Full-section detection method, device, equipment and storage medium for reinforced rail welds

Abstract

This invention provides a method, apparatus, equipment, and storage medium for full-section inspection of reinforced rail welds, relating to the field of non-destructive testing technology. The method includes: setting multiple first phased array probes on the rail head tread and rail bottom surfaces of a first and second rail, respectively; and setting a second phased array probe directly above the weld. The inspection method includes: determining the optimal parameters of the transducer based on the rail material, the dimensions of the rail cross-section, and the sound pressure intensity at a preset focusing depth position; determining the optimal scanning angle range of the first phased array probes based on the propagation speed of ultrasonic longitudinal waves in the wedge and rail, the propagation speed of ultrasonic transverse waves in the rail, and Snell's law; controlling the first phased array probes to perform fan-shaped scanning imaging within the optimal scanning angle range, and controlling the second phased array probes to perform zero-degree line scanning imaging, thereby inspecting the full-section of the weld. This invention enables accurate weld inspection without removing the clamping plate.

Description

Technical Field

[0001] This invention relates to the field of nondestructive testing technology, and in particular to a method, apparatus, equipment, and storage medium for full-section inspection of reinforced rail welds. Background Technology

[0002] Seamless train operation is the foundation for the development of high-speed passenger transport and heavy-haul freight transport. The key technology for achieving seamless tracks is rail welding technology.

[0003] However, seamless track rails experience significant temperature stress due to thermal expansion and contraction. Combined with the impact of high-speed, heavy-load trains, this makes welded joints highly susceptible to cracking and track breakage. Therefore, the health of the rail welded joints is crucial for the safe and reliable operation of seamless track.

[0004] After rail welding, steel rails are often reinforced with steel plates to ensure safety. According to railway industry regulations on weld flaw detection, welds must undergo regular full-section damage inspection. Currently, the primary inspection method is ultrasonic testing. However, ultrasonic testing requires removing the reinforcing steel plates to perform full-section inspection of the reinforced rail welds, and the removed plates must be promptly reinstalled after inspection, making the process time-consuming and labor-intensive. Therefore, finding a way to perform rapid and accurate inspection without removing the steel plates has become a pressing technical problem that needs to be solved. Summary of the Invention

[0005] This invention provides a method, apparatus, equipment, and storage medium for full-section inspection of reinforced rail welds, to solve the problem of how to quickly and accurately inspect welds without removing the clamping plates.

[0006] In a first aspect, embodiments of the present invention provide a full-section inspection method for reinforced rail welds. Multiple first phased array probes are respectively installed on the rail head tread and rail bottom surface of the first and second rails, and each first phased array probe is mounted on a wedge, with the wedge fitting snugly against the rail head tread or rail bottom surface. A second phased array probe is installed directly above the weld, which is the welded joint of the first and second rails. The inspection method includes:

[0007] Based on the material of the rail, the dimensions of the rail cross section, and the sound pressure intensity at the preset focusing depth position, the optimal parameters of the transducer are determined; among them, the parameters of the transducer corresponding to the first phased array probe are the same as those of the transducer corresponding to the second phased array probe.

[0008] Based on the propagation speed of ultrasonic longitudinal waves in the wedge and rail, the propagation speed of ultrasonic transverse waves in the rail, and Snell's law, the optimal scanning angle range of the first phased array probe is determined.

[0009] 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 inspect the entire cross-section of the weld.

[0010] In one possible implementation, the first phased array probe is controlled to perform sector scanning imaging within the scanning angle, and the second phased array probe is controlled to perform zero-degree line scanning imaging, so as to inspect the entire cross-section of the weld, including:

[0011] Control all transducers to emit excitation signals; wherein, all transducers include the transducer corresponding to the first phased array probe and the transducer corresponding to the second phased array probe.

[0012] Based on the direct wave field and the adjoint wave field corresponding to the excitation signal emitted by the transducer, a topological gradient function is constructed.

[0013] Based on the topological gradient function, the imaging function corresponding to the excitation signal is determined;

[0014] Based on the imaging function, the defects in all phased array sector scans are sharpened to obtain the optimized phased array sector scans.

[0015] Based on the optimized phased array sector scan, the entire cross-section of the weld is inspected.

[0016] In one possible implementation, the numerator of the topological gradient function is the absolute value of the integral of the product of the direct wave field and the adjoint wave field, and the denominator is the integral of the square of the magnitude of the direct wave field.

[0017] The imaging function is obtained by normalizing the topological gradient function.

