On-orbit passing type train wheel automatic flaw detection device

Abstract

The utility model relates to an on-orbit through-type train wheel automatic flaw detection device which comprises a plurality of wheel flaw detection assemblies, and each wheel flaw detection assembly comprises a guide rail and a plurality of probe assemblies arranged on the guide rail. The probe assembly comprises a moving frame matched with the guide rail, a plurality of scanning probes arranged on the moving frame and a displacement driving device for driving the moving frame to move along the guide rail. The on-orbit passing type train wheel automatic flaw detection device further comprises a plurality of position sensors located on one side of the guide rail. According to the on-orbit passing type train wheel automatic flaw detection device disclosed by the utility model, the ultrasonic probe can move along with the detected wheel, so that the cost of the whole device is very low, the stability and the reliability of the system are very high, and on-orbit passing type detection can be realized.

Description

Technical Field

[0001] The utility model relates to a workpiece flaw detection device, in particular to an on-track passing type train wheel automatic flaw detection device, and also relates to an automatic wheel flaw detection method. Background Art

[0002] In order to ensure the safe operation of trains, inspectors need to conduct on-track flaw detection on train wheels regularly to ensure that they are intact and thus ensure the safe operation of the vehicles.

[0003] The Chinese patent with the publication number "CN 110672722 A" discloses an electromagnetic ultrasonic-based online detection system and method for locomotive wheel tread defects, which sets a number of electromagnetic ultrasonic sensors between the outer offset rail and the guard rail, and uses the electromagnetic ultrasonic sensors to directly detect the central surface and near-surface defects of the train wheel tread online. However, in actual application, the sensitivity of the electromagnetic ultrasonic sensor is extremely low, so the detection effect is extremely poor.

[0004] At present, wheel flaw detection devices mostly use piezoelectric crystal ultrasonic probe arrays to perform online inspection of wheels. However, in existing inspection devices, the ultrasonic probes are fixedly installed in the inspection track grooves. In order to achieve comprehensive inspection of wheels, it is necessary to use more than 700 ultrasonic probes and more than 60 sets of flaw detection instrument modules to drive the ultrasonic probes. The overall equipment cost is extremely high, the system stability is poor, and the inspection reliability is low.

[0005] The Chinese patent with publication number "CN 117549936 A" discloses a wheelset flaw detection system that uses relatively few ultrasonic probes, but its overall structure is still relatively complex and has low reliability. At the same time, its detection probe is mounted above the wheel through a gantry, which limits its scope of application and cannot realize on-track detection of train wheels. Utility Model Content

[0006] In order to solve the technical problems of high equipment cost, poor system stability and low detection reliability caused by the above-mentioned fixed ultrasonic probe, the utility model provides an on-track passing type train wheel automatic flaw detection device, which has an ultrasonic probe that can move with the wheel to be inspected, has low equipment cost, high system stability and reliability, and can detect on-track. The on-track passing type train wheel automatic flaw detection device of the utility model includes a plurality of wheel flaw detection components, the wheel flaw detection components include a guide rail and a plurality of probe components arranged on the guide rail, the probe components include a moving frame adapted to the guide rail, a plurality of scanning probes arranged on the moving frame, and a displacement driving device that drives the moving frame to move along the guide rail, and the on-track passing type train wheel automatic flaw detection device also includes a plurality of position sensors located on one side of the guide rail.

[0007] The advantage of the on-track passing train wheel automatic flaw detection device is that its probe assembly can follow the wheel movement under the drive of the displacement drive device, and during the movement, several scanning probes of the probe assembly can perform follow-up scanning on the wheel tread. Since the scanning probe has a follow-up function, the on-track passing train wheel automatic flaw detection device can greatly reduce the number of required scanning probes and corresponding ultrasonic instrument modules, thereby improving the stability of system operation and the reliability of detection, and reducing the overall preparation cost of the equipment and the detection cost of the wheel.

[0008] Furthermore, in the on-track passing train wheel automatic flaw detection device of the utility model, the surface of the guide rail is provided with a guide groove matching the movable frame, a flange is provided on the inner wall of the guide groove, and a roller is provided at the bottom of the movable frame.

