A device and method for detecting variable cross-section of a turnout rail piece

Abstract

Provided are a turnout rail piece variable cross-section detection device and method, which have a rail piece conveying load-bearing structure that conveys a workpiece to be detected along the length direction of the rail, the workpiece is adapted to multiple guide devices, the workpiece detection part is conveyed into and fully immersed in a coupling medium tank, the coupling medium tank is externally provided with a cantilever beam support, the cantilever beam support is installed with multiple probe combinations and mechanical tooling, and the multiple probe combinations are also immersed in the coupling medium, the coupling medium tank is externally provided with an ultrasonic detector and an automatic control system, the ultrasonic detector is interconnected with the probe combinations, and the automatic control system is interconnected with the ultrasonic detector and the mechanical tooling. The present application realizes automatic and efficient detection of the full cross-section of the turnout rail piece, especially the variable cross-section part, reduces the risk of damage to the rail piece in service, prolongs the service life, improves the cross-section coverage and detection accuracy, and records and replays defects.

Description

Technical Field

[0001] This invention belongs to the field of physical measurement and testing using ultrasonic testing technology, specifically relating to a variable cross-section testing device and method for turnout rail components, mainly used for testing switch rails and frog rails. Background Technology

[0002] Although the turnout rail components have undergone ultrasonic testing at the steel mill, it is necessary to ensure that the minimum cross-sectional area of ​​the inspected portion is not less than 70% for the rail head portion, not less than 60% for the rail web portion, and not less than the rail bottom triangular area.

[0003] Currently, in the manufacturing stage of turnout rail components, after the raw rail materials arrive at the factory, the condition of the raw materials is tested using a manual contact method with A-type pulse-echo ultrasonic testing to detect internal defects in the raw materials during the steel mill manufacturing process. However, this testing method has low efficiency. For finished turnout rail components, it cannot effectively test the spatial curved surfaces composed of arcs and inclined planes at the variable cross-section parts of the turnout switch rail and frog rail, and the test results cannot be recorded. Therefore, the following improved technical solution is proposed. Summary of the Invention

[0004] The technical problem solved by this invention is to provide a detection device and method for variable cross-section turnout rail components. The device uses a specially designed apparatus and a probe array to detect the variable cross-section parts of the turnout switch rail and frog rail through a coupling medium. This solves the technical problem that finished turnout rail components cannot effectively detect the spatial curved surfaces composed of arcs and inclined planes in the variable cross-section parts of the turnout switch rail and frog rail.

[0005] The technical solution adopted in this invention is as follows: A variable cross-section detection device for turnout rail components, comprising a rail component conveying and bearing structure, which carries and conveys the workpiece to be tested along the length of the rail. The workpiece to be tested is fitted with multiple guiding devices for constraining and positioning the workpiece. The part to be tested of the workpiece is conveyed and completely immersed in the coupling medium tank. A cantilever beam support is provided outside the coupling medium tank. Multiple probe combinations and mechanical fixtures are suspended on the cantilever beam support 15, and all probes of the multiple probe combinations and mechanical fixtures are immersed in the coupling medium tank. An ultrasonic detector and an automatic control system are provided outside the coupling medium tank. The ultrasonic detector is interconnected with the probe combinations, and the automatic control system is interconnected with the ultrasonic detector and the mechanical fixtures.

[0006] In the above technical solutions, the preferred option is that the workpiece to be tested is a switch rail or a center rail.

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

[0008] In the above technical solution, further: the guide device I and guide device III in the guide device are fixed in position, and the guide device II moves with the workpiece while maintaining clamping force as the width of the rail bottom changes; the bottom of the guide device I and guide device II in the guide device are connected to the top of the rail component conveying load-bearing structure, the guide device I constrains the left vertical end face of the bottom of the workpiece rail, the guide device II constrains the right vertical end face of the bottom of the workpiece rail, and the guide device III presses down to constrain the upper end face of the rail leg of the bottom of the workpiece rail.

[0009] Probe assemblies and mechanical tooling I and II are angled and positioned on the left and right sides of the rail head, used for detecting the spatial curved surface of the turnout rail component composed of arcs and inclined planes; Probe assemblies and mechanical tooling IV and VIII are symmetrically positioned on the left and right sides of the rail web, used for detecting the rail web of the turnout rail component; Probe assemblies and mechanical tooling V and VII are vertically spaced and parallel on the left and right sides of the rail base, used for detecting the left and right sides of the rail base of the turnout rail component; Probe assembly and mechanical tooling III is positioned at the bottom of the rail base and used in combination with other probes for detecting the rail head, rail web, and rail base of the turnout rail component; Probe assembly and mechanical tooling VI is positioned at the bottom of the rail base and used in combination with other probes for detecting the rail base of the turnout rail component; The mechanical tooling in the probe assembly and mechanical tooling is used for precise control of probe position and coupling layer thickness.

[0010] In the above technical solution, further: the position of the probe assembly and mechanical tooling VII follows the guide device II; the positions of the probe assembly and mechanical tooling III, IV, V, VI, and VIII are fixed; the probe assembly and mechanical tooling III is used to detect defects at the rail head, rail web, and rail bottom parallel to the rail bottom; the probe assembly and mechanical tooling IV and VIII are used to detect defects at the rail web parallel to the rail web; the probe assembly and mechanical tooling V is used to detect rail limb defects parallel to the rail web; and the probe assembly and mechanical tooling VI is used to detect rail limb defects parallel to the rail bottom.

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

[0012] This invention also claims protection for a method for detecting variable cross-section rail components of turnouts, employing the detection device described above, and including the following steps: S1. Before testing, the switch rail or core rail is guided by the guide device through the steel rail component conveying load-bearing structure, so that the part of the switch rail or core rail to be tested is stably conveyed into the coupling medium tank, and the part of the switch rail or core rail to be tested is completely immersed in the coupling medium.

[0013] S2. As the probe assembly and mechanical tooling control the probe to move along the length of the rail component, the ultrasonic testing instrument emits focused ultrasonic waves through the probe assembly based on the phased array detection principle. The ultrasonic waves generate interface reflection waves on the surface of the rail component through medium coupling. The ultrasonic testing instrument receives the interface reflection waves through the probe assembly, calculates the interface profile of the sound beam coverage area through the ultrasonic testing instrument, and processes it to form the surface profile of the switch rail or the center rail.

