Ultrasonic flaw detection method and device for steel rail welded joint

Abstract

The invention discloses an ultrasonic flaw detection method and device for a steel rail welded joint. Initial flaw detection equipment, a reference block and a to-be-detected welded joint are obtained; calibrating the initial flaw detection equipment to obtain calibrated flaw detection equipment; adjusting the sensitivity of the calibrated flaw detection equipment by using the reference block to obtain the adjusted flaw detection equipment; and performing flaw detection on the to-be-detected welding joint by using the adjusted flaw detection equipment to obtain a flaw detection result. The sensitivity of the calibrated flaw detection equipment is adjusted through the reference block, so that the adjusted flaw detection equipment can accurately position the defects of the steel rail welded joint.

Description

Technical Field

[0001] This application relates to the field of non-destructive testing technology, and particularly to an ultrasonic flaw detection method and device for rail welding joints. Background Art

[0002] Rail welding is a key technology for seamless railways, and this method is used in major railway rail welding bases. However, when there are internal defects in the welding joints, it will affect the mechanical properties of the rails, and in severe cases, it may lead to rail breakage accidents. Through ultrasonic testing technology, defects can be detected in advance to reduce potential safety hazards.

[0003] Currently, ultrasonic testing technologies and related standards for rail base metals and in-service rail welding joints have been established and are applicable to general railway lines. However, for rail welding joints not on the line, there is still a lack of standards and specifications for manual ultrasonic flaw detection technology, resulting in a lack of unified standards during the detection process and the inability to accurately locate the defects of rail welding joints.

[0004] Therefore, how to accurately locate the defects of rail welding joints has become an urgent problem to be solved in this field. Summary of the Invention

[0005] This application provides an ultrasonic flaw detection method and device for rail welding joints, aiming to accurately locate the defects of rail welding joints.

[0006] To achieve the above object, this application provides the following technical solutions:

[0007] An ultrasonic flaw detection method for rail welding joints includes:

[0008] Obtain an initial flaw detection device, a reference block, and a welding joint to be detected; the reference block includes defect holes;

[0009] Calibrate the initial flaw detection device to obtain a calibrated flaw detection device;

[0010] Use the reference block to adjust the sensitivity of the calibrated flaw detection device to obtain an adjusted flaw detection device;

[0011] Use the adjusted flaw detection device to detect the welding joint to be detected to obtain a flaw detection result; the flaw detection result is the flaw detection results of the rail head, rail web, and rail base of the welding joint to be detected.

[0012] Optionally, the calibrating the initial flaw detection device to obtain a calibrated flaw detection device includes:

[0013] Adjust the incident point of the probe of the initial flaw detection device to obtain an adjusted initial flaw detection device;

[0014] Calculate the distance between the probe value of the adjusted initial flaw detection device and the arc top, and calculate the difference between the preset value and the distance to obtain the probe front parameter;

[0015] Adjust the adjusted initial flaw detection device according to the probe front parameter;

[0016] After the adjustment of the adjusted initial flaw detection device is completed, calibrate the slope of the probe of the adjusted initial flaw detection device to obtain the calibrated flaw detection device.

[0017] Optionally, before obtaining the comparison test block and the weld joint to be detected, it further includes:

[0018] Obtain the initial comparison test block;

[0019] Perform defect treatment on the jaw position of the rail head of the initial comparison test block to obtain the first comparison test block;

[0020] Perform defect treatment on the web position of the first comparison test block to obtain the second comparison test block;

[0021] Perform defect treatment on the bottom position of the rail of the second comparison test block to obtain the comparison test block.