[0009] The setting of guide grooves and rollers ensures the linearity, stability and accuracy of the movement of the mobile frame.

[0010] Furthermore, in the on-track passing type train wheel automatic flaw detection device of the utility model, a roller groove adapted to the flange is provided on the outer peripheral surface of the roller, and the flange is stuck in the roller groove.

[0011] The arrangement of the flange and the roller groove not only makes the moving frame more stable, but also, since the flange is stuck in the roller groove, the roller cannot move vertically perpendicular to the flange, so the moving frame cannot be loosened from the guide rail, thereby further ensuring the stability of the probe assembly operation.

[0012] Furthermore, in the utility model, the on-track automatic flaw detection device for passing train wheels, the displacement drive device includes a hollow motor arranged on a movable frame, the wheel flaw detection assembly also includes a screw rod, the screw rod is arranged above the guide rail, support plates are respectively provided at both ends of the guide rail, both ends of the screw rod are respectively arranged on the support plates, and the hollow shaft of the hollow motor is threadedly connected to the screw rod.

[0013] The arrangement of the hollow motor, lead screw and other components realizes the linear displacement drive of the mobile frame. At the same time, the hollow motor has a compact structure, which is convenient for connecting and installing the displacement drive device and the mobile frame.

[0014] Furthermore, in the on-track passing train wheel automatic flaw detection device of the utility model, the movable frame includes a mounting frame, the body of the hollow motor is arranged in the mounting frame, a plurality of scanning probes are installed on the top plate of the mounting frame, and the screw rod passes through the through hole on the side wall of the mounting frame and is threadedly connected to the hollow shaft of the hollow motor.

[0015] The setting of the installation frame realizes the connection and installation of the hollow motor and the scanning probe.

[0016] Furthermore, in the on-track passing type train wheel automatic flaw detection device of the utility model, a guard rail is also provided on the other side of the wheel flaw detection assembly. During detection, the wheel flaw detection assembly is located between the guard rail and the rail.

[0017] The guardrail is set to provide auxiliary support for the wheels and protect the wheel flaw detection components.

[0018] Furthermore, the on-track passing train wheel automatic flaw detection device of the utility model also includes a mounting base plate, and the guardrail, wheel flaw detection assembly and position sensor are all arranged on the mounting base plate.

[0019] The setting of the mounting base plate facilitates the installation of wheel flaw detection components, guardrails, position sensors and other components by operators, thereby realizing automatic detection of wheels.

[0020] Furthermore, the on-track through-type train wheel automatic flaw detection device of the utility model also includes a wire pipe and a water pipe, and the output ends of the wire pipe and the water pipe are located above the mounting base.

[0021] The water pipe setting enables the system to locally inject water into the wheel flaw detection component through the water pipe so that the water level is flush with the wheel tread detection part, thereby ensuring reliable coupling between the scanning probe ultrasonic wave and the wheel tread detection part. The setting of the wire pipe facilitates the wiring of the power supply and control lines of each electrical component.

[0022] Furthermore, the on-track through-type train wheel automatic flaw detection device of the utility model further includes a bottom plate, the output ends of the wire tube and the water pipe penetrate from the side of the bottom plate, then penetrate the mounting base plate above it and pass out from the surface of the mounting base plate, the bottom plate is located below the rail and the mounting base plate, and the rail, the guard rail and the mounting base plate surround and form a groove for installing the wheel flaw detection component,

[0023] The setting of the bottom plate realizes the installation of components such as the base plate and wheel flaw detection components, making it convenient for operators to quickly install and maintain them.

[0024] Furthermore, the on-track passing train wheel automatic flaw detection device of the utility model also includes a speed measuring radar, which is arranged on one side of the rail and located in front of the wheel flaw detection assembly.

[0025] The setting of the speed radar enables the host computer to obtain the real-time speed of the train according to the signal of the speed radar, so as to feedback control the displacement drive device so that it can drive the moving frame to move with the train at the same speed.