[0014] S3. The ultrasonic testing instrument, based on surface contour information, uses an ultrasonic beam control method to focus and deflect the ultrasonic beam generated by the probe assembly, producing a beam parallel to the direction of the switch rail or core rail. Through an automatic control system and mechanical tooling, the position of the probe assembly is controlled, achieving precise control of the probe position and coupling layer thickness. This completes the inspection of the spatial curved surface structure of the switch rail or core rail head, composed of arcs and inclined planes. Simultaneously, the probe assembly corresponding to other inspection parts of the switch rail or core rail is controlled by the ultrasonic testing instrument to generate focused and deflected ultrasonic beams. Through an automatic control system and mechanical tooling, the position of the probe assembly is controlled, achieving precise control of the probe position and coupling layer thickness. This completes the inspection of other relatively regular structural parts of the switch rail or core rail, ultimately achieving full-section inspection of the switch rail or core rail.

[0015] In the above technical solution, further: in step S3, for the plane part of the switch rail or the center rail, a probe combination is used to control the focusing and deflection of the ultrasonic beam using the phased array detection technology principle, and the incident angle and the thickness of the medium layer are adjusted in real time according to the angle change between the plane and the axis of symmetry of the rail to ensure the maximum beam coverage and defect detection rate; for the spatial curved surface of the switch rail or the center rail, a specific phased array focusing law is used to control the focusing and deflection of the ultrasonic beam, and an automatic control system is used to control the beam to detect the variable cross section of the rail component from two opposite directions and one mutually perpendicular direction.

[0016] In the above technical solution, furthermore: the detection method involves a one-time detection of the switch rail or frog rail when it leaves the factory.

[0017] Advantages of this invention compared to existing technologies: This invention can achieve low-cost, high-efficiency, and automated inspection of the spatial curved surfaces composed of arcs and inclined planes in the variable cross-section parts of turnout switch rails and frog rails. The inspection information can be recorded, ultimately realizing full-section inspection of turnout switch rails and frog rails, reducing the risk of damage to turnout rail components during track use, and extending the service life of turnout rail components.

[0018] In this invention, the entire area of ​​the turnout rail component to be inspected is immersed in the coupling medium used for inspection, resulting in a stable coupling effect. By employing automatic control technology combined with mechanical tooling, precise control of the coupling layer thickness can be achieved. By using a combination of probes and based on the principle of phased array technology, the ultrasonic beam can be deflected and focused, enabling low-cost automated inspection of the spatial curved surfaces composed of arcs and inclined planes in the variable cross-section parts of turnout switch rails, frog rails, and other rail components. Ultimately, this achieves full-section inspection of turnouts, especially switch rails, frog rails, and other rail components.

[0019] For planar sections of rail components, this invention employs a probe combination utilizing phased array detection technology to control the focusing and deflection of the ultrasonic beam. Based on the change in angle between the plane and the rail's axis of symmetry, the incident angle and dielectric layer thickness are adjusted in real time to ensure maximum beam coverage and defect detection rate. For curved surfaces, a specific phased array focusing method is used for internal defect detection, improving the defect detection rate of variable cross-section sections of rail components and reducing the risk of in-service fracture. Furthermore, for variable cross-section sections of switch rails or frog rails, automated control is used to direct the ultrasonic beam to detect the variable cross-section of the rail component from two opposing directions and one mutually perpendicular direction, thereby reducing surface blind spots, increasing beam coverage, improving the signal-to-noise ratio, and enhancing the defect detection rate. Attached Figure Description

[0020] Figure 1(a) is a schematic diagram of the device structure for detecting the cross-sectional shape 1 of the workpiece to be tested according to the present invention; Figure 1(b) is a schematic diagram of the device structure for detecting the cross-sectional shape 1 of the workpiece to be tested according to the present invention. Figure 2(a) is a schematic diagram of the device structure for detecting the cross-sectional shape 2 of the workpiece to be tested according to the present invention; Figure 2(b) is a schematic diagram of the device structure for detecting the cross-sectional shape 2 of the workpiece to be tested according to the present invention; Figure 3(a) is a schematic diagram of the device structure for detecting the cross-sectional shape 3 of the workpiece to be tested according to the present invention; Figure 3(b) is a schematic diagram of the device structure for detecting the cross-sectional shape 3 of the workpiece to be tested according to the present invention. Figure 4 This is a schematic diagram showing the division of the rail head, rail base, rail web, and rail limbs of the workpiece to be inspected according to the present invention; Figure 5 This is a schematic diagram of the detection area when the probe assembly and mechanical tooling I, II, and III of the present invention are used in combination. Figure 6 This is a schematic diagram of the detection area when the probe assembly and mechanical tooling V, VI, and VII of the present invention are used in combination. Figure 7 This is a process flow diagram of the present invention; In the diagram: 1-Workpiece to be tested, 2-Coupling medium tank, 3-Steel rail conveyor load-bearing structure, 4-Guiding device I, 5-Guiding device II, 6-Guiding device III, 7-Probe assembly and mechanical tooling I, 8-Probe assembly and mechanical tooling II, 9-Probe assembly and mechanical tooling III, 10-Probe assembly and mechanical tooling IV, 11-Probe assembly and mechanical tooling V, 12-Probe assembly and mechanical tooling VI, 13-Probe assembly and mechanical tooling VII, 14-Probe assembly and mechanical tooling VIII, 15-Cantilever beam support, 16-Ultrasonic testing instrument, 17-Automatic control system. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to Figures 1-7. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] A variable cross-section detection device for turnout rail components (Figures 1-3) includes a rail component conveying and bearing structure 3, which carries and conveys the workpiece 1 to be tested along the length of the rail. The workpiece 1 is adapted to multiple guide devices for constraining and positioning the workpiece. The part to be tested of the workpiece 1 is conveyed and completely immersed in the coupling medium tank 2. A cantilever beam support 15 is provided outside the coupling medium tank 2. Multiple probe combinations and mechanical fixtures are suspended on the cantilever beam support 15, and all probes of the multiple probe combinations and mechanical fixtures are immersed in 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 combinations, and the automatic control system 17 is interconnected with the ultrasonic detector 16 and the mechanical fixtures.

