Turnout steel rail piece variable cross-section detection device and method

Abstract

The turnout steel rail piece variable cross-section detection device is provided with a steel rail piece conveying bearing structure which conveys a to-be-detected workpiece in the length direction of a steel rail, the workpiece is matched with a plurality of guiding devices, the to-be-detected part of the workpiece is conveyed, contained and completely immersed in a medium of a coupling medium groove, and a cantilever beam support is arranged outside the coupling medium groove. A plurality of probe assemblies and a mechanical tool are installed on the cantilever beam support, the probe assemblies are also immersed in the coupling medium, an ultrasonic detector and an automatic control system are arranged outside the coupling medium groove, the ultrasonic detector is in interactive connection with the probe assemblies, and the automatic control system is in interactive connection with the ultrasonic detector and the mechanical tool. According to the invention, automatic and efficient detection of the full section, especially the variable section part, of the turnout steel rail piece is realized, the in-service damage risk of the rail piece is reduced, the service life is prolonged, the section coverage range and the detection precision are improved, and defects can be recorded and replayed.

Description

Technical Field

[0001] The present invention belongs to the technical field of physical measurement and testing using ultrasonic detection technology, and specifically relates to a variable cross-section detection device and method for turnout rail components, mainly used for the detection of switch rails and crossing rails. Background Art

[0002] Although ultrasonic detection has been carried out on turnout rail components in the steel mill, it is necessary to ensure that the minimum cross-sectional area to be inspected is not less than 70% for the rail head part, not less than 60% for the rail web part, and not less than the rail bottom triangular area for the rail bottom part.

[0003] Currently, at the manufacturing stage of turnout rail components, after the rail raw materials are delivered to the factory, the state of the rail raw materials is detected by the A-type pulse echo method using the manual contact method to detect internal defects of the turnout rail component raw materials during the manufacturing stage in the steel mill. However, the detection efficiency of this detection method is low. For the finished turnout rail components, the spatial curved surface composed of arcs and inclined planes at the variable cross-section parts of the switch rails and crossing rails cannot be effectively detected, and the detection results cannot be recorded. In view of this, the following improved technical solutions are proposed. Summary of the Invention

[0004] The technical problem solved by the present invention: Provide a variable cross-section detection device and method for turnout rail components. By using a specially designed device and combining a probe array through a coupling medium to detect the variable cross-section parts of the switch rails and crossing rails, the technical problem that the finished turnout rail components cannot effectively detect the spatial curved surface composed of arcs and inclined planes at the variable cross-section parts of the switch rails and crossing rails is solved.

[0005] The technical solution adopted by the present invention: A variable cross-section detection device for turnout rail components has a rail component conveying and load-bearing structure. The rail component conveying and load-bearing structure carries and conveys the workpiece to be detected along the length direction of the rail. The workpiece to be detected is adapted to a plurality of guiding devices for restricting and positioning the workpiece. The part to be detected of the workpiece to be detected is conveyed and fully immersed in the coupling medium in the coupling medium tank. Outside the coupling medium tank, there is a cantilever beam bracket. The cantilever beam bracket is suspended and installed with a plurality of probe combinations and mechanical toolings, and the probes of the plurality of probe combinations and mechanical toolings are all immersed in the coupling medium in the coupling medium tank. Outside the coupling medium tank, there is an ultrasonic detector and an automatic control system. The ultrasonic detector is interconnected with the probe combination, and the automatic control system is interconnected with the ultrasonic detector and the mechanical tooling.

[0006] In the above technical solution, preferably: the workpiece to be detected is a switch rail or a crossing rail.

[0007] In the above technical solution, further: the guiding device adapted to the workpiece to be detected has three groups; the probe combination and mechanical tooling for detecting the defective parts of the workpiece to be detected have eight groups.

[0008] In the above technical solution, further: In the guiding device, the guiding device I and the guiding device III are fixed in position, and the guiding device II moves with the workpiece while maintaining the clamping force as the width of the rail base changes; the bottoms of the guiding device I and the guiding device II in the guiding device are connected to the top of the rail member conveying and load-bearing structure. The guiding device I restricts the left vertical end face of the rail base part of the workpiece, the guiding device II restricts the right vertical end face of the rail base part of the workpiece, and the guiding device III presses down to restrict the upper end face of the rail limb of the rail base of the workpiece.

[0009] In the probe assembly and the mechanical tooling, the probe assembly and the mechanical tooling I, and the probe assembly and the mechanical tooling II are arranged obliquely at an angle on the left and right sides of the rail head and are used for detecting the spatial curved surface part composed of an arc and an inclined plane at the variable cross-section of the turnout rail member; the probe assembly and the mechanical tooling IV, and the probe assembly and the mechanical tooling VIII are symmetrically arranged vertically on the left and right sides of the rail web and are used for detecting the rail web part of the turnout rail member; the probe assembly and the mechanical tooling V, and the probe assembly and the mechanical tooling VII are arranged parallel to each other vertically at intervals on the left and right sides of the rail base and are used for detecting the left and right sides of the rail base of the turnout rail member; the probe assembly and the mechanical tooling III is arranged at the bottom of the rail base and is used in combination with other probe assemblies for detecting the rail head, rail web, and rail base parts of the turnout rail member; the probe assembly and the mechanical tooling VI is arranged at the bottom of the rail base and is used in combination with other probe assemblies for detecting the rail base part of the turnout rail member; the mechanical tooling in the probe assembly and the mechanical tooling is used for precise control of the probe position and the thickness of the coupling layer.

[0010] In the above technical solution, further: The position of the probe assembly and the mechanical tooling VII follows the movement of the guiding device; the positions of the probe assembly and the mechanical tooling III, the probe assembly and the mechanical tooling IV, the probe assembly and the mechanical tooling V, the probe assembly and the mechanical tooling VI, and the probe assembly and the mechanical tooling VIII are fixed; the probe assembly and the mechanical tooling III is used for detecting defects in the rail head, rail web, and rail base parts parallel to the rail base; the probe assembly and the mechanical tooling IV, and the probe assembly and the mechanical tooling VIII are used for detecting defects in the rail web part parallel to the rail web; the probe assembly and the mechanical tooling V is used for detecting defects in the rail limb parallel to the rail web; the probe assembly and the mechanical tooling VI is used for detecting defects in the rail limb parallel to the rail base.

[0011] In the above technical solution, further: The detection data of the probe assembly and the mechanical tooling are recorded in real time by an ultrasonic detector.

[0012] The present invention also claims protection for a method for detecting the variable cross-section of a turnout rail member, which uses the detection device described above and includes the following steps:

[0013] S1. Before detection, through the rail member conveying and load-bearing structure, the switch rail or the stock rail is guided by the guiding device, so that the part to be detected of the switch rail or the stock rail is stably conveyed into the coupling medium tank, and the part to be detected of the switch rail or the stock rail is completely immersed in the coupling medium.

[0014] S2. As the probe assembly and the mechanical tooling control the movement of the probe along the length direction of the rail member, the ultrasonic detector emits focused ultrasonic waves through the probe assembly according to the phased array detection principle. The ultrasonic waves generate interface reflection waves on the surface of the rail member through medium coupling. The ultrasonic detector receives the interface reflection waves through the probe assembly, calculates the interface profile of the sound beam coverage area through the ultrasonic detector, and processes it to form the surface profile of the switch rail or the stock rail.

