A manual ultrasonic probe positioning device for railway passenger car wheel axles

Abstract

This utility model relates to the field of non-destructive testing and discloses a manual ultrasonic probe positioning device for railway passenger car wheel axles. It includes a protective component, a fixed support component, a core functional component, and a human-machine interface component. The protective component includes a shell and a top cover, which together form a closed protective space to house the core functional component. The fixed support component includes a fixing plate, a handle, a threaded post, a connecting plate, a clamping block, a support leg, a gasket, and a magnetic roller. This utility model employs triangular laser ranging technology (such as the Keyence LR-Z series ranging sensor), achieving sub-millimeter accuracy and a refresh rate of up to 700Hz. It can capture minute distance changes between the probe and the wheel axle surface in real time (e.g., ±0.1mm deviation), solving the problems of traditional mechanical positioning's inability to report minute offsets and manual visual positioning's fuzzy positioning. It also avoids coupling failures caused by vibration and thermal expansion and contraction, ensuring the probe is always in an effective inspection position.

Description

Technical Field

[0001] This utility model relates to the field of non-destructive testing, and in particular to a manual ultrasonic probe positioning device for railway passenger car wheel axles. Background Technology

[0002] In the railway transportation system, railway passenger car wheel axles are core components that bear the weight of the car body and transmit power. Whether there are defects such as cracks and inclusions inside them is directly related to the safety of train operation. Therefore, wheel axle quality inspection is a key process in railway maintenance. Among them, ultrasonic flaw detection technology has become the core means of detecting internal defects in railway passenger car wheel axles due to its advantages such as strong penetration ability, high detection sensitivity and no damage to wheel axles. The positioning accuracy of the ultrasonic probe and the coupling state with the wheel axle surface during flaw detection directly determine the accuracy and reliability of the test results.

[0003] Traditional mechanical positioning devices limit the probe's movement range through fixed supports, guide rails, and other structures. However, due to the influence of the railway site operating environment (such as irregular wheel and axle surfaces, equipment vibration during the inspection process, and thermal expansion and contraction of components caused by changes in ambient temperature), the mechanical structure is prone to slight displacement. This makes it impossible to provide real-time feedback on the subtle offset between the probe and the wheel and axle surface, which in turn leads to the failure of the coupling between the probe and the wheel and axle surface. When the distance between the probe and the wheel and axle surface exceeds the effective coupling range, the ultrasonic wave propagation path changes, which can easily cause missed defects or misjudgments. Utility Model Content

[0004] To overcome the above shortcomings, this utility model provides a manual ultrasonic probe positioning device for railway passenger car wheel axles, which aims to improve the problems of existing mechanical positioning "unable to provide feedback on minute offsets" and manual visual positioning "fuzzy".

[0005] To achieve the above objectives, this utility model provides the following technical solution: a manual ultrasonic probe positioning device for railway passenger car wheel axles, comprising a protective component, a fixed support component, a core functional component, and a human-machine interaction component; the protective component includes a shell and a top cover, which together form a closed protective space for accommodating the core functional component; the fixed support component includes a fixed plate, a handle, a threaded post, a connecting plate, a clamping block, a support leg, a gasket, and a magnetic roller; the shell is fitted inside the fixed plate; the handle is fixedly connected to one end of the threaded post; the other end of the threaded post passes through the fixed plate and is threadedly connected to the connecting plate; both sides of the connecting plate are fixedly connected to the clamping block; a gasket is pasted on the inner side of the clamping block; the bottom of the fixed plate is fixedly connected to the top of the support leg; a magnetic roller is rotatably mounted on the bottom end of the support leg; the core functional component includes a mainboard with a display screen and an ultrasonic... The system includes a probe, a ranging sensor, a charging port, and a battery. The mainboard with a display screen and the battery are all fixedly installed inside the protective space of the housing. The mainboard with the display screen is equipped with an ESP32 chip and a power management chip (TP4056 model). The mainboard with the display screen also integrates a PWM voltage regulation circuit. The ultrasonic probe is fixed to the outside of the housing using a special clamp. The ranging sensor is fixedly connected to the special clamp, and the laser projection direction is parallel to the axis of the ultrasonic probe. The ranging sensor is a Keyence LR-Z series. The charging port is located on the side wall of the housing and is electrically connected to the battery. The battery is electrically connected to the mainboard with the display screen and the ranging sensor respectively through the PWM voltage regulation circuit. The human-machine interface includes an alarm indicator, control buttons, and a power switch. The alarm indicator, control buttons, and power switch are all installed on the surface of the housing and electrically connected to the mainboard with the display screen.

