Welded rail intelligent flaw detection device and method

Abstract

The invention relates to the technical field of steel rail flaw detection, in particular to a welded rail intelligent flaw detection device and method.The welded rail intelligent flaw detection device comprises a mechanical arm, and a flaw detection assembly is arranged at the front end of the mechanical arm and comprises an ultrasonic detection head and a reciprocating deflection assembly; the reciprocating deflection assembly drives the ultrasonic detection head to deflect back and forth between a first deflection position and a second deflection position so as to switch the detection direction; and the coupling assembly is used for conveying a coupling agent to the detection surface. The structure of the flaw detection device is optimized, and the detection area can be enlarged through the reciprocating deflection structure of the ultrasonic detection head, so that the detection coverage is improved; under driving of the mechanical arm, the flaw detection assembly can be driven to advance along the scanning path more automatically and intelligently, flaw detection of the steel rail is completed accurately, and therefore flaw detection efficiency and result accuracy are guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of rail flaw detection, and in particular to an intelligent flaw detection device and method for welded rails. Background Art

[0002] At present, rail ultrasonic flaw detection mainly relies on multi-channel ultrasonic detection systems, which use array probes to identify defects.

[0003] In recent years, through a lot of practical verification and technical analysis, it is found that the automatic online equipment has a weak ability to detect damage in some special parts of the rail bottom during the flaw detection process, or even cannot detect it, especially in special parts such as the shallow surface of the rail bottom and the triangular area of ​​the rail bottom. The details are as follows:

[0004] 1. For the surface damage of the rail bottom, if there is a small defect in the protruding part of the weld bar, it is not easy to find it by flaw detection on the rail bottom side. This is mainly because the original flaw detection process of the equipment adopts K1 rail bottom side K-shaped flaw detection, and the test block adopts R2 semicircular groove and 0.3mm horizontal through groove.

[0005] 2. The automatic rail bottom flaw detection process is not easy to effectively detect area defects in the middle and upper layers (triangular area) of the rail bottom.

[0006] The traditional flaw detection process is to have skilled flaw detectors hold the probe and swing it constantly at different angles to conduct detection. This process cannot clearly distinguish some damage signals from the grain wave area of ​​the weld rail, resulting in missed detections. Even if the flaw detector finds a suspected damage signal, the damage signal is affected by the optimal position and optimal angle of the damage detection probe. The signal often flashes by and needs to be moved back and forth and adjusted repeatedly to confirm. This requires very high flaw detection skills and work experience of the flaw detector, and it is very easy to miss detections and missed judgments. This is why the flaw detectors in the weld rail factory miss judgments before leaving the factory, or do not judge because they think the judgment standards are not met. After the rail is shipped out of the factory according to the qualified mark, the flaw detectors in the railway engineering section find objections to damage during work. This often happens in actual flaw detection work on weld rail welds.

[0007] With the current technology, there are still significant defects in practical applications. As follows:

[0008] First, the detection efficiency is limited by the coordination between manual operation and equipment movement. Traditional equipment needs to rely on manual cart operation, and the coupling state between the probe and the rail surface needs to be adjusted repeatedly, resulting in a single detection taking too long. Especially in complex sections such as turnouts and welds, the flaw detection speed is very low, and it is difficult to meet the full coverage detection requirements of long and large sections of rails. In addition, the existing systems mostly use a fixed-interval intermittent scanning mode, and the detection interval generally exceeds 20mm, which is easy to cause the missed detection of local defects such as small cracks and peeling blocks.

[0009] Second, the detection accuracy is constrained by multiple interference factors. Existing coupling media (such as water-based coupling agents) are prone to lubrication film rupture during high-speed movement, resulting in ultrasonic signal instability and a signal-to-noise ratio drop of more than 40%. Pollutants such as oxide layers and oil stains on the rail surface will further aggravate the acoustic impedance mismatch and cause fluctuations in the amplitude of defect echoes. At the same time, problems such as probe deflection caused by environmental vibration and sound velocity drift caused by temperature changes have not been effectively solved. The existing compensation algorithm can only correct ±5% of the error, which cannot meet the quantitative detection requirements of submillimeter defects in high-speed rails.

