Spool, probe wheel and ultrasonic flaw detection system integrated with temperature and pressure monitoring

Abstract

This application discloses an integrated temperature and pressure monitoring spool, probe wheel, and ultrasonic flaw detection system. The spool includes: a housing, a temperature and pressure acquisition module disposed within the housing, and a temperature and pressure signal connector and an ultrasonic signal connector disposed on the housing. The temperature and pressure signal connector is electrically connected to the temperature and pressure acquisition module, and the ultrasonic signal connector is electrically connected to an ultrasonic sensing probe. A temperature and pressure probe is disposed on the temperature and pressure acquisition module and is exposed to the fluid in the probe wheel for acquiring temperature and pressure signals inside the probe wheel. This application solves the technical problem that the internal working state of existing probe wheels cannot be monitored, and the temperature and pressure inside the wheel affect the flaw detection effect and accuracy.

Description

Technical Field

[0001] This application relates to the field of railway rail flaw detection technology, and is applied to large railway maintenance machinery. In particular, it relates to an integrated temperature and pressure monitoring spool, a lightweight wheeled probe, and an ultrasonic flaw detection system for ultrasonic non-destructive testing of rails. Background Technology

[0002] A wheel-type probe is a flexible rubber wheel that rolls at high speed on a rail. It integrates multiple ultrasonic transducers and is filled with a liquid coupling medium that transmits ultrasonic waves. It can detect horizontal defects, cracks, deformed bolt holes, core damage, weld defects, and vertical splitting of the rail head, among other damages. The rail is the object being measured, and the wheel-type probe assembly is equivalent to the probe itself. It is a flexible rubber wheel that conforms to the rail surface. Driven by external force, it rolls along the rail surface. The integrated ultrasonic sensor generates pulsed ultrasonic waves under high-voltage pulses. These pulses are transmitted into the rail through internal and external coupling, reflected back by defects within the rail, and converted into electrical signals through the piezoelectric effect. Sensors at different angles detect damage at different locations and in different directions. By analyzing feedback information from different locations within the rail, damage of various orientations can be detected. Wheel-type ultrasonic flaw detection technology has seen rapid development in the railway flaw detection field due to its advantages such as high detection speed, high detection accuracy, and precise positioning. Detection speeds can reach 60km / h-80km / h, and it is applicable to rail types with pressure capacities of 43kg / m, 50kg / m, 60kg / m, and 75kg / m. However, the performance of the testing wheel is greatly influenced by its internal working environment: pressure, temperature, and signal transmission quality.

[0003] Among the existing technologies, the following documents are most similar to this application: This document is a Chinese invention application filed by Hangzhou Shenhao Technology Co., Ltd. on December 23, 2021, and published on April 5, 2022, with publication number CN114280161A. This application discloses a probe wheel for a dual-rail ultrasonic flaw detector, including a wheel-shaped coupling medium container and a probe frame disposed within the container. The bottom ends of the probe frame are fixedly connected to the flaw detection vehicle body via support shafts passing through the container. The probe frame has a flat surface in the middle, with symmetrically arranged inclined surfaces on both sides. First and second blocks are symmetrically arranged on the inclined surfaces, and mounting holes are symmetrically arranged on both sides of the connection points between the first and second blocks. Ultrasonic transducers are installed on the flat surface, multiple first and second blocks, and mounting holes. Temperature sensors, tilt sensors, and pressure sensors are also fixedly installed on the probe frame. By incorporating temperature, tilt, and pressure sensors, this application effectively improves the efficiency and accuracy of ultrasonic transducers in detecting flaws in rails, reducing false detections and missed detections.

[0004] However, the sensor used in the probe disclosed in this document is bulky and only suitable for low-speed applications, making it unsuitable for miniaturized applications and unable to achieve high-speed flaw detection operations. Furthermore, the probe's lead wire, sealing, and maintenance all present difficulties. Summary of the Invention

[0005] In view of this, the purpose of this application is to provide an integrated temperature and pressure monitoring spool, probe wheel, and ultrasonic flaw detection system to solve the technical problems that existing probe wheels are not suitable for miniaturized applications, cannot achieve high-speed flaw detection operations, and have difficulties in probe wheel lead wire, sealing, and maintenance.

