Railway track broken rail detection device

Abstract

The utility model provides a railway track broken rail detection device relates to track detection technical field, and the detection device includes the base plate, walking mechanism and the magnetic flux leakage detection device, and walking mechanism is located in the base plate bottom surface, and drives device moves along the track. The magnetic flux leakage detection device contains magnetizing device, magnetic field acquisition module and signal processing module. Magnetizing device adopts the permanent magnet and magnetically permeable component of opposite polarity, forms closed magnetic circuit in the steel rail inside, makes the broken rail place produce the magnetic flux leakage. The magnetic field acquisition module captures the magnetic flux leakage signal through the magnetic sensor array, and the signal processing module is through amplification, filtering and AD conversion output digital signal. The device has realized efficient mobile detection, internal defect identification and all-weather work, solved the problem that traditional method is low in efficiency, poor in precision.

Description

Technical Field

[0001] This utility model relates to the field of track inspection technology, and in particular to a railway track breakage detection device. Background Technology

[0002] As a vital artery of the national economy, the safe operation of railway transportation is of paramount importance. Rails, as the fundamental carrier of trains, are essential for ensuring safe operation. However, during long-term service, rails suffer various types of damage due to complex stress, fatigue, corrosion, and external impacts, with rail breaks being one of the most serious and dangerous defects. Therefore, efficient and accurate periodic inspections of rails to promptly identify potential rail breakage risks are a core task of railway maintenance departments.

[0003] Currently, there are various technical means for inspecting the condition of rails in the railway engineering field, but all of them have certain limitations.

[0004] The most traditional and common method relies on manual inspections by patrol personnel along the tracks. This method is not only inefficient and requires a large workforce, but the results also heavily depend on the personal experience and mental state of the inspectors. The human eye struggles to detect minute cracks inside and on the surface of the rails, especially in inclement weather or at night, where the rate of missed inspections increases significantly. This highly subjective and low-automation model is no longer sufficient to meet the efficiency and reliability requirements of modern railway operations characterized by high density and high speed.

[0005] To improve the objectivity and accuracy of inspections, non-destructive testing (NDT) technology has been introduced into the field of rail flaw detection. Currently applied or researched automated inspection technologies, such as ultrasonic testing, image recognition, and electrical signal detection based on track circuits, all have significant limitations. While ultrasonic testing offers high accuracy, it relies on coupling agents, requires stringent rail surface cleanliness, and is slow. Image recognition technology is susceptible to ambient light and weather conditions, can only detect surface defects, and cannot detect internal damage. Electrical signal detection based on track circuits is merely a post-incident alarm mechanism, triggering signal interruption only after a rail breakage occurs, failing to provide early warning of risks. Therefore, existing technologies struggle to balance efficiency, accuracy, and environmental robustness, failing to meet the urgent need for rapid and preventative inspection of internal rail defects. Utility Model Content

[0006] In view of this, this utility model proposes a railway track breakage detection device to solve the problem that existing technologies cannot efficiently and accurately detect potential rail breakage defects.

[0007] The technical solution of this utility model is implemented as follows: This utility model provides a railway track breakage detection device, comprising: substrate; A walking mechanism is disposed on the bottom surface of the base plate and is used to walk on the surface of the rail to drive the base plate to move along the longitudinal direction of the rail. A magnetic flux leakage detection device, mounted on a substrate, includes a magnetization device, a magnetic field acquisition module, and a signal processing module; wherein, The magnetization device includes two permanent magnets with opposite polarities and a magnetic guiding component. The two permanent magnets are arranged longitudinally along the track and close to the track surface. The magnetic guiding component covers the upper part and side of the permanent magnets and guides the magnetic lines of force of the two permanent magnets into the interior of the rail to form a closed magnetic circuit. The magnetic field acquisition module includes several magnetic sensors, which are arranged at intervals along the transverse direction of the track and positioned close to the surface of the rail. They are used to capture the leakage magnetic field signal generated by the rail due to the rail breakage defect during the movement of the substrate. The signal processing module includes an amplifier, a filter, and an analog-to-digital converter. The input terminal of the amplifier is electrically connected to the magnetic field acquisition module. The input terminal of the filter is connected to the output terminal of the amplifier. The analog signal input terminal of the analog-to-digital converter is connected to the output terminal of the filter. The digital signal output terminal of the analog-to-digital converter constitutes the output terminal of the signal processing module.

[0008] Based on the above technical solution, preferably, the walking mechanism includes walking wheels and guide wheels; The number of the traveling wheels is two, which are respectively set at both ends of the base plate along its length, and are used to contact the top surface of the rail and support the base plate; The guide wheels are four in number, arranged in pairs, and located on both sides of the base plate in the width direction, for contacting the sidewall of the track to achieve guidance.

