Ultrasonic phased array virtual source probe for rail head of steel rail

Abstract

The utility model belongs to the technical field of ultrasonic phased array virtual source online flaw detection of various natural defects in a steel rail head, and particularly relates to a steel rail head ultrasonic phased array virtual source probe which comprises a shell, a multi-conductor coaxial cable is fixedly connected to the top of the shell, a supporting plate is welded between the inner walls of the two sides of the shell, and the supporting plate is fixedly connected with the multi-conductor coaxial cable. The supporting plate is fixedly connected with a plurality of signal lines. The shell is used as an external protection structure of the probe, the multi-conductor coaxial cable is used for transmitting high-frequency ultrasonic signals and receiving reflected signals, the signal line is connected with the probe and the signal processing system and is used for transmitting control signals and detection data, the array element is composed of 64 independently controlled ultrasonic transducers, and the array element is composed of 64 independently controlled ultrasonic transducers. Each transducer can independently excite ultrasonic waves, wave beams in specific directions and shapes are synthesized through the phase control technology, accurate scanning of different areas of the rail head is achieved, and various internal defect samples in the actual metallurgy and rolling process of the steel rail head can be effectively detected.

Description

Technical Field

[0001] The utility model relates to the technical field of ultrasonic phased array virtual source on-line flaw detection for various natural defects inside the rail head, and specifically relates to an ultrasonic phased array virtual source probe for the rail head. Background Technique

[0002] The ultrasonic scanning direction specified in the on-line ultrasonic flaw detection standard for rails TB / T 2344-2020 is different from that specified in the standard for ultrasonic flaw detectors for in-service railway lines TB / T 2340-2012, resulting in ineffective detection of specific-angle metallurgical defects before the rails leave the factory; the ultrasonic coverage area specified in the iron standard TB / T 2344-2020 does not overlap with the coverage area specified in the standard for ultrasonic flaw detectors for in-service railway lines TB / T 2340-2012 in the double upper arc of the rail head and the lower jaw area of the rail head, and it is easy to miss defects in the double upper arc of the rail head and the lower jaw area when the rails leave the factory. At the same time, the standard for ultrasonic flaw detectors for rails TB / T 2340-2012 stipulates that the effective detection area of the rail head is ≥70%, and there is a large detection blind area in the rail head area, which is prone to missing internal defects in the rail head area. Therefore, we propose an ultrasonic phased array virtual source probe for the rail head to solve the above problems. Content of the Utility Model

[0003] (I) Technical Problems to be Solved

[0004] In view of the deficiencies of the prior art, the utility model provides an ultrasonic phased array virtual source probe for the rail head, which solves the problems raised in the above background technique.

[0005] (II) Technical Solutions

[0006] The utility model specifically adopts the following technical solutions to achieve the above purposes:

[0007] An ultrasonic phased array virtual source probe for the rail head includes a housing. A multi-conductor coaxial cable is fixedly connected to the top of the housing. A support plate is welded between the inner walls on both sides of the housing. A plurality of signal lines are fixedly connected to the support plate. The signal lines are electrically connected to the multi-conductor coaxial cable. An installation plate is fixedly connected between the inner walls on both sides of the housing. A plurality of rectangular holes are formed in the installation plate. An array element is fixedly connected to the rectangular hole. The array element is electrically connected to the corresponding signal line. A backing layer is provided on the inner wall of the housing. A dust-proof plate is fixedly connected to the bottom of the housing. A plurality of heat dissipation holes are formed in the dust-proof plate.

[0008] Furthermore, the array element is made of an extremely thin piezoelectric ceramic composite material and is placed parallel in sequence to form a phased array transducer array.

[0009] Further, two rectangular blocks are welded to both sides of the housing, and a limiting rod is welded to one side of the rectangular block.

[0010] Further, a pin is slidably connected to the limiting rod, and a spring is welded between the end of the pin and one side of the corresponding rectangular block. The spring is movably sleeved on the corresponding limiting rod.

[0011] Further, mounting blocks are welded to both sides of the dust-proof plate, and clamping grooves are formed on both sides of the mounting blocks. The clamping grooves are clamped with the corresponding pins.

[0012] Further, four limiting columns are welded to the top of the dust-proof plate, and four limiting grooves are formed at the bottom of the housing. The limiting grooves are in movable contact with the corresponding limiting columns.

