axis electromagnetic push-pull rod 8356 is de-energized, and the K1 probe 8357 on the bottom side of the main slider rail adheres tightly to the bottom side of the rail under the action of the compression spring; then, the K1 probe 8357 on the bottom side of the main slider rail is driven to move linearly along the X-axis to realize the flaw detection work of the K1 probe 8357 on the bottom side of the rail.

[0262] This invention provides a fully automatic weld seam scanning frame and method. The scanning frame 1 is mounted above the rail 10 and moved longitudinally along the rail 10. A laser positioning device 6 detects the presence of weld seams in real time. When a weld seam is detected, an alarm is triggered. The scanning frame 1 is then securely locked onto the rail 10 using a rail locking device 5, and the detection program is initiated. The main slider unit 8 and the auxiliary slider unit 9 simultaneously or separately perform detection, completing a comprehensive scan of the top surface, side surface, bottom slope, and side surface of the rail 10, achieving full-area weld seam detection. The data acquisition box 7 collects and processes the detection data and displays it on a monitor screen for easy viewing and analysis by the flaw detection personnel. After the inspection of a weld seam is completed, the personnel can use the tension rod 3 and the track wheel mechanism 4 to move the device to the next weld seam.

[0263] The present invention provides a fully automatic weld inspection frame and weld inspection method, which changes the traditional manual operation mode of weld flaw detection, replaces manual flaw detection, realizes the automation of flaw detection, reduces the labor intensity of flaw detection personnel, and improves the accuracy and efficiency of weld flaw detection.

[0264] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A fully automatic weld seam scanning frame, characterized in that, include: The instrument scanning frame consists of (1), handle (2), tension rod (3), track wheel mechanism (4), rail locking device (5), laser positioning device (6), acquisition box (7), main slider unit (8), and auxiliary slider unit (9). The instrument scanning frame (1) is mounted above the steel rail (10); The handle (2) is fixedly installed on the top of the instrument scanning frame (1) to provide a gripping position for the operator to open and close the instrument and move up and down the track. The tension rod (3) is hinged to the top of the instrument scanning frame (1) and is used to drag the instrument scanning frame (1) to move longitudinally along the rail (10); The track wheel mechanism (4) is symmetrically hinged and installed at the front and rear of the instrument scanning frame (1), and has two states: unfolded and retracted. In the unfolded state, it supports the instrument scanning frame (1) above the rail (10) and provides a guiding movement function for longitudinal movement along the rail (10). In the retracted state, it causes the instrument scanning frame (1) to fall and clamp on the left and right sides of the rail (10). The rail locking device (5) is used to achieve stable clamping and fixing between the instrument scanning frame (1) and the rail (10) when the instrument scanning frame (1) moves to the target weld scanning area. The laser positioning device (6) is fixedly installed at the top center of the instrument scanning frame (1) and is used to emit a horizontal laser line in the start state so that the horizontal laser line is aligned with the center face of the target weld, thereby realizing the positioning of the instrument scanning frame (1) in the longitudinal direction of the rail (10). The acquisition box (7) is fixedly installed on the top of the instrument scanning frame (1) and is used to connect with the main slider unit (8) and the auxiliary slider unit (9) to acquire and store the detection results of the target weld. The main slider unit (8) and the auxiliary slider unit (9) are both located inside the instrument scanning frame (1) and are used to detect the target weld. The instrument scans the interior of the frame (1), and the main slider unit (8) and the auxiliary slider unit (9) are installed on the left and right sides of the rail (10), respectively; wherein the longitudinal direction of the rail (10) is X-direction, the width direction of the rail (10) is Y-direction, and the height direction of the rail (10) is Z-direction; The main slider unit (8) includes a main slider X-axis drive mechanism (81), a main slider X-axis optical axis (82), and a main slider module (83); the secondary slider unit (9) includes a secondary slider X-axis drive mechanism (91), a secondary slider X-axis optical axis (92), and a secondary slider module (93). The main slider X-axis (82) and the auxiliary slider X-axis (92) are fixedly installed on the left and right sides inside the instrument scanning frame (1), respectively; the main slider module (83) is slidably connected to the main slider X-axis (82), and under the drive of the main slider X-axis driving mechanism (81), the main slider module (83) moves in the X direction along the main slider X-axis (82); The secondary slider module (93) is slidably connected to the X-axis (92) of the secondary slider. Under the drive of the X-axis driving mechanism (91) of the secondary slider, the secondary slider module (93) moves in the X direction along the X-axis (92) of the secondary slider.

