Wheel flaw detection device and flaw detection method

Abstract

This application relates to a wheel flaw detection device and method. The wheel flaw detection device includes a flaw detection carriage, at least one wheel-finding detection component, multiple positioning detection components, and a control module. The wheel-finding detection component is disposed on the flaw detection carriage and is used to acquire the identification position information of the wheel to be inspected. Multiple positioning detection components are also disposed on the flaw detection carriage and are used to acquire the identification position information of the wheel to be inspected. At least two positioning detection components are located on opposite sides of the wheel-finding detection component, and the distances between the two positioning detection components and the wheel-finding detection component are equal in the extension direction of the travel rail. The control module stores the wheel-finding chord length R of the wheel to be inspected. The wheel flaw detection device provided by this application, through a primary coarse positioning by the wheel-finding detection component and a secondary fine positioning by multiple positioning detection components, can ensure the alignment accuracy between the flaw detection carriage and the wheel axle position of the wheel to be inspected, enabling the flaw detection carriage to smoothly perform the flaw detection operation of the wheel to be inspected, and improving the reliability and safety of the wheel flaw detection device.

Description

Technical Field

[0001] This application relates to the field of railway flaw detection equipment technology, and in particular to a wheel flaw detection device and flaw detection method. Background Technology

[0002] Currently, in online train wheel flaw detection, a flaw detection robot travels along a small rail laid under the train. The robot is equipped with a flaw detection probe. When the robot reaches the wheelset to be inspected, the probe performs flaw detection. Specifically, the robot moves along the laid rail and automatically locates the wheel. After successfully locating the wheel, it stops, and the clamping arm extends to support the rail and retracts to hold the wheelset to be inspected. The wheelset is passively detached from the rail, and the flaw detection probe comes into contact with the wheel to perform flaw detection.

[0003] The photoelectric detection probe (wheel-finding sensor) is typically positioned at the center of the flaw detection cart. When the flaw detection robot moves along the laid track and the photoelectric detection probe detects an obstruction signal, the robot continues moving for 0.5 "wheel-finding chord lengths" before stopping. The "wheel-finding chord length" is the chord length track scanned by the photoelectric detection probe on the flaw detection robot as it moves, from one wheel rim to the wheel spoke and then away from the other rim. It is a set of theoretical data, defined as R, theoretically calculated based on the size of the wheel under inspection and the installation position of the wheel-finding sensor, and stored in the control module. However, due to the different wear and repair levels of each wheel, the wheel diameters also vary. Furthermore, the wear of the small rails that guide the flaw detection robot can also cause changes in the robot's trajectory. Due to these factors, in most cases, the photoelectric detection probe cannot be completely positioned at the preset wheel axle position even after moving 0.5 "wheel chord lengths". This leads to alignment failure of the flaw detection robot, the risk of the clamping arm mechanism colliding with the wheel under inspection during extension, the inability to perform flaw detection on the wheel under inspection, and even damage to the flaw detection robot. Summary of the Invention

[0004] Therefore, it is necessary to provide a wheel flaw detection device and method to address the problem of misalignment of flaw detection robots in existing online train wheel inspection processes.

[0005] A wheel flaw detection device, the wheel flaw detection device comprising:

[0006] A flaw detection trolley is installed in the inspection trench and can move along a travel rail;

[0007] At least one wheel-finding detection device is provided on the flaw detection trolley and is used to obtain the identification position information of the wheel to be inspected;

[0008] Multiple positioning detection devices are provided on the flaw detection trolley to obtain the identification position information of the wheel to be inspected. At least two of the positioning detection devices are located on opposite sides of the wheel finding detection device, and the distance between the two positioning detection devices and the wheel finding detection device is equal in the extension direction of the travel rail.

[0009] The control module stores the wheel chord length R of the wheel to be inspected and is communicatively connected to the flaw detection trolley, the wheel detection component, and the positioning detection component.

[0010] In one embodiment, the wheel flaw detection device further includes a lifting mechanism and a wheel lifting and rotating assembly;

[0011] The lifting mechanism is used to lift the flaw detection trolley until the lifting wheel assembly is above the rail surface;

[0012] The wheel-lifting assembly is disposed on the lifting mechanism and is used to hook onto the rail and lift the wheel to be inspected.

[0013] In one embodiment, the lifting wheel assembly includes a hook-and-rail module and a clamping wheel lifting module;

[0014] The hook-claw rail-connecting module includes two sets of hooks, which are spaced apart along a direction perpendicular to the extension of the traveling rail, and the hooks can hook onto the rail.

[0015] The wheel clamping and lifting module includes two sets of clamping arms and rotating guide wheels disposed at the ends of the clamping arms. The two sets of clamping arms are spaced apart along a direction perpendicular to the travel rail. The rotating guide wheels can contact the wheel to be inspected and lift the wheel to be inspected.