[0013] (III) Beneficial effects

[0014] Compared with the prior art, the utility model provides an ultrasonic phased array virtual source probe for the rail head, which has the following beneficial effects:

[0015] In the utility model, the housing is used as the external protection structure of the probe, the multi-conductor coaxial cable is used to transmit high-frequency ultrasonic signals and receive the reflected signals, the signal line connects the probe and the signal processing system to transmit control signals and detection data, the array element is composed of 64 independently controlled ultrasonic transducers, each transducer can independently excite ultrasonic waves, and the phased technology is used to synthesize beams with specific directions and shapes to achieve precise scanning of different regions of the rail head. The ultrasonic phased array virtual source probe for the rail head adopts 64 vibration sources, with a frequency of 5 MHz and a repetition frequency of 1 KHz. The ultrasonic phased array virtual source probe is divided into 3 detection regions. One probe is arranged above the tread of the rail head, and ultrasonic virtual source phased array detection is carried out on the rail head part from the top of the tread of the rail. The other two probes are respectively arranged on the two sides of the rail head, and ultrasonic virtual source phased array detection is carried out on the rail head part from both sides, which can effectively detect various internal defect samples in the actual metallurgy and rolling processes of the rail head. Description of the drawings

[0016] Figure 1 is a three-dimensional structural schematic diagram of the utility model;

[0017] Figure 2 is an inclined three-dimensional structural schematic diagram of the utility model;

[0018] Figure 3 is a three-dimensional structural schematic diagram of the utility model with the dust-proof plate removed;

[0019] Figure 4 is a partial three-dimensional structural schematic diagram of the utility model;

[0020] Figure 5 is the utility modelFigure 1 Schematic diagram of the enlarged structure of Area A.

[0021] In the figure: 1. housing; 2. multi-conductor coaxial cable; 3. support plate; 4. signal line; 5. mounting plate; 6. rectangular hole; 7. array element; 8. backing layer; 9. dust-proof plate; 10. rectangular block; 11. limiting rod; 12. retaining pin; 13. spring; 14. mounting block; 15. card slot; 16. limiting column; 17. limiting groove. Specific implementation manner

[0022] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention. Embodiment

[0023] As Figures 1-5As shown in the figure, a virtual source probe for ultrasonic phased array of rail head of the present utility model in an embodiment includes a housing 1. A multi-conductor coaxial cable 2 is fixedly connected to the top of the housing 1. A support plate 3 is welded between the inner walls on both sides of the housing 1. A plurality of signal lines 4 are fixedly connected to the support plate 3. The signal lines 4 are electrically connected to the multi-conductor coaxial cable 2. An installation plate 5 is fixedly connected between the inner walls on both sides of the housing 1. A plurality of rectangular holes 6 are formed in the installation plate 5. An array element 7 is fixedly connected to the rectangular hole 6. The array element 7 is electrically connected to the corresponding signal line 4. A backing layer 8 is provided on the inner wall of the housing 1. A dust-proof plate 9 is fixedly connected to the bottom of the housing 1. A plurality of heat dissipation holes are formed in the dust-proof plate 9. The housing 1 serves as an external protection structure of the probe to ensure that internal components are protected from the external environment. The multi-conductor coaxial cable 2 is used to transmit high-frequency ultrasonic signals and receive the reflected signals, ensuring the high efficiency and accuracy of signal transmission. The signal lines 4 connect the probe to the signal processing system to transmit control signals and detection data. The array element 7 is composed of 64 independently controlled ultrasonic transducers. Each transducer can independently generate ultrasonic waves. Through phased technology, a beam with a specific direction and shape is synthesized to achieve precise scanning of different regions of the rail head. The virtual source probe for ultrasonic phased array of rail head adopts 64 vibration sources, with a frequency of 5 MHz and a repetition frequency of 1 KHz. The virtual source probe for ultrasonic phased array of rail head is divided into 3 detection regions. One probe is arranged above the tread of the rail head to perform ultrasonic virtual source phased array detection on the rail head part from the top of the tread of the rail head. The other two probes are respectively arranged on the two sides of the rail head to perform ultrasonic virtual source phased array detection on the rail head part from both sides. The 3 virtual source probes for ultrasonic phased array of rail head form a detection system to ensure that the effective detection area of the rail head is greater than 90%. The 3 probes are installed on a phased array detection device for rail head that can ensure the real-time follow-up of the horizontal and vertical positions of the probe with respect to the rail. The phased array detection device for rail head completes the detection actions required for the virtual source detection of ultrasonic phased array of rail head under the automatic control of the PLC automatic control system, and completes the on-line automatic detection of virtual source defects of ultrasonic phased array of rail head, which can effectively detect various internal defect samples in the actual metallurgy and rolling processes of the rail head.

[0024] In some embodiments, the array element 7 is made of an extremely thin piezoelectric ceramic composite material and is placed in parallel in sequence to form a phased array transducer array.

[0025] In some embodiments, two rectangular blocks 10 are welded to both sides of the housing 1. A limiting rod 11 is welded to one side of the rectangular block 10. The setting of the rectangular block 10 plays a supporting role.

[0026] In some embodiments, a pin 12 is slidably connected to the limiting rod 11. A spring 13 is welded between the end of the pin 12 and one side of the corresponding rectangular block 10. The spring 13 is movably sleeved on the corresponding limiting rod 11. The setting of the spring 13 plays a resetting role.

