Ultrasonic flaw detection device for steel rail

Abstract

The utility model relates to a flaw detection device, in particular to an ultrasonic flaw detection device for a steel rail. The flaw detection device comprises conveying frames, wherein a lower rail bottom detection probe is arranged between the symmetrically arranged conveying frames through a rail bottom conveying mechanism; a blocking frame is arranged at the end of the conveying frame, and an upper rail bottom detection probe, a rail waist detection probe, a rail top detection probe and a rail side detection probe are installed on one side of the conveying frame through an on-rail conveying mechanism. According to the flaw detection device, the bottom end lower surface, the bottom end upper surface, the rail web, the rail top and the two sides of the rail head of the steel rail can be detected through the detection probes respectively, and due to the fact that different parts of the steel rail are detected respectively, the false detection rate can be effectively reduced, and the accuracy of the detection result is guaranteed; meanwhile, the detection probe can be driven by the rail bottom conveying mechanism and the on-rail conveying mechanism to repeatedly detect back and forth, so that the false detection rate is further reduced, and the detection result is accurate. The problems that an existing flaw detection device is high in false detection rate and inaccurate in detection result are solved.

Description

Technical Field

[0001] The utility model relates to a flaw detection device, in particular to an ultrasonic flaw detection device for steel rails. Background Art

[0002] With the continuous increase in the passenger volume of the railway system and the train speed, the quality requirements for steel rails are getting higher and higher. The quality of steel rails is related to major life safety and property safety. During the smelting, rolling, and heat treatment processes of steel rails, some surface defects and non-metallic inclusions may occur, such as rolling scars, surface cracks, white spots, internal cracks, micro-cracks, etc. Under the long-term load of the wheels, these defects will gradually reduce the effective cross-section of the steel rail, and finally cause the steel rail to break, resulting in serious accidents.

[0003] To ensure safety, in current domestic and foreign steel rail standards, it is required that all steel rails must pass flaw detection before leaving the factory before they can be put into use. Currently, ultrasonic flaw detection is generally used for steel rail flaw detection. Ultrasonic flaw detection has many advantages, such as high sensitivity, fast speed, and no damage to the steel rail surface.

[0004] The patent application with the publication number CN218584722U discloses a fixed steel rail flaw detection device, which includes an outer frame, a probe wheel structure for flaw detection of the steel rail, and an encoder assembly for detecting the displacement of the steel rail. The probe wheel structure and the encoder assembly are installed in the outer frame, and the probe wheel structure is above the encoder assembly; in the utility model, steel rail conveying ports are opened on both sides of the outer frame to convey the steel rail. The steel rail is transmitted inside the outer frame, and then the probe wheel structure is used to perform flaw detection on the steel rail, and the encoder is used for displacement detection. The probe wheel and the encoder cooperate to determine the position of the steel rail damage. This device can be installed on the steel rail production line. After one section of the steel rail is detected, the next section can be immediately detected, realizing the automatic detection of multiple sections of steel rails leaving the factory without manual assistance. The detection process is simple, greatly improving the efficiency of steel rail factory inspection and solving the problems of low efficiency and cumbersome process of manual inspection.

[0005] The above flaw detection device can detect the steel rails leaving the factory. However, when it detects through the probe wheel structure, it detects from the top of the steel rail downwards. Due to the occlusion of the rail top, there is a high false detection rate for the detection of the rail waist and rail bottom of the steel rail. Therefore, it is necessary to redesign an ultrasonic flaw detection device for steel rails to solve the above problems. Summary of the Invention

[0006] The purpose of the utility model is to provide an ultrasonic flaw detection device for steel rails that can effectively reduce the false detection rate and improve the detection accuracy.

