Full-section detection method, device and equipment for reinforcing steel rail welding seam and storage medium

Abstract

The invention provides a full-section detection method, device and equipment for reinforcing a steel rail welding seam and a storage medium, and relates to the technical field of nondestructive testing. The method comprises the following steps: respectively arranging a plurality of first phased array probes on rail head treads and rail bottom surfaces of a first steel rail and a second steel rail, and arranging a second phased array probe right above a welding seam; the detection method comprises the following steps: determining optimal parameters of a transducer based on the material of the steel rail, the size of the cross section of the steel rail and the sound pressure intensity at a preset focusing depth position; determining the optimal scanning angle range of the first phased array probe based on the propagation velocity of the ultrasonic longitudinal wave in the wedge block and the steel rail, the propagation velocity of the ultrasonic transverse wave in the steel rail and the Snell's law; and controlling the first phased array probe to carry out sector scanning imaging within the optimal scanning angle range, and controlling the second phased array probe to carry out zero-degree line scanning imaging, so as to detect the full section of the welding seam. According to the invention, the welding seam can be accurately detected without dismounting the clamping plate.

Description

Technical Field

[0001] The present invention relates to the technical field of nondestructive testing, and in particular to a full-section testing method, device, equipment and storage medium for reinforced rail welds. Background Art

[0002] Seamless train lines are the basis for the development of high-speed passenger and heavy-load freight, and the key technology to achieve seamless lines is rail welding technology.

[0003] However, the thermal expansion and contraction of CWR rails generate significant thermal stress. This, coupled with the impact of high-speed, heavy-load trains on the rails, can easily cause cracks in welded joints, leading to rail breakage. Therefore, the health of rail welded joints is crucial for the safe and reliable operation of CWR rails.

[0004] After rail welding, plywood is often used to reinforce the rails for safety. According to the railway industry's weld flaw detection regulations, welds must undergo regular full-section flaw inspection. Currently, ultrasonic testing is the primary method used. However, ultrasonic testing requires the removal of the reinforcement plywood to conduct full-section flaw detection of the reinforced rail welds. After testing, the removed plywood must be promptly reinstalled, making the process time-consuming and labor-intensive. The ability to quickly and accurately perform inspections without removing the plywood has become a pressing technical challenge. Summary of the Invention

[0005] The embodiments of the present invention provide a full-section detection method, device, equipment and storage medium for reinforced rail welds to solve the problem of how to quickly and accurately detect welds without removing splints.

[0006] In a first aspect, an embodiment of the present invention provides a full-section inspection method for reinforced rail welds, wherein a plurality of first phased array probes are respectively disposed on the rail head tread and rail bottom surface of a first rail and a second rail, and each first phased array probe is disposed on a wedge that is disposed in contact with the rail head tread or rail bottom surface; a second phased array probe is disposed directly above the weld, which is the welded joint between the first rail and the second rail; the inspection method comprises: Determining optimal transducer parameters based on the material and cross-sectional dimensions of the rail, and the sound pressure intensity at a preset focal depth; wherein the parameters of the transducer corresponding to the first phased array probe are the same as the parameters of the transducer corresponding to the second phased array probe; Determine the optimal scanning angle range of the first phased array probe based on the propagation velocity of ultrasonic longitudinal waves in the wedge and rail, the propagation velocity of ultrasonic shear waves in the rail, and Snell's law; The first phased array probe is controlled to perform sector scanning imaging within the optimal scanning angle range, and the second phased array probe is controlled to perform zero-degree line scanning imaging to detect the entire cross-section of the weld.

[0007] In one possible implementation, controlling the first phased array probe to perform sector scanning imaging within a scanning angle and controlling the second phased array probe to perform zero-degree line scanning imaging to inspect the entire cross-section of the weld includes: Controlling all transducers to transmit excitation signals; wherein all transducers include transducers corresponding to the first phased array probe and transducers corresponding to the second phased array probe; Based on the direct wave field and the accompanying wave field corresponding to the excitation signal emitted by the transducer, a topological gradient function is constructed; Based on the topological gradient function, determining the imaging function corresponding to the excitation signal; Based on the imaging function, all defects in the phased array sector scan image are sharpened to obtain the optimized phased array sector scan image; Based on the optimized phased array fan scan image, the full cross-section of the weld is inspected.

[0008] In a possible implementation, the numerator of the topological gradient function is the absolute value of the integral of the product of the direct wavefield and the adjoint wavefield, and the denominator is the integral of the square of the modulus of the direct wavefield; The imaging function is obtained by normalizing the topological gradient function.

[0009] In one possible implementation, the optimal parameters of the transducer are determined based on the material of the rail, the dimensions of the rail cross section, and the sound pressure intensity at a preset focal depth, including: Selecting a plurality of different parameters of the transducer; wherein the parameters include the transducer center frequency, array element center distance, array element width, and the number of array elements; Based on the single variable analysis method, the sound pressure intensity at the preset focal depth position is analyzed according to the material and cross-sectional dimensions of the rail. The transducer center frequency, array element center distance, array element width and number of array elements corresponding to the maximum sound pressure intensity at the preset focal depth position are determined as the optimal parameters of the transducer.

