Steel rail welding seam detection system, method and device, computer equipment and storage medium

Abstract

The invention relates to a steel rail welding seam detection system, method and device, computer equipment and a storage medium. The method comprises the following steps: in response to a steel rail preprocessing instruction, controlling a derusting, dedusting and couplant coating device to perform derusting operation, dedusting operation and couplant coating operation on a to-be-detected steel rail, in response to a welding seam detection instruction carrying scanning parameters, controlling each phased array probe to emit an ultrasonic signal according to the scanning parameters, receiving an echo signal of the ultrasonic signal, and performing ultrasonic detection on the to-be-detected steel rail according to the echo signal. And acquiring the environment temperature and the weld joint temperature of the to-be-measured steel rail, correcting the propagation speed parameter of the ultrasonic wave in the echo signal in the to-be-measured steel rail based on the environment temperature and the weld joint temperature, and generating and displaying a weld joint full-section image of the to-be-measured steel rail based on the corrected echo signal. By adopting the method, efficient and accurate steel rail welding seam detection can be realized.

Description

Technical Field

[0001] The present application relates to the technical field of rail detection, and in particular to a rail weld detection system, method, apparatus, computer equipment, computer-readable storage medium, and computer program product. Background Art

[0002] Ultrasonic testing of rail welds is directly related to the service life and driving safety of seamless rail lines. Because thermite weld flaw detection is distributed across the entire cross-section, and thermite weld defects are complex and can include light spots, gray spots, overburning, slag inclusions, porosity, and looseness, each with its own distinct shape, making them extremely difficult to distinguish and detect. Therefore, early detection of rail thermite weld damage is crucial.

[0003] Due to the special cross-sectional shape and large size of rail welds, the current rail weld inspection process requires the replacement of probes with different K values ​​to inspect different areas of the weld. This detection process is time-consuming, and existing rail weld inspection equipment and methods require the removal of reinforcing plates on both sides of the rail weld, which is time-consuming and labor-intensive, and creates blind spots in inspection.

[0004] It can be seen that there is a need to provide an efficient and accurate rail weld detection solution. Summary of the Invention

[0005] Based on this, it is necessary to provide a rail weld detection system, method, computer equipment, computer-readable storage medium and computer program product that can efficiently and accurately detect the above technical problems.

[0006] In a first aspect, the present application provides a rail weld detection system, the system comprising:

[0007] The ultrasonic phased array control device is configured to: display a human-computer interaction interface, receive a weld detection instruction for a rail to be tested input by a user on the human-computer interaction interface, control the phased array probe to transmit, receive, and process ultrasonic signals, obtain weld detection results, and visually display the weld detection results;

[0008] The rail top scanning device is installed on the rail top of the rail to be tested, including:

[0009] At least one phased array probe disposed at the center of the rail top weld of the rail to be inspected, for inspecting the entire cross-section of the weld, and at least one movable phased array probe disposed in the rail top region of the rail to be inspected, for scanning the rail top region, rail waist region, and rail bottom region covering the weld;

[0010] The rail bottom scanning device is installed at the bottom of the rail to be tested, including:

[0011] At least one movable phased array probe disposed in the rail bottom area of ​​the rail to be inspected, for scanning the rail top area, rail waist area and rail bottom area covering the weld;

[0012] At least one rust removal, dust removal and coupling agent coating device is arranged on one side of the rail bottom scanning device, and is used for performing rust removal, dust removal and coupling agent coating operations on the rail bottom of the steel rail to be tested.

[0013] In one exemplary embodiment, the ultrasonic phased array control device includes a main control module, and a display module, a signal excitation processing module, and a phased array transducer respectively connected to the main control module.

[0014] In one exemplary embodiment, the system further includes an ambient temperature sensor and a rail temperature sensor for communicating with the main control module, the ambient temperature sensor sends the measured ambient temperature to the main control module, and the rail temperature sensor sends the measured weld temperature of the rail to be tested to the main control module, and the main control module dynamically corrects the sound velocity parameters of the ultrasonic wave in the rail to be tested based on the weld temperature and the ambient temperature.

[0015] In one exemplary embodiment, the rail top scanning device further includes a rust removal, dust removal and coupling agent coating device disposed on one side of the rail top scanning device, for performing rust removal, dust removal and coupling agent coating operations on the rail to be tested.

[0016] In one exemplary embodiment, the rust removal, dust removal and coupling agent coating device is a triangular prism actuator, and the three surfaces of the triangular prism actuator are respectively provided with a rust removal grinding block, a fan and a nozzle.

[0017] In one exemplary embodiment, the rail bottom scanning device further includes at least one camera communicatively connected to the main control module for collecting image data during rail bottom operation.

[0018] In one exemplary embodiment, the frequency range of the phased array probe is 0.5 MHz-20 MHz, the number of array elements is greater than or equal to 64 elements, and the center distance between adjacent array elements is 0.2 mm-2.0 mm.

[0019] In one exemplary embodiment, the rail top scanning device and the rail bottom scanning device are fixed to the rail to be tested by magnetic attraction.