[0026] The above description is only an overview of the technical solution of the utility model. In order to more clearly understand the technical means of the utility model and implement it in accordance with the contents of the specification, the following embodiments of the utility model are described in detail. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a front view of the on-track through-type train wheel automatic flaw detection device of embodiment 1.

[0028] Figure 2 yes Figure 1 A top view of the automatic flaw detection device for on-track passing train wheels.

[0029] Figure 3 yes Figure 1 A three-dimensional view of the automatic flaw detection device for on-track passing train wheels.

[0030] Figure 4 yes Figure 1 Disassembly diagram of the automatic flaw detection device for on-track passing train wheels.

[0031] Figure 5 It is a stereoscopic image of the wheel flaw detection assembly.

[0032] Figure 6 This is the front view of the guide rail.

[0033] Figure 7 yes Figure 6 Sectional view along AA direction.

[0034] Figure 8 It is the front view of the probe assembly and the displacement drive device.

[0035] Fig. 9 yes Figure 8 A three-dimensional diagram of the probe assembly and the displacement drive device.

[0036] Fig.10 It is a three-dimensional diagram of the mobile rack.

[0037] Fig.11 This is a perspective view of the mounting base plate.

[0038] Fig.12 It is a structural block diagram of an on-track through-type train wheel automatic flaw detection device according to a second embodiment.

[0039] In the figure, the wheel flaw detection component 1, the guide rail 2, the probe component 3, the moving frame 4, the scanning probe 5, the displacement drive device 6, the position sensor 7, the hollow motor 8, the screw rod 9, the support plate 10, the installation frame 11, the U-shaped frame 12, the top plate 13, the guide groove 14, the roller 15, the flange 16, the roller groove 17, the sliding plate 18, the rail 19, the guard rail 20, the installation base plate 21, the wire tube and the water pipe 22, the bottom plate 23, the groove 24, the positioning groove 25, and the speed radar 26. DETAILED DESCRIPTION

[0040] The following is a further detailed description of the specific implementation of the present invention in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0041] Example 1: See Figures 1 to 11 The on-track passing type train wheel automatic flaw detection device of this embodiment includes a plurality of wheel flaw detection components 1, the wheel flaw detection components include a guide rail 2 and a plurality of probe components 3 arranged on the guide rail, the probe components include a moving frame 4 adapted to the guide rail, a plurality of scanning probes 5 arranged on the moving frame, and a displacement driving device 6 for driving the moving frame to move along the guide rail. The on-track passing type train wheel automatic flaw detection device also includes a plurality of position sensors 7 located on one side of the guide rail.

[0042] The advantage of the on-track passing train wheel automatic flaw detection device is that its probe assembly can follow the wheel movement under the drive of the displacement drive device, and during the movement, several scanning probes of the probe assembly can perform follow-up scanning on the wheel tread. Since the scanning probe has a follow-up function, the on-track passing train wheel automatic flaw detection device can greatly reduce the number of required scanning probes and corresponding ultrasonic instrument modules, thereby improving the stability of system operation and the reliability of detection, and reducing the overall preparation cost of the equipment and the detection cost of the wheel.

[0043] The movable frame is used to install a plurality of scanning probes, which can move along the guide rail under the drive of the displacement driving device, thereby driving the scanning probes thereon to move, and then performing a follow-up scan on the wheel tread.

[0044] The displacement drive device is used to drive the mobile frame to move along the guide rail. It is a linear displacement drive device. It can be a displacement drive device such as an electric cylinder that is separately arranged on one side of the guide rail and the output end is connected to the mobile frame. It can also be a linear displacement drive device such as a rack and pinion type or a screw type that is arranged on the mobile frame.

[0045] In this embodiment, the linear displacement drive device includes a hollow motor 8 arranged on the mobile frame, and the wheel flaw detection assembly also includes a screw 9. The screw can be arranged above the guide rail, and the two ends of the guide rail can be respectively provided with support plates 10 for mounting the screw, and the two ends of the screw are respectively arranged on the support plates, and the hollow shaft of the hollow motor is threadedly connected with the screw. When working, as the hollow motor runs, its body can drive the mobile frame to move along the screw, thereby realizing the displacement drive of the scanning probe.

