Steel rail welding seam ultrasonic flaw detection method and device

Abstract

The invention discloses a steel rail welding seam ultrasonic flaw detection method and device. The method comprises a TOFD detection method, a single-probe reflection detection method and a double-probe K-type detection method. A plurality of pairs of rail side flaw detection probes and different combinations of zero-degree rail surface probes and inclined rail surface probes are arranged on two sides of the inner and outer side surfaces of a steel rail from bottom to top by taking a welding seam as a center, and a TOFD detection method, a single-probe reflection detection method and a double-probe K-type detection method are adopted, so that all-directional and multi-angle detection of a steel rail welding seam area is realized. By means of the method, longitudinal defects, transverse defects and defects at different depth positions in the welding seam can be effectively detected, the leakage detection risk is greatly reduced, and the comprehensiveness and reliability of steel rail welding seam quality detection are ensured.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of rail flaw detection, in particular to a steel rail weld ultrasonic flaw detection method and device. BACKGROUND

[0002] The ultrasonic TOFD detection technology, i.e. ultrasonic time of flight diffraction method, was first proposed by Dr. Silk of the National Nondestructive Testing Center in Havell, England in the 1970s. Its principle is derived from the study of crack tip diffraction signals. Until the 1990s, with the development of computer technology, the development of digital ultrasonic flaw detector became mature, and it became possible to develop portable and cost-acceptable TOFD detectors. This technology uses two wideband narrow pulse probes for detection, and the probes are symmetrically arranged relative to the center line of the weld. The transmitting probe generates a non-focused longitudinal wave beam to enter the detected workpiece at a certain angle, part of which propagates along the near surface and is received by the receiving probe, and part of which is reflected by the bottom surface and is received by the probe. The receiving probe determines the position and height of the defect by receiving the diffraction signals of the defect tip and their time difference. The advantage of ultrasonic TOFD detection technology is that it can almost cover the entire weld area in one scan, and can achieve very high detection speed. It has high detection rate and good reliability for defects in the middle of the weld. It can detect various types of defects and is not sensitive to the direction of the defects. It can identify defects extending to the surface. D-scan imaging is used, and defect interpretation is more intuitive. The quantitative and positioning of defects in the vertical direction are very accurate, with an accuracy error of less than 1mm. In the past decade, this technology has been maturely applied to steel plate and steel pipe weld detection, and can meet the high-precision and high-efficiency requirements of weld quality detection in industrial production, effectively ensuring the safety and reliability of related equipment and structures.

[0003] Currently, the ultrasonic single-probe reflection method, dual-probe K-type method, and dual-probe serial scanning method are the main methods for inspecting in-service rail welds. All of these methods require manual inspection. Inspectors need to carry a variety of tools, which makes the operation complex and labor-intensive, resulting in lengthy inspection times. The defect detection rate and inspection reliability depend on the inspector's experience and level of expertise, resulting in low efficiency. Railway rails are shaped like an "I" and have a unique shape and structure, significantly different from those of steel plates and pipes. This necessitates specialized probe design and inspection process adjustments tailored to the rail geometry, increasing the technical complexity. Furthermore, railway rails are often exposed to the elements and are significantly affected by natural environmental factors, such as temperature, humidity, and wind and sand. These factors can interfere with the propagation and reception of ultrasonic signals, thereby impacting the accuracy and reliability of TOFD inspections. Existing TOFD inspection technology may have limitations in adapting to complex field environments. TOFD inspection technology also struggles to reliably detect near-surface defects, such as surface cracks and subsurface pores, that may occur in rail welds. Compared to longitudinal defects, TOFD technology is less effective at detecting transverse defects. However, transverse defects that may exist in rail welds can also seriously impact rail safety. TOFD equipment is relatively expensive and requires high operator skill, requiring specialized training to master the technology and equipment operation. This, to a certain extent, limits the widespread application of this technology in railway rail weld inspection.

[0004] Therefore, the current problem is how to combine TOFD detection technology with various ultrasonic detection methods such as ultrasonic reflection method, and use on-board automated detection equipment to detect in-service rail welds to improve detection efficiency, defect detection rate and detection reliability. Summary of the Invention

[0005] The purpose of the present invention is to overcome the shortcomings of the above-mentioned background technology and provide a rail weld ultrasonic flaw detection method and device that combines the TOFD detection method with other multiple probe detection methods to improve the accuracy and reliability of rail weld flaw detection.

[0006] To achieve this purpose, the present invention designs a rail weld ultrasonic flaw detection method, which includes a TOFD detection method, a single probe reflection detection method and a dual probe K-type detection method;

[0007] The TOFD inspection method includes: arranging multiple pairs of rail side flaw detection probes on the outer surface and the inner surface of the rail from bottom to top, located on the left and right sides of the rail, arranging at least one pair of oblique rail surface probes on the top surface of the rail, located on the left and right sides of the rail, and inspecting the weld area of ​​the rail according to a first flaw detection rule;

[0008] The single-probe reflection detection method comprises: arranging a plurality of pairs of rail side flaw detection probes on the left and right sides of the rail on the outer side surface and the inner side surface of the rail from bottom to top; arranging at least one pair of oblique rail surface probes on the left and right sides of the rail on the top surface of the rail and at least one zero-degree rail surface probe between the at least one pair of oblique rail surface probes or at least one pair of zero-degree rail surface probes on the left and right sides of the rail; and detecting the weld area of the rail according to a second flaw detection rule.

[0009] The double-probe K-type detection method comprises: arranging a plurality of groups of rail side flaw detection probes on the inner and outer side surfaces of the rail, each group of rail side flaw detection probes comprising two rail side flaw detection probes symmetrically arranged on the inner and outer side surfaces of the rail; and detecting the weld area of the rail according to a third flaw detection rule.