[0018] 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 focusing depth position, including:

[0019] Select multiple different parameters of the transducer; wherein, the parameters include the transducer center frequency, the element center distance, the element width, and the number of elements;

[0020] Based on the single-variable analysis method and according to the material and cross-sectional dimensions of the rail, the sound pressure intensity at the preset focusing depth position is analyzed. The transducer center frequency, array element center distance, array element width, and array element number corresponding to the maximum sound pressure intensity at the preset focusing depth position are determined as the optimal parameters of the transducer.

[0021] In one possible implementation, the optimal scanning angle range of the first phased array probe is determined based on the propagation speed of the ultrasonic longitudinal wave in the wedge and the rail, the propagation speed of the ultrasonic transverse wave in the rail, and Snell's law, including:

[0022] Based on the propagation speed of ultrasonic longitudinal waves in the wedge and rail, the propagation speed of ultrasonic transverse waves in the rail, and the relationship of refracted waves in Snell's law, the critical angle of ultrasonic incident angle and the range of scanning angle of refracted transverse waves in the rail are determined when performing transverse wave detection.

[0023] Calculate the deflection angle of the ultrasonic shear wave refracted within the rail;

[0024] Based on the scanning angle range of the refracted transverse wave within the rail and the deflection angle of the refracted transverse wave, the optimal scanning angle range of the first phased array probe is determined.

[0025] 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.

[0026] All the first phased array probes installed on the rail head tread of the first rail and all the first phased array probes installed on the rail head tread of the second rail are symmetrically arranged with respect to the weld.

[0027] All the first phased array probes installed on the bottom surface of the first rail and all the first phased array probes installed on the bottom surface of the second rail are symmetrically arranged with respect to the weld.

[0028] In one possible implementation, the distance between the first phased array probe and the center of the weld is 50~180mm;

[0029] The wedge is made of plexiglass, and the optimal scanning angle range of the first phased array probe is 40°~70°.

[0030] Secondly, embodiments of the present invention provide a full-section inspection device for reinforcing rail welds. Multiple first phased array probes are respectively installed on the rail head tread and rail bottom surface of the first and second rails, and each first phased array probe is mounted on a wedge, with the wedge fitting snugly against the rail head tread or rail bottom surface. A second phased array probe is positioned directly above the weld, which is the welded joint of the first and second rails. The inspection device includes:

[0031] The parameter determination module is used to determine 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 the preset focusing depth position. The optimal parameters include the transducer center frequency, the center distance between array elements, the array element width, and the number of array elements. The parameters of the transducer corresponding to the first phased array probe are the same as those of the transducer corresponding to the second phased array probe.

[0032] The range determination module is used to determine the optimal scanning angle range of the first phased array probe based on the propagation speed of ultrasonic longitudinal waves in the wedge and rail, the propagation speed of ultrasonic transverse waves in the rail, and Snell's law.

[0033] 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 entire cross-section of the weld.

[0034] Thirdly, embodiments of the present invention provide an electronic device, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the method described in the first aspect or any possible implementation thereof.

[0035] Fourthly, embodiments of the present invention provide a computer-readable storage medium storing a computer program that, when executed by a processor, implements the method described in the first aspect or any possible implementation thereof.

[0036] Fifthly, embodiments of the present invention provide a computer program product, including a computer program that, when executed by a processor, implements the method described in the first aspect or any possible implementation thereof.

[0037] In this embodiment of the invention, by setting multiple first phased array probes on the rail head tread and rail bottom surfaces 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 rail material, the dimensions of the rail cross-section, and the sound pressure intensity at a preset focusing depth position. Next, based on the propagation speed of ultrasonic longitudinal waves in the wedge and rail, the propagation speed of ultrasonic transverse waves in the rail, and Snell's law, the optimal scanning angle range of the first phased array probes is determined. Finally, the first phased array probes can be controlled to perform fan-shaped scanning imaging within the optimal scanning angle range, and the second phased array probes can be controlled to perform zero-degree line scanning imaging, thereby achieving full-section inspection of the weld. By using the detection method provided by this invention, the removal of the clamping plate can be avoided, the flaw detection process can be simplified, and full-section sound beam coverage of the weld can be achieved, offering advantages such as high detection efficiency and no blind spots. Attached Figure Description

[0038] Figure 1 This is a flowchart illustrating the implementation of the full-section inspection method for reinforced rail welds provided in this embodiment of the invention.

[0039] Figure 2 This is a comparison diagram of sound pressure intensity at different frequencies along the axial distance provided in the embodiments of the present invention;

[0040] Figure 3 This is a comparison diagram of sound pressure intensity at different frequencies over lateral distance, provided in an embodiment of the present invention.

[0041] Figure 4This is a comparison diagram of the sound pressure intensity of different array element center distances in axial distance provided by the embodiments of the present invention;

[0042] Figure 5 This is a comparison diagram of the sound pressure intensity of different array element center distances in the lateral direction, provided by an embodiment of the present invention.