[0023] It should be noted that the rail-mounted load-bearing structure 3 can carry and transport the workpiece 1 to be inspected along the length of the rail, ensuring continuous and stable movement of the workpiece during the inspection process. This improves inspection efficiency and reduces the time and labor intensity of manual handling. The workpiece 1 is equipped with multiple guiding devices for constraining and positioning the workpiece, ensuring the positional accuracy of the workpiece during transport. This allows the inspected part to be accurately transported into the coupling medium tank 2, guaranteeing the accuracy and repeatability of the inspection. The inspected part of the workpiece 1 is transported and completely immersed in the coupling medium tank 2, and simultaneously, multiple probe combinations and the probes of the mechanical tooling are also completely immersed in the coupling medium tank 2. The coupling medium effectively reduces the energy loss of ultrasonic waves during propagation, improves the transmission efficiency of ultrasonic waves, and allows ultrasonic waves to better couple with the workpiece, thereby enhancing the strength and clarity of the detection signal and improving the sensitivity and accuracy of the inspection. The coupling medium tank 2 provides a relatively stable environment for inspection, reducing the influence of external factors on ultrasonic inspection, such as air disturbances and dust, which helps ensure the reliability of the inspection results. The cantilever beam bracket 15 suspends multiple probe combinations and mechanical tooling. This layout allows for flexible adjustment of the probe position and angle to adapt to the inspection needs of workpieces of different shapes and sizes, improving the versatility and adaptability of the device. Simultaneously, the suspended structure avoids interference between the probe and the workpiece or other components, ensuring smooth inspection. The coupling medium tank 2 externally houses an ultrasonic testing instrument 16 and an automatic control system 17. The ultrasonic testing instrument 16 is interconnected with the probe combinations, and the automatic control system 17 is interconnected with the ultrasonic testing instrument 16 and the mechanical tooling. This highly integrated layout makes the entire inspection device compact, easy to install and maintain, and also reduces signal transmission distance and interference, improving system stability and reliability. The automatic control system 17 can interconnect with the ultrasonic testing instrument 16 and the mechanical tooling to achieve automated control of the inspection process. It can automatically adjust the probe position, angle, and inspection parameters according to a preset program, control the movement of the mechanical tooling, coordinate the work between various components, improve inspection efficiency and consistency, and reduce the impact of human factors on the inspection results. The automatic control system 17 can also process and analyze the detection data collected by the ultrasonic detector 16, provide real-time feedback on the detection results, promptly detect defects and problems in the workpiece, and adjust the detection strategy according to the detection results to improve the accuracy and reliability of the detection.

[0024] In the above embodiments, preferably, the workpiece 1 to be tested is a switch rail or a center rail.

[0025] It should be noted that switch rails and frog rails have unique variable cross-sectional shapes and complex contour curves, making it difficult for ordinary testing devices to fully cover their key inspection areas. However, this device, with its multiple guiding devices, probe combinations, and mechanical tooling, can precisely position and constrain the switch rails or frog rails according to their shape. This allows the probes to accurately align with key inspection areas of the switch rails or frog rails, such as the variable cross-sectional transition areas at the rail head, rail web, and rail bottom, effectively avoiding missed inspections and improving the comprehensiveness and accuracy of the inspection. The variable cross-section areas of switch rails and frog rails are stress concentration points and prone to defects, requiring a high inspection depth. In this device, the probes are completely immersed in the coupling medium tank. The coupling medium enhances the penetration ability of ultrasonic waves, allowing them to penetrate deep into the interior of the switch rails or frog rails and detect minute defects at the variable cross-section areas, such as internal cracks and inclusions. The application of an automated control system for the switch rails or frog rails reduces the degree of human intervention in the inspection process, lowering labor costs and reducing human error. Operators only need to perform simple monitoring and parameter settings, and the testing device can automatically complete the inspection of the switch rails or frog rails.

[0026] In the above embodiments, the guide device adapted to the workpiece 1 to be inspected has three sets; the probe assembly and mechanical tooling for detecting the defective parts of the workpiece 1 to be inspected have eight sets.

[0027] It should be noted that the three sets of guiding devices can constrain and position the switch rails or pigeon rails from different directions, maintaining a stable posture and accurate position without swaying or deviation. They can also adapt to the constrained positioning of complex-shaped workpieces. The three sets of guiding devices can be flexibly designed and arranged according to the shape characteristics of the workpiece, preventing swaying or deviation and thus better meeting the inspection needs of complex-shaped workpieces. The three sets of guiding devices distribute the force on the workpiece during the transfer process, avoiding deformation or damage caused by excessive local force. Each guiding device bears a relatively small force, ensuring smooth movement of the workpiece during transfer and reducing inspection errors caused by vibration and swaying. The eight-probe combination and mechanical tooling can inspect the switch rails or pigeon rails from multiple angles. For example, probes at different angles can be set to inspect different parts of the workpiece, including the sides of the rail head, rail web, and rail bottom. This multi-angle coverage can detect various defects hidden inside the workpiece, such as transverse cracks, longitudinal cracks, and inclusions, greatly improving the comprehensiveness of the inspection. For variable cross-section sections of the switch rails and pigeon rails, the eight sets of probes can inspect areas at different depths. By adjusting the probe's position and focal length, it's possible to penetrate deep into the workpiece and detect minute defects at variable cross-sections, ensuring the safety performance of the turnout. Different types of defects require different detection methods and probe parameters. The eight-probe combination and mechanical fixture can be flexibly configured according to the type and characteristics of the defect, selecting the appropriate probe and detection mode. For example, high-frequency probes can be used for surface defects, while low-frequency probes can be used for internal defects, improving the targeting and flexibility of the detection. In actual inspection processes, different specifications and models of switch rails or frog rails may be encountered. The eight-probe combination and mechanical fixture can quickly switch detection schemes to adapt to the inspection needs of different workpieces. Through adjustments to the automatic control system, probe reconfiguration and parameter settings can be completed in a short time, improving the adaptability and efficiency of the detection. The eight-probe combination and mechanical fixture have a certain degree of redundancy; when one probe group malfunctions or the detection result is inaccurate, 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 probe groups can be cross-verified, improving the accuracy and reliability of the detection results. The detection data collected by the eight probes can be comprehensively analyzed. By comparing the detection results of different probes, the location, size, and nature of defects can be determined more accurately. This comprehensive analysis method reduces the possibility of false positives and false negatives, improving the reliability of the detection. The three guiding devices, the eight probes, and the mechanical tooling work together efficiently through an automatic control system. The guiding devices ensure accurate workpiece positioning, providing favorable conditions for probe detection; the probe assembly and mechanical tooling automatically adjust according to the workpiece position and detection requirements, achieving rapid and accurate detection. This collaborative working method improves the overall operating efficiency and detection quality of the detection device.During the inspection process, the automatic control system can adjust the probe's detection parameters and position in real time based on the workpiece position information fed back by the guide device, ensuring the stability and accuracy of the inspection process. Simultaneously, it can process and analyze the inspection data in real time, promptly identifying problems and issuing alarms, thus improving the automation and intelligence level of the inspection. Comprehensive inspection and efficient operation can reduce rework and maintenance costs caused by inaccurate inspection. By promptly detecting defects in the switch rail or frog rail, early repair or replacement can be carried out, preventing the defects from escalating and causing more serious damage to the turnout, thereby reducing turnout maintenance costs. Stable operation of the inspection device reduces equipment failure rate and maintenance frequency, lowering equipment maintenance costs. Furthermore, the application of the automated control system reduces manual intervention, lowers labor costs, and improves the economic efficiency of the inspection device.