[0007] The technical solution of the utility model is:

[0008] A rail ultrasonic flaw detection device is composed of a conveying frame, a rail bottom conveying mechanism, a blocking frame and a rail upper conveying mechanism, and is characterized in that: a rail bottom conveying mechanism is arranged between symmetrically arranged conveying frames, and a lower rail bottom detection probe for detecting the middle part of the lower surface of the bottom end of the rail is arranged on the rail bottom conveying mechanism; a blocking frame is arranged at the end of the conveying frame, a rail upper conveying mechanism is arranged on one side of the conveying frame, upper rail bottom detection probes for detecting the upper surface of the bottom end of the rail are symmetrically arranged on the rail upper conveying mechanism, a rail waist detection probe for detecting the waist of the rail is arranged above one of the upper rail bottom detection probes, a rail top detection probe for detecting the top of the rail head is arranged above the rail waist detection probe, and rail side detection probes for detecting the side surfaces of the rail head are respectively arranged on both sides of the rail top detection probe.

[0009] The said conveying frame is composed of a frame, conveying rollers and a conveying motor. The conveying rollers are evenly installed on the frame through bearings, and the conveying rollers are connected to each other through a transmission chain; a conveying motor is arranged on one side of the middle part of the frame, and the conveying motor is respectively connected to the conveying rollers adjacent above the conveying motor through a driving chain.

[0010] The said blocking frame is composed of a baffle, a lifting lead screw, a lifting nut, a gear box, a lifting slide rail and a lifting slide seat. One end of the baffle is provided with a lifting lead screw, and the lifting lead screw is connected to the baffle through a lifting nut; the bottom end of the lifting lead screw is provided with a gear box; a lifting slide rail is arranged on the other side of the baffle, and the lifting slide rail is connected to the baffle through a lifting slide seat.

[0011] The said rail bottom conveying mechanism and rail upper conveying mechanism are respectively composed of a conveying slide rail, a conveying lead screw, a lead screw motor, a conveying nut and a support plate. The conveying lead screw is installed above the conveying slide rail through a bearing seat, the end of the conveying lead screw is provided with a lead screw motor, and the output shaft of the lead screw motor is fixedly connected to the conveying lead screw through a coupling; a conveying nut is threadedly installed on the conveying lead screw, and the conveying nut is movably connected to the conveying slide rail through a conveying slide seat; a support plate is arranged on the conveying nut.

[0012] The top end of the support plate of the rail bottom conveying mechanism is fixedly connected to the lower rail bottom detection probe; the ends of the support plates of the rail upper conveying mechanism are in an inverted U shape, and the support plates of the rail upper conveying mechanism are respectively fixedly connected to the upper rail bottom detection probe, the rail waist detection probe, the rail top detection probe and the rail side detection probe.

[0013] Preferably, the said lower rail bottom detection probe, upper rail bottom detection probe, rail waist detection probe, rail top detection probe and rail side detection probe are respectively double-crystal ultrasonic probes.

[0014] The beneficial effects of the utility model are as follows:

[0015] The rail ultrasonic flaw detection device can detect the lower surface of the bottom end, the upper surface of the bottom end, the web, the head, and both sides of the head of the rail respectively through the detection probes. Since it detects different parts of the rail separately, it can effectively reduce the false detection rate and ensure the accuracy of the detection results. At the same time, the bottom rail transmission mechanism and the upper rail transmission mechanism can drive the detection probes to detect back and forth multiple times, further reducing the false detection rate and ensuring the accuracy of the detection results. It solves the problems of high false detection rate and inaccurate detection results of the existing flaw detection devices. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a schematic structural diagram of the present utility model;

[0017] Figure 2 is a schematic structural diagram of the transfer rack of the present utility model;

[0018] Figure 3 is a schematic structural diagram of the blocking rack of the present utility model;

[0019] Figure 4 is a schematic structural diagram of the bottom rail detection mechanism of the present utility model;

[0020] Figure 5 is a schematic structural diagram of the upper rail detection mechanism of the present utility model.