[0046] In order to facilitate the installation of the hollow motor by the operator, the above-mentioned mobile frame includes a mounting frame 11, which is composed of a U-shaped frame 12 and a top plate 13 on the top. The above-mentioned hollow motor is installed in the mounting frame, and a plurality of scanning probes are installed on the top plate. When connected, the screw rod passes through the through hole on the side wall of the mounting frame and is threadedly connected with the hollow shaft of the hollow motor.

[0047] In this embodiment, the length of the guide rail is about 1 meter, and two sets of probe assemblies are arranged on a single guide rail. Several sets of wheel flaw detection assemblies can be connected end to end in sequence to form an on-track through-type train wheel automatic flaw detection device with multiple sets of wheel flaw detection assemblies. The number of wheel flaw detection assemblies can be set as required according to the wheelbase of the front and rear wheels of the train, the length of the guide rail, the number of probe assemblies in a single wheel flaw detection assembly, and the detection accuracy.

[0048] In order to facilitate connection, the surface of the guide rail can be provided with a guide groove or guide rail matching the moving frame. In this embodiment, the surface of the guide rail has a guide groove 14, and the bottom of the moving frame has a slider or roller 15 adapted to the guide groove.

[0049] In order to improve the stability of the movement of the mobile frame and prevent it from falling off the guide rail, in this example, a flange 16 is provided on the inner wall of the guide groove, a roller is provided at the bottom of the mobile frame, and a roller groove 17 adapted to the flange is provided on the outer peripheral surface of the roller, and the flange is stuck in the roller groove.

[0050] The arrangement of the flange and the roller groove not only makes the moving frame more stable when moving, but also, since the flange is stuck in the roller groove, the roller cannot move vertically perpendicular to the flange, so the moving frame is not easy to loosen from the guide rail, thereby further ensuring the stability of the probe assembly operation.

[0051] During installation, a sliding plate 18 is connected to the bottom of the U-shaped frame, and the roller is installed on the sliding plate.

[0052] The above-mentioned position sensor is used to sense the position of the wheel. When working, the host computer controls the operation of the displacement drive device according to the signal transmitted by the position sensor, thereby realizing the follow-up function of the scanning probe. In this embodiment, the position sensor is preferably an eddy current position sensor, which adopts a 24G microwave velocimeter, has high accuracy in position triggering and speed detection, and has strong adaptability to the system operating environment, thereby greatly expanding the applicable environmental conditions of the equipment.

[0053] In specific implementation, several wheel flaw detection components are arranged on one side of the rail 19, and a guardrail 20 can also be arranged on the other side of the wheel flaw detection component to realize auxiliary support for the wheel and protection of the wheel flaw detection component. In order to realize the detection of the wheel set, the wheel flaw detection components can be symmetrically arranged on the left and right sides of the rail. During installation, the guide rail of the wheel flaw detection component is basically parallel to the rail, and in the initial state, the probe component is located at the position corresponding to the position sensor. During detection, the system partially injects water into the wheel flaw detection component through a water pipe so that the water level is flush with the wheel tread detection part, thereby ensuring the reliable coupling of the ultrasonic wave of the scanning probe with the wheel tread detection part.

[0054] When the wheel passes the position sensor, the position sensor sends a corresponding signal to the host computer. After receiving the signal, the host computer controls the corresponding displacement drive device through the interface to make the corresponding probe assembly move with the wheel. During the movement, several probes of the probe assembly can scan the wheel. After the scanning is completed, the probe assembly resets, and the adjacent next group of scanning probes scans the wheel according to the above similar process until the entire wheel is scanned.

[0055] In order to facilitate installation and detection, the on-track passing train wheel automatic flaw detection device also includes a mounting base plate 21, and the guardrail, wheel flaw detection assembly and position sensor are all arranged on the mounting base plate.

[0056] In order to facilitate threading and water injection, the on-track through-type train wheel automatic flaw detection device also includes a wire tube and a water tube 22, and the output ends of the wire tube and the water tube are located above the installation base plate.