[0028] In the above embodiments, further: the guide device I4 and guide device III6 in the guide device are fixed in position, and the guide device II5 moves with the workpiece while maintaining clamping force as the width of the rail bottom changes; the bottom of the guide device I4 and guide device II5 in the guide device are connected to the top of the rail component conveying load-bearing structure 3, the guide device I4 constrains the left vertical end face of the bottom of the workpiece rail, the guide device II5 constrains the right vertical end face of the bottom of the workpiece rail, and the guide device III6 presses down to constrain the upper end face of the rail leg of the bottom of the workpiece rail.

[0029] It should be noted that: guide device I4 constrains the left vertical end face of the workpiece's rail bottom, guide device II5 constrains the right vertical end face of the workpiece's rail bottom, and guide device III6 presses down to constrain the upper end face of the rail leg of the workpiece's rail bottom. This three-dimensional constraint method can accurately position the workpiece from different directions, ensuring that the workpiece will not shift or shake during the transfer process. For example, when inspecting switch rails, the shape of the switch rail bottom is relatively complex. Through this multi-directional constraint, the switch rail can always maintain the correct position, ensuring that the probe can accurately align with the inspection area and improve the accuracy of the inspection. Guide devices I4 and III6 are fixed in position, providing a stable reference benchmark for the workpiece. Guide device II5 moves with the workpiece while maintaining clamping force, changing with the width of the rail bottom. This design not only ensures the horizontal positioning accuracy of the workpiece but also adapts to workpieces with different rail bottom widths. For example, when inspecting different types of mandrels, the width of the mandrel bottom may be different. Guide device II5 can automatically adjust its position to always closely fit the workpiece, ensuring the accuracy of positioning. Guide device II5 moves with the change in rail base width, allowing it to adapt to various switch rails or frog rails with different base widths. During turnout production and maintenance, different specifications of switch rails and frog rails may be used. This design eliminates the need to replace the guide device, enabling the positioning and inspection of workpieces of different specifications, thus improving the device's versatility and adaptability. The base shapes of switch rails and frog rails are often complex, featuring features such as arcs and slopes. The combined design of guide devices I4, II5, and III6 can well adapt to these complex rail base shapes. For example, guide device III6 presses down to constrain the upper end face of the rail leg, conforming to the slope or arc portion of the rail base, ensuring good contact between the workpiece and the guide device during transport, improving positioning stability and accuracy. The bottoms of guide devices I4 and II5 are connected to the top of the rail component transport load-bearing structure 3. This connection method makes the guide device and the transport structure a unified whole, enhancing the stability of the workpiece during transport. During the conveying process, the gravity and conveying force on the workpiece are evenly transferred to the conveying load-bearing structure through the guiding device, reducing workpiece vibration and swaying, and ensuring a smooth inspection process. The guiding device II5 maintains clamping force as it moves with the workpiece, ensuring the workpiece is always firmly constrained between the guiding devices. This stable clamping force prevents workpiece displacement due to external forces during conveying, further improving workpiece positioning accuracy and inspection stability. Because the workpiece can be positioned quickly and accurately during conveying, the time spent adjusting the workpiece position is reduced, improving inspection efficiency. Simultaneously, the stable conveying state allows the probe to continuously and efficiently inspect the workpiece, shortening the inspection cycle and improving production efficiency. The structure of this guiding device is relatively simple, and the connections and cooperation between its various components are clear.When the guide device malfunctions or requires maintenance, maintenance personnel can easily inspect, replace, and adjust each component, reducing maintenance difficulty and cost. Guide devices I4, II5, and III6 can be considered as independent modules. When a module malfunctions, it can be quickly replaced without requiring large-scale disassembly and repair of the entire guide device, improving maintenance efficiency and flexibility.

[0030] ( Figures 4-6 The probe assembly and mechanical tooling I7 and II8 are angled and installed on the left and right sides of the rail head, and are used for detecting the spatial curved surface of the turnout rail component with variable cross-section composed of arcs and inclined planes; the probe assembly and mechanical tooling IV10 and VIII14 are symmetrically installed on the left and right sides of the rail web, and are used for detecting the rail web of the turnout rail component; the probe assembly and mechanical tooling V11 and VII13 are installed parallel to each other on the left and right sides of the rail bottom, and are used for detecting the left and right sides of the rail bottom of the turnout rail component; the probe assembly and mechanical tooling III9 is ​​installed at the bottom of the rail bottom and is used in combination with other probes for detecting the rail head, rail web, and rail bottom of the turnout rail component; the probe assembly and mechanical tooling VI12 is installed at the bottom of the rail bottom and is used in combination with other probes for detecting the rail bottom of the turnout rail component; the mechanical tooling in the probe assembly and mechanical tooling is used for precise control of probe position and coupling layer thickness.

[0031] It should be noted that due to the complex shape of the rail head, ordinary inspection methods cannot fully cover its curved surface features. The probe assembly and mechanical fixtures I and II are angled and positioned on the left and right sides of the rail head, enabling inspection of the spatial curved surface of the turnout rail component, composed of arcs and inclined planes. This ensures that no potentially defective areas are missed, greatly improving the comprehensiveness of the inspection. The mechanical fixtures are used for precise control of the probe position and coupling layer thickness, ensuring that the probe is accurately aligned with the inspection area. During inspection, probe position deviation directly affects the accuracy of the results. Precise control of the mechanical fixtures minimizes probe position errors, improving inspection accuracy. Precise control of the coupling layer thickness is crucial for ultrasonic testing. A suitable coupling layer thickness ensures effective ultrasonic wave transmission, reducing energy loss and signal interference. The mechanical fixtures can precisely adjust the coupling layer thickness according to different inspection areas and requirements, maintaining stable ultrasonic wave transmission characteristics during inspection and improving the clarity and accuracy of the detection signal. The various probe assemblies and mechanical fixtures work collaboratively through an automatic control system. During the inspection process, different probe combinations can simultaneously or sequentially inspect different parts of the rail component, and the inspection data can be shared and analyzed in real time. This collaborative working method improves inspection efficiency, and by comprehensively analyzing the inspection results of multiple probes, the location, size, and nature of defects can be determined more accurately. For example, when the probe at the rail head detects an abnormal signal, probes at the rail web and rail bottom can simultaneously perform auxiliary inspections to further confirm the defect and avoid misjudgment. The probe combination and mechanical tooling work in conjunction with the rail component conveying load-bearing structure, coupling medium tank, and other components to form a complete inspection system. The rail component conveying load-bearing structure ensures stable rail component transport, the coupling medium tank provides a good inspection environment, and the probe combination and mechanical tooling are responsible for accurate inspection. All components cooperate with each other to achieve efficient and accurate inspection.