[0006] Furthermore, the power management chip is used to implement overcharge protection and over-discharge protection of the battery, and the PWM voltage regulation circuit can output a 3.3V voltage to power the ranging sensor, and at the same time output a 5V voltage to power the motherboard with the display screen.

[0007] Furthermore, the ranging sensor incorporates a converging lens, a receiving lens, and a CMOS sensor. The ranging sensor can emit a laser beam, which is focused by the converging lens and projected vertically onto the surface of the wheel axle. The scattered light reflected from the wheel axle surface is captured by the receiving lens and imaged onto the CMOS sensor. The chip built into the ranging sensor can calculate the real-time distance between the probe and the surface of the wheel axle based on the principles of trigonometric geometry, combined with the displacement of the light spot on the CMOS sensor and preset optical parameters.

[0008] Furthermore, the ranging sensor has a measurement accuracy of sub-millimeter level, a refresh rate of up to 700Hz, and an automatic temperature compensation function, which can adapt to an ambient temperature of -20℃ to 60℃. It also integrates an ambient light filtering algorithm.

[0009] Furthermore, the motherboard with display screen has a built-in database, and the control button can trigger the motherboard with display screen to enter the configuration mode. The motherboard with display screen can call the corresponding scanning range threshold from the database and automatically complete the zero-point calibration of the ranging.

[0010] Furthermore, the ranging sensor is connected to the motherboard with a display screen via a UART serial port and can transmit real-time distance data to the motherboard with a display screen every 10ms. The motherboard with a display screen has a built-in algorithm that can compare the real-time distance data with a preset standard coupling distance, calculate the position deviation, and the position deviation threshold is ±2mm, and determine whether the real-time distance is within the threshold of the called scanning range.

[0011] Furthermore, when the real-time distance is within the scanning range threshold, the mainboard with display screen controls the alarm indicator to keep the green light on, and simultaneously controls its own display screen to show the "compliant" status; when the real-time distance exceeds the scanning range threshold, the mainboard with display screen controls the alarm indicator to flash the red light, and simultaneously controls its own display screen to show the "violation" status and the current distance deviation value.

[0012] Furthermore, the display screen of the motherboard with the display screen can display the current distance value, wheel pair model, probe model, detection surface, scanning range threshold, and remaining battery power in real time; the motherboard with the display screen can also communicate with an external ultrasonic flaw detection host via a UART serial port, and can send an abnormal interrupt signal to the ultrasonic flaw detection host when the real-time distance exceeds the scanning range threshold.

[0013] Furthermore, the charging port is a Type-C interface, compatible with a 5V charger. The device must be powered on while charging. During charging, the display shows the battery level as 100%. After unplugging the charging cable, the display shows the actual remaining battery level.

[0014] Furthermore, rotating the handle can drive the threaded column to rotate, and when the threaded column rotates, it can drive the connecting plate to slide the clamping block towards the outer wall of the fixed plate, so that the clamping block clamps and fixes the outer shell. The gasket can prevent the clamping block from directly contacting the surface of the outer shell. The magnetic roller can be attracted to the surface of the axle and can roll along the surface of the axle.

[0015] This utility model has the following beneficial effects:

[0016] 1. In this utility model, triangular laser ranging technology (such as Keyence LR-Z series ranging sensors) is adopted, with measurement accuracy reaching sub-millimeter level and a refresh rate of up to 700Hz. It can capture minute distance changes between the probe and the wheel axle surface in real time (such as ±0.1mm level deviation), solving the problems of traditional mechanical positioning "cannot feed back minute offsets" and manual visual "positioning ambiguity". It avoids coupling failure caused by vibration and thermal expansion and contraction, ensuring that the probe is always in an effective flaw detection position.

