Ultrasonic detection probe layout method for rim and spoke of motor train unit

Abstract

The invention relates to a motor train unit rim and spoke ultrasonic detection probe layout method, and belongs to the technical field of motor train detection. Six phased array probes and fifteen conventional probes are adopted to detect the defects of a rim, a rim, a spoke and a transition area between the rim and the spoke of a single wheel of the same wheel pair at the same time, wherein four phased array probes (PA1-PA4), five bicrystal normal probes (TR1-TR5) and four single crystal angle probes (A1-A4) are arranged on a tread; and two phased array probes (PA5 and PA6), four single crystal angle probes (A5-A8) and two bicrystal normal probes (TR6 and TR7) are arranged on the inner side surface of the rim. The wheel spoke and rim detection device has the effects of improving the detection accuracy and efficiency of the wheel spoke and the rim and ensuring the running safety of a wheel.

Description

Technical Field

[0001] The present application relates to the technical field of motor vehicle inspection, and in particular to a method for arranging ultrasonic inspection probes for the wheel rim and spokes of a motor vehicle. Background Art

[0002] At present, the safety of EMU wheels is of vital importance in railway transportation. During long-term operation, various fatigue defects may occur in the rims and spokes of the wheels, such as circumferential, radial, oblique and axial cracks. If these defects are not detected and handled in time, they may lead to serious safety accidents.

[0003] Prior art, such as the Chinese patent with publication number CN201548525U, proposes an ultrasonic detection device for train wheel spoke defects, whose ultrasonic probes include four pairs of single-transmitting and single-receiving probes and six transceiver-integrated probes. Although the device can perform all-round detection of defects in various wheel spokes, the detection process does not require manual participation, the detection rate is high, the detection method is simple and the detection results are reliable, but there are problems such as low detection accuracy and lack of comprehensiveness, which makes it difficult to meet the high requirements of modern railway transportation for wheel detection.

[0004] Therefore, a more accurate and comprehensive probe layout method for ultrasonic inspection of EMU wheel rims and spokes is needed to improve the inspection accuracy and efficiency and ensure the safe operation of wheels. Summary of the invention

[0005] In order to improve the detection accuracy and efficiency of wheel spokes and rims and ensure the safe operation of wheels, the present application provides a method for arranging ultrasonic detection probes for wheel rims and spokes of EMUs.

[0006] The present application provides a method for arranging ultrasonic detection probes for EMU wheel rims and spokes using the following technical solutions: A method for ultrasonic detection probe layout of EMU wheel rim and spoke, comprising: using the tread and the inner side of the rim as the flaw detection contact surface, using 6 phased array probes and 15 conventional probes to simultaneously detect defects in the rim, flange, spoke and transition area between the rim and spoke of a single wheel of the same wheelset, wherein 4 phased array probes (PA1-PA4), 5 dual crystal straight probes (TR1-TR5) and 4 single crystal oblique probes (A1-A4) are arranged on the tread; 2 phased array probes (PA5, PA6), 4 single crystal oblique probes (A5-A8) and 2 dual crystal straight probes (TR6, TR7) are arranged on the inner side of the rim; The distribution of probes on the tread (detection area): a dual-crystal straight probe is set at the center of the tread (TR1), and the other four dual-crystal straight probes are distributed in a quadrangular shape (TR2-TR5) with the dual-crystal straight probe (TR1) at the center as the center; four phased array probes (PA1-PA4) are distributed on both sides of TR1 in groups of two along the length direction of the tread with TR1 as the center; four single-crystal oblique probes (A1-A4) are distributed on both sides of TR1 in groups of two along the width direction of the tread with TR1 as the center; The distribution of probes on the inner side of the rim (detection area): one dual-crystal straight probe is set at the center of the inner side of the rim (TR7), and the other dual-crystal straight probe is set at either end of the inner side of the rim (TR6); two phased array probes (PA5 and PA6) are symmetrically distributed on both sides of TR7; four single-crystal oblique probes (A5-A8) are spaced above TR7 along the length direction of the inner side of the rim.