[0009] Based on the above technical solution, preferably, the guide wheel includes a connecting rod and a roller rotatably disposed at the bottom end of the connecting rod, and an adjustment device is provided between the upper end of the connecting rod and the base plate, the adjustment device including an adjustment screw and a guide rod; The bottom surface of the substrate has a mounting groove at the corner, and the upper end of the connecting rod is inserted into the mounting groove and can slide along the direction perpendicular to the length of the substrate. One end of the adjusting screw is rotatably inserted into the side wall of the substrate along the width direction and extends into the mounting groove. The connecting rod has a threaded hole that mates with the adjusting screw. The guide rod is fixedly installed in the mounting groove and moves through the connecting rod, and the guide rod is parallel to the adjusting screw.

[0010] Based on the above technical solution, preferably, the magnetization device further includes a magnetization mounting base. A through hole is provided in the middle of the substrate. The magnetization mounting base is fixedly disposed on the top surface of the substrate, and its lower part extends through the through hole to the bottom surface of the substrate. The bottom contour of the magnetization mounting base matches the top contour of the rail, and there is a gap between the bottom surface of the magnetization mounting base and the top surface of the rail. Two receiving cavities are provided at intervals along the length direction of the substrate on the top of the magnetization mounting base. A permanent magnet and a magnetic conductive component are respectively disposed in each receiving cavity.

[0011] Based on the above technical solution, preferably, the inner bottom surface contour of the accommodating cavity matches the bottom surface contour of the magnetized mounting base.

[0012] Based on the above technical solution, preferably, the magnetic field acquisition module further includes a fixing frame, the bottom surface of the magnetization mounting base is provided with an installation groove along the length direction perpendicular to the substrate, the fixing frame is fixedly installed in the installation groove, the fixing frame has an assembly groove along its length direction, and a number of magnetic sensors are fixedly installed in the assembly groove at intervals along the length direction of the assembly groove, and the detection end of the magnetic sensor is not higher than the bottom surface of the fixing frame.

[0013] Based on the above technical solution, preferably, the bottom surface of the fixing frame is flush with the bottom surface of the magnetized mounting base.

[0014] Based on the above technical solution, preferably, both the magnetized mounting base and the fixing frame are made of non-magnetic materials.

[0015] Based on the above technical solution, preferably, a protective cover is also fixedly provided on the top surface of the substrate, the protective cover covers the magnetization mounting base and the signal processing module, a battery connected to the signal processing module is also provided inside the protective cover, and a handle is provided on the top surface of the protective cover.

[0016] Based on the above technical solution, preferably, it also includes an operating lever, one end of which is hinged to one end of the base plate along its length. A lifting arm is provided at one end of the operating lever near the base plate. One end of the lifting arm is fixedly connected to the bottom surface of the operating lever in a radial direction perpendicular to it, and the other end is used to contact the top surface of the rail. The length of the lifting arm is greater than or equal to the vertical distance from the top surface of the rail to the hinged end of the operating lever.

[0017] The present invention has the following advantages over the prior art: (1) The railway track breakage detection device disclosed in this utility model drives the entire device to move along the track through a walking mechanism supported by a base plate. At the same time, it uses permanent magnets with opposite polarities and magnetic conductive components to construct a high-intensity directional magnetic field inside the rail, so that a significant leakage magnetic signal is generated at the rail breakage defect. The magnetic sensor array dynamically captures the spatial distribution characteristics of the signal, and completes signal amplification, noise suppression and digital conversion in real time through a pure hardware signal processing link (amplifier → filter → analog-to-digital converter) to form high-fidelity output data. This closed-loop technology achieves a significant improvement in detection efficiency, accurate identification of internal defects and breakthroughs in all-weather environmental adaptability. It integrates magnetization excitation, multi-channel signal acquisition and hardware processing system into a mobile platform to build a physical detection system that does not require software intervention, solving the technical problems of low efficiency of traditional manual inspection, reliance on coupling agent for ultrasonic flaw detection, environmental constraints on image recognition and delays in software processing.

[0018] (2) By setting an adjustment device, the distance between two rollers opposite each other in the width direction of the substrate can be adjusted to adapt to the width difference of different rail types and enhance the versatility of the detection device.

[0019] (3) By matching the curved bottom surface of the magnetized mounting base with the rail top profile, the magnetic field is efficiently coupled through a small gap; the double cavities are arranged longitudinally along the rail, and the pairs of opposite pole permanent magnets with magnetically conductive coating are embedded to build a high-intensity gradient magnetic field inside the rail; when there is a rail breakage defect, the magnetic field is violently refracted and escaped at the edge of the defect, generating a leakage magnetic signal with obvious spatial distribution characteristics, breaking through the magnetic field strength bottleneck of the traditional single magnet scheme.