[0017] 2. In this utility model, the device has a built-in database that stores the scanning range thresholds corresponding to different wheelset models (such as RD3, RC4, RD13), probe models (such as K1.0, K1.2, K1.7), and detection surfaces (such as axle body, journal, dust cover) in the "Rules for Assembly, Inspection and Management of Railway Passenger Wheel Axles" (TG / CL206-2013). For example, the moving area of ​​the K1.0 probe when detecting the axle body of the RD3 wheelset is 60mm to 184mm. By accurately calling the threshold, the compliance of the probe position is judged, avoiding "over-range missed detection" or "under-range false detection" caused by the deviation of manually memorized thresholds. From a technical point of view, it ensures that the flaw detection covers all key parts.

[0018] 3. In this utility model, the device can quickly fix the outer shell through the clamping structure composed of a fixing plate, threaded column and clamping block. With the design of bottom magnetic roller and support leg, it can not only realize the smooth rolling of the device along the wheel axle surface, but also enhance the fit stability through magnetic adsorption and reduce the shaking interference when the probe is manually held. At the same time, it supports the configuration of "one probe and one tracker", eliminating the need for frequent disassembly and adjustment, and greatly shortening the preparation time for probe installation and positioning.

[0019] 4. In this utility model, the operator can quickly enter the configuration mode through the control button and select parameters step by step according to the logic of "wheelset model → probe K value → detection surface". The main board with display screen displays the configuration results and current key information (such as wheelset model, detection part, starting position, and remaining power) in real time. There is no need to rely on professional personnel to memorize complex parameters, which reduces the operation threshold and is especially suitable for efficient operation in long-term operation scenarios of flaw detection personnel.

[0020] 5. In this utility model, the device uses a red / green dual-color alarm indicator and a display screen to provide feedback on the position status. When the probe is within the compliant range, the green light is constantly on and the display shows "compliant". When it is outside the range, the red light flashes and the display shows "non-compliant" and the current deviation value. This eliminates the need for continuous manual visual inspection and directly reminds the operator to adjust the position, avoiding operational negligence due to fatigue.

[0021] 6. In this utility model, the core control module (ESP32 motherboard) can be linked with the flaw detection host via UART serial port. When the probe position is irregular, it can send an abnormal interrupt signal to the host to forcibly suspend the detection process until the position is adjusted to comply with the requirements and resumed. This solves the problem of "unsupervised process and difficulty in tracing abnormalities" in traditional detection. At the same time, it records distance data and operation status in real time, providing data support for subsequent review of the detection process and quality traceability.

[0022] 7. In this utility model, the device is equipped with an ESP32 motherboard and a polymer battery, and works with a TP4056 power management chip to achieve overcharge / over-discharge protection. It provides precise power to different modules (3.3V for the ranging sensor and 5V for the motherboard) through a PWM voltage regulation circuit, and supports sleep mode (standby power consumption <1mA). The overall battery life is extended to more than 8 hours, which meets the operational requirements of "continuous flaw detection of multiple wheel axles" on railway sites, and eliminates the need for frequent charging interruptions to detection.

[0023] 8. In this utility model, the ranging sensor has an automatic temperature compensation function and can work stably in the temperature difference environment of railway site from -20℃ to 60℃; at the same time, it integrates an ambient light filtering algorithm, which can reduce interference from external light such as strong light and shadow, avoid fluctuations in ranging data caused by environmental factors, ensure detection stability in different scenarios such as outdoors and garages, and solve the problems of "poor anti-interference and susceptibility to electromagnetic / light influence" of traditional discrete components.

[0024] 9. In this utility model, the device uses a UART universal serial port to connect with the ultrasonic flaw detection host, and supports parameter configuration and data transmission via Bluetooth / Wi-Fi. It does not require large-scale modification of the existing flaw detection host, and can quickly connect to manual ultrasonic flaw detection equipment of different brands and models, reducing the equipment replacement and upgrade costs of railway maintenance units.

[0025] 10. In this utility model, the built-in database supports updating the scanning threshold according to the new wheelset model (such as the special axle type added later) and probe type. The scope of application can be expanded through OTA remote upgrade or local button configuration without replacing hardware, which meets the long-term use needs after the iteration of railway wheel and axle maintenance technology and enhances the life cycle value of the equipment. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the main structure of a manual ultrasonic probe positioning device for railway passenger car wheel axles proposed in this utility model;

[0027] Figure 2 This is a schematic diagram of the outer shell structure of a manual ultrasonic probe positioning device for railway passenger car wheel axles proposed in this utility model.