2. The fully automatic weld seam scanning frame according to claim 1, characterized in that, The instrument scanning frame (1) includes an instrument guard plate (11) and a main support plate (12) fixed at both ends of the instrument guard plate (11); scales (13) are set on the left and right sides of the instrument guard plate (11) along the longitudinal direction to assist in adjusting the longitudinal position of the instrument scanning frame (1) on the rail (10); an alignment baseline (14) is set at the top center of the instrument guard plate (11) to align with the center face of the target weld, thereby realizing the positioning of the instrument scanning frame (1) in the longitudinal direction of the rail (10).

3. The fully automatic weld seam scanning frame according to claim 2, characterized in that, The track wheel mechanism (4) includes a track wheel (41), a left wheel leg (42), a right wheel leg (43), a free hinge (44), and a folding hinge (45). The shape of the track wheel (41) matches the top shape of the rail (10) and is used to slide longitudinally along the top of the rail (10); the left side of the track wheel (41) is hinged to one end of the left wheel leg (42), the other end of the left wheel leg (42) is fixed to the bottom of the free hinge (44), and the side of the free hinge (44) is fixed to the main support plate (12); the right side of the track wheel (41) is hinged to one end of the right wheel leg (43), the other end of the right wheel leg (43) is fixed to the bottom of the folding hinge (45), and the side of the folding hinge (45) is fixed to the main support plate (12); The bottom of the free hinge (44) can be folded or unfolded freely relative to the side of the free hinge (44); the bottom of the folding hinge (45) can be folded or unfolded under the action of external force relative to the side of the folding hinge (45).

4. The fully automatic weld seam scanning frame according to claim 2, characterized in that, The rail locking device (5) includes a top positioning block (51), a main side clamping block (52), a main side limiting rod (53), a main side spring (54), a secondary side clamping block (55), a secondary side limiting rod (56), a secondary side spring (57), and a quick clamp (58). The top positioning block (51) is fixedly installed on the side of the main support plate (12), and the bottom shape of the top positioning block (51) matches the top shape of the rail (10). On the left and right sides of the top positioning block (51), the secondary side limiting rod (56) and the main side limiting rod (53) are fixedly installed along the width direction of the rail (10). The secondary side clamping block (55) is installed on the outer surface of the secondary side limiting rod (56), and the secondary side spring (57) is installed on the inner side of the secondary side clamping block (55). The main side clamping block (52) is installed on the outer surface of the main side limiting rod (53), and the main side spring (54) is installed on the inner side of the main side clamping block (52). The quick clamp (58) is installed on the top of the main side clamping block (52). When the instrument scanning frame (1) is in a drag state, under the elastic force of the secondary side spring (57) and the main side spring (54), the secondary side clamping block (55) slides to the outermost side along the secondary side limiting rod (56), and the main side clamping block (52) slides to the outermost side along the main side limiting rod (53); When the instrument scanning frame (1) is lowered and in working condition, the secondary side clamping block (55) and the primary side clamping block (52) move to the innermost side and are fixed together by the quick clamp (58). At this time, the bottom of the top positioning block (51) is attached to the top of the rail (10). The secondary side clamping block (55) and the primary side clamping block (52) are respectively clamped on the left and right sides of the bottom of the rail top of the rail (10). At this time, the left and right sides of the instrument scanning frame (1) are clamped on the left and right sides of the bottom of the rail (10), thereby realizing the multi-point positioning and fixing between the instrument scanning frame (1) and the rail (10).