[0016] In one embodiment, the rotating guide wheel is fitted with a bushing, and the two positioning detection elements are respectively disposed on the two bushings.

[0017] In one embodiment, the positioning detection element is disposed on the side of the bushing near the center of the flaw detection trolley.

[0018] In one embodiment, the wheel-finding detection component can emit detection light toward one side of the wheel to be inspected in order to obtain the identification position information of the wheel to be inspected.

[0019] The positioning detection component can emit detection light towards one side of the wheel to be inspected, in order to obtain the identification position information of the wheel to be inspected.

[0020] In one embodiment, the wheel-finding detection component is positioned on the centerline of the flaw detection trolley along the extension direction of the traveling track.

[0021] A method for detecting flaws in a wheel flaw detector as described in any of the above technical solutions, the method comprising the following steps:

[0022] The control module controls the flaw detection trolley to move along the extension direction of the travel track;

[0023] When the flaw detection carriage moves to the point where the wheel finding detection component first senses the wheel flange of the wheel to be inspected, the wheel finding detection component outputs a first detection signal and feeds it back to the control module, and the control module records the position of the flaw detection carriage as W1;

[0024] The control module drives the flaw detection carriage to continue moving to position W2. If |W2-W1|=R / 2, the control module controls the flaw detection carriage to stop in order to perform a coarse positioning of the flaw detection carriage.

[0025] In one embodiment, the flaw detection method further includes the following steps:

[0026] The two positioning detection elements sense whether they are blocked by the wheel to be inspected;

[0027] If both positioning detection devices sense that they are not blocked by the wheel to be inspected, a second detection signal is fed back to the control module, indicating that the secondary fine positioning of the flaw detection trolley is successful. The control module then controls the flaw detection trolley to perform flaw detection on the wheel to be inspected.

[0028] If at least one of the two positioning detection elements is blocked by the wheel under inspection, a third detection signal is fed back to the control module, indicating that the flaw detection trolley is at risk of colliding with the wheel under inspection, and the flaw detection trolley needs to be adjusted again or the flaw detection process needs to be manually intervened.

[0029] In one embodiment, if one of the two positioning detection devices is blocked by the wheel to be inspected, a fourth detection signal is fed back to the control module. The control module drives the flaw detection trolley to make fine adjustments along the extension direction of the travel rail until both positioning detection devices are not blocked by the wheel to be inspected and feed back a second detection signal to the control module. The control module then continues to control the flaw detection trolley to perform flaw detection on the wheel to be inspected.

[0030] If both positioning detection components are sensed to be blocked by the wheel under inspection, a fifth detection signal is fed back to the control module, requiring manual intervention in the flaw detection process.

[0031] The aforementioned wheel flaw detection device and method involve a control module that controls the flaw detection trolley to move along the extension direction of the travel rail. When the flaw detection trolley reaches the wheel flange of the wheel to be inspected and is first sensed by the wheel-finding detection component, the wheel-finding detection component outputs a first detection signal and feeds it back to the control module. The control module records the position of the flaw detection trolley and drives it to continue moving R / 2 before stopping, completing the first coarse positioning of the flaw detection trolley. Then, two positioning detection components sense whether they are obstructed by the wheel to be inspected. If both positioning detection components sense that they are not obstructed by the wheel to be inspected, a second detection signal is fed back to the control module, indicating that the second fine positioning of the flaw detection trolley is successful. The control module then controls the flaw detection trolley to perform flaw detection on the wheel to be inspected. If at least one of the two positioning detection components senses that it is obstructed by the wheel to be inspected, a third detection signal is fed back to the control module, indicating that there is a risk of the flaw detection trolley colliding with the wheel to be inspected, requiring secondary adjustment of the flaw detection trolley or manual intervention in the flaw detection process. The wheel flaw detection device provided in this application, through a coarse positioning of the wheel-finding detection component and a secondary fine positioning of multiple positioning detection components, can ensure the alignment accuracy between the flaw detection carriage and the wheel axle position of the wheel to be inspected. During the inspection process, the components on the flaw detection carriage will not experience adverse phenomena such as collision, overload, jamming, or overturning, enabling the flaw detection carriage to smoothly carry out the flaw detection operation of the wheel to be inspected, and improving the stability, reliability, and safety of the wheel flaw detection device. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the wheel flaw detection device provided in some embodiments.

[0033] Figure 2 This is a schematic diagram of the wheel flaw detection device provided in some embodiments.

[0034] Figure 3 for Figure 2 A magnified view of a portion of region A in the middle.

[0035] Figure 4 This is a schematic diagram illustrating the interaction between the wheel flaw detection device provided in some embodiments and the wheel to be inspected during the flaw detection process.

[0036] Figure 5 This is a flowchart illustrating the flaw detection method provided in some embodiments.