[0027] In some embodiments, mounting blocks 14 are welded on both sides of the dustproof plate 9, and card slots 15 are opened on both sides of the mounting block 14. The card slots 15 are snap-fitted with corresponding card pins 12, and the setting of the mounting block 14 plays a connecting role.

[0028] In some embodiments, four limiting columns 16 are welded on the top of the dustproof plate 9, and four limiting grooves 17 are opened on the bottom of the shell 1. The limiting grooves 17 are in active contact with the corresponding limiting columns 16. The setting of the limiting columns 16 plays a limiting role.

[0029] Working principle or structural principle, when in use, the shell 1 serves as the external protection structure of the probe to ensure that the internal components are protected from the external environment. The multi-conductor coaxial cable 2 is used to transmit high-frequency ultrasonic signals and receive reflected signals to ensure the efficiency and accuracy of signal transmission. The signal line 4 connects the probe with the signal processing system to transmit control signals and detection data. The array element 7 is composed of 64 independently controlled ultrasonic transducers, each of which can excite ultrasonic waves individually, and synthesize beams of specific directions and shapes through phased technology to achieve accurate scanning of different areas of the rail head. The rail head ultrasonic phased array virtual source probe uses 64 vibration sources with a frequency of 5MHz and a repetition frequency of 1KHz. The ultrasonic phased array virtual source probe is divided into 3 detection areas. A probe is arranged above the rail head tread, and ultrasonic virtual source phased array detection is performed on the rail head part from the top of the rail head tread. The other two probes are respectively It is arranged on two sides of the rail head, and ultrasonic virtual source phased array detection is performed on the rail head part from both sides. Three ultrasonic phased array virtual source probes form a detection system to ensure that the effective detection area of ​​the rail head is greater than 90%. The three probes are installed on a rail head phased array detection device that can ensure that the probe follows the horizontal and vertical positions of the rails in real time. The rail head ultrasonic phased array detection device completes the detection actions required for the rail head ultrasonic phased array virtual source detection under the automatic control of the PLC automatic control system, and completes the online automatic detection of the rail head ultrasonic phased array virtual source defects, which can effectively detect various internal defects in the actual metallurgical and rolling processes of the rail head. When the dustproof plate 9 needs to be removed, the bayonet 12 is moved, and the bayonet 12 slides on the corresponding limit rod 11 and compresses the spring 13, so that the bayonet 12 is separated from the corresponding slot 15, and the dustproof plate 9 is moved to remove it, and the interior of the shell 1 can be repaired.

[0030] Finally, it should be noted that the above description is only a preferred embodiment of the utility model and is not intended to limit the utility model. Although the utility model is described in detail with reference to the above embodiments, those skilled in the art can still modify the technical solutions recorded in the above embodiments or replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the utility model shall be included in the protection scope of the utility model.

Claims

1. A rail head ultrasonic phased array virtual source probe, comprising a housing (1), characterized in that: The top of the shell (1) is fixedly connected to a multi-conductor coaxial cable (2); a support plate (3) is welded between the inner walls on both sides of the shell (1); a plurality of signal lines (4) are fixedly connected to the support plate (3); the signal lines (4) are electrically connected to the multi-conductor coaxial cable (2); a mounting plate (5) is fixedly connected between the inner walls on both sides of the shell (1); a plurality of rectangular holes (6) are formed on the mounting plate (5); array elements (7) are fixedly connected to the rectangular holes (6); the array elements (7) are electrically connected to the corresponding signal lines (4); a backing layer (8) is provided on the inner wall of the shell (1); a dustproof plate (9) is fixedly connected to the bottom of the shell (1); the dustproof plate (9) is formed with a plurality of heat dissipation holes.

2. The rail head ultrasonic phased array virtual source probe according to claim 1, characterized in that: The array elements (7) are made of extremely thin piezoelectric ceramic composite material and are placed in parallel in sequence to form a phased array transducer array.

3. The rail head ultrasonic phased array virtual source probe according to claim 1, characterized in that: Two rectangular blocks (10) are welded to both sides of the housing (1), and a limiting rod (11) is welded to one side of the rectangular block (10).

4. The rail head ultrasonic phased array virtual source probe according to claim 3, characterized in that: A latch pin (12) is slidably connected to the limit rod (11), a spring (13) is welded between the end of the latch pin (12) and one side of the corresponding rectangular block (10), and the spring (13) is movably sleeved on the corresponding limit rod (11).

5. The rail head ultrasonic phased array virtual source probe according to claim 4, characterized in that: Mounting blocks (14) are welded on both sides of the dustproof plate (9), and clamping grooves (15) are provided on both sides of the mounting block (14), and the clamping grooves (15) are clamped with corresponding clamping pins (12).

6. The rail head ultrasonic phased array virtual source probe according to claim 5, characterized in that: Four limiting columns (16) are welded to the top of the dustproof plate (9), and four limiting grooves (17) are opened at the bottom of the shell (1), and the limiting grooves (17) are in active contact with corresponding limiting columns (16).

Images