[0010] Further, the TOFD detection method further comprises: resetting the at least one pair of oblique rail surface probes after translating the at least one pair of oblique rail surface probes in the same direction along the length direction of the rail by a set distance, or resetting the at least one pair of oblique rail surface probes after translating the at least one pair of oblique rail surface probes in opposite directions along the length direction of the rail by a set distance, and resetting the plurality of pairs of rail side flaw detection probes after translating the plurality of pairs of rail side flaw detection probes in opposite directions along the length direction of the rail by a set distance.

[0011] Further, the single-probe reflection detection method further comprises: resetting the at least one zero-degree rail surface probe, or the at least one pair of zero-degree rail surface probes and the at least one pair of oblique rail surface probes, after translating the at least one zero-degree rail surface probe, or the at least one pair of zero-degree rail surface probes and the at least one pair of oblique rail surface probes, in the same direction along the length direction of the rail by a set distance, and resetting the plurality of pairs of rail side flaw detection probes, the at least one pair of zero-degree rail surface probes and the at least one pair of oblique rail surface probes, after translating the plurality of pairs of rail side flaw detection probes, the at least one pair of zero-degree rail surface probes and the at least one pair of oblique rail surface probes, in opposite directions along the length direction of the rail by a set distance.

[0012] Further, the double-probe K-type detection method further comprises: resetting the plurality of groups of rail side flaw detection probes after translating the plurality of groups of rail side flaw detection probes in opposite directions along the length direction of the rail by a set distance.

[0013] Further, the first flaw detection rule comprises: triggering a rail side flaw detection probe on one side of the outer side surface of the rail, so that a rail side flaw detection probe on the other side of the outer side surface of the rail receives an ultrasonic wave signal corresponding to the rail side flaw detection probe on the other side of the outer side surface of the rail; triggering a rail side flaw detection probe on one side of the inner side surface of the rail, so that a rail side flaw detection probe on the other side of the inner side surface of the rail receives an ultrasonic wave signal corresponding to the rail side flaw detection probe on the other side of the inner side surface of the rail; and triggering an oblique rail surface probe on one side of the rail, so that an oblique rail surface probe on the other side of the rail receives an ultrasonic wave signal corresponding to the oblique rail surface probe on the other side of the rail.

[0014] Further, the first flaw detection rule comprises: triggering a rail side flaw detection probe on one side of the outer side surface of the rail, so that the triggered rail side flaw detection probe receives an ultrasonic wave signal emitted by itself; and triggering a rail side flaw detection probe on the other side of the outer side surface of the rail, so that the triggered rail side flaw detection probe receives an ultrasonic wave signal emitted by itself.

[0015] triggering the rail side flaw detection probe on one side of the inner side surface of the steel rail, so that the triggered rail side flaw detection probe receives the ultrasonic wave signal emitted by itself; triggering the rail side flaw detection probe on the other side of the inner side surface of the steel rail, so that the triggered rail side flaw detection probe receives the ultrasonic wave signal emitted by itself;

[0016] triggering the oblique rail surface probe on one side of the top surface of the steel rail, so that the triggered oblique rail surface probe receives the ultrasonic wave signal emitted by itself; triggering the oblique rail surface probe on the other side of the top surface of the steel rail, so that the triggered oblique rail surface probe receives the ultrasonic wave signal emitted by itself;

[0017] triggering at least one zero-degree rail surface probe located between at least one pair of the oblique rail surface probes, so that the triggered zero-degree rail surface probe receives the ultrasonic wave signal emitted by itself; or triggering at least one pair of the zero-degree rail surface probes located on the left and right sides of the top surface of the steel rail in sequence, so that the triggered zero-degree rail surface probe receives the ultrasonic wave signal emitted by itself.

[0018] Further, the third flaw detection rule comprises: triggering the rail side flaw detection probe on one side of the outer side surface of the steel rail, so that the rail side flaw detection probe on one side of the inner side surface of the steel rail receives the corresponding ultrasonic wave signal; triggering the rail side flaw detection probe on the other side of the outer side surface of the steel rail, so that the rail side flaw detection probe on the other side of the inner side surface of the steel rail receives the corresponding ultrasonic wave signal; triggering the rail side flaw detection probe on one side of the inner side surface of the steel rail, so that the rail side flaw detection probe on one side of the outer side surface of the steel rail receives the corresponding ultrasonic wave signal; triggering the rail side flaw detection probe on the other side of the inner side surface of the steel rail, so that the rail side flaw detection probe on the other side of the outer side surface of the steel rail receives the corresponding ultrasonic wave signal.

[0019] Still further, the present application also designs a device for realizing the ultrasonic flaw detection method of the steel rail weld, which comprises probe supports arranged on the rail surface, the rail head side surface, the rail jaw, the rail waist and the rail bottom, and the rail side flaw detection probe, the oblique rail surface probe and the zero-degree rail surface probe are all fixed on the probe supports.

[0020] Preferably, the probe support is a magnetic support which is detachably fixed on the steel rail through magnetic attraction.

[0021] Still further, the probe support comprises a rail surface probe support for fixing the oblique rail surface probe or the zero-degree rail surface probe or both the oblique rail surface probe and the zero-degree rail surface probe; a rail head side surface probe support for fixing the rail side flaw detection probe located on the rail head side surface; a first rail side probe support for fixing the rail side flaw detection probe located on the rail jaw and the rail waist; a second rail side probe support located below the first rail side probe support, for fixing the rail side flaw detection probe located on the rail bottom; and a rail bottom probe support located below the second rail side probe support, for fixing the rail side flaw detection probe located on the rail bottom side surface.