[0037] Figure label:

[0038] 100. Wheel flaw detection device;

[0039] 110. Flaw detection carriage; 120. Wheel finding inspection component; 130. Positioning inspection component; 131. First positioning inspection component; 132. Second positioning inspection component; 140. Wheel lifting and rotating assembly; 141. Hook and claw rail mounting module; 1411. Hook and claw; 142. Wheel clamping and lifting module; 1421. Clamping arm; 1422. Rotating guide wheel; 1423. Bushing; 150. Hydraulic module;

[0040] 200. Inspection trench; 300. Travel rail; 400. Wheel to be inspected; 500. Steel rail. Detailed Implementation

[0041] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0042] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0043] Furthermore, where the terms "first" and "second" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0044] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0045] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0046] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.

[0047] The technical solutions provided by the embodiments of this application are described below with reference to the accompanying drawings.

[0048] See Figures 1-4As shown, this application provides a wheel flaw detection device 100, which includes a flaw detection trolley 110, at least one wheel-finding detection element 120, multiple positioning detection elements 130, and a control module (not shown in the figure). The wheel flaw detection device 100 is used to automatically detect flaws in the wheel 400 to be inspected. It is understood that the above-mentioned wheel flaw detection device 100 can be applied to the online flaw detection of EMU train wheels, and can also be applied to the online flaw detection of locomotive wheels and subway wheels, etc. Generally, the maintenance area of ​​the rail train has a detection trench 200, and the detection trench 200 has a traveling rail 300 for the movement of the wheel flaw detection device 100. The edges of the detection trench 200 have rails 500 for the rail train to travel on. The wheel flaw detection device 100 on the traveling rail 300 can perform flaw detection on the wheel 400 to be inspected on the rail 500.

[0049] The flaw detection trolley 110 is installed in the inspection trench 200, and the flaw detection trolley 110 can move along the travel rail 300. For example, see [reference needed]. Figure 1 As shown, the inspection trench 200, the travel rail 300, and the steel rail 500 all extend towards direction A. There are generally two steel rails 500, spaced apart along direction B. When the railcar travels on the steel rails 500, the theoretical center of the two wheels 400 to be inspected coincides with the center of the steel rail 500. Since the travel rail 300 extends towards direction A, when the flaw detection trolley 110 moves along the travel rail 300, the wheel flaw detection device 100 can perform flaw detection on the wheels 400 to be inspected.

[0050] A wheel-finding detection component 120 is disposed on the flaw detection cart 110. The wheel-finding detection component 120 is used to acquire the position information to be identified of the wheel 400 to be inspected. For example, in this embodiment, the wheel-finding detection component 120 is a photoelectric detection sensor. When the wheel-finding detection component 120 emits visible light and illuminates the wheel 400 to be inspected, the visible light is reflected and received by the wheel-finding detection component 120. If the intensity of the visible light received by the wheel-finding detection component 120 exceeds a preset threshold, the wheel-finding detection component 120 outputs a switch signal, analog signal, or other means to the control module, indicating that the wheel-finding detection component 120 has moved to the vicinity of the wheel 400 to be inspected. The wheel-finding detection component 120 acquires the position information to be identified of the wheel 400 to be inspected in a non-contact manner, thus avoiding the undesirable phenomenon of collision between the wheel-finding detection component 120 and the wheel 400 to be inspected. The position information to be identified by the wheel-finding detection component 120 refers to the positions of the two wheel flanges of the wheel 400 to be inspected.

[0051] Multiple positioning detection elements 130 are disposed on the flaw detection carriage 110. The positioning detection elements 130 are used to acquire the position information of the wheel 400 to be inspected. At least two positioning detection elements 130 are located on opposite sides of the wheel-finding detection element 120, and the distance between the two positioning detection elements 130 and the wheel-finding detection element 120 is equal in the extending direction of the travel rail 300. For example, see [reference needed]. Figure 4 As shown, the two positioning detection elements 130 are defined as the first positioning detection element 131 and the second positioning detection element 132. The distance between the first positioning detection element 131 and the wheel-finding detection element 120 is L1, and the distance between the second positioning detection element 132 and the wheel-finding detection element 120 is L2, where L1=L2. Furthermore, the positioning detection element 130 is a photoelectric detection sensor. When the positioning detection element 130 emits visible light and illuminates the wheel 400 to be inspected, the visible light is emitted and received by the positioning detection element 130. If the intensity of the visible light received by the positioning detection element 130 exceeds a preset threshold, the positioning detection element 130 outputs a switch signal, analog signal, or other means to the control module to assist the wheel-finding detection element 120 in obtaining the position information of the flaw detection carriage 110 in a non-contact manner, so as to adjust the flaw detection carriage 110 to be aligned with the axle center position of the wheel 400 to be inspected. The position information to be identified by the positioning detection element 130 is the position of the wheel flange and rim of the wheel 400 to be inspected.