[0021] In the figure: 1, lower bottom rail detection probe; 2, upper bottom rail detection probe; 3, web detection probe; 4, head detection probe; 5, side detection probe; 6, frame; 7, transfer roller; 8, transfer motor; 9, transmission chain; 10, drive chain; 11, baffle; 12, lifting lead screw; 13, lifting nut; 14, gear box; 15, lifting slide rail; 16, lifting slide block; 17, transfer slide rail; 18, transfer lead screw; 19, lead screw motor; 20, transfer nut; 21, support plate; 22, transfer slide block; 23, detection camera; 24, rail. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] The ultrasonic flaw detector for steel rails is composed of a conveying rack, a bottom rail conveying mechanism, a blocking rack and an upper rail conveying mechanism. A bottom rail conveying mechanism is arranged between the symmetrically arranged conveying racks. A lower bottom rail detection probe 1 for detecting the middle part of the lower surface of the bottom end of the steel rail is arranged on the bottom rail conveying mechanism. A blocking rack is arranged at the end of the conveying rack. An upper rail conveying mechanism is arranged on one side of the conveying rack. Upper bottom rail detection probes 2 for detecting the upper surface of the bottom end of the steel rail are symmetrically arranged on the upper rail conveying mechanism. Above one of the upper bottom rail detection probes 2, a rail waist detection probe 3 for detecting the rail waist is arranged. Above the rail waist detection probe 3, a rail top detection probe 4 for detecting the top of the rail head is arranged. Rail side detection probes 5 for detecting the side surfaces of the rail head are respectively arranged on both sides of the rail top detection probe 4. The function of the conveying rack is to convey the steel rail through the conveying rack so that it enters the movement ranges of the bottom rail conveying mechanism and the upper rail conveying mechanism, enabling the bottom rail conveying mechanism and the upper rail conveying mechanism to drive the detection probes to scan various positions of the steel rail, thereby enabling a comprehensive detection of the steel rail. The function of the bottom rail conveying mechanism is to drive the lower bottom rail detection probe 1 to move at the bottom of the steel rail through the bottom rail conveying mechanism, thereby comprehensively detecting the lower surface of the bottom end of the steel rail. The function of the upper rail conveying mechanism is to drive the upper bottom rail detection probes 2, the rail waist detection probe 3, the rail top detection probe 4 and the rail side detection probes 5 to move along the steel rail respectively through the upper rail conveying mechanism, thereby respectively comprehensively detecting the upper surface of the bottom end of the steel rail, the rail waist, the rail top and the two sides of the rail head. Since it can comprehensively detect the lower surface of the bottom end, the upper surface of the bottom end, the rail waist, the rail top and the two sides of the rail head of the steel rail, it can detect each part of the steel rail separately, rather than just detecting from top to bottom. Therefore, the false detection rate can be effectively reduced. At the same time, through the back-and-forth movement of the detection probes along the steel rail, the steel rail can be comprehensively detected, which can further reduce the false detection rate and ensure the accuracy of the detection results. The function of the blocking rack is to block the steel rail through the blocking rack to limit the position of the steel rail, thereby ensuring a comprehensive detection of the steel rail.

[0023] The conveying rack is composed of a frame 6, conveying rollers 7 and a conveying motor 8. The conveying rollers 7 are evenly installed on the frame 6 through bearings, and the conveying rollers 7 are connected to each other through a transmission chain 9. A conveying motor 8 is arranged on one side of the middle of the frame 6, and the conveying motor 8 is connected to the conveying roller 7 adjacent above the conveying motor 8 respectively through a driving chain 10.

[0024] The blocking frame is composed of a baffle 11, a lifting screw rod 12, a lifting nut 13, a gearbox 14, a lifting slide rail 15 and a lifting slide block 16. One end of the baffle 11 is provided with the lifting screw rod 12, and the lifting screw rod 12 is connected to the baffle 11 through the lifting nut 13; the bottom end of the lifting screw rod 12 is provided with the gearbox 14; on the other side of the baffle 11, there is the lifting slide rail 15, and the lifting slide rail 15 is connected to the baffle 11 through the lifting slide block 16. In the middle of the baffle 11, there is a detection camera 23, and the detection camera 23 is connected to the PLC. The detection camera 23 can detect the rail, so as to control the actions of the blocking frame, the bottom-rail conveying mechanism and the on-rail conveying mechanism. Thus, after the rail arrives, the detection of the rail is controlled. The lifting screw rod 12 can be connected to the motor through the gearbox 14, and then the lifting screw rod 12 is driven to rotate through the motor and the gearbox 14 in sequence. Therefore, during the rotation of the lifting screw rod 12, the baffle 11 is driven to lift through the lifting nut 13, so that the baffle 11 can block the rail during the detection process, and after the detection, the baffle 11 moves upward to release the rail, enabling the rail to continue to be conveyed forward.