[0015] S3. Based on the surface profile information, the ultrasonic detector uses the ultrasonic beam control method to focus and deflect the ultrasonic beam generated by the probe assembly, generating a sound beam parallel to the direction of the switch rail or the stock rail. The position of the probe assembly is controlled through the automatic control system and the mechanical tooling to achieve precise control of the probe position and the coupling layer thickness, and complete the detection of the spatial curved surface structure part composed of an arc and an inclined plane at the variable cross-section of the switch rail or the stock rail head. At the same time, the probe assemblies corresponding to other detection parts of the switch rail or the stock rail are controlled by the ultrasonic detector to generate ultrasonic beam focusing and deflection. The position of the probe assembly is controlled through the automatic control system and the mechanical tooling to achieve precise control of the probe position and the coupling layer thickness, and complete the detection of other relatively regular structure parts of the switch rail or the stock rail, ultimately realizing the full-section detection of the switch rail or the stock rail.

[0016] In the above technical solution, further: in step S3, for the flat part of the switch rail or the stock rail, the probe assembly uses the phased array detection technology principle to control the focusing and deflection of the ultrasonic beam, and adjusts the incident angle and the thickness of the medium layer in real time according to the angle change between the plane and the symmetry axis of the rail, ensuring the maximum sound beam coverage range and defect detection rate; for the spatial curved surface of the switch rail or the stock rail, a specific phased array focusing rule is adopted to control the focusing and deflection of the ultrasonic beam, and an automatic control system is used to control the sound beam to detect the variable cross-section of the rail member from two opposite directions and one mutually perpendicular direction.

[0017] In the above technical solution, further: the detection method is carried out once when the switch rail or the stock rail leaves the factory.

[0018] Advantages of the present invention compared with the prior art:

[0019] 1. The present invention can especially achieve low-cost, high-efficiency and automated detection of the spatial curved surface composed of an arc and an inclined plane at the variable cross-section of the switch rail and the stock rail of the turnout, and the detection information can be recorded, ultimately realizing the full-section detection of the switch rail and the stock rail of the turnout, reducing the damage risk of the turnout rail member during line use, and prolonging the service life of the turnout rail member.

[0020] 2. All the parts to be detected of the turnout rail parts of the present invention are completely immersed in the coupling medium for detection, and the coupling effect is stable. By adopting the automatic control technology combined with mechanical tooling, the precise control of the coupling layer thickness can be realized. By adopting the probe combination and according to the principle of phased array technology, the ultrasonic beam can be deflected and focused, so as to realize the low-cost automatic detection of the spatial curved surface composed of arc and inclined plane at the variable cross-section parts of turnout switch rails, stock rails, etc., and finally realize the full-section detection of turnouts, especially the switch rails, stock rails and other rail parts.

[0021] 3. For the plane parts of the rail parts, the present invention adopts the probe combination to utilize the principle of phased array detection technology to control the focusing and deflection of the ultrasonic beam, and according to the angle change between the plane and the symmetry axis of the rail, the incident angle and the thickness of the medium layer are adjusted in real time, which can ensure the maximum beam coverage range and defect detection rate. For the spatial curved surface, a specific phased array focusing rule is adopted for internal defect detection, which improves the defect detection rate of the variable cross-section parts of the rail parts and reduces the risk of in-service fracture of the rail parts. In addition, for the variable cross-section parts of the switch rail or stock rail, automatic control is adopted to control the beam to detect the variable cross-section of the rail part from two opposite directions and one perpendicular direction, so as to reduce the surface blind area, increase the beam coverage, improve the signal-to-noise ratio and improve the defect detection rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Fig. 1(a) is a schematic diagram (I) of the device structure of the workpiece cross-sectional shape 1 to be detected according to the present invention;

[0023] Fig. 1(b) is a schematic diagram (II) of the device structure of the workpiece cross-sectional shape 1 to be detected according to the present invention;

[0024] Fig. 2(a) is a schematic diagram (I) of the device structure of the workpiece cross-sectional shape 2 to be detected according to the present invention;

[0025] Fig. 2(b) is a schematic diagram (II) of the device structure of the workpiece cross-sectional shape 2 to be detected according to the present invention;

[0026] Fig. 3(a) is a schematic diagram (I) of the device structure of the workpiece cross-sectional shape 3 to be detected according to the present invention;

[0027] Fig. 3(b) is a schematic diagram (II) of the device structure of the workpiece cross-sectional shape 3 to be detected according to the present invention;

[0028] Figure 4 is a schematic diagram for dividing the rail head, rail bottom, rail web and rail limb of the workpiece to be detected according to the present invention;

[0029] Figure 5 is a schematic diagram of the detection parts when the probe combination and the mechanical tooling I, II, III of the present invention are used in combination;

[0030] Figure 6 is a schematic diagram of the detection parts when the probe combination and the mechanical tooling V, VI, VII of the present invention are used in combination;

[0031] Figure 7 This is the process flow diagram of the present invention;

[0032] In the figure: 1 - workpiece to be detected, 2 - coupling medium tank, 3 - load-bearing structure for conveying rail parts, 4 - guiding device I, 5 - guiding device II, 6 - guiding device III, 7 - probe combination and mechanical tooling I, 8 - probe combination and mechanical tooling II, 9 - probe combination and mechanical tooling III, 10 - probe combination and mechanical tooling IV, 11 - probe combination and mechanical tooling V, 12 - probe combination and mechanical tooling VI, 13 - probe combination and mechanical tooling VII, 14 - probe combination and mechanical tooling VIII, 15 - cantilever beam support, 16 - ultrasonic detector, 17 - automatic control system. Specific embodiments

[0033] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings 1-7 in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0034] A variable cross-section detection device for turnout rail parts, (Figs. 1-3) has a load-bearing structure 3 for conveying rail parts, the load-bearing structure 3 for conveying rail parts carries and conveys the workpiece 1 to be detected along the length direction of the rail, the workpiece 1 to be detected is adapted to a plurality of guiding devices for restricting and positioning the workpiece, the part to be detected of the workpiece 1 to be detected is conveyed into and completely immersed in the medium of the coupling medium tank 2, a cantilever beam support 15 is provided outside the coupling medium tank 2, the cantilever beam support 15 is suspended and installed with a plurality of probe combinations and mechanical toolings, and the probes of the plurality of probe combinations and mechanical toolings are all immersed in the medium of the coupling medium tank 2, an ultrasonic detector 16 and an automatic control system 17 are provided outside the coupling medium tank 2, the ultrasonic detector 16 is interconnected with the probe combination, and the automatic control system 17 is interconnected with the ultrasonic detector 16 and the mechanical tooling.