[0052] The control module stores the wheel chord length R of the wheel 400 to be inspected, and is communicatively connected to the flaw detection carriage 110, the wheel detection component 120, and the positioning detection component 130. The control module can communicate with these components via cables, Wi-Fi, Bluetooth, etc. In this embodiment, the control module is an integrated module of a host computer (such as a computer or mobile phone) and a programmable logic controller (PLC). The host computer can communicate with and process the instructions of the flaw detection carriage 110 during the flaw detection process and send instructions to the PLC, which then controls the movement and detection actions of the flaw detection carriage 110. For example, the control module can control the flaw detection carriage 110 to move along the travel rail 300. When the flaw detection carriage 110 moves to the wheel rim of the wheel 400 to be inspected for the first time, the wheel rim detection device 120 outputs a first detection signal and feeds it back to the control module. The control module records the position of the flaw detection carriage 110 and drives the flaw detection carriage 110 to continue moving R / 2 and then stop, completing one coarse positioning of the flaw detection carriage 110. Then, it checks whether the first positioning detection device 131 and the second positioning detection device 132 are blocked by the wheel 400 to be inspected. If both positioning detection devices are blocked, the control module checks whether the first positioning detection device 131 and the second positioning detection device 132 are blocked by the wheel 400 to be inspected. If all the test pieces 130 are not obstructed by the wheel 400 under inspection, a second detection signal is fed back to the control module, indicating that the secondary fine positioning of the flaw detection carriage 110 is successful. The control module then controls the flaw detection carriage 110 to perform flaw detection on the wheel 400 under inspection. If at least one of the first positioning test pieces 131 and the second positioning test pieces 132 is obstructed by the wheel 400 under inspection, a third detection signal is fed back to the control module, indicating that there is a risk of the flaw detection carriage 110 colliding with the wheel 400 under inspection. The flaw detection carriage 110 needs to be adjusted again or the flaw detection process needs to be manually intervened.

[0053] The aforementioned wheel flaw detection device 100, through the primary coarse positioning of the wheel-finding detection component 120 and the secondary fine positioning of multiple positioning detection components 130, can ensure the alignment accuracy between the flaw detection carriage 110 and the wheel axle position of the wheel to be inspected 400. During the flaw detection process, the components on the flaw detection carriage 110 will not experience adverse phenomena such as collision, overload, jamming, or overturning, allowing the flaw detection carriage 110 to smoothly carry out the flaw detection operation of the wheel to be inspected 400, and improving the stability, reliability, and safety of the wheel flaw detection device 100.

[0054] In one embodiment, see Figures 1-4As shown, the wheel flaw detection device 100 also includes a lifting mechanism (not shown) and a wheel lifting and rotating assembly 140. The lifting mechanism is used to lift the flaw detection trolley 110 to a height slightly above the rail surface of the rail 500 (this height is preset by the control module). Since the flaw detection trolley 110 moves on the traveling rail 300, in order to avoid the risk of collision between the flaw detection trolley 110 and the rail train, the height of the wheel lifting and rotating assembly 140 of the flaw detection trolley 110 is lower than the bearing surface of the rail 500. Therefore, after the wheel finding detection component 120 completes the wheel finding, that is, after the first coarse positioning of the flaw detection trolley 110 is completed, the lifting mechanism needs to lift the wheel lifting and rotating assembly 140 to a height above the rail surface of the rail 500. At this time, the positioning detection component 130 can illuminate the wheel 400 to be inspected, and the second fine positioning of the flaw detection trolley 110 by the positioning detection component 130 can continue. A wheel-lifting and rotating assembly 140 is disposed on the flaw detection trolley 110. The wheel-lifting and rotating assembly 140 is used to hook onto the rail 500 and lift the wheel 400 to be inspected. In this embodiment, the wheel-lifting and rotating assembly 140 communicates or is connected to the control module via I / O. After the flaw detection trolley 110 completes its secondary precision positioning, the control module controls the wheel-lifting and rotating assembly 140 to hook onto the rail 500, keeping the flaw detection trolley 110 in this position to perform flaw detection on the wheel 400. At the same time, the wheel-lifting and rotating assembly 140 lifts the wheel 400 to be inspected, causing the wheel 400 to be passively detached from the rail 500 and rotate, so as to perform flaw detection on the tread of the wheel 400.