[0025] The bottom-rail conveying mechanism and the on-rail conveying mechanism are respectively composed of a conveying slide rail 17, a conveying screw rod 18, a screw rod motor 19, a conveying nut 20 and a support plate 21. Above the conveying slide rail 17, the conveying screw rod 18 is installed through a bearing seat, and the end of the conveying screw rod 18 is provided with the screw rod motor 19. The output shaft of the screw rod motor 19 is fixedly connected to the conveying screw rod 18 through a coupling; the conveying nut 20 is threadedly installed on the conveying screw rod 18, and the conveying nut 20 is movably connected to the conveying slide rail 17 through a conveying slide block 22; the support plate 21 is arranged on the conveying nut 20. The top end of the support plate 21 of the bottom-rail conveying mechanism is fixedly connected to the lower bottom-rail detection probe 1; the end of the support plate 21 of the on-rail conveying mechanism is in an inverted U shape, and the support plates 21 of the on-rail conveying mechanism are respectively fixedly connected to the upper bottom-rail detection probe 2, the web detection probe 3, the head detection probe 4 and the side detection probe 5. The function of the screw rod motor 19 is to drive the conveying screw rod 18 to rotate through the screw rod motor 19, and then drive the conveying nut 20 to move along the conveying screw rod 18. Thus, during the movement of the conveying nut 20, the lower bottom-rail detection probe 1, the upper bottom-rail detection probe 2, the web detection probe 3, the head detection probe 4 and the side detection probe 5 are respectively driven to move through the support plate 21, so as to comprehensively detect the rail through the lower bottom-rail detection probe 1, the upper bottom-rail detection probe 2, the web detection probe 3, the head detection probe 4 and the side detection probe 5 during the movement process. Preferably, the lower bottom-rail detection probe 1, the upper bottom-rail detection probe 2, the web detection probe 3, the head detection probe 4 and the side detection probe 5 are respectively double-crystal ultrasonic probes.

[0026] When the rail ultrasonic flaw detection device is working, the rail is conveyed to the conveying roller 7 of the conveying frame, and the conveying motor 8 conveys the rail forward through the driving chain 10, the transmission chain 9 and the conveying roller 7. When the rail is detected by the detection camera 23 during the conveying process, the baffle 11 is driven to descend by the motor, the gearbox 14, the lifting lead screw 12 and the lifting nut 13 to block the rail. After the rail is in place, the lead screw motors 19 of the bottom rail conveying mechanism and the upper rail conveying mechanism are started. The lead screw motors 19 drive the lower bottom rail detection probe 1, the upper bottom rail detection probe 2, the rail waist detection probe 3, the rail top detection probe 4 and the rail side detection probe 5 to reciprocate along the rail through the conveying lead screws 18, the conveying nuts 20 and the support plates 21 respectively. During the process of the lower bottom rail detection probe 1, the upper bottom rail detection probe 2, the rail waist detection probe 3, the rail top detection probe 4 and the rail side detection probe 5 reciprocating along the rail, the lower bottom rail detection probe 1, the upper bottom rail detection probe 2, the rail waist detection probe 3, the rail top detection probe 4 and the rail side detection probe 5 respectively detect all parts of the rail comprehensively.