[0035] It should be noted that: The rail component transmission and load-bearing structure 3 can carry and transmit the workpiece to be detected 1 along the length direction of the rail, ensuring the continuous and stable movement of the workpiece during the detection process, which is beneficial to improving the detection efficiency and reducing the time and labor intensity of manual handling. The workpiece to be detected 1 is adapted to a plurality of guiding devices for restricting and positioning the workpiece, which can ensure the position accuracy of the workpiece during the transmission process, so that the part to be detected can be accurately transmitted and incorporated into the coupling medium tank 2, ensuring the accuracy and repeatability of the detection. The part to be detected of the workpiece to be detected 1 is transmitted and incorporated and completely immersed in the medium of the coupling medium tank 2, and at the same time, the probes of the plurality of probe combinations and the mechanical tooling are also completely immersed in the medium of the coupling medium tank 2. The coupling medium can effectively reduce the energy loss of ultrasonic waves during propagation, improve the transmission efficiency of ultrasonic waves, enable ultrasonic waves to better couple with the workpiece, thereby enhancing the intensity and clarity of the detection signal and improving the sensitivity and accuracy of the detection. The coupling medium tank 2 provides a relatively stable environment for the detection, reducing the influence of external factors on ultrasonic detection, such as air disturbance, dust, etc., which helps to ensure the reliability of the detection results. The cantilever beam bracket 15 is suspended and installed with a plurality of probe combinations and mechanical tooling. This layout method can flexibly adjust the position and angle of the probes to meet the detection requirements of workpieces with different shapes and sizes, improving the versatility and adaptability of the device. At the same time, the suspended structure can also avoid interference between the probes and the workpiece or other components, ensuring the smooth progress of the detection. An ultrasonic detector 16 and an automatic control system 17 are provided outside the coupling medium tank 2, and the ultrasonic detector 16 is interconnected with the probe combination, and the automatic control system 17 is interconnected with the ultrasonic detector 16 and the mechanical tooling. This highly integrated layout makes the entire detection device compact in structure, convenient for installation and maintenance. At the same time, it also reduces the signal transmission distance and interference, improving the stability and reliability of the system. The automatic control system 17 can be interconnected with the ultrasonic detector 16 and the mechanical tooling to realize the automatic control of the detection process. It can automatically adjust the position, angle and detection parameters of the probes according to the preset program, control the actions of the mechanical tooling, coordinate the work of each component, improve the detection efficiency and consistency, and reduce the influence of human factors on the detection results. The automatic control system 17 can also process and analyze the detection data collected by the ultrasonic detector 16, feedback the detection results in real time, timely detect defects and problems in the workpiece, and can adjust the detection strategy according to the detection results to improve the accuracy and reliability of the detection.

[0036] In the above embodiment, preferably: The workpiece to be detected 1 is a switch rail or a crossing nose rail.

[0037] It should be noted that: The switch rail and the crossing nose have unique variable cross-section shapes and complex contour curves, and it is difficult for ordinary detection devices to comprehensively cover their key detection parts. In this device, multiple guiding devices, probe combinations and mechanical toolings can accurately position and restrain according to the shapes of the switch rail or the crossing nose, so that the probes can accurately align with each key detection area of the switch rail or the crossing nose, such as the variable cross-section transition parts of the rail head, rail web and rail bottom, effectively avoiding missed detections and improving the comprehensiveness and accuracy of detection. The variable cross-section parts of the switch rail and the crossing nose are the parts where stress concentration and defects are likely to occur, and have relatively high requirements for detection depth. In this device, all the probes are immersed in the coupling medium in the coupling medium tank, and the coupling medium can enhance the penetration ability of ultrasonic waves, enabling the ultrasonic waves to penetrate deep into the interior of the switch rail or the crossing nose and detect minute defects at the variable cross-section parts, such as internal cracks and inclusions. The application of the automatic control system for the switch rail or the crossing nose reduces the degree of manual participation in the detection process, reducing labor costs and human errors. The operator only needs to perform simple monitoring and parameter settings, and the detection device can automatically complete the detection work of the switch rail or the crossing nose.

[0038] In the above-mentioned embodiment, further: There are three groups of guiding devices adapted to the workpiece 1 to be detected; There are eight groups of probe combinations and mechanical toolings for detecting the defective parts of the workpiece 1 to be detected.

[0039] It should be noted that: The three groups of guiding devices can constrain and position the switch rail or the movable point rail from different directions, always maintaining a stable posture and an accurate position, without shaking or deviation. At the same time, they can adapt to the constraint positioning of workpieces with complex shapes. The three groups of guiding devices can be flexibly designed and arranged according to the shape characteristics of the workpiece, without shaking or deviation, so as to better meet the detection requirements for workpieces with complex shapes. The three groups of guiding devices disperse the force on the workpiece during the conveying process, avoiding deformation or damage of the workpiece caused by excessive local force. The force borne by each guiding device is relatively small, which can ensure the stable movement of the workpiece during the conveying process and reduce the detection errors caused by vibration and shaking. The eight groups of probe combinations and mechanical toolings can detect the switch rail or the movable point rail from multiple angles. For example, probes with different angles can be set to detect different parts of the workpiece, including all sides of the rail head, rail web, and rail base. This multi-angle coverage method can detect various defects hidden inside the workpiece, such as transverse cracks, longitudinal cracks, inclusions, etc., greatly improving the comprehensiveness of the detection. For the variable cross-section parts of the switch rail and the movable point rail, the eight groups of probes can detect different depth areas respectively. By adjusting the position and focal length of the probes, it is possible to penetrate into the interior of the workpiece and detect the tiny defects at the variable cross-section, ensuring the safety performance of the turnout. Different types of defects require different detection methods and probe parameters. The eight groups of probe combinations and mechanical toolings can be flexibly configured according to the type and characteristics of the defects, and the appropriate probes and detection modes can be selected. For example, high-frequency probes can be used for surface defects, and low-frequency probes can be used for internal defects, improving the pertinence and flexibility of the detection. During the actual detection process, switch rails or movable point rails of different specifications and models may be encountered. The eight groups of probe combinations and mechanical toolings can quickly switch the detection scheme to adapt to the detection requirements of different workpieces. Through the adjustment of the automatic control system, the reconfiguration of the probes and the parameter setting can be completed in a short time, improving the adaptability and efficiency of the detection. The eight groups of probe combinations and mechanical toolings have a certain degree of redundancy. When a certain group of probes fails or the detection result is inaccurate, the other probes can still continue to detect, ensuring the continuity and reliability of the detection process. At the same time, the detection results of multiple groups of probes can be mutually verified, improving the accuracy and credibility of the detection results. The detection data collected by the eight groups of probes can be comprehensively analyzed. By comparing the detection results of different probes, it is possible to more accurately judge the position, size, and nature of the defects. This comprehensive analysis method can reduce the possibility of misjudgment and missed judgment, improving the reliability of the detection. The three groups of guiding devices and the eight groups of probe combinations and mechanical toolings achieve efficient collaborative work through the automatic control system. The guiding devices ensure the accurate positioning of the workpiece, providing good conditions for the probe detection; the probe combinations and mechanical toolings are automatically adjusted according to the position of the workpiece and the detection requirements to achieve fast and accurate detection. This collaborative work method improves the operation efficiency and detection quality of the entire detection device.During the detection process, the automatic control system can adjust the detection parameters and position of the probe in real time according to the workpiece position information fed back by the guiding device, ensuring the stability and accuracy of the detection process. At the same time, it can also process and analyze the detection data in real time, discover problems in a timely manner and give alarms, improving the automation and intelligent level of detection. Comprehensive detection and efficient operation methods can reduce the rework and maintenance costs caused by inaccurate detection. By detecting the defects of the switch rail or crossing rail in a timely manner, repairs or replacements can be carried out at an early stage, avoiding more serious damage to the turnout caused by the expansion of the defects and reducing the maintenance cost of the turnout. The stable operation of the detection device reduces the failure rate and maintenance frequency of the equipment, reducing the maintenance cost of the equipment. At the same time, the application of the automatic control system reduces manual intervention, lowers the labor cost and improves the economic benefits of the detection device.