[0057] In this embodiment, the output ends of the wire tube and the water pipe penetrate from the side of the bottom plate 23, then penetrate the mounting base plate above it and pass out from the surface of the mounting base plate. The above-mentioned bottom plate is located below the rail and the mounting base plate. The above-mentioned rail, guard rail and mounting base plate surround to form a groove 24 for installing the wheel flaw detection component. When working, the two ends of the groove can be blocked by baffles to facilitate water injection.

[0058] In order to facilitate installation and positioning, the bottom edge of the installation base plate has a positioning groove 25 adapted to the rail. During installation, the bottom edge of the rail can be inserted into the positioning groove, thereby realizing the positioning of the installation base plate and the components thereon.

[0059] In order to enable the moving frame and the probe to follow the movement of the wheel at a specific speed, the on-track passing train wheel automatic flaw detection device also includes a speed measuring radar, which is arranged on one side of the rail and located in front of the wheel flaw detection assembly.

[0060] The setting of the speed radar enables the host computer to obtain the speed of the train according to the signal of the speed radar, so as to feedback control the displacement drive device so that it can drive the mobile frame to move at a specific speed following the wheels.

[0061] Example 2: See Fig.11The automatic flaw detection device for on-track passing train wheels of this embodiment adds the following technical contents on the basis of the automatic flaw detection device for on-track passing train wheels of embodiment 1. Specifically, the automatic flaw detection device for on-track passing train wheels of this embodiment includes 4 probe assemblies, T1, T2, T3, and T4, and five position sensors, S1, S2, S3, S4, and S5. Each probe assembly and position sensor are sequentially arranged on one side of the guide rail according to the position shown in the figure. Several scanning probes of the four probe assemblies are respectively connected to two 12-channel ultrasonic instrument modules (UT module-12) through wires, and each position sensor and displacement drive device are respectively connected to the PLC electromechanical control module through a data line. The above-mentioned ultrasonic instrument module and PLC electromechanical control module are connected to the host computer through a network switch. The network switch is also connected to the speed measuring radar 26 and the touch screen through a data line. The speed measuring radar is arranged on one side of the rail and is located in front of the wheel flaw detection assembly.

[0062] During the inspection, the host computer program in the host computer senses the wheel through the position sensor, so that the PLC electromechanical control module drives the probe assembly to move through the displacement drive device. The host computer program obtains the train speed information through the speed radar and controls the moving speed of the probe assembly accordingly, so that it can follow the wheel movement and scan the wheel. The following is the specific inspection process of the on-track through-type train wheel automatic flaw detection device.

[0063] 1. The front wheel of the train triggers the position sensor S1, and the T1 scanning probe block moves forward to detect flaws, and the speed follows the speed of the train (collected by the speed radar);

[0064] 2. The front wheel of the train triggers the position sensor S2, and the T1 scanning probe starts to return until it stops at the starting position of the position sensor S1. At the same time, the T2 scanning probe moves forward and detects flaws, and its speed follows the speed of the train;

[0065] 3. The front wheel of the train triggers the position sensor S3, and the T2 scanning probe starts to return until it stops at the starting position of the position sensor S2. At the same time, the T3 scanning probe moves forward and detects flaws, and its speed follows the speed of the train;

[0066] 4. The front wheel of the train triggers the position sensor S4, and the T3 scanning probe starts to return until it stops at the starting position of the position sensor S3. At the same time, the T4 scanning probe moves forward and detects flaws, and its speed follows the speed of the train;

[0067] 5. The front wheel of the train triggers the position sensor S5, and the T4 scanning probe starts to return until it stops at the starting position of the position sensor S4. At this time, the front wheel flaw detection of the train is completed;

[0068] During the front wheel flaw detection process of the train, when the front wheel position is between position sensors S2 and S4, the rear wheel of the train also triggers the position sensor S1 while the front wheel flaw detection is in progress, and the rear wheel flaw detection process of the train begins. The rear wheel flaw detection process is the same as the above steps S1-S5, which will not be repeated here.

[0069] The application of multiple position sensors enables the wheel to be detected, cleared and calibrated every 1 meter when it moves. This eliminates the impact of accumulated errors in wheel position and speed measurement, greatly improves the system's accuracy in wheel position and speed measurement, and ensures the accuracy of flaw detection position tracking.