[0032] In the above embodiments, further: the position of the probe assembly and mechanical tooling VII13 follows the guide device II5; the positions of the probe assembly and mechanical tooling III9, IV10, V11, VI12, and VIII14 are fixed; wherein, when used alone, the probe assembly and mechanical tooling III9 is ​​used to detect defects at the rail head, rail web, and rail bottom parallel to the rail base; the probe assembly and mechanical tooling IV10 and VIII14 are used to detect defects at the rail web parallel to the rail web; the probe assembly and mechanical tooling V11 is used to detect defects at the rail limb parallel to the rail web; and the probe assembly and mechanical tooling VI12 is used to detect defects at the rail limb parallel to the rail base. The mechanical tooling is used for precise control of the probe position and coupling layer thickness, and its debugging and calibration process is relatively simple. Through precise adjustment mechanisms and parameter settings, the probe position and coupling layer thickness can be adjusted quickly and accurately to ensure the normal operation of the detection device. Meanwhile, maintenance personnel can periodically calibrate the probe assembly and mechanical tooling as needed to ensure the accuracy and reliability of the test results.

[0033] Specifically: the probe assembly and mechanical fixture I7 and probe assembly and mechanical fixture II8 are used together to detect defects in the rail head area parallel to the rail web; the ultrasonic detector 16 controls the probe assembly and mechanical fixture I7 and mechanical fixture II8 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 tested, forming interface reflected waves that are received by the probe assembly and mechanical fixture I7 and mechanical fixture II8. The ultrasonic detector 16 calculates the acoustic... Based on the surface contour information of the interface contour of the beam coverage area, the ultrasonic detector 16 uses a specific ultrasonic beam control method to focus and deflect the ultrasonic beam generated by the probe assembly for curved surfaces, generating a beam parallel to the rail bottom direction. The automatic control system 17 and the probe assembly and mechanical tooling I7 and II8 control the position of the probe assembly and mechanical tooling I7 and II8, achieving precise control of the probe position and coupling layer thickness, and completing the detection of the spatial curved surface part of the turnout rail component with variable cross-section composed of arcs and inclined surfaces.

[0034] It should be noted that the ultrasonic testing instrument 16 can accurately calculate the interface profile of the area covered by the sound beam based on the interface reflected waves received by the probe assembly and mechanical fixtures I7 and II8. In the inspection of variable cross-section rail components of turnouts, the interface profile of the rail head is complex and varied, including features such as arcs and slopes. Through this precise calculation, the actual shape of the rail head interface can be accurately understood, providing accurate basic data for subsequent inspection. For curved surfaces, the ultrasonic testing instrument 16 focuses and deflects the ultrasonic beam generated by the probe assembly based on the surface profile information through a specific ultrasonic beam control method, producing a beam parallel to the rail base. This precise control ensures that the ultrasonic beam accurately irradiates the area to be inspected, improving the resolution and sensitivity of the inspection. The probe assembly and mechanical fixtures I7 and II8 are used together specifically for inspecting defects in the rail head area parallel to the rail web, and are particularly suitable for the spatial curved surface areas of turnout rail components with variable cross-sections composed of arcs and slopes. This design can adapt well to the complex spatial shape of the rail head, and can effectively inspect both the curvature of the arc and the inclination angle of the slope. This technology can detect various types of defects, such as internal cracks, porosity, and inclusions. Because ultrasonic testing exhibits different reflection characteristics for defects in different materials, by analyzing the reflected waves from the interface and precisely controlling the sound beam, different types of defects can be accurately identified, providing comprehensive information for the quality assessment of turnout rail components. The ultrasonic testing instrument 16 controls the probe assembly and mechanical fixtures I7 and II8 to emit ultrasonic waves and receive reflected waves, making the entire process fast and efficient. The probe assembly can perform a large-area scan of the rail head in a short time, greatly improving detection efficiency. The automatic control system 17 and the probe assembly and mechanical fixtures I7 and II8 precisely control the probe position and coupling layer thickness, achieving automation of the detection process. Operators only need to perform simple parameter settings and monitoring; the detection device can automatically complete tasks such as probe movement, sound beam adjustment, and data acquisition, reducing manual intervention and further improving detection efficiency. The automatic control system 17 can precisely control the position of the probe assembly and mechanical fixtures I7 and II8, accurately moving the probe to the designated position according to the detection requirements and rail head interface contour information. This precise control ensures consistent and repeatable testing, avoiding errors caused by probe position deviations. The automatic control system can also precisely control the coupling layer thickness, ensuring effective transmission of ultrasonic waves between the coupling medium and the workpiece interface. Automatic adjustment of the coupling layer thickness can be optimized for different testing locations and requirements, improving the stability and reliability of the testing signal. Thanks to precise interface contour calculation, beam focusing and deflection control, and an automated testing process, the technology acquires accurate and reliable testing data. Comprehensive analysis of reflected waves received by multiple probes reduces the possibility of false positives and false negatives, improving the reliability of the testing results.The entire testing system exhibits high stability, with an automatic control system capable of monitoring and adjusting testing parameters in real time to ensure stable operation of the testing process. Furthermore, the design of the probe assembly and mechanical tooling prioritizes reliability and durability, maintaining excellent performance over extended periods of use.

[0035] In the above embodiments, the detection data of the probe assembly and mechanical tooling are further recorded in real time by the ultrasonic testing instrument 16.