[0040] In the above embodiments, further: the guiding device I 4 and the guiding device III 6 in the guiding device are fixed in position, and the guiding device II 5 moves with the workpiece while maintaining the clamping force as the rail bottom width changes; the bottoms of the guiding device I 4 and the guiding device II 5 in the guiding device are connected to the top of the rail member conveying and load-bearing structure 3, the guiding device I 4 restricts the left vertical end face of the rail bottom part of the workpiece, the guiding device II 5 restricts the right vertical end face of the rail bottom part of the workpiece, and the guiding device III 6 presses down to restrict the upper end face of the rail limb of the rail bottom of the workpiece.

[0041] It should be noted that: The guiding device I 4 restricts the left vertical end face of the rail bottom part of the workpiece, the guiding device II 5 restricts the right vertical end face of the rail bottom part of the workpiece, and the guiding device III 6 presses down to restrict the upper end face of the rail limb of the rail bottom of the workpiece. This three-way restraint method can accurately position the workpiece from different directions, ensuring that the workpiece will not shift or shake during the conveying process. For example, when detecting the switch rail, the shape of the rail bottom of the switch rail is relatively complex. Through this multi-directional restraint, the switch rail can always be kept in the correct position, ensuring that the probe can accurately align with the detection part and improving the detection accuracy. The guiding device I 4 and the guiding device III 6 are fixed in position, providing a stable reference benchmark for the workpiece. The guiding device II 5 moves with the workpiece while maintaining the clamping force as the width of the rail bottom changes. This design not only ensures the positioning accuracy of the workpiece in the horizontal direction but also can adapt to workpieces with different rail bottom widths. For example, when detecting switch rails of different models, the width of the rail bottom of the switch rail may be different. The guiding device II 5 can automatically adjust its position and always closely fit the workpiece to ensure the accuracy of positioning. The guiding device II 5 moves as the width of the rail bottom changes, enabling this guiding device to adapt to switch rails or crossing rails with a variety of different rail bottom widths. During the production and maintenance process of the turnout, switch rails and crossing rails of different specifications may be used. This design can position and detect workpieces of different specifications without replacing the guiding device, improving the versatility and adaptability of the device. The shapes of the rail bottoms of the switch rail and the crossing rail are usually relatively complex, with features such as arcs and inclined planes. The combined design of the guiding devices I 4, II 5, and III 6 can well adapt to these complex rail bottom shapes. For example, the guiding device III 6 presses down to restrict the upper end face of the rail limb, which can fit the inclined plane or arc part of the rail bottom, ensuring good contact between the workpiece and the guiding device during the conveying process and improving the stability and accuracy of positioning. The bottoms of the guiding device I 4 and the guiding device II 5 are connected to the top of the rail component conveying load-bearing structure 3. This connection method makes the guiding device and the conveying structure form an integral whole, enhancing the stability of the workpiece during the conveying process. During the conveying process, the gravity and conveying force acting on the workpiece can be evenly transmitted to the conveying load-bearing structure through the guiding device, reducing the vibration and shaking of the workpiece and ensuring the smooth progress of the detection process. The guiding device II 5 can maintain the clamping force during the process of moving with the workpiece, ensuring that the workpiece is always firmly constrained between the guiding devices. This stable clamping force can prevent the workpiece from being displaced due to external forces during the conveying process, further improving the positioning accuracy and detection stability of the workpiece. Since the workpiece can be quickly and accurately positioned during the conveying process, the time spent on adjusting the position of the workpiece is reduced, improving the detection efficiency. At the same time, the stable conveying state also enables the probe to continuously and efficiently detect the workpiece, shortening the detection cycle and improving the production efficiency. The structure of this guiding device is relatively simple, and the connection and cooperation between each component are relatively clear.When the guiding device fails or needs maintenance, maintenance personnel can conveniently inspect, replace, and adjust each component, reducing the maintenance difficulty and cost. The guiding devices Ⅰ4, Ⅱ5, and Ⅲ6 can be regarded as independent modules. When a problem occurs in a certain module, it can be quickly replaced without large-scale disassembly and repair of the entire guiding device, improving the maintenance efficiency and flexibility.

[0042] ( Figures 4 - 6 ) The probe combinations and mechanical toolings in the probe combination and mechanical tooling, namely, the probe combination and mechanical tooling Ⅰ7 and the probe combination and mechanical tooling Ⅱ8, are arranged at an angle on the left and right sides of the rail head and are used for detecting the spatial curved surface part composed of an arc and an inclined plane with a variable cross-section of the turnout rail member; the probe combination and mechanical tooling Ⅳ10 and the probe combination and mechanical tooling Ⅷ14 are symmetrically arranged vertically on the left and right sides of the rail web and are used for detecting the rail web part of the turnout rail member; the probe combination and mechanical tooling Ⅴ11 and the probe combination and mechanical tooling Ⅶ13 are arranged parallel to each other with a vertical interval on the left and right sides of the rail base and are used for detecting the left and right sides of the rail base of the turnout rail member; the probe combination and mechanical tooling Ⅲ9 is arranged at the bottom of the rail base and is used in combination with other probe combinations for detecting the rail head, rail web, and rail base parts of the turnout rail member; the probe combination and mechanical tooling Ⅵ12 is arranged at the bottom of the rail base and is used in combination with other probe combinations for detecting the rail base part of the turnout rail member; the mechanical tooling in the probe combination and mechanical tooling is used for precise control of the probe position and the coupling layer thickness.

[0043] It should be noted that: due to the complex shape of the rail head part, it is difficult for ordinary detection methods to comprehensively cover its surface features. The probe assemblies and mechanical tooling Ⅰ7 and the probe assemblies and mechanical tooling Ⅱ8 are arranged at an angle on the left and right sides of the rail head, and can detect the spatial curved surface part composed of an arc and an inclined plane of the variable cross-section of the turnout rail component, ensuring that no area where defects may exist is missed, greatly improving the comprehensiveness of detection. The mechanical tooling is used for precise control of the probe position and the thickness of the coupling layer, and can ensure that the probe accurately aligns with the detection part. During the detection process, the position deviation of the probe will directly affect the accuracy of the detection result. Through the precise control of the mechanical tooling, the probe position error can be controlled within a very small range, improving the precision of detection. Precise control of the coupling layer thickness is crucial for ultrasonic detection. A suitable coupling layer thickness can ensure the effective transmission of ultrasonic waves, reduce energy loss and signal interference. The mechanical tooling can precisely adjust the coupling layer thickness according to different detection parts and requirements, so that the ultrasonic waves maintain stable transmission characteristics during the detection process, improving the clarity and accuracy of the detection signal. The various probe assemblies and mechanical tooling work together through an automatic control system. During the detection process, different probe assemblies can detect different parts of the rail component simultaneously or sequentially, and the detection data can be shared and analyzed in real time. This collaborative working method can improve the detection efficiency, and at the same time, through the comprehensive analysis of the detection results of multiple probes, the position, size and nature of the defect can be judged more accurately. For example, when the probe at the rail head part detects an abnormal signal, the probes at the rail web and rail bottom parts can simultaneously conduct auxiliary detection to further confirm the situation of the defect and avoid misjudgment. The probe assemblies and mechanical tooling work together with components such as the rail component transmission and load-bearing structure and the coupling medium tank to form a complete detection system. The rail component transmission and load-bearing structure ensures the stable transmission of the rail component, the coupling medium tank provides a good detection environment, and the probe assemblies and mechanical tooling are responsible for precise detection. Each component cooperates with each other to jointly achieve efficient and accurate detection.