[0022] The present application has the following advantages: The present application arranges multiple pairs of rail side flaw detection probes on the inner and outer surfaces of the steel rail on both sides of the weld from bottom to top, and different combinations of zero rail surface probes and inclined rail surface probes, adopts TOFD detection method, single probe reflection detection method and double probe K type detection method, and realizes omnidirectional and multi-angle detection of the steel rail weld area. Whether it is longitudinal defects, transverse defects inside the weld, or defects at different depths, effective detection can be achieved, greatly reducing the risk of missed detection, and ensuring the comprehensiveness and reliability of the steel rail weld quality detection. For example, the rail side flaw detection probe can effectively detect defects on the side surface and near surface of the weld, while the rail surface probe of different angles can deeply detect defects of different directions inside the weld, and the three detection methods complement each other to form a rigorous detection network. The TOFD detection method is based on the time difference principle of ultrasonic wave diffraction, which can accurately measure the height and position of the defect, and has high sensitivity to small defects; the single probe reflection detection method can analyze the nature and size of the defect through the characteristics of the reflected wave; the double probe K type detection method utilizes the interaction between the two probes, which can better detect some special types of defects, such as inclined defects. The three methods work together to analyze the detection data comprehensively, which can more accurately judge the true situation of the weld defects, avoid misjudgment or missed judgment due to the limitations of a single detection method, effectively improve the detection accuracy, and provide more reliable data support for the safe use of the steel rail. Different types of probes and detection methods have unique detection advantages for different types of defects. For example, the inclined rail surface probe has remarkable effect in detecting inclined defects at a certain angle to the surface of the steel rail, while the zero rail surface probe is better at detecting defects parallel to the surface of the steel rail. This flexible configuration of probes and detection methods according to the characteristics of the defects makes the flaw detection method adapt to various complex defect situations that may occur in the actual use of the steel rail weld. Whether it is common defects such as pores, slag inclusion, incomplete fusion, or special defects such as fatigue cracks and stress corrosion cracks caused by long-term use, they can be effectively detected and identified, so that problems can be found and handled in time to ensure the safety of railway transportation. Arranging multiple pairs of rail side flaw detection probes and various rail surface probes on both sides of the weld can detect multiple parts simultaneously in one detection process. Compared with the traditional single probe or a small number of probes for sequential detection, the detection time is greatly shortened, and the detection efficiency is improved. Especially in the case of large-scale railway track maintenance or new steel rail laying acceptance, which requires a large amount of detection work, the efficient detection method can significantly reduce the detection period, reduce the impact on railway operation, and improve the overall efficiency of railway maintenance work. The three detection methods have their own specific flaw detection rules, namely the first flaw detection rule, the second flaw detection rule and the third flaw detection rule. This standardized operation process makes the flaw detection work have good repeatability, and different detection personnel can operate according to the same process and rules to obtain consistent detection results.This not only helps to ensure the stability of the detection quality, but also facilitates the unified management and analysis of the detection data, provides convenient conditions for the long-term tracking and evaluation of the rail weld quality, and helps to establish a scientific and reasonable rail maintenance management system. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 The figure is a schematic diagram of the flaw detection area of the rail head probe in the application;

[0024] Figure 2 The figure is a schematic diagram of the flaw detection area of the rail side flaw detection probe arranged on the rail head side in the application;

[0025] Figure 3 The figure is a schematic diagram of the flaw detection area of the rail side flaw detection probe arranged on the rail jaw area in the application;

[0026] Figure 4 The figure is a schematic diagram of the flaw detection area of the rail side flaw detection probe arranged on the rail waist area in the application;

[0027] Figure 5 The figure is a schematic diagram of the flaw detection area of the rail side flaw detection probe arranged on the rail bottom area in the application;

[0028] Figure 6 The figure is a schematic diagram of the flaw detection area of the rail side flaw detection probe arranged on the rail bottom area in the application; Figure 1 ;

[0029] Figure 7 The figure is a schematic diagram of the flaw detection area of the rail side flaw detection probe arranged on the rail bottom area in the application; Figure 2 ;

[0030] Figure 8 The figure is a schematic diagram of the flaw detection area of the rail side flaw detection probe arranged on the rail bottom area in the application;

[0031] Figure 9 The figure is a schematic diagram of the flaw detection area of the rail side flaw detection probe arranged on the rail bottom area in the application;

[0032] Figure 10 The figure is a schematic diagram of the flaw detection area of the rail side flaw detection probe arranged on the rail bottom area in the application;

[0033] Wherein, 1-weld, 2-rail, 3-integrated rail head probe, 4-rail side flaw detection probe, 5-rail head probe support, 6-rail head side probe support, 7-first rail side probe support, 8-second rail side probe support, 9-rail bottom probe support. DETAILED DESCRIPTION

[0034] Clearly, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. In the description of the present application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only used to facilitate the description of the present application and simplify the description, and therefore cannot be understood as indicating or implying that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.

[0035] As shown in Fig. 1, the rail 2 is welded by a plurality of welds 1, and the rail 2 is provided with a plurality of rail side flaw detection probes 4 arranged on the side surface of the rail 2, and a pair of integrated rail surface flaw detection probes 3 arranged on the top surface of the rail 2. Figure 1 As shown in Fig. 5, the flaw detection probes arranged at different positions of the rail 2 can scan different areas of the rail 2, and the combination of a plurality of flaw detection probes can perform full-coverage flaw detection operation on the set area. Based on this principle, the present application designs the following three embodiments of flaw detection methods.