[0010] Third, the lack of intelligence leads to a high misjudgment rate. The existing system relies on manual experience to extract defect features, and the recognition accuracy of complex defect types such as rail head core damage and rail waist oblique cracks is low. Although deep learning algorithms have been partially applied, they are limited by the size of the sample library and on-site noise interference, and the false alarm rate is high. In addition, there is a lack of dynamic correlation analysis between flaw detection data and rail service status parameters (such as axle load and wear), making it difficult to accurately predict the defect expansion trend. These problems have seriously restricted the transformation and upgrading of rail flaw detection from "post-detection" to "preventive maintenance".

[0011] It can be seen that the current rail ultrasonic flaw detection scheme still has room for improvement. It should be optimized and the efficiency of flaw detection should be improved to ensure the accuracy of flaw detection. Therefore, it is necessary to propose a more reasonable technical solution to solve the technical problems existing in the existing technology. Summary of the invention

[0012] In order to overcome at least one of the defects mentioned above, the present invention proposes an intelligent flaw detection device and method for welded rails, combines the characteristics of automated flaw detection and the flaw detection process of a welded rail factory, absorbs the flaw detection operation specifications of a maintenance section, and proposes a structure and method for intelligent flaw detection on the upper surface of the bottom of a welded rail using a robotic arm, so as to realize automated flaw detection, improve flaw detection efficiency, simplify flaw detection process, reduce flaw detection operation steps, and effectively discover damage to special parts of the bottom of the welded rail weld head.

[0013] In order to achieve the above-mentioned purpose, the flaw detection device disclosed in the present invention can adopt the following technical solutions:

[0014] The intelligent flaw detection device for welding rails includes a mechanical arm, a flaw detection component is arranged at the front end of the mechanical arm, the flaw detection component includes an ultrasonic detection head and a reciprocating deflection component, the reciprocating deflection component drives the ultrasonic detection head to reciprocate between a first deflection position and a second deflection position to switch the detection direction; and also includes a coupling component, the coupling component is used to transport a coupling agent to the detection surface.

[0015] The above-disclosed flaw detection device expands the flaw detection detection area during the moving flaw detection process by causing the flaw detection component to swing, and forms a full coverage flaw detection on the area to be detected after multiple scanning flaw detections; the flaw detection component is driven by a mechanical arm to automatically perform flaw detection actions on the area to be detected, which can ensure the execution efficiency, the accuracy of the flaw detection action and the accuracy and reliability of the flaw detection structure.

[0016] Furthermore, the flaw detection assembly can adopt a variety of schemes and can be constructed in a variety of forms. Its structure is not limited to a single one. Here, it is optimized and one of the feasible options is proposed: the flaw detection assembly includes a mounting seat that cooperates with the mechanical arm, and a rotating seat is arranged on the mounting seat. The ultrasonic detection head is arranged on the rotating seat and rotates synchronously with the rotating seat to achieve deflection. The reciprocating deflection assembly cooperates with the rotating seat and drives the rotating seat to reciprocate. When the above scheme is adopted, the mounting seat moves synchronously with the mechanical arm, thereby driving the flaw detection assembly to move synchronously; the rotating seat can adopt a rotating shaft, a rotating bearing and other structures, which rotate relative to the mounting seat, thereby driving the flaw detection assembly to rotate synchronously.

[0017] Furthermore, the reciprocating deflection assembly is used to drive the deflection of the flaw detection assembly, thereby forming a swing detection flaw detection during the process of moving, which can expand the detection area. The reciprocating deflection assembly can adopt a variety of structures, and its structure is not limited to a single one. Here, it is optimized and one of the feasible options is proposed: the reciprocating deflection assembly includes a shift fork and a rotating shaft, the rotating shaft is arranged on the mounting seat, and the middle part of the shift fork rotates to match the rotating shaft; the rear end of the shift fork is connected to the driving assembly, and the driving assembly causes the shift fork to reciprocate, and the front end of the shift fork cooperates with the rotating seat and drives the rotating seat to deflect. When the above scheme is adopted, the driving assembly can drive the rear end of the shift fork to reciprocate, and under the action of the rotating shaft, the front end of the shift fork reciprocates, thereby driving the rotating seat to reciprocate, thereby realizing the reciprocating deflection of the ultrasonic detection head.