[0044] In the above embodiments, further: the positions of the probe assembly and the mechanical tooling VII 13 follow the movement of the guiding device 5; the positions of the probe assembly and the mechanical tooling III 9, the probe assembly and the mechanical tooling IV 10, the probe assembly and the mechanical tooling V 11, the probe assembly and the mechanical tooling VI 12, and the probe assembly and the mechanical tooling VIII 14 are fixed; when the probe assembly and the mechanical tooling III 9 are used alone, they are used to detect defects in the rail head, rail web, and rail base parts parallel to the rail base; the probe assembly and the mechanical tooling IV 10 and the probe assembly and the mechanical tooling VIII 14 are used to detect defects in the rail web part parallel to the rail web; the probe assembly and the mechanical tooling V 11 are used to detect defects in the rail limb parallel to the rail web; the probe assembly and the mechanical tooling VI 12 are used to detect defects in the rail limb parallel to the rail base. The mechanical tooling is used for precise control of the probe position and the coupling layer thickness, and its debugging and calibration processes are relatively simple. Through precise adjustment mechanisms and parameter settings, the probe position and the coupling layer thickness can be adjusted quickly and accurately to ensure the normal operation of the detection device. At the same time, maintenance personnel can calibrate the probe assembly and the mechanical tooling regularly as needed to ensure the accuracy and reliability of the detection results.

[0045] Specifically: the probe assembly and the mechanical tooling I 7 and the probe assembly and the mechanical tooling II 8 are used in combination to detect defects in the rail head part parallel to the rail web; the ultrasonic detector 16 controls the probe assembly and the mechanical tooling I 7 and the probe assembly and the mechanical tooling II 8 to emit ultrasonic waves. Through the coupling medium, the ultrasonic waves are reflected at the interface between the coupling medium and the workpiece 1 to be detected, forming an interface reflection wave that is received by the probe assembly and the mechanical tooling I 7 and the probe assembly and the mechanical tooling II 8. The ultrasonic detector 16 calculates the interface profile of the sound beam coverage area based on the interface reflection wave received by the probe assembly and the mechanical tooling I 7 and the probe assembly and the mechanical tooling II 8. According to the surface profile information, for the curved surface part of the surface profile, the ultrasonic detector 16 uses a specific ultrasonic beam control method to focus and deflect the ultrasonic beam generated by the probe assembly, generating a sound beam parallel to the rail base direction. The position of the probe assembly and the mechanical tooling I 7 and the probe assembly and the mechanical tooling II 8 is controlled through the automatic control system 17 and the probe assembly and the probe assembly and the mechanical tooling I 7 and the probe assembly and the mechanical tooling II 8 to achieve precise control of the probe position and the coupling layer thickness, and complete the detection of the spatial curved surface part composed of an arc and an inclined plane at the variable cross-section of the turnout rail part.

[0046] It should be noted that: Based on the interface reflection waves received by the ultrasonic detector 16 from the probe assembly and mechanical toolings I 7 and II 8, the interface contour of the sound beam coverage area can be accurately calculated. In the inspection of the variable cross-section of turnout rail parts, the interface contour of the rail head part is complex and variable, including features such as arcs and inclined planes. Through this accurate calculation, the actual shape of the rail head interface can be accurately understood, providing accurate basic data for subsequent inspections. For the curved surface part of the surface contour, the ultrasonic detector 16, based on the surface contour information, makes the ultrasonic beam generated by the probe assembly focus and deflect through a specific ultrasonic beam control method, generating a sound beam parallel to the direction of the rail bottom. This precise control can ensure that the ultrasonic beam accurately irradiates the part to be inspected, improving the resolution and sensitivity of the inspection. The probe assembly and mechanical toolings I 7 and II 8 are used in combination and are specifically designed to detect defects in the rail head part parallel to the rail web, especially suitable for the spatial curved surface part composed of arcs and inclined planes in the variable cross-section of turnout rail parts. This design can well adapt to the complex spatial shape of the rail head. Whether it is the bending degree of the arc or the inclination angle of the inclined plane, effective inspections can be carried out. This technology can detect various types of defects, such as internal cracks, pores, inclusions, etc. Since ultrasonic inspection has different reflection characteristics for defects of different materials, through the analysis of interface reflection waves and precise control of the sound beam, different types of defects can be accurately identified, providing comprehensive information for the quality assessment of turnout rail parts. The ultrasonic detector 16 controls the probe assembly and mechanical toolings I 7 and II 8 to emit ultrasonic waves and receive reflection waves, and the whole process is fast and efficient. The probe assembly can scan a large area of the rail head part in a short time, greatly improving the inspection efficiency. Through the precise control of the probe position and the coupling layer thickness by the automatic control system 17 and the probe assembly and mechanical toolings I 7 and II 8, the automation of the inspection process is achieved. The operator only needs to perform simple parameter settings and monitoring, and the inspection device can automatically complete tasks such as probe movement, sound beam adjustment, and data acquisition, reducing manual intervention and further improving the inspection efficiency. The automatic control system 17 can accurately control the positions of the probe assembly and mechanical toolings I 7 and II 8, and accurately move the probe to the specified position according to the inspection requirements and the rail head interface contour information. This precise control ensures the consistency and repeatability of the inspection and avoids inspection errors caused by probe position deviation. The automatic control system can also accurately control the coupling layer thickness to ensure the effective transmission of ultrasonic waves between the coupling medium and the interface of the workpiece to be inspected. The automatic adjustment of the coupling layer thickness can be optimized according to different inspection parts and requirements, improving the stability and reliability of the inspection signal. Due to the adoption of accurate interface contour calculation, sound beam focusing and deflection control, and an automated inspection process, the inspection data obtained by this technology is accurate and reliable. By comprehensively analyzing the reflection waves received by multiple probes, the possibility of misjudgment and missed judgment can be reduced, and the credibility of the inspection results can be improved.The entire detection system has high stability. The automatic control system can monitor and adjust the detection parameters in real time to ensure the stable operation of the detection process. At the same time, the design of the probe combination and the mechanical tooling also takes into account reliability and durability, and can maintain good performance during long-term use.

[0047] In the above embodiments, further: the detection data of the probe combination and the mechanical tooling are recorded in real time by the ultrasonic detector 16.