[0006] To achieve the aforementioned objectives, this application provides a technical solution for an integrated temperature and pressure monitoring spool, comprising: a housing, a temperature and pressure acquisition module disposed within the housing, and a temperature and pressure signal connector and an ultrasonic signal connector disposed on the housing. The temperature and pressure signal connector is electrically connected to the temperature and pressure acquisition module, and the ultrasonic signal connector is electrically connected to an ultrasonic sensing probe. A temperature and pressure probe is disposed on the temperature and pressure acquisition module, and the temperature and pressure probe is exposed in the probe fluid for acquiring temperature and pressure signals inside the probe.

[0007] Furthermore, the temperature and pressure probe employs a MEMS sensor.

[0008] Furthermore, the temperature and pressure acquisition module adopts a miniature PCB structure, and the part of the temperature and pressure acquisition module, except for the temperature and pressure probe, is encapsulated in the shell with resin.

[0009] Furthermore, the temperature and pressure acquisition module also includes a communication circuit, which comprises an ARM processor and an RS485 circuit. The ARM processor acquires digital temperature and pressure sensing signals from the temperature and pressure probe via the SPI bus, and then transmits them to a host computer or human-machine interface via the RS485 circuit according to the Modbus protocol, for analysis and display by the host computer, or for use in acquiring closed-loop control signals for the auxiliary system.

[0010] This application also provides a specific technical implementation scheme for a probe wheel, including: a spool as described above, a probe wheel diaphragm, a probe wheel frame, a wheel axle, a valve-side flange seat, a bearing, a flange seat, a probe assembly, and a pressure ring. The valve-side flange seat, the spool, and the bearing are coaxially press-fitted to form a valve-side flange assembly, with the bearing positioned between the valve-side flange seat and the spool. The flange seat, the wheel axle, and another bearing are coaxially press-fitted to form a valveless-side flange assembly, with the bearing positioned between the flange seat and the wheel axle. The valve-side flange assembly and the valveless-side flange assembly are respectively fastened to both sides of the probe assembly along the axial direction, and the probe assembly is equipped with several ultrasonic sensors. The probe wheel diaphragm is fastened to the valve-side flange seat and the flange seat by a pressure ring. The probe wheel diaphragm is filled with probe wheel fluid, and one side of the probe wheel frame is mounted on the wheel axle, while the other side is mounted on the spool. Magnetic seals are provided between the valve-side flange seat and the spool, and between the flange seat and the wheel axle.

[0011] Furthermore, an inner retaining spring, a spring washer one, a spring washer two, and a flat washer are sequentially provided between the valve-side flange seat and the spool, and between the flange seat and the wheel axle.

[0012] Furthermore, the ultrasonic sensors include a 37.5-degree ultrasonic sensor, a 0-degree ultrasonic sensor, a 70-degree ultrasonic sensor, and a side-impact sensor. The probe assembly also includes a heat sink, a central frame, a transducer base, a transducer seat, and a sound-damping plate. The transducer seat is fixedly installed below the central frame, and the ultrasonic sensors and the sound-damping plate are both mounted on the transducer seat. The heat sink is fastened to the central frame via a wheel axle connection, and the 0-degree ultrasonic sensor is mounted on the transducer seat via the transducer base.

[0013] Furthermore, the spool, axle, valve-side flange seat, pressure ring, and flange seat are all made of titanium alloy. The center frame, radiator, transducer base, and transducer seat are all made of aluminum alloy.

[0014] This application also provides a specific technical implementation scheme for an ultrasonic flaw detection system, including: the probe wheel as described above, an ultrasonic excitation circuit, an echo processing circuit, a human-machine interface unit, a flaw detection system, and an auxiliary system. The ultrasonic excitation circuit sends a high-voltage excitation signal to the ultrasonic sensor, which generates an ultrasonic flaw detection signal to scan the tested rail and receives the ultrasonic echo signal reflected from the rail. The ultrasonic echo signal is conditioned and processed by the echo processing circuit and then output to the flaw detection system for flaw detection. The human-machine interface unit is connected to the temperature and pressure acquisition module and the auxiliary system, and is used for displaying and monitoring the temperature and pressure of the coupling fluid inside the probe wheel. The auxiliary system receives the temperature and pressure monitoring signals sent by the temperature and pressure acquisition module and controls the temperature and pressure of the coupling fluid inside the probe wheel within a set range based on these monitoring signals.