[0007] By adopting the above technical solution, a dual crystal straight probe (TR1) is set at the center of the tread, which can effectively detect defects in the area near the center of the tread. This is the part where the wheel is subjected to concentrated pressure and wear during operation, and the detection of this area is crucial. The remaining four dual crystal straight probes (TR2-TR5) are distributed in a quadrangular shape with TR1 as the center, which can expand the detection range of different positions of the tread and ensure that defects in all directions of the tread can be detected to avoid omissions. The four phased array probes (PA1-PA4) are distributed on both sides of TR1 along the length of the tread, which can better detect defects in the spokes in the length direction of the tread, because defects such as cracks in the spokes in this direction may have an important impact on the structural strength of the wheel. The four single crystal oblique probes (A1-A4) are distributed on both sides of TR1 along the width of the tread, which can detect defects in the spokes in the width direction of the tread, supplementing the detection capabilities of other probes in different directions and achieving more comprehensive coverage of the tread area. The distribution of probes on the inner side of the rim creates the advantages of coordinated detection of the center and edge, and the cooperation of phased array and single crystal oblique probes. The detection is carried out from two flaw detection contact surfaces, the tread and the inner side of the rim, to achieve all-round detection of the wheel and avoid the blind spots that may exist in the detection of a single contact surface. Probes of different types and positions cooperate with each other to detect various defects in the rim, flange, spoke, and the transition area between the rim and the spoke. Whether it is an internal defect or a surface defect, whether it is a circumferential, radial or oblique crack, it can be effectively detected. Ultimately, the accuracy and efficiency of the detection of spokes and rims are improved, and the safe operation of the wheels is ensured.

[0008] Optionally, the four phased array probes (PA1-PA4) are used for bidirectional coverage, and circumferential defects are detected using a phased array PC (transmit-receive) mode, and oblique and radial defects are detected using a PE (pulse reflection method) mode.

[0009] By adopting the above technical solution, specific modes are used to detect crack defects in different directions of the spoke. The PC mode has high sensitivity for circumferential defect detection, and the PE mode can effectively detect oblique and radial defects. The two-way coverage ensures the comprehensiveness and accuracy of the spoke defect detection and avoids missed detection.

[0010] Optionally, the dual crystal straight probe (TR6, TR7) adopts a dual crystal longitudinal wave straight probe, and the single crystal oblique probe (A5-A8) adopts a shear wave oblique probe. The dual crystal longitudinal wave straight probe (TR6, TR7) is combined with the shear wave oblique probe (A5-A8) to perform coverage detection for detecting volume defects inside the rim.

[0011] By adopting the above technical solution, "longitudinal wave" is a limitation on the wave type emitted and received by the probe. Longitudinal wave has unique advantages in detecting volume defects in the rim. It can more effectively penetrate the internal material of the rim and is more sensitive to volume defects such as looseness and inclusions that may exist inside the rim. Compared with shear wave, longitudinal wave has a stronger ability to detect the internal structure of the material during propagation, and can better detect deep-seated defects inside the rim. "Shear wave" is also a limitation on the probe wave type. Shear wave is more effective in detecting surface and near-surface defects, especially in reducing surface blind areas. When the shear wave is incident on the rim surface at a certain angle, it can better detect defects within a certain depth range below the surface, avoiding detection blind areas caused by complex surface structure or surface conditions. The combination of dual-crystal longitudinal wave straight probe and large-angle shear wave oblique probe can effectively detect different types of defects inside the rim. The longitudinal wave has a larger detection depth, and the shear wave is sensitive to surface and near-surface defects. The combination of the two improves the accuracy of internal defect detection of the rim.

[0012] Optionally, the shear wave emitted by the shear wave oblique probe is incident on the inner side of the rim at an angle of 50°-70°.

[0013] By adopting the above technical solution, when the shear wave is incident on the rim surface at an angle of 50°-70°, defects within a certain depth range below the surface can be better detected, avoiding detection blind spots caused by complex surface structures or surface conditions.

[0014] Optionally, the four single crystal oblique probes (A1-A4) are shear wave probes and two are in a group. The detection directions of the two groups of shear wave probes are set in directions away from each other to detect mirror image crack defects at the top and root of the rim.

