Full-automatic ultrasonic detection probe for draw ring of car coupler
By designing an ultrasonic detection probe and probe angle detector with arc-shaped three-dimensional structure, the accuracy and efficiency of the detection of fatigue cracks of the hook pull-up ring are solved, ensuring the safe operation of the EMU.
Patent Information
- Application Number
- CN202421960048.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-13
- Publication Date
- 2025-07-25
- Estimated Expiration
- 2034-08-13
AI Technical Summary
In the prior art, fatigue crack detection of the hook pull ring is difficult to accurately determine, the operation is complex and the efficiency is low, which brings hidden dangers to the safe operation of the EMU.
An ultrasonic detection probe with an arc-shaped three-dimensional structure was designed. The top and bottom surfaces of the probe are rectangular, and the second end surface is an arc-shaped curved surface. The incident point is on the plane and the incident angle is controllable. Combined with the probe angle detector, the incident point and angle are determined to realize the full circumferential scanning.
It improves the accuracy and efficiency of fatigue crack detection of the hook pull-ring, ensures the safe operation of the EMU, and provides good repeatability and operability.
Smart Images
Figure CN223154936U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the field of detection of coupler pull rings, and particularly relates to an ultrasonic detection probe for a full-automatic coupler pull ring. Background Art
[0002] The full-automatic coupler assembly is a key device for the connection of high-speed multiple units. The coupler pull ring X at the tail Z of the coupler is the most critical part of the entire coupler assembly. See Figure 1 . The coupler pull ring X bears the traction and connection tasks of the multiple units. The coupler pull ring X is connected to the mounting seat coupler tail pin and the buffer housing to ensure that the multiple units can be stably and safely connected together during driving. In order to ensure excellent mechanical properties and durability, the coupler pull ring usually uses high-strength alloy steel bars as the main material and is processed through processes such as forging, rough machining, heat treatment, and finish machining.
[0003] As Figure 2 shown, the full-automatic coupler pull ring X is located at the tail of the full-automatic coupler. One end of the full-automatic coupler pull ring X is a pull ring body X1, and a through hole is provided on the pull ring body X1. The full-automatic coupler pull ring X is connected to the mounting seat coupler tail pin through the through hole. The other end of the full-automatic coupler pull ring X is a fixing part X2, and the full-automatic coupler pull ring X is connected to the buffer housing through the fixing part X2. A connecting part X3 is provided between the pull ring body X1 and the fixing part X2. Both ends of the connecting part X3 are smoothly connected to the fixing part X2 and the pull ring body X1 respectively. The smooth connection part of the connecting part X3 and the fixing part X2 is an ultrasonic detection area Y.
[0004] However, the coupler pull ring is subjected to the action of traction force (dynamic load) during operation. This continuous force may cause fatigue cracks at the structural mutation. If the fatigue cracks are not discovered and processed in time, it will pose a serious threat to the structural integrity and functional stability of the coupler pull ring, and further affect the driving safety of the high-speed multiple units. Therefore, it is very necessary to regularly perform ultrasonic non-destructive testing on the coupler pull ring. Ultrasonic non-destructive testing is an efficient and accurate testing method that can detect internal defects and cracks without damaging the material. By performing ultrasonic testing on the coupler pull ring, potential fatigue cracks can be discovered in time, and corresponding repair or replacement measures can be taken to ensure that the coupler pull ring works in a crack-free state.
[0005] Figure 3 The position framed at W in Figure 4, a transverse wave inclined probe is placed at point A for a full circumferential 360-degree scan. Although the A position is the most easily achievable detection position, in actual applications, the position where fatigue cracks occur (the crack root) usually appears at the root of the R3.5 arc of the pull ring structure. When ultrasonic waves are incident here, regardless of whether there are cracks, reflected echoes from the R3.5 arc will always be received. If there are cracks, a "double peak" situation will occur in the A-scan display when the probe is detected at position A. Sometimes the two signals almost merge into one signal, causing great difficulties in defect detection and determination. Secondly, since there is still a certain space before and after the A position, the probe needs to move back and forth at the A position during the detection process (see A1 and A2 in Figure 5 to find the detection area of the red box. Therefore, in actual detection, to detect the coupler pull ring, it is necessary to first find the detection position, which requires relatively high skills for the operator, brings certain difficulties to the operator, and results in low detection efficiency. Utility Model Content
[0006] To solve the above problems, the present utility model proposes an ultrasonic detection probe for a fully automatic coupler pull ring. The shape of the ultrasonic detection probe fits the ultrasonic detection area, the incident point position of the ultrasonic detection probe is on a plane, and the incident angle is controllable.