[0010] In one possible implementation, the optimal scanning angle range of the first phased array probe is determined based on the propagation velocity of ultrasonic longitudinal waves in the wedge and rail, the propagation velocity of ultrasonic shear waves in the rail, and Snell's law, including: Based on the propagation speed of ultrasonic longitudinal waves in the wedge and rail, the propagation speed of ultrasonic shear waves in the rail, and the relationship between refracted waves in Snell's law, the critical angle of incidence of the ultrasonic wave and the scanning angle range of the refracted shear wave in the rail are determined during shear wave testing. Calculate the deflection angle of the refracted ultrasonic shear wave in the rail; The optimal scanning angle range of the first phased array probe is determined based on the scanning angle range of the refracted shear wave in the rail and the deflection angle of the refracted shear wave.

[0011] In one possible implementation, the first phased array probe is a phased array shear wave probe, and the second phased array probe is a phased array longitudinal wave probe; All first phased array probes disposed on the rail head and tread of the first rail and all first phased array probes disposed on the rail head and tread of the second rail are symmetrically disposed relative to the weld; All first phased array probes arranged on the bottom surface of the rail bottom of the first rail and all first phased array probes arranged on the bottom surface of the rail bottom of the second rail are symmetrically arranged relative to the weld.

[0012] In one possible implementation, the distance between the first phased array probe and the weld center is 50 to 180 mm; The wedge is made of organic glass, and the optimal scanning angle range of the first phased array probe is 40°~70°.

[0013] In a second aspect, an embodiment of the present invention provides a full-section inspection device for reinforced rail welds, wherein a plurality of first phased array probes are respectively disposed on the rail head tread and rail bottom surface of a first rail and a second rail, and each first phased array probe is disposed on a wedge, which is disposed in contact with the rail head tread or rail bottom surface; a second phased array probe is disposed directly above the weld, which is the welded joint between the first rail and the second rail; the inspection device comprises: a parameter determination module for determining optimal transducer parameters based on the material and cross-sectional dimensions of the rail, and the sound pressure intensity at a preset focal depth; wherein the optimal parameters include the transducer center frequency, array element center spacing, array element width, and number of array elements, and the parameters of the transducer corresponding to the first phased array probe are the same as the parameters of the transducer corresponding to the second phased array probe; a range determination module, configured to determine an optimal scanning angle range of the first phased array probe based on a propagation velocity of an ultrasonic longitudinal wave in the wedge and the rail, a propagation velocity of an ultrasonic shear wave in the rail, and Snell's law; The detection module is used to control the first phased array probe to perform sector scanning imaging within the optimal scanning angle range, and to control the second phased array probe to perform zero-degree line scanning imaging, so as to detect the full cross-section of the weld.

[0014] In a third aspect, an embodiment of the present invention provides an electronic device comprising a memory and a processor, wherein the memory stores a computer program, and when the processor executes the computer program, the method in the first aspect or any possible implementation of the first aspect is implemented.

[0015] In a fourth aspect, an embodiment of the present invention provides a computer-readable storage medium storing a computer program, which, when executed by a processor, implements the method in the first aspect or any possible implementation of the first aspect.

[0016] In a fifth aspect, an embodiment of the present invention provides a computer program product, including a computer program, which, when executed by a processor, implements the method in the first aspect or any possible implementation of the first aspect.

[0017] In an embodiment of the present invention, by respectively setting a plurality of first phased array probes on the rail head tread and rail bottom surface of the rails on both sides of the weld, and setting a second phased array probe directly above the weld, the optimal parameters of the transducer can be determined based on the material of the rail, the size of the rail cross section, and the sound pressure intensity at the preset focus depth position. Next, based on the propagation speed of ultrasonic longitudinal waves in the wedge and rail, the propagation speed of ultrasonic shear waves in the rail, and Snell's law, the optimal scanning angle range of the first phased array probe is determined. Finally, the first phased array probe can be controlled to perform sector scanning imaging within the optimal scanning angle range, and the second phased array probe can be controlled to perform zero-degree line scanning imaging, thereby achieving full-section inspection of the weld. By adopting the inspection method provided by the present invention, it is possible to avoid removing the splint, simplify the flaw detection process, and achieve full-section acoustic beam coverage of the weld, with the advantages of high detection efficiency and no flaw detection blind spots. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a flow chart for implementing a full-section detection method for reinforced rail welds provided by an embodiment of the present invention; Figure 2 is a comparison diagram of sound pressure intensities at different frequencies at different axial distances provided by an embodiment of the present invention; Figure 3 is a comparison diagram of sound pressure intensities at different frequencies at different lateral distances provided by an embodiment of the present invention; Figure 4 This is a comparison diagram of the sound pressure intensity at different axial distances for different array element center distances provided by an embodiment of the present invention; Figure 5 This is a comparison diagram of the sound pressure intensity at different lateral distances for different array element center distances provided by an embodiment of the present invention; Figure 6 is a comparison diagram of the sound pressure intensity at axial distances for different array element widths provided by an embodiment of the present invention; Figure 7 is a comparison diagram of sound pressure intensity at lateral distances for different array element widths provided by an embodiment of the present invention; Figure 8 This is a comparison chart of sound pressure intensity at axial distances for different numbers of array elements provided by an embodiment of the present invention; Figure 9 This is a comparison chart of sound pressure intensity at lateral distances for different numbers of array elements provided by an embodiment of the present invention; Figure 10 This is a schematic diagram of the detection position of the phased array probe for reinforced rail welds provided by an embodiment of the present invention; Figure 11 This is a waveform conversion principle diagram provided by an embodiment of the present invention; Figure 12 1 is a schematic diagram of a simulation of an acoustic beam field of a phased array probe provided by an embodiment of the present invention; Figure 13 1 is a schematic structural diagram of a full-section inspection device for reinforced rail welds provided by an embodiment of the present invention; Figure 14 is a schematic diagram of an electronic device provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0019] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0020] Seamless train lines are fundamental to the development of high-speed passenger and heavy-load freight transport. Rail welding technology is crucial to achieving seamless lines. Thermal expansion and contraction of seamless rails generate significant thermal stress. Combined with the impact of high-speed, heavy-load train operation, welded joints are prone to cracking, potentially leading to line failure. Therefore, the health of rail weld joints is crucial for the safe and reliable operation of seamless lines.