[0020] (4) By integrating the magnetic sensor onto the bottom surface of the magnetized mounting base via a fixed frame, and with the mounting slot centrally located between the two accommodating cavities, a three-dimensional spatial compact layout of the permanent magnet, magnetic conductive components, and sensor array on the magnetized mounting base is achieved: the magnetized mounting base simultaneously supports the permanent magnet in the two accommodating cavities and the magnetic sensor in the central fixed frame, making the magnetic field source and signal acquisition end form an integrated and compact structure; the central mounting slot allows the magnetic sensor array to be precisely located at the sensitive axis of the dual magnetic field, directly capturing the maximum gradient leakage magnetic signal, while eliminating the assembly accumulation error of the traditional split structure; this highly integrated design fundamentally reduces the overall height and volume of the device, avoids vibration offset caused by component separation when the walking mechanism moves, and ensures the long-term stability of magnetic field coupling efficiency and signal acquisition accuracy.

[0021] (5) By hinged one end of the operating rod to the end of the base plate to form a fulcrum, and with the lifting arm vertically fixed to the bottom of the rod using the rail surface as a temporary fulcrum, when the free end of the operating rod is pressed down, the lever force is concentrated at the contact interface between the magnetization device and the rail surface, effectively overcoming the strong attraction force generated by the permanent magnet. This design combines the lever principle with the characteristics of the magnetic circuit, and through mechanical amplification, enables a single person to complete the non-destructive separation of the device from the rail surface, greatly improving the disassembly efficiency. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a three-dimensional structural schematic diagram of the railway track breakage detection device disclosed in this utility model. Figure 2 This is a front view of the railway track breakage detection device and railway track assembly structure disclosed in this utility model; Figure 3 This is a schematic diagram of the bottom structure of the railway track breakage detection device disclosed in this utility model; Figure 4 This is an exploded view of the railway track breakage detection device disclosed in this utility model. Figure 5 This is a top view of the railway track breakage detection device and railway track assembly structure disclosed in this utility model; Figure 6 for Figure 5 Planar sectional view at point AA; Figure 7 for Figure 5 Plan view at point BB; Figure label: S, rail; 1, base plate; 2, traveling mechanism; 21, traveling wheel; 22, guide wheel; 221, connecting rod; 222, roller; 11, mounting groove; 12, through hole; 3. Magnetizing device; 31. Permanent magnet; 32. Magnetic conductive component; 33. Magnetizing mounting base; 331. Receiving cavity; 332. Mounting slot; 4. Magnetic field acquisition module; 41. Magnetic sensor; 42. Mounting bracket; 421. Assembly slot; 5. Signal processing module; 51. Amplifier; 52. Filter; 53. Analog-to-digital converter; 6. Adjusting device; 61. Adjusting screw; 62. Guide rod; 7. Protective cover; 71. Battery; 72. Handle; 8. Operating lever; 81. Lifting arm; 9. Control module; 91. Power switch; 92. Alarm; 93. Alarm reset switch; 94. Wireless transmission module. Detailed Implementation

[0024] The technical solutions of this utility model will be clearly and completely described below with reference to the embodiments of this utility model. Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. Based on the embodiments of this utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of this utility model.

[0025] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0026] In the description of the embodiments of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this utility model based on the specific circumstances.

[0027] In the description of the embodiments of this utility model, it should be noted that the terms "center", "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this utility model.

[0028] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0029] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0030] The following disclosure provides numerous different embodiments or examples for implementing various structures of the present invention. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the scope of the invention. Furthermore, reference numerals and / or letters may be repeated in different examples. Such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. In addition, examples of various specific processes and materials are provided in this invention; however, those skilled in the art will recognize the applicability of other processes and / or the use of other materials.

[0031] like Figure 1 As shown, combined with Figure 2-7 This utility model discloses a railway track breakage detection device, including a base plate 1, a traveling mechanism 2, and a missed detection device.

[0032] The base plate 1 serves as the rigid support platform for the entire device. The walking mechanism 2 is located on the bottom surface of the base plate 1. The walking mechanism 2 on the bottom surface makes physical contact with the top surface / side wall of the rail S and moves longitudinally along the rail under the action of human force or traction.

[0033] The base plate 1 and the walking mechanism 2 work together to provide stable support and directional movement capability for the detection device, ensuring that the detection process continuously covers the predetermined length of the rail and overcoming the problem of low efficiency of manual inspection.

[0034] A magnetic flux leakage detection device is mounted on a substrate 1 and includes a magnetization device 3, a magnetic field acquisition module 4, and a signal processing module 5.

[0035] The magnetization device 3 is used to construct a closed magnetic circuit. Specifically, the magnetization device 3 includes two permanent magnets 31 with opposite polarities and a magnetic guiding component 32. The two permanent magnets 31 are arranged longitudinally along the track and are close to the track surface. The magnetic guiding component 32 covers the upper part and side of the permanent magnets 31 and guides the magnetic lines of force of the two permanent magnets 31 into the interior of the rail to form a closed magnetic circuit.