5. The fully automatic weld seam scanning frame according to claim 1, characterized in that, The main slider X-axis drive mechanism (81) and the auxiliary slider X-axis drive mechanism (91) are both stepper motors, each connected to a synchronous belt (A1); the main slider module (83) and the auxiliary slider module (93) are respectively fixed to the fixed points of their respective synchronous belts (A1) through synchronous belt clamping blocks (A2).

6. The fully automatic weld seam scanning frame according to claim 1, characterized in that, The main slider module (83) includes a main slider support plate (831), a main slider rail top surface detection component (832), a main slider rail top side surface K1 detection component (833), a main slider rail bottom inclined surface K2.5 detection component (834), and a main slider rail bottom side surface K1 detection component (835). The main slider rail top surface detection component (832) includes a rail top surface Y-axis drive motor (8321), a rail top surface Y-axis optical axis (8322), a rail top surface probe slider seat (8323), a rail top surface K1 probe (8324), a rail top surface K0.8 probe (8325), a rail top surface 0 degree probe (8326), a rail top surface K2.5 probe (8327), and a rail top surface K2.5 probe drive servo motor (8328). The main slider support plate (831) is fixedly mounted on the upper part of the rail top surface Y-axis (8322); the rail top surface probe slider seat (8323) is sleeved on the outside of the rail top surface Y-axis (8322), and slides in the Y direction along the rail top surface Y-axis (8322) under the drive of the rail top surface Y-axis drive motor (8321); The bottom of the rail top surface probe slider seat (8323) is fixedly installed with the rail top surface K1 probe (8324), the rail top surface K0.8 probe (8325), and the rail top surface 0 degree probe (8326). The rail top surface K1 probe (8324), the rail top surface 0 degree probe (8326), and the rail top surface K0.8 probe (8325) are arranged sequentially along the Y direction. Under the drive of the rail top surface Y direction drive motor (8321), the rail top surface K1 probe (8324), the rail top surface 0 degree probe (8326), and the rail top surface K0.8 probe (8325) are moved sequentially to the center position of the rail top surface Y direction to perform target weld flaw detection work. The bottom of the rail top surface probe slider seat (8323) is equipped with the rail top surface K2.5 probe drive servo motor (8328), and the bottom of the rail top surface K2.5 probe drive servo motor (8328) is equipped with the rail top surface K2.5 probe (8327). Driven by the rail top surface K2.5 probe drive servo motor (8328), the rail top surface K2.5 probe (8327) is rotated by a certain angle to realize flaw detection at different positions on the rail top surface. At the same time, after the main slider module (83) crosses the target weld, the rail top surface K2.5 probe drive servo motor (8328) drives the rail top surface K2.5 probe (8327) to rotate 180° to perform flaw detection work on the other side of the target weld. The main slider rail top side K1 detection component (833) includes a rail top side motor (8331), a rail top side connecting rod (8332), a rail top side slide rail (8333), a rail top side main compartment (8334), a rail top side slide compartment (8335), and a main slider rail top side K1 probe (8336). The rail top side connecting rod (8332) is fixedly installed on the side of the main slider support plate (831), and the rail top side connecting rod (8332) is inclined at a certain angle to the Z-axis; the rail top side slide rail (8333) is arranged in the same direction as the rail top side connecting rod (8332) and is fixed to the rail top side connecting rod (8332); the rail top side main compartment (8334) slides along the rail top side connecting rod (8332) and inside the rail top side slide rail (8333) under the drive of the rail top side motor (8331); the rail top side slide compartment (8335) arranged along the Y direction is installed at the bottom of the rail top side main compartment (8334), and the main slider rail top side K1 probe (8336) arranged along the Y direction is installed on the end face of the rail top side slide compartment (8335). Driven by the side motor (8331) on the rail top, the main compartment (8334) on the rail top moves along the inner wall of the side slide (8333) in the YZ direction, thereby driving the side slide (8335) on the rail top to move in the YZ direction. A compression spring is installed between the main compartment (8334) on the rail top and the side slide (8335) on the rail top, thereby ensuring that the main slider side K1 probe (8336) on the rail top is in contact with the side of the rail top and moves in the Z-axis direction, thereby realizing full-range scanning of different heights on