[0036] In the present application, the rail side flaw detection probe 4 includes all the flaw detection probes arranged on the side surface of the rail 2, i.e. the flaw detection probes arranged on the side surface of the rail head, the rail foot, the rail waist and the rail bottom are collectively referred to as the rail side flaw detection probe 4.

[0037] Embodiment one:

[0038] As shown in Fig. 10, the TOFD detection method is mainly combined with the single probe reflection detection method: a plurality of pairs of rail side flaw detection probes are arranged on the inside and outside of the weld 1, a pair of integrated rail surface flaw detection probes 3 integrated with a zero-degree rail surface flaw detection probe and an inclined rail surface flaw detection probe are arranged on the top surface of the rail 2, the outside surface of the rail 2 and the inside surface of the rail 2 are both centered on the weld 1, and a plurality of pairs of rail side flaw detection probes are arranged on both sides thereof from bottom to top, so as to perform flaw detection on the weld area of the rail 2 according to the set flaw detection rule; the plurality of pairs of rail side flaw detection probes on both sides of the weld 1 and the pair of integrated rail surface flaw detection probes are translated towards or away from each other along the length direction of the rail 2 to a set distance and then reset. Figure 9 The set flaw detection rule is: triggering the rail side flaw detection probe 4 on one side of the outside surface of the rail 2, so that the rail side flaw detection probe 4 on the other side of the outside surface of the rail 2 receives the corresponding ultrasonic wave signal; triggering the zero-degree rail surface flaw detection probe of the integrated rail surface flaw detection probe 3 on one side of the rail 2; triggering the rail side flaw detection probe 4 on one side of the inside surface of the rail 2, so that the rail side flaw detection probe 4 on the other side of the inside surface of the rail 2 receives the corresponding ultrasonic wave signal; triggering the zero-degree rail surface flaw detection probe of the integrated rail surface flaw detection probe 3 on the other side of the rail 2; triggering the inclined rail surface flaw detection probe of the integrated rail surface flaw detection probe 3 on one side of the rail 2, so that the inclined rail surface flaw detection probe of the integrated rail surface flaw detection probe 3 on the other side of the rail 2 receives the corresponding ultrasonic wave signal.

[0039] ​

[0040] In particular, a specific embodiment is provided:

[0041] Flaw detection operation time: ≤5min / strip weld (≤2min for scanning frame alignment, ≤2min for flaw detection, ≤1min for scanning frame removal)

[0042] Probe moving speed: 20mm / s

[0043] Display mode: radio frequency, D-type display

[0044] TOFD scanning mode: contact scanning, all shear wave probes are symmetrically translated by 100mm to both sides of the weld along the center line of the weld as the origin according to the trigger rule and working state of the probes, and then are relatively translated to reset, to complete a TOFD detection operation cycle.

[0045] Probe trigger sequence:

[0046] Step 1: the left side probe of the outer side weld of the rail is triggered, the right side probe of the outer side weld of the rail is collected, and the probes are triggered in the order from small to large (A is triggered → B is collected, then C is triggered → D is collected, then E is triggered → F is collected, … O is triggered → P is collected);

[0047] Step 2: 0° probe detection (the 0° probe of the integrated rail surface probe Q is triggered, and the integrated rail surface Q integrates a zero-degree rail surface probe and an inclined rail surface probe);

[0048] Step 3: the left side probe of the rail head tread weld is triggered, and the right side probe of the rail head tread weld is collected (the inclined rail surface probe of the integrated rail surface Q is triggered → the inclined rail surface probe of the integrated rail surface R is collected, and the integrated rail surface probe R also integrates a zero-degree rail surface probe and an inclined rail surface probe);

[0049] Step 4: 0° probe detection (the zero-degree rail surface probe of the integrated rail surface probe R is triggered);

[0050] Step 5: the left side probe of the inner side weld of the rail is triggered, and the right side probe of the inner side weld of the rail is collected, and the probes are triggered in the order from small to large (A' is triggered → B' is collected, then C' is triggered → D' is collected, then E' is triggered → F' is collected, … O' is triggered → P' is collected);

[0051] Step 6: 0° probe detection (the zero-degree rail surface probe of the integrated rail surface probe Q is triggered);

[0052] Step 7: the left side probe of the inner side weld of the rail head tread is triggered, and the right side probe of the rail head tread weld is collected (the inclined rail surface probe of the integrated rail surface probe Q is triggered → the inclined rail surface probe of the integrated rail surface probe R is collected);

[0053] Step 8: 0° probe detection (the zero-degree rail surface probe of the integrated rail surface probe R is triggered); after step 8 is completed, the cycle is started again until the cycle program is ended.

[0054] The second time, the transmitting and receiving objects are exchanged, and the steps are as follows:

[0055] Step 9: The right side probe of the outside weld of the steel rail is transmitted, the left side probe of the outside weld of the steel rail is received, and the order from small to large is triggered (B transmit→A receive, then D transmit→C receive, then F transmit→E receive, …, P transmit→O receive);

[0056] Step 10: 0° probe detection (the 0° probe of the integrated rail surface probe R is triggered);

[0057] Step 11: The right side probe of the rail head weld is transmitted, the left side probe of the rail head weld is received (the oblique rail surface probe of the integrated rail surface probe R is transmitted→the oblique rail surface probe of the integrated rail surface probe Q is received);

[0058] Step 12: 0° probe detection (the 0° probe of the integrated rail surface probe Q is triggered);

[0059] Step 13: The left side probe of the inside weld of the steel rail is transmitted, the right side probe of the inside weld of the steel rail is received, and the order from small to large is triggered (B' transmit→A' receive, then D' transmit→C' receive, then F' transmit→E' receive, …, P' transmit→O' receive);

[0060] Step 14: 0° probe detection (the 0° probe of the integrated rail surface probe R is triggered);

[0061] Step 15: The right side probe of the inside weld of the rail head is transmitted, the left side probe of the rail head weld is received (the oblique rail surface probe of the integrated rail surface probe R is transmitted→the oblique rail surface probe of the integrated rail surface probe Q is received);

[0062] Step 16: 0° probe detection (the 0° probe of the integrated rail surface probe Q is triggered); after step 16 is completed, return to step 1 until the cycle program is completed.