[0021] However, rail weld flaw detection is far more challenging than conventional rail flaw detection. First, the equipment and methods used are fundamentally different, and weld damage is distributed across the entire cross-section. Second, weld defects are highly complex, with some formed during the welding process, others arising from service. Defects vary in shape and are extremely difficult to distinguish and detect. Therefore, accurately detecting rail weld damage early and accurately has become a critical task and a pressing challenge for maintenance organizations.

[0022] Current ultrasonic testing technologies are primarily divided into two categories: conventional ultrasonic testing and ultrasonic phased array testing. The key difference between the two lies in the probe control method. Conventional ultrasonic testing operates with a single probe, while ultrasonic phased array testing achieves detection through the precise control of a phased array probe composed of multiple elements. Conventional ultrasonic probes can only detect defects in a fixed orientation. To detect defects in different locations, the probe must be continuously rotated and moved, which not only increases detection complexity but also reduces efficiency. Furthermore, conventional ultrasonic testing relies more on analyzing time-domain signals and can typically only locate defects, with limited capabilities for defect identification and quantitative assessment. This manual testing method makes test results highly dependent on the operator's experience and skill level, resulting in certain limitations in detection reliability and accuracy. Numerous conventional ultrasonic methods exist that employ a dual-probe mode for tandem scanning of defects in different areas of rail welds. However, these methods are limited in their inability to determine damage size, require high technical expertise, and are relatively inefficient.

[0023] Ultrasonic phased array testing technology significantly improves these limitations. By controlling the delay of multiple array elements, ultrasonic phased arrays can dynamically deflect and focus the acoustic beam while maintaining a fixed probe position, significantly expanding the inspection coverage. Without frequent probe movement, the focused acoustic field can be varied over a wide range, enabling comprehensive scanning of defects at varying orientations and depths. Furthermore, the linear array arrangement enables two-dimensional imaging, and combined with encoding equipment, three-dimensional imaging is also possible, which is crucial for defect identification, condition analysis, and quantitative assessment. This technology significantly improves inspection accuracy and efficiency, reducing the impact of human error. Ultrasonic phased array testing technology offers flexible beam deflection and focusing capabilities. Adjusting the beam deflection angle eliminates the need for plate removal and frequent probe replacement, offering high accuracy and minimal structural blind spots in nondestructive testing. Therefore, phased array technology has been introduced for ultrasonic flaw detection of rail welds. Through research on key technologies for ultrasonic phased array testing of rail welds, full-section flaw detection of rail welds can be achieved without plate removal, achieving accuracy that meets regulatory requirements.

[0024] In order to be able to detect the entire cross-section of the weld, it is necessary to install multiple first phased array probes on the rail head tread and rail bottom surface of the first rail and the second rail, respectively, and each first phased array probe is installed on a wedge, and the wedge is installed in contact with the rail head tread or rail bottom surface. A second phased array probe is installed directly above the weld, which is the welded joint between the first rail and the second rail, and the first rail and the second rail are made of the same material. The first phased array probe can scan the rail head, rail waist and rail bottom. The second phased array probe is mainly used to detect the vertical projection area of ​​the rail head, rail waist upper part and rail waist lower part of the weld. In addition, the installation position of the first phased array probe and the second phased array probe will not interfere with the plywood on both sides of the rail, which can avoid the removal of the plywood, simplify the flaw detection process, and achieve full-section acoustic beam coverage of the weld, with the advantages of high efficiency and no flaw detection blind spots.

[0025] See also Figure 1 , which shows a flow chart for implementing a full-section detection method for reinforced rail welds provided by an embodiment of the present invention, and is described in detail as follows: S110 , determining optimal parameters of the transducer based on the material of the rail, the size of the rail cross section, and the sound pressure intensity at a preset focus depth position.