[0015] Furthermore, the echo processing circuit includes: a T / R high-voltage isolation unit, a low-noise operational amplifier, a variable gain amplifier, a programmable gain operational amplifier, a low-pass filter unit, a signal discretization processing unit, and an FPGA connected in sequence. The ultrasonic echo signal is processed sequentially by the T / R high-voltage isolation unit, the low-noise operational amplifier, the variable gain amplifier, the programmable gain operational amplifier, the low-pass filter unit, and the signal discretization processing unit to generate a digital ultrasonic echo signal. The FPGA then extracts key features from the digital ultrasonic echo signal through digital orthogonal envelope detection, threshold control, gate superposition, and time extraction processing, thereby achieving damage extraction and location. The signal is then transmitted via Ethernet to a flaw detection system for B-mode ultrasound display.

[0016] By implementing the technical solution of the integrated temperature and pressure monitoring spool, probe wheel, and ultrasonic flaw detection system provided in this application, the following beneficial effects are achieved: (1) This application integrates a temperature and pressure monitoring spool, a probe wheel, and an ultrasonic flaw detection system. The probe wheel integrates ultrasonic flaw detection, temperature and pressure monitoring functions. Based on the miniaturization of the probe wheel, it realizes wheel breakage and over-temperature alarms. It can effectively monitor and control the internal state of the probe wheel, and improve the flaw detection effect and accuracy. (2) The present application integrates temperature and pressure monitoring spools, probe wheels and ultrasonic flaw detection systems. It uses lightweight materials such as aluminum alloy and titanium alloy to replace copper and stainless steel materials, which greatly reduces the weight of the probe wheel, greatly reduces the workload of operators changing wheels in railway sections and improves maintenance efficiency. (3) This application integrates a temperature and pressure monitoring spool, a probe wheel, and an ultrasonic flaw detection system. The thermometer and pressure sensor are integrated into the spool, which greatly reduces the difficulty of the probe wheel lead wire, improves the sealing performance of the probe wheel, and makes the maintenance of the probe wheel simpler. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other embodiments can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a three-dimensional structural schematic diagram of a specific embodiment of the spool integrating temperature and pressure monitoring according to this application; Figure 2 This is a schematic cross-sectional view of a specific embodiment of the spool integrating temperature and pressure monitoring according to this application; Figure 3 This is a structural perspective view of a specific embodiment of the spool integrating temperature and pressure monitoring according to this application; Figure 4This is a partial sectional view of the installation structure of a specific embodiment of the spool integrating temperature and pressure monitoring according to this application; Figure 5 This is a partial installation structure diagram of a specific embodiment of the spool integrating temperature and pressure monitoring in this application; Figure 6 This is a schematic front view of a specific embodiment of the probe wheel of this application; Figure 7 This is a schematic side view of the structure of a specific embodiment of the probe wheel of this application; Figure 8 This is a cross-sectional structural schematic diagram of a specific embodiment of the probe wheel of this application; Figure 9 This is a schematic diagram of the assembly structure of a specific embodiment of the probe wheel in this application; Figure 10 This is a schematic diagram of the assembly structure of the ultrasonic probe in a specific embodiment of the probe wheel of this application; Figure 11 This is a three-dimensional structural diagram of a specific embodiment of the probe of this application; Figure 12 This is a three-dimensional structural schematic diagram of a specific embodiment of the probe of this application from another perspective; Figure 13 This is a system structure block diagram of a specific embodiment of the ultrasonic flaw detection system of this application; Figure 14 This is a schematic diagram illustrating the detection principle of a specific embodiment of the ultrasonic flaw detection system of this application.

[0019] In the diagram: 1-Probe wheel, 2-Temperature and pressure probe, 3-37.5°C ultrasonic sensor, 4-0°C ultrasonic sensor, 5-70°C ultrasonic sensor, 6-Rail, 7-Communication circuit, 8-Ultrasonic excitation circuit, 9-Echo processing circuit, 10-Spool, 11-Human-machine interface unit, 12-Flaw detection system, 13-Auxiliary system, 14-Temperature and pressure signal connector, 15-Ultrasonic signal connector, 16-Housing, 17-Temperature and pressure acquisition module, 18-Probe wheel diaphragm 19-Probe frame, 20-Thermostatic connecting pipe, 21-Axle, 22-Magnetic seal, 23-Outer snap ring, 24-Valve side flange seat, 25-Bearing, 26-Inner snap ring, 27-Spring washer one, 28-Spring washer two, 29-Flat washer, 30-Probe assembly, 31-Pressure ring, 32-Flange seat, 33-Radiator, 34-Center frame, 35-Transducer base, 36-First sound baffle, 37-Second sound baffle, 38-Transducer seat, 39-Side seat, 40-Side sensor. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0021] As attached Figure 1 To be continued Figure 14 As shown, a specific embodiment of the integrated temperature and pressure monitoring spool, probe wheel, and ultrasonic flaw detection system of this application is given. The application will be further described below with reference to the accompanying drawings and specific embodiments.