[0018] Furthermore, in some schemes, the swivel seat and the shift fork are matched with each other through a matching clamp and a matching column. The matching clamp can be set on the shift fork, and the matching column can be set on the swivel seat. In some other schemes, the settings can also be swapped.

[0019] Furthermore, the drive assembly may also adopt a variety of schemes, and its structure is not limited to a single one. Here, an optimization is made and one of the feasible options is proposed: the drive assembly includes a drive motor, the drive shaft of the drive motor is connected to a cam, the rear end of the fork forms a switching groove, the cam enters the switching groove and pushes the fork to reciprocate. When the above scheme is adopted, the switching groove can be set as a waist-shaped groove, extending along the length direction of the fork, and the cam moves the groove wall of the waist-shaped groove during the rotation of the drive shaft to make the fork reciprocate.

[0020] Furthermore, the mounting seat can be constructed in various forms for setting corresponding components, and its structure is not limited to a single one. Here, an optimization is made and one feasible option is proposed: the mounting seat includes a connecting plate that cooperates with the mechanical arm, and the connecting plate moves synchronously with the mechanical arm; the mounting seat also includes a mounting plate arranged on the connecting plate, and the flaw detection component and the coupling component are both arranged on the mounting plate. When the above scheme is adopted, the connecting plate and the mounting plate can be connected and fixed by multiple fasteners, such as multiple bolts or connecting pins.

[0021] Furthermore, during the ultrasonic detection process, the coupling agent is used to ensure the stability of ultrasonic transmission. The coupling component is used to form a coupling between the flaw detection component and the surface of the rail to be tested, thereby facilitating the propagation of ultrasonic waves. The coupling component can adopt a variety of schemes, and its structure is not limited to a single one. Here, it is optimized and one of the feasible options is proposed: the coupling component includes a nozzle, and the nozzle is connected to a delivery pipe. When the flaw detection device is turned on, the delivery pipe delivers the coupling agent to the nozzle and sprays it to the detection surface through the nozzle. When the above scheme is adopted, the coupling agent can be a liquid substance such as water and engine oil.

[0022] Furthermore, in order to form a more stable coupling between the surface to be inspected and the flaw detection component and reduce interference caused by the entry of debris, an optimization is made here and one of the feasible options is proposed: a cleaning component is also provided on the mounting seat, and the cleaning component is used to clean the inspection surface. When the above solution is adopted, the cleaning component can adopt a structure such as a cleaning brush.

[0023] Furthermore, in order to better analyze the condition of the rail surface, the analysis can be assisted by visual images, which can be implemented through a variety of solutions. The structure is not limited to a single one. Here, an optimization is made and one of the feasible options is proposed: the front end of the mechanical arm is also provided with a visual component, which is used to obtain image data of the detection surface and transmit it to the processor. When the above solution is adopted, the visual component includes a camera, the number of which is not limited to a single one, including cameras for obtaining pictures and videos respectively, and the processor is used to collect and analyze image data to assist in judging the damage.

[0024] The above content introduces the composition and structure of the flaw detection device. The present invention also discloses a flaw detection method, which will be described in detail below.

[0025] Intelligent flaw detection method for weld rails, including:

[0026] Delimiting the flaw detection area of ​​the rail bottom inclined surface, setting the rail scanning path in the flaw detection area, including a plurality of parallel scanning paths arranged at intervals on the rail bottom inclined surface, and the scanning path extending along the length direction of the rail;

[0027] The flaw detection component is made to move along one of the scanning paths. During the moving process, the ultrasonic detection head of the flaw detection component is reciprocated and swung to the left and right sides of the moving path to scan and detect flaws on the rail bottom inclined surface;

[0028] When the flaw detection component has completed flaw detection along one scanning path, the flaw detection component is reset and switched to an adjacent scanning path and repeats the flaw detection action, forming an overlapped area in the flaw detection areas of the two adjacent scanning paths;

[0029] When one flaw detection area completes the traveling flaw detection, the flaw detection component moves to the next flaw detection area and repeats the above traveling flaw detection action until all flaw detection areas are completed.