[0028] Figure 3 This is a schematic diagram of the composition structure of a manual ultrasonic probe positioning device for railway passenger car wheel axles proposed in this utility model.

[0029] Figure 4 This is a cross-sectional schematic diagram of the fixing plate of a manual ultrasonic probe positioning device for railway passenger car wheel axles proposed in this utility model.

[0030] Figure 5This is a schematic diagram of the support leg structure of a manual ultrasonic probe positioning device for railway passenger car wheel axles proposed in this utility model.

[0031] Legend:

[0032] 1. Outer shell; 2. Top cover; 3. Main board with display screen; 4. Alarm indicator; 5. Control button; 6. Ultrasonic probe; 7. Mounting plate; 8. Power switch; 9. Distance sensor; 10. Charging port; 11. Battery; 12. Handle; 13. Threaded post; 14. Connecting plate; 15. Clamping block; 16. Support leg; 17. Gasket; 18. Magnetic roller. Detailed Implementation

[0033] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0034] Reference Figure 1 - Figure 5This utility model provides an embodiment of a manual ultrasonic probe positioning device for railway passenger car wheel axles, comprising a protective component, a fixed support component, a core functional component, and a human-machine interaction component; the protective component includes a shell 1 and a top cover 2, which together form a closed protective space for accommodating the core functional component; the fixed support component includes a fixed plate 7, a handle 12, a threaded post 13, a connecting plate 14, a clamping block 15, a support leg 16, a gasket 17, and a magnetic roller 18; the shell 1 is fitted inside the fixed plate 7; the handle 12 is fixedly connected to one end of the threaded post 13, and the other end of the threaded post 13 passes through the fixed plate 7 and is threadedly connected to the connecting plate 14; both sides of the connecting plate 14 are fixedly connected to the clamping block 15; a gasket 17 is pasted on the inner side of the clamping block 15; the bottom of the fixed plate 7 is fixedly connected to the top of the support leg 16; and a magnetic roller 18 is rotatably mounted on the bottom of the support leg 16; the core functional component includes a main board 3 with a display screen, an ultrasonic... The ultrasonic probe 6, ranging sensor 9, charging port 10, and battery 11, along with the mainboard 3 with display screen and battery 11, are all fixedly installed inside the protective space of the housing 1. The mainboard 3 with display screen is equipped with an ESP32 chip and a power management chip, the power management chip being a TP4056 model. The mainboard 3 with display screen also integrates a PWM voltage regulation circuit. The ultrasonic probe 6 is fixed to the outside of the housing 1 using a special clamp. The ranging sensor 9 is fixedly connected to the special clamp, and the laser projection direction is parallel to the axis of the ultrasonic probe 6. The ranging sensor 9 is a Keyence LR-Z series. The charging port 10 is located on the side wall of the housing 1 and is electrically connected to the battery 11. The battery 11 is electrically connected to the mainboard 3 with display screen and the ranging sensor 9 via the PWM voltage regulation circuit. The human-machine interface components include an alarm indicator 4, control buttons 5, and a power switch 8. The alarm indicator 4, control buttons 5, and power switch 8 are all installed on the surface of the housing 1 and electrically connected to the mainboard 3 with display screen.

[0035] Specifically, the device mainly consists of a shell 1 and a top cover 2 forming a robust protective housing. Its interior is carefully designed to securely fix core components such as the motherboard 3 with a display screen, the high-performance battery 11, and the high-precision distance sensor 9 in specific positions, effectively avoiding positional shifts caused by vibration. The ultrasonic probe 6 is linked to the distance sensor 9 through a special clamp, ensuring that the laser projection direction of the distance sensor is strictly parallel to the probe axis, thereby ensuring that the collected distance data can accurately and directly reflect the relative position of the probe and the wheel axle surface.