[0022] Example 1 As attached Figure 1 To be continued Figure 5 As shown, an embodiment of the spool 10 integrating temperature and pressure monitoring according to this application specifically includes: a housing 16, a temperature and pressure acquisition module 17 disposed within the housing 16, and a temperature and pressure signal connector 14 and an ultrasonic signal connector 15 disposed on the housing 16. The temperature and pressure signal connector 14 is electrically connected to the temperature and pressure acquisition module 17, and the ultrasonic signal connector 15 is electrically connected to an ultrasonic sensing probe. A temperature and pressure probe 2 is disposed on the temperature and pressure acquisition module 17, and the temperature and pressure probe 2 is exposed in the probe fluid for collecting temperature and pressure signals inside the probe 1.

[0023] The temperature and pressure probe 2 further employs a MEMS (Micro-Electro-Mechanical Systems) sensor. The temperature and pressure acquisition module 17 adopts a miniature PCB (Printed Circuit Board) structure, and the part of the temperature and pressure acquisition module 17, except for the temperature and pressure probe 2, is encapsulated in resin inside the housing 16.

[0024] As attached Figure 14As shown, the temperature and pressure acquisition module 17 also includes a communication circuit 7, which comprises an ARM (Advanced RISC Machine, a central processing unit based on a reduced instruction set architecture) processor and an RS485 circuit. The ARM processor acquires digital temperature and pressure sensing signals from the temperature and pressure probe 2 via an SPI (Serial Peripheral Interface) bus, and then transmits them to a host computer or human-machine interface via the RS485 circuit according to the Modbus protocol for analysis and display by the host computer, or for use in the acquisition of closed-loop control signals for the auxiliary system 13. The temperature and pressure acquisition module 17 is constructed using an ARM 32-bit processor + MEMS sensor + RS485 circuit. The spool supports the Modbus protocol and accepts access and response from the Modbus master station. The temperature and pressure acquisition module 17 adopts a miniature PCB design, with a MEMS sensor integrated in the head. The sensor part is exposed in the internal liquid of the probe 1, and has digital signal communication capabilities. It is fully integrated, with a modular design, and uses a waterproof encapsulation design, with resin potting in the bearing shaft. The PCB includes a CPU (Central Processing Unit), MEMS sensors, an RS485 chip, a crystal oscillator, a debug port, a DC / DC converter, a power supply and communication interface, and the circuit implements the Modbus-RTU protocol - slave function.

[0025] Example 2 As attached Figure 6 To be continued Figure 12 As shown, one embodiment of the probe wheel 1 of this application is mainly installed on a large rail flaw detection vehicle, specifically including: a spool 10 as described in Embodiment 1, a probe wheel diaphragm 18, a probe wheel frame 19, a wheel axle 21, a valve-side flange seat 24, a bearing 25, a flange seat 32, a probe assembly 30, and a pressure ring 31. The valve-side flange seat 24, the spool 10, and the bearing 25 are coaxially press-fitted to form a valve-side flange assembly, with the bearing 25 disposed between the valve-side flange seat 24 and the spool 10. The flange seat 24, the wheel axle 21, and another bearing 25 are coaxially press-fitted to form a valveless side flange assembly, with the bearing 25 disposed between the flange seat 24 and the wheel axle 21. The valve-side flange assembly and the valveless side flange assembly are respectively fastened to both sides of the probe assembly 30 along the axial direction. The probe assembly 30 is provided with several ultrasonic sensors. The probe wheel diaphragm 18 is fastened to the valve-side flange seat 24 and the flange seat 32 by the pressure ring 31. The probe diaphragm 18 is filled with probe fluid. One side of the probe frame 19 is mounted on the axle 21, and the other side is mounted on the spool 10. Magnetic seals 22 are provided between the valve-side flange seat 24 and the spool 10, and between the flange seat 32 and the axle 21.