[0022] Optionally, the sensitivity adjustment of the calibrated flaw detection device by using the comparison test block to obtain the adjusted flaw detection device includes:

[0023] Set the probe of the calibrated flaw detection device at the defect hole position of the comparison test block;

[0024] After the probe of the calibrated flaw detection device is set, perform ultrasonic detection on the defect hole of the comparison test block by using the probe of the calibrated flaw detection device to obtain the highest echo;

[0025] Adjust the calibrated flaw detection device according to the highest echo so that the highest echo is a preset percentage of the full screen amplitude of the flaw detection device;

[0026] After the adjustment of the calibrated flaw detection device is completed, record the decibel value corresponding to the highest echo;

[0027] Set the decibel value as the reference sensitivity of the calibrated flaw detection device to obtain the adjusted flaw detection device.

[0028] Optionally, the flaw detection of the weld joint to be detected by using the adjusted flaw detection device to obtain the flaw detection result includes:

[0029] Sweep the rail head of the weld joint to be detected by using the adjusted flaw detection device within the first preset angle range to obtain the rail head sweep result;

[0030] Using the adjusted flaw detection device, perform parallel scanning on the web of the weld joint to be detected perpendicular to the weld seam to obtain the web scanning result;

[0031] According to the second preset angle range, use the adjusted flaw detection device to scan the bottom of the weld joint to be detected to obtain the bottom scanning result;

[0032] Generate a flaw detection result based on the head scanning result, the web scanning result, and the bottom scanning result.

[0033] An ultrasonic flaw detection device for a rail weld joint, comprising:

[0034] An acquisition unit for acquiring an initial flaw detection device, a reference test block, and a weld joint to be detected; the reference test block includes a defect hole;

[0035] A calibration unit for calibrating the initial flaw detection device to obtain a calibrated flaw detection device;

[0036] An adjustment unit for adjusting the sensitivity of the calibrated flaw detection device using the reference test block to obtain an adjusted flaw detection device;

[0037] A flaw detection unit for performing flaw detection on the weld joint to be detected using the adjusted flaw detection device to obtain a flaw detection result; the flaw detection result is the flaw detection results of the head, web, and bottom of the weld joint to be detected.

[0038] Optionally, the calibration unit is specifically used for:

[0039] Adjust the incident point of the probe of the initial flaw detection device to obtain an adjusted initial flaw detection device;

[0040] Calculate the distance between the probe value of the adjusted initial flaw detection device and the arc top, and calculate the difference between a preset value and the distance to obtain the probe front parameter;

[0041] Adjust the adjusted initial flaw detection device according to the probe front parameter;

[0042] When the adjustment of the adjusted initial flaw detection device is completed, calibrate the slope of the probe of the adjusted initial flaw detection device to obtain a calibrated flaw detection device.

[0043] Optionally, it further includes:

[0044] A target acquisition unit for acquiring an initial reference test block;

[0045] The first processing unit is used to perform defect processing on the jaw position of the rail head of the initial reference block to obtain a first reference block;

[0046] The second processing unit is used to perform defect processing on the web position of the first reference block to obtain a second reference block;

[0047] The third processing unit is used to perform defect processing on the bottom position of the second reference block to obtain a reference block.

[0048] Optionally, the adjustment unit is specifically configured to:

[0049] Set the probe of the calibrated flaw detection device at the defect hole position of the reference block;

[0050] After the probe of the calibrated flaw detection device is set, use the probe of the calibrated flaw detection device to perform ultrasonic detection on the defect hole of the reference block to obtain the highest echo;

[0051] Adjust the calibrated flaw detection device according to the highest echo so that the highest echo is a preset percentage of the full screen amplitude of the flaw detection device;

[0052] After the calibrated flaw detection device is adjusted, record the decibel value corresponding to the highest echo;

[0053] Set the decibel value as the reference sensitivity of the calibrated flaw detection device to obtain an adjusted flaw detection device.

[0054] Optionally, the flaw detection unit is specifically configured to:

[0055] Scan the rail head of the weld joint to be detected using the adjusted flaw detection device within a first preset angle range to obtain a rail head scan result;

[0056] Use the adjusted flaw detection device to perform parallel scanning on the web of the weld joint to be detected perpendicular to the weld to obtain a web scan result;

[0057] Scan the rail bottom of the weld joint to be detected using the adjusted flaw detection device within a second preset angle range to obtain a rail bottom scan result;

[0058] Generate a flaw detection result based on the rail head scan result, the web scan result, and the rail bottom scan result.

