Steel rail welding seam detection device

Abstract

The utility model discloses a steel rail welding seam detection device. The device comprises a stress wave transmitting end and a stress wave receiving end, the stress wave transmitting end is connected with one end of a weld joint to be detected, and the stress wave receiving end is connected with the other end of the weld joint to be detected. Through the stress wave transmitting end and the stress wave receiving end, ultrasonic nondestructive testing of the steel rail welding seam can be achieved, the detection efficiency is improved, the detection effect is improved, and the ultrasonic nondestructive testing device can be widely applied to the technical field of ultrasonic nondestructive testing.

Description

Technical Field

[0001] This application relates to the field of ultrasonic nondestructive testing technology, and in particular to a rail weld inspection device. Background Technology

[0002] Rail weld damage detection is a crucial means of ensuring the safe and stable service of rails. Currently, active monitoring technology is commonly used for rail inspection. However, this technology typically employs piezoelectric sensors and actuators, which are usually attached to the structural surface or embedded within the structure. This makes installation and removal difficult, and the bonding surface between the transducer and the structural surface is prone to peeling, affecting the sensing and actuation effects, resulting in poor detection results and low detection efficiency. Summary of the Invention

[0003] The main objective of this application is to provide a rail weld inspection device that can perform ultrasonic non-destructive testing on rail welds, thereby improving inspection efficiency and enhancing inspection results.

[0004] This application provides a rail weld inspection device, which includes a stress wave emitting end and a stress wave receiving end.

[0005] The stress wave emitting end is connected to one end of the weld to be inspected, and the stress wave receiving end is connected to the other end of the weld to be inspected.

[0006] In some embodiments, the stress wave receiver includes a signal generating component and a first piezoelectric transducer;

[0007] The signal generating component is connected to one end of the first piezoelectric transducer, and the other end of the first piezoelectric transducer is connected to one end of the weld to be inspected.

[0008] In some embodiments, the stress wave receiver includes a second piezoelectric transducer and a signal processing component;

[0009] One end of the second piezoelectric transducer is connected to the other end of the weld to be inspected, and the other end of the second piezoelectric transducer is connected to the signal processing component.

[0010] In some embodiments, the signal generating component includes a signal generator and a power amplifier;

[0011] The signal generator is connected to one end of the power amplifier, and the other end of the power amplifier is connected to one end of the first piezoelectric transducer.

[0012] In some embodiments, the signal processing component includes a charge amplifier and a data acquisition unit;

[0013] One end of the charge amplifier is connected to one end of the second piezoelectric transducer, and the other end of the charge amplifier is connected to the data acquisition instrument.

[0014] In some embodiments, the first piezoelectric transducer includes a piezoelectric component, a cable, a spring assembly, and a base;

[0015] One end of the spring assembly is fixed to the base, and the other end of the spring assembly is connected to and fixed to the piezoelectric assembly. One end of the cable is connected to the piezoelectric assembly, and the other end of the cable is connected to the power amplifier.

[0016] In some embodiments, the second piezoelectric transducer includes a piezoelectric component, a cable, a spring assembly, and a base;

[0017] One end of the spring assembly is fixed to the base, and the other end of the spring assembly is connected to and fixed to the piezoelectric assembly. One end of the cable is connected to the piezoelectric assembly, and the other end of the cable is connected to the charge amplifier.

[0018] In some embodiments, the piezoelectric component includes a piezoelectric ceramic, a metal electrode, a curing layer, a metal encapsulation layer, and a metal protective layer;

[0019] The metal electrode is attached to the piezoelectric ceramic, the curing layer encapsulates the piezoelectric ceramic after the metal electrode is attached, the metal encapsulation layer encapsulates the curing layer, and the metal protective layer encapsulates the metal encapsulation layer.

[0020] In some embodiments, the metal electrode is a copper electrode, the curing layer is an epoxy resin layer, the metal encapsulation layer is a copper foil shielding layer, and the metal protective layer is an aluminum alloy protective layer.

[0021] The embodiments of this application include at least the following beneficial effects: This application provides a rail weld inspection device, which includes a stress wave emitting end and a stress wave receiving end. The stress wave emitting end is connected to one end of the weld to be inspected, and the stress wave receiving end is connected to the other end of the weld to be inspected. This application can achieve ultrasonic non-destructive testing of rail welds through the stress wave emitting end and the stress wave receiving end, improving inspection efficiency and enhancing inspection results. Attached Figure Description

[0022] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with the present invention and, together with the description, serve to explain the principles of the present invention.

[0023] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the structure of a rail weld inspection device provided in an embodiment of this application;

[0025] Figure 2 This is another structural schematic diagram of a rail weld inspection device provided in an embodiment of this application;

[0026] Figure 3 This is a schematic diagram of a self-shielded piezoelectric transducer. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of this application and are not intended to limit it. In the following description, when referring to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with those of this application; they are merely examples of apparatuses and methods consistent with some aspects of the embodiments of this application as detailed in the appended claims.