[0055] Specifically, see Figures 1-4 As shown, the wheel-lifting assembly 140 includes a hook-and-rail module 141 and a wheel-clamping lifting module 142. The hook-and-rail module 141 includes two sets of hooks 1411, which are spaced apart along the direction extending from the vertical travel rail 300. The hooks 1411 can hook onto the rail 500 to hold the flaw detection trolley 110 at a preset position on the axle of the wheel 400 to be inspected for flaw detection, ensuring the stability and reliability of the flaw detection results of the wheel 400. For example, see [reference needed]. Figure 1 and Figure 2 As shown, the two sets of hooks 1411 along Figure 1 The hooks are spaced apart along direction B, and each group of hooks 1411 includes two hooks 1411, with the two hooks 1411 along... Figure 1As shown in direction A, a hydraulic module 150 is installed on the flaw detection trolley 110. The hydraulic module 150 is connected to each hook 1411 in a transmission manner. The hydraulic module 150 can drive the two sets of hooks 1411 to move in opposite directions or towards each other. When flaw detection is required on the wheel 400 to be inspected, the hydraulic module 150 drives the two sets of hooks 1411 to move in opposite directions and hook onto the rail 500 to achieve hooking and fixation of the flaw detection trolley 110 on the rail 500. Conversely, after the flaw detection of the wheel 400 to be inspected is completed, the hydraulic module 150 drives the two sets of hooks 1411 to move towards each other to separate from the rail 500, so that the flaw detection trolley 110 can continue to move along the travel rail 300 to other wheels 400 to be inspected for further flaw detection.

[0056] Furthermore, the clamping wheel lifting module 142 includes two sets of clamping arms 1421 and rotating guide wheels 1422 disposed at the ends of the clamping arms 1421. The two sets of clamping arms 1421 are spaced apart along the direction extending from the vertical travel rail 300. When the two sets of clamping arms 1421 retract to a set value, the rotating guide wheels 1422 can contact the wheel 400 to be inspected and lift the wheel 400 to be inspected. The rotating guide wheels 1422 can actively rotate under the control of the control module, and drive the wheel 400 to be inspected to rotate, thereby completing the flaw detection operation of the wheel 400 to be inspected by the flaw detection probe. For example, see [reference needed]. Figure 1 and Figure 2 As shown, the two sets of clamping arms 1421 along Figure 1 The clamping arms 1421 are spaced apart along direction B, and each set of clamping arms 1421 includes two clamping arms 1421, with the two clamping arms 1421 along... Figure 1 As shown in direction A, the hydraulic module 150 is driven to each clamping arm 1421. The hydraulic module 150 can drive the two sets of clamping arms 1421 to move in opposite directions or towards each other. When it is necessary to perform flaw detection on the wheel 400 to be inspected, the hydraulic module 150 drives the two sets of clamping arms 1421 to move in opposite directions to move to below the wheel 400 to be inspected. The wheel 400 to be inspected is lifted by rotating guide wheel 1422. The wheel 400 to be inspected is passively separated from the rail 500 and passively rotated under the drive of rotating guide wheel 1422 to perform flaw detection on the tread of the wheel 400 to be inspected. Conversely, after the flaw detection of the wheel 400 to be inspected is completed, the hydraulic module 150 drives the two sets of clamping arms 1421 to move towards each other to separate from the wheel 400 to be inspected, so that the flaw detection trolley 110 can continue to move along the travel rail 300 to other wheels 400 to be inspected to continue flaw detection.

[0057] Specifically, see Figures 1-4As shown, the rotating guide wheel 1422 is fitted with a bushing 1423, and two positioning detection elements 130 are respectively disposed on the two bushings 1423. In this way, with the rotating guide wheel 1422 fitted with the bushing 1423, the rotating guide wheel 1422 will not drive the bushing 1423 to rotate during rotation, thereby fixing the positioning detection elements 130 and facilitating the positioning detection elements 130 to perform the positioning and identification operation of the wheel 400 to be inspected in a stationary state.

[0058] When there are two positioning detection elements 130, the two positioning detection elements 130 can be set along the... Figure 1 The two bushings 1423 are spaced apart in direction A as shown; when there are two positioning detection elements 130, the two positioning detection elements 130 can also be set on the two bushings 1423 installed diagonally.

[0059] Further, see Figure 2 and Figure 3 As shown, the positioning detection element 130 is positioned on the side of the bushing 1423 near the center of the flaw detection carriage 110, resulting in a relatively large distance between the positioning detection element 130 and the wheel 400 to be inspected. Since the rotating guide wheel 1422 needs to move towards the side closest to the wheel 400 during flaw detection, positioning the positioning detection element 130 near the center of the flaw detection carriage 110 allows for detection and determination of whether there is positional interference between the positioning detection element 130 and the wheel 400. This ensures that the rotating guide wheel 1422 extends smoothly and lifts the wheel 400 to be inspected, while also protecting the positioning detection element 130.

[0060] In one embodiment, see Figures 1-4 As shown, the wheel-finding detection component 120 emits detection light towards the wheel 400 to be inspected. The wheel-finding detection component 120 is used to acquire the position information of the wheel 400 to be inspected. For example, the wheel-finding detection component 120 is a photoelectric detection sensor. When the wheel-finding detection component 120 emits visible light and illuminates the wheel 400 to be inspected, the visible light is reflected and received by the wheel-finding detection component 120. If the intensity of the visible light received by the wheel-finding detection component 120 exceeds a preset threshold, the wheel-finding detection component 120 outputs a value to control the module in the form of a switch signal, analog signal, etc., indicating that the wheel-finding detection component 120 has moved to the vicinity of the wheel 400 to be inspected. Furthermore, the wheel-finding detection component 120 acquires the position information of the wheel 400 to be inspected in a non-contact manner, thus avoiding the adverse phenomenon of collision between the wheel-finding detection component 120 and the wheel 400 to be inspected.