[0059] The technical solution provided by this application is to obtain an initial flaw detection device, a reference block, and a welded joint to be detected; calibrate the initial flaw detection device to obtain a calibrated flaw detection device; adjust the sensitivity of the calibrated flaw detection device using the reference block to obtain an adjusted flaw detection device; and perform flaw detection on the welded joint to be detected using the adjusted flaw detection device to obtain a flaw detection result. By adjusting the sensitivity of the calibrated flaw detection device using the reference block, the adjusted flaw detection device can accurately locate the defects in the rail welded joint. Description of the Drawings

[0060] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following-described drawings are only some embodiments of this application. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0061] Figure 1 It is a flowchart of an ultrasonic flaw detection method for a rail welded joint provided by an embodiment of this application;

[0062] Figure 2 It is a flowchart of a defect treatment method for a reference block provided by an embodiment of this application;

[0063] Figure 3 It is a schematic diagram of the defect treatment position of the rail head provided by an embodiment of this application;

[0064] Figure 4 It is a schematic diagram of the defect treatment positions of the rail web and the rail head provided by an embodiment of this application;

[0065] Figure 5 It is a flowchart of a calibration method for an initial flaw detection device provided by an embodiment of this application;

[0066] Figure 6 It is a flowchart of an adjustment method for a flaw detection device provided by an embodiment of this application;

[0067] Figure 7 It is a schematic diagram of the flaw detection area of a welded joint to be detected provided by an embodiment of this application;

[0068] Figure 8 It is a schematic diagram of the architecture of an ultrasonic flaw detection device for a rail welded joint provided by an embodiment of this application. Detailed Embodiments

[0069] Next, the technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present application.

[0070] In the present application, the term "including", "comprising" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "including one..." does not exclude the existence of another identical element in the process, method, article or device including the said element.

[0071] As Figure 1 shown, it is a flowchart of an ultrasonic flaw detection method for a rail welding joint provided by an embodiment of the present application, including the following steps:

[0072] S101: Obtain an initial flaw detection device, a reference block and a welding joint to be detected.

[0073] Among them, the reference block includes defect holes, and both the reference block and the welding joint to be detected are rail welding joints.

[0074] Optionally, the initial flaw detection device indicates a flaw detection device that has not been debugged (such as a portable digital ultrasonic flaw detector).

[0075] Before step S101, it is also necessary to first perform defect treatment on the initial reference block to obtain a reference block with defects, which can provide a basis for adjusting the sensitivity of the flaw detection device according to the reference block subsequently, so as to ensure that the flaw detection device can accurately detect defects. Therefore, in another embodiment of the present application, a method for defect treatment of a reference block is provided. As Figure 2 shown, it includes the following steps:

[0076] S201: Obtain an initial reference block.

[0077] Among them, the initial reference block indicates a reference block that has not been processed.

[0078] Optionally, the length of the initial reference block is L.

[0079] S202: Perform defect treatment on the position of the lower jaw of the rail head of the initial reference block to obtain a first reference block.

[0080] Specifically, refer to Figure 3, a schematic diagram showing the treatment positions of head defects is presented. A set of defects is machined at the position l from both end faces of the rail and at the center of the rail length. Each set of defects is located at the corner of the head jaw and at a distance H from it. H is the horizontal distance from the center of the artificial defect hole in the head jaw to the end face of the head. The defects are all flat-bottom holes. Specifically, the diameter accuracy of the defect holes is ±0.05 mm, and the depth accuracy is ±0.1 mm; the shape accuracy (including the roundness, cylindricity of the defect holes and the straightness of the axis) is ±0.05 mm; the surface roughness Ra of the defect holes is ≤0.8 μm.