[0030] Furthermore, one-to-one corresponding scanning paths are formed in two opposite flaw detection areas, and the corresponding scanning paths are in opposite directions; when the flaw detection component moves along the corresponding scanning paths in the two opposite flaw detection areas, the direction of the flaw detection component is correspondingly switched by 180°.

[0031] Compared with the prior art, some beneficial effects of the technical solution disclosed in the present invention include:

[0032] The present invention optimizes the structure of the flaw detection device and can increase the detection area through the reciprocating deflection structure of the ultrasonic detection head, thereby improving the detection coverage; driven by the mechanical arm, it can drive the flaw detection component along the scanning path in a more automated and intelligent manner, accurately complete the flaw detection of the rail, thereby ensuring the efficiency of flaw detection and the accuracy of the results. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only represent some embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0034] Figure 1 It is a schematic diagram of the overall structure of the flaw detection device and an enlarged schematic diagram of the local structure.

[0035] Figure 2 for Figure 1 A schematic diagram of the enlarged local structure in the middle.

[0036] Figure 3 for Figure 1 Enlarged schematic diagram of the local structure at point B in the middle.

[0037] Figure 4 It is a front view schematic diagram of the flaw detection device.

[0038] Figure 5 for Figure 4 Enlarged schematic diagram of the local structure at point C in the middle.

[0039] Figure 6 It is a top view schematic diagram of the flaw detection device.

[0040] Figure 7 for Figure 6 Enlarged schematic diagram of the local structure at point D in the middle.

[0041] Figure 8 It is a side view schematic diagram of the flaw detection device.

[0042] Fig. 9 for Figure 8 Enlarged schematic diagram of the local structure at point E in the middle.

[0043] Fig.10 It is the flaw detection coverage area when the rail bottom slope S1 baseline is used as the scanning path.

[0044] Fig.11 It is the flaw detection coverage area when the rail bottom slope S2 baseline is used as the scanning path.

[0045] Fig.12 It is the flaw detection coverage area when the rail bottom slope S3 baseline is used as the scanning path.

[0046] Fig.13 It is the flaw detection coverage area when the S4 baseline of the rail bottom slope is used as the scanning path.

[0047] Fig.14 It is the flaw detection coverage area when the S5 baseline of the rail bottom slope is used as the scanning path.

[0048] Fig.15 It is the flaw detection coverage area when the S6 baseline of the rail bottom slope is used as the scanning path.

[0049] Fig.16 It is the total coverage area after the intersection of the baseline flaw detection coverage area of ​​the rail bottom slope S1-S6.

[0050] Fig.17 It is the blind area for flaw detection on the rail bottom slope.

[0051] Fig.18 A solution to supplement the blind area of ​​flaw detection in rail bottom process.

[0052] Fig.19 Another solution to supplement the blind area of ​​flaw detection for rail bottom process.

[0053] Fig. 20 This is a schematic diagram of the defect echo of the damage head 1000-1.

[0054] Fig.21 This is a schematic diagram of the defect echo of the damage head 674-4.

[0055] Fig. 22 This is a schematic diagram of the A2 defect echo of the damage head.

[0056] Fig.23 This is a schematic diagram of the defect echo of the damage head 1003-3.

[0057] In the above drawings, the meanings of the symbols are as follows:

[0058] 1. Rail; 2. Robotic arm; 3. Flaw detection assembly; 301. Mounting seat; 3011. Connecting plate; 3012. Mounting plate; 302. Rotating seat; 3021. Matching column; 303. Rotating shaft; 304. Fork; 3041. Matching chuck; 305. Cam; 306. Ultrasonic detection head; 307. Cleaning assembly; 308. Nozzle. DETAILED DESCRIPTION

[0059] The present embodiment is further explained below in conjunction with the accompanying drawings and specific embodiments.

[0060] In view of the shortcomings of the existing rail ultrasonic flaw detection solutions, such as low efficiency and large errors, the following embodiments are optimized and overcome the defects in the prior art.

[0061] Example 1

[0062] The present embodiment provides an intelligent flaw detection device for a weld rail, including a robotic arm 2, a flaw detection component 3 is provided at the front end of the robotic arm 2, the flaw detection component 3 includes an ultrasonic detection head 306 and a reciprocating deflection component, the reciprocating deflection component drives the ultrasonic detection head 306 to reciprocate between a first deflection position and a second deflection position to switch the detection direction; and also includes a coupling component, the coupling component is used to transport a coupling agent to the detection surface.