[0070] In this embodiment, the probe and the wheel are ultrasonically coupled using the water layer method, the scanning probe has no direct contact with the wheel, and the scanning probe has no wear, which greatly improves the durability, reliability and stability of the system equipment.

[0071] In this embodiment, the position sensor is an eddy current position sensor, which uses a 24G microwave velocimeter, has high accuracy in position triggering and speed detection, and has strong adaptability to the system operating environment, which greatly expands the applicable environmental conditions of the system.

[0072] The above is only a preferred implementation of the utility model, which is used to assist those skilled in the art to implement the corresponding technical solution, and is not used to limit the scope of protection of the utility model. The scope of protection of the utility model is defined by the attached claims. It should be pointed out that for ordinary technicians in this field, on the basis of the technical solution of the utility model, several equivalent improvements and variations can be made, and these improvements and variations should also be regarded as the scope of protection of the utility model. At the same time, it should be understood that although this specification is described in accordance with the above-mentioned implementation mode, not every implementation mode contains only one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions of each embodiment can also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. An automatic wheel flaw detection device for an on-track passing train, comprising a plurality of wheel flaw detection components (1), characterized in that: The wheel flaw detection assembly comprises a guide rail (2) and a plurality of probe assemblies (3) arranged on the guide rail, the probe assemblies comprising a moving frame (4) adapted to the guide rail, a plurality of scanning probes (5) arranged on the moving frame, and a displacement driving device (6) for driving the moving frame to move along the guide rail. The on-track through-type train wheel automatic flaw detection device also comprises a plurality of position sensors (7) located on one side of the guide rail.

2. The on-track passing train wheel automatic flaw detection device according to claim 1 is characterized in that: A guide groove matching the movable frame is arranged on the surface of the guide rail, a flange (16) is arranged on the inner wall of the guide groove, and a roller (15) is arranged at the bottom of the movable frame.

3. The on-track passing train wheel automatic flaw detection device according to claim 2 is characterized in that: A roller groove (17) adapted to the flange is provided on the outer peripheral surface of the roller, and the flange is clamped in the roller groove.

4. The on-track passing train wheel automatic flaw detection device according to claim 1 is characterized in that: The displacement drive device comprises a hollow motor (8) arranged on a movable frame, and the wheel flaw detection assembly further comprises a screw rod (9), which is arranged above the guide rail, and support plates (10) are respectively arranged at both ends of the guide rail, and both ends of the screw rod are respectively arranged on the support plates, and the hollow shaft of the hollow motor is threadedly connected to the screw rod.

5. The automatic flaw detection device for on-track passing train wheels according to claim 4 is characterized in that: The movable frame comprises a mounting frame (11), the body of the hollow motor is arranged in the mounting frame, a plurality of scanning probes are mounted on the top plate of the mounting frame, and the screw rod passes through a through hole on a side wall of the mounting frame and is threadedly connected to the hollow shaft of the hollow motor.

6. The on-track passing train wheel automatic flaw detection device according to claim 1 is characterized in that: A guard rail (20) is also provided on the other side of the wheel flaw detection assembly. During detection, the wheel flaw detection assembly is located between the guard rail and the rail.

7. The automatic flaw detection device for on-track passing train wheels according to claim 6 is characterized in that: It also comprises a mounting base plate (21), on which the guard rail, the wheel flaw detection assembly and the position sensor are all arranged.

8. The automatic flaw detection device for on-track passing train wheels according to claim 7 is characterized in that: It also includes a wire pipe and a water pipe (22), wherein the output ends of the wire pipe and the water pipe are located above the installation base plate.

9. The on-track passing train wheel automatic flaw detection device according to claim 8 is characterized in that: It also includes a bottom plate, wherein the output ends of the wire tube and the water pipe penetrate through the side of the bottom plate (23), then penetrate the mounting base plate above it and pass out from the surface of the mounting base plate, and the bottom plate is located below the steel rail and the mounting base plate, and the steel rail, the guard rail and the mounting base plate surround and form a groove (24) for installing the wheel flaw detection component.

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