[0007] The present utility model proposes an ultrasonic detection probe for a fully automatic coupler pull ring. The ultrasonic detection probe is a three-dimensional structure with an arc. The top surface and the bottom surface of the ultrasonic detection probe are parallel and both are rectangular. The first end surface of the ultrasonic detection probe is also rectangular and the first end surface is perpendicular to the top surface and the bottom surface. The second end surface of the ultrasonic detection probe is a convex arc-shaped surface, and the two side surfaces of the ultrasonic detection probe are also perpendicular to the top surface and the bottom surface respectively;
[0008] Wherein, the second end surface and the bottom surface of the ultrasonic detection probe are attached to the ultrasonic detection area on the coupler pull ring.
[0009] In one embodiment, the ultrasonic detection probe includes:
[0010] A probe housing, the probe housing is a three-dimensional structure with an arc. The second end surface of the probe housing is the second end surface of the ultrasonic detection probe. There is a groove provided inward from the second end surface of the probe housing;
[0011] A probe body, placed in the groove. The size and shape of the probe body match the size and shape of the groove. A wafer is provided in the probe body.
[0012] In one embodiment, the probe body is made of plexiglass and the probe housing is made of resin material.
[0013] In one embodiment, the size of the wafer is 6*6 mm.
[0014] In one embodiment, the center echo frequency of the ultrasonic detection probe is 5 MHz.
[0015] In one embodiment, the error of the center echo frequency of the ultrasonic detection probe is Δf / f ≤ 15%.
[0016] In one embodiment, the refraction angle β of the ultrasonic detection probe is 68 degrees.
[0017] In one embodiment, the error of the refraction angle β of the ultrasonic detection probe is Δβ ≤ 1.5 degrees.
[0018] In one embodiment, the ultrasonic detection area is an arc with a radius of 18 mm, and the second end face of the ultrasonic detection probe is also an arc with a radius of 18 mm.
[0019] In one embodiment, the incident point position of the ultrasonic detection probe is on a plane.
[0020] The beneficial effects of the ultrasonic detection probe for the fully automatic coupler pull ring of the present utility model are as follows:
[0021] The specially designed ultrasonic detection probe has a good detection effect on detecting fatigue cracks at special positions of the coupler pull ring, solves the difficulty of defect determination caused by the part contour echo before, and improves the detection efficiency and reliability. The entire scanning detection process has good repeatability and operability, escorts the safe operation of the EMU, and also provides experience for the detection of similar workpieces. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Figure 1 It is a schematic structural diagram of a fully automatic coupler assembly.
[0023] Figure 2 It is Figure 1 a schematic cross-sectional view at Z in , and Z is the coupler tail.
[0024] Figure 3 It is Figure 2 an enlarged schematic view at Y in , where the area W is the place most prone to fatigue cracks.
[0025] Figure 4 It is Figure 2 an enlarged schematic view at Y in , where A is a schematic diagram of the position of the probe during ultrasonic detection in the prior art.
[0026] Figure 5 It is Figure 2Enlarged schematic view at Y in the middle, where A1 and A2 are schematic views of the probe moving back and forth at position A during ultrasonic testing.
[0027] Figure 6 Schematic diagram of the overall structure of the ultrasonic testing probe for the full - automatic coupler pull - ring of an embodiment of the present utility model.
[0028] Figure 7 Schematic diagram of the specific structure of the ultrasonic testing probe for the full - automatic coupler pull - ring of an embodiment of the present utility model.
[0029] Figure 8 is Figure 2 Enlarged schematic view at Y in the middle, where B is the schematic view of the detection position of the ultrasonic testing probe for the full - automatic coupler pull - ring of an embodiment of the present utility model.
[0030] Figure 9 Schematic diagram of the incident point adopted by the ultrasonic testing probe for the full - automatic coupler pull - ring of an embodiment of the present utility model.
[0031] Figure 10 Schematic diagram of the incident point to be avoided by the ultrasonic testing probe for the full - automatic coupler pull - ring of an embodiment of the present utility model.
[0032] Figure 11 Schematic diagram of workpiece scanning using the ultrasonic testing probe for the full - automatic coupler pull - ring of an embodiment of the present utility model.