[0026] As a key component in the field of acoustics, the acoustic characteristics of the transducer are crucial for evaluating weld performance. Transducer parameters, including the transducer center frequency, array element center distance, array element width, and number of elements, can affect the detection sound field.

[0027] In some embodiments, multiple different transducer parameters can be selected first. Then, based on a single variable analysis method and the material and cross-sectional dimensions of the rail, the sound pressure intensity at a preset focal depth is analyzed. The transducer center frequency, array element center distance, array element width, and number of array elements corresponding to the maximum sound pressure intensity at the preset focal depth are determined as the optimal transducer parameters.

[0028] In this embodiment, three different transducer center frequencies, f1, f2, and f3, can be set based on the rail material, and the other parameters remain the same. A frequency domain field simulation analysis is performed in the simulation software. First, based on the cross-sectional dimensions of the rail, a preset focus depth is set to H. Using the center position of the linear array element group and the focus point coordinates as references, two axes, axial distance and lateral distance, are established to analyze the sound pressure intensity of the focused sound field. Figure 2 and 3 As shown, it can be concluded that the sound field intensity of the transducer center frequency f2 is the largest at this focusing depth.

[0029] Set the center frequency of the transducer to f2, the propagation speed of the ultrasonic wave in the rail c and the sector scanning angle When the distance between the center of the array element is determined, three different distances between the center of the array element are set at the same time, namely p1, p2 and p3, and the other parameters remain the same. Also set the preset focus depth to H, and compare the sound pressure intensity under different distances between the center of the array element. Figure 4 and 5 As shown in FIG, the analysis shows that the sound field intensity of p1 at this focusing depth is the largest. It can be determined based on the equation that the array element spacing and the wavelength of the sound wave in the workpiece being inspected satisfy.

[0030] Phased array can only achieve focusing in the near field. After determining the center frequency of the transducer as f2 and the array element spacing as p1, and in order to avoid the generation of grating lobes (not exceeding half a wavelength), two different array element widths can be set, d1 and d2, respectively, while keeping the other parameters the same. The preset focus depth is H, and the sound pressure intensity under different array element widths is compared, as shown in the following example. Figure 6 and 7 As shown in FIG, the analysis shows that the sound field intensity at the focal depth d2 is the largest.

[0031] Set the center frequency of the transducer to f2, the array element spacing to p1, the array element width to d2, and set two different numbers of array elements, N1 and N2, respectively, while keeping the other parameters the same. Preset the focus depth to H and compare the sound pressure intensity under different numbers of array elements, such as Figure 8 and 9 As shown, analysis shows that the acoustic field intensity is maximum at this focal depth, N2. The number of array elements, N, can be determined based on the rail head geometry and the existing probe technology. A larger number of elements increases the cost. Phased array testing typically uses 32 or 64 elements.

[0032] Through the above analysis, the optimal parameters of the transducer can be determined according to the method provided above: center frequency is f2, array element center distance is p1, array element width is d2, and the number of array elements is N2.

[0033] It should be noted that sound pressure intensity can be calculated using simulation software and analyzed in the frequency domain. For example, if the focal point depth is preset to 20 mm, the linear array element center position is (0, 0) during the modeling process, and the focal point coordinates are (0, 20), two virtual axes are established. The axial line (similar to the y-axis) is defined as the line connecting points (0, 0) and (0, 40); the transverse axis is defined as the line connecting points (-20, 20) and (20, 20), with the focal point coordinates as the reference. Once these two axes are obtained, the sound pressure intensity of each axis in the focal field is analyzed.

[0034] S120. Determine the optimal scanning angle range of the first phased array probe based on the propagation velocity of the ultrasonic longitudinal wave in the wedge and the rail, the propagation velocity of the ultrasonic shear wave in the rail, and Snell's law.

[0035] In some embodiments, as Figure 10 As shown, the first phased array probe 630 is a phased array shear wave probe, which can be placed on the rail head tread and the rail bottom surface respectively with the organic glass wedge 640 for sector scanning. The second phased array probe 650 is a phased array longitudinal wave probe, which is placed directly above the weld in a direct contact manner. All the first phased array probes 630 set on the rail head tread of the first rail 610 and all the first phased array probes 630 set on the rail head tread of the second rail 620 are symmetrically arranged with respect to the weld. All the first phased array probes 630 set on the rail bottom surface of the first rail 610 and all the first phased array probes 630 set on the rail bottom surface of the second rail 620 are symmetrically arranged with respect to the weld.

[0036] In this embodiment, the distance between the first phased array probe and the center of the weld is 50-180 mm.

[0037] In some embodiments, the critical angle of the ultrasonic incident angle and the scanning angle range of the refracted shear wave in the rail can be determined first based on the propagation velocity of the ultrasonic longitudinal wave in the wedge block and the rail, the propagation velocity of the ultrasonic shear wave in the rail, and the relationship between the refracted waves in Snell's law when performing shear wave detection.

[0038] Then, the deflection angle of the refracted ultrasonic shear wave in the rail is calculated.

[0039] Finally, the optimal scanning angle range of the first phased array probe is determined based on the scanning angle range of the refracted shear wave in the rail and the deflection angle of the refracted shear wave.