[0036] When using this device, the operator can place the outer casing 1 stably inside the fixing plate 7, and then control the threaded column 13 to rotate clockwise or counterclockwise by holding the handle 12. At this time, the threaded column 13 will drive the clamping blocks 15 on both sides to slide towards the outer wall of the fixing plate 7 through the connecting plate 14, and finally the clamping blocks 15 will firmly clamp and fix the outer casing 1. In addition, the clamping blocks 15 also play a protective role, preventing the gasket 17 from causing unnecessary damage to the surface of the outer casing 1. After fixing, the device can be stably placed on the axle through the support leg 16 at the bottom of the fixing plate 7, and the magnetic roller 18 at the bottom of the support leg 16 will achieve rolling engagement. This not only facilitates the smooth movement of the device along the surface of the axle during flaw detection, but also enhances the contact stability between the device and the axle through magnetic adsorption, effectively reducing shaking interference during manual operation.

[0037] Before testing, the operator needs to connect a 5V charger to the charging port 10 to charge the built-in battery 11. (Note that the device must be powered on during charging; the screen displaying 100% only indicates charging status. The actual remaining battery level will only be displayed after the charging cable is disconnected.) At the start of testing, the device is activated by pressing the power switch 8, and the battery 11 immediately provides a stable power supply to the entire unit. Simultaneously, the power management chip (e.g., TP4056) built into the motherboard 3 with the display screen provides overcharge / over-discharge protection and a stable voltage output to the ranging sensor 9 (operating voltage 3.3V) and the motherboard (operating voltage 5V) via a PWM voltage regulation circuit, ensuring that each module operates normally and efficiently.

[0038] This device employs advanced triangular laser ranging technology, which uses a ranging sensor 9 to acquire precise distance data between the probe and the wheel axle surface in real time, providing a reliable basis for position determination. The specific measurement process is as follows: The ranging sensor 9 (e.g., Keyence LR-Z series) emits a laser beam, which is focused by an internal converging lens and projected vertically onto the surface of the wheel axle being measured; the scattered light reflected from the wheel axle surface is captured by the receiving lens of the sensor and imaged onto the internal CMOS sensor. When the probe moves and changes position during the flaw detection operation, the change in the relative position between the wheel axle surface and the sensor causes a corresponding displacement of the laser spot on the CMOS imaging surface. Based on the "trigonometric geometry principle," the chip built into the sensor calculates the real-time distance between the probe and the wheel axle surface by accurately calculating the spot displacement and preset optical parameters (such as lens focal length and the distance between the sensor and the lens). The measurement accuracy can reach the sub-millimeter level, and the refresh rate can reach up to 700Hz, fully meeting the needs of dynamic tracking. In addition, the ranging sensor 9 also has an automatic temperature compensation function, which can adapt to the temperature difference environment of railway sites from -20℃ to 60℃. At the same time, through an advanced ambient light filtering algorithm, it effectively reduces external interference such as strong light and shadow, ensuring the stability and accuracy of distance data.

[0039] The mainboard 3 with a display screen serves as the core control unit of the entire device. Equipped with a high-performance ESP32 chip, it efficiently processes the ranging data using complex software algorithms and determines the compliance of the probe position based on preset rules. The specific operating logic is as follows: Before testing, the operator enters the configuration mode via control button 5 (press and hold the left button for about 1 second until the ranging data stabilizes), and sequentially selects the corresponding wheelset model (e.g., RD3, RC4), probe model (e.g., K1.0, K1.2), and detection surface (e.g., axle body, journal). The mainboard retrieves the corresponding scanning range threshold from its built-in database according to the "Railway Passenger Wheel Axle Assembly, Inspection and Management Rules" (TG / CL206-2013) (e.g., when detecting the axle body of the RD3 wheelset with the K1.0 probe, the moving area is 60mm to 184mm from the rear shoulder of the wheel seat). Simultaneously, it automatically completes the ranging zero-point calibration to eliminate mechanical installation errors.

[0040] During the detection process, the ranging sensor 9 sends real-time distance data (transmitted every 10 milliseconds) to the motherboard 3 with a display screen via the UART serial port. The algorithm built into the motherboard compares the real-time distance value with the preset "standard coupling distance (H0)" to calculate the position deviation (threshold ±2mm) and determine whether the current distance is within the preset scanning range. If the real-time distance is within the scanning range threshold (e.g., 60mm to 184mm), the probe position is deemed compliant and the flaw detection operation is valid; if it exceeds the threshold range (e.g., less than 60mm or greater than 184mm), the probe position is deemed non-compliant, and there is a risk of missed detection.