[0081] It should be noted that there should be multiple sets of comparison blocks for each specification model of the head. The diameters of the flat-bottom holes in the jaw of each set of comparison blocks are Φ0.1~3.0 mm respectively, and the corresponding hole depths are 0.5~10 mm respectively.

[0082] S203: Perform defect treatment on the web position of the first comparison block to obtain the second comparison block.

[0083] Among them, there is one or more defect holes in the web position.

[0084] S204: Perform defect treatment on the bottom position of the second comparison block to obtain the comparison block.

[0085] Specifically, the defect treatment positions of the web and the head are as Figure 4 shown. a is the distance from the center of the artificial defect hole at the bottom to the end face of the rail; R2 is the radius of the rounded corner at the bottom corner. A set of artificial defects is machined at the position a from both end faces of the rail. The artificial defects are all flat-bottom holes. There are 4 in total on the web and 8 in total on the bottom. Specifically, there should be multiple sets of comparison blocks for each specification model of the web and the bottom. The diameters of the different flat-bottom holes in each set of comparison blocks are Φ0.1~5.0 mm respectively, and the corresponding hole depths are 0.5~5 mm respectively.

[0086] It should be noted that the position accuracy between the defect holes, between the defect holes and the tread of the rail, and at the bottom foot is ±0.2 mm; the diameter accuracy of the defect holes is ±0.05 mm, and the depth accuracy is ±0.1 mm; the shape accuracy (including the roundness, cylindricity of the defect holes and the straightness of the axis) is ±0.05 mm; the surface roughness Ra of the defect holes is ≤0.8 μm.

[0087] S102: Calibrate the initial flaw detection equipment to obtain the calibrated flaw detection equipment.

[0088] It can be understood that by calibrating the initial flaw detection equipment, during ultrasonic testing, it can accurately reflect the true situation of the object to be detected. The equipment is adjusted to the best state through calibration to ensure that it can reliably detect defects and avoid false alarms or missed detections.

[0089] Optionally, in another embodiment of the present application, the specific implementation manner of step S102 is as follows Figure 5 shown, including the following steps:

[0090] S501: Adjust the probe incident point of the initial flaw detection device to obtain an adjusted initial flaw detection device.

[0091] Optionally, the R50mm and R100mm arc end faces of a standard test block (such as CSK-IA) can be used for adjustment, that is, the standard test block is adjusted to the "automatic calibration" mode, the inclined probe is placed at the upper arc end face and moved back and forth, and after finding the highest echo of R100mm, confirmation can complete the zero offset adjustment of the instrument.

[0092] S502: Calculate the distance between the probe value of the adjusted initial flaw detection device and the arc top, and calculate the difference between the preset value and the distance to obtain the probe front parameter.

[0093] Among them, the preset value includes but is not limited to 100.

[0094] Optionally, a ruler can be used to measure the distance between the probe value of the adjusted initial flaw detection device and the arc top.

[0095] S503: Adjust the adjusted initial flaw detection device according to the probe front parameter.

[0096] Among them, adding the front parameter to the adjusted initial flaw detection device can complete the adjustment of the initial flaw detection device.

[0097] S504: When the adjustment of the adjusted initial flaw detection device is completed, calibrate the slope of the probe of the adjusted initial flaw detection device to obtain a calibrated flaw detection device.

[0098] It can be understood that the probe of the adjusted initial flaw detection device is placed at the end face corresponding to the 50-mm diameter circular hole on the standard test block, and the probe is moved to obtain the highest echo. After confirming the maximum echo value, the calibration of the refraction angle K of the inclined probe can be completed, and the angle β between the ultrasonic wave emission direction and the plane perpendicular to the detection plane. According to the formula K = tanβ, the slope of the probe can be obtained, thus completing the calibration of the initial flaw detection device.

[0099] S103: Use a comparison test block to adjust the sensitivity of the calibrated flaw detection device to obtain an adjusted flaw detection device.