[0043] Figure 6 This is a comparison diagram of the sound pressure intensity of different array element widths along the axial distance provided in the embodiments of the present invention;

[0044] Figure 7 This is a comparison diagram of the sound pressure intensity of different array element widths over a lateral distance, provided in an embodiment of the present invention.

[0045] Figure 8 This is a comparison diagram of sound pressure intensity with different numbers of array elements in the axial distance provided in the embodiments of the present invention;

[0046] Figure 9 This is a comparison diagram of sound pressure intensity with different numbers of array elements in the lateral distance provided in the embodiments of the present invention;

[0047] Figure 10 This is a schematic diagram of the detection position of the phased array probe for reinforced rail welds provided in an embodiment of the present invention;

[0048] Figure 11 This is a waveform conversion principle diagram provided in an embodiment of the present invention;

[0049] Figure 12 This is a schematic diagram of the acoustic beam field simulation of the phased array probe provided in the embodiment of the present invention;

[0050] Figure 13 This is a schematic diagram of the structure of the full-section inspection device for reinforcing rail welds provided in an embodiment of the present invention;

[0051] Figure 14 This is a schematic diagram of an electronic device provided in an embodiment of the present invention. Detailed Implementation

[0052] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0053] Seamless train tracks are the foundation for the development of high-speed passenger transport and heavy-haul freight transport. The key to achieving seamless tracks lies in rail welding technology. Seamless track rails experience significant temperature stress due to thermal expansion and contraction. Combined with the impact of high-speed, heavy-load trains, this makes welded joints highly susceptible to cracking and track breakage. Therefore, the health of the rail weld joints is crucial for the safe and reliable operation of seamless tracks.

[0054] However, inspecting rail welds is far more difficult than inspecting ordinary rails. Firstly, the equipment and methods used are substantially different, and weld damage is distributed across the entire cross-section. Secondly, the defects in the welds are extremely complex; some are formed during the welding process, while others develop during use, and the defects vary in shape, making them very difficult to distinguish and detect. Therefore, how to accurately detect rail weld damage as early as possible has become an important task and a pressing problem for maintenance units.

[0055] Current ultrasonic testing technologies are mainly divided into two categories: conventional ultrasonic testing and ultrasonic phased array testing. The core difference lies in the probe control method. Conventional ultrasonic testing operates with a single probe, while ultrasonic phased array testing achieves detection by precisely controlling a phased array probe composed of multiple array elements. Conventional ultrasonic probes can only detect defects in a fixed direction. To detect defects in different locations, the probe needs to be constantly rotated and moved, which increases the complexity of the test and reduces efficiency. Furthermore, conventional ultrasound relies heavily on the analysis of time-domain signals, typically only able to locate defects, and is limited in defect identification and quantitative assessment. This manual testing method makes the results highly dependent on the operator's experience and skill level, resulting in certain deficiencies in reliability and accuracy. While there are numerous conventional ultrasonic testing techniques using a dual-probe mode for tandem flaw detection of defects in different areas of rail welds, these techniques are limited by their inability to determine the size of the damage, high skill requirements for technicians, and relatively low efficiency.

[0056] Ultrasonic phased array testing technology significantly improves upon the aforementioned limitations. By controlling the delay of multiple array elements, ultrasonic phased arrays can achieve dynamic deflection and focusing of the sound beam while maintaining a fixed probe position, significantly expanding the detection coverage. It eliminates the need for frequent probe movements and allows for changes in the focused sound field position over a wide range, enabling comprehensive scanning of defects at different orientations and depths. Furthermore, the linear array arrangement allows for two-dimensional imaging, and combined with coding equipment, three-dimensional imaging can be achieved, which is crucial for defect identification, condition analysis, and quantitative assessment. This technology greatly improves the accuracy and efficiency of testing and reduces the impact of human error. Ultrasonic phased array testing technology offers flexible beam deflection and focusing performance; by adjusting the beam deflection angle, the removal of clamps and frequent probe replacements can be avoided. In non-destructive testing, it offers advantages such as high accuracy and fewer structural blind spots. Therefore, the introduction of phased array technology into ultrasonic flaw detection of rail welds, through research on key technologies for ultrasonic phased array testing of rail welds, enables full-section flaw detection of rail welds without removing clamps, achieving accuracy that meets specifications.