[0033] Figure 12 Schematic diagram of the overall structure of the probe angle detector of an embodiment of the present utility model.
[0034] Figure 13 Schematic diagram of the specific structure of the probe angle detector of an embodiment of the present utility model.
[0035] Figure 14 Schematic diagram of the position of the artificial groove.
[0036] Reference numerals
[0037] 1. Arc - shaped probe, 11. Probe body, 12. Probe housing, 2. Probe angle detector, 21. Probe angle detector body, 22. Probe angle detector housing. Detailed implementation manners
[0038] In order to make the objectives, technical solutions and advantages of the present utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the utility model and are not used to limit the utility model.
[0039] The present utility model proposes an ultrasonic detection probe 1 for a full-automatic coupler pull ring. The ultrasonic detection probe 1 has a three-dimensional structure with an arc shape. Refer to Figure 6 . The top surface and the bottom surface of the ultrasonic detection probe 1 are parallel and both are rectangular. The first end surface of the ultrasonic detection probe 1 is also rectangular and the first end surface is perpendicular to the top surface and the bottom surface. The second end surface of the ultrasonic detection probe 1 is an outwardly convex arc-shaped curved surface, and the two side surfaces of the ultrasonic detection probe are also perpendicular to the top surface and the bottom surface respectively. Among them, the second end surface and the bottom surface of the ultrasonic detection probe 1 are attached to the ultrasonic detection area Y on the coupler pull ring. Refer to Figure 8 .
[0040] Furthermore, the ultrasonic detection probe 1 includes: a probe body 11 and a probe housing 12. As Figure 7 shown, the probe housing 12 has a three-dimensional structure with an arc shape, and its overall structure is the same as the overall structure of the ultrasonic detection probe 1 described above. The second end surface of the probe housing 12 is the second end surface of the ultrasonic detection probe 1. The difference between the probe housing 12 and the ultrasonic detection probe 1 is that a groove is provided inward from the second end surface of the probe housing 12, and this groove is used to place the probe body 11. The size and shape of the probe body 11 match the size and shape of the groove, and a wafer is provided inside the probe body 11. In a specific embodiment, leads are connected to the wafer. As Figure 11 shown, the ultrasonic detection probe 1 is used to make a 360-degree full circumferential scanning imaging by attaching to the ultrasonic detection area.
[0041] Furthermore, the probe body is made of plexiglass, and the probe housing is made of resin material. It should be understood that the probe body can also be made of other sound guiding materials according to the actual situation.
[0042] In this embodiment, preferably, the size of the wafer is 6*6mm. The center echo frequency of the ultrasonic detection probe is 5MHz, and the error of the center echo frequency of the ultrasonic detection probe is Δf / f≤15%. The refraction angle β of the ultrasonic detection probe is 68 degrees, and the error of the refraction angle β of the ultrasonic detection probe is Δβ≤1.5 degrees. The ultrasonic detection area is an arc with a radius of 18mm, and the second end surface of the ultrasonic detection probe is also an arc with a radius of 18mm.
[0043] As Figure 8 shown, ultrasonic waves enter the workpiece to be measured from the direction of position B. Detecting from this direction can avoid the contour echo of the R3.5 arc. After preparing a probe that matches the 18mm arc, it is also necessary to select the incident point of the probe. As Figure 9 shown, when the incident point position is on a plane, the incident angle is controllable. As Figure 10As shown, it is necessary to avoid the situation where the incident point is on the arc. If the incident point is on the arc, the incident angle will be uncontrollable, which will have a great impact on the positioning and quantification of defects. Therefore, how to accurately find the incident point at the arc so that the ultrasonic wave can enter the part at a known and controllable angle in the plane position is a problem to be solved.
[0044] Determining the probe incident angle and the incident point is the biggest difficulty in the manufacture of the arc-shaped probe. If we test one angle by one, we need to make too many probes, which is obviously not the best solution. In order to accurately find the probe incident point and the probe incident angle at the radian, a probe angle detector 2 is developed (see Figure 12 ). The radian of the probe angle detector 2 coincides with the radian of the ultrasonic detection area Y. Place the probe angle detector 2 on the workpiece to be tested. The instrument can rotate at the arc of the workpiece to be tested (i.e., the ultrasonic detection area Y) until the defect echo is found, and then determine the incident angle and the incident point of the arc-shaped probe 1.