[0015] By adopting the above technical solution, two-way detection ensures the comprehensiveness of the detection, effectively discovers defects in key parts of the rim, ensures the safety of the rim, and prevents wheel failures caused by rim defects.

[0016] Optionally, the shear waves emitted by the shear wave probes (A1-A4) are incident on the top and root of the rim at an angle of 55°-75°.

[0017] By adopting the above technical solution, the 55°-75° angle shear wave probe can better adapt to the special structure of the top and root of the rim, and improve the detection sensitivity of radial crack defects in these parts.

[0018] Optionally, the two phased array probes (PA5, PA6) perform shear wave sector scanning for detecting radial cracks on the outer side of the rim.

[0019] By adopting the above technical solution, PA5 and PA6 are arranged on the inner side of the rim, mainly to utilize the characteristics of the phased array probe to detect defects inside the rim from the inner side. The phased array probe can realize the focusing and deflection of the sound beam through electronic control, and the ultrasonic wave emitted from the inner side of the rim can penetrate deep into the rim to detect the internal structure. For example, casting defects and fatigue cracks that may exist inside the rim can be effectively detected at this position to ensure the internal quality of the rim. When it is necessary to detect radial crack defects on the outer side of the rim, by controlling and adjusting the working parameters of PA5 and PA6, the transverse waves emitted by them can scan the outer area of ​​the rim in a fan-shaped manner. The propagation characteristics of the transverse wave in the material make it more sensitive to surface and near-surface defects. Through fan-shaped scanning, a larger area on the outer side of the rim can be covered, thereby increasing the probability of detecting radial crack defects. This method takes advantage of the flexible control of the phased array probe's acoustic beam. It can detect specific defects on the outside of the rim without changing the physical position of the probe. It complements the function of detecting internal defects of the rim from the inside to complete the task of comprehensive inspection of the rim.

[0020] Optionally, the detection directions of the two groups of phased array probes (PA1-PA4) are both along the direction toward TR1.

[0021] By adopting the above technical solution, the effect of focusing on key area detection is achieved. TR1 is located in the center of the tread. It is one of the areas where the wheel is subjected to more concentrated pressure and wear during operation, and it is also a key part that is prone to defects. The detection direction of the two sets of phased array probes (PA1-PA4) is towards TR1, which can ensure that TR1 and its surrounding areas are focused on detection, and the circumferential, radial and oblique crack defects that may exist in this area can be discovered in time.

[0022] In summary, the present application includes at least one of the following beneficial technical effects: 1. The use of multiple types of probes (phased array probes, dual crystal straight probes, single crystal oblique probes) combined with different detection modes (PC mode, PE mode, shear wave sector scanning, etc.) can accurately detect defects of different positions and types on the rim and spokes. For example, the PC mode of the phased array probe has a good effect on the detection of circumferential defects, and the PE mode is effective for the detection of oblique and radial defects. The coordinated work of multiple modes can avoid missed detection and improve detection accuracy; 2. Through the reasonable layout of probes, such as the multi-probe arrangement on the tread and the inner side of the rim, the rim, flange, spokes and transition area are fully covered, ensuring that all potential defects can be detected, further improving the accuracy of detection; 3. Multiple parts of a single wheel of the same wheel pair can be inspected at the same time in one inspection, without repeated inspection of different areas, saving inspection time and improving inspection efficiency. Probe layout is carried out on the two inspection contact surfaces of the tread and the inner side of the rim. Combining probes of different angles and types, the circumferential, radial, oblique and axial fatigue defects of the rim and spoke can be fully inspected without leaving blind spots for inspection, ensuring the safety of the wheel. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the arrangement of tread probes; Figure 2 This is a schematic diagram of the probe arrangement on the inner side of the rim; Figure 3 This is the ultrasonic configuration diagram for single-side wheel detection. DETAILED DESCRIPTION

[0024] The following is combined with Figure 1-Figure 3 This application is described in further detail.

[0025] The embodiment of the present application discloses a method for arranging ultrasonic detection probes for the rim and spokes of a motor vehicle unit.

[0026] refer to Figure 1 , Figure 2 and Figure 3 A method for arranging ultrasonic detection probes for rims and spokes of EMUs includes using 6 phased array probes and 15 conventional probes to simultaneously detect defects in the rim, flange, spoke, and transition area between the rim and spoke of a single wheel of the same wheelset.