the side of the rail top. The main slider rail bottom slope K2.5 detection component (834) includes a rail bottom slope Y-direction drive motor (8341), a rail bottom slope Y-direction lead screw (8342), a rail bottom slope Y-direction optical axis (8343), a rail bottom slope Y-direction slider (8344), a rail bottom slope Z-direction optical axis (8345), a rail bottom slope servo base (8346), a rail bottom slope servo (8347), a bottom slope probe swing frame (8348), a bottom slope probe limiting plate (8349), and a main slider rail bottom slope K2.5 probe (83410). The bottom of the main slider support plate (831) is parallel to the bottom of the rail bottom inclined surface Y-axis screw (8342) and the rail bottom inclined surface Y-axis optical shaft (8343); the guide hole of the rail bottom inclined surface Y-axis slider (8344) is fitted outside the rail bottom inclined surface Y-axis optical shaft (8343), and the rail bottom inclined surface Y-axis slider (8344) and the rail bottom inclined surface Y-axis screw (8342) are threadedly engaged; the rail bottom inclined surface Y-axis drive motor (8341) drives the rail bottom inclined surface Y-axis screw (8342). When rotated, the Y-axis slider (8344) on the inclined surface of the rail base slides along the Y-axis optical axis (8343) of the inclined surface of the rail base in the Y direction; the bottom of the Y-axis slider (8344) on the inclined surface of the rail base is fixedly installed with the Z-axis optical axis (8345) of the inclined surface of the rail base; the servo mount (8346) on the inclined surface of the rail base is sleeved on the outside of the Z-axis optical axis (8345) of the inclined surface of the rail base, and can move in the Z direction along the Z-axis optical axis (8345) of the inclined surface of the rail base; and the outer sleeve of the Z-axis optical axis (8345) of the inclined surface of the rail base is... A compression spring is installed, which applies downward pressure to the rail-bottom inclined surface servo mount (8346), thereby causing the main slider rail-bottom inclined surface K2.5 probe (83410) to conform to the rail-bottom inclined surface and adapt to the height difference of the rail-bottom inclined surface; the rail-bottom inclined surface servo mount (8346) is installed at the bottom of the Z-axis optical axis (8345) of the rail-bottom inclined surface, the rail-bottom inclined surface servo (8347) is assembled inside the rail-bottom inclined surface servo mount (8346), and the bottom surface of the rail-bottom inclined surface servo (8347) is mounted with... The bottom-angle probe swing frame (8348) is used to drive the bottom-angle probe swing frame (8348) to rotate around the X-axis. The bottom-angle probe swing frame (8348) houses the main slider rail bottom-angle surface K2.5 probe (83410) arranged along the Z-axis. The bottom-angle probe limiting plate (8349) is installed on the outside of the bottom-angle probe swing frame (8348). The bottom-angle probe limiting plate (8349) is used to prevent the main slider rail bottom-angle surface K2.5 probe (83410) from rotating along the Y-axis. When moving in the axial direction, the slide rail bottom inclined surface servo motor (8347) drives the main slide rail bottom inclined surface K2.5 probe (83410) to rotate around the X-axis direction through the bottom inclined probe swing frame (8348), and adjusts the deflection angle of the main slide rail bottom inclined surface K2.5 probe (83410). At the same time, when the main slide module (83) passes the target weld, the main slide rail bottom inclined surface K2.5 probe (83410) rotates 180° to achieve detection on the other side of the target weld. The main slider rail bottom side K1 detection component (835) includes a rail bottom side slide platform (8351), a rail bottom side Z-axis drive motor (8352), a rail bottom side Z-axis lead screw (8353), a rail bottom side Z-axis optical axis (8354), a rail bottom side probe frame (8355), a Y-axis electromagnetic push-pull rod (8356), a main slider rail bottom side K1 probe (8357), and a lifting baffle (8358); the bottom of the main slider support plate (831) is fixedly installed with... The rail bottom side slide platform (8351) is described above; a rail bottom side Z-axis lead screw (8353) and a rail bottom side Z-axis optical axis (8354) are slidably installed on each side of the rail bottom side slide platform (8351) along the Z-direction; the tops of the rail bottom side Z-axis lead screw (8353) and the rail bottom side Z-axis optical axis (8354) can slide upward along the Z-direction; the bottom of the rail bottom side Z-axis lead screw (8353) is threadedly fitted with the rail bottom side probe frame (8355). Furthermore, the bottom of the rail bottom side probe frame (8355) is fixed to the bottom of the rail bottom side Z-axis optical axis (8354); when the rail