[0036] In this embodiment, two permanent magnets 31 are spaced apart along the length of the substrate 1. The two permanent magnets 31 have opposite polarities at the ends facing the rail. The magnetic guiding component 32 is wrapped around the perimeter and top surface of the permanent magnets 31. In this embodiment, the magnetic guiding component 32 is a magnetic yoke made of electrical pure iron. The permanent magnets 31 generate a constant magnetic field, and the magnetic guiding component 32 guides and concentrates the magnetic field, vertically guiding the magnetic field generated by the permanent magnets 31 to the surface of the rail.

[0037] For example, the two permanent magnets 31 along the length of the substrate 1 are defined as the left permanent magnet 31 and the right permanent magnet 31. The permanent magnet 31 can be a neodymium iron boron permanent magnet 31. The magnetic field lines emitted by the S pole of the left permanent magnet are oriented and guided to the surface of the rail by the magnetic guide component 32 on the left side, so that the inside of the rail is saturated with magnetization. The magnetic force passes through the rail and returns to the N pole of the right permanent magnet under the guidance of the magnetic guide component 32. The magnetic poles with opposite polarities form a closed magnetic circuit through the rail under the constraint of the magnetic guide component 32.

[0038] When there is a crack in the rail, the magnetic permeability at the crack drops sharply, and the magnetic field lines cannot pass through. The magnetic field lines are refracted and escape at the edge of the crack, forming a spatial leakage magnetic field.

[0039] A high-intensity directional magnetic field is established inside the rail, causing the rail breakage defect to generate a significant magnetic leakage signal, which makes the detection sensitivity of internal cracks far exceed that of surface observation methods.

[0040] It should be noted that when rails are magnetized, if the internal material of the rail is uniform and continuous, the magnetic field lines in the material are confined within the rail, and the magnetic flux is essentially parallel to the rail surface. In this case, there is almost no magnetic field on the surface of the rail being inspected. However, once defects such as cracks appear on the surface or subsurface of the rail, because the defect area is mostly air, its permeability is much lower than that of the rail material itself, while its magnetic reluctance is greater. Magnetic flux that should have passed through the defect will either pass directly through the defect or bypass it from within the rail material, while the remaining magnetic flux will leak into the space on the rail surface, thus creating a leakage magnetic field on the rail surface at the defect location.

[0041] When magnetic flux encounters a broken rail defect, the magnetic field lines bend and redistribute near the crack, similar to the flow of water around an obstacle, but occurring in three-dimensional space. Some magnetic field lines "leak" from inside the rail into the air, forming magnetic field components that are both perpendicular and parallel to the rail surface. The intensity of these components varies at the crack edge and center, creating unique magnetic field characteristics that can be used to locate and assess defects. The microstructure of the rail material further complicates this process. Grain boundaries, micro-inclusions, or residual stress from heat treatment within the rail can cause localized changes in permeability, affecting the magnetic field distribution. However, as a through-type defect, a broken rail has a much greater impact on magnetic flux than these microscopic effects, generating a significant magnetic leakage signal. The magnetization level is also crucial: near saturation, the significant difference in permeability between the rail and the crack maximizes the magnetic leakage effect, improving detection sensitivity.

[0042] In order to detect the leakage magnetic field, this embodiment sets up a magnetic field acquisition module 4, which includes several magnetic sensors 41. The magnetic sensors 41 are arranged at intervals along the transverse direction of the track and are located close to the surface of the rail. They are used to capture the leakage magnetic field signal generated by the rail due to the rail breakage defect during the movement of the substrate 1.

[0043] When the magnetic sensor 41 passes over the rail breakage defect, it captures the spatial distribution signal of the leakage magnetic field and converts it into an electrical signal. The layout of multiple magnetic sensors 41 covers the entire width of the rail top, and can collect data synchronously to eliminate detection blind spots.

[0044] In this embodiment, the magnetic sensor 41 is a linear Hall element (model SS49E) with a sensitivity of 1.3mV / G. The magnetic sensors 41 are arranged laterally at 10mm intervals, covering the standard rail top width (70mm).

[0045] The signal processing module 5 includes an amplifier 51, a filter 52, and an analog-to-digital converter 53. The input terminal of the amplifier 51 is electrically connected to the magnetic field acquisition module 4. The input terminal of the filter 52 is connected to the output terminal of the amplifier 51. The analog signal input terminal of the analog-to-digital converter 53 is connected to the output terminal of the filter 52. The digital signal output terminal of the analog-to-digital converter 53 constitutes the output terminal of the signal processing module 5.

[0046] In this embodiment, amplifier 51 is an instrumentation operational amplifier INA128 with a gain resistor of 100kΩ, filter 52 adopts a second-order RC low-pass network with a cutoff frequency of 1kHz, and analog-to-digital converter 53 is a 12-bit ADC chip ADS7828.