[0027] refer to Figure 1, the distribution of probes on the tread (detection area): 4 phased array probes (PA1-PA4), 5 dual crystal straight probes (TR1-TR5) and 4 single crystal oblique probes (A1-A4) are arranged on the tread; one dual crystal straight probe is set at the center of the tread (TR1), and the other four dual crystal straight probes are distributed in a quadrangle shape (TR2-TR5) with the dual crystal straight probe (TR1) at the center as the center; the four phased array probes (PA1-PA4) are centered on TR1, distributed in groups of two on both sides of TR1 along the length direction of the tread; the four single crystal oblique probes (A1-A4) are centered on TR1, distributed in groups of two on both sides of TR1 along the width direction of the tread.

[0028] refer to Figure 2 , the distribution of probes on the inner side of the rim (detection area): 2 phased array probes (PA5, PA6), 4 single crystal oblique probes (A5-A8) and 2 dual crystal straight probes (TR6, TR7) are arranged on the inner side of the rim; one dual crystal straight probe is set at the center of the inner side of the rim (TR7), and the other dual crystal straight probe is set at either end of the inner side of the rim (TR6); two phased array probes (PA5, PA6) are symmetrically distributed on both sides of TR7; four single crystal oblique probes (A5-A8) are spaced above TR7 along the length direction of the inner side of the rim.

[0029] refer to Figure 1 , four phased array probes (PA1-PA4) are used for bidirectional coverage, circumferential defects are detected using phased array PC (one transmit and one receive) mode, and oblique and radial defects are detected using PE (pulse reflection method) mode. Bidirectional coverage: The detection direction of the two sets of phased array probes (PA1-PA4) is along the direction towards TR1.

[0030] When these four phased array probes (PA1-PA4) detect spoke-related defects, different detection modes are used according to the characteristics of defects in different directions: when detecting circumferential defects, the phased array PC (transmit-receive) mode is used. This mode can more effectively detect the defects of the spoke in the circumferential direction through a specific sound wave emission and reception method, and improve the detection sensitivity and accuracy of defects such as circumferential cracks; while when detecting oblique and radial defects, the PE (pulse reflection method) mode is used. The characteristics of the phased array probe emitting ultrasonic waves and receiving reflected waves in this mode are used to analyze and judge the defects of the spoke in the oblique and radial directions, thereby realizing effective detection of defects such as oblique and radial cracks. By flexibly controlling the direction and focus of the sound beam, the phased array probe can perform high-precision detection of defects of different depths and angles on the tread and spoke, especially for the complex structural area where the spoke and tread are connected, and circumferential, radial and oblique crack defects can be accurately detected. The single crystal oblique probe is more sensitive to defects on the tread surface and near the surface, and can detect defects such as surface cracks caused by wear and abrasions, thereby ensuring the quality of the tread surface.

[0031] refer to Figure 2 The dual crystal straight probe (TR6, TR7) uses a dual crystal longitudinal wave straight probe, and the single crystal oblique probe (A5-A8) uses a shear wave oblique probe. The shear wave emitted by the shear wave oblique probe (A5-A8) is incident on the inner side of the rim at an angle of 50°-70°. The dual crystal longitudinal wave straight probe (TR6, TR7) is combined with the shear wave oblique probe (A5-A8) for coverage detection to detect volume defects inside the rim. The dual crystal straight probe has advantages in detecting volume defects inside the tread. The ultrasonic waves it transmits and receives can more effectively penetrate the tread and find possible defects inside, such as inclusions and looseness. The dual crystal longitudinal wave straight probe (TR6, TR7) is set on the inner side of the rim to detect the inside of the rim from another angle, which complements the probe on the tread. It further enhances the detection capability of deep defects inside the rim, improves the coverage rate of the overall internal defect detection of the rim, ensures the integrity of the rim structure, and ensures the safety performance of the wheel during operation.

[0032] refer to Figure 1 The four single crystal oblique probes (A1-A4) use shear wave probes and two are in a group. The detection directions of the two groups of shear wave probes are set in directions away from each other. The shear waves emitted by the shear wave probes (A1-A4) are incident on the top and root of the rim at an angle of 55°-75°, thereby detecting the mirror crack defects at the top and root of the rim.