[0100] It can be understood that the acoustic wave propagation characteristics of different materials, the shape, size and position of holes or defects may all have different effects on the reflection and propagation of ultrasonic signals. The sensitivity adjustment is to use a comparison test block to adjust the flaw detection device so that it can accurately detect various defects that may occur in actual detection.

[0101] Optionally, in another embodiment of the present application, the specific implementation manner of step S103 is as follows Figure 6 shown, including the following steps:

[0102] S601: Set the probe of the calibrated flaw detection device at the defect hole position of the reference block.

[0103] Specifically, the probe of the calibrated flaw detection device can be set at the defect hole positions of the rail head, rail web, and rail web of the reference block.

[0104] S602: After the probe of the calibrated flaw detection device is set, use the probe of the calibrated flaw detection device to perform ultrasonic detection on the defect hole of the reference block to obtain the highest echo.

[0105] Among them, when the ultrasonic wave emitted by the probe propagates in the reference block and encounters a defect, it will be reflected back to form an echo. The intensity (i.e., wave height) of this echo is related to the size and position of the defect. In this step, find the highest echo corresponding to the defect hole with a diameter in the range of Φ0.5 - 3 mm and a hole depth in the range of 1 - 8 mm on the reference block.

[0106] S603: Adjust the calibrated flaw detection device according to the highest echo so that the highest echo is a preset percentage of the full screen amplitude of the flaw detection device.

[0107] Optionally, the preset percentage includes but is not limited to 80%.

[0108] It can be understood that the calibrated flaw detection device is adjusted according to the highest echo so that the displayed echo reaches 80% of the full screen amplitude of the instrument. This is usually to ensure that the sensitivity of the instrument is within a controllable range so as to accurately measure the defect.

[0109] S604: After the calibrated flaw detection device is adjusted, record the decibel value corresponding to the highest echo.

[0110] Among them, record the decibel value corresponding to this highest echo, and this decibel value represents the sensitivity of the instrument under this condition.

[0111] S605: Set the decibel value as the reference sensitivity of the calibrated flaw detection device to obtain the adjusted flaw detection device.

[0112] S104: Use the adjusted flaw detection device to detect the weld joint to be detected to obtain the detection result.

[0113] Among them, the detection result is the detection results of the rail head, rail web, and rail bottom of the weld joint to be detected.

[0114] It can be understood that the rail head of the weld joint to be detected should generally be detected at both ends of the weld tread, the rail web should generally be detected on both sides of the double-sided side, and the rail base should generally be detected on both sides of the single-sided side. When detecting the rail weld joint with the adjusted flaw detection equipment, the detection sensitivity can be appropriately increased by 1 dB to 9 dB as the scanning sensitivity.

[0115] Optionally, in another embodiment of the present application, the specific implementation manner of step S104 includes processes A1 to A4.

[0116] A1: Scan the rail head of the weld joint to be detected with the adjusted flaw detection equipment according to the first preset angle range to obtain the rail head scan result.

[0117] Among them, the first preset angle range includes but is not limited to 0° to 60°. The first preset angle range is the included angle between the beam axis of the oblique probe and the longitudinal center line of the rail head.

[0118] It can be understood that, according to the first preset angle range, the rail head of the weld joint to be detected is scanned with the adjusted flaw detection equipment. During the scanning process, the probe can be appropriately swung left and right. The scanning area covers all areas of the rail head, and the focus is on scanning the area of the rail head jaw.

[0119] A2: Use the adjusted flaw detection equipment to perform parallel scanning on the rail web of the weld joint to be detected perpendicular to the weld to obtain the rail web scan result.

[0120] It can be understood that the adjusted flaw detection equipment is used to perform a parallel scan along the rail web of the weld joint to be detected (i.e., the side of the weld joint to be detected). During the scan, the probe of the adjusted flaw detection equipment is placed perpendicular to the weld surface, that is, the scanning direction of the probe is perpendicular to the direction of the weld.