[0047] The weak electrical signal output from the magnetic field acquisition module 4 is sequentially input to amplifier 51 to improve the signal-to-noise ratio, filtered by filter 52 to suppress high-frequency interference, and finally converted into a digital signal by analog-to-digital converter 53. The entire process of signal conditioning and conversion is achieved through hardware circuitry. The leakage magnetic signal of a broken rail typically exhibits sharp, high-amplitude peaks, reflecting the depth and width of the crack. By acquiring the leakage magnetic signal, the condition of cracks and defects on the rail surface can be detected.

[0048] The railway track breakage detection device disclosed in this embodiment is driven to move along the track by a walking mechanism 2 supported by a base plate 1. Simultaneously, a high-intensity directional magnetic field is constructed inside the track using permanent magnets 31 with opposite polarities and a magnetically conductive component 32, generating a significant leakage magnetic signal at the track breakage defect. An array of magnetically sensitive sensors 41 dynamically captures the spatial distribution characteristics of this signal, and a pure hardware signal processing link (amplifier 51 → filter 52 → analog-to-digital converter 53) performs real-time signal amplification, noise suppression, and digital conversion to form high-fidelity output data. This closed-loop technology significantly improves detection efficiency, accurately identifies internal defects, and achieves breakthroughs in all-weather environmental adaptability. It integrates magnetization excitation, multi-channel signal acquisition, and hardware processing systems onto a mobile platform, constructing a physical detection system that requires no software intervention. This solves the technical problems of low efficiency in traditional manual inspections, reliance on coupling agents in ultrasonic flaw detection, environmental constraints on image recognition, and delays in software processing.

[0049] As some implementations, the walking mechanism 2 includes a walking wheel 21 and a guide wheel 22.

[0050] Two traveling wheels 21 are respectively disposed at both ends of the base plate 1 along its length, for contacting the top surface of the rail and supporting the base plate 1. When the device is subjected to traction force, the traveling wheels 21 roll longitudinally along the rail, transferring the weight of the base plate 1 and the leakage magnetic field detection device to the rail surface, while providing forward driving force.

[0051] There are four guide wheels 22, arranged in pairs, located on both sides of the base plate 1 in the width direction, for contacting the sidewall of the track to achieve guidance. When the traveling wheel 21 drives the device forward, the guide wheels 22 roll along the side of the rail and constrain the lateral displacement of the base plate 1.

[0052] In the above embodiments, the walking wheel 21 and the guide wheel 22 can be made of metal or plastic.

[0053] Since railway tracks come in different widths, the following technical solution is adopted in this embodiment to achieve the universality of the detection device.

[0054] Specifically, the guide wheel 22 includes a connecting rod 221 and a roller 222 rotatably disposed at the bottom end of the connecting rod 221. Since the distance between the two rollers 222 needs to be adapted to the width of the rail, when the rail signal changes, it is necessary to be able to adjust the distance between the two rollers 222.

[0055] Therefore, in this embodiment, an adjustment device 6 is provided between the upper end of the connecting rod 221 and the substrate 1. The adjustment device 6 includes an adjustment screw 61 and a guide rod 62.

[0056] Mounting grooves 332 are provided on the bottom surface of the corner of the substrate 1. Specifically, mounting grooves 332 are provided on two corners on one side of the width direction of the substrate 1. Mounting grooves 332 are not provided on the other two corners. The connecting rod 221 is directly rigidly connected to the substrate 1. The two guide wheels 22 are adjusted only on one side of the width direction of the substrate 1.

[0057] The upper end of the connecting rod 221 on one side of the substrate 1 in the width direction is inserted into the mounting groove 332 and can slide along the direction perpendicular to the length of the substrate 1. One end of the adjusting screw 61 is rotatably inserted into the side wall of the substrate 1 along the width direction of the substrate 1 and extends into the mounting groove 332. The connecting rod 221 has a threaded hole that mates with the adjusting screw 61. The guide rod 62 is fixedly disposed in the mounting groove 332 and moves through the connecting rod 221, and the guide rod 62 is parallel to the adjusting screw 61.

[0058] Specifically, the adjusting screw 61 passes through the mounting groove 332 along the width direction of the substrate 1, forming a threaded pair with the threaded hole on the connecting rod 221. When the screw is rotated, the threaded pair converts the rotational motion into linear displacement of the connecting rod 221 along the guide rod 62, thereby changing the position of the roller 222 in the mounting groove 332. This adjusts the distance between the two rollers 222 opposite each other in the width direction of the substrate 1, adapting to the width differences of different rail types.

[0059] In order to realize the installation of permanent magnet 31 and magnetic conductive component 32, the magnetization device 3 of this embodiment is also provided with magnetization mounting base 33. Specifically, a through hole 12 is opened in the middle of the substrate 1, the magnetization mounting base 33 is fixedly disposed on the top surface of the substrate 1, and its lower part extends through the through hole 12 to the bottom surface of the substrate 1. The bottom surface contour of the magnetization mounting base 33 is adapted to the top surface contour of the rail, and there is a gap between the bottom surface of the magnetization mounting base 33 and the top surface of the rail.