[0020] The above-mentioned rail weld inspection system provides a human-machine interactive interface. Users can directly operate on the human-machine interactive interface to realize the automated deployment of the weld inspection process and lower the threshold for use. In addition, by arranging a rust removal, dust removal and coupling agent coating device that integrates rust removal, dust removal and coupling agent coating functions on the rail bottom scanning device, rust removal, dust removal and coupling agent spraying operations can be performed simultaneously on the rail bottom of the rail to be inspected before weld inspection. Different from the time-consuming and labor-intensive manual pretreatment method, the efficiency of rail pretreatment is effectively improved, and, At least three phased array probes are deployed in the rail top scanning device and the rail bottom scanning device. By adjusting the sound beam deflection angle of the phased array probe, the rail to be tested can be scanned in all directions to detect the entire cross-section of the rail top, rail waist and rail bottom covering the thermite weld. Without removing the reinforcing plates on both sides of the rail and frequently replacing the probes, full cross-section coverage is achieved, reducing detection blind spots and achieving comprehensive weld coverage detection without blind spots. It is also possible to directly observe the full cross-section image of the weld of the rail to be tested, thus achieving efficient and accurate weld detection.

[0021] In a second aspect, the present application further provides a rail weld detection method, which is applied to a system as described in any of the above rail weld detection system embodiments, and the method includes:

[0022] In response to the rail pre-processing instruction, the rust removal, dust removal and coupling agent coating device is controlled to perform rust removal, dust removal and coupling agent coating operations on the rail to be tested;

[0023] In response to a weld inspection instruction carrying scanning parameters, each phased array probe is controlled to transmit an ultrasonic signal according to the scanning parameters and receive an echo signal of the ultrasonic signal;

[0024] Acquiring the ambient temperature and the weld temperature of the rail to be measured, and correcting a velocity parameter of the ultrasonic wave in the echo signal propagating in the rail to be measured based on the ambient temperature and the weld temperature;

[0025] A full-section image of the weld of the rail to be tested is generated and displayed based on the corrected echo signal.

[0026] In a third aspect, the present application further provides a rail weld detection device, comprising:

[0027] A pre-processing module is used to control the rust removal, dust removal and coupling agent coating device to perform rust removal, dust removal and coupling agent coating operations on the rail to be tested in response to the rail pre-processing instruction;

[0028] an ultrasonic signal control module, configured to respond to a weld inspection instruction carrying scanning parameters, control each phased array probe to transmit an ultrasonic signal according to the scanning parameters, and receive an echo signal of the ultrasonic signal;

[0029] a temperature compensation module, configured to obtain the ambient temperature and the weld temperature of the rail to be measured, and to correct the sound velocity parameter in the echo signal based on the ambient temperature and the weld temperature;

[0030] The image display module is used to generate and display a full-section image of the weld of the rail to be tested based on the corrected echo signal.

[0031] In a fourth aspect, the present application further provides a computer device comprising a memory and a processor, wherein the memory stores a computer program, and the processor implements the steps in the embodiment of the rail weld detection method when executing the computer program.

[0032] In a fifth aspect, the present application further provides a computer-readable storage medium having a computer program stored thereon, which implements the steps in the embodiment of the rail weld detection method when executed by a processor.

[0033] In a sixth aspect, the present application further provides a computer program product, comprising a computer program, which implements the steps in the embodiment of the rail weld detection method when executed by a processor.

[0034] The above-mentioned rail weld detection method, device, computer equipment, computer-readable storage medium and computer program product can be operated directly by users on the human-computer interaction interface, thereby realizing efficient and automated rail preprocessing operations and full-section coverage of welds, reducing detection blind spots. In addition, considering the influence of temperature on the refraction angle of ultrasonic waves in the rail and defect location, the sound velocity parameters of the rail in the echo signal are corrected by the weld temperature and ambient temperature, so that more accurate defect location data can be obtained, and then a more accurate full-section image of the weld can be generated and displayed, so that users can accurately evaluate the defects of the weld based on the image. In this way, the above-mentioned method can achieve efficient and accurate weld detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the technical solutions in the embodiments of the present application or related technologies, the following briefly introduces the drawings required for use in the embodiments of the present application or related technical descriptions. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without paying any creative work.

[0036] Figure 1 Schematic diagram of the structure of a rail weld detection system in one embodiment;

[0037] Figure 2 2. It is a schematic diagram of the specific structure of a rail top scanning device in one embodiment;

[0038] Figure 3 Schematic diagram of imaging results of the probe 1 in the rail top scanning device in one embodiment;

[0039] Figure 4 Schematic diagram of imaging results of the probe 2 in the rail top scanning device in one embodiment;

[0040] Figure 5 A schematic diagram of the specific structure of a rail bottom scanning device in one embodiment;

[0041] Figure 6 Schematic diagram of imaging results of the probe 3 in the rail bottom scanning device in one embodiment;

[0042] Figure 7 This is a schematic structural diagram of a coupling agent coating device for rust removal and dust removal according to one embodiment;

[0043] Figure 8 A schematic structural diagram of a rail bottom scanning device in another embodiment;

[0044] Figure 9 A schematic flow chart of a rail weld detection method in another embodiment;

[0045] Figure 10 1 is a structural block diagram of a rail weld detection device according to an embodiment;

[0046] Figure 11 FIG. 1 is a diagram showing the internal structure of a computer device in one embodiment. DETAILED DESCRIPTION

[0047] In order to make the purpose, technical solutions and advantages of this application more clear, the following further describes this application in detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain this application and are not intended to limit this application.