[0026] As attached Figure 9As shown, between the valve-side flange seat 24 and the spool 10, and between the flange seat 32 and the wheel axle 21, there are also arranged in sequence an inner retaining spring 26, a spring washer 27, a spring washer 28 and a flat washer 29 for achieving limit or gap adjustment.

[0027] As attached Figure 10 As shown, the ultrasonic sensor further includes a 37.5-degree ultrasonic sensor 3, a 0-degree ultrasonic sensor 4, a 70-degree ultrasonic sensor 5, and a side-impact sensor 40. The probe assembly 30 also includes a heat sink 33, a central frame 34, a transducer base 35, a transducer seat 38, and a sound baffle. The transducer seat 38 is fixedly installed below the central frame 34, and the ultrasonic sensor and the sound baffle are both mounted on the transducer seat 38. The heat sink 33 is fastened to the central frame 34 by cooperating with the wheel axle 21, and the 0-degree ultrasonic sensor 4 is mounted on the transducer seat 38 through the transducer base 35. This embodiment integrates a multi-sensor probe wheel 1, providing a multifunctional wheel-type probe assembly integrating acoustic, electrical, and magnetic sealing technologies. The probe wheel 1 integrates a digital pressure sensor, a digital temperature sensor, a 0-degree ultrasonic sensor 4, a 37.5-degree ultrasonic sensor 3, a 70-degree ultrasonic sensor 5, and a side-impact sensor 40, and is covered with a rubber probe wheel diaphragm 18. The probe wheel 1 is filled with ultrasonic coupling fluid. The probe wheel 1 adopts an integrated electromechanical bobbin structure that combines a sensor-bearing mechanism, a rotating bearing, and electrical signal transmission. It uses this integrated bobbin for signal transmission, enabling both digital transmission of temperature and pressure signals and analog transmission of ultrasonic signals. The central processing circuit of the temperature and pressure acquisition module 17 uses a communication circuit 7 composed of an ARM processor. It acquires signals from digital temperature and pressure sensors via the SPI bus and sends them to a host computer or human-machine interface according to the Modbus protocol for analysis and display. It can also be used as the closed-loop control signal acquisition terminal for the auxiliary system 13.

[0028] The probe wheel 1 integrates digital pressure and temperature sensors (temperature and pressure probes 2) to sense environmental parameters such as working temperature and pressure inside the wheel. It also provides a digital communication interface to output digital data, which can be used as display signals for the human-machine interface or as feedback signals for closed-loop control. The probe wheel 1 can dynamically scan the rail 6 being measured, outputting analog ultrasonic echo signals and digital temperature and pressure signals inside the wheel, which are then output to the subsequent processing circuit via a dedicated spool 10.

[0029] The spool 10, wheel axle 21, valve-side flange seat 24, pressure ring 31, and flange seat 32 are all made of titanium alloy. The center frame 24, radiator 33, transducer base 35, and transducer seat 38 are all made of aluminum alloy. The key components of the probe wheel 1 are designed using lightweight materials, replacing copper and stainless steel with lightweight aluminum alloy and titanium alloy. As can be seen from the following material densities (aluminum alloy 2.71, titanium alloy 4.51, copper 8.21, iron 7.83), titanium alloy is 0.576 times that of iron, aluminum alloy is 0.33 times that of copper, and aluminum alloy is 0.347 times that of iron. The weight differences of the lightweight materials in each component are detailed in Table 1 below. In this embodiment, the weight of the lightweight material structure design can be reduced to 45% of that of non-lightweight materials.

[0030] Table 1

[0031] The lightweight probe 1 described in Example 2 is installed on a large rail flaw detection vehicle and can detect fatigue damage such as rail head defects, bolt hole cracks, and horizontal longitudinal cracks in the rail 6. Two probes 1 are arranged facing each other on one side of the rail 6. Each probe 1 is equipped with one 0-degree ultrasonic sensor 4, one 37.5-degree ultrasonic sensor 3, one 70-degree ultrasonic sensor 5, and one side-impact sensor 40. The 0-degree ultrasonic sensor 4 can detect horizontal orientation defects, bolt hole cracks, and defective bolt holes in the rail 6; the 37.5-degree ultrasonic sensor 3 can detect bolt hole cracks, vertical splitting of the rail web, oblique cracks of the rail web, and transverse cracks at the rail base; the 70-degree ultrasonic sensor 5 can detect rail head defects and weld defects; and the side-impact sensor 40 can detect vertical splitting of the rail head.