[0060] In this embodiment, the precise spatial positioning of the rail is machined on the bottom surface of the mounting base to ensure that the magnetic field is efficiently injected into the interior of the rail, avoiding magnetic energy loss caused by air gap magnetic resistance.

[0061] Two accommodating cavities 331 are spaced apart at the top of the magnetization mounting base 33 along the length of the substrate 1. Each accommodating cavity 331 contains a permanent magnet 31 and a magnetically conductive component 32 covering the top and side surfaces of the permanent magnet 31. The magnetic poles of the two permanent magnets 31 are arranged in opposite directions.

[0062] In this embodiment, the magnetically conductive component 32 is a cover with an open bottom, which wraps around the permanent magnet 31 to form a magnetic shielding layer, constraining the magnetic lines of force to be oriented vertically and guided to the rail surface. The magnetizing mounting base 33 in this embodiment is made of a non-magnetically conductive material, such as aluminum, nylon, or other non-magnetically conductive materials.

[0063] Two permanent magnets 31 are respectively embedded in the accommodating cavity 331, with their magnetic poles facing opposite directions (i.e., N and S poles are opposite). The magnetic guiding component 32 connects the permanent magnets 31 to form a closed magnetic circuit, so that the magnetic lines of force are concentrated and pass through the rail head section.

[0064] Through the three-dimensional coordination of magnetized mounting base 33, accommodating cavity 331, and opposite polarity permanent magnet 31: the curved bottom surface of magnetized mounting base 33 matches the rail top contour, achieving efficient magnetic field coupling through a tiny gap; the double accommodating cavity 331 is arranged longitudinally along the track, with a pair of opposite polarity permanent magnets 31 embedded in it, constructing a high-intensity gradient magnetic field inside the rail; when there is a rail break defect, the magnetic field is violently refracted and escaped at the edge of the defect, generating a leakage magnetic signal with obvious spatial distribution characteristics, breaking through the magnetic field strength bottleneck of the traditional single magnet scheme.

[0065] As one implementation, the inner bottom profile of the accommodating cavity 331 matches the bottom profile of the magnetized mounting base 33.

[0066] Specifically, the inner bottom surface of the accommodating cavity 331 strictly replicates the curved contour of the bottom surface of the magnetized mounting base 33, forming a geometrically conformal structure. When the permanent magnet 31 is embedded in the accommodating cavity 331, its bottom surface completely fits the curved surface of the cavity, eliminating air gaps; simultaneously, this curved surface undulates synchronously with the bottom surface of the magnetized mounting base 33, maintaining an equidistant gap with the rail top contour. This ensures that the magnetic lines of force of the permanent magnet 31 penetrate the bottom of the cavity perpendicularly, avoiding magnetic flux scattering caused by interface mismatch, eliminating local saturation regions in the magnetic circuit, ensuring uniform diffusion of the magnetic field inside the rail, and enhancing the consistency of response to micro-cracks.

[0067] The magnetic field acquisition module 4 in this embodiment also includes a fixing frame 42. The bottom surface of the magnetization mounting base 33 is provided with a mounting groove 332 along the length direction perpendicular to the substrate 1, and the mounting groove 332 is located between two accommodating cavities 331. The fixing frame 42 is fixedly installed in the mounting groove 332. The fixing frame 42 has an assembly groove 421 along its length direction. A plurality of magnetic sensors 41 are fixedly installed at intervals in the assembly groove 421 along the length direction of the assembly groove 421.

[0068] Specifically, the mounting slot 332 is located between the two accommodating cavities 331, placing the fixing frame 42 and the array of magnetic sensors 41 at the symmetrical central axis of the dual magnetic field. When the permanent magnet 31 is working, the magnetic field gradient is at its maximum here, and the leakage magnetic field distortion caused by the track break defect is most significant.

[0069] The detection end of the magnetic sensor 41 is not higher than the bottom surface of the fixing frame 42, which can avoid the magnetic sensor 41 from contacting the rail surface and maintain the detection end of the magnetic sensor 41 and the top surface of the rail at equal distances in the vertical direction.

[0070] By integrating the magnetic sensor 41 onto the bottom surface of the magnetized mounting base 33 via the fixing frame 42, and with the mounting groove 332 centrally located between the two accommodating cavities 331, a three-dimensional spatial compact layout of the permanent magnet 31, the magnetic conductive component 32, and the sensor array on the magnetized mounting base 33 is achieved. The magnetized mounting base 33 simultaneously supports the permanent magnet 31 in both accommodating cavities 331 and the magnetic sensor 41 in the central fixing frame 42, forming an integrated and compact structure between the magnetic field source and the signal acquisition end. The centrally located mounting groove 332 ensures that the magnetic sensor 41 array is precisely positioned at the sensitive axis of the dual magnetic field, directly capturing the maximum gradient leakage magnetic signal, while eliminating the assembly accumulation error of the traditional split structure. This highly integrated design fundamentally reduces the overall height and volume of the device, avoids vibration and displacement caused by component separation when the walking mechanism 2 moves, and ensures the long-term stability of magnetic field coupling efficiency and signal acquisition accuracy.