[0036] It should be noted that the ultrasonic testing instrument 16 can record all data detected by the probe combination and mechanical tooling in real time, including the location, size, shape, and intensity of reflected waves of defects. This data comprehensively reflects the internal and surface conditions of the turnout rail components, providing rich material for subsequent analysis and evaluation. For example, when inspecting switch rails, the instrument can record defects at various points on the rail head, rail web, and rail base, accurately recording even tiny, barely noticeable defects to ensure comprehensive data. During the inspection process, the instrument continuously records data, capturing dynamic changes. This is crucial for analyzing defect development trends and assessing the stability of inspection results. For instance, during long-term inspections, observing changes in defect reflected wave intensity can indicate whether a defect is expanding, allowing for timely intervention. The real-time recorded data can be directly transmitted to a computer or other analytical equipment for rapid processing using specialized analysis software. This software can automatically classify, statistically analyze, and process large amounts of inspection data, significantly reducing data processing time. For example, analysis software can generate defect distribution maps and defect size statistics tables in a short time, enabling inspectors to quickly understand the quality status of turnout rail components. Inspectors can view inspection data and analysis results in real time during the inspection process, promptly identifying problems and making adjustments. If abnormal inspection data is found in a certain area, inspection can be stopped immediately, and that area can be focused on for inspection, improving efficiency. For instance, if the detector shows abnormal reflected wave intensity at a rail head, inspectors can immediately conduct further inspection of that area, avoiding wasted time and resources. Real-time recorded inspection data can establish a complete quality file for each turnout rail component. The quality file contains all inspection information for that rail component, including inspection time, inspectors, and inspection results. These files can be used for quality traceability; when problems occur during rail component use, the root cause can be found by consulting the quality file. Analysis of historical inspection data can assess the reliability and stability of the inspection process. Analyzing inspection data from different times and by different inspectors can identify potential problems during the inspection process, such as probe aging or unstable coupling agent quality, allowing for timely improvement measures. Real-time recorded inspection data provides a scientific basis for quality assessment and maintenance decisions regarding turnout rail components. Based on the inspection data, it can be determined whether rail components meet quality standards and whether repair or replacement is necessary. For example, if inspection data shows that the defect size of a rail base exceeds the specified standard, it can be decided to repair or replace that rail base to ensure the safe operation of the turnout. Analysis of large amounts of inspection data can reveal problems in the production process of turnout rail components, providing a reference for optimizing production processes. For example, if a batch of rail components is found to have numerous defects, factors such as raw materials and processing techniques can be analyzed to identify the causes of the problems and implement improvements.Real-time recorded inspection data can be transmitted to a remote monitoring center via network, enabling remote monitoring of turnout rail component inspections. Staff at the remote monitoring center can view the inspection data and analysis results in real time, promptly identify problems, and provide guidance. Real-time recording and sharing of inspection data promotes collaboration and communication among different departments and professionals. Inspection personnel, analysts, and maintenance personnel can share inspection data to jointly analyze problems and develop solutions.

[0037] ( Figure 7 This invention also claims protection for a method for detecting variable cross-section rail components of a turnout, employing the aforementioned detection device, comprising the following steps: S1. Before testing, the switch rail or core rail is guided by the guide device through the steel rail component conveying load-bearing structure 3, so that the switch rail or core rail to be tested is stably conveyed into the coupling medium tank 2, and the switch rail or core rail to be tested is completely immersed in the coupling medium.

[0038] S2. As the probe assembly and mechanical tooling control the probe to move along the length of the rail component, the ultrasonic detector 16 emits focused ultrasonic waves through the probe assembly based on 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 and calculates the interface profile of the sound beam coverage area and processes it to form the surface profile of the switch rail or the center rail.

[0039] S3. The ultrasonic testing instrument 16, based on the surface contour information, uses an ultrasonic beam control method to focus and deflect the ultrasonic beam generated by the probe assembly, producing a beam parallel to the direction of the switch rail or the core rail. The automatic control system 17 and mechanical tooling control the position of the probe assembly, achieving precise control of the probe position and coupling layer thickness, and completing the detection of the spatial curved surface structure of the switch rail or core rail head composed of arcs and inclined planes. At the same time, the probe assembly corresponding to other detection parts of the switch rail or core rail is controlled by the ultrasonic testing instrument 16 to generate focused and deflected ultrasonic beams. The automatic control system 17 and mechanical tooling control the position of the probe assembly, achieving precise control of the probe position and coupling layer thickness, and completing the detection of other relatively regular structural parts of the switch rail or core rail, ultimately achieving full-section detection of the switch rail or core rail.

[0040] It should be noted that this method enables full-section inspection of the switch rail or frog rail, covering spatial curved surface structures composed of arcs and inclined planes with varying cross-sections at the rail head, as well as other relatively regular structural parts. Whether it's a complex spatial curved surface or a regular plane or inclined plane, comprehensive and detailed inspection can be performed, ensuring that no potentially defective areas are missed. Different types of probes work simultaneously, inspecting different parts of the switch rail or frog rail respectively. This collaborative inspection method fully utilizes the advantages of each probe combination, improving inspection efficiency and accuracy. The ultrasonic testing instrument receives interface reflected waves through the probe combination, calculates the interface profile of the sound beam coverage area, and processes it to form the surface profile of the switch rail or frog rail. This precise calculation provides accurate basic data for subsequent sound beam focusing and deflection, ensuring that the ultrasonic waves accurately irradiate the areas to be inspected. For example, when inspecting spatial curved surfaces with varying cross-sections at the rail head, accurate interface profile calculation allows the ultrasonic beam to better adapt to the shape of the surface, improving inspection resolution and sensitivity. Based on surface contour information, the ultrasonic testing instrument uses a specific beam control method to focus and deflect the ultrasonic beam generated by the probe assembly, producing a beam parallel to the direction of the switch rail or center rail. This precise control ensures that the ultrasonic energy is concentrated in critical areas, effectively detecting minute defects. For example, for the curved surface of the center rail head, beam focusing and deflection can generate strong reflection signals at specific locations on the curved surface, thus more accurately detecting potential defects. The automatic control system can precisely control the position of the probe assembly and the coupling layer thickness. During the inspection process, according to the inspection requirements and interface contour information, the automatic control system can quickly and accurately move the probe to the designated position and adjust the coupling layer thickness to ensure effective ultrasonic transmission. For example, when inspecting different types of switch rails, the automatic control system can automatically adjust the probe position and coupling layer thickness according to the size and shape of the switch rail, without manual intervention, improving the automation level of the inspection. The ultrasonic testing instrument has intelligent data processing and analysis functions. It can process and analyze the received interface reflection waves in real time, automatically identify the location, size, and shape of defects, and generate an inspection report. For example, the detector can analyze the intensity and frequency changes of reflected waves to determine the type and severity of defects, providing a basis for subsequent maintenance and decision-making. Under the control of an automatic control system, the probe assembly moves along the length of the rail component, enabling rapid large-area scanning of the switch rail or frog rail. This rapid scanning method significantly shortens inspection time and improves inspection efficiency. For instance, on a turnout rail component production line, this method can inspect multiple rail components in a short time, meeting the needs of large-scale production. The entire inspection process is highly automated, reducing the need for manual intervention. Operators only need to perform simple parameter settings and monitoring; the detection device can automatically complete tasks such as probe movement, sound beam adjustment, and data acquisition, reducing labor intensity and improving work efficiency.This method is adaptable to switch rails or frog rails of different shapes and sizes. By adjusting the position of the probe assembly, the acoustic beam parameters, and the coupling layer thickness, various types of switch rails and frog rails can be effectively inspected. For example, for switch rails with different head widths and variable cross-sectional shapes, the inspection system can automatically adjust the inspection parameters to ensure the accuracy and reliability of the inspection. 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 of the acoustic beam, the inspection can be optimized for different types of defects, improving the defect detection rate.