[0040] In this embodiment, the wedge is made of organic glass as an example. Figure 11 When the ultrasonic longitudinal wave is incident obliquely from one solid material to another solid material, refraction will occur at the interface between the two materials. The ultrasonic longitudinal wave is incident obliquely from the organic glass material to the rail material, and the incident angle is , generating refracted longitudinal waves in the rails , the refraction angle is , and refracted shear waves will also be generated , the refraction angle is At the same time, reflection through the interface will produce reflected longitudinal waves and reflected shear waves, and the reflection angles are and .

[0041] According to Snell's law, the refracted wave follows formula (1):

[0042] Where, and Represent the propagation speed of longitudinal waves in organic glass and steel rails respectively, Represents the propagation speed of shear waves in the rail.

[0043] According to formula (1), the first critical angle of longitudinal wave incidence is 27.6°, and the second critical angle is 57.6°. Therefore, when performing shear wave detection on rails, the incident angle of the ultrasonic wave must be between the first critical angle and the second critical angle, so that the corresponding refracted shear wave can be obtained. The scanning angle inside the rail is about 33°~90°. Considering that in phased array ultrasonic testing, the larger the deflection angle, the smaller the sound energy will be and the worse the detection capability will be, in order to allow the sound energy to better enter the interior of the rail, it is necessary to calculate the deflection angle of the refracted shear wave, and then obtain the angle range of the phased array sector scan. According to Snell's law, the relationship between the amplitude of the reflected sound wave and the transmitted sound wave at the solid-solid slip interface of the longitudinal wave is:

[0044] Where: , and are the amplitudes of the incident longitudinal wave, reflected longitudinal wave, and refracted longitudinal wave, respectively; and are the amplitudes of reflected and refracted shear waves, respectively.

[0045] The transmittance between the organic glass wedge and the rail can be calculated by formula (2). Combined with the scanning characteristics of the shear wave inside the rail, it can be obtained that when the shear wave refraction angle is 37°, longitudinal waves and shear waves exist simultaneously inside the rail. Since the longitudinal wave velocity is greater than the shear wave velocity, clutter interference signals are generated. When it is close to 90°, most of the energy is converted into surface waves. Therefore, the optimal phased array sector scanning angle range of the first phased array probe is between 40° and 70°, and the detection capability is best at this time.

[0046] S130, controlling the first phased array probe to perform sector scanning imaging within an optimal scanning angle range, and controlling the second phased array probe to perform zero-degree line scanning imaging, so as to detect the entire cross-section of the weld.

[0047] After determining the optimal scanning angle range of the first phased array probe, in order to verify the feasibility of the ultrasonic phased array probe parameters and scanning angle, the optimal parameters and optimal scanning angle range of the transducer of the present invention are verified by the coverage diagram of the acoustic beam field, such as Figure 12 shown.

[0048] In some embodiments, in order to improve the accuracy of flaw detection and make the displayed image more intuitive, it is also necessary to perform signal compensation processing on the detected image.

[0049] In this embodiment, first, all transducers may be controlled to transmit excitation signals, wherein all transducers include transducers corresponding to the first phased array probe and transducers corresponding to the second phased array probe.

[0050] Then, a topological gradient function is constructed based on the direct wave field and the accompanying wave field corresponding to the excitation signal emitted by the transducer.

[0051] Next, based on the topological gradient function, an imaging function corresponding to the excitation signal is determined.

[0052] Secondly, all phased array sector scan images are processed based on the imaging function to obtain the optimized phased array sector scan image.

[0053] Finally, the entire cross-section of the weld is inspected based on the optimized phased array fan scan image.

[0054] Specifically, the numerator of the topological gradient function is the absolute value of the integral of the product of the direct wavefield and the adjoint wavefield, and the denominator is the integral of the square of the modulus of the direct wavefield.

[0055] , Where Q(x, y) is the topological gradient function, u(x, y, ω) is the direct wavefield, v(x, y, ω) is the companion wavefield, x is the abscissa, y is the ordinate, and ω is the angular frequency.

[0056] The imaging function Z(x, y) is obtained by normalizing the topological gradient function.

[0057] .

[0058] Specifically, N array elements transmit excitation signals from transducers, generating both in-plane and out-of-plane polarization. Each array element sequentially acts on the transducer, resulting in N sets of different measurement values. By sharpening the resulting defects in the phased array sector image using the imaging function Z(x, y), defects are highlighted, compensating for irregular rail geometry, and making the inspection image clearer, thereby improving the accuracy of defect detection.

[0059] The specific detection process is as follows: Read the echo signal G, the number of which is (N×N), where N is the number of array elements.

[0060] Enter the relevant parameters of the transducer, including center frequency, array element center distance, array element width, and number of array elements.

[0061] Based on the time window truncation method, the residual wave is removed. The residual wave is the acoustic wave signal directly transmitted between the probe and the rail surface or the acoustic wave signal between the probe and the coupling agent.

[0062] Traverse each pixel point (x, y) in the imaging area, calculate the distance from the transmitting probe and the receiving probe to each pixel point (x, y) respectively, and determine the total sound path distance L.