[0057] To enable full-section inspection of the weld, multiple first phased array probes are installed on the rail head tread and rail base surfaces of the first and second rails, respectively. Each first phased array probe is mounted on a wedge, which is fitted against the rail head tread or rail base surface. A second phased array probe is positioned directly above the weld, which is the welded joint of the first and second rails, made of the same material. The first phased array probes can scan the rail head, rail web, and rail base. The second phased array probes are primarily used to inspect the vertical projection areas of the rail head, upper rail web, and lower rail web of the weld. Furthermore, the installation positions of the first and second phased array probes do not interfere with the rail clamps on both sides, eliminating the need to remove the clamps, simplifying the inspection process, and achieving full-section acoustic beam coverage of the weld. This provides advantages such as high efficiency and no blind spots in the inspection.

[0058] See Figure 1 The document illustrates a flowchart of the full-section inspection method for reinforced rail welds provided in this embodiment of the invention, detailed below:

[0059] S110. Based on the material of the rail, the dimensions of the rail cross section, and the sound pressure intensity at the preset focusing depth position, determine the optimal parameters of the transducer.

[0060] As a key component in the field of acoustics, the acoustic characteristics of transducers are crucial for evaluating weld performance. These parameters, including transducer center frequency, element spacing, element width, and number of elements, can influence the detection sound field.

[0061] In some embodiments, multiple different parameters of the transducer can be selected first. Then, based on the single-variable analysis method and according to the material and cross-sectional dimensions of the rail, the sound pressure intensity at the preset focusing depth position is analyzed, and the transducer center frequency, array element center distance, array element width, and array element number corresponding to the maximum sound pressure intensity at the preset focusing depth position are determined as the optimal parameters of the transducer.

[0062] In this embodiment, based on the rail material, three different transducer center frequencies can be set, namely f1, f2, and f3, while other parameters remain consistent. Frequency domain field simulation analysis is performed in simulation software. First, based on the dimensions of the rail cross-section, a preset focusing depth of H is set. Using the center position of the linear array elements and the coordinates of the focal point as references, two axes—axial distance and lateral distance—are established. The sound pressure intensity of the focused sound field at this location is then analyzed. Figure 2 and 3 As shown, the sound field intensity is greatest at the center frequency f2 of the transducer at this focusing depth.

[0063] The transducer's center frequency is set to f2, the ultrasonic wave propagation speed c on the rail, and the sector scanning angle is... Given a fixed target, three different element center distances are set simultaneously: p1, p2, and p3, while keeping other parameters constant. The preset focusing depth is also set to H, and the sound pressure intensity under different element center distances is compared. Figure 4 and 5 As shown, the analysis shows that the sound field intensity of p1 is the largest at the focusing depth. The distance between array elements and the wavelength of the sound wave in the workpiece being tested can be determined according to the formula.

[0064] Phased arrays can only achieve focusing in the near-field region. Given a transducer center frequency of f2 and an element spacing of p1, and to avoid grating lobes (not exceeding half a wavelength), two different element widths, d1 and d2, can be set, while other parameters remain consistent. The preset focusing depth is H. The sound pressure levels under different element widths are compared, such as... Figure 6 and 7 As shown, the analysis shows that the sound field intensity of d2 is the largest at the focusing depth.

[0065] The transducer's center frequency was set to f2, the element spacing to p1, and the element width to d2. Two different element numbers, N1 and N2, were set, while keeping other parameters constant. The preset focusing depth was H. The sound pressure intensity was compared under different element numbers, such as... Figure 8 and 9 As shown, the analysis reveals that the sound field intensity is greatest at the focusing depth N2. The number of array elements N can be determined based on the geometry of the rail head and the existing probe manufacturing process; a higher number of elements results in higher costs. Typically, phased array detection uses 32 or 64 elements.

[0066] Based on the above analysis, the optimal parameters of the transducer can be determined using the method provided above: center frequency f2, element center distance p1, element width d2, and number of elements N2.

[0067] It should be noted that sound pressure level can be calculated using simulation software and analyzed in the frequency domain. For example, with a preset focal point depth of 20mm, the center position of the linear array element is (0, 0) during modeling, and the focal point coordinates are (0, 20). Therefore, two virtual axes are established. The axial line (similar to the y-axis) is defined as the line connecting the points (0, 0) and (0, 40); the transverse axis, with the focal point coordinates as a reference, is the line connecting the points (-20, 20) and (20, 20). After obtaining these two axes, the magnitude of the sound pressure level along these axes in the focal field is analyzed.

[0068] S120. Based on the propagation speed of ultrasonic longitudinal waves in the wedge and rail, the propagation speed of ultrasonic transverse waves in the rail, and Snell's law, determine the optimal scanning angle range of the first phased array probe.

[0069] In some embodiments, such 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 rail bottom surface respectively with the plexiglass wedge 640 to perform fan-shaped 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.

[0070] In this embodiment, the distance between the first phased array probe and the center of the weld is 50~180mm.