[0061] Furthermore, the positioning detection element 130 can emit detection light towards the side of the wheel 400 to be inspected. The positioning detection element 130 is used to obtain the position information of the wheel 400 to be inspected. For example, the positioning detection element 130 is a photoelectric detection sensor. When the positioning detection element 130 emits visible light and illuminates the wheel 400 to be inspected, the visible light is emitted and received by the positioning detection element 130. If the intensity of the visible light received by the positioning detection element 130 exceeds a preset threshold, the positioning detection element 130 outputs to the control module in the form of a switch signal, analog signal, etc., so as to assist the wheel finding detection element 120 in obtaining the position information of the flaw detection carriage 110 in a non-contact manner, so as to adjust the flaw detection carriage 110 to a position that will not collide with the wheel 400 to be inspected.

[0062] In one embodiment, see Figures 1-4 As shown, the wheel-finding detection component 120 is positioned on the centerline of the flaw detection trolley 110 along the extension direction of the travel rail 300. This ensures that, on the one hand, the wheel-finding detection component 120 will not collide with the wheel 400 to be inspected during the movement of the flaw detection trolley 110, effectively protecting the flaw detection safety of the wheel flaw detection device 100. On the other hand, the movement path of the wheel-finding detection component 120 is determined, and it can acquire the identification position information of the wheels 400 to be inspected on both the left and right sides, ensuring the reliability of the wheel-finding position information.

[0063] Additionally, see Figures 1-5 As shown, this application also provides a flaw detection method, which is applied to a wheel flaw detection device 100 to automatically detect flaws in the wheel 400 to be inspected. The flaw detection method includes the following steps:

[0064] Step S110: The control module controls the flaw detection carriage 110 to move along the extension direction of the travel rail 300. The control module stores the wheel chord length R of the wheel 400 to be inspected, and controls the flaw detection carriage 110 to move forward or backward to the vicinity of the wheel 400 to be inspected.

[0065] Step S120: When the flaw detection carriage 110 moves to the point where the wheel-finding detection component 120 first senses the flange of the wheel 400 to be inspected, the wheel-finding detection component 120 outputs a first detection signal and feeds it back to the control module. The control module records the position of the flaw detection carriage 110 as W1. Specifically, when the flaw detection carriage 110 moves along the travel rail 300 to the point where the wheel-finding detection component 120 first senses the flange of the wheel 400 to be inspected, the output signal of the wheel-finding detection component 120 changes abruptly, indicating that the wheel-finding detection component 120 has detected the flange position of the wheel 400 to be inspected and feeds the position information back to the control module. The control module records the position of the flaw detection carriage 110 as W1.

[0066] Step S130: The control module drives the flaw detection carriage 110 to continue moving to position W2. If |W2-W1| = R / 2, the control module stops the flaw detection carriage 110 to perform a coarse positioning of the flaw detection carriage 110. The control module has a built-in displacement measuring counter, which can be an encoder, meter counter, etc., and its output signal can be a digital pulse signal, digital communication signal, etc. After the wheel detection component 120 first senses the wheel flange position, the control module drives the flaw detection carriage 110 to move slowly. The displacement measuring counter measures the movement distance of the flaw detection carriage 110. After the flaw detection carriage 110 moves to the position |W2-W1| = R / 2, the displacement measuring counter feeds back a signal to the control module, and the control module immediately applies the brake to the flaw detection carriage 110 to stop it. The coarse positioning of the flaw detection carriage 110 is successful.

[0067] Due to the different wear and repair levels of each wheel 400 to be inspected, the diameter of each wheel 400 to be inspected is also different. In addition, the wear of the travel rail 300 that allows the flaw detection trolley 110 to travel will also cause changes in the travel trajectory of the flaw detection trolley 110 (the flaw detection trolley 110 slips), resulting in deviations in the displacement data of the flaw detection trolley 110 measured by the displacement measuring counter. Due to the above factors, in most cases, the movement of the wheel detection component 120 by R / 2 cannot completely avoid the risk of the flaw detection trolley 110 colliding with the wheel 400 to be inspected during the subsequent inspection process. If the wheel lifting and rotating assembly 140 is forcibly executed to hook and lift the wheel 400 to be inspected, the wheel lifting and rotating assembly 140 will collide with the rim or spoke of the wheel 400 to be inspected. If the rotating guide wheel 1422 extends and touches the rim or spoke of the wheel 400 to be inspected, it will cause damage to the wheel flaw detection device 100. Based on this, after performing the above steps S110, S120 and S130, the flaw detection method also includes the following steps:

[0068] Step S140: The two positioning detection elements 130 sense whether they are obstructed by the wheel 400 to be inspected. It should be noted that before the two positioning detection elements 130 perform secondary fine positioning, the main body of the flaw detection trolley 110 needs to be lifted by the lifting mechanism to a position exceeding the rail surface 500, in preparation for the subsequent secondary fine positioning of the two positioning detection elements 130.