[0048] It should be noted that the ultrasonic detector 16 can record all the data detected by the probe combination and mechanical tooling in real time, including the location, size, shape, reflected wave intensity and other information of the defect. These data fully reflect the internal and surface conditions of the turnout rail parts, and provide rich materials for subsequent analysis and evaluation. For example, when detecting the point rail, the detector can record the defects of the rail head, rail waist and rail bottom. Even some small and imperceptible defects can be accurately recorded to ensure the comprehensiveness of the detection data. During the detection process, the detector continuously records data and can capture dynamic changes during the detection process. This is of great significance for analyzing the development trend of defects and judging the stability of the detection results. For example, during a long detection process, by observing the changes in the intensity of the defect reflected wave, it can be judged whether the defect is expanding, so as to take corresponding measures in time. The real-time recorded data can be directly transmitted to a computer or other analysis equipment, and quickly processed using professional analysis software. The analysis software can automatically classify, count and analyze a large amount of detection data, greatly shortening the data processing time. For example, the analysis software can generate defect distribution maps, defect size statistics, etc. in a short time, so that the inspectors can quickly understand the quality status of the turnout rail parts. The inspectors can view the test data and analysis results in real time during the test process, find problems in time and make adjustments. If the test data of a certain part is found to be abnormal, the test can be stopped immediately, and the part can be inspected in detail to improve the test efficiency. For example, when the detector shows that the reflected wave intensity of a certain rail head part is abnormal, the inspectors can immediately conduct further inspections on the part to avoid wasting time and resources. The real-time recorded test data can establish a complete quality file for each turnout rail part. The quality file contains all the test information of the rail part, including the test time, the inspector, the test results, etc. These files can be used for quality traceability. When problems occur in the use of the rail parts, the root cause of the problem can be found by consulting the quality files. The reliability and stability of the test process can be evaluated by analyzing the historical test data. By analyzing the test data of different times and different inspectors, possible problems in the test process can be found, such as probe aging, unstable coupling agent quality, etc., and timely measures can be taken to improve them. The real-time recorded test data provides a scientific basis for the quality assessment and maintenance decision-making of turnout rail parts. Based on the test data, it can be determined whether the rail parts meet the quality standards and whether they need to be repaired or replaced. For example, if the test data shows that the defect size of a certain rail bottom exceeds the specified standard, it can be decided to repair or replace the rail bottom to ensure the safe operation of the turnout. By analyzing a large amount of test data, it is possible to understand the problems existing in the production process of turnout rail parts and provide a reference for optimizing the production process. For example, if a batch of rail parts is found to have many defects, the raw materials, processing technology and other factors in the production process can be analyzed to find out the cause of the problem and make improvements.The detected data recorded in real time can be transmitted to the remote monitoring center through the network to achieve remote monitoring of the turnout rail component detection. The staff at the remote monitoring center can view the detected data and analysis results in real time, discover problems in a timely manner and provide guidance. The real-time recording and sharing of the detected data can promote the collaborative communication among different departments and different professionals. Detection personnel, analysis personnel, maintenance personnel, etc. can jointly analyze problems and formulate solutions by sharing the detected data.

[0049] ( Figure 7 ) The present invention also claims protection for a method for detecting the variable cross-section of a turnout rail component. Using the said detection device, it includes the following steps:

[0050] S1. Before detection, through the rail component conveying and load-bearing structure 3, the switch rail or the crossing nose is guided by the guiding device, so that the part to be detected of the switch rail or the crossing nose is stably conveyed into the coupling medium tank 2, and the part to be detected of the switch rail or the crossing nose is completely immersed in the coupling medium.

[0051] S2. As the probe assembly and the mechanical tooling control the probe to move along the length direction of the rail component, the ultrasonic detector 16 emits focused ultrasonic waves through the probe assembly according to the phased array detection principle. The ultrasonic waves generate interface reflection waves on the surface of the rail component through medium coupling. The ultrasonic detector 16 receives the interface reflection waves through the probe assembly, calculates the interface contour of the sound beam coverage area through the ultrasonic detector 16 and processes it to form the surface contour of the switch rail or the crossing nose.

[0052] S3. Based on the surface contour information, the ultrasonic detector 16 makes the ultrasonic beam generated by the probe assembly focus and deflect through the ultrasonic beam control method, generates an ultrasonic beam parallel to the direction of the switch rail or the crossing nose, controls the position of the probe assembly through the automatic control system 17 and the mechanical tooling, realizes precise control of the probe position and the coupling layer thickness, and completes the detection of the spatial curved surface structure part composed of an arc and an inclined plane at the variable cross-section of the switch rail or the crossing nose rail head; at the same time, the probe assemblies corresponding to other detection parts of the switch rail or the crossing nose are controlled by the ultrasonic detector 16 to generate ultrasonic beam focusing and deflection, control the position of the probe assembly through the automatic control system 17 and the mechanical tooling, realize precise control of the probe position and the coupling layer thickness, complete the detection of other relatively regular structure parts of the switch rail or the crossing nose, and finally realize the full-section detection of the switch rail or the crossing nose.

[0053] It should be noted that: This method can achieve full-section detection of the switch rail or the crossing nose, covering the spatial curved surface structure part where the rail head has a variable cross-section composed of an arc and an inclined plane, as well as other relatively regular structure parts. Whether it is a complex spatial curved surface or a regular plane, inclined plane, etc., comprehensive and detailed detection can be carried out to ensure that no area that may have defects is missed. Different types of probe combinations work simultaneously to detect different parts of the switch rail or the crossing nose. This collaborative detection method can make full use of the advantages of each probe combination to improve the detection efficiency and accuracy. The ultrasonic detector receives the interface reflection wave through the probe combination, calculates the interface contour of the sound beam coverage area, and processes it to form the surface contour of the switch rail or the crossing nose. This precise calculation can provide accurate basic data for subsequent sound beam focusing and deflection, ensuring that the ultrasonic wave can accurately irradiate the part to be detected. For example, when detecting the spatial curved surface of the rail head with a variable cross-section, the precise interface contour calculation can make the ultrasonic sound beam better adapt to the shape of the curved surface, improving the detection resolution and sensitivity. Based on the surface contour information, the ultrasonic detector makes the ultrasonic sound beam generated by the probe combination focus and deflect through a specific sound beam control method, generating a sound beam parallel to the direction of the switch rail or the crossing nose. This precise control can ensure that the ultrasonic energy is concentrated in the key area, effectively detecting tiny defects. For example, for the curved surface part of the crossing nose rail head, through sound beam focusing and deflection, the ultrasonic wave can generate a strong reflection signal at a specific position on the curved surface, thus more accurately discovering potential defects. The automatic control system can precisely control the position of the probe combination and the thickness of the coupling layer. During the detection process, according to the detection requirements and interface contour information, the automatic control system can quickly and accurately move the probe to the specified position and adjust the thickness of the coupling layer to ensure the effective transmission of ultrasonic waves. For example, when detecting switch rails of different models, the automatic control system can automatically adjust the probe position and the thickness of the coupling layer according to the size and shape of the switch rail, without manual intervention, improving the degree of automation of the detection. The ultrasonic detector has intelligent data processing and analysis functions. It can perform real-time processing and analysis on the received interface reflection wave, automatically identify information such as the location, size, and shape of the defect, and generate a detection report. For example, the detector can judge the type and severity of the defect by analyzing the intensity and frequency changes of the reflection wave, providing a basis for subsequent maintenance and decision-making. The probe combination moves along the length direction of the rail component under the control of the automatic control system, and can quickly scan a large area of the switch rail or the crossing nose. This fast scanning method greatly shortens the detection time and improves the detection efficiency. For example, on the production line of turnout rail components, using this method, multiple rail components can be detected in a short time to meet the needs of large-scale production. The entire detection process realizes a high degree of automation, reducing the need for manual intervention. The operator only needs to perform simple parameter settings and monitoring, and the detection device can automatically complete tasks such as probe movement, sound beam adjustment, and data acquisition, reducing the labor intensity and improving the work efficiency.This method can adapt to switch rails or crossing rails with different shapes and sizes. By adjusting the position of the probe combination, the acoustic beam parameters, and the thickness of the coupling layer, effective detection can be carried out on various types of switch rails and crossing rails. For example, for switch rails with different rail head widths and variable cross-section shapes, the detection system can automatically adjust the detection parameters to ensure the accuracy and reliability of the detection. Ultrasonic testing has high sensitivity to different types of defects and can detect various defects such as internal cracks, pores, and inclusions. By adjusting the focusing and deflection methods of the acoustic beam, optimized detection can be carried out for different types of defects to improve the defect detection rate.