[0033] The probe models used in the embodiments of the present application are: phased array probe (PA1-PA6): 5L18-0.6-10; dual crystal straight probe (TR1-TR7): DA2, 5P12FS20; shear wave angle probe (A1-A4): 5P8-9A70; shear wave angle probe (A5-A8): 5P8*9K2.

[0034] The implementation principle of the method for arranging ultrasonic detection probes for the wheel rim and spokes of a train set in the embodiment of the present application is as follows: 1. Push the EMU wheel to be tested to the position of the ultrasonic testing equipment so that the tread of the wheel and the inner side of the rim are aligned with the corresponding probe position. The cylinder on the clamping device is controlled by the controller to adjust the opening angle of the clamping device so that the probe can fit closely to the wheel surface. At the same time, the other two cylinders are used to adjust the distance between the probe installed on the clamping arm and the rim to ensure good coupling between the probe and the wheel to obtain the best probe signal. All probe signals collected by the ultrasonic testing equipment are analyzed through a series of processing algorithms based on region segmentation, region growth, automatic contrast adjustment, periodic superposition extension, KMEANS clustering and HOUGH transformation. According to the results of data processing and analysis, the quality of the wheel rim, flange, spoke and the transition area between the rim and the spoke is comprehensively evaluated.

[0035] The ultrasonic detection equipment here is the existing technology, and the cylinder and other equipment and algorithm analysis are not described in detail. This application only provides a detailed introduction to the layout of the probe.

[0036] 2. Tread detection: Start the ultrasonic detection equipment to detect the wheel tread. The dual crystal straight probes TR1-TR5 start working, emitting ultrasonic waves and receiving reflected signals. At the same time, the four phased array probes PA1-PA4 perform bidirectional coverage detection in the direction set to TR1. For circumferential defects, the phased array probe works in PC (transmit and receive) mode, and improves the detection sensitivity of circumferential crack defects by precisely controlling the direction and focus of the sound beam. When a circumferential defect is detected, the position and length of the defect in the circumferential direction are determined based on the time, amplitude and other characteristics of the reflected signal. For oblique and radial defects, the phased array probe adopts PE (pulse reflection method) mode, emitting ultrasonic waves and receiving defect reflected waves, and analyzing the characteristics of the reflected waves to determine the situation of oblique and radial crack defects. The four single crystal oblique probes A1-A4 detect defects on the tread surface and near the surface in a distributed manner along the tread width direction. The ultrasonic waves they emit can effectively detect defects such as surface cracks caused by wear, abrasions, etc., which supplements the shortcomings of dual crystal straight probes and phased array probes in the detection of defects at different depths and types.

[0037] 3. Inspection of the inner side of the rim: While the tread is being inspected, the probe on the inner side of the rim also starts working. Dual crystal straight probes TR6 and TR7 (using dual crystal longitudinal wave straight probes) emit longitudinal waves to detect volume defects deep inside the rim. Four single crystal oblique probes A5-A8 (using shear wave oblique probes, the emitted shear waves are incident on the inner side of the rim at an angle of 50°-70°) are spaced above TR7 along the length direction of the inner side of the rim to detect defects on the inner side of the rim. Two phased array probes PA5 and PA6 are symmetrically distributed on both sides of TR7. When it is necessary to detect radial crack defects on the outer side of the rim, shear wave fan-shaped scanning is performed through software control. The shear waves emitted by the phased array probe cover the outer area of ​​the rim in a fan-shaped manner, expanding the detection range and increasing the probability of detecting radial crack defects on the outer side of the rim.

[0038] 4. Wheel rim inspection: Four single crystal oblique probes A1-A4 (two shear wave probes are used as a group, and the detection directions of the two groups of shear wave probes are set in directions away from each other) detect mirror crack defects at the top and root of the wheel rim. The shear wave is incident on the top and root of the wheel rim at an angle of 55°-75°.