[0069] If both positioning detection elements 130 sense that they are not blocked by the wheel 400 under inspection, such as the first positioning detection element 131 and the second positioning detection element 132 sense that they are not blocked by the wheel 400 under inspection, then the second detection signal is fed back to the control module, indicating that the flaw detection carriage 110 has successfully performed secondary fine positioning. The control module then controls the flaw detection carriage 110 to perform flaw detection on the wheel 400 under inspection.

[0070] Conversely, if at least one of the two positioning detection elements 130 is blocked by the wheel 400 under inspection, a third detection signal is fed back to the control module, indicating that the flaw detection carriage 110 is at risk of colliding with the wheel 400 under inspection. This necessitates secondary adjustments to the flaw detection carriage 110 or manual intervention in the flaw detection process. Thus, by using the two positioning detection elements 130 for secondary precision positioning, the alignment accuracy between the flaw detection carriage 110 and the wheel axle position of the wheel-finding detection element 120 can be ensured, improving the reliability of flaw detection of the wheel 400 under inspection.

[0071] Specifically, if one of the two positioning detection elements 130 is blocked by the wheel 400 under inspection, a fourth detection signal is sent to the control module. The control module then drives the flaw detection carriage 110 to make minor adjustments along the extension direction of the travel rail 300 until both positioning detection elements 130 are no longer blocked by the wheel 400 under inspection and send a second detection signal back to the control module. The control module then continues to control the flaw detection carriage 110 to perform flaw detection on the wheel 400 under inspection. For example, if the flaw detection carriage 110 moves along... Figure 4 As shown, the movement proceeds from left to right. If the first positioning detection element 131 senses that it is blocked by the wheel 400 under inspection, while the second positioning detection element 132 senses that it is not blocked by the wheel 400 under inspection, then the flaw detection carriage 110 is fed back to a preset position on the axle of the wheel 400 under inspection (the flaw detection position of the flaw detection carriage 110 relative to the wheel 400 under inspection). The control module drives the flaw detection carriage 110 to slowly retreat a short distance for secondary fine positioning, so that the rotating guide wheel 1422 can extend smoothly and lift the rotating wheel 400 under inspection. 10. Perform tread flaw detection on the wheel 400 to be inspected; if the first positioning detection element 131 is not blocked by the wheel 400 to be inspected, but the second positioning detection element 132 is blocked by the wheel 400 to be inspected, then the flaw detection carriage 110 is delayed behind the preset position of the wheel axle of the wheel 400 to be inspected. The control module drives the flaw detection carriage 110 to slowly advance a short distance to perform secondary fine positioning, so that the rotating guide wheel 1422 can extend smoothly and lift the rotating wheel 400 to be inspected. The flaw detection carriage 110 performs tread flaw detection on the wheel 400 to be inspected.

[0072] Furthermore, if both positioning detection elements 130 sense that they are obstructed by the wheel 400 under inspection, a fifth detection signal is sent to the control module, requiring manual intervention in the flaw detection process. Specifically, if both positioning detection elements 130 sense that they are obstructed by the wheel 400 under inspection, the control module determines that the wheel flaw detection device 100 is malfunctioning. This could be due to interference from foreign objects in the working environment or a fault in the wheel flaw detection device 100. In this case, the control module reports the abnormality to the human-machine interface system and stops the flaw detection operation on the wheel 400 under inspection until manual intervention resolves the issue, at which point the flaw detection operation on the wheel 400 under inspection resumes.

[0073] In the above-mentioned flaw detection method, the wheel-finding detection component 120 completes the first coarse positioning of the wheel 400 to be inspected. If the wheel-finding detection component 120 directly achieves the alignment of the flaw detection carriage 110 with the preset position of the wheel axle of the wheel 400 to be inspected during the first coarse positioning process, there is no need to perform the second fine positioning of the positioning detection component 130. This ensures that the rotating guide wheel 1422 can extend smoothly and lift and rotate the wheel 400 to be inspected, and the flaw detection carriage 110 performs tread flaw detection on the wheel 400 to be inspected. If, after the wheel-finding detection component 120 completes the first coarse positioning of the wheel 400 to be inspected, at least one of the two positioning detection components 130 is blocked by the wheel 400 to be inspected, the control module drives the flaw detection carriage 110 to make fine adjustments to complete the second fine positioning of the wheel 400 to be inspected. Through the first coarse positioning of the wheel-finding detection component 120 and the second fine positioning of multiple positioning detection components 130, the alignment accuracy between the flaw detection carriage 110 and the wheel axle position of the wheel 400 to be inspected can be guaranteed. During the inspection process, the components on the flaw detection carriage 110 will not experience adverse phenomena such as collision, overload, jamming, or overturning, so that the flaw detection carriage 110 can smoothly carry out the flaw detection operation of the wheel 400 to be inspected, and improve the stability, reliability, and safety of the wheel flaw detection device 100.