[0063] The flaw detection device disclosed in this embodiment expands the detection area of ​​flaw detection during the process of moving flaw detection by causing the flaw detection component 3 to swing, and forms full coverage flaw detection on the area to be detected after multiple scanning flaw detections; the flaw detection component 3 is driven by the mechanical arm 2 to automatically perform flaw detection actions on the area to be detected, thereby ensuring the efficiency of execution, the accuracy of the flaw detection action and the accuracy and reliability of the flaw detection structure.

[0064] The flaw detection component 3 can adopt a variety of schemes and can be constructed in a variety of forms. Its structure is not limited to a single one. This embodiment is optimized and adopts one of the feasible options: the flaw detection component 3 includes a mounting seat 301 that cooperates with the mechanical arm 2, and a rotating seat 302 is arranged on the mounting seat 301. The ultrasonic detection head 306 is arranged on the rotating seat 302 and rotates synchronously with the rotating seat 302 to achieve deflection. The reciprocating deflection component cooperates with the rotating seat 302 and drives the rotating seat 302 to reciprocate. When the above scheme is adopted, the mounting seat 301 moves synchronously with the mechanical arm 2, thereby driving the flaw detection component 3 to move synchronously; the rotating seat 302 can adopt a rotating shaft 303, a rotating shaft 303 bearing and other structures to rotate relative to the mounting seat 301, thereby driving the flaw detection component 3 to rotate synchronously.

[0065] The reciprocating deflection assembly is used to drive the flaw detection assembly 3 to deflect, thereby forming a swing detection flaw detection during the process of moving, which can expand the detection area. The reciprocating deflection assembly can adopt a variety of structures, and its structure is not limited to the only one. This embodiment is optimized and adopts one of the feasible options: the reciprocating deflection assembly includes a fork 304 and a rotating shaft 303, the rotating shaft 303 is arranged on the mounting seat 301, and the middle part of the fork 304 rotates to fit the rotating shaft 303; the rear end of the fork 304 is connected to the driving assembly, and the driving assembly makes the fork 304 reciprocate, and the front end of the fork 304 cooperates with the rotating seat 302 and drives the rotating seat 302 to deflect. When the above scheme is adopted, the driving assembly can drive the rear end of the fork 304 to reciprocate, and under the action of the rotating shaft 303, the front end of the fork 304 reciprocates, thereby driving the rotating seat 302 to reciprocate, thereby realizing the reciprocating deflection of the ultrasonic detection head 306.

[0066] In some embodiments, the swivel seat 302 and the fork 304 are matched with each other through the matching clamp head 3041 and the matching column 3021. The matching clamp head 3041 can be set on the fork 304, and the matching column 3021 can be set on the swivel seat 302. In some other embodiments, the settings can also be swapped.

[0067] The drive assembly can also adopt a variety of schemes, and its structure is not limited to a single one. This embodiment is optimized and adopts one of the feasible options: the drive assembly includes a drive motor, the drive shaft of the drive motor is connected to a cam 305, the rear end of the fork 304 forms a switching groove, and the cam 305 enters the switching groove and pushes the fork 304 to reciprocate. When the above scheme is adopted, the switching groove can be set as a waist-shaped groove, extending along the length direction of the fork 304. When the cam 305 rotates with the drive shaft, it moves the groove wall of the waist-shaped groove to reciprocate the fork 304.

[0068] The mounting seat 301 can be constructed in various forms for setting corresponding components, and its structure is not limited to a single one. This embodiment is optimized and adopts one of the feasible options: the mounting seat 301 includes a connecting plate 3011 that cooperates with the mechanical arm 2, and the connecting plate 3011 moves synchronously with the mechanical arm 2; the mounting seat 301 also includes a mounting plate 3012 arranged on the connecting plate 3011, and the flaw detection component 3 and the coupling component are both arranged on the mounting plate 3012. When the above solution is adopted, the connecting plate 3011 and the mounting plate 3012 can be connected and fixed by multiple fasteners, such as multiple bolts or connecting pins.