[0071] In some embodiments, the critical angle of the ultrasonic wave incident angle and the range of scanning angles of the refracted shear wave in the rail can be determined first, based on the propagation speed of the ultrasonic longitudinal wave in the wedge and the rail, the propagation speed of the ultrasonic transverse wave in the rail, and the relationship of the refracted wave in Snell's law.

[0072] Then, the deflection angle of the ultrasonic shear wave refracted within the rail is calculated.

[0073] Finally, based on the scanning angle range of the refracted transverse wave within the rail and the deflection angle of the refracted transverse wave, the optimal scanning angle range of the first phased array probe is determined.

[0074] In this embodiment, the wedge is made of plexiglass as an example. Figure 11 When an ultrasonic longitudinal wave is obliquely incident from one solid material to another, refraction will occur at the interface between the two materials. The ultrasonic longitudinal wave is obliquely incident from the plexiglass material into the rail material at an angle of incidence of... Refracted longitudinal waves are generated in the rails. The angle of refraction is In addition, it will also generate refracted transverse waves. The angle of refraction is Simultaneously, reflection from the interface generates reflected longitudinal waves and reflected transverse waves, with reflection angles of respectively... and .

[0075] According to Snell's law, refracted waves follow equation (1):

[0076]

[0077] In the formula, and These represent the propagation speeds of longitudinal waves in plexiglass and steel rails, respectively. This represents the propagation speed of the transverse wave in the rail.

[0078] According to equation (1), the first critical angle for longitudinal wave incident is 27.6° and the second critical angle is 57.6°. Therefore, when performing transverse wave detection on the rail, the incident angle of the ultrasonic wave must be between the first and second critical angles to obtain the corresponding refracted transverse wave. The scanning angle within the rail is approximately 33°~90°. Considering that in phased array ultrasonic testing, the larger the deflection angle, the smaller the acoustic energy and the worse the detection capability, in order to allow the acoustic energy to better enter the interior of the rail, it is necessary to calculate the deflection angle of the refracted transverse wave to obtain the angle range of the phased array fan-shaped scan. According to Snell's law, the relationship between the amplitude of the reflected and transmitted acoustic waves at the solid-solid slip interface of the longitudinal wave incident is:

[0079]

[0080] In the formula: , and These are the amplitudes of the incident longitudinal wave, the reflected longitudinal wave, and the refracted longitudinal wave, respectively. and These represent the amplitudes of the reflected transverse wave and the refracted transverse wave, respectively.

[0081] The transmittance between the plexiglass wedge and the rail can be calculated using equation (2). Combined with the scanning characteristics of the transverse waves inside the rail, we can obtain the following: when the transverse wave refraction angle is 37°, both longitudinal and transverse waves exist inside the rail. Since the longitudinal wave velocity is greater than the transverse wave velocity, clutter interference signals are generated. When the angle approaches 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°, at which point the detection capability is optimal.

[0082] S130. 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 inspect the entire cross-section of the weld.

[0083] 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 were verified by the coverage diagram of the sound beam field, such as... Figure 12 As shown.

[0084] In some embodiments, in order to improve the accuracy of flaw detection and make the displayed image more intuitive, signal compensation processing is also required for the detected image.

[0085] In this embodiment, all transducers can first be controlled to emit excitation signals. These transducers include those corresponding to the first phased array probe and those corresponding to the second phased array probe.

[0086] Then, a topological gradient function is constructed based on the direct wave field and the associated wave field corresponding to the excitation signal emitted by the transducer.

[0087] Next, based on the topological gradient function, the imaging function corresponding to the excitation signal is determined.

[0088] Secondly, signal processing is performed on all phased array sector scans based on the imaging function to obtain optimized phased array sector scans.

[0089] Finally, based on the optimized phased array sector scan, the entire cross-section of the weld was inspected.

[0090] Specifically, the numerator of the topological gradient function is the absolute value of the integral of the product of the direct wave field and the adjoint wave field, and its denominator is the integral of the square of the magnitude of the direct wave field.

[0091] ,

[0092] Where Q(x, y) is the topological gradient function, u(x, y, ω) is the direct wave field, v(x, y, ω) is the adjoint wave field, x is the abscissa, y is the ordinate, and ω is the angular frequency.

[0093] The imaging function Z(x, y) is obtained by normalizing the topological gradient function.

[0094] .

[0095] Specifically, an excitation signal is emitted using a transducer with N array elements, simultaneously generating in-plane and out-of-plane polarization. Each array element acts sequentially on the transducer, resulting in N different sets of measurement values. By using the imaging function Z(x, y) to sharpen the defects in the obtained phased array sector scan image, the defects can be highlighted, and the irregular geometry in the rail can be compensated for, making the detection image clearer and thus improving the accuracy of defect identification.