[0054] In the above embodiments, further: in step S3, for the planar part of the switch rail or crossing rail, a probe combination is used to utilize the principle of phased array detection technology to control the focusing and deflection of the ultrasonic acoustic beam, and according to the angle change between the plane and the symmetry axis of the rail, the incident angle and the thickness of the medium layer are adjusted in real time to ensure the maximum acoustic beam coverage and defect detection rate; for the spatial curved surface of the switch rail or crossing rail, a specific phased array focusing rule is adopted to control the focusing and deflection of the ultrasonic acoustic beam, and an automatic control system 17 is used to control the acoustic beam to detect the variable cross-section of the rail component from two opposite directions and one mutually perpendicular direction.

[0055] It should be noted that: By adopting a specific phased array focusing rule for the spatial surface of the switch rail or the frog rail, the focusing and deflection of the ultrasonic beam can be precisely controlled. The shape of the spatial surface is complex, and it is difficult for ordinary detection methods to ensure the effective coverage of the beam. However, the specific focusing rule can make the beam achieve precise focusing at different positions on the surface according to the geometric shape and curvature change of the surface. For example, when detecting the surface of the planed part of the switch rail, the specific focusing rule can make the beam form a high-energy focusing point in the key area of the surface, improving the detection ability for micro defects. By adjusting the incident angle and the thickness of the medium layer in real time, the maximum beam coverage range can be ensured in the planar part. Different incident angles and medium layer thicknesses will affect the propagation path and coverage area of the beam. Reasonable adjustment can make the beam cover the entire planar area as much as possible and avoid detection blind spots. For example, when detecting the bottom surface of the rail, by adjusting the incident angle and the thickness of the medium layer, the beam can cover every corner of the rail bottom to ensure that defects at any position can be detected. For multi-directional detection of the spatial surface, by using an automatic control system to detect the variable cross-section of the rail component from two opposite directions and one perpendicular direction, the full coverage of the spatial surface can be achieved. Defects on the spatial surface may exist in different directions and positions. Multi-directional detection can greatly increase the probability of detecting defects. For example, for the spatial surface of the frog rail, detecting from two opposite directions and one perpendicular direction can cover all sides and the top surface of the surface, effectively discovering defects in different directions. The specific phased array focusing rule and the automatic control system can adapt to the complex spatial surface shape of the switch rail or the frog rail. The curvature, distortion degree, etc. of the spatial surface are different. This detection method can adapt to various complex spatial surface structures by precisely controlling the focusing and deflection of the beam and multi-directional detection. For example, for some specially designed frog rails with a relatively complex spatial surface shape, this method can still effectively detect them. The specific phased array focusing rule and the multi-directional detection method can enhance the ability to discover defects on the spatial surface. Defects on the spatial surface may be hidden in different parts and directions of the surface. Multi-directional beam coverage and precise focusing can make these defects more easily exposed. For example, for inclusions on the spatial surface of the frog rail, by detecting from multiple directions, the reflection signal is more easily captured by the probe, thus improving the detection rate of inclusions.

[0056] In the above-mentioned embodiment, further: The detection method is performed once when the switch rail or the frog rail leaves the factory.

[0057] It should be noted that: One-time inspection can comprehensively screen the quality of the switch rail or the stock rail. By conducting one-time inspection according to strict inspection standards and specifications, it can ensure that the switch rail or the stock rail entering the factory meets the quality requirements. Only the switch rail or the stock rail with inspection results meeting the quality standards can enter the subsequent production and use links, guaranteeing the quality of the turnout from the source. The one-time inspection at the time of entering the factory can promptly detect quality problems and avoid putting defective switch rails or stock rails into subsequent production and use. One-time inspection can quickly and accurately evaluate the quality of the switch rail or the stock rail, reducing production delays caused by quality problems. Through the one-time inspection at the time of entering the factory, the quality status of the switch rail or the stock rail can be accurately understood, providing a basis for the arrangement of the production plan. One-time inspection helps to optimize inventory management. The one-time inspection at the time of entering the factory can promptly detect and eliminate potential safety hazards, reducing the risk of turnout failures during operation and ensuring the safety of railway transportation. A large amount of inspection data will be generated during the one-time inspection process, and these data can establish a complete quality file for each switch rail or stock rail. The quality file contains information such as the inspection results, defect locations, dimensions, etc. of the switch rail or the stock rail, providing a basis for subsequent quality traceability and problem troubleshooting. By statistically analyzing the one-time inspection data, the quality status and existing problems of the switch rail or the stock rail can be understood. Through in-depth research on these data, weak links in the manufacturing process can be discovered, providing data support for quality improvement and promoting the continuous improvement of product quality.

[0058] The ultrasonic inspection working principle of the present invention in combination with a special device is as follows: Before inspection, all turnout rail components are immersed in the coupling medium for inspection. Through the guiding device, the rail components are stably introduced into the inspection tooling composed of a probe combination. The ultrasonic detector generates ultrasonic waves through the probe combination. The ultrasonic waves pass through the coupling medium and generate interface reflection waves on the workpiece surface. The ultrasonic detector receives the interface reflection waves through the probe combination and forms the workpiece surface contour through the processing of the ultrasonic detector. Based on the surface contour information, the ultrasonic detector makes the ultrasonic beam generated by the probe combination focus and deflect through a specific ultrasonic beam control method, and controls the position of the probe combination through the automatic control system and the mechanical tooling to achieve precise control of the probe position and the coupling layer thickness, and complete the inspection of the spatial curved surface structure part composed of an arc and an inclined plane with variable cross-sections of the turnout rail components; at the same time, the probe combinations corresponding to other inspection parts are controlled by the ultrasonic detector to generate ultrasonic beam focusing and deflection, and control the position of the probe combination through the automatic control system and the mechanical tooling to achieve precise control of the probe position and the coupling layer thickness, and complete the inspection of other relatively regular parts of the turnout rail components; finally, the full-section inspection of the turnout rail components is realized.

[0059] The simplified working principle of the ultrasonic detection of the present invention is as follows: Step S1, immerse all or part of the turnout rail member and the calibration rail for detecting the rail member in the coupling medium for detection. Step S2, as the detection device moves along the length direction of the turnout rail member, the ultrasonic detector controls the probe assembly to emit focused ultrasonic waves according to the phased array detection principle. The ultrasonic waves pass through the coupling medium, are transmitted into the turnout rail member, and are reflected by the defects of the turnout rail member. The defect reflection waves are collected by the probe assembly and transmitted to the ultrasonic detector. Step S3, the ultrasonic detector performs image processing on the defect reflection wave signals collected by the probe assembly to complete the visual detection of the defects of the turnout rail member.

[0060] In summary, the present invention realizes the detection of the full cross-section of the turnout rail member, especially the spatial curved surface structure part composed of an arc and an inclined surface at the finished variable cross-section of the turnout rail member, reduces the in-service damage risk of the turnout rail member, and extends the service life of the turnout rail member. By adopting surface profile detection and feedback and using a specific ultrasonic beam control method for a specific cross-section, the rail cross-section coverage range and detection accuracy can be improved. By using an automated detection device, defects can be recorded and replayed.