bottom side Z-axis drive motor (8352) drives the rail bottom side Z-axis lead screw (8353) to rotate, it drives the rail bottom side probe frame (8355) to perform Z-axis lifting and lowering motion; the bottom of the rail bottom side probe frame (8355) is equipped with the Y-axis electromagnetic push-pull rod (8356), and the bottom of the Y-axis electromagnetic push-pull rod (8356) is... The K1 probe (8357) on the bottom side of the main slider rail is installed along the Y direction; the lifting baffles (8358) are fixedly installed on both sides of the K1 probe (8357) on the bottom side of the main slider rail, so as to drive the K2.5 probe (834) on the bottom slope of the main slider rail to be lifted synchronously when the K1 detection component (835) on the bottom side of the main slider rail is lifted to a certain height, so as to avoid collision with the weld protrusion when the main slider module (83) passes the weld.

7. The fully automatic weld seam scanning frame according to claim 6, characterized in that, The secondary slider module (93) includes a secondary slider support plate (931), a secondary slider rail top surface detection component (932), a secondary slider rail top side surface K1 detection component (933), a secondary slider rail bottom inclined surface K2.5 detection component (934), and a secondary slider rail bottom side surface K1 detection component (935). The auxiliary slider rail top surface detection component (932) is different from the main slider rail top surface detection component (832); the auxiliary slider rail top surface detection component (932) includes an auxiliary slider rail top surface probe bracket (9321) and an auxiliary slider rail top surface K0.8 probe (9322); the auxiliary slider rail top surface probe bracket (9321) is fixed to the auxiliary slider support plate (931); the auxiliary slider rail top surface K0.8 probe (9322) is fixedly installed at the end of the auxiliary slider rail top surface probe bracket (9321), so that when the fully automatic weld seam scanning frame is in working condition, the auxiliary slider rail top surface K0.8 probe (9322) is pressed tightly against the center position of the Y direction of the rail top surface; The structures of the auxiliary slider rail top side K1 detection component (933), the auxiliary slider rail bottom inclined surface K2.5 detection component (934), and the auxiliary slider rail bottom side K1 detection component (935) are the same as those of the main slider module (83) main slider rail top side K1 detection component (833), main slider rail bottom inclined surface K2.5 detection component (834), and main slider rail bottom side K1 detection component (835); in: The auxiliary slider rail top side K1 detection component (933) includes the auxiliary slider rail top side K1 probe (9336). The detection component (934) of the inclined surface K2.5 of the auxiliary slider rail includes the probe (93410) of the inclined surface K2.5 of the auxiliary slider rail. The K1 detection component (935) on the bottom side of the auxiliary slider rail includes the K1 probe (9357) on the bottom side of the auxiliary slider rail.

8. A weld seam scanning method using a fully automatic weld seam scanning frame as described in any one of claims 1-7, characterized in that, Includes the following steps: Step 1: The fully automatic weld seam scanning frame has both a drag state and a working state; In the drag state, first operate the track wheel mechanism (4), lift the handle (2) with one hand and press the track wheel (41) with the other hand to unfold the track wheel mechanism (4). At this time, the track wheel (41) slides in contact with the surface of the rail (10), and the support instrument scanning frame (1) is higher than the top surface of the rail (10). Then, hold the tension rod (3) and drag the fully automatic weld seam scanning frame along the rail (10). When the horizontal line emitted by the laser positioning device (6) coincides with the target weld seam, it indicates that the target position has been reached. Then, press the folding hinge (45) to retract the track wheel mechanism (4) and lower the instrument scanning frame (1). After the instrument scanning frame (1) is lowered into place, lock the rail locking device (5). Through the joint support and positioning effect of the instrument scanning frame (1) and the rail locking device (5), the instrument scanning frame (1) is stably fixed in the target position, and the fully automatic weld seam scanning frame is put into working state. Step 2: After the fully automatic weld seam scanning frame is put into working state, the main slider unit (8) and the auxiliary slider unit (9) are controlled to realize a comprehensive scan of the target weld seam and the rail area where it is located, and the scan results are transmitted to the acquisition box (7).

