Phased array weld joint flaw detector

Abstract

The utility model relates to the technical field of track welding seam detection, in particular to a phased array welding seam flaw detector which comprises a main body, the moving assembly comprises a falling unit and a displacement unit, and the moving assembly is used for adjusting and controlling the working position of the flaw detector; the flaw detection assembly comprises a first flaw detection assembly and a second flaw detection assembly, the first flaw detection assembly is used for detecting a rail head and a rail web part, the angle between the second flaw detection assembly and a steel rail can be adjusted, and the second flaw detection assembly is used for detecting a rail bottom triangular area, an upper slope area and a lower slope area. Due to the integrated design, each part only needs to be positioned once, and the rest parts are automatically operated, so that the positioning difficulty is greatly reduced, and the operation steps are simplified; and automatic scanning is realized, so that the time required by detection is greatly shortened, the efficiency is improved, and the manual operation difficulty is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of rail weld detection, in particular to a phased array weld flaw detector. Background Art

[0002] Railway transportation is one of my country's most important modes of transportation. my country's operating railway mileage reaches 140,000 kilometers, with high-speed rail operating mileage exceeding 30,000 kilometers, ranking first in the world. The longer the railway line, the more potential hazards it faces. Railway flaw detection is becoming increasingly important. Welds are a crucial part of rail flaw detection, and existing inspection methods require significant manpower and resources. Phased array weld flaw detectors offer simple detection methods and fast inspection times, significantly improving weld inspection efficiency.

[0003] However, existing phased array weld flaw detector technology is immature, making it difficult to meet large-scale practical applications and actual work needs. Existing weld flaw detection techniques generally rely on manual labor or the use of multiple scanning frames to inspect various weld locations. These methods require multiple manual positioning operations and place high demands on the operator. Existing weld flaw detection technology consumes a long time to inspect each weld. Given my country's global railway mileage and the countless welds involved, inefficiency is a significant problem. Utility Model Content

[0004] The purpose of the utility model is to solve the deficiencies of the prior art and provide a phased array flaw detector with an integrated design that is convenient for detecting welds in all areas of a rail.

[0005] To achieve the above object, the utility model provides a phased array weld flaw detector, comprising

[0006] main body;

[0007] A moving assembly, comprising a positioning unit and a displacement unit, wherein the positioning unit is arranged on the peripheral side of the main body, and the displacement unit is arranged on the upper surface of the main body, and the moving assembly is used to adjust and control the working position of the flaw detector;

[0008] The flaw detection component includes a first flaw detection component and a second flaw detection component. The first flaw detection component is fixedly arranged at the bottom of the main body and is used to detect the rail head and rail waist. The second flaw detection component is arranged at the bottom of the landing unit, and the angle between the second flaw detection component and the rail can be adjusted. The second flaw detection component is used to detect the rail bottom triangular area, the upslope area and the downslope area.

[0009] Preferably, the landing unit comprises an upper support landing guide rail and a lower support landing guide rail, wherein the upper support landing guide rail is arranged in the middle of the main body, and the upper support landing guide rail can drive the first flaw detection component to move up and down;

[0010] The lower bracket positioning guide rails are arranged on both sides of the main body, and the lower bracket positioning guide rails are used to drive the second flaw detection component to move obliquely to facilitate detection by the second flaw detection component.

[0011] Preferably, the displacement unit includes a front-rear displacement guide rail and a left-right displacement guide rail, the front-rear displacement guide rail is clamped on the top of the main body, and the main body can move along the surface of the front-rear displacement guide rail;

[0012] The left and right displacement guide rails are arranged at both ends of the front and rear displacement guide rails, and the front and rear displacement guide rails can perform limiting movement on the surfaces of the left and right displacement guide rails.

[0013] Preferably, the first flaw detection component includes a rail head serial probe and a rail head scanning probe, the rail head serial probe and the rail head scanning probe are both arranged on the surface of the rail head scanning guide rail, and the rail head scanning guide rail is arranged in the middle of the lower surface of the main body.

[0014] Preferably: the second flaw detection component includes a phased array probe group and a difficult area probe group, the phased array probe group is connected to the phased array probe corner device, the phased array probe corner device is driven by a corner motor, the difficult area probe group is arranged on both sides of the phased array probe group, and the difficult area probe group is used to assist in detecting angles that are difficult to cover by the phased array probe group.

[0015] Preferably, an electric control box is further provided on one side of the main body, and a laser and alignment camera are provided at the bottom of the electric control box, and the laser and alignment camera are used to position the flaw detector.

[0016] Preferably, a rail head positioning device is provided at the bottom of the main body, and the rail head positioning device is used to improve the stability of the flaw detector during operation.

[0017] Preferably, a positioning guide wheel is further provided on one side of the bottom of the main body, and the positioning guide wheel is engaged with the surface of the inspected rail during operation.