[0041] The device uses an alarm indicator 4, a screen on the mainboard 3 with a display screen, and status lights to provide real-time feedback on the position determination results to the operator, ensuring timely correction of any violations. The specific feedback method is as follows: when the probe position is compliant, the green light on the alarm indicator 4 will remain constantly lit, and the screen on the mainboard 3 with the display screen will show a "compliant" status; when the position is non-compliant, the red light on the alarm indicator 4 will flash, and the screen will simultaneously display "non-compliant" and the current deviation value, reminding the operator to adjust the probe position promptly. The screen on the mainboard 3 with the display screen also displays key information in real-time, including the current distance value, wheel pair model, probe model, detection surface, scanning range threshold, and remaining battery power, allowing the operator to monitor the equipment status and operational boundaries in real time.

[0042] If further enhanced control is required, the motherboard 3 with display screen can also send an abnormal interrupt signal to the ultrasonic flaw detection host via the UART serial port to forcibly suspend the detection process until the probe position is adjusted to the compliant range before the detection can be resumed, thereby ensuring the accuracy and reliability of the flaw detection process.

[0043] Working principle: The device consists of a protective housing 1 and a top cover 2, which secures core components such as the motherboard 3 with display screen, battery 11, and distance sensor 9, preventing positional shifts caused by vibration. The ultrasonic probe 6 is installed in conjunction with the distance sensor 9 using a special clamp, ensuring that the laser projection direction of the distance sensor 9 is parallel to the probe axis, guaranteeing that the collected distance data directly reflects the relative position between the probe and the wheel axle surface. In use, the housing 1 can be placed inside the fixing plate 7, and the threaded post 13 can be rotated via the handle 12. The threaded post 13 will then drive the clamping blocks 15 on both sides to slide towards the outer wall of the fixing plate 7 via the connecting plate 14, thereby clamping and fixing the housing 1. The clamping blocks 15 also prevent the gasket 17 from damaging the surface of the housing 1. Damage can be detected by placing the device on the axle using the support leg 16 at the bottom of the fixed plate 7, and by the rolling action of the magnetic roller 18 at the bottom of the support leg 16. This facilitates the movement of the device along the axle surface during flaw detection and enhances the stability of the fit with the axle through magnetic adsorption, reducing shaking interference during manual operation. Before detection, the battery 11 is charged by connecting a 5V charger through the charging port 10 (it must be kept on; the screen will only show 100% during charging, and the actual remaining power will be displayed after disconnecting the charging cable). During detection, the device is started by the power switch 8, and the battery 11 powers the entire device. At the same time, the power management chip (such as TP4056) built into the motherboard 3 with display screen provides overcharge / over-discharge protection, and the PWM voltage regulation circuit powers the ranging sensor 9 (3).The device provides stable voltage to the motherboard (3V) and motherboard (5V) to ensure the normal operation of each module. It employs triangular laser ranging technology, using a ranging sensor 9 to acquire real-time distance data between the probe and the axle surface, providing the initial basis for position determination. The specific process is as follows: The ranging sensor 9 (such as the Keyence LR-Z series) emits a laser beam, which is focused by an internal converging lens and projected vertically onto the surface of the axle being measured. The scattered light reflected from the axle surface is captured by the sensor's receiving lens and imaged onto the internal CMOS sensor. When the probe moves during the flaw detection operation, the change in the relative position between the axle surface and the sensor causes the laser spot to shift on the CMOS imaging surface. The sensor's built-in chip, based on the "triangular geometry principle," calculates the real-time distance between the probe and the axle surface by calculating the spot displacement and preset optical parameters (such as lens focal length and the distance between the sensor and lens). The measurement accuracy can reach sub-millimeter level, with a refresh rate of [missing information]. With a high 700Hz refresh rate to meet dynamic tracking requirements, the ranging sensor 9 features automatic temperature compensation, adapting to temperature variations of -20℃ to 60℃ in railway environments. Simultaneously, an ambient light filtering algorithm reduces interference from strong light and shadows, ensuring the stability of distance data. The motherboard 3, with its display screen, serves as the core control unit, equipped with an ESP32 chip. It processes the ranging data using software algorithms and combines preset rules to determine if the probe position is compliant. The specific logic is as follows: Before testing, the operator enters configuration mode via control button 5 (press and hold the left button for approximately 1 second until the ranging data stabilizes), sequentially selecting the wheelset model (e.g., RD3, RC4), probe model (e.g., K1.0, K1.2), and detection surface (e.g., axle body, axle journal). The motherboard retrieves the corresponding scanning range threshold (e.g., RD3 wheelset K1) from its built-in database according to the "Railway Passenger Wheel Axle Assembly, Maintenance and Management Rules" (TG / CL206-2013).When the probe is used for shaft detection, the moving area is 60mm to 184mm from the rear shoulder of the wheel seat. Simultaneously, it automatically completes zero-point calibration of the ranging sensor to eliminate mechanical installation errors. During the detection process, the ranging sensor 9 sends real-time distance data (transmitted once every 10ms) to the mainboard 3 with a display screen via a UART serial port. The mainboard's built-in algorithm compares the real-time distance value with the preset "standard coupling distance (H0)", calculates the position deviation (threshold ±2mm), and determines whether the current distance is within the preset scanning range. If the real-time distance is within the scanning range threshold (e.g., 60mm to 184mm), the probe position is deemed compliant, and the flaw detection operation is effective. If it exceeds the threshold (e.g., <60mm or >184mm), the probe position is deemed non-compliant, posing a risk of missed detection. The device responds through an alarm indicator 4, the screen of the mainboard 3 with a display screen, and status updates. The alarm indicator 4 provides real-time feedback on the probe's position to the operator, ensuring timely correction of any violations. The feedback process is as follows: When the probe position is compliant, the green light on the alarm indicator 4 remains constantly lit, and the mainboard 3 with display screen shows a "compliant" status. When the position is non-compliant, the red light on the alarm indicator 4 flashes, and the screen simultaneously displays "non-compliant" and the current deviation value, reminding the operator to adjust the probe position. The mainboard 3 with display screen displays key information in real-time, including the current distance, wheel pair model, probe model, detection surface, scanning range threshold, and remaining battery power, allowing the operator to monitor the equipment status and operational boundaries. For enhanced control, the mainboard 3 with display screen can send an abnormal interrupt signal to the ultrasonic flaw detection host via the UART serial port, forcibly pausing the detection process until the probe position is adjusted to the compliant range before resuming detection.