[0069] During ultrasonic detection, the coupling agent is used to ensure the stability of ultrasonic transmission. The coupling component is used to form a coupling between the flaw detection component 3 and the surface to be tested of the rail 1, so as to facilitate the propagation of ultrasonic waves. The coupling component can adopt a variety of schemes, and its structure is not limited to the only one. This embodiment is optimized and adopts one of the feasible options: the coupling component includes a nozzle 308, and the nozzle 308 is connected to a delivery pipe. When the flaw detection device is turned on, the delivery pipe delivers the coupling agent to the nozzle 308 and sprays it to the detection surface through the nozzle 308. When the above scheme is adopted, the coupling agent can be a liquid substance such as water and engine oil.

[0070] In order to form a more stable coupling between the surface to be inspected and the flaw detection component 3 and reduce interference caused by the entry of debris, this embodiment is optimized and adopts one of the feasible options: the mounting seat 301 is also provided with a cleaning component 307, and the cleaning component 307 is used to clean the inspection surface. When adopting the above solution, the cleaning component 307 can adopt a structure such as a cleaning brush.

[0071] In order to better analyze the surface of the rail 1, the analysis can be assisted by visual images. This can be achieved through a variety of solutions, and its structure is not limited to a single one. This embodiment is optimized and adopts one of the feasible options: the front end of the mechanical arm 2 is also provided with a visual component, which is used to obtain image data of the detection surface and transmit it to the processor. When the above solution is adopted, the visual component includes a camera, the number of which is not limited to a single one, including cameras for obtaining pictures and videos respectively, and the processor is used to collect and analyze image data to assist in judging the damage.

[0072] Example 2

[0073] The content of the above-mentioned embodiment 1 introduces the composition structure of the flaw detection device. This embodiment discloses a flaw detection method, which is described in detail below.

[0074] Intelligent flaw detection method for weld rails, including:

[0075] Delimiting a flaw detection area of ​​the rail bottom inclined surface of the rail 1, setting a scanning path of the rail 1 in the flaw detection area, including a plurality of parallel scanning paths spaced apart on the rail bottom inclined surface, and the scanning paths extending along the length direction of the rail 1;

[0076] The flaw detection component 3 is made to move along one of the scanning paths. During the moving process, the ultrasonic detection head 306 of the flaw detection component 3 is reciprocated and swung to the left and right sides of the moving path to scan and detect flaws on the rail bottom inclined surface;

[0077] When the flaw detection component 3 completes flaw detection along one scanning path, the flaw detection component 3 is reset and switched to an adjacent scanning path and repeats the flaw detection action, forming an overlapped area in the flaw detection areas of the two adjacent scanning paths;

[0078] When one flaw detection area completes the traveling flaw detection, the flaw detection component 3 moves to the next flaw detection area and repeats the above-mentioned traveling flaw detection action until all flaw detection areas are completed.

[0079] One-to-one corresponding scanning paths are formed in two opposite flaw detection areas, and the corresponding scanning paths are in opposite directions; when the flaw detection component 3 moves along the corresponding scanning paths in the two opposite flaw detection areas, the direction of the flaw detection component 3 is correspondingly switched by 180°.

[0080] The flaw detection method provided in this embodiment can be applied to the flaw detection operation of the tread and the bottom surface of the welded rail. Some cases and data are listed below to illustrate the effect of this embodiment.

[0081] Case 1

[0082] In this case, the flaw detection device provided by the invention is used to scan and detect flaws on the inclined surface of the bottom of the rail. The specific device configuration and the effects after scanning and flaw detection are as follows:

[0083] Ultrasonic detection head: 5P10X12 K2.5 oblique probe is used.

[0084] The scanning method is: the probe is scanned along the baseline S1-S6 with a left deflection of plus or minus 20°.

[0085] After testing, the single-zone flaw detection time is 32 seconds, and the single-side flaw detection time can be controlled within 2 minutes (each side of the robotic arm is responsible for detecting 2 areas, i.e. 64 seconds, and preparation work such as benchmarking and oiling takes time during the detection process).