[0041] In the above embodiments, further: in step S3, for the plane part of the switch rail or the core rail, a probe combination is used to control the focusing and deflection of the ultrasonic beam using the phased array detection technology principle, and the incident angle and the thickness of the medium layer are adjusted in real time according to the angle change between the plane and the axis of symmetry of the rail to ensure the maximum beam coverage and defect detection rate; for the spatial curved surface of the switch rail or the core rail, a specific phased array focusing law is used to control the focusing and deflection of the ultrasonic beam, and an automatic control system 17 is used to control the beam to detect the variable cross section of the rail component from two opposite directions and one mutually perpendicular direction.

[0042] It should be noted that applying a specific phased array focusing law to the spatial curved surface of the switch rail or center rail can precisely control the focusing and deflection of the ultrasonic beam. The complex shape of the spatial curved surface makes it difficult for ordinary detection methods to guarantee effective beam coverage. However, the specific focusing law can precisely focus the beam at different positions on the curved surface based on its geometry and curvature variations. For example, when inspecting the curved surface of the cut section of the switch rail, the specific focusing law can create a high-energy focal point in the key area of ​​the surface, improving the detection capability of minute defects. By adjusting the incident angle and the dielectric layer thickness in real time, maximum beam coverage is ensured in planar areas. Different incident angles and dielectric layer thicknesses affect the beam propagation path and coverage area; reasonable adjustments can ensure the beam covers the entire planar area as much as possible, avoiding detection blind spots. For example, when inspecting the rail bottom plane, by adjusting the incident angle and dielectric layer thickness, the beam can cover every corner of the rail bottom, ensuring that defects at any location can be detected. Multi-directional detection of spatial curved surfaces employs an automatic control system to inspect the variable cross-section of rail components from two opposite directions and one mutually perpendicular direction, achieving omnidirectional coverage of the spatial curved surface. Defects on spatial curved surfaces may exist in different directions and locations; multi-directional detection significantly increases the probability of defect detection. For example, for the spatial curved surface of a point rail, detection from two opposite directions and one perpendicular direction can cover all sides and the top surface of the surface, effectively detecting defects in different directions. Specific phased array focusing laws and automatic control systems can adapt to the complex spatial curved surface shapes of point rails or point rails. The curvature and degree of twist of spatial curved surfaces vary; this detection method, through precise control of sound beam focusing and deflection, and multi-directional detection, can adapt to various complex spatial curved surface structures. For example, some specially designed point rails have complex spatial curved surface shapes, yet this method can still effectively detect them. Specific phased array focusing laws and multi-directional detection methods enhance the ability to detect defects on spatial curved surfaces. Defects on a spatial curved surface may be hidden in different parts and directions. Multi-directional sound beam coverage and precise focusing can make these defects easier to expose. For example, inclusions on the spatial curved surface of the heart track can be detected more easily by the probe by detecting them from multiple directions, thereby improving the detection rate of inclusions.

[0043] In the above embodiments, the detection method further includes a one-time detection of the switch rail or frog rail when it leaves the factory.

[0044] It should be noted that one-time inspection allows for a comprehensive quality screening of switch rails or frog rails. Conducting one-time inspections according to strict testing standards and specifications ensures that incoming switch rails or frog rails meet quality requirements. Only switch rails or frog rails that meet the quality standards can proceed to subsequent production and use, guaranteeing turnout quality from the source. One-time inspection upon arrival at the factory can promptly identify quality problems, preventing defective switch rails or frog rails from being used in subsequent production and use. One-time inspection allows for rapid and accurate quality assessment of switch rails or frog rails, reducing production delays caused by quality issues. Through one-time inspection upon arrival at the factory, the quality status of switch rails or frog rails can be accurately understood, providing a basis for production planning. One-time inspection helps optimize inventory management. One-time inspection upon arrival at the factory can promptly identify and eliminate potential safety hazards, reducing the risk of turnout malfunctions during operation and ensuring the safety of railway transportation. The one-time inspection process generates a large amount of inspection data, which can be used to establish a complete quality file for each switch rail or frog rail. The quality file contains information such as the inspection results, defect location, and dimensions of the switch rail or frog rail, providing a basis for subsequent quality traceability and problem investigation. Statistical analysis of one-time test data can reveal the quality status and existing problems of the switch rails or frog rails. In-depth study of this data can uncover weaknesses in the manufacturing process, providing data support for quality improvement and promoting continuous product quality enhancement.

[0045] The working principle of ultrasonic testing in this invention, combined with a specially designed device, is as follows: Before testing, the entire turnout rail component is immersed in the coupling medium for testing. A guiding device guides the rail component stably into a testing fixture composed of a probe assembly. The ultrasonic testing instrument generates ultrasonic waves through the probe assembly. These ultrasonic waves pass through the coupling medium, generating interface reflection waves on the workpiece surface. The ultrasonic testing instrument receives these interface reflection waves and processes them to form the workpiece surface contour. Based on the surface contour information, the ultrasonic testing instrument uses a specific ultrasonic beam control method to focus and deflect the ultrasonic beam generated by the probe assembly. An automatic control system and mechanical fixture control the position of the probe assembly, achieving precise control of the probe position and coupling layer thickness, thus completing the testing of the spatial curved surface structure of the turnout rail component with variable cross-sections composed of arcs and inclined planes. Simultaneously, probe assemblies corresponding to other testing locations are controlled by the ultrasonic testing instrument to generate focused and deflected ultrasonic beams. An automatic control system and mechanical fixture control the position of the probe assemblies, achieving precise control of the probe position and coupling layer thickness, thus completing the testing of other relatively regular parts of the turnout rail component. Ultimately, this achieves full-section testing of the turnout rail component.

[0046] The simplified working principle of ultrasonic testing in this invention is as follows: Step S1: Immerse all or part of the turnout rail component and the calibration rail used for rail component testing in the coupling medium used for testing. Step S2: As the testing device moves along the length of the turnout rail component, the ultrasonic testing instrument controls the probe assembly to emit focused ultrasonic waves according to the phased array testing principle. The ultrasonic waves are transmitted through the coupling medium to the interior of the turnout rail component and reflected by defects in the turnout rail component. The defect reflection waves are collected by the probe assembly and transmitted to the ultrasonic testing instrument. Step S3: The ultrasonic testing instrument performs image processing on the defect reflection wave signals collected by the probe assembly to complete the visual detection of defects in the turnout rail component.