[0121] A3: Scan the rail base of the weld joint to be detected with the adjusted flaw detection equipment according to the second preset angle range to obtain the rail base scan result.

[0122] Among them, the second preset angle range includes but is not limited to 0° to 55°.

[0123] It can be understood that the adjusted flaw detection equipment is used to scan the rail base of the weld joint to be detected. During the scanning process, the probe can be appropriately swung left and right. The scanning area covers all areas of the rail base, and the focus is on scanning the triangular area of the rail base and the rail base corner.

[0124] Specifically, refer to Figure 7 the schematic diagram of the flaw detection area of a weld joint to be detected shown in Figure 7 which includes the adjusted flaw detection equipment, the rail head, the rail base and the rail web. When scanning the rail head with the adjusted flaw detection equipment, the scanning area coversFigure 7 In area 1 of , the key scanning area is the shaded part of area 1; the web of the weld joint to be detected is scanned parallelly, and the scanning area covers Figure 7 area 2 in ; the adjusted flaw detection equipment is used to scan the rail bottom of the weld joint to be detected, and the scanning area covers Figure 7 area 3 and area 4 in , and the key scanning areas are area 3 (the rail bottom triangular area) and the shaded part (the rail bottom corner) in area 4.

[0125] A4: Generate a flaw detection result based on the rail head scanning result, the rail web scanning result, and the rail bottom scanning result.

[0126] In summary, by adjusting and calibrating the sensitivity of the flaw detection equipment with the reference block, the adjusted flaw detection equipment can accurately locate the defects of the rail weld joint.

[0127] As Figure 8 shown, it is a schematic structural diagram of an ultrasonic flaw detection device for a rail weld joint provided by an embodiment of the present application. The ultrasonic flaw detection device includes: an acquisition unit 100, a calibration unit 200, an adjustment unit 300, and a flaw detection unit 400.

[0128] The acquisition unit 100 is used to acquire an initial flaw detection device, a reference block, and a weld joint to be detected; the reference block includes a defect hole.

[0129] The calibration unit 200 is used to calibrate the initial flaw detection device to obtain a calibrated flaw detection device.

[0130] Specifically, the calibration unit 200 is used to: adjust the incident point of the probe of the initial flaw detection device to obtain an adjusted initial flaw detection device; calculate the distance between the probe value of the adjusted initial flaw detection device and the arc top, and calculate the difference between the preset value and the distance to obtain the probe front parameter; adjust the adjusted initial flaw detection device according to the probe front parameter; when the adjustment of the adjusted initial flaw detection device is completed, calibrate the slope of the probe of the adjusted initial flaw detection device to obtain a calibrated flaw detection device.

[0131] The adjustment unit 300 is used to adjust the sensitivity of the calibrated flaw detection device with the reference block to obtain an adjusted flaw detection device.

[0132] The adjustment unit 300 is specifically configured to: place the probe of the calibrated flaw detection device at the defect hole position of the reference test block; after the probe of the calibrated flaw detection device is set, use the probe of the calibrated flaw detection device to perform ultrasonic detection on the defect hole of the reference test block to obtain the highest echo; adjust the calibrated flaw detection device according to the highest echo so that the highest echo is a preset percentage of the full screen amplitude of the flaw detection device; after the calibrated flaw detection device is adjusted, record the decibel value corresponding to the highest echo; set the decibel value as the reference sensitivity of the calibrated flaw detection device to obtain the adjusted flaw detection device.

[0133] The flaw detection unit 400 is used to perform flaw detection on the weld joint to be detected by using the adjusted flaw detection device to obtain a flaw detection result; the flaw detection result is the flaw detection results of the rail head, rail waist and rail bottom of the weld joint to be detected.