[0074] The technical features of the above embodiments can be combined in any way. For the sake of brevity, 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 specification.

[0075] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A wheel flaw detection device, characterized in that, The wheel flaw detection device includes: A flaw detection trolley is installed in the inspection trench and can move along a travel rail; At least one wheel-finding detection device is provided on the flaw detection trolley and is used to obtain the identification position information of the wheel to be inspected; Multiple positioning detection devices are provided on the flaw detection trolley to obtain the identification position information of the wheel to be inspected. At least two of the positioning detection devices are located on opposite sides of the wheel finding detection device, and the distance between the two positioning detection devices and the wheel finding detection device is equal in the extension direction of the travel rail. The control module stores the wheel chord length R of the wheel to be inspected and is communicatively connected to the flaw detection trolley, the wheel detection component, and the positioning detection component.

2. The wheel flaw detection device according to claim 1, characterized in that, The wheel flaw detection device also includes a lifting mechanism and a wheel lifting and rotating assembly; The lifting mechanism is used to lift the flaw detection trolley until the lifting wheel assembly is above the rail surface; The wheel-lifting assembly is disposed on the lifting mechanism and is used to hook onto the rail and lift the wheel to be inspected.

3. The wheel flaw detection device according to claim 2, characterized in that, The lifting wheel assembly includes a hook-claw rail-connecting module and a clamp wheel lifting module; The hook-claw rail-connecting module includes two sets of hooks, which are spaced apart along a direction perpendicular to the extension of the traveling rail, and the hooks can hook onto the rail. The wheel clamping and lifting module includes two sets of clamping arms and rotating guide wheels disposed at the ends of the clamping arms. The two sets of clamping arms are spaced apart along a direction perpendicular to the travel rail. The rotating guide wheels can contact the wheel to be inspected and lift the wheel to be inspected.

4. The wheel flaw detection device according to claim 3, characterized in that, The rotating guide wheel is fitted with a bushing, and the two positioning detection components are respectively disposed on the two bushings.

5. The wheel flaw detection device according to claim 4, characterized in that, The positioning and detection component is located on the side of the bushing near the center of the flaw detection trolley.

6. The wheel flaw detection device according to claim 1, characterized in that, The wheel-finding detection component can emit detection light towards one side of the wheel to be inspected, in order to obtain the identification position information of the wheel to be inspected; The positioning detection component can emit detection light towards one side of the wheel to be inspected, in order to obtain the identification position information of the wheel to be inspected.

7. The wheel flaw detection device according to claim 1, characterized in that, Along the extension direction of the traveling track, the wheel-finding detection component is positioned on the centerline of the flaw detection trolley.

8. A method for detecting flaws in a wheel flaw detector as described in any one of claims 1-7, characterized in that, The flaw detection method includes the following steps: The control module controls the flaw detection trolley to move along the extension direction of the travel track; When the flaw detection carriage moves to the point where the wheel finding detection component first senses the wheel flange of the wheel to be inspected, the wheel finding detection component outputs a first detection signal and feeds it back to the control module, and the control module records the position of the flaw detection carriage as W1; The control module drives the flaw detection carriage to continue moving to position W2. If |W2-W1|=R / 2, the control module controls the flaw detection carriage to stop in order to perform a coarse positioning of the flaw detection carriage.

9. The flaw detection method according to claim 8, characterized in that, The flaw detection method further includes the following steps: The two positioning detection elements sense whether they are blocked by the wheel to be inspected; If both positioning detection devices sense that they are not blocked by the wheel to be inspected, a second detection signal is fed back to the control module, indicating that the secondary fine positioning of the flaw detection trolley is successful. The control module then controls the flaw detection trolley to perform flaw detection on the wheel to be inspected. If at least one of the two positioning detection elements is blocked by the wheel under inspection, a third detection signal is fed back to the control module, indicating that the flaw detection trolley is at risk of colliding with the wheel under inspection, and the flaw detection trolley needs to be adjusted again or the flaw detection process needs to be manually intervened.

10. The flaw detection method according to claim 8, characterized in that, If one of the two positioning detection devices is blocked by the wheel under inspection, a fourth detection signal is fed back to the control module. The control module drives the flaw detection trolley to make slight adjustments along the extension direction of the travel rail until both positioning detection devices are not blocked by the wheel under inspection and feed back a second detection signal to the control module. The control module then continues to control the flaw detection trolley to perform flaw detection on the wheel under inspection. If both positioning detection components are sensed to be blocked by the wheel under inspection, a fifth detection signal is fed back to the control module, requiring manual intervention in the flaw detection process.

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