[0044] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A manual ultrasonic probe positioning device for railway passenger car wheel axles, characterized in that: This includes protective components, fixed support components, core functional components, and human-computer interaction components; The protective component includes a shell (1) and a top cover (2), which together form a closed protective space for accommodating the core functional components; The fixed support assembly includes a fixed plate (7), a handle (12), a threaded post (13), a connecting plate (14), a clamping block (15), a support leg (16), a gasket (17), and a magnetic roller (18). The outer shell (1) is adapted to be placed inside the fixed plate (7). The handle (12) is fixedly connected to one end of the threaded post (13). The other end of the threaded post (13) passes through the fixed plate (7) and is threadedly connected to the connecting plate (14). The two sides of the connecting plate (14) are fixedly connected to the clamping block (15). A gasket (17) is pasted on the inner side of the clamping block (15). The bottom of the fixed plate (7) is fixedly connected to the top of the support leg (16). A magnetic roller (18) is rotatably installed at the bottom of the support leg (16). The core functional components include a motherboard with a display screen (3), an ultrasonic probe (6), a distance sensor (9), a charging port (10), and a battery (11). The motherboard with a display screen (3) and the battery (11) are fixedly installed in the protective space inside the shell (1). The motherboard with a display screen (3) is equipped with an ESP32 chip and a power management chip. The power management chip is a TP4056 model. The motherboard with a display screen (3) also integrates a PWM voltage regulation circuit. The ultrasonic probe (6) is fixed to the outside of the shell (1) by a special clamp. The distance sensor (9) is fixedly connected to the special clamp and the laser projection direction is parallel to the axis of the ultrasonic probe (6). The distance sensor (9) is a Keyence LR-Z series. The charging port (10) is opened on the side wall of the shell (1) and electrically connected to the battery (11). The battery (11) is electrically connected to the motherboard with a display screen (3) and the distance sensor (9) respectively through the PWM voltage regulation circuit. The human-computer interaction component includes an alarm indicator (4), a control button (5), and a power switch (8). The alarm indicator (4), control button (5), and power switch (8) are all installed on the surface of the housing (1) and electrically connected to the motherboard (3) with a display screen.