[0063] In the above two cycle processes, the integrated rail surface probes Q and R can also be integrated into one body, which includes one or more pairs of oblique rail surface probes and one or more 0° rail surface probes located in the middle of the pairs of oblique rail surface probes, or one or more pairs of oblique rail surface probes and one or more pairs of 0° rail surface probes, the triggering rules remain unchanged, and the movement direction of the rail side flaw detection probe 4 also remains unchanged, only the movement mode of the integrated rail surface probe 3 changes from moving from one side to the other side of the length direction of the steel rail 2 to moving from one side to the other side of the length direction of the steel rail 2 and resetting after reaching the set distance.

[0064] Embodiment two:

[0065] As Figure 9—10 shows a single probe reflection detection method: a plurality of pairs of rail side flaw detection probes are arranged on the inner and outer sides of the weld 1, a pair of zero-degree rail surface probes are arranged on the top surface of the steel rail 2, the outer surface of the steel rail 2 and the inner surface of the steel rail 2 are both centered on the weld 1, a plurality of pairs of rail side flaw detection probes are arranged on both sides of the weld 1 from bottom to top, and the weld area of the steel rail 2 is detected according to the set detection rule; the plurality of pairs of rail side flaw detection probes on both sides of the weld 1 and the pair of zero-degree rail surface probes are translated towards or away from each other along the length direction of the steel rail 2 to a set distance and then reset.

[0066] The set detection rule is: triggering the rail side flaw detection probe 4 on one side of the outer surface of the steel rail 2, making the triggered rail side flaw detection probe 4 receive the ultrasonic wave signal emitted by itself; triggering the zero-degree rail surface probe on one side of the steel rail 2; triggering the rail side flaw detection probe 4 on the other side of the outer surface of the steel rail 2, making the triggered rail side flaw detection probe 4 receive the ultrasonic wave signal emitted by itself; triggering the rail side flaw detection probe 4 on one side of the inner surface of the steel rail 2, making the triggered rail side flaw detection probe 4 receive the ultrasonic wave signal emitted by itself; triggering the zero-degree rail surface probe on the other side of the steel rail 2; triggering the rail side flaw detection probe 4 on the other side of the inner surface of the steel rail 2, making the triggered rail side flaw detection probe 4 receive the ultrasonic wave signal emitted by itself.

[0067] Specifically, a specific embodiment is provided:

[0068] Single probe reflection method A, B type display. Single probe reflection method scanning mode: contact scanning, all shear wave probes are translated symmetrically and reversely by 120mm on both sides of the weld with the weld center line as the origin according to the trigger rule and working state of the probes, and then relatively translated to reset, to complete a reflection method detection operation cycle.

[0069] Probe trigger sequence:

[0070] Step 1: The probes on the left side of the outer weld of the steel rail are triggered in ascending order (A emits A, C emits C, …, O emits O);

[0071] Step 2: 0° probe detection (zero-degree rail surface probe trigger of integrated rail surface probe Q);

[0072] Step 3: The probes on the left side of the inner weld of the steel rail are triggered in ascending order (A' emits A', C' emits C', …, O' emits O');

[0073] Step 4: 0° probe detection (zero-degree rail surface probe trigger of integrated rail surface probe R);

[0074] Step 5: The probes on the right side of the outer weld of the steel rail are triggered in ascending order (B emits B, D emits D, …, P emits P);

[0075] Step 6: 0° probe detection (zero degree rail head probe trigger of integrated rail head probe Q);

[0076] Step 7: Right side probe of rail inner weld from small to large order trigger (B' send B' receive, D' send D' receive, ……P' send P' receive);

[0077] Step 8: 0° probe detection (zero degree rail head probe trigger of integrated rail head probe R);

[0078] After step 8 is completed, the cycle is started again until the cycle program is completed.

[0079] In the second cycle, the left and right side sending and receiving orders can be exchanged, and the steps are as follows:

[0080] Step 9: Right side probe of rail outer weld from small to large order trigger (B send B receive, D send D receive, ……P send P receive);

[0081] Step 10: 0° probe detection (zero degree rail head probe trigger of integrated rail head probe R);

[0082] Step 11: Right side probe of rail inner weld from small to large order trigger (B' send B' receive, D' send D' receive, ……P' send P' receive);

[0083] Step 12: 0° probe detection (zero degree rail head probe trigger of integrated rail head probe Q);

[0084] Step 13: Left side probe of rail outer weld from small to large order trigger (A send A receive, C send C receive, ……O send O receive);

[0085] Step 14: 0° probe detection (zero degree rail head probe trigger of integrated rail head probe R);

[0086] Step 15: Left side probe of rail inner weld from small to large order trigger (A' send A' receive, C' send C' receive, ……O' send O' receive);

[0087] Step 16: 0° probe detection (zero degree rail head probe trigger of integrated rail head probe Q);

[0088] After step 9 is completed, it returns to step 1 again, and the cycle is started again or the cycle program is completed.