[0071] In this embodiment, the bottom surface of the mounting bracket 42 is flush with the bottom surface of the magnetization mounting base 33. This arrangement ensures that the sensor array and the magnetic field output interface of the magnetization device 3 form a continuous detection plane, eliminating the air gap magnetic resistance caused by the traditional stepped layout.

[0072] In some implementations, both the magnetized mounting base 33 and the mounting bracket 42 are made of non-magnetic materials. This arrangement allows the magnetic field lines of the permanent magnet 31 to pass through the mounting base and be guided to the rail. If the magnetized mounting base 33 and the mounting bracket 42 were made of magnetically conductive materials, the magnetic field lines of the permanent magnet 31 would preferentially flow to the mounting base and mounting bracket 42 rather than the rail, resulting in a significant attenuation of the magnetic field strength and a noticeable decrease in the sensor's signal acquisition.

[0073] Preferably, the magnetized mounting base 33 and the fixing bracket 42 are made of aluminum alloy or nylon. Furthermore, in this embodiment, the fixing bracket 42 is preferably made of nylon, as its insulation properties block eddy current paths, significantly improving the signal-to-noise ratio of the sensor's acquired signal.

[0074] In some implementations, a protective cover 7 is fixedly mounted on the top surface of the substrate 1, covering the magnetization mounting base 33 and the signal processing module 5. This configuration provides physical shielding and protection for the magnetization device 3 and the signal processing module 5. A battery 71 connected to the signal processing module 5 is also housed inside the protective cover 7, providing the necessary power for the entire detection device. A handle 72 is provided on the top surface of the protective cover 7 for easy carrying of the entire detection device.

[0075] It is worth noting that the detection device disclosed in this embodiment also includes a control module 9. The control module 9 includes a circuit board, an amplifier 51, a filter 52 and an analog-to-digital converter 53 are electrically mounted on the circuit board, and a battery 71 is electrically connected to the circuit board. In addition, a wireless transmission module 94 electrically connected to the battery is also provided on the protective cover 7, which can transmit the acquired digital signals to a terminal, such as a computer, mobile phone, tablet or other handheld device, so as to obtain the rail fracture crack data in real time through the device.

[0076] In addition, the protective cover 7 is also equipped with a power switch 91, an alarm 92, and an alarm reset switch 93. These components are all electrically connected to the circuit board. The power switch 91 is used to control the circuit of the entire detection device to turn on or off. The alarm 92 is used to emit an alarm signal. If a break is detected, it can be indicated by sound or an alarm light, so that the inspector is aware that there is a break in the section of rail. The alarm reset switch 93 is used to turn off the sound or light of the alarm 92.

[0077] It is worth noting that the permanent magnet 31 disclosed in this embodiment is a strong magnet. During use, the permanent magnet 31 will strongly attract the rail. When it is necessary to disassemble the entire detection device, it will take a lot of effort to pull the detection device upward by the handle, which is inconvenient to disassemble. Therefore, this embodiment also adopts the following technical solution.

[0078] Specifically, it also includes an operating lever 8, one end of which is hinged to one end of the base plate 1 along its length. A lifting arm 81 is provided at one end of the operating lever 8 near the base plate 1. One end of the lifting arm 81 is fixedly connected to the bottom surface of the operating lever 8 in a radial direction, and the other end is used to contact the top surface of the rail. The length of the lifting arm 81 is greater than or equal to the vertical distance from the top surface of the rail to the hinged end of the operating lever 8.

[0079] Using the above technical solution, one end of the operating rod 8 is hinged to the end of the base plate 1 to form a fulcrum. The lifting arm 81, which is vertically fixed to the bottom of the rod, uses the rail surface as a temporary fulcrum. When the free end of the operating rod 8 is pressed down, the lever force is concentrated at the contact interface between the magnetizing device 3 and the rail surface, effectively overcoming the strong attraction force generated by the permanent magnet 31. This design combines the lever principle with the characteristics of the magnetic circuit, and through mechanical amplification, enables a single person to complete the non-destructive separation of the device from the rail surface, greatly improving the disassembly efficiency.

[0080] In actual use, the operating lever 8 can be connected to the inspection vehicle. The inspection vehicle travels at a constant speed on the rails, which drives the entire inspection device to move and inspect on the rails. After the inspection task is completed, the operating lever 8 is removed from the inspection vehicle, and then the entire inspection device is removed from the rails through the lever principle.