[0039] Through the reasonable layout of the probes, multiple parts of a single wheel of the same wheel pair can be inspected at the same time in one test, without repeated inspection of different areas, saving inspection time and improving inspection efficiency. The probe layout is carried out from the two flaw detection contact surfaces of the tread and the inner side of the rim. In combination with probes of different angles and types, the circumferential, radial, oblique and axial fatigue defects of the rim and spoke can be fully inspected without leaving blind spots for inspection, ensuring the safety of the wheel.

[0040] The embodiments of this specific implementation method are all preferred embodiments of the present application, and are not intended to limit the protection scope of the present application. Therefore, all equivalent changes made based on the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. A method for arranging ultrasonic detection probes for wheel rims and spokes of a train set, characterized in that: The system uses the tread and the inner side of the rim as the flaw detection contact surfaces, and adopts 6 phased array probes and 15 conventional probes to simultaneously detect the defects of the rim, flange, spoke and the transition area between the rim and spoke of a single wheel of the same wheelset. Among them, 4 phased array probes (PA1-PA4), 5 dual-crystal straight probes (TR1-TR5) and 4 single-crystal oblique probes (A1-A4) are arranged on the tread; 2 phased array probes (PA5, PA6), 4 single-crystal oblique probes (A5-A8) and 2 dual-crystal straight probes (TR6, TR7) are arranged on the inner side of the rim. The distribution of probes on the tread (detection area): a dual-crystal straight probe is set at the center of the tread (TR1), and the other four dual-crystal straight probes are distributed in a quadrangular shape (TR2-TR5) with the dual-crystal straight probe (TR1) at the center as the center; four phased array probes (PA1-PA4) are distributed on both sides of TR1 in groups of two along the length direction of the tread with TR1 as the center; four single-crystal oblique probes (A1-A4) are distributed on both sides of TR1 in groups of two along the width direction of the tread with TR1 as the center; The distribution of probes on the inner side of the rim (detection area): one dual-crystal straight probe is set at the center of the inner side of the rim (TR7), and the other dual-crystal straight probe is set at either end of the inner side of the rim (TR6); two phased array probes (PA5 and PA6) are symmetrically distributed on both sides of TR7; four single-crystal oblique probes (A5-A8) are spaced above TR7 along the length direction of the inner side of the rim.

2. The method for arranging ultrasonic detection probes for EMU wheel rims and spokes according to claim 1, characterized in that: The four phased array probes (PA1-PA4) are used for bidirectional coverage, and circumferential defects are detected using the phased array PC (one transmit and one receive) mode, and oblique and radial defects are detected using the PE (pulse reflection method) mode.

3. The method for arranging ultrasonic detection probes for EMU wheel rims and spokes according to claim 1, characterized in that: The dual crystal straight probe (TR6, TR7) adopts a dual crystal longitudinal wave straight probe, and the single crystal oblique probe (A5-A8) adopts a shear wave oblique probe. The dual crystal longitudinal wave straight probe (TR6, TR7) is combined with the shear wave oblique probe (A5-A8) to perform coverage detection for detecting volume defects in the rim.

4. The method for arranging ultrasonic detection probes for EMU wheel rims and spokes according to claim 3, characterized in that: The shear waves emitted by the shear wave oblique probes (A5-A8) are incident on the inner side of the rim at an angle of 50°-70°.

5. The method for arranging ultrasonic detection probes for EMU wheel rims and spokes according to claim 1, characterized in that: The four single crystal oblique probes (A1-A4) are shear wave probes and two are in a group. The detection directions of the two groups of shear wave probes are arranged in directions away from each other for detecting mirror image crack defects at the top and root of the rim.

6. The method for arranging ultrasonic detection probes for EMU wheel rims and spokes according to claim 5, characterized in that: The shear waves emitted by the shear wave probes (A1-A4) are incident on the top and root of the rim at an angle of 55°-75°.

7. The method for arranging ultrasonic detection probes for EMU wheel rims and spokes according to claim 1, characterized in that: The two phased array probes (PA5, PA6) perform shear wave sector scanning for detecting radial cracks on the outer side of the rim.

8. The method for arranging ultrasonic detection probes for EMU wheel rims and spokes according to claim 2, characterized in that: The detection directions of the two groups of phased array probes (PA1-PA4) are both along the direction toward TR1.

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