[0032] Example 3 As attached Figure 13 As shown, an embodiment of an ultrasonic flaw detection system based on the probe wheel described in Embodiment 2 specifically includes: a probe wheel 1 as described in Embodiment 1, an ultrasonic excitation circuit 8, an echo processing circuit 9, a human-machine interface unit 11, a flaw detection system 12, and an auxiliary system 13. The ultrasonic excitation circuit 8 sends a high-voltage excitation signal to the ultrasonic sensor, which generates an ultrasonic flaw detection signal to scan the tested rail 6 and receives the ultrasonic echo signal reflected by the rail 6. The ultrasonic echo signal is conditioned and processed by the echo processing circuit 9 and then output to the flaw detection system 12 for flaw detection. The human-machine interface unit 11 is connected to the temperature and pressure acquisition module 17 and the auxiliary system 13, and is used for displaying and monitoring the temperature and pressure of the coupling fluid inside the probe wheel 1. The auxiliary system 13 receives the temperature and pressure monitoring signals sent by the temperature and pressure acquisition module 17 and controls the temperature and pressure of the coupling fluid inside the probe wheel 1 within a set range based on these monitoring signals.

[0033] The echo processing circuit 9 further includes: a T / R (transmit / receive) high-voltage isolation unit, a low-noise operational amplifier, a variable gain amplifier, a programmable gain operational amplifier, a low-pass filter unit, a signal discretization processing unit, and an FPGA (Field-Programmable Gate Array) connected in sequence. The ultrasonic echo (electrical) signal is processed sequentially by the T / R high-voltage isolation unit, the low-noise operational amplifier, the variable gain amplifier, the programmable gain operational amplifier, the low-pass filter unit, and the signal discretization processing unit to generate a digital ultrasonic echo signal. The FPGA then processes this signal using digital orthogonal envelope detection, threshold control, gate superposition, and time extraction to extract key features, thereby achieving damage extraction and location. The signal is then transmitted via Ethernet to the flaw detection system 12 for B-mode ultrasound display.

[0034] The Human Machine Interface (HMI) of the probe wheel temperature and pressure monitoring unit 11 allows operators to understand the internal temperature and real-time hydraulic status of multiple probe wheels. It also provides over-limit alarms for temperature and pressure, wheel breakage alarms, communication prompts, parameter configuration, and the main interface functions include a real-time information bar, real-time temperature and pressure monitoring, multi-channel temperature and pressure trend curves, alarm management, and system settings. The (probe wheel constant temperature) auxiliary system 13 is a closed-loop temperature control device that works with the ultrasonic rail flaw detection probe wheel and uses a coupling fluid closed-loop temperature control as its core. Combined with temperature and pressure monitoring, it stabilizes the internal coupling fluid of probe wheel 1 within the standard temperature range of 20-30℃ (commonly set at 25℃) through summer compressor cooling and winter electric heating circulation heat exchange, ensuring a suitable working environment for probe wheel 1 regardless of extreme temperatures. The transducer (ultrasonic sensor) of the probe wheel 1 receives the ultrasonic echo reflected from the rail 6. The original signal is only in the μV~mV range. After the ultrasonic signal is isolated by T / R high voltage through the echo processing circuit 9, it enters the low-noise operational amplifier (LNA), variable gain amplifier (VCA), programmable gain amplifier (PGA), low-pass filter (LPF), and signal discretization processing ADC (analog-to-digital converter). It then enters the back-end FPGA, where digital signal processing is used to extract key features from the digitized ultrasonic echo information. Damage is extracted and located through several functional algorithms, including digital orthogonal envelope detection, threshold control, gate superposition, and time extraction. The signal is then transmitted to the host computer via Ethernet for B-ultrasound display.

[0035] As attached Figure 14As shown, during operation, the electrical cable of the probe wheel 1 is connected to the ultrasonic excitation circuit 8. The ultrasonic excitation circuit 8 generates a high-voltage pulse to excite the ultrasonic sensor to generate ultrasonic waves. The ultrasonic waves enter the rail 6 through the probe wheel fluid, the probe wheel diaphragm 18, and the coupling fluid. The ultrasonic echo reflected from the rail 6 returns to the probe wheel 1, is received by the ultrasonic sensor receiving component, and is converted into an electrical signal containing echo information. This signal is then transmitted via the cable of the probe wheel 1 to the flaw detection system 12 for subsequent analysis and processing. The probe wheel 1 rotates continuously, thereby achieving uninterrupted and rapid detection of internal damage to the rail 6.