[0134] The flaw detection unit 400 is specifically configured to: scan the rail head of the weld joint to be detected by using the adjusted flaw detection device according to the first preset angle range to obtain a rail head scan result; use the adjusted flaw detection device to perform a parallel scan on the rail waist of the weld joint to be detected perpendicular to the weld to obtain a rail waist scan result; scan the rail bottom of the weld joint to be detected by using the adjusted flaw detection device according to the second preset angle range to obtain a rail bottom scan result; generate a flaw detection result based on the rail head scan result, the rail waist scan result and the rail bottom scan result.

[0135] In summary, by adjusting the sensitivity of the calibrated flaw detection device through the reference test block, the adjusted flaw detection device can accurately locate the defects of the rail weld joint.

[0136] Combined with Figure 8 the content shown, the ultrasonic flaw detection device further includes:

[0137] The target acquisition unit is used to acquire an initial reference test block;

[0138] The first processing unit is used to perform defect processing on the lower jaw position of the rail head of the initial reference test block to obtain a first reference test block;

[0139] The second processing unit is used to perform defect processing on the rail waist position of the first reference test block to obtain a second reference test block;

[0140] The third processing unit is used to perform defect processing on the rail bottom position of the second reference test block to obtain a reference test block.

[0141] The various embodiments in this specification are described in a progressive manner. The key point of each embodiment is to illustrate the differences from other embodiments. For the same or similar parts among the embodiments, reference can be made to each other. The key point of each embodiment is to illustrate the differences from other embodiments. In particular, for a system or a system embodiment, since it is basically similar to a method embodiment, the description is relatively simple. For the relevant parts, reference can be made to the partial description of the method embodiment. The systems and system embodiments described above are merely illustrative. The units described as separate components may or may not be physically separated. The components shown as units may or may not be physical units, that is, they may be located in one place or distributed to multiple network units. Some or all of the modules can be selected according to actual needs to achieve the purpose of the solution of this embodiment. A person of ordinary skill in the art can understand and implement it without creative efforts.

[0142] Those skilled in the art can further realize that the units and algorithm steps of each example described in combination with the embodiments disclosed herein can be implemented by electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the composition and steps of each example have been generally described according to functions in the above description. Whether these functions are executed in a hardware or software manner depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered to exceed the scope of the present invention.

[0143] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present application. Various modifications to these embodiments will be obvious to those skilled in the art. The general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An ultrasonic flaw detection method for a rail welding joint, characterized in that, Including: Obtain an initial flaw detection device, a reference block, and a welded joint to be detected; the reference block includes defect holes; Calibrate the initial flaw detection device to obtain a calibrated flaw detection device; Adjust the sensitivity of the calibrated flaw detection device using the reference block to obtain an adjusted flaw detection device; Detect the welded joint to be detected using the adjusted flaw detection device to obtain a flaw detection result; the flaw detection result is the flaw detection results of the rail head, rail web, and rail base of the welded joint to be detected.

2. The method according to claim 1, characterized in that, The calibrating the initial flaw detection device to obtain a calibrated flaw detection device includes: Adjust the probe incident point of the initial flaw detection device to obtain an adjusted initial flaw detection device; Calculate the distance between the probe value of the adjusted initial flaw detection device and the arc top, and calculate the difference between a preset value and the distance to obtain a probe front parameter; Adjust the adjusted initial flaw detection device according to the probe front parameter; After the adjustment of the adjusted initial flaw detection device is completed, calibrate the slope of the probe of the adjusted initial flaw detection device to obtain a calibrated flaw detection device.

3. The method according to claim 1, wherein Before obtaining the reference block and the welded joint to be detected, it further includes: Obtain an initial reference block; Perform defect treatment on the rail head jaw position of the initial reference block to obtain a first reference block; Perform defect treatment on the rail web position of the first reference block to obtain a second reference block; Perform defect treatment on the rail base position of the second reference block to obtain a reference block.