[0048] It should be noted that the terms "including" and "having" and any variations thereof used in this application are intended to cover non-exclusive inclusions. The term "plurality" used in this application refers to two or more. The term "and / or" used in this application refers to one or more solutions.

[0049] like Figure 1 As shown, the embodiment of the present application provides a rail weld detection system 100, comprising:

[0050] The ultrasonic phased array control device 120 is configured to: display a human-computer interaction interface, receive weld detection instructions for the rail to be tested input by the user in the human-computer interaction interface, control the phased array probe to transmit, receive and process ultrasonic signals, obtain weld detection results, and visualize the weld detection results.

[0051] The rail top scanning device 140 is disposed in the rail top weld area of ​​the rail to be tested and includes:

[0052] At least one phased array probe is set at the center of the rail top weld of the rail to be inspected, which is used to detect the full section of the weld. At least one movable phased array probe is set in the rail top area of ​​the rail to be inspected, which is used to scan the rail top area, rail waist area and rail bottom area covering the weld.

[0053] The rail bottom scanning device 160 is installed at the bottom of the rail to be tested, and includes:

[0054] At least one movable phased array probe disposed in the rail bottom area of ​​the rail to be inspected, for scanning the rail top area, rail waist area and rail bottom area covering the weld;

[0055] At least one rust removal, dust removal and coupling agent application device is provided on one side of the rail bottom scanning device 160 and is used to perform rust removal, dust removal and coupling agent application operations on the rail bottom of the rail to be tested.

[0056] For example, in this embodiment, the steel rail to be tested may be a railway rail, and the weld of the steel rail to be tested may be an aluminothermic weld, i.e., a weld formed by the exothermic reaction of aluminum powder and iron oxide to generate high-temperature molten metal, which fills the gap at the end of the rail. The rail top scanning device 140 may also be called a rail top flaw detection device. Figure 2 As shown, the rail top scanning device 140 can be fixed to one side of the rail to be tested by magnetic attraction, and includes a magnetic attraction device, a guide rail, a handle, a phased array probe (hereinafter referred to as probe) 1, a phased array probe 2, and probe clamps 1 and 2 for fixing probes 1 and 2 respectively. Specifically, the rail top scanning device 140 includes at least one phased array probe (i.e., probe 1) set at the center of the rail top weld of the rail to be tested, and is used to detect the entire cross-section of the weld, and the imaging is as follows. Figure 3 As shown. Specifically, in this embodiment, the frequency range of the phased array probe is 0.5MHz (megahertz)-20MHz, the number of array elements is greater than or equal to 64 chips, and the center distance between adjacent array elements is 0.2mm (millimeter)-2.0mm. Specifically, the probe 1 can excite a chip group consisting of 16 to 32 chips at a time, the total number of array elements of the probe is 64 to 128 chips, and a 0° line scan is performed to detect the entire thermite weld. It is understandable that in other embodiments, the frequency range, number of array elements, and center distance between adjacent array elements of the phased array probe can also be other values, which can be determined according to actual conditions and are not limited to the only value here.

[0057] The rail top scanning device 140 also includes at least one movable phased array probe (i.e., probe 2) positioned in the rail top region of the rail to be inspected, for scanning the rail top, rail waist, and rail bottom regions covering the weld. For example, probe 2 can be moved to three positions, ranging from 10 to 200 mm from the weld center. Each time, a chip group consisting of 16 to 32 chips can be excited, and a 40° to 70° sector scan can be performed three times perpendicular to the rail direction to inspect the rail top, rail waist, and rail bottom of the thermite weld. Phased array imaging is shown below. Figure 4 shown.

[0058] The rail bottom scanning device 160 can also be fixed near the rail bottom weld of the rail by a magnetic clamp. Figure 5 As shown, the rail bottom scanning device 160 includes a probe 3, a probe clamp 3 for fixing the probe 3, a magnetic clamp, a rust removal and dust removal coupling agent device, and a clamp for fixing the rust removal and dust removal coupling agent device.

[0059] The rust removal, dust removal, and coupling agent application device, also known as an automatic rust removal, dust removal, and coupling agent application device, is an integrated device that combines rust removal, dust removal, and coupling agent application functions. The rust removal, dust removal, and coupling agent application device can be fixed to one side of the rail bottom scanning device 160 via a clamp. The rail bottom scanning device 160 is connected to the host computer. Its primary function is to automatically remove rust, dust, and other impurities from the rail weld surface in response to commands from the host computer before weld inspection. It also evenly applies coupling agent (a medium used to enhance ultrasonic transmission) to ensure effective acoustic coupling between the probe and the rail, thereby improving inspection accuracy.

[0060] Probe 3 can be moved to three positions 10 to 200 mm from the weld center. It can stimulate a chip group consisting of 16 to 32 chips each time, start a 40-70° sector scan, and perform three vertical track direction scans to detect the rail top / rail waist / rail bottom of the thermite weld. The specific imaging of probe 3 can be as follows: Figure 6 shown.