[0063] Determine whether the total acoustic path distance L of each pixel is less than the maximum imaging distance DL. If so, ignore the pixel. If not, calculate the signal arrival time t based on the acoustic path.

[0064] Accumulate the signal value corresponding to t to the pixel point (x, y).

[0065] Processes image matrices based on the Hilbert transform.

[0066] A direct wavefield and a companion wavefield are determined, and a topological gradient function Q(x,y) is determined based on the direct wavefield and the companion wavefield.

[0067] The imaging function Z(x, y) is determined based on the topological gradient function Q(x, y).

[0068] The optimized phased array sector scan image is obtained after signal processing of the image matrix based on the imaging function Z(x, y).

[0069] Finally, the entire cross-section of the weld can be inspected based on the optimized phased array fan scan image.

[0070] The full-section weld inspection method provided by the present invention comprises a plurality of first phased array probes disposed on the rail head tread and rail bottom surfaces on both sides of the weld, and a second phased array probe disposed directly above the weld. The optimal transducer parameters can then be determined based on the rail material, the cross-sectional dimensions of the rail, and the sound pressure intensity at a preset focal depth. Subsequently, the optimal scanning angle range of the first phased array probe is determined based on the propagation velocity of ultrasonic longitudinal waves in the wedge and rail, the propagation velocity of ultrasonic shear waves in the rail, and Snell's law. Finally, the first phased array probe can be controlled to perform sector scanning imaging within the optimal scanning angle range, and the second phased array probe can be controlled to perform zero-degree line scanning imaging, thereby achieving full-section weld inspection. By adopting the inspection method provided by the present invention, the removal of the splint can be avoided, the inspection process can be simplified, and full-section acoustic beam coverage of the weld can be achieved, with the advantages of high inspection efficiency and no blind spots.

[0071] It should be understood that the size of the serial numbers of the steps in the above embodiments does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0072] The following are device embodiments of the present invention. For details not fully described therein, reference may be made to the corresponding method embodiments described above.

[0073] Figure 13 The following is a schematic diagram showing the structure of a full-section inspection device for reinforced rail welds provided by an embodiment of the present invention. For ease of explanation, only the parts related to the embodiment of the present invention are shown, which are described in detail as follows: like Figure 13 As shown, a full-section inspection device 900 for reinforced rail welds comprises a plurality of first phased array probes disposed on the rail head tread and rail bottom surface of a first rail and a second rail, respectively. Each first phased array probe is disposed on a wedge that is fitted against the rail head tread or rail bottom surface. A second phased array probe is disposed directly above the weld, which is the welded joint between the first rail and the second rail. The inspection device comprises: Parameter determination module 910 is configured to determine optimal transducer parameters based on the rail material, rail cross-sectional dimensions, and sound pressure intensity at a preset focal depth. The optimal parameters include the transducer center frequency, element center spacing, element width, and number of elements. The transducer parameters corresponding to the first phased array probe and the transducer parameters corresponding to the second phased array probe are the same. a range determination module 920 for determining an optimal scanning angle range of the first phased array probe based on the propagation velocity of ultrasonic longitudinal waves in the wedge and the rail, the propagation velocity of ultrasonic shear waves in the rail, and Snell's law; The detection module 930 is used to control the first phased array probe to perform sector scanning imaging within the optimal scanning angle range and control the second phased array probe to perform zero-degree line scanning imaging to detect the entire cross-section of the weld.

[0074] In one possible implementation, the detection module 930 is configured to control all transducers to transmit excitation signals; wherein all transducers include transducers corresponding to the first phased array probe and transducers corresponding to the second phased array probe; Based on the direct wave field and the accompanying wave field corresponding to the excitation signal emitted by the transducer, a topological gradient function is constructed; Based on the topological gradient function, determining the imaging function corresponding to the excitation signal; Perform signal processing on all phased array sector scan images based on the imaging function to obtain optimized phased array sector scan images; Based on the optimized phased array fan scan image, the full cross-section of the weld is inspected.

[0075] In a possible implementation, the numerator of the topological gradient function is the absolute value of the integral of the product of the direct wavefield and the adjoint wavefield, and the denominator is the integral of the square of the modulus of the direct wavefield; The imaging function is obtained by normalizing the topological gradient function.

[0076] In one possible implementation, the parameter determination module 910 is configured to select a plurality of different parameters of the transducer; wherein the parameters include a transducer center frequency, an array element center distance, an array element width, and the number of array elements; Based on the single variable analysis method, the sound pressure intensity at the preset focal depth position is analyzed according to the material and cross-sectional dimensions of the rail. The transducer center frequency, array element center distance, array element width and number of array elements corresponding to the maximum sound pressure intensity at the preset focal depth position are determined as the optimal parameters of the transducer.

[0077] In one possible implementation, the range determination module 920 is configured to determine the critical angle of incidence of the ultrasonic wave and the scanning angle range of the refracted shear wave in the rail during shear wave detection based on the propagation velocity of the ultrasonic longitudinal wave in the wedge and the rail, the propagation velocity of the ultrasonic shear wave in the rail, and the relationship between refracted waves in Snell's law. Calculate the deflection angle of the refracted ultrasonic shear wave in the rail; The optimal scanning angle range of the first phased array probe is determined based on the scanning angle range of the refracted shear wave in the rail and the deflection angle of the refracted shear wave.