[0028] It is understood that the terms “first,” “second,” etc., used in this application may be used herein to describe various concepts, but unless otherwise stated, these concepts are not limited by these terms. These terms are only used to distinguish one concept from another. For example, without departing from the scope of the embodiments of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the words “if,” “when,” or “in response to a determination” as used herein may be interpreted as “when…” or “when…” or “in response to a determination.”

[0029] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing embodiments of this application only and is not intended to limit this application.

[0030] Reference Figure 1 , Figure 1This is an optional structural schematic diagram of a rail weld inspection device provided in an embodiment of this application. The device includes a stress wave emitting end and a stress wave receiving end. The stress wave emitting end is connected to one end of the weld to be inspected, and the stress wave receiving end is connected to the other end of the weld to be inspected.

[0031] In some embodiments, the stress wave receiver includes a signal generating component and a first piezoelectric transducer, wherein the signal generating component is connected to one end of the first piezoelectric transducer and the other end of the first piezoelectric transducer is connected to one end of the weld to be inspected.

[0032] In some embodiments, the stress wave receiving end includes a second piezoelectric transducer and a signal processing component, one end of the second piezoelectric transducer is connected to the other end of the weld to be inspected, and the other end of the second piezoelectric transducer is connected to the signal processing component.

[0033] In some embodiments, refer to Figure 2 , Figure 2 This is another optional structural schematic diagram of a rail weld inspection device provided in this application embodiment. The stress wave receiving end includes a signal generating component and a first piezoelectric transducer 101. The stress wave receiving end also includes a second piezoelectric transducer 102 and a signal processing component. The signal generating component includes a signal generator 103 and a power amplifier 104. One end of the signal generator 103 is connected to one end of the power amplifier 104, and the other end of the power amplifier 104 is connected to one end of the first piezoelectric transducer. The signal processing component includes a charge amplifier 105 and a data acquisition instrument 106. One end of the charge amplifier 105 is connected to one end of the second piezoelectric transducer, and the other end of the charge amplifier 105 is connected to the data acquisition instrument 106. The first piezoelectric transducer 101 is connected to one end of the weld 107 to be inspected, and the second piezoelectric transducer 102 is connected to one end of the weld 107 to be inspected. The weld 107 to be inspected has a weld defect 108. The rail weld inspection device enables non-destructive testing and positioning of the weld defect 108.

[0034] In some embodiments, the first piezoelectric transducer and the second piezoelectric transducer have the same structure, both being self-shielded piezoelectric transducers, as shown in the reference. Figure 3 , Figure 3This is an optional structural diagram of a self-shielded piezoelectric transducer, including a cable 201, a spring assembly 202, a cable hole 203, a base 204, a piezoelectric ceramic 205, a metal electrode 206, a curing layer 207, a metal encapsulation layer 208, and a metal protective layer 209. The piezoelectric ceramic 205, metal electrode 206, curing layer 207, metal encapsulation layer 208, and metal protective layer 209 constitute a piezoelectric assembly. The metal electrode 206 is attached to the piezoelectric ceramic 205. The curing layer 207 encapsulates the piezoelectric ceramic 205 with the attached metal electrode 206. The metal encapsulation layer 208 encapsulates the curing layer 207, and the metal protective layer 209 encapsulates the metal encapsulation layer 208. Optionally, the metal electrode 206 is a copper electrode, the curing layer 207 is an epoxy resin layer, and the metal encapsulation layer 208 is a copper foil shielding layer. The protective layer 209 is an aluminum alloy protective layer. A cable hole 203 is opened in the base 204. The cable 201 passes through the cable hole 203 and connects to external electrical equipment (including the aforementioned signal generating component and signal processing component). The base 204 is a stainless steel base, on which a neodymium iron boron magnet 210 is installed. The piezoelectric component and the base 204 are connected by a spring assembly 202. In the free state, the top of the piezoelectric transducer is higher than the top of the neodymium iron boron magnet 210, which compresses the spring assembly 202 in the weld inspection state, providing pre-tightening force. This allows the piezoelectric component to be tightly attached to the surface of the weld to be inspected. Combined with the use of an interface coupling agent, the self-shielded piezoelectric transducer is prevented from peeling off from the contact surface. This eliminates the reliance on mechanical connectors and adhesives when using traditional piezoelectric transducers for rail weld inspection, enabling rapid installation and removal.