[0061] Specifically, the ultrasonic phased array control device 120 includes a main control module, an ultrasonic phased array detection module connected to the main control module, and a display module. The display module is used to display a human-machine interface for users to enter data such as detection parameters and probe scanning modes. Through the human-machine interface, the user can activate the "rust removal, dust removal, and coupling agent coating device" with a single click, triggering the device to begin operation, including rust and dust removal from the bottom of the rail and evenly spraying coupling agent on the rail. Subsequently, the user can enter data such as detection parameters and probe scanning modes through the human-machine interface and send a "weld inspection" command. The main control module responds to the weld inspection command sent by the user, carrying the detection parameters, and controls the ultrasonic phased array detection module to transmit, receive, and process ultrasonic signals to scan and inspect the rail under test. The main control module processes the echo signals of the ultrasonic signals using a total focusing method to obtain a full-section image of the weld of the rail under test, and displays the full-section image of the weld on the display module, allowing personnel to promptly check whether there are any problems with the rail weld.

[0062] The above-mentioned rail weld inspection system provides a human-machine interactive interface. Users can directly operate on the human-machine interactive interface to realize the automated deployment of the weld inspection process and lower the threshold for use. In addition, by arranging a rust removal, dust removal and coupling agent coating device that integrates rust removal, dust removal and coupling agent coating functions on the rail bottom scanning device, rust removal, dust removal and coupling agent spraying operations can be performed simultaneously on the rail bottom of the rail to be inspected before weld inspection. Different from the time-consuming and labor-intensive manual pretreatment method, the efficiency of rail pretreatment is effectively improved, and, At least three phased array probes are deployed in the rail top scanning device and the rail bottom scanning device. By adjusting the sound beam deflection angle of the phased array probe, the rail to be tested can be scanned in all directions to detect the entire cross-section of the rail top, rail waist and rail bottom covering the thermite weld. Full cross-section coverage can be achieved without removing the reinforcing plates on both sides of the rail and frequently replacing probes, reducing detection blind spots and achieving comprehensive weld coverage detection without blind spots. The full cross-section image of the weld of the rail to be tested can also be directly observed, thus achieving efficient and accurate weld detection.

[0063] In some exemplary embodiments, the ultrasonic phased array control device 120 includes a main control module, and a display module, a signal excitation processing module, and an ultrasonic phased array transducer respectively connected to the main control module.

[0064] In this embodiment, the ultrasonic phased array control device 120 includes a main control module (i.e., a host computer, hereinafter referred to as a host computer) and a display module, a USB-based signal excitation and reception processing module, and a phased array transducer. The ultrasonic phased array transducer is the core sensor of the ultrasonic phased array detection module, achieving flexible deflection and focusing of the acoustic beam through electronic control.

[0065] Specifically, the weight of the host is less than or equal to 5 kg, and the host is internally provided with a battery, which can be a detachable battery, and can work continuously for at least 8 hours or more, and the host is also internally provided with at least one backup battery. In addition, the host is also provided with a color liquid crystal touch screen with a size of 8.4 inches or more than 8.4 inches, the color image displayed on the touch screen is delicate, and the user operation is convenient and sensitive. The user can operate on the man-machine interface displayed on the touch screen, and set the related parameters of the to-be-tested steel rail according to the specific detection task, such as the weld position, the steel rail thickness material, the phased array transducer working parameter, and the probe scanning mode information. The host transmits the parameter information set by the user to the signal excitation and receiving processing module through the USB bus, and when the weld detection information is transmitted to the host through the USB bus, the weld detection information is visually displayed. The signal excitation and receiving processing module based on the USB bus is an important part of the entire ultrasonic phased array control device 120, and its task is to complete the whole process of phased ultrasonic signal transmission, reception and processing. There are many functional modules involved in this module, the circuit structure is complex, and the data throughput is huge. The digital signal processing part adopts FPGA (Field-Programmable Gate Array) to complete the delay weighted summation operation required in beam synthesis.

[0066] In the ultrasonic signal transmission stage, the related parameters are set from the operation interface of the host computer, the host computer transmits the transmission delay to the FPGA through the USB controller, the analog switch of the receiving circuit is closed, the analog switch of the transmission circuit is opened, the USB controller sends a pulse trigger instruction to the FPGA, the FPGA generates a trigger pulse to start the transmission circuit, and the voltage signal generated by the transmission circuit is added to the phased array transducer through the analog switch, and the signal transmission process is completed.

[0067] In the signal receiving stage, the host computer transmits the receiving delay and weighting parameters required for beam synthesis to the FPGA through the USB controller, the analog switch of the transmission circuit is closed, the analog switch of the receiving circuit is opened, the signals collected by the phased array transducer pass through the front-end circuit and are converted into digital signals by the A / D, the digital signals complete beam synthesis in the FPGA, and finally are transmitted to the host computer through the USB interface. The software of the host computer displays the echo signal, and the signal receiving process is completed.

[0068] In the embodiment, the user can quickly set the parameters through the touch screen operation, reduce the operation threshold, synchronously manage the probe control, temperature compensation and surface treatment program, improve the system response speed, and can realize the full-face scanning of the weld by single deployment.

[0069] In some exemplary embodiments, the system also includes an ambient temperature sensor and a rail temperature sensor for communicating with the main control module. The ambient temperature sensor sends the measured ambient temperature to the main control module, and the rail temperature sensor sends the measured weld temperature of the rail to be tested to the main control module. The main control module dynamically corrects the sound velocity parameters of the ultrasonic wave in the rail to be tested based on the weld temperature and the ambient temperature.