[0096] The specific testing process is as follows:

[0097] Read the echo signal G, the number of which is (N×N), where N is the number of array elements.

[0098] Input the relevant parameters of the transducer, including center frequency, element center distance, element width, and number of elements.

[0099] The residual sound is removed using a time window truncation method. The residual sound refers to the acoustic signal propagating directly between the probe and the rail surface, or the acoustic signal propagating between the probe and the coupling agent.

[0100] Traverse each pixel (x, y) within the imaging area, calculate the distance from the transmitting probe and the receiving probe to each pixel (x, y), and determine the total sound path distance L.

[0101] Determine if the total sound path distance L of each pixel is less than the maximum imaging distance DL. If it is greater, ignore that pixel. If it is less, calculate the signal arrival time t based on the sound path distance.

[0102] The signal value corresponding to t is accumulated onto the pixel (x, y).

[0103] Image matrices are processed based on Hilbert transform.

[0104] Determine the direct wave field and the adjoint wave field, and based on the direct wave field and the adjoint wave field, determine the topological gradient function Q(x,y).

[0105] The imaging function Z(x, y) is determined based on the topological gradient function Q(x, y).

[0106] The optimized phased array sector scan is obtained by processing the image matrix based on the imaging function Z(x, y).

[0107] Finally, the entire cross-section of the weld can be inspected based on the optimized phased array sector scan.

[0108] The full-section inspection method for welds provided by this invention involves setting multiple first phased array probes on the rail head tread and rail bottom surfaces on both sides of the weld, and setting a second phased array probe directly above the weld. Based on the rail material, the dimensions of the rail cross-section, and the sound pressure intensity at a preset focusing depth, the optimal parameters of the transducer can be determined. Next, based on the propagation speeds of ultrasonic longitudinal waves in the wedge and rail, the propagation speeds of ultrasonic transverse waves in the rail, and Snell's law, the optimal scanning angle range of the first phased array probes is determined. Finally, the first phased array probes can be controlled to perform fan-shaped scanning imaging within the optimal scanning angle range, and the second phased array probes can be controlled to perform zero-degree line scanning imaging, thereby achieving full-section inspection of the weld. By using the inspection method provided by this invention, the removal of the clamping plate can be avoided, the flaw detection process can be simplified, and full-section sound beam coverage of the weld can be achieved, offering advantages such as high inspection efficiency and no blind spots.

[0109] It should be understood that the sequence number of each step in the above embodiments does not imply 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.

[0110] The following are device embodiments of the present invention. For details not described in detail, please refer to the corresponding method embodiments described above.

[0111] Figure 13 A schematic diagram of the full-section inspection device for reinforcing rail welds provided in an embodiment of the present invention is shown. For ease of explanation, only the parts relevant to the embodiment of the present invention are shown, and are described in detail below:

[0112] like Figure 13 As shown, the full-section inspection device 900 for reinforcing rail welds includes multiple first phased array probes installed on the rail head tread and rail bottom surfaces of the first and second rails, respectively. Each first phased array probe is mounted on a wedge, which is fitted against the rail head tread or rail bottom surface. A second phased array probe is positioned directly above the weld, which is the welded joint of the first and second rails. The inspection device includes:

[0113] The parameter determination module 910 is used to determine 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 the preset focusing depth position. The optimal parameters include the transducer center frequency, the center distance between array elements, the array element width, and the number of array elements. The parameters of the transducer corresponding to the first phased array probe are the same as those of the transducer corresponding to the second phased array probe.

[0114] The range determination module 920 is used to determine the optimal scanning angle range of the first phased array probe based on the propagation speed of ultrasonic longitudinal waves in the wedge and rail, the propagation speed of ultrasonic transverse waves in the rail, and Snell's law.

[0115] 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 to control the second phased array probe to perform zero-degree line scanning imaging, so as to detect the entire cross section of the weld.

[0116] In one possible implementation, the detection module 930 is used to control all transducers to emit excitation signals; wherein, all transducers include the transducer corresponding to the first phased array probe and the transducer corresponding to the second phased array probe.

[0117] Based on the direct wave field and the adjoint wave field corresponding to the excitation signal emitted by the transducer, a topological gradient function is constructed.

[0118] Based on the topological gradient function, the imaging function corresponding to the excitation signal is determined;

[0119] Signal processing is performed on all phased array sector scans based on the imaging function to obtain optimized phased array sector scans;

[0120] Based on the optimized phased array sector scan, the entire cross-section of the weld is inspected.

[0121] In one possible implementation, the numerator of the topological gradient function is the absolute value of the integral of the product of the direct wave field and the adjoint wave field, and the denominator is the integral of the square of the magnitude of the direct wave field.