[0061] It should be understood that although this specification is described according to an embodiment, this embodiment does not only include an independent technical solution. This narrative way of the specification is only for clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in this embodiment can also be properly arranged and combined to form other embodiments understandable by those skilled in the art.

[0062] The above-mentioned preferred embodiment is not used to limit the scope of implementation of the present invention. Therefore, all equivalent changes made to the content described in the claims of the present invention should be included within the scope of the claims of the present invention. It should be noted that: the components and materials used in the above-mentioned embodiments are commercially available unless otherwise specified.

Claims

1. A device for detecting variable cross-section of a turnout rail member, characterized in that: The invention comprises a steel rail conveying load-bearing structure (3), wherein the steel rail conveying load-bearing structure (3) bears and conveys a workpiece (1) to be inspected along the length direction of the steel rail, wherein the workpiece (1) to be inspected is adapted to a plurality of guide devices for constraining and positioning the workpiece, wherein the part to be inspected of the workpiece (1) to be inspected is conveyed and incorporated into and completely immersed in a medium of a coupling medium tank (2), wherein a cantilever beam bracket (15) is provided outside the coupling medium tank (2), wherein a plurality of probe assemblies and mechanical fixtures are suspendedly mounted on the cantilever beam bracket (15), and wherein the probes of the plurality of probe assemblies and mechanical fixtures are completely immersed in the medium of the coupling medium tank (2), wherein an ultrasonic detector (16) and an automatic control system (17) are provided outside the coupling medium tank (2), wherein the ultrasonic detector (16) is interactively connected to the probe assembly, and the automatic control system (17) is interactively connected to the ultrasonic detector (16) and the mechanical fixture.

2. The detection device according to claim 1, characterized in that: The workpiece (1) to be inspected is a point rail or a center rail.

3. The detection device according to claim 2, characterized in that: There are three groups of guide devices adapted to the workpiece (1) to be inspected; and there are eight groups of probe assemblies and mechanical tools for detecting defective parts of the workpiece (1) to be inspected.

4. The detection device according to claim 3, characterized in that: The guide device I (4) and the guide device III (6) in the guide device are fixed in position, and the guide device II (5) moves with the workpiece while maintaining the clamping force as the width of the rail bottom changes; the bottoms of the guide device I (4) and the guide device II (5) in the guide device are connected to the top of the rail conveying load-bearing structure (3), the guide device I (4) constrains the left vertical end face of the workpiece rail bottom, the guide device II (5) constrains the right vertical end face of the workpiece rail bottom, and the guide device III (6) presses down to constrain the upper end face of the rail limb of the workpiece rail bottom; The probe assembly and mechanical tooling I (7) and the probe assembly and mechanical tooling II (8) in the probe assembly and mechanical tooling are arranged at an angle on the left and right sides of the rail head, and are used for detecting the space curved surface part of the turnout rail part with a variable cross-section composed of a circular arc and an inclined surface; the probe assembly and mechanical tooling IV (10) and the probe assembly and mechanical tooling VIII (14) are symmetrically arranged on the left and right sides of the rail waist about the left and right vertical axes, and are used for detecting the rail waist part of the turnout rail part; the probe assembly and mechanical tooling V (11) and the probe assembly and mechanical tooling Ⅶ (13) is arranged at parallel left and right sides of the rail bottom at vertical intervals, and is used for detecting the left and right sides of the rail bottom of the turnout rail member; the probe combination and mechanical tooling III (9) is arranged at the bottom of the rail bottom, and is used in combination with other probes for detecting the position of the rail head, rail waist and rail bottom of the turnout rail member; the probe combination and mechanical tooling VI (12) is arranged at the bottom of the rail bottom, and is used in combination with other probes for detecting the position of the rail bottom of the turnout rail member; the mechanical tooling in the probe combination and mechanical tooling is used for precise control of the probe position and the coupling layer thickness.

5. The detection device according to claim 4, characterized in that: The position of the probe assembly and mechanical tooling VII (13) follows the guide device (5); the positions of the probe assembly and mechanical tooling III (9), the probe assembly and mechanical tooling IV (10), the probe assembly and mechanical tooling V (11), the probe assembly and mechanical tooling VI (12), and the probe assembly and mechanical tooling VIII (14) are fixed; the probe assembly and mechanical tooling III (9) is used to detect defects in the rail head, rail waist, and rail bottom parts parallel to the rail bottom; the probe assembly and mechanical tooling IV (10), the probe assembly and mechanical tooling VIII (14) are used to detect defects in the rail waist parts parallel to the rail waist; the probe assembly and mechanical tooling V (11) are used to detect defects in the rail limbs parallel to the rail waist; the probe assembly and mechanical tooling VI (12) are used to detect defects in the rail limbs parallel to the rail bottom.

6. The detection device according to claim 5, characterized in that: The detection data of the probe assembly and the mechanical tooling are recorded in real time by the ultrasonic detector (16).

7. A method for detecting variable cross-section of a turnout rail member, characterized in that: The detection device according to claim 6 is used, and comprises the following steps: S1. Before testing, the tip rail or the center rail is guided by the guide device through the rail conveying load-bearing structure (3), so that the tip rail or the center rail to be tested is stably conveyed into the coupling medium groove (2), and the tip rail or the center rail to be tested is completely immersed in the coupling medium; S2, as the probe assembly and the mechanical tooling control the probe to move along the length direction of the rail, the ultrasonic detector (16) transmits focused ultrasonic waves through the probe assembly according to the phased array detection principle, and the ultrasonic waves are coupled to the surface of the rail through the medium to generate interface reflection waves, and the ultrasonic detector (16) receives the interface reflection waves through the probe assembly, and calculates the interface profile of the area covered by the sound beam through the ultrasonic detector (16) and processes it to form the surface profile of the point rail or the center rail; S3, the ultrasonic detector (16) focuses and deflects the ultrasonic sound beam generated by the probe combination according to the surface profile information through the ultrasonic sound beam control method, so as to generate a sound beam parallel to the direction of the point rail or the center rail, and controls the position of the probe combination through the automatic control system (17) and the mechanical tooling to achieve precise control of the probe position and the thickness of the coupling layer, so as to complete the detection of the spatial curved surface structure part of the point rail or the center rail head with a variable cross-section composed of a circular arc and an inclined surface; at the same time, the probe combination corresponding to other detection parts of the point rail or the center rail is controlled by the ultrasonic detector (16) to generate ultrasonic sound beam focusing and deflection, and controls the position of the probe combination through the automatic control system (17) and the mechanical tooling to achieve precise control of the probe position and the thickness of the coupling layer, so as to complete the detection of other relatively regular structural parts of the point rail or the center rail, and finally achieve the full section detection of the point rail or the center rail.

8. The detection method according to claim 7, characterized in that: In step S3, for the plane part of the point rail or the center rail, a probe combination is used to utilize the principle of phased array detection technology to control the focusing and deflection of the ultrasonic sound beam, and the incident angle and the thickness of the dielectric layer are adjusted in real time according to the angle change between the plane and the symmetry axis of the rail to ensure the maximum sound beam coverage and defect detection rate; for the spatial curved surface of the point rail or the center rail, a specific phased array focusing law is used to control the focusing and deflection of the ultrasonic sound beam, and an automatic control system (17) is used to control the sound beam to detect the variable cross-section of the rail part from two relative directions and one mutually perpendicular direction.

9. The detection method according to claim 8, characterized in that: The detection method is to perform a one-time detection on the point rail or the center rail when it leaves the factory.

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