[0070] In this embodiment, the rail temperature sensor can be attached near the rail weld to directly measure the rail surface temperature. The ambient temperature sensor can be placed in a designated location, as long as it can collect ambient temperature data. The rail temperature sensor and the ambient temperature sensor transmit their respective monitored temperature data to the main control module via wired or wireless means.

[0071] In practice, the speed at which ultrasonic waves propagate through rails (such as longitudinal wave velocity) varies with temperature, affecting the refraction angle of the ultrasonic wave within the workpiece and the accuracy of defect location. This can cause the imaged location to differ from the actual location, resulting in inaccurate results and even missed detections. Therefore, when performing phased array flaw detection, it is necessary to consider the workpiece material temperature and adjust the ultrasonic velocity parameters within the rail accordingly.

[0072] In specific implementations, after receiving the weld temperature and ambient temperature, the main control module can correct the velocity parameter of the ultrasonic wave propagating in the rail based on the relationship between temperature and the speed of ultrasonic wave propagation in the rail (hereinafter referred to as the sound velocity). Specifically, the weld temperature can be used to first correct the velocity parameter of the ultrasonic wave propagating in the rail in combination with the relationship between the sound velocity and temperature. Subsequently, based on the law of refraction and reflection, the shear wave refraction angle in the rail to be tested is corrected to obtain the horizontal and vertical scanning scale correction coefficients of the probe. Subsequently, based on the horizontal and vertical scanning scale correction coefficients of the probe, the actual horizontal and vertical distances of the defect in the rail to be tested are obtained.

[0073] The relationship between the speed of sound and temperature can be described by the approximate formula (1). This relationship is mainly affected by the thermal expansion of steel and the change of elastic modulus with temperature:

[0074] v = v0 + α(T - T0) (1)

[0075] Where T is the current rail temperature, T0 is the reference temperature, v is the longitudinal wave speed at temperature T (unit: m / s), v0 is the longitudinal wave speed at reference temperature T0, and α is the coefficient of the speed of sound with temperature (unit: m / (s·K)), which depends on the specific type of material and the temperature range.

[0076] Specifically, the sound velocity parameters can be dynamically corrected based on the law of refraction and reflection:

[0077] (2)

[0078] Wherein, α is the longitudinal wave incident angle of the probe, c is the longitudinal wave sound velocity of the probe, β is the shear wave refraction angle in the test rail, v is the shear wave sound velocity in the test rail, β0 is the shear wave refraction angle in the test rail at the reference temperature, and v0 is the shear wave sound velocity in the test rail at the reference temperature.

[0079] The horizontal scanning ratio correction coefficient of the probe can be obtained from the above formulas (1) and (2): and vertical scan ratio correction factor They are:

[0080]

[0081]

[0082] Where l1 is the theoretical horizontal distance of the defect (the horizontal distance of the defect when the actual temperature is equal to the reference temperature, that is, the original horizontal distance of the defect before correction), l2 is the actual horizontal distance of the defect of the rail to be tested, d1 is the theoretical vertical distance of the defect (the vertical distance of the defect when the actual temperature is equal to the reference temperature, that is, the original vertical distance of the defect before correction), and d2 is the actual vertical distance of the defect of the rail to be tested.

[0083] Finally, we have:

[0084]

[0085]

[0086] Through the above processing, the main control module can and The data is transmitted to the FPGA via the USB bus. When receiving the echo signal, the FPGA synchronously completes A / D conversion → beam synthesis → coordinate correction, and then displays an accurate full-section color image of the weld on the host screen.

[0087] In this embodiment, taking into account the influence of temperature on the refraction angle of ultrasonic waves in the rail and the accuracy of defect positioning, the sound velocity parameters can be corrected based on the weld temperature and ambient temperature to obtain the actual horizontal distance and actual vertical distance of the defect in the rail to be tested, thereby generating a more accurate full-section image of the weld, thereby facilitating the staff to accurately assess the defect condition of the weld.

[0088] In some embodiments, the rail top scanning device 140 further includes a rust removal, dust removal and coupling agent coating device disposed on one side of the rail top scanning device 140 for performing rust removal, dust removal and coupling agent coating operations on the rail to be tested.

[0089] In this embodiment, since the rail surface is susceptible to rust due to various factors, a rust removal, dust removal, and coupling agent application device is also provided on the side of the rail top scanning device 140. Before weld inspection, the user can activate the rust removal, dust removal, and coupling agent application device with a single button. This device simultaneously removes rust, dust, and applies coupling agent to both the top and bottom of the rail under inspection, effectively improving rail pretreatment efficiency and reducing ultrasonic energy attenuation.

[0090] like Figure 7 As shown, in some exemplary embodiments, the rust removal, dust removal and coupling agent coating device is a triangular prism actuator, and the three surfaces of the triangular prism actuator are respectively provided with a rust removal grinding block, a fan and a nozzle.

[0091] In this embodiment, the rust removal, dust removal and coupling agent coating device is designed to be a triangular prism, and a rust removal grinding block, a fan and a nozzle are respectively provided on the three faces of the triangular prism. The rust removal grinding block is used to grind the rail to remove rust on the rail, the fan is used to blow away dust to reduce dust retention and eliminate sound wave scattering noise, and the nozzle is used to spray the coupling agent to evenly apply the coupling agent (water-based coupling agent) to the top and bottom of the rail.