[0045] Furthermore, as Figure 12 shown, the probe angle detector 2 is an arc-shaped cylinder, and the radian of the first end of the probe angle detector 2 coincides with the radian of the ultrasonic detection area Y. As Figure 13 shown, in one embodiment, the probe angle detector 2 includes a probe angle detector body 21 and a probe angle detector housing 22. A groove is opened at the first end of the probe angle detector body 21, and a probe angle detector wafer is arranged in the groove. The probe angle detector wafer is connected to the ultrasonic detector. By using the ultrasonic detector to find the defect echo, the incident angle and the incident point of the arc-shaped probe 1 can be determined.
[0046] Verify the feasibility of the technical solution of the present invention by making a comparison test block. The comparison test block is made of a complete coupler pull ring. Using the same material, steel grade and heat treatment process, problems such as sound attenuation compensation and coupling compensation are avoided. The comparison test block has artificial defects, which are used to simulate various defect situations that may occur in the actual workpiece, so as to help the detection personnel evaluate the accuracy and reliability of the flaw detection technology. The artificial reference defect uses a grooved to simulate a fatigue crack. The artificial grooving is processed by wire cutting. However, since the pull ring part is an arc, when wire cutting, when the middle depth is 0.5 mm, the edge depth is about 5 mm. Considering that fatigue cracks do not occur only at one point, but within the entire frame indicated in Figure 14 . Therefore, another artificial groove b is processed on the left side of the artificial groove a. The position between these two grooves is where fatigue cracks are most likely to occur. See Figure 14 .
[0047] After repeated trials, the refraction angle of the arc-shaped probe was finally made 68 degrees. The 68-degree refraction angle probe can simultaneously detect the artificial notch a and the artificial notch b, thus ensuring to the greatest extent that the sound velocity of the arc-shaped probe can cover the area where cracks are most likely to appear.
[0048] The method for determining the sensitivity of the arc-shaped probe in the present invention is as follows:
[0049] Referring to the requirements for ultrasonic flaw detection of wheelsets in Chapter 5 of the "Rules for Assembly, Inspection, and Management of Railway Passenger Car Wheelsets", and combining with the usage environment and importance of the coupler pull ring, the depth of the artificial notch is processed to be 0.5 mm deep, and the notch echo is adjusted to 80% of the full screen height and then increased by 3 dB, which is used as the detection sensitivity. During the detection process, attention should be paid to observing the change of the echo signal, promptly discovering and recording potential defects and cracks. Evaluate the safety and reliability of the coupler pull ring according to the flaw detection results. If defects or cracks exceed the specified standards, repair or replacement measures should be taken promptly.
[0050] The specific implementation method of the ultrasonic detection equipment and detection method for the full-automatic coupler pull ring according to an embodiment of the present utility model is as follows:
[0051] In view of the fact that there is no special detection standard for the coupler pull ring, the following requirements for the coupler pull ring detection are made here by referring to the requirements for ultrasonic flaw detection of wheelsets in Chapter 5 of the "Rules for Assembly, Inspection, and Management of Railway Passenger Car Wheelsets":
[0052] a. The center echo frequency of the transverse wave inclined probe is 5 MHz;
[0053] b. The refraction angle of the transverse wave probe is 68 degrees;
[0054] c. The error of the probe center echo frequency Δf / f ≤ 15%;
[0055] d. The error of the refraction angle (β) Δβ ≤ 1.5 degrees;
[0056] The parameters of the newly manufactured arc-shaped probe should meet the above requirements.
[0057] In actual verification and application, ultrasonic flaw detection was carried out on the scrapped housing assemblies for various reasons. A total of more than 120 scrapped housing assemblies were detected, and one housing assembly with abnormal echo was found. After cutting its pull ring, visual inspection, penetrant inspection, and magnetic particle inspection were carried out, and the inspection results were consistent with the ultrasonic flaw detection results. Penetrant inspection was carried out on the pull ring with abnormal wave. After penetrant inspection, a circumferential crack defect was found. After cutting, fluorescent magnetic particle inspection was carried out. To further verify the reliability of this ultrasonic detection method, the remaining more than 120 pull rings with normal ultrasonic detection results were all cut and dissected one by one, and then visual inspection, penetrant inspection, and magnetic particle inspection were carried out. No fatigue cracks were found, which was consistent with the ultrasonic flaw detection results, and no defects existed.