[0035] In some embodiments, cable 201 is an electromagnetically shielded cable. Copper electrodes are attached to the surface of the piezoelectric ceramic 205 in the self-shielded piezoelectric transducer. The piezoelectric ceramic 205 with the copper electrodes is encapsulated by an epoxy resin layer. A copper foil shielding layer wraps around the epoxy resin layer, and an aluminum alloy protective layer is adhered to the copper foil shielding layer. The copper electrodes are connected to the ends of the electromagnetically shielded cable, and the copper foil shielding layer is connected to the metal shielding layer of the electromagnetically shielded cable. The self-shielded piezoelectric transducer exhibits superior insulation and electromagnetic shielding performance compared to traditional piezoelectric transducers, and provides strong anti-interference capabilities when used as a sensor.

[0036] In some embodiments, the spring assembly 202 is a mold spring, and the preload force provided by the spring assembly 202 is calculated by the following formula:

[0037] ;

[0038] in, It is the preload. It refers to the stiffness of the mold spring. It is the height of the self-shielded piezoelectric transducer. It is the free length of the mold spring. It is the height of the cylindrical neodymium iron boron magnet. It is the magnetic attraction of neodymium iron boron magnets to the rails.

[0039] In some embodiments, for example, the signal generator 103 generates a 10Hz-1MHz sweep frequency signal and connects to the power amplifier 104 to amplify the excitation voltage. The power amplifier 104 is connected to the metal electrode 206 attached to the piezoelectric ceramic 205 inside the first piezoelectric transducer. Utilizing the inverse piezoelectric effect, the piezoelectric ceramic 205 is driven to generate a 10Hz-1MHz sweep frequency vibration signal. At the stress wave emitting end, the first piezoelectric transducer is pressed tightly against the surface of the rail weld under the preload of the spring assembly 202. The vibration signal generated at the stress wave emitting end propagates in the rail weld in the form of a stress wave and is received by the stress wave receiving end.

[0040] The stress wave receiver consists of a second piezoelectric transducer, a charge amplifier 105, and a data acquisition instrument 106. Under the action of the stress wave, the piezoelectric ceramic 205 inside the second piezoelectric transducer generates a charge using the piezoelectric effect. The metal electrode 206 attached to the piezoelectric ceramic 205 is connected to the charge amplifier 105. The charge is amplified by the charge amplifier 105, and the amplified charge is stored in the data acquisition instrument 106 in the form of a voltage signal. Finally, the voltage signal stored at the stress wave receiver under undamaged conditions is used as a reference to compare and analyze the amplitude, phase, total energy, and other characteristic values ​​of the voltage signal measured on-site to determine whether there is damage to the weld between the stress wave transmitter and receiver.

[0041] In some embodiments, the self-shielded piezoelectric transducer described above can be used as both an actuator and a sensor. The position of the excitation end can be changed by altering the connection of the external device. Multiple devices of this patent can be used to perform multi-position and multi-angle detection, thereby achieving damage localization.

[0042] The rail weld inspection device provided in this application can realize ultrasonic non-destructive testing of rail welds through a stress wave emitting end and a stress wave receiving end, thereby improving inspection efficiency and enhancing inspection results.

[0043] The embodiments described in this application are for the purpose of more clearly illustrating the technical solutions of the embodiments of this application, and do not constitute a limitation on the technical solutions provided by the embodiments of this application. As those skilled in the art will know, with the evolution of technology and the emergence of new application scenarios, the technical solutions provided by the embodiments of this application are also applicable to similar technical problems.

[0044] Those skilled in the art will understand that the technical solutions shown in the figures do not constitute a limitation on the embodiments of this application, and may include more or fewer steps than shown, or combine certain steps, or different steps.

[0045] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0046] Those skilled in the art will understand that all or some of the steps in the methods disclosed above, as well as the functional modules / units in the systems and devices, can be implemented as software, firmware, hardware, or suitable combinations thereof.

[0047] The terms “first,” “second,” “third,” “fourth,” etc. (if present) in the specification and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms “comprising” and “having,” and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0048] It should be understood that in this application, "at least one (item)" means one or more, and "more than" means two or more. "And / or" is used to describe the relationship between related objects, indicating that three relationships can exist. For example, "A and / or B" can represent three cases: only A exists, only B exists, and both A and B exist simultaneously, where A and B can be singular or plural. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship. "At least one (item) of the following" or similar expressions refer to any combination of these items, including any combination of single or plural items. For example, at least one (item) of a, b, or c can represent: a, b, c, "a and b", "a and c", "b and c", or "a and b and c", where a, b, and c can be single or multiple.

[0049] The preferred embodiments of the present application have been described above with reference to the accompanying drawings, but this does not limit the scope of the claims of the present application. Any modifications, equivalent substitutions, and improvements made by those skilled in the art without departing from the scope and substance of the embodiments of the present application shall be within the scope of the claims of the present application.

Claims

1. A rail weld inspection device, characterized in that, The device includes a stress wave emitting end and a stress wave receiving end; The stress wave emitting end is connected to one end of the weld to be inspected, and the stress wave receiving end is connected to the other end of the weld to be inspected.

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