[0018] Compared with the existing technology, the technical solution proposed in this application has the following beneficial effects: integrated design: each part only needs to be positioned once, and the rest are all automated operations, which greatly reduces the difficulty of positioning and simplifies the operation steps; automated scanning: greatly reduces the time required for detection, improves efficiency, and reduces the difficulty of manual operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Other features, objects and advantages of the present invention will become more apparent from the detailed description of the non-limiting embodiments with reference to the following drawings:

[0020] Figure 1 This is the overall structural diagram of the flaw detector of the present utility model;

[0021] Figure 2 It is a side view of the flaw detector of the present utility model;

[0022] Figure 3 It is a top view of the flaw detector of the present utility model;

[0023] Figure 4 It is a front view of the flaw detector of the present utility model;

[0024] Figure 5 This is a schematic diagram of the detection area of the flaw detector of the present utility model;

[0025] In the figure: 1: front and rear displacement guide rails; 2: left and right displacement guide rails; 3: electrical control box; 4: positioning guide wheel; 5: laser and alignment camera; 6: water-locking waterway housing; 7: lower bracket positioning guide rail; 8: upper bracket positioning guide rail; 9: rail head positioning device; 10: corner motor; 11; rail head serial probe (2 probes in total); 12: rail head scanning probe (7 probes in total); 13: phased array probe group (8 probes in total); 14: difficult area probe group (4 probes in total); 15: phased array probe corner device; 16: upper limiter; 17: left and right limiters; 18: rail head scanning guide rail; 19: locking screw. DETAILED DESCRIPTION

[0026] The following will clearly and completely describe and discuss the technical solutions in the embodiments of the present invention in conjunction with the drawings of the present invention. Obviously, what is described here is only a part of the examples of the present invention, not all the examples. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0027] It should be noted that when a component is referred to as being "fixed to" another component, it may be directly on the other component or there may also be a central component. When a component is considered to be "connected to" another component, it may be directly connected to the other component or there may also be a central component. When a component is considered to be "set on" another component, it may be directly set on the other component or there may also be a central component. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only.

[0028] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention pertains. The terms used herein in the specification of this invention are intended only to describe specific embodiments and are not intended to limit the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0029] See also Figure 1-Figure 5 The utility model provides a phased array weld flaw detector, comprising

[0030] A main body; a moving component, the moving component including a landing unit and a displacement unit, the landing unit being arranged on the peripheral side of the main body, the displacement unit being arranged on the upper surface of the main body, the moving component being used to adjust and control the working position of the flaw detector; a flaw detection component, the flaw detection component including a first flaw detection component and a second flaw detection component, the first flaw detection component being fixedly arranged at the bottom of the main body, the first flaw detection component being used to detect the rail head and rail waist, the second flaw detection component being arranged at the bottom of the landing unit, and the angle between the second flaw detection component and the rail being adjustable, the second flaw detection component being used to detect the rail bottom triangular area, the upslope area and the downslope area.

[0031] The positioning unit includes an upper support positioning guide rail and a lower support positioning guide rail. The upper support positioning guide rail is set in the middle of the main body and can drive the first flaw detection component to move up and down; the lower support positioning guide rail is set on both sides of the main body and is used to drive the second flaw detection component to move diagonally to facilitate detection by the second flaw detection component. The displacement unit includes a front-to-back displacement guide rail and a left-to-right displacement guide rail. The front-to-back displacement guide rail is clamped to the top of the main body and the main body can move along the surface of the front-to-back displacement guide rail; the left-to-right displacement guide rail is set at both ends of the front-to-back displacement guide rail and can perform limiting movement on the surface of the left-to-right displacement guide rail.

[0032] The first flaw detection assembly includes a rail head serial probe and a rail head scanning probe, both of which are mounted on the surface of a rail head scanning guide rail. The rail head scanning guide rail is located in the middle of the lower surface of the main body. The second flaw detection assembly includes a phased array probe group and a difficult area probe group. The phased array probe group is connected to a phased array probe angle device, which is driven by an angle motor. The difficult area probe group is located on both sides of the phased array probe group and is used to assist in detecting angles that are difficult for the phased array probe group to cover.

[0033] An electrical control box is also installed on one side of the main body. A laser and alignment camera are installed at the bottom of the box to help position the flaw detector. A rail head locking device is installed at the bottom of the main body to improve the stability of the flaw detector during operation. A locking guide wheel is also installed on one side of the bottom of the main body to engage the surface of the inspected rail during operation.