9. The weld inspection method of a fully automatic weld inspection frame according to claim 8, characterized in that, Step 2 is as follows: Step 2.1, the working process of the K2.5 probe (8327) on the top surface of the main slider module (83): The scanning range and scanning method are determined as follows: taking the target weld as the reference, the scanning range is extended by a distance L1 to both ends along the X direction to form a scanning range; within the scanning range, the K2.5 probe (8327) on the top surface of the drive rail is driven to perform a set number of scans with different deflection angles. When the K2.5 probe (8327) on the top surface of the rail is performing scanning detection, the emission direction is continuously aligned with the center of the target weld; the deflection angles include 0°, a left deflection set angle, and a right deflection set angle. The specific process of a single round-trip scan is as follows: Start the X-direction drive mechanism (81) of the main slider, drive the main slider module (83) to move along the X direction, and move the K2.5 probe (8327) on the top surface of the rail to the initial detection position at one end of the scanning range; The Y-axis drive motor (8321) on the top surface of the rail is started, which drives the K2.5 probe (8327) on the top surface of the rail to move along the Y-axis to the center position of the top surface of the rail along the Y-axis; and, since the K2.5 probe (8327) on the top surface of the rail is equipped with a pressure spring, the K2.5 probe (8327) on the top surface of the rail is pressed tightly against the top surface of the rail. Start the X-direction drive mechanism (81) of the main slider, and drive the K2.5 probe (8327) on the top surface of the rail to move along the X direction, from the initial detection position at one end of the scanning range to the target weld position, and complete the forward single-pass scanning of one side of the target weld; The drive servo motor (8328) drives the K2.5 probe on the top surface of the drive rail to rotate the K2.5 probe (8327) on the Z-axis until it forms a set angle with the center of the top surface of the drive rail; then the X-axis drive mechanism (81) of the main slider is activated to drive the K2.5 probe (8327) on the top surface of the drive rail to move along the X-axis from the target weld position to the initial detection position, thus completing the reverse one-way scan of one side of the target weld. When the flaw detection work on one side of the target weld is completed, drive the main slider module (83) to move to the other side of the target weld, and drive the servo motor (8328) of the rail top surface K2.5 probe to adjust the rail top surface K2.5 probe (8327) to rotate. Repeat the above steps to complete the flaw detection work on the other side of the target weld. Step 2.2, the working process of the 0-degree probe (8326) on the rail top surface: When the 0-degree probe (8326) on the top surface of the rail is used to detect the weld, it is necessary to monitor the bottom wave and identify the reflected wave. Taking the target weld as the reference, the probe extends a distance L2 to both ends along the X direction to form a scanning range. Within the scanning range, the 0-degree probe (8326) on the top surface of the rail is moved longitudinally at a constant speed according to the set number of round trips. When the 0-degree probe (8326) on the top surface of the rail is scanned above the target weld, the probe (8326) on the top surface of the rail is moved laterally within the width of the rail head to detect horizontal cracks in the weld bead. The specific process of a single round-trip scan is as follows: Start the X-direction drive mechanism (81) of the main slider, drive the main slider module (83) to move along the X direction, and move the 0-degree probe (8326) on the top surface of the rail to the initial detection position at one end of the scanning range; The Y-axis drive motor (8321) on the top surface of the rail is started, which drives the 0-degree probe (8326) on the top surface of the rail to move along the Y-axis to the detection position on the top surface of the rail along the Y-axis; and, since the 0-degree probe (8326) on the top surface of the rail is equipped with a pressure spring, the 0-degree probe (8326) on the top surface of the rail is pressed tightly against the top surface of the rail. Start the main slider X-axis drive mechanism (81) to drive the rail top surface 0 degree probe (8326) to move along the X-axis from one end of the scanning range to the other end, and complete a single flaw detection scan; after completing the scan of one path, the rail top surface 0 degree probe (8326) moves a certain distance along the Y-axis to continue the detection of the next area of ​​the rail top surface, and so on until the entire area is scanned; Step 2.3, the working process of the K0.8 probe (9322) on the top surface of the auxiliary slider rail and the K0.8 probe (8325) on the top surface of the main slider rail: The detection process on one side of the target weld: On one side of the target weld, the K0.8 probe (9322) on the top surface of the auxiliary slider rail and the K0.8 probe (8325) on the top surface of the main slider rail are both located at the center position in the Y direction of the top surface of the rail, but at different positions in the X direction. Then, the K0.8 probe (9322) on the top surface of the auxiliary slider rail and the K0.8 probe (8325) on the top surface of the main slider rail are driven to move relative to each other in the X direction to realize the serial scanning of K0.