[0078] In a possible implementation, the first phased array probe is a phased array shear wave probe, and the second phased array probe is a phased array longitudinal wave probe; All first phased array probes disposed on the rail head and tread of the first rail and all first phased array probes disposed on the rail head and tread of the second rail are symmetrically disposed relative to the weld; All first phased array probes arranged on the bottom surface of the rail bottom of the first rail and all first phased array probes arranged on the bottom surface of the rail bottom of the second rail are symmetrically arranged relative to the weld.

[0079] In one possible implementation, the distance between the first phased array probe and the weld center is 50 to 180 mm; The wedge is made of organic glass, and the optimal scanning angle range of the first phased array probe is 40°~70°.

[0080] Figure 14 Schematic diagram of an electronic device provided by an embodiment of the present invention. Figure 14 As shown, the electronic device 14 of this embodiment includes a processor 140 and a memory 141. The memory 141 stores a computer program 142. When the processor 140 executes the computer program 142, the steps of the above-described method embodiments are implemented. Alternatively, when the processor 140 executes the computer program 142, the functions of the modules / units in the above-described device embodiments are implemented.

[0081] For example, the computer program 142 may be divided into one or more modules / units, which are stored in the memory 141 and executed by the processor 140 to implement the present invention. The one or more modules / units may be a series of computer program instruction segments capable of implementing specific functions, and the instruction segments are used to describe the execution process of the computer program 142 in the electronic device 14.

[0082] The electronic device 14 may include, but is not limited to, a processor 140 and a memory 141. Those skilled in the art will appreciate that Figure 14 It is only an example of the electronic device 14 and does not constitute a limitation of the electronic device 14. It may include more or fewer components than shown in the figure, or a combination of certain components, or different components. For example, the electronic device 14 may also include input and output devices, network access devices, buses, etc.

[0083] The processor 140 may be a central processing unit (CPU), or other general-purpose processors, digital signal processors (DSP), application-specific integrated circuits (ASIC), field-programmable gate arrays (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor may be a microprocessor or any conventional processor.

[0084] The memory 141 may be an internal storage unit of the electronic device 14, such as the hard drive or memory of the electronic device 14. The memory 141 may also be an external storage device of the electronic device 14, such as a plug-in hard drive, a Smart Media Card (SMC), a Secure Digital (SD) card, a flash memory card, etc. equipped on the electronic device 14. Furthermore, the memory 141 may include both the internal storage unit of the electronic device 14 and an external storage device. The memory 141 is used to store the computer program 142 and other programs and data required by the electronic device 14. The memory 141 may also be used to temporarily store data that has been output or is about to be output.

[0085] For the sake of convenience and brevity, the division of the above functional modules / units is only used as an example. In actual applications, the above functions can be assigned to different functional modules / units as needed. The above modules / units can be implemented in the form of hardware, software, or a combination of hardware and software.

[0086] An embodiment of the present invention further provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the methods in the above-mentioned method embodiments.

[0087] An embodiment of the present invention further provides a computer program product, including a computer program, which, when executed by a processor, implements the methods in the above-mentioned method embodiments.

[0088] The term "computer program" includes computer program code, which may be in source code form, object code form, executable file, or some intermediate form. Computer-readable media may include any entity or device capable of carrying computer program code, recording media, USB flash drives, removable hard drives, magnetic disks, optical disks, computer memory, read-only memory (ROM), random access memory (RAM), electrical carrier signals, telecommunications signals, and software distribution media.

[0089] In the above embodiments, the descriptions of each embodiment have their own focus. For parts not described or recorded in detail in one embodiment, please refer to the relevant descriptions of other embodiments. Unless otherwise specified or there is a logical conflict, the terms and / or descriptions between different embodiments are consistent and can be referenced to each other. The technical features of different embodiments can be combined to form new embodiments based on their inherent logical relationships.

[0090] The embodiments described above are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention, and should all be included in the scope of protection of the present invention.

Claims

1. A full-section inspection method for reinforced rail welds, characterized in that: A plurality of first phased array probes are respectively provided on the rail head tread and the rail bottom surface of the first rail and the second rail, and each first phased array probe is provided on a wedge, and the wedge is provided in contact with the rail head tread or the rail bottom surface; a second phased array probe is provided directly above a weld, and the weld is a welded joint between the first rail and the second rail; the detection method includes: Determining optimal transducer parameters based on the material of the rail, the dimensions of the rail cross section, and the sound pressure intensity at a preset focal depth; wherein the parameters of the transducer corresponding to the first phased array probe are the same as the parameters of the transducer corresponding to the second phased array probe; Determining an optimal scanning angle range of the first phased array probe based on the propagation velocity of ultrasonic longitudinal waves in the wedge and the rail, the propagation velocity of ultrasonic shear waves in the rail, and Snell's law; The first phased array probe is controlled to perform sector scanning imaging within the optimal scanning angle range, and the second phased array probe is controlled to perform zero-degree line scanning imaging, so as to detect the entire cross-section of the weld.