[0086] The flaw detection adopts the mechanical arm to move in a straight line, and the external motor realizes the probe deflection. According to the test, when the motor speed is 750 revolutions per minute, the flaw detection effect of the mechanical arm remains good, and the tooth pitch L of the probe when walking on the baseline can be calculated to be 2.26mm;

[0087] The flaw detection time for each baseline is t=32÷6=5.3 seconds, the number of motor rotations for each baseline flaw detection is N=750÷60×t=66.25 circles, and the tooth pitch is L=150÷N=2.26mm.

[0088] During the flaw detection process, the tooth pitch L formed by the yaw movement of the ultrasonic detection head can be comprehensively adjusted according to the walking speed of the robot arm and the speed of the yaw motor.

[0089] When a groove with a radius of 2mm is set at the bottom of the rail, the flaw detection operation is driven by the device. The specific flaw detection conditions are as follows:

[0090] 1) On each scanning path, the area covered by the flaw detection is as follows: Figure 10-Figure 15 As shown, the detection area covered by each scanning path is as follows Fig.16 shown.

[0091] 2) Combination Fig.16 It can be seen that the area for scanning and flaw detection along the rail bottom slope cannot completely cover the entire rail flaw detection area. The three uncovered blind areas are as follows: Fig.17 As shown, blind area 1 and blind area 2 can be supplemented by scanning and flaw detection along the bottom surface of the rail by other flaw detection mechanisms, such as Fig.18 , Fig.19 As shown, scanning and flaw detection can be achieved according to two different ultrasonic detection head layout methods; and the blind area 3 is supplemented by the traditional waist-rail flaw detection process, which will not be repeated here.

[0092] The specific results of scanning and flaw detection of the rail bottom in the above manner are shown in Table 1 below.

[0093] Table 1 Robot flaw detection results of rail bottom bevel of welded rail joint

[0094]

[0095] Case 2

[0096] According to the method disclosed in the above embodiment, other parts of the rail are scanned and inspected. The device provided by the present invention can also detect surface structures at different positions. In this case, the tread and head sides of the rail can be inspected. Therefore, test blocks with different scanning and inspection positions (wound heads with different numbers) are set for scanning and inspection comparison to confirm the actual effect of the inspection by comparison and verification. After actual testing, specific inspection results are obtained, as shown in Table 2 below.

[0097] Table 2 Results of flaw detection on the beveled edge of the rail bottom of the welded rail joint

[0098]

[0099] When performing scanning and flaw detection verification, the defect echoes of each flaw head, such as Figure 20 to Figure 23 As shown, they are 1000-1 defect echo, 674-4 defect echo, A2 defect echo, and 1003-3 defect echo respectively.

[0100] According to the data shown in Table 2, it can be seen that the defects of the four damaged heads with natural damage can be effectively detected after being scanned and inspected by the device of the present invention.

[0101] In addition, in the above case 1 or case 2, considering the selection of coupling agent, engine oil is currently used as the coupling medium for flaw detection scanning on the upper surface of the rail bottom. In actual automated flaw detection and intelligent flaw detection, more environmentally friendly and recyclable water can be used as the coupling medium. However, the ultrasonic detection head needs to swing back and forth at a certain speed during the flaw detection process. The vibration of water during the swinging process affects the collection and identification of flaw detection information. Therefore, the device needs to blow away excess water in time during the flaw detection process. Specifically, the cleaning components can be optimized, such as setting a blowing nozzle and other structures to blow away excess water.

[0102] After practical application, the flaw detection device provided by the present invention can achieve the beneficial effects shown in Table 3 below compared with conventional technologies:

[0103] Table 3 Comparative analysis of the flaw detection effect of this device and manual flaw detection effect

[0104]

[0105]

[0106] The above are the implementation methods listed in this embodiment, but this embodiment is not limited to the above optional implementation methods. Those skilled in the art can arbitrarily combine the above methods to obtain other various implementation methods. Anyone can derive other various implementation methods under the inspiration of this embodiment. The above specific implementation methods should not be understood as limiting the protection scope of this embodiment. The protection scope of this embodiment should be based on the definition in the claims.