[0092] During specific implementation, the rust removal, dust removal and coupling agent coating device responds to the start-up command sent by the main control module, and synchronously starts the rust removal, dust removal and coupling agent coating operations. The rust removal grinding block is used to grind the rail to remove the rust on the rail as much as possible, reducing the problem of ultrasonic energy attenuation. At the same time, the fan is used to blow away the dust to reduce dust retention and eliminate sound wave scattering noise. At the same time, the coupling agent is evenly applied to the top and bottom of the rail through the nozzle, so that the coupling agent fills the micro gap to ensure the acoustic impedance matching of the probe and the rail interface.

[0093] In this embodiment, by respectively arranging a rust removal, dust removal and coupling agent coating device on the rail top scanning device and the rail bottom scanning device, which integrates the three functions of rust removal, dust removal and coupling agent coating, the efficiency of rail pretreatment can be greatly improved, and the rail can achieve consistent coupling quality across the entire area, thereby ensuring the acoustic wave transmittance and greatly improving the defect detection rate.

[0094] In some exemplary embodiments, the rail bottom scanning device 160 further includes at least one camera in communication with the main control module for collecting image data during rail bottom operation.

[0095] In this embodiment, the camera may include but is not limited to a pinhole camera or a micro camera with a high definition or higher level. Figure 8As shown, a camera can be installed on one side of the rail bottom scanning device 160 to capture the entire process of rail bottom flaw detection during thermite weld inspection. The camera then displays the captured image data on the host computer interface in real time. This allows staff to monitor the rail bottom flaw detection process in a timely manner.

[0096] like Figure 9 As shown, in some embodiments, the present application further provides a rail weld detection method, which is applied to the main control module of the rail weld detection system described in any of the above embodiments. The method includes the following steps (hereinafter referred to as S) 200 to S800, wherein:

[0097] S200 , in response to the rail pre-processing instruction, controlling the rust removal, dust removal and coupling agent coating device to perform rust removal, dust removal and coupling agent coating operations on the rail to be tested.

[0098] S400 , in response to a weld detection instruction, controlling each phased array probe to transmit an ultrasonic signal and receive an echo signal of the ultrasonic signal.

[0099] S600: Acquire the ambient temperature and the weld temperature of the rail to be measured, and based on the ambient temperature and the weld temperature, correct the velocity parameter of the ultrasonic wave in the echo signal propagating in the rail to be measured.

[0100] S800: Generate and display a full-section image of the weld of the rail to be tested based on the corrected echo signal.

[0101] In this embodiment, a rail weld detection system including an ultrasonic phased array control device, a rail top scanning device, a rail bottom scanning device, a rail temperature sensor and an ambient temperature sensor is used as an example for explanation, wherein both the rail top scanning device and the rail bottom scanning device are provided with a rust removal, dust removal and coupling agent coating device, and the rail bottom scanning device includes at least one high-definition pinhole camera.

[0102] In actual application, the operator can use the magnetic device to arrange the rail top scanning device and the rail bottom scanning device near the weld of the rail to be tested, so that probe 1 is aligned with the center of the weld, probe 2 is aligned with the rail top, and probe 3 is aligned with the rail bottom, and the rail temperature sensor is tightly attached to the rail.

[0103] The operator then enters data such as weld parameters, rail thickness and material parameters, probe scanning parameters, and ultrasonic transducer operating parameters into the host interface. The operator then presses the "Pre-process" button on the host interface. The main control module responds by sending a rail pre-processing signal to the rust removal, dust removal, and coupling agent coating device. The rust removal, dust removal, and coupling agent coating device, in response to the pre-processing signal, simultaneously removes rust, dust, and applies coupling agent to both the top and bottom of the rail under test. During this process, the operator can view the rail bottom process in real time using the camera's image data to confirm the removal of rust, the presence of dust, and the even application of coupling agent. After confirming that rust and dust are removed from both the top and bottom of the rail, and that the coupling agent has been evenly applied, the operator presses the "Stop" button on the rust removal, dust removal, and coupling agent coating device to terminate operation.

[0104] The operator then presses the "Weld Inspection" button on the human-machine interface. The main control module responds by issuing scanning parameters (e.g., probe 1: 0°, line scan; probes 2 / 3: 40°-70°, sector scan). The FPGA controls each phased array probe to begin operating according to the operator's specified scanning parameters, transmitting ultrasonic signals and receiving echo signals, which contain the ultrasonic velocity parameters on the rail. The main control module converts the received echo signals into digital signals and, based on the weld and ambient temperatures transmitted by the ambient and rail temperature sensors, corrects the ultrasonic velocity parameters on the rail to obtain more accurate coordinates of the weld defect and, consequently, a more accurate full-section image of the weld. The correction process is described in the aforementioned rail weld inspection system embodiment and will not be further elaborated here. The main control module then controls the display module to display the full-section image of the weld, allowing the operator to accurately assess the weld defect.