[0089] During the above two cycles, the integrated rail surface probes Q and R can also be integrated into a whole, which includes one or more pairs of inclined rail surface probes and one or more zero-degree rail surface probes located in the middle of the multiple pairs of inclined rail surface probes, or it can include one or more pairs of inclined rail surface probes and one or more pairs of zero-degree rail surface probes. The triggering rules remain unchanged, and the movement direction of the rail side flaw detection probe 4 remains unchanged. Only the movement mode of the integrated rail surface probe 3 is changed from moving from both sides to the middle or from the middle to both sides to: the integrated rail surface probe 3 moves from one side to the other side in the length direction of the rail 2, and resets after reaching the set distance.

[0090] Example 3:

[0091] The dual-probe K-type detection method is mainly used, combined with the TOFD detection method: with the weld 1 as the center, multiple groups of rail side flaw detection probes are arranged on the inner and outer sides of the weld 1, and a pair of inclined rail surface probes are placed on the top surface of the rail 2. Each group of rail side flaw detection probes includes two rail side flaw detection probes 4 symmetrically arranged on the inner and outer surfaces of the rail 2. The weld area of ​​the rail 2 is inspected according to the set flaw detection rules; the multiple groups of rail side flaw detection probes on the inner and outer sides of the weld 1 and the pair of inclined rail surface probes are translated toward or away from each other along the length direction of the rail 2 to reach a set distance and then reset.

[0092] The set flaw detection rules are: triggering the rail side flaw detection probe 4 on the outer surface side of the rail 2 so that the rail side flaw detection probe 4 on the inner surface side of the rail 2 receives the corresponding ultrasonic signal; triggering the oblique rail surface probe on one side of the rail 2 so that the oblique rail surface probe on the other side of the rail 2 receives the corresponding ultrasonic signal; triggering the rail side flaw detection probe 4 on the other side of the outer surface of the rail 2 so that the rail side flaw detection probe 4 on the other side of the inner surface of the rail 2 receives the corresponding ultrasonic signal.

[0093] Dual probe combined with TOFD detection method:

[0094] Dual-probe method A and B display. Dual-probe method scanning mode: contact scanning, all shear wave probes follow the probe triggering rules and working status, with the weld centerline as the origin, and move symmetrically 100mm in opposite directions on both sides of the weld, and then move relative to each other to reset, completing a reflection method detection operation cycle.

[0095] Probe triggering sequence:

[0096] Step 1: The probes on the left side of the rail outer weld are triggered in order from small to large (A sends A', C sends C', ..., O sends O');

[0097] Step 2: Tread probe detection (the oblique rail probe of the integrated rail probe Q is sent out, and the oblique rail probe of the integrated rail probe P is received);

[0098] Step 3: The probes on the right side of the rail outer weld are triggered in order from small to large (B sends B', D sends D', ..., P sends P').

[0099] After step 3 is completed, it returns to step 1 and starts the cycle again until the cycle program ends.

[0100] In the second cycle, the order of sending and receiving can be changed. The steps are as follows:

[0101] Step 4: The probes on the right side of the rail outer weld are triggered in order from small to large (B sends B', D sends D', ..., P sends P').

[0102] Step 5: Tread probe detection (the oblique rail surface probe of the integrated rail surface probe R is sent out, and the oblique rail surface probe of the integrated rail surface probe Q is received);

[0103] Step 6: The probes on the left side of the rail outer weld are triggered in order from small to large (A sends A', C sends C', ... O sends O');

[0104] After step 6 is completed, it returns to step 1 and starts the cycle again or the cycle program ends.

[0105] During the above two cycles, the integrated rail surface probes Q and R can also be integrated into a whole, which includes one or more pairs of inclined rail surface probes and one or more zero-degree rail surface probes located in the middle of the multiple pairs of inclined rail surface probes, or it can include one or more pairs of inclined rail surface probes and one or more pairs of zero-degree rail surface probes. The triggering rules remain unchanged, and the movement direction of the rail side flaw detection probe 4 remains unchanged. Only the movement mode of the integrated rail surface probe 3 is changed from moving from both sides to the middle or from the middle to both sides to: the integrated rail surface probe 3 moves from one side to the other side in the length direction of the rail 2, and resets after reaching the set distance.

[0106] Example 4:

[0107] like Figure 6 As shown in FIG8 , the present invention also provides an embodiment of a device for implementing the above-mentioned rail weld ultrasonic flaw detection method, which includes probe brackets arranged on the rail surface, rail jaw, rail head side, rail waist and rail bottom, and the rail side flaw detection probe 4, the integrated rail surface probe 3, the oblique rail surface probe and the zero-degree rail surface probe are all fixed on the probe brackets.

[0108] In some embodiments, the probe bracket is a magnetic bracket that is detachably fixed to the rail 2 by magnetic attraction.

[0109] In some embodiments, the probe support includes a rail head probe support 5 for fixing the integrated rail head probe 3 or the oblique rail head probe or the zero-degree rail head probe, a rail head side probe support 6 for fixing the rail side probe 4 located at the rail head side, a first rail side probe support 7 for fixing the rail side probe 4 located at the rail jaw and the rail waist, a second rail side probe support 8 located below the first rail side probe support 7 for fixing the rail side probe 4 located at the rail bottom, and a rail bottom probe support 9 located below the second rail side probe support 8 for fixing the rail side probe 4 located at the rail bottom side.