[0036] In the description of this specification, the references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0037] In the description of this application, it should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly set on the other element or indirectly set on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element.

[0038] It should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used 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. Therefore, they should not be construed as limitations on this application.

[0039] Furthermore, the terms "first" and "second" are used 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 as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" or "several" means two or more, unless otherwise explicitly specified.

[0040] It should be noted that the structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only used to complement the content disclosed in the specification for those skilled in the art to understand and read, and are not intended to limit the conditions under which this application can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and purposes that this application can produce, should still fall within the scope of the technical content disclosed in this application.

[0041] By implementing the technical solution of the integrated temperature and pressure monitoring spool, probe wheel, and ultrasonic flaw detection system described in the specific embodiments of this application, the following technical effects can be achieved: (1) The integrated temperature and pressure monitoring spool, probe wheel and ultrasonic flaw detection system described in the specific embodiments of this application integrates ultrasonic flaw detection, temperature and pressure monitoring functions in the probe wheel. Based on the miniaturization of the probe wheel, it realizes the alarm of wheel breakage and over-temperature. It can effectively monitor and control the internal state of the probe wheel, and improve the flaw detection effect and accuracy. (2) The integrated temperature and pressure monitoring spool, probe wheel and ultrasonic flaw detection system described in the specific embodiments of this application uses lightweight materials such as aluminum alloy and titanium alloy to replace copper and stainless steel materials, which greatly reduces the weight of the probe wheel, greatly reduces the workload of operators changing wheels in railway sections and improves maintenance efficiency; (3) The integrated temperature and pressure monitoring spool, probe wheel and ultrasonic flaw detection system described in the specific embodiments of this application integrates a thermometer and pressure sensor in the spool, which greatly reduces the difficulty of the probe wheel lead wire, improves the sealing performance of the probe wheel, and makes the maintenance of the probe wheel simpler.

[0042] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0043] The above description is merely a preferred embodiment of this application and is not intended to limit this application in any way. Although this application has been disclosed above with reference to preferred embodiments, it is not intended to limit this application. Any person skilled in the art can make many possible variations and modifications to the technical solutions of this application using the methods and techniques disclosed above, or modify them into equivalent embodiments with equivalent changes, without departing from the spirit and technical essence of this application. Therefore, any simple modifications, equivalent substitutions, equivalent changes, and modifications made to the above embodiments based on the technical essence of this application without departing from the content of the technical solutions of this application shall still fall within the protection scope of the technical solutions of this application.

Claims

1. An integrated temperature and pressure monitoring spool, characterized by, include: The housing (16), the temperature and pressure acquisition module (17) disposed inside the housing (16), and the temperature and pressure signal connector (14) and the ultrasonic signal connector (15) disposed on the housing (16); the temperature and pressure signal connector (14) is electrically connected to the temperature and pressure acquisition module (17), and the ultrasonic signal connector (15) is electrically connected to the ultrasonic sensor probe; the temperature and pressure acquisition module (17) is provided with a temperature and pressure probe (2), which is exposed in the probe fluid and is used to acquire the temperature and pressure signals inside the probe (1).

2. The integrated temperature and pressure monitored spool of claim 1, wherein: The temperature and pressure probe (2) is a MEMS sensor.

3. The spool with integrated temperature and pressure monitoring according to claim 1 or 2, characterized in that: The temperature and pressure acquisition module (17) adopts a micro PCB structure. Except for the temperature and pressure probe (2), the part of the temperature and pressure acquisition module (17) is encapsulated in the shell (16) with resin.

4. The integrated temperature and pressure monitored spool of claim 3, wherein: The temperature and pressure acquisition module (17) also includes a communication circuit (7), which includes an ARM processor and an RS485 circuit. The ARM processor acquires digital temperature and pressure sensing signals from the temperature and pressure probe (2) via the SPI bus, and then sends them to the host computer or human-machine interface via the RS485 circuit according to the Modbus protocol, so that the host computer can analyze and display them, or use them to assist the closed-loop control signal acquisition of the system (13).