[0105] The above-mentioned rail weld detection method can be operated directly by the user on the human-computer interaction interface to achieve efficient and automated rail preprocessing operations and full-section coverage of the weld, reducing detection blind spots. In addition, considering the influence of temperature on the refraction angle of ultrasonic waves in the rail and defect location, the sound velocity parameters of the rail in the echo signal are corrected by the weld temperature and ambient temperature, so that more accurate defect location data can be obtained, and then a more accurate full-section image of the weld can be generated and displayed, so that the user can accurately evaluate the defect condition of the weld based on the image. In this way, the above-mentioned method can achieve efficient and accurate weld detection.

[0106] It should be understood that, although the various steps in the flowcharts involved in the various embodiments described above are displayed in sequence according to the instructions of the arrows, these steps are not necessarily performed in sequence in the order indicated by the arrows. Unless clearly stated herein, the execution of these steps is not strictly limited in order, and these steps can be performed in other orders. Moreover, at least a portion of the steps in the flowcharts involved in the various embodiments described above may include multiple steps or multiple stages, and these steps or stages are not necessarily performed at the same time, but can be performed at different times, and the execution order of these steps or stages is not necessarily performed in sequence, but can be performed in turn or alternately with at least a portion of the steps or stages in other steps or other steps. It is understandable that the various steps in different embodiments can be freely combined as needed, and the various non-contradictory schemes formed by the combination all fall within the scope of protection of this application.

[0107] Based on the same inventive concept, embodiments of the present application also provide a rail weld detection device for implementing the aforementioned rail weld detection method. The solution provided by this device is similar to the solution described in the aforementioned method. Therefore, the specific limitations of one or more rail weld detection device embodiments provided below can be found in the aforementioned limitations of the rail weld detection method and will not be further elaborated here.

[0108] In an exemplary embodiment, Figure 10 As shown, a rail weld detection device 900 is provided, comprising: a pre-processing module 910, an ultrasonic signal control module 920, a temperature compensation module 930 and an image display module 940, wherein:

[0109] The pre-processing module 910 is used to control the rust removal, dust removal and coupling agent coating device to perform rust removal, dust removal and coupling agent coating operations on the rail to be tested in response to the rail pre-processing instruction.

[0110] The ultrasonic signal control module 920 is used to respond to the weld detection instruction carrying the scanning parameters, control each phased array probe to transmit the ultrasonic signal according to the scanning parameters, and receive the echo signal of the ultrasonic signal.

[0111] The temperature compensation module 930 is used to obtain the ambient temperature and the weld temperature of the rail to be measured, and based on the ambient temperature and the weld temperature, correct the velocity parameter of the ultrasonic wave in the echo signal propagating in the rail to be measured.

[0112] The image display module 940 is used to generate and display a full-section image of the weld of the rail to be tested based on the corrected echo signal.

[0113] Each module in the rail weld detection device can be implemented in whole or in part through software, hardware, or a combination thereof. Each module can be embedded in or independent of a processor in a computer device in hardware form, or can be stored in a computer device memory in software form, so that the processor can call and execute the corresponding operations of each module.

[0114] In an exemplary embodiment, a computer device is provided. The computer device may be a terminal, and its internal structure diagram may be as shown in FIG. Figure 11 As shown. The computer device includes a processor, memory, an input / output interface, a communication interface, a display unit, and an input device. The processor, memory, and input / output interface are connected via a system bus, and the communication interface, display unit, and input device are connected to the system bus via the input / output interface. The processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes a non-volatile storage medium and internal memory. The non-volatile storage medium stores an operating system and a computer program. The internal memory provides an environment for the operation of the operating system and computer program in the non-volatile storage medium. The input / output interface of the computer device is used to exchange information between the processor and external devices. The communication interface of the computer device is used to communicate with external terminals via wired or wireless means. The wireless means can be implemented via Wi-Fi, a mobile cellular network, near-field communication (NFC), or other technologies. When executed by the processor, the computer program implements a rail weld detection method. The display unit of the computer device is used to produce a visually visible image and can be a display screen, a projection device, or a virtual reality imaging device. The display screen can be a liquid crystal display screen or an electronic ink display screen, and the input device of the computer device can be a touch layer covering the display screen, or a button, trackball or touchpad set on the computer device casing, or an external keyboard, touchpad or mouse.

[0115] Those skilled in the art will understand that Figure 11 The structure shown in the figure is only a block diagram of a part of the structure related to the solution of the present application, and does not constitute a limitation on the computer device to which the solution of the present application is applied. The specific computer device may include more or fewer components than shown in the figure, or combine certain components, or have a different component arrangement.

[0116] In an exemplary embodiment, a computer device is provided, including a memory and a processor. The memory stores a computer program, and the processor implements the steps in the above-mentioned rail weld detection method embodiment when executing the computer program.

[0117] In one embodiment, a computer-readable storage medium is provided, on which a computer program is stored. When the computer program is executed by a processor, the steps in the above-mentioned rail weld detection method embodiment are implemented.

[0118] In one embodiment, a computer program product is provided, comprising a computer program, which, when executed by a processor, implements the steps in the above-mentioned rail weld detection method embodiment.

[0119] It should be noted that the user information (including but not limited to user device information, user personal information, etc.) and data (including but not limited to data used for analysis, stored data, displayed data, etc.) involved in this application are all information and data authorized by the user or fully authorized by all parties, and the collection, use and processing of relevant data must comply with relevant regulations.