[0110] The rail flaw detection method designed by the present application combines TOFD detection technology with various ultrasonic detection methods such as ultrasonic reflection method according to the geometric characteristics of the steel rail and the existing flaw detection process requirements, and can use the vehicle-mounted automatic detection equipment to detect the in-service rail weld, improve the work efficiency, detection rate and detection reliability, and has a wide application prospect. The present application is a special flaw detection program developed by using multi-channel flaw detection technology, which automatically switches the TOFD detection method, single probe reflection detection method and double probe detection method in a set of flaw detection program, selects a multi-channel digital ultrasonic flaw detector with multi-channel TOFD, multi-channel transceiver, multi-channel single reflection function, and uses the rail head and the rail head side, the rail head jaw side, the rail waist side, the rail waist and the rail bottom mechanism combination arc surface and the rail bottom inclined surface on both sides of the rail weld as the detection surface, uses the automatic flaw detection scanning frame to fix the multi-chip combined probe on the rail, and performs ultrasonic automatic flaw detection on the in-service rail butt weld according to the rules.

[0111] In summary, the present application arranges multiple pairs of rail side flaw detection probes on the inner and outer surfaces of the steel rail on both sides from bottom to top with the weld as the center, and different combinations of integrated rail surface probes, zero-degree rail surface probes and oblique rail surface probes, adopts TOFD detection method, single probe reflection detection method and double probe K type detection method, realizes all-around and multi-angle detection of the steel rail weld area. Whether it is longitudinal defects, transverse defects inside the weld, or defects at different depths, effective detection can be achieved, greatly reducing the risk of missed detection, ensuring the comprehensiveness and reliability of the steel rail weld quality detection. For example, the rail side flaw detection probe can effectively detect defects on the side surface and near surface of the weld, while the rail surface probe at different angles can deeply detect defects of different directions inside the weld, and the three detection methods complement each other to form a rigorous detection network. The TOFD detection method is based on the time difference principle of ultrasonic wave diffraction, which can accurately measure the height and position of the defect, and has high sensitivity to small defects; the single probe reflection detection method can analyze the nature and size of the defect through the characteristics of the reflected wave; the double probe K type detection method utilizes the interaction between the two probes, which can better detect some special types of defects, such as inclined defects. The three methods work together to analyze the detection data comprehensively, which can more accurately judge the real situation of the weld defects, avoid misjudgment or missed judgment due to the limitations of a single detection method, effectively improve the detection accuracy, and provide more reliable data support for the safe use of steel rails. Different types of probes and detection methods have unique detection advantages for different types of defects. For example, the oblique rail surface probe has remarkable effect in detecting inclined defects at a certain angle to the surface of the steel rail, while the zero-degree rail surface probe is better at detecting defects parallel to the surface of the steel rail. This flexible configuration of probes and detection methods according to the characteristics of the defects makes the flaw detection method adapt to various complex defect situations that may occur in the actual use of the steel rail weld, whether it is common defects such as pores, slag inclusion, incomplete fusion, or special defects such as fatigue cracks and stress corrosion cracks caused by long-term use, which can be effectively detected and identified, so as to discover and handle problems in time and ensure the safety of railway transportation. Arranging multiple pairs of rail side flaw detection probes and various rail surface probes on both sides of the weld can simultaneously detect multiple parts during one detection process. Compared with the traditional sequential detection of single probe or a small number of probes, the detection time is greatly shortened, and the detection efficiency is improved. Especially in the case of large-scale railway track maintenance or new steel rail laying acceptance, which requires a large amount of detection work, the efficient detection method can significantly reduce the detection period, reduce the impact on railway operation, and improve the overall efficiency of railway maintenance work. The three detection methods have their own clear flaw detection rules, namely the first flaw detection rule, the second flaw detection rule and the third flaw detection rule. This standardized operation process makes the flaw detection work have good repeatability, and different detection personnel can operate according to the same process and rules to obtain relatively consistent detection results.This not only helps to ensure the stability of the detection quality, but also facilitates the unified management and analysis of the detection data, provides convenient conditions for long-term tracking and evaluation of the rail weld quality, and helps to establish a scientific and reasonable rail maintenance management system.

[0112] Finally, it should be pointed out that the above embodiments are only more representative examples of the present application. Obviously, the present application is not limited to the above embodiments, but can also have many variations. Any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present application should be considered to be within the protection scope of the present application.

Claims

1. A rail weld ultrasonic flaw detection method, characterized by: It includes TOFD detection method, single probe reflection detection method and dual probe K-type detection method; The TOFD detection method comprises: arranging multiple pairs of rail side flaw detection probes located on the left and right sides of the rail (2) on both the outer surface of the rail (2) and the inner surface of the rail (2) from bottom to top, arranging at least one pair of oblique rail surface probes located on the left and right sides of the rail (2) on the top surface of the rail (2), and performing flaw detection on the weld area of ​​the rail (2) according to a first flaw detection rule; The single-probe reflection detection method comprises: arranging multiple pairs of rail side flaw detection probes located on the left and right sides of the rail (2) on both the outer surface of the rail (2) and the inner surface of the rail (2) from bottom to top, arranging at least one pair of oblique rail surface probes located on the left and right sides of the rail (2) and at least one zero-degree rail surface probe located between the at least one pair of oblique rail surface probes or at least one pair of zero-degree rail surface probes located on the left and right sides of the rail (2) on the top surface of the rail (2), and performing flaw detection on the weld area of ​​the rail (2) according to the second flaw detection rule; The dual-probe K-type detection method comprises: arranging multiple groups of rail side flaw detection probes on the inner and outer surfaces of the rail (2), each group of rail side flaw detection probes comprising two rail side flaw detection probes symmetrically arranged on the inner and outer surfaces of the rail (2), and performing flaw detection on the weld area of ​​the rail (2) according to a third flaw detection rule.

2. The rail weld ultrasonic flaw detection method according to claim 1, wherein: The TOFD detection method further comprises: translating at least one pair of the inclined rail surface probes in the same direction along the length direction of the rail (2) to a set distance and then resetting, or translating at least one pair of the inclined rail surface probes in opposite directions or opposite directions along the length direction of the rail (2) to a set distance and then resetting, and translating multiple pairs of the rail side flaw detection probes in opposite directions or opposite directions along the length direction of the rail (2) to a set distance and then resetting.