[0034] Composition: 21 probes, 4 steering motors, 6 limiters, 1 frame, 5 guide rails, 6 motors, 1 camera, a laser unit, 2 sets of positioning guide wheels, 1 electric control box, 4 locking screws

[0035] Equipment Principle: The rail head and rail waist are scanned using traditional serial and six profile probes. The three areas on both sides of the rail bottom (rail bottom triangle area, upslope area and downslope area) are scanned by difficult area probes and phased array probes. The difficult area probe is composed of four conventional K2.5 probes to scan the rail bottom triangle area. The phased array probe cooperates with the motor to achieve three lateral angles and 40° vertical fan scanning area covering the two outer areas.

[0036] The equipment process is as follows: Aim the laser at the center of the weld; operate the control panel to automatically place the upper bracket; operate the control panel to start the serial scan and rail head scan, and scan the rail head and center projection area of the rail; operate the panel to start the 0° scan, turn on the water spray to make the lower bracket fall to the rail foot, and scan the weld at an angle of 0° to the horizontal within a range of 35°-75°. Save the data, and at the same time, scan the rail bottom triangle area with the probe. After completion, put away the lower bracket. Layer bracket; operation panel, start 7° scanning, turn on the water spray to make the lower bracket fall on the bottom of the rail, and the phased array scans the weld in a range of 35°-75° at an inward angle of 7°. After saving the data, put away the lower bracket; operation panel, start 10° scanning, turn on the water spray to make the lower bracket fall on the bottom of the rail, and the phased array scans the weld in a range of 35°-75° at an outward angle of 10°. After saving the data, put away the probe; operation panel, put away the bracket and reset it.

[0037] The above describes specific embodiments of the present invention. It should be understood that the present invention is not limited to the specific embodiments described above, and that one or more of the above embodiments may be combined. Those skilled in the art may make various changes, modifications, or combinations within the scope of the claims, without affecting the essence of the present invention. Unless there is a conflict, the embodiments of the present application and the features in the embodiments may be combined with each other in any manner.

Claims

1. A phased array weld flaw detector, characterized in that: include main body; A moving assembly, comprising a positioning unit and a displacement unit, wherein the positioning unit is arranged on the peripheral side of the main body, and the displacement unit is arranged on the upper surface of the main body, and the moving assembly is used to adjust and control the working position of the flaw detector; The flaw detection component includes a first flaw detection component and a second flaw detection component. The first flaw detection component is fixedly arranged at the bottom of the main body and is used to detect the rail head and rail waist. The second flaw detection component is arranged at the bottom of the landing unit, and the angle between the second flaw detection component and the rail can be adjusted. The second flaw detection component is used to detect the rail bottom triangular area, the upslope area and the downslope area.

2. The phased array weld flaw detector according to claim 1, characterized in that: The positioning unit includes an upper support positioning guide rail and a lower support positioning guide rail, wherein the upper support positioning guide rail is arranged in the middle of the main body, and the upper support positioning guide rail can drive the first flaw detection component to move up and down; The lower bracket positioning guide rails are arranged on both sides of the main body, and the lower bracket positioning guide rails are used to drive the second flaw detection component to move obliquely to facilitate detection by the second flaw detection component.

3. The phased array weld flaw detector according to claim 2, characterized in that: The displacement unit includes a front-to-back displacement guide rail and a left-to-right displacement guide rail. The front-to-back displacement guide rail is clamped on the top of the main body, and the main body can move along the surface of the front-to-back displacement guide rail. The left and right displacement guide rails are arranged at both ends of the front and rear displacement guide rails, and the front and rear displacement guide rails can perform limiting movement on the surfaces of the left and right displacement guide rails.

4. The phased array weld flaw detector according to claim 1, characterized in that: The first flaw detection component includes a rail head serial probe and a rail head scanning probe, the rail head serial probe and the rail head scanning probe are both arranged on the surface of the rail head scanning guide rail, and the rail head scanning guide rail is arranged in the middle of the lower surface of the main body.

5. The phased array weld flaw detector according to claim 2, characterized in that: The second flaw detection component includes a phased array probe group and a difficult area probe group. The phased array probe group is connected to the phased array probe corner device, and the phased array probe corner device is driven by a corner motor. The difficult area probe group is arranged on both sides of the phased array probe group. The difficult area probe group is used to assist in detecting angles that are difficult to cover by the phased array probe group.

6. The phased array weld flaw detector according to claim 3 or 5, characterized in that: An electric control box is also provided on one side of the main body, and a laser and alignment camera are provided at the bottom of the electric control box. The laser and alignment camera are used to position the flaw detector.

7. The phased array weld flaw detector according to claim 6, characterized in that: A rail head clamping device is provided at the bottom of the main body, and the rail head clamping device is used to improve the stability of the flaw detector during operation.

8. The phased array weld flaw detector according to claim 7, characterized in that: A positioning guide wheel is also provided on one side of the bottom of the main body, and the positioning guide wheel is engaged with the surface of the detected rail during operation.

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