[0058] The requirement for the coupler pull ring is that there are no cracks. After measuring more than 120 coupler pull rings, the test results are analyzed and evaluated using statistical methods. When the evaluation threshold is set at 20%, the detection rate is 95%. Under the condition of a confidence level of 95%, the detection rate of the detection system (POD is 0.5 mm).
[0059] The usage method of the ultrasonic detection probe for a fully automatic coupler pull ring of the present utility model is as follows:
[0060] The wafer in the ultrasonic detection probe 1 is electrically connected to the ultrasonic detector through a lead wire. The ultrasonic detection probe 1 is used to emit ultrasonic waves. The ultrasonic waves hit an object and bounce back, and then are sensed by the ultrasonic detection probe 1. The ultrasonic detection probe 1 transmits the signal to the ultrasonic detector, and judges the damage that cannot be seen by the human eye of the object to be detected through the change of the ultrasonic waves.
[0061] The beneficial effects of the ultrasonic detection probe for a fully automatic coupler pull ring of the present utility model are as follows:
[0062] The specially designed ultrasonic detection probe has a good detection effect on detecting fatigue cracks in special positions of the coupler pull ring, solves the difficulty in defect judgment caused by the part contour echo before, and improves the detection efficiency and reliability. The entire scanning detection process has good repeatability and operability, escorts the safe operation of the EMU, and also provides experience for the detection of similar workpieces.
[0063] The above embodiments are only further descriptions of the present utility model, rather than other forms of limitation on the present utility model. The present utility model can also have many other embodiments. Without departing from the spirit and essence of the present utility model, those skilled in the art can make various corresponding modifications and changes according to the present utility model, but these corresponding modifications and changes should all fall within the protection scope of the present utility model.
Claims
1. An ultrasonic detection probe for a fully automatic coupler pull ring, characterized in that, The ultrasonic detection probe has a three-dimensional structure with an arc shape. The top and bottom surfaces of the ultrasonic detection probe are parallel and both are rectangular. The first end face of the ultrasonic detection probe is also rectangular and is perpendicular to the top and bottom surfaces. The second end face of the ultrasonic detection probe is an outwardly convex arc-shaped surface, and the second end face is arranged opposite to the first end face. The two side faces of the ultrasonic detection probe are arranged opposite to each other, and the two side faces of the ultrasonic detection probe are also perpendicular to the top and bottom surfaces respectively; Among them, the second end face and the bottom surface of the ultrasonic detection probe are attached to the ultrasonic detection area on the coupler drawbar.
2. The ultrasonic detection probe for the full-automatic coupler pull ring according to claim 1, characterized in that, The ultrasonic detection probe includes: A probe housing, the probe housing has a three-dimensional structure with an arc shape. The second end face of the probe housing is the second end face of the ultrasonic detection probe, and there is a groove arranged inward from the second end face of the probe housing; A probe body, which is placed in the groove. The size and shape of the probe body match the size and shape of the groove, and a wafer is arranged in the probe body.
3. The ultrasonic detection probe for the full-automatic coupler pull ring according to claim 2, wherein, The probe body is made of plexiglass, and the probe housing is made of resin material.
4. The ultrasonic detection probe for the full-automatic coupler pull ring according to claim 2, characterized in that, The size of the wafer is 6*6mm.
5. The ultrasonic detection probe for the full-automatic coupler pull ring according to claim 1, characterized in that, The center echo frequency of the ultrasonic detection probe is 5MHz.
6. The ultrasonic detection probe for the full - automatic coupler pull - ring according to claim 5, characterized in that, The error of the center echo frequency of the ultrasonic detection probe is Δf / f≤15%.
7. The ultrasonic detection probe for the full-automatic coupler pull ring according to claim 1, characterized in that, The refraction angle β of the ultrasonic detection probe is 68 degrees.
8. The ultrasonic detection probe for the full - automatic coupler pull - ring according to claim 7, characterized in that, The error of the refraction angle β of the ultrasonic detection probe is Δβ≤1.5 degrees.
9. The ultrasonic detection probe for the full-automatic coupler pull ring according to claim 1, characterized in that, The ultrasonic detection area is an arc with a radius of 18mm, and the second end face of the ultrasonic detection probe is also an arc with a radius of 18mm.
10. The ultrasonic detection probe for the full - automatic coupler pull - ring according to claim 1, characterized in that, The position of the incident point of the ultrasonic detection probe is on a plane.