3. The rail weld ultrasonic flaw detection method according to claim 1, wherein: The single-probe reflection detection method further comprises: translating at least one zero-degree rail surface probe, or at least one pair of zero-degree rail surface probes and at least one pair of oblique rail surface probes in the same direction along the length direction of the rail (2) to a set distance and then resetting the probes; and translating multiple pairs of rail side flaw detection probes, at least one pair of zero-degree rail surface probes and at least one pair of oblique rail surface probes in opposite directions or opposite directions along the length direction of the rail (2) to a set distance and then resetting the probes.

4. The rail weld ultrasonic flaw detection method according to claim 1, wherein: The dual-probe K-type detection method further comprises: moving the plurality of rail side flaw detection probes in opposite directions or in opposite directions along the length direction of the rail (2) to a set distance and then resetting the probes.

5. The rail weld ultrasonic flaw detection method according to claim 1 or 2, wherein: The first flaw detection rule comprises: triggering the rail side flaw detection probe (4) on one side of the outer surface of the rail (2), so that the rail side flaw detection probe (4) on the other side of the outer surface of the rail (2) receives an ultrasonic signal corresponding thereto; triggering the rail side flaw detection probe (4) on one side of the inner surface of the rail (2), so that the rail side flaw detection probe (4) on the other side of the inner surface of the rail (2) receives an ultrasonic signal corresponding thereto; and triggering the oblique rail surface probe on one side of the rail (2), so that the oblique rail surface probe on the other side of the rail (2) receives an ultrasonic signal corresponding thereto.

6. The rail weld ultrasonic flaw detection method according to claim 1 or 3, wherein: The second flaw detection rule includes: triggering the rail side flaw detection probe (4) on one side of the outer surface of the rail (2), so that the triggered rail side flaw detection probe (4) receives the ultrasonic signal emitted by itself; triggering the rail side flaw detection probe (4) on the other side of the outer surface of the rail (2), so that the triggered rail side flaw detection probe (4) receives the ultrasonic signal emitted by itself; Triggering the rail side flaw detection probe (4) on one side of the inner surface of the rail (2) so that the triggered rail side flaw detection probe (4) receives the ultrasonic signal emitted by itself; triggering the rail side flaw detection probe (4) on the other side of the inner surface of the rail (2) so that the triggered rail side flaw detection probe (4) receives the ultrasonic signal emitted by itself; Triggering the inclined rail surface probe on one side of the top surface of the rail (2) so that the triggered inclined rail surface probe receives the ultrasonic signal emitted by itself, and triggering the inclined rail surface probe on the other side of the top surface of the rail (2) so that the triggered inclined rail surface probe receives the ultrasonic signal emitted by itself; Trigger at least one of the zero-degree rail surface probes located between at least one pair of the oblique rail surface probes, so that the triggered zero-degree rail surface probe receives the ultrasonic signal emitted by itself; or sequentially trigger at least one pair of the zero-degree rail surface probes located on the left and right sides of the top surface of the rail (2), so that the triggered zero-degree rail surface probe receives the ultrasonic signal emitted by itself.

7. The rail weld ultrasonic flaw detection method according to claim 1 or 4, characterized in that: The third flaw detection rule includes: triggering the rail side flaw detection probe (4) on one side of the outer surface of the rail (2) so that the rail side flaw detection probe (4) on the inner surface of the rail (2) receives an ultrasonic signal corresponding thereto; triggering the rail side flaw detection probe (4) on the other side of the outer surface of the rail (2) so that the rail side flaw detection probe (4) on the other side of the inner surface of the rail (2) receives an ultrasonic signal corresponding thereto; triggering the rail side flaw detection probe (4) on one side of the inner surface of the rail (2) so that the rail side flaw detection probe (4) on the outer surface of the rail (2) receives an ultrasonic signal corresponding thereto; triggering the rail side flaw detection probe (4) on the other side of the inner surface of the rail (2) so that the rail side flaw detection probe (4) on the other side of the outer surface of the rail (2) receives an ultrasonic signal corresponding thereto.

8. A device for implementing the rail weld ultrasonic flaw detection method according to any one of claims 1 to 7, characterized in that: It comprises probe brackets arranged on the rail surface, the side of the rail head, the rail jaw, the rail waist and the rail bottom, wherein the rail side flaw detection probe (4), the inclined rail surface probe and the zero-degree rail surface probe are all fixed on the probe brackets.

9. A device for implementing the method for ultrasonic flaw detection of rail welds according to claim 8, characterized in that: The probe bracket is a magnetic bracket that is detachably fixed to the steel rail (2) by magnetic attraction.

10. A device for implementing the method for ultrasonic flaw detection of rail welds according to claim 9, characterized in that: The probe bracket comprises a rail surface probe bracket (5) for fixing the inclined rail surface probe or the zero-degree rail surface probe or fixing the inclined rail surface probe and the zero-degree rail surface probe at the same time; a rail head side probe bracket (6) for fixing the rail side flaw detection probe (4) located on the side of the rail head; a first rail side probe bracket (7) for fixing the rail side flaw detection probe (4) located on the rail jaw and the rail waist; a second rail side probe bracket (8) located below the first rail side probe bracket (7) for fixing the rail side flaw detection probe (4) located on the rail bottom; and a rail bottom probe bracket (9) located below the second rail side probe bracket (8) for fixing the rail side flaw detection probe (4) located on the side of the rail bottom.

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