8. During the movement, the K0.8 probe (8325) on the top surface of the main slider rail emits detection waves to different depth positions of the target weld along the Z direction, and the K0.8 probe (9322) on the top surface of the auxiliary slider rail receives the reflected waves, thus completing the detection of the entire depth of the target weld and completing the detection process on one side of the target weld. After the top surface K0.8 probe (9322) of the auxiliary slider rail and the top surface K0.8 probe (8325) of the main slider rail have completed the scanning of one side of the target weld, the positions of the top surface K0.8 probe (9322) of the auxiliary slider rail and the top surface K0.8 probe (8325) of the main slider rail are reversed, and then moved along the X direction to the other side of the target weld, repeating the detection process on one side of the target weld. Specifically: When swapping the front and rear positions, the position of the K0.8 probe (9322) on the top surface of the auxiliary slider rail remains unchanged, while the K0.8 probe (8325) on the top surface of the main slider rail moves along the X direction. When it is close to the K0.8 probe (9322) on the top surface of the auxiliary slider rail and needs to pass, the K0.8 probe (8325) on the top surface of the main slider rail moves along the Y direction to the inside of the main slider to avoid the K0.8 probe (9322) on the top surface of the auxiliary slider rail. Then, the K0.8 probe (8325) on the top surface of the main slider rail moves along the X direction to the other side of the K0.8 probe (9322) on the top surface of the auxiliary slider rail, thus completing the swapping of the front and rear positions of the main and auxiliary sliders. Step 2.4, the working process of the K1 probe (8324) on the rail top surface: The scanning range and scanning method are determined as follows: taking the target weld as the reference, the scanning range is extended to both ends along the X direction by a distance L3 to form a scanning range; within the scanning range, the K1 probe (8324) on the top surface of the drive rail is driven to perform a set number of scans back and forth. When the K1 probe (8324) on the top surface of the rail is performing scanning and detection, the emission direction is continuously aimed at the center of the target weld. Start the X-axis drive mechanism (81) of the main slider, and drive the K1 probe (8324) on the top surface of the drive rail to move along the X-axis to one end of the scanning range; Start the Y-axis drive motor (8321) on the top surface of the rail, and drive the K1 probe (8324) on the top surface of the rail to move along the Y-axis to the center position of the top surface of the rail along the Y-axis; Start the main slider X-direction drive mechanism (81) to drive the K1 probe (8324) on the top surface of the rail to move along the X direction, from one end of the scanning range to the other end, and complete a single scan; After completing the scan of one path, the K1 probe (8324) on the top rail surface moves a certain distance along the Y-axis and continues to detect the next area on the top rail surface. This cycle continues until the entire area is scanned. Step 2.5, the working process of the K1 probe (8336) on the top side of the main slider rail and the K1 probe (9336) on the top side of the auxiliary slider rail: The main slider rail top side K1 probe (8336) and the auxiliary slider rail top side K1 probe (9336) serve as the transmitting probe and the receiving probe, respectively. They are placed on both sides of the target weld rail head, with the transmitting probe and the receiving probe close to the upper height surface of the rail top side. At this upper height position, the transmitting and receiving directions of the probes are aligned with the center of the target weld. First, one probe is fixed, and then the other probe is moved along the X direction within a set range for scanning. Then, the fixed probe is moved forward a set distance, and the scanning process is repeated. This process is repeated to complete the set number of scans. Then adjust the height of the transmitting and receiving probes on the side of the top of the rail to the height of the lower layer, and repeat the scan. Step 2.6, the working process of the K2.5 probe (83410) on