2. The manual ultrasonic probe positioning device for railway passenger car wheel axles according to claim 1, characterized in that: The power management chip is used to implement overcharge protection and over-discharge protection of the battery (11). The PWM voltage regulation circuit can output 3.3V voltage to power the ranging sensor (9) and output 5V voltage to power the motherboard (3) with display screen.

3. The manual ultrasonic probe positioning device for railway passenger car wheel axles according to claim 1, characterized in that: The ranging sensor (9) has a built-in converging lens, a receiving lens and a CMOS sensor. The ranging sensor (9) can emit a laser beam, which is focused by the converging lens and projected vertically onto the surface of the wheel axle. The scattered light reflected from the surface of the wheel axle is captured by the receiving lens and imaged onto the CMOS sensor. The chip built into the ranging sensor (9) can calculate the real-time distance between the probe and the surface of the wheel axle based on the principle of trigonometric geometry, combined with the displacement of the light spot on the CMOS sensor and the preset optical parameters.

4. The manual ultrasonic probe positioning device for railway passenger car wheel axles according to claim 3, characterized in that: The ranging sensor (9) has a measurement accuracy of sub-millimeter level, a refresh rate of up to 700Hz, and an automatic temperature compensation function. It can adapt to ambient temperatures of -20℃ to 60℃ and integrates an ambient light filtering algorithm.

5. The manual ultrasonic probe positioning device for railway passenger car wheel axles according to claim 1, characterized in that: The motherboard (3) with display screen has a built-in database. The control button (5) can trigger the motherboard (3) with display screen to enter the configuration mode. The motherboard (3) with display screen can call the corresponding scanning range threshold from the database and automatically complete the zero-point calibration of the ranging.

6. The manual ultrasonic probe positioning device for railway passenger car wheel axles according to claim 5, characterized in that: The ranging sensor (9) is connected to the motherboard (3) with display screen via UART serial port and can transmit real-time distance data to the motherboard (3) with display screen once every 10ms. The motherboard (3) with display screen has a built-in algorithm that can compare the real-time distance data with the preset standard coupling distance (H0), calculate the position deviation, and the position deviation threshold is ±2mm, and determine whether the real-time distance is within the threshold of the scanning range called.

7. The manual ultrasonic probe positioning device for railway passenger car wheel axles according to claim 6, characterized in that: When the real-time distance is within the scanning range threshold, the mainboard (3) with display screen controls the alarm indicator (4) to keep the green light on and simultaneously controls its own display screen to show the "compliant" status; when the real-time distance exceeds the scanning range threshold, the mainboard (3) with display screen controls the alarm indicator (4) to flash the red light and simultaneously controls its own display screen to show the "violation" status and the current distance deviation value.

8. The manual ultrasonic probe positioning device for railway passenger car wheel axles according to claim 1, characterized in that: The display screen of the motherboard (3) with display screen can display the current distance value, wheel pair model, probe model, detection surface, scanning range threshold and remaining battery power (11) in real time; the motherboard (3) with display screen can also communicate with the external ultrasonic flaw detection host through the UART serial port, and when the real-time distance exceeds the scanning range threshold, it can send an abnormal interrupt signal to the ultrasonic flaw detection host.

9. The manual ultrasonic probe positioning device for railway passenger car wheel axles according to claim 1, characterized in that: The charging port (10) is a Type-C interface, which is compatible with a 5V charger. The device must be powered on during charging. During the charging process, the display shows that the battery level is 100%. After the charging cable is unplugged, the display shows the actual remaining battery level (11).

10. The manual ultrasonic probe positioning device for railway passenger car wheel axles according to claim 1, characterized in that: Rotating the handle (12) can drive the threaded column (13) to rotate. When the threaded column (13) rotates, it can drive the connecting plate (14) to drive the clamping block (15) to slide towards the outer wall of the fixing plate (7), so that the clamping block (15) clamps and fixes the outer shell (1). The gasket (17) can prevent the clamping block (15) from directly contacting the surface of the outer shell (1). The magnetic roller (18) can be attracted to the surface of the wheel axle and can roll along the surface of the wheel axle.

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