[0027] The rail ultrasonic flaw detection device can detect the lower surface of the bottom end, the upper surface of the bottom end, the rail waist, the rail top and both sides of the rail head of the rail respectively through the detection probes. Since it detects different parts of the rail separately, it can effectively reduce the false detection rate and ensure the accuracy of the detection results. At the same time, through the bottom rail conveying mechanism and the upper rail conveying mechanism, the detection probes can be driven to detect back and forth multiple times, further reducing the false detection rate and ensuring the accuracy of the detection results. It solves the problems of high false detection rate and inaccurate detection results of the existing flaw detection devices.

Claims

1. A rail ultrasonic flaw detection device, which consists of a conveying frame, a rail bottom conveying mechanism, a blocking frame and a rail conveying mechanism, characterized in that: A rail bottom conveying mechanism is arranged between symmetrically arranged conveying frames, and a lower rail bottom detection probe (1) for detecting the middle of the lower surface of the bottom end of the steel rail is arranged on the rail bottom conveying mechanism; a blocking frame is arranged at the end of the conveying frame, and an upper rail conveying mechanism is arranged on one side of the conveying frame, and upper rail bottom detection probes (2) for detecting the upper surface of the bottom end of the steel rail are symmetrically arranged on the upper rail conveying mechanism, wherein a rail waist detection probe (3) for detecting the waist of the steel rail is arranged above the upper rail bottom detection probe (2) on one side, a rail top detection probe (4) for detecting the top of the rail head is arranged above the rail waist detection probe (3), and rail side detection probes (5) for detecting the side surfaces of the rail head are respectively arranged on both sides of the rail top detection probe (4).

2. A rail ultrasonic flaw detection device according to claim 1, characterized in that: The conveying frame is composed of a frame (6), conveying rollers (7) and a conveying motor (8). The conveying rollers (7) are evenly mounted on the frame (6) via bearings, and the conveying rollers (7) are connected to each other via a transmission chain (9). A conveying motor (8) is arranged on one side of the middle of the frame (6), and the conveying motor (8) is respectively connected to the conveying rollers (7) adjacent to the upper side of the conveying motor (8) via a drive chain (10).

3. The rail ultrasonic flaw detection device according to claim 1, characterized in that: The blocking frame is composed of a baffle (11), a lifting screw (12), a lifting nut (13), a gear box (14), a lifting slide rail (15) and a lifting slide seat (16). A lifting screw (12) is arranged at one end of the baffle (11), and the lifting screw (12) is connected to the baffle (11) through the lifting nut (13); a gear box (14) is arranged at the bottom end of the lifting screw (12); a lifting slide rail (15) is arranged on the other side of the baffle (11), and the lifting slide rail (15) is connected to the baffle (11) through the lifting slide seat (16).

4. A rail ultrasonic flaw detection device according to claim 1, characterized in that: The rail bottom transmission mechanism and the rail top transmission mechanism are respectively composed of a transmission slide rail (17), a transmission screw rod (18), a screw motor (19), a transmission nut (20) and a support plate (21). A transmission screw rod (18) is installed above the transmission slide rail (17) through a bearing seat. A screw motor (19) is arranged at the end of the transmission screw rod (18). The output shaft of the screw motor (19) is fixedly connected to the transmission screw rod (18) through a coupling. A transmission nut (20) is threadedly installed on the transmission screw rod (18). The transmission nut (20) is movably connected to the transmission slide rail (17) through a transmission slide seat (22). A support plate (21) is arranged on the transmission nut (20).

5. A rail ultrasonic flaw detection device according to claim 4, characterized in that: The top end of the rail bottom transmission mechanism support plate (21) is fixedly connected to the lower rail bottom detection probe (1); the end of the rail top transmission mechanism support plate (21) is in an inverted U shape, and the rail top transmission mechanism support plate (21) is respectively fixedly connected to the upper rail bottom detection probe (2), the rail waist detection probe (3), the rail top detection probe (4), and the rail side detection probe (5).

6. The rail ultrasonic flaw detection device according to claim 1, characterized in that: The lower rail bottom detection probe (1), the upper rail bottom detection probe (2), the rail waist detection probe (3), the rail top detection probe (4) and the rail side detection probe (5) are respectively double crystal ultrasonic probes.

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