5. A probe wheel characterized in that, include: The spool (10) as described in any one of claims 1 to 4, the probe diaphragm (18), the probe frame (19), the axle (21), the valve-side flange seat (24), the bearing (25), the flange seat (32), the probe assembly (30), and the pressure ring (31); the valve-side flange seat (24), the spool (10), and the bearing (25) are coaxially press-fitted to form a valve-side flange assembly, and the bearing (25) is disposed between the valve-side flange seat (24) and the spool (10); the flange seat (24), the axle (21), and another bearing (25) are coaxially press-fitted to form a valveless side flange assembly, and the bearing (25) is disposed between the flange seat (24) and the spool (10). Between the wheel axle (21); the valve-side flange assembly and the valveless-side flange assembly are respectively fastened to both sides of the probe assembly (30) along the axial direction, and the probe assembly (30) is provided with a number of ultrasonic sensors; the probe wheel diaphragm (18) is fastened to the valve-side flange seat (24) and the flange seat (32) by the pressure ring (31); the probe wheel diaphragm (18) is filled with probe wheel fluid, one side of the probe wheel frame (19) is installed on the wheel axle (21), and the other side is installed on the spool (10); magnetic seals (22) are provided between the valve-side flange seat (24) and the spool (10), and between the flange seat (32) and the wheel axle (21).

6. The probe wheel of claim 5, wherein: An inner retaining spring (26), a spring washer one (27), a spring washer two (28) and a flat washer (29) are sequentially provided between the valve side flange seat (24) and the spool (10), and between the flange seat (32) and the wheel axle (21).

7. A probe wheel according to claim 5 or 6, characterised in that: The ultrasonic sensor includes a 37.5-degree ultrasonic sensor (3), a 0-degree ultrasonic sensor (4), a 70-degree ultrasonic sensor (5), and a side-impact sensor (40); the probe assembly (30) also includes a heat sink (33), a central frame (34), a transducer base (35), a transducer seat (38), and a sound baffle; the transducer seat (38) is fixedly installed below the central frame (34), and the ultrasonic sensor and the sound baffle are both set on the transducer seat (38); the heat sink (33) is connected and fastened to the central frame (34) by cooperating with the axle (21), and the 0-degree ultrasonic sensor (4) is installed on the transducer seat (38) through the transducer base (35).

8. The probe wheel of claim 7, wherein: The spool (10), wheel axle (21), valve side flange seat (24), pressure ring (31) and flange seat (32) are all made of titanium alloy; the center frame (24), radiator (33), transducer base (35) and transducer seat (38) are all made of aluminum alloy.

9. An ultrasonic flaw detection system, characterized in that, include: The probe wheel (1) as described in any one of claims 5 to 8 comprises an ultrasonic excitation circuit (8), an echo processing circuit (9), a human-machine interaction unit (11), a flaw detection system (12), and an auxiliary system (13); the ultrasonic excitation circuit (8) sends a high-voltage excitation signal to the ultrasonic sensor, the ultrasonic sensor generates an ultrasonic flaw detection signal to scan the rail under test (6), and receives the ultrasonic echo signal reflected by the rail (6); the ultrasonic echo signal is conditioned and processed by the echo processing circuit (9) and then output to the flaw detection system (12) for flaw detection; the human-machine interaction unit (11) is connected to the temperature and pressure acquisition module (17) and the auxiliary system (13) for displaying and monitoring the temperature and pressure of the coupling fluid inside the probe wheel (1); the auxiliary system (13) receives the temperature and pressure monitoring signal sent by the temperature and pressure acquisition module (17), and controls the temperature and pressure of the coupling fluid inside the probe wheel (1) within a set range according to the monitoring signal.

10. The ultrasonic inspection system of claim 9, wherein, The echo processing circuit (9) includes: a T / R high-voltage isolation unit, a low-noise operational amplifier, a variable gain amplifier, a programmable gain operational amplifier, a low-pass filter unit, a signal discretization processing unit and an FPGA connected in sequence; the ultrasonic echo signal is processed by the T / R high-voltage isolation unit, the low-noise operational amplifier, the variable gain amplifier, the programmable gain operational amplifier, the low-pass filter unit and the signal discretization processing unit in sequence to generate a digital ultrasonic echo signal, and then the FPGA extracts key features from the digital ultrasonic echo signal through digital orthogonal envelope detection, threshold control, gate superposition and time extraction processing, thereby realizing damage extraction and positioning, and transmitting it to the flaw detection system (12) via Ethernet for B-ultrasound display.

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