[0122] The imaging function is obtained by normalizing the topological gradient function.

[0123] In one possible implementation, the parameter determination module 910 is used to select multiple different parameters of the transducer; wherein, the parameters include the transducer center frequency, the element center distance, the element width, and the number of elements;

[0124] Based on the single-variable analysis method and according to the material and cross-sectional dimensions of the rail, the sound pressure intensity at the preset focusing depth position is analyzed. The transducer center frequency, array element center distance, array element width, and array element number corresponding to the maximum sound pressure intensity at the preset focusing depth position are determined as the optimal parameters of the transducer.

[0125] In one possible implementation, the range determination module 920 is used to determine the critical angle of the ultrasonic wave incident angle and the range of the scanning angle of the refracted shear wave in the rail when performing shear wave detection, based on the propagation speed of the ultrasonic longitudinal wave in the wedge and the rail, the propagation speed of the ultrasonic transverse wave in the rail, and the relationship of the refracted wave in Snell's law.

[0126] Calculate the deflection angle of the ultrasonic shear wave refracted within the rail;

[0127] Based on the scanning angle range of the refracted transverse wave within the rail and the deflection angle of the refracted transverse wave, the optimal scanning angle range of the first phased array probe is determined.

[0128] 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.

[0129] All the first phased array probes installed on the rail head tread of the first rail and all the first phased array probes installed on the rail head tread of the second rail are symmetrically arranged with respect to the weld.

[0130] All the first phased array probes installed on the bottom surface of the first rail and all the first phased array probes installed on the bottom surface of the second rail are symmetrically arranged with respect to the weld.

[0131] In one possible implementation, the distance between the first phased array probe and the center of the weld is 50~180mm;

[0132] The wedge is made of plexiglass, and the optimal scanning angle range of the first phased array probe is 40°~70°.

[0133] Figure 14 This is a schematic diagram of an electronic device provided in an embodiment of the present invention. For example... 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, it implements the steps in the various method embodiments described above. Alternatively, when the processor 140 executes the computer program 142, it implements the functions of each module / unit in the various device embodiments described above.

[0134] For example, computer program 142 may be divided into one or more modules / units, which are stored in memory 141 and executed by processor 140 to complete the present invention. The one or more modules / units may be a series of computer program instruction segments capable of performing a specific function, which describe the execution process of computer program 142 in electronic device 14.

[0135] Electronic device 14 may include, but is not limited to, processor 140 and memory 141. Those skilled in the art will understand that... Figure 14 This is merely an example of electronic device 14 and does not constitute a limitation on electronic device 14. It may include more or fewer components than shown, or combine certain components, or different components. For example, electronic device 14 may also include input / output devices, network access devices, buses, etc.

[0136] The processor 140 can be a central processing unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor.

[0137] The memory 141 can be an internal storage unit of the electronic device 14, such as a hard disk or RAM of the electronic device 14. The memory 141 can also be an external storage device of the electronic device 14, such as a plug-in hard disk, Smart Media Card (SMC), Secure Digital (SD) card, or Flash Card equipped on the electronic device 14. Furthermore, the memory 141 can include both internal and external storage units of the electronic device 14. 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 can also be used to temporarily store data that has been output or will be output.

[0138] For the sake of simplicity and clarity, only the above-described functional modules / units are used as examples. In practical applications, the functions described above can be assigned to different functional modules / units as needed. These modules / units can be implemented in hardware, software, or a combination of both.

[0139] This invention also provides a computer-readable storage medium storing a computer program. When the computer program is executed by a processor, it implements the methods described in the above-described method embodiments.

[0140] This invention also provides a computer program product, including a computer program. When the computer program is executed by a processor, it implements the methods described in the above-described method embodiments.

[0141] Computer programs include computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. Computer-readable media can include: any entity or device capable of carrying computer program code, recording media, USB flash drives, portable hard drives, magnetic disks, optical disks, computer memory, read-only memory (ROM), random access memory (RAM), electrical carrier signals, telecommunication signals, and software distribution media, etc.

[0142] In the above embodiments, the descriptions of each embodiment have their own emphasis. Parts not detailed or described in a particular embodiment can be referred to in the relevant descriptions of other embodiments. Unless otherwise specified or in conflict with logic, the terminology and / or descriptions between different embodiments are consistent and can be referenced interchangeably. Technical features in different embodiments can be combined to form new embodiments based on their inherent logical relationships.

[0143] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be included within the protection scope of the present invention.