Claims

1. Intelligent flaw detection device for welding rails, characterized by: The invention comprises a mechanical arm (2), wherein a flaw detection component (3) is arranged at the front end of the mechanical arm (2), wherein the flaw detection component (3) comprises an ultrasonic detection head (306) and a reciprocating deflection component, wherein the reciprocating deflection component drives the ultrasonic detection head (306) to reciprocate between a first deflection position and a second deflection position to switch the detection direction; and further comprises a coupling component, wherein the coupling component is used to transport a coupling agent to a detection surface.

2. The intelligent flaw detection device for welding rails according to claim 1 is characterized in that: The flaw detection assembly (3) comprises a mounting seat (301) matched with the mechanical arm (2); a rotating seat (302) is arranged on the mounting seat (301); the ultrasonic detection head (306) is arranged on the rotating seat (302) and rotates synchronously with the rotating seat (302) to achieve deflection; the reciprocating deflection assembly cooperates with the rotating seat (302) and drives the rotating seat (302) to reciprocate.

3. The intelligent flaw detection device for welding rails according to claim 2 is characterized in that: The reciprocating deflection assembly comprises a shift fork (304) and a rotating shaft (303), wherein the rotating shaft (303) is arranged on the mounting seat (301), and the middle part of the shift fork (304) is rotatably matched to the rotating shaft (303); the rear end of the shift fork (304) is connected to the driving assembly, and the driving assembly causes the shift fork (304) to reciprocate and deflect, and the front end of the shift fork (304) is matched with the rotating seat (302) and drives the rotating seat (302) to deflect.

4. The intelligent flaw detection device for welding rails according to claim 3 is characterized in that: The driving assembly comprises a driving motor, a driving shaft of the driving motor is connected to a cam (305), a switching groove is formed at the rear end of the shift fork (304), and the cam (305) enters the switching groove and pushes the shift fork (304) to reciprocate.

5. The intelligent flaw detection device for welding rails according to any one of claim 4, characterized in that: The mounting seat (301) comprises a connecting plate (3011) matched with the mechanical arm (2), and the connecting plate (3011) moves synchronously with the mechanical arm (2); the mounting seat (301) also comprises a mounting plate (3012) arranged on the connecting plate (3011), and the flaw detection component (3) and the coupling component are both arranged on the mounting plate (3012).

6. The intelligent flaw detection device for welding rails according to claim 1 is characterized in that: The coupling assembly comprises a nozzle (308), and the nozzle (308) is connected to a delivery pipe. When the flaw detection device is turned on, the delivery pipe delivers coupling agent to the nozzle (308) and sprays the coupling agent onto the detection surface through the nozzle (308).

7. The intelligent flaw detection device for welding rails according to any one of claims 2 to 5, characterized in that: The mounting seat (301) is also provided with a cleaning component (307), and the cleaning component (307) is used to clean the detection surface.

8. The intelligent flaw detection device for welding rails according to claim 1 is characterized in that: The front end of the mechanical arm (2) is also provided with a visual component, which is used to obtain image data of the detection surface and transmit it to the processor.

9. Intelligent flaw detection method for weld rails, characterized in that: include: Delimiting a flaw detection area on the rail bottom inclined surface of a steel rail (1), setting a scanning path for the steel rail (1) in the flaw detection area, including a plurality of parallel scanning paths arranged at intervals on the rail bottom inclined surface, the scanning paths extending along the length direction of the steel rail (1); The flaw detection component (3) is caused to move along one of the scanning paths, and during the moving process, the ultrasonic detection head (306) of the flaw detection component (3) is reciprocated and swung to the left and right sides of the moving path to scan and detect flaws on the rail bottom inclined surface; When the flaw detection component (3) completes flaw detection along one scanning path, the flaw detection component (3) resets and switches to an adjacent scanning path and repeats the flaw detection action, forming an overlapped area in the flaw detection areas of the two adjacent scanning paths; When one flaw detection area completes the forward flaw detection, the flaw detection component (3) moves to the next flaw detection area and repeats the forward flaw detection action until all flaw detection areas have completed the detection.

10. The intelligent flaw detection method for weld rails according to claim 9, characterized in that: A one-to-one corresponding scanning path is formed in two opposite flaw detection areas, and the corresponding scanning paths are in opposite directions; when the flaw detection component (3) moves along the corresponding scanning path in the two opposite flaw detection areas, the direction of the flaw detection component (3) is correspondingly switched by 180 degrees.

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