[0047] In summary, this invention enables the inspection of the entire cross-section of turnout rail components, especially the spatial curved surface structures composed of circular arcs and inclined planes in finished turnout rail components. This reduces the risk of damage to turnout rail components during service and extends their service life. By employing surface contour detection and feedback, and using specific ultrasonic beam control methods for specific cross-sections, the coverage and accuracy of the rail cross-section can be improved. The use of automated inspection equipment allows for the recording and playback of defects.

[0048] It should be understood that although this specification describes one embodiment, it does not mean that the embodiment contains only one independent technical solution. This way of describing 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 appropriately arranged and combined to form other embodiments that can be understood by those skilled in the art.

[0049] The above preferred embodiments are not intended to limit the scope 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 embodiments are commercially available unless otherwise specified.

Claims

1. A detection device for variable cross-section of turnout rail components, characterized in that: The device has a rail component conveying load-bearing structure (3), which carries and conveys the workpiece to be tested (1) along the length of the rail. The workpiece to be tested (1) is adapted to multiple guide devices for constraining and positioning the workpiece. The part to be tested of the workpiece to be tested (1) is conveyed into and completely immersed in the coupling medium tank (2). A cantilever beam support (15) is provided outside the coupling medium tank (2). Multiple probe combinations and mechanical tooling are suspended on the cantilever beam support (15), and all probes of the multiple probe combinations and mechanical tooling are immersed in 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. The workpiece to be tested (1) is a switch rail or a center rail; The guide device adapted to the workpiece (1) to be inspected has three sets; the probe assembly and mechanical tooling for detecting the defective parts of the workpiece (1) to be inspected have eight sets. The guide device Ⅰ (4) and guide device Ⅲ (6) in the guide device are fixed in position, and guide device Ⅱ (5) moves with the workpiece while maintaining clamping force as the width of the rail bottom changes; the bottom of guide device Ⅰ (4) and guide device Ⅱ (5) in the guide device are connected to the top of the rail component conveying load-bearing structure (3); guide device Ⅰ (4) constrains the left vertical end face of the bottom of the workpiece rail, guide device Ⅱ (5) constrains the right vertical end face of the bottom of the workpiece rail, and guide device Ⅲ (6) presses down to constrain the upper end face of the rail leg of the bottom of the workpiece rail; the probe assembly and mechanical tooling Ⅰ (7) and probe assembly and mechanical tooling Ⅱ (8) in the probe assembly and mechanical tooling are inclined at an angle on the left and right sides of the rail head and are used for the spatial curved surface of the turnout rail component with variable cross section composed of arc and inclined surface. Position detection; Probe assembly and mechanical tooling IV (10) and probe assembly and mechanical tooling VIII (14) are symmetrically arranged on the left and right sides of the rail web and are used for the detection of the rail web of the turnout rail component; Probe assembly and mechanical tooling V (11) and probe assembly and mechanical tooling VII (13) are arranged parallel to each other on the left and right sides of the rail bottom and are used for the detection of the left and right sides of the rail bottom of the turnout rail component; Probe assembly and mechanical tooling III (9) is set at the bottom of the rail bottom and is used in combination with other probes for the position detection of the rail head, rail web and rail bottom of the turnout rail component; Probe assembly and mechanical tooling VI (12) is set at the bottom of the rail bottom and is used in combination with other probes for the position detection of the rail bottom of the turnout rail component; The mechanical tooling in the probe assembly and mechanical tooling is used for the precise control of the probe position and the thickness of the coupling layer; The position of the probe assembly and mechanical tooling VII (13) moves with the guide device II (5); the positions of the probe assembly and mechanical tooling III (9), probe assembly and mechanical tooling IV (10), probe assembly and mechanical tooling V (11), probe assembly and mechanical tooling VI (12), and 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 web, and rail bottom parallel to the rail bottom; the probe assembly and mechanical tooling IV (10) and probe assembly and mechanical tooling VIII (14) are used to detect defects in the rail web parallel to the rail web; the probe assembly and mechanical tooling V (11) is used to detect defects in the rail limb parallel to the rail web; and the probe assembly and mechanical tooling VI (12) is used to detect defects in the rail limb parallel to the rail bottom.

2. The detection device according to claim 1, characterized in that: The detection data of the probe assembly and mechanical tooling are recorded in real time by the ultrasonic testing instrument (16).

3. A method for detecting variable cross-section rail components of a turnout, characterized in that, The detection device described in claim 2 is used, and includes the following steps: S1. Before testing, the switch rail or core rail is guided by the guide device through the steel rail component conveying load-bearing structure (3) to stably convey the switch rail or core rail to be tested into the coupling medium tank (2) and make the switch rail or core rail to be tested completely immersed in the coupling medium. S2. As the probe assembly and mechanical tooling control the probe to move along the length of the rail, the ultrasonic detector (16) emits focused ultrasonic waves through the probe assembly based on the phased array detection principle. The ultrasonic waves generate interface reflection waves on the surface of the rail through medium coupling. The ultrasonic detector (16) receives the interface reflection waves through the probe assembly. The ultrasonic detector (16) calculates the interface profile of the sound beam coverage area and processes it to form the surface profile of the tip rail or the core rail. S3. The ultrasonic testing instrument (16) focuses and deflects the ultrasonic beam generated by the probe combination based on the surface contour information through the ultrasonic beam control method, generating a beam parallel to the direction of the switch rail or the core rail. The position of the probe combination is controlled by the automatic control system (17) and mechanical tooling to achieve precise control of the probe position and coupling layer thickness, and completes the detection of the spatial curved surface structure of the switch rail or core rail head composed of arcs and inclined planes. At the same time, the probe combination corresponding to other detection parts of the switch rail or core rail is controlled by the ultrasonic testing instrument (16) to generate ultrasonic beam focusing and deflection. The position of the probe combination is controlled by the automatic control system (17) and mechanical tooling to achieve precise control of the probe position and coupling layer thickness, and completes the detection of other relatively regular structural parts of the switch rail or core rail, and finally achieves the full-section detection of the switch rail or core rail.

4. The detection method according to claim 3, characterized in that: In step S3, for the plane part of the switch rail or the core rail, a probe combination is used to control the focusing and deflection of the ultrasonic beam using the phased array detection technology principle. The incident angle and the thickness of the medium layer are adjusted in real time according to the angle change between the plane and the axis of symmetry of the rail to ensure the maximum coverage of the sound beam and the defect detection rate. For the spatial curved surface of the switch rail or the core rail, a specific phased array focusing law is used to control the focusing and deflection of the ultrasonic beam. An automatic control system (17) is used to control the sound beam to detect the variable cross section of the rail component from two opposite directions and one mutually perpendicular direction.

5. The detection method according to claim 3, characterized in that: The aforementioned testing method involves a one-time test performed on the switch rail or frog rail when it leaves the factory.

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