Claims

1. A method for full-section inspection of reinforced rail welds, characterized in that, Multiple first phased array probes are respectively installed on the rail head tread and rail bottom surface of the first and second rails, and each first phased array probe is mounted on a wedge block, with the wedge block fitting snugly against the rail head tread or rail bottom surface; a second phased array probe is installed directly above the weld joint, wherein the weld joint is the welded joint of the first and second rails; the detection method includes: Based on the material of the rail, the dimensions of the rail cross section, and the sound pressure intensity at the preset focusing depth position, the optimal parameters of the transducer are determined; 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. Based on the propagation speed of ultrasonic longitudinal waves in the wedge and rail, the propagation speed of ultrasonic transverse waves in the rail, and Snell's law, the optimal scanning angle range of the first phased array probe is determined. 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. The method of controlling the first phased array probe to perform sector scanning imaging within the optimal scanning angle range and controlling the second phased array probe to perform zero-degree line scanning imaging to inspect the entire cross-section of the weld includes: Control all transducers to emit excitation signals; wherein, all transducers include the transducer corresponding to the first phased array probe and the transducer corresponding to the second phased array probe; Based on the direct wave field and the associated wave field corresponding to the excitation signal emitted by the transducer, a topological gradient function is constructed; wherein, the numerator of the topological gradient function is the absolute value of the integral of the product of the direct wave field and the associated wave field, and its denominator is the integral of the square of the magnitude of the direct wave field. Based on the topological gradient function, an imaging function corresponding to the excitation signal is determined; wherein, the imaging function is obtained by normalizing the topological gradient function. Based on the imaging function, signal processing is performed on all phased array sector scans to obtain optimized phased array sector scans; Based on the optimized phased array sector scan, the entire cross-section of the weld is inspected.

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

3. The method for full-section inspection of reinforced rail welds according to claim 1, characterized in that, The determination of the optimal scanning angle range for the first phased array probe based on the propagation speeds of ultrasonic longitudinal waves in the wedge and rail, the propagation speeds of ultrasonic transverse waves 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 transverse waves in the rail, and the relationship of refracted waves in Snell's law, the critical angle of ultrasonic incident angle and the range of scanning angle of refracted transverse waves in the rail are determined when performing transverse wave detection. Calculate the deflection angle of the ultrasonic shear wave refracted within the rail; Based on the scanning angle range of the refracted shear wave within the rail and the deflection angle of the refracted shear wave, the optimal scanning angle range of the first phased array probe is determined.

4. The method for full-section inspection of 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 the first phased array probes installed on the rail head tread of the first rail and all the first phased array probes installed on the rail head tread of the second rail are symmetrically arranged with respect to the weld. All the first phased array probes installed on the bottom surface of the first rail and all the first phased array probes installed on the bottom surface of the second rail are symmetrically arranged with respect to the weld.

5. The method for full-section inspection of reinforced rail welds according to any one of claims 1-4, characterized in that, The distance between the first phased array probe and the center of the weld is 50~180mm; The wedge is made of plexiglass, and the optimal scanning angle range of the first phased array probe is 40°~70°.

6. A full-section inspection device for reinforcing rail welds, characterized in that, Multiple first phased array probes are respectively installed on the rail head tread and rail bottom surface of the first and second rails, and each first phased array probe is installed on a wedge block, with the wedge block fitting 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 of the first and second rails. The detection device includes: The parameter determination module is used to determine 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 the preset focusing depth position. The optimal parameters include the transducer center frequency, the array element center distance, the array element width, and the number of array elements. The parameters of the transducer corresponding to the first phased array probe are the same as those of the transducer corresponding to the second phased array probe. The range determination module is used to determine the optimal scanning angle range of the first phased array probe based on the propagation speed of ultrasonic longitudinal waves in the wedge and rail, the propagation speed of ultrasonic transverse waves in the rail, and Snell's law. The detection module is used to control the first phased array probe to perform fan-shaped 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 entire cross-section of the weld. The detection module is specifically used to control all transducers to emit excitation signals. All transducers include the transducer corresponding to the first phased array probe and the transducer corresponding to the second phased array probe. A topological gradient function is constructed based on the direct wave field and the associated wave field corresponding to the excitation signal emitted by the transducer. The numerator of the topological gradient function is the absolute value of the integral of the product of the direct wave field and the associated wave field, and the denominator is the integral of the square of the magnitude of the direct wave field. An imaging function corresponding to the excitation signal is determined based on the topological gradient function. The imaging function is obtained by normalizing the topological gradient function. Signal processing is performed on all phased array sector scans based on the imaging function to obtain optimized phased array sector scans. The entire cross-section of the weld is inspected based on the optimized phased array sector scans.

7. An electronic device, characterized in that, It includes a memory and a processor, the memory storing a computer program, and the processor executing the computer program to implement the method as described in any one of claims 1 to 5.

8. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a computer program that, when executed by a processor, implements the method as described in any one of claims 1 to 5.

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