4. The method according to claim 1, characterized in that, The adjusting the sensitivity of the calibrated flaw detection device using the reference block to obtain an adjusted flaw detection device includes: Set the probe of the calibrated flaw detection device at the defect hole position of the reference block; After the probe of the calibrated flaw detection device is set, perform ultrasonic detection on the defect hole of the reference block using the probe of the calibrated flaw detection device to obtain the highest echo; Adjust the calibrated flaw detection device according to the highest echo so that the highest echo is a preset percentage of the full screen amplitude of the flaw detection device; After the adjustment of the calibrated flaw detection device is completed, record the decibel value corresponding to the highest echo; Set the decibel value as the reference sensitivity of the calibrated flaw detection device to obtain an adjusted flaw detection device.

5. The method according to claim 1, wherein The detecting the welded joint to be detected using the adjusted flaw detection device to obtain a flaw detection result includes: Scan the rail head of the welded joint to be detected using the adjusted flaw detection device within a first preset angle range to obtain a rail head scan result; Use the adjusted flaw detection device to perform parallel scanning on the rail web of the welded joint to be detected perpendicular to the weld to obtain a rail web scan result; Scan the rail base of the welded joint to be detected using the adjusted flaw detection device within a second preset angle range to obtain a rail base scan result; Generate a flaw detection result based on the rail head scan result, the rail web scan result, and the rail base scan result.

6. An ultrasonic flaw detection device for a rail welding joint, characterized in that, Including: An acquisition unit for acquiring an initial flaw detection device, a reference block, and a welded joint to be detected; The reference block includes defect holes; A calibration unit for calibrating the initial flaw detection device to obtain a calibrated flaw detection device; An adjustment unit for adjusting the sensitivity of the calibrated flaw detection device by using the reference block to obtain an adjusted flaw detection device; A flaw detection unit for detecting the weld joint to be detected by using the adjusted flaw detection device to obtain a flaw detection result; the flaw detection result is the flaw detection results of the head, web and bottom of the weld joint to be detected.

7. The device according to claim 6, characterized in that The calibration unit is specifically used for: Adjusting the probe incident point of the initial flaw detection device to obtain an adjusted initial flaw detection device; Calculating the distance between the probe value of the adjusted initial flaw detection device and the arc top, and calculating the difference between a preset value and the distance to obtain a probe front parameter; Adjusting the adjusted initial flaw detection device according to the probe front parameter; When the adjustment of the adjusted initial flaw detection device is completed, calibrating the slope of the probe of the adjusted initial flaw detection device to obtain a calibrated flaw detection device.

8. The device according to claim 6, characterized in that, It further includes: A target acquisition unit for acquiring an initial reference block; A first processing unit for performing defect processing on the head jaw position of the initial reference block to obtain a first reference block; A second processing unit for performing defect processing on the web position of the first reference block to obtain a second reference block; A third processing unit for performing defect processing on the bottom position of the second reference block to obtain a reference block.

9. The device according to claim 6, characterized in that, The adjustment unit is specifically used for: Setting the probe of the calibrated flaw detection device at the defect hole position of the reference block; When the setting of the probe of the calibrated flaw detection device is completed, performing ultrasonic detection on the defect hole of the reference block by using the probe of the calibrated flaw detection device to obtain the highest echo; Adjusting the calibrated flaw detection device according to the highest echo so that the highest echo is a preset percentage of the full screen amplitude of the flaw detection device; When the adjustment of the calibrated flaw detection device is completed, recording the decibel value corresponding to the highest echo; Setting the decibel value as the reference sensitivity of the calibrated flaw detection device to obtain an adjusted flaw detection device.

10. The device according to claim 6, characterized in that The flaw detection unit is specifically used for: Scanning the head of the weld joint to be detected by using the adjusted flaw detection device within a first preset angle range to obtain a head scanning result; Performing parallel scanning on the web of the weld joint to be detected by using the adjusted flaw detection device perpendicular to the weld seam to obtain a web scanning result; Scanning the bottom of the weld joint to be detected by using the adjusted flaw detection device within a second preset angle range to obtain a bottom scanning result; Generating a flaw detection result based on the head scanning result, the web scanning result and the bottom scanning result.

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