the bottom inclined surface of the main slider rail and the K2.5 probe (93410) on the bottom inclined surface of the auxiliary slider rail: The main sliding block rail bottom slope K2.5 probe (83410) and the auxiliary sliding block rail bottom slope K2.5 probe (93410) are located on the rail bottom slopes on both sides of the rail, and each probe independently detects the rail bottom slope on the corresponding side, and the detection methods are the same. The working process of the K2.5 probe (83410) on the inclined surface of the main slide rail is as follows: When the K2.5 probe (83410) on the bottom slope of the main slide rail is used for detection, its emission direction is aligned with the center of the target weld. It scans multiple times from the outside to the inside starting from the edge of the bottom corner of the rail to ensure full coverage of the bottom of the rail. Each probe scan should cover a certain width of the previous scan. Then, it checks once in reverse along the edge of the bottom corner of the rail. In addition, the probe is deflected outward at a certain angle during each check. The specific work process is as follows: When the K2.5 probe (83410) on the bottom slope of the main slide rail moves to the set position along the X direction, the Y-direction drive motor (8341) on the bottom slope of the rail drives the K2.5 probe (83410) on the bottom slope of the main slide rail to move along the Y-axis, so that the K2.5 probe (83410) on the bottom slope of the main slide rail reaches the set position in the Y direction of the bottom slope of the rail. Drive the K2.5 probe (83410) on the inclined surface of the main slide rail to perform a straight-line scan of the inclined surface of the rail bottom along the X direction; When the probe needs to move at an angle for scanning, the rail bottom inclined surface servo motor (8347) causes the main slider rail bottom inclined surface K2.5 probe (83410) to rotate a certain angle along the Z axis and then scan along the X direction; When performing a fan-shaped scanning action, the rail bottom inclined surface servo motor (8347) is activated, driving the main slider rail bottom inclined surface K2.5 probe (83410) to rotate left and right to achieve fan-shaped scanning; When the K2.5 probe (83410) on the bottom slope of the main slide rail crosses the weld and reaches the other side, the rail bottom slope servo motor (8347) drives the K2.5 probe (83410) on the bottom slope of the main slide rail to rotate 180°, adjust the orientation of the wedge block, and perform the scanning work on the other side of the weld. Step 2.7, the working process of the K1 probe (8357) on the bottom side of the main slider rail and the K1 probe (9357) on the bottom side of the auxiliary slider rail: The K1 probe (8357) on the bottom side of the main slider rail and the K1 probe (9357) on the bottom side of the auxiliary slider rail are used as transmitting probes and receiving probes, respectively. They are placed on both sides of the bottom of the target weld rail, with the transmitting and receiving directions of the probes aligned with the center of the target weld and the incident point set at a distance from the center of the weld. First, fix one probe, then move the other probe within the set range to scan; then move the fixed probe forward 15mm and repeat the scan, and so on, for a total of the set number of scans; both sides of the weld need to be scanned during the detection. The motion trajectories of the K1 probe (8357) on the bottom side of the main slide rail and the K1 probe (9357) on the bottom side of the auxiliary slide rail are the same on the target weld side; for the K1 probe (8357) on the bottom side of the main slide rail, its motion trajectory is as follows: The K1 probe (8357) on the bottom side of the main slider rail descends along the Z-axis to the bottom side of the rail. The Y-axis electromagnetic push-pull rod (8356) is de-energized, and the K1 probe (8357) on the bottom side of the main slider rail adheres to the bottom side of the rail under the action of the compression spring. Then, the K1 probe (8357) on the bottom side of the main slider rail is driven to move linearly along the X-axis to realize the flaw detection work of the K1 probe (8357) on the bottom side of the rail.

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