[0120] Those skilled in the art will understand that all or part of the processes in the above-mentioned embodiments can be implemented by instructing the relevant hardware through a computer program. The computer program can be stored in a non-volatile computer-readable storage medium. When the computer program is executed, it can include the processes of the embodiments of the above-mentioned methods. In particular, any reference to memory, database, or other media used in the embodiments provided in this application can include at least one of non-volatile memory and volatile memory. Non-volatile memory can include read-only memory (ROM), magnetic tape, floppy disk, flash memory, optical memory, high-density embedded non-volatile memory, resistive random access memory (ReRAM), magnetic random access memory (MRAM), ferroelectric random access memory (FRAM), phase change memory (PCM), graphene memory, etc. Volatile memory can include random access memory (RAM) or external cache memory, etc. By way of illustration and not limitation, RAM can take various forms, such as static random access memory (SRAM) or dynamic random access memory (DRAM). The databases involved in the various embodiments provided herein may include at least one of a relational database and a non-relational database. Non-relational databases may include, but are not limited to, blockchain-based distributed databases. The processors involved in the various embodiments provided herein may be, but are not limited to, general-purpose processors, central processing units (CPUs), graphics processing units (GPUs), digital signal processors (DSPs), programmable logic devices (PLDs), quantum computing-based data processing logic devices, artificial intelligence (AI) processors, and the like.

[0121] The technical features of the above embodiments can be combined arbitrarily. In order to make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this application.

[0122] The above-described embodiments merely represent several implementation methods of the present application. While the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present application. It should be noted that a person of ordinary skill in the art may make various modifications and improvements without departing from the spirit of the present application, and these modifications and improvements fall within the scope of protection of the present application. Therefore, the scope of protection of the present application shall be determined by the appended claims.

Claims

1. A rail weld detection system, characterized in that: The system comprises: The ultrasonic phased array control device is configured to: display a human-computer interaction interface, receive a weld detection instruction for a rail to be tested input by a user on the human-computer interaction interface, control the phased array probe to transmit, receive, and process ultrasonic signals, obtain weld detection results, and visually display the weld detection results; The rail top scanning device is installed on the rail top of the rail to be tested, including: At least one phased array probe disposed at the center of the rail top weld of the rail to be inspected, for inspecting the entire cross-section of the weld, and at least one movable phased array probe disposed in the rail top region of the rail to be inspected, for scanning the rail top region, rail waist region, and rail bottom region covering the weld; The rail bottom scanning device is installed at the bottom of the rail to be tested, including: At least one movable phased array probe disposed in the rail bottom area of ​​the rail to be inspected, for scanning the rail top area, rail waist area and rail bottom area covering the weld; At least one rust removal, dust removal and coupling agent coating device is arranged on one side of the rail bottom scanning device, and is used for performing rust removal, dust removal and coupling agent coating operations on the rail bottom of the steel rail to be tested.

2. The system according to claim 1, wherein: The ultrasonic phased array control device includes a main control module, and a display module, a signal excitation processing module and a phased array transducer respectively connected to the main control module.

3. The system according to claim 2, characterized in that The system also includes an ambient temperature sensor and a rail temperature sensor for communicating with the main control module. The ambient temperature sensor sends the measured ambient temperature to the main control module, and the rail temperature sensor sends the measured weld temperature of the rail to be tested to the main control module. The main control module dynamically corrects the sound velocity parameters of the ultrasonic wave in the rail to be tested based on the weld temperature and the ambient temperature.

4. The system according to claim 3, characterized in that The rail top scanning device further comprises a rust removal, dust removal and coupling agent coating device provided on one side of the rail top scanning device, which is used for performing rust removal, dust removal and coupling agent coating operations on the rail to be tested.

5. The system according to claim 1 or 4, characterized in that The rust removal, dust removal and coupling agent coating device is a triangular prism actuator, and the three surfaces of the triangular prism actuator are respectively provided with a rust removal grinding block, a fan and a nozzle.

6. The system according to claim 2, wherein: The rail bottom scanning device also includes at least one camera in communication with the main control module, which is used to collect image data during the rail bottom operation process.

7. The system according to claim 6, characterized in that The frequency range of the phased array probe is 0.5 MHz to 20 MHz, the number of array elements is greater than or equal to 64 chips, and the center distance between adjacent array elements is 0.2 mm to 2.0 mm.

8. The system according to any one of claims 1 to 4, characterized in that: The rail top scanning device and the rail bottom scanning device are fixed to the rail to be tested by magnetic attraction.

9. The system according to any one of claims 2 to 4, characterized in that: The display module includes a color liquid crystal touch screen.

10. A rail weld detection method, characterized in that: Applicable to the rail weld detection system according to any one of claims 1 to 9; the method comprises: In response to the rail pre-processing instruction, the rust removal, dust removal and coupling agent coating device is controlled to perform rust removal, dust removal and coupling agent coating operations on the rail to be tested; In response to a weld inspection instruction carrying scanning parameters, each phased array probe is controlled to transmit an ultrasonic signal according to the scanning parameters and receive an echo signal of the ultrasonic signal; Acquiring the ambient temperature and the weld temperature of the rail to be measured, and correcting a velocity parameter of the ultrasonic wave in the echo signal propagating in the rail to be measured based on the ambient temperature and the weld temperature; A full-section image of the weld of the rail to be tested is generated and displayed based on the corrected echo signal.

Images