2. The full-section inspection method for reinforced rail welds according to claim 1, characterized in that: The controlling the first phased array probe to perform sector scanning imaging within the scanning angle and the controlling the second phased array probe to perform zero-degree line scanning imaging to detect the entire cross-section of the weld includes: Controlling all transducers to transmit excitation signals; wherein all transducers include transducers corresponding to the first phased array probe and transducers corresponding to the second phased array probe; constructing a topological gradient function based on a direct wave field and a companion wave field corresponding to the excitation signal emitted by the transducer; determining an imaging function corresponding to the excitation signal based on the topological gradient function; Performing signal processing on all phased array sector scan images based on the imaging function to obtain optimized phased array sector scan images; Based on the optimized phased array fan scan image, the entire cross-section of the weld is inspected.

3. The full-section inspection method for reinforced rail welds according to claim 2, characterized in that: The numerator of the topological gradient function is the absolute value of the integral of the product of the direct wavefield and the companion wavefield, and the denominator is the integral of the square of the modulus of the direct wavefield; The imaging function is obtained by normalizing the topological gradient function.

4. The full-section inspection method for reinforced rail welds according to claim 1, characterized in that: The method of determining the optimal parameters of the transducer based on the material of the rail, the size of the rail cross section, and the sound pressure intensity at a preset focus depth position includes: Selecting a plurality of different parameters of the transducer; wherein the parameters include the transducer center frequency, array element center distance, array element width, and the number of array elements; Based on the single variable analysis method, the sound pressure intensity at the preset focal depth position is analyzed according to the material and cross-sectional dimensions of the rail, and the transducer center frequency, array element center distance, array element width and number of array elements corresponding to the maximum sound pressure intensity at the preset focal depth position are determined as the optimal parameters of the transducer.

5. The full-section inspection method for reinforced rail welds according to claim 1, characterized in that: The determining of the optimal scanning angle range of the first phased array probe based on the propagation velocity of the ultrasonic longitudinal wave in the wedge and the rail, the propagation velocity of the ultrasonic shear wave in the rail, and Snell's law includes: Based on the propagation speed of ultrasonic longitudinal waves in the wedge and rail, the propagation speed of ultrasonic shear waves in the rail, and the relationship between refracted waves in Snell's law, the critical angle of incidence of the ultrasonic wave and the scanning angle range of the refracted shear wave in the rail are determined during shear wave testing. Calculate the deflection angle of the refracted ultrasonic shear wave in the rail; An optimal scanning angle range of the first phased array probe is determined based on a scanning angle range of the refracted shear wave in the rail and a deflection angle of the refracted shear wave.

6. The full-section inspection method for reinforced rail welds according to claim 1, characterized in that: The first phased array probe is a phased array shear wave probe, and the second phased array probe is a phased array longitudinal wave probe; All first phased array probes provided on the rail head and tread of the first rail and all first phased array probes provided on the rail head and tread of the second rail are symmetrically arranged relative to the weld; All first phased array probes disposed on the bottom surface of the rail bottom of the first rail and all first phased array probes disposed on the bottom surface of the rail bottom of the second rail are symmetrically arranged relative to the weld.

7. The full-section inspection method for reinforced rail welds according to any one of claims 1 to 6, characterized in that: The distance between the first phased array probe and the center of the weld is 50-180 mm; The wedge is made of organic glass, and the optimal scanning angle range of the first phased array probe is 40° to 70°.

8. A full-section inspection device for reinforced rail welds, characterized in that: A plurality of first phased array probes are respectively provided on the rail head tread and the rail bottom surface of the first rail and the second rail, and each first phased array probe is provided on a wedge, and the wedge is provided in contact with the rail head tread or the rail bottom surface; a second phased array probe is provided directly above the weld, and the weld is the welded joint between the first rail and the second rail; The detection device comprises: a parameter determination module, configured to determine optimal transducer parameters based on the material of the rail, the dimensions of the rail cross section, and the sound pressure intensity at a preset focal depth; wherein the optimal parameters include the transducer center frequency, array element center distance, array element width, and the number of array elements; and the parameters of the transducer corresponding to the first phased array probe and the parameters of the transducer corresponding to the second phased array probe are the same; a range determination module, configured to determine an optimal scanning angle range of the first phased array probe based on a propagation velocity of an ultrasonic longitudinal wave in the wedge and the rail, a propagation velocity of an ultrasonic shear wave in the rail, and Snell's law; The detection module is used to control the first phased array probe to perform sector scanning imaging within the optimal scanning angle range, and control the second phased array probe to perform zero-degree line scanning imaging, so as to detect the entire cross-section of the weld.

9. An electronic device, characterized in that: The method comprises a memory and a processor, wherein the memory stores a computer program, and when the processor executes the computer program, the method according to any one of claims 1 to 7 is implemented.

10. A computer-readable storage medium, characterized in that The computer-readable storage medium stores a computer program, and when the computer program is executed by a processor, the method according to any one of claims 1 to 7 is implemented.

Images