[0081] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. 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 railway track breakage detection device, characterized in that, include: base(1); The walking mechanism (2) is disposed on the bottom surface of the base plate (1) and is used to walk on the surface of the rail to drive the base plate (1) to move along the longitudinal direction of the rail. A magnetic flux leakage detection device, mounted on a substrate (1), includes a magnetization device (3), a magnetic field acquisition module (4), and a signal processing module (5); wherein, The magnetization device (3) includes two permanent magnets (31) with opposite polarities and a magnetic guiding component (32). The two permanent magnets (31) are arranged longitudinally along the track and close to the track surface. The magnetic guiding component (32) covers the upper part and side of the permanent magnets (31) and guides the magnetic lines of force of the two permanent magnets (31) into the interior of the rail to form a closed magnetic circuit. The magnetic field acquisition module (4) includes several magnetic sensors (41). The magnetic sensors (41) are arranged at intervals along the transverse direction of the track and are located close to the surface of the rail. They are used to capture the leakage magnetic field signal generated by the rail due to the rail breakage defect during the movement of the substrate (1). The signal processing module (5) includes an amplifier (51), a filter (52), and an analog-to-digital converter (53). The input terminal of the amplifier (51) is electrically connected to the magnetic field acquisition module (4). The input terminal of the filter (52) is connected to the output terminal of the amplifier (51). The analog signal input terminal of the analog-to-digital converter (53) is connected to the output terminal of the filter (52). The digital signal output terminal of the analog-to-digital converter (53) constitutes the output terminal of the signal processing module (5).

2. The railway track breakage detection device as described in claim 1, characterized in that: The walking mechanism (2) includes walking wheels (21) and guide wheels (22); The number of the walking wheels (21) is two, which are respectively set at both ends of the base plate (1) in the length direction, and are used to contact the top surface of the rail and support the base plate (1); The guide wheels (22) are four in number, in pairs, located on both sides of the width direction of the base plate (1), and are used to contact the sidewall of the track to achieve guidance.

3. The railway track breakage detection device as described in claim 2, characterized in that: The guide wheel (22) includes a connecting rod (221) and a roller (222) rotatably disposed at the bottom end of the connecting rod (221). An adjustment device (6) is provided between the upper end of the connecting rod (221) and the base plate (1). The adjustment device (6) includes an adjustment screw (61) and a guide rod (62). The bottom surface of the substrate (1) at the corner is provided with a mounting groove (332), and the upper end of the connecting rod (221) is inserted into the mounting groove (332) and can slide along the direction perpendicular to the length of the substrate (1); One end of the adjusting screw (61) is rotatably inserted into the side wall of the substrate (1) along the width direction of the substrate (1) and extends into the mounting groove (332). The connecting rod (221) has a threaded hole that mates with the adjusting screw (61). The guide rod (62) is fixedly installed in the mounting groove (332) and moves through the connecting rod (221), and the guide rod (62) is parallel to the adjusting screw (61).

4. The railway track breakage detection device as described in claim 2, characterized in that: The magnetization device (3) further includes a magnetization mounting base (33). A through hole (12) is provided in the middle of the substrate (1). The magnetization mounting base (33) is fixedly disposed on the top surface of the substrate (1). Its lower part extends through the through hole (12) to the bottom surface of the substrate (1). The bottom contour of the magnetization mounting base (33) matches the top contour of the rail. There is a gap between the bottom surface of the magnetization mounting base (33) and the top surface of the rail. Two accommodating cavities (331) are provided at intervals along the length direction of the substrate (1) on the top of the magnetization mounting base (33). A permanent magnet (31) and a magnetic conductive component (32) are respectively disposed in each accommodating cavity (331).

5. The railway track breakage detection device as described in claim 4, characterized in that: The inner bottom surface profile of the accommodating cavity (331) matches the bottom surface profile of the magnetized mounting base (33).

6. The railway track breakage detection device as described in claim 4, characterized in that: The magnetic field acquisition module (4) also includes a fixing frame (42). The bottom surface of the magnetization mounting base (33) is provided with a mounting groove (332) along the length direction perpendicular to the substrate (1), and the mounting groove (332) is located between two accommodating cavities (331). The fixing frame (42) is fixedly installed in the mounting groove (332). The fixing frame (42) has an assembly groove (421) along its length direction. Several magnetic sensors (41) are fixedly installed at intervals in the assembly groove (421) along the length direction of the assembly groove (421). The detection end of the magnetic sensor (41) is not higher than the bottom surface of the fixing frame (42).

7. The railway track breakage detection device as described in claim 6, characterized in that: The bottom surface of the fixing frame (42) is flush with the bottom surface of the magnetization mounting base (33).

8. The railway track breakage detection device as described in claim 6, characterized in that: Both the magnetized mounting base (33) and the fixing frame (42) are made of non-magnetic materials.

9. The railway track breakage detection device as described in claim 4, characterized in that: The top surface of the substrate (1) is also provided with a protective cover (7), which covers the magnetization mounting base (33) and the signal processing module (5). Inside the protective cover (7) is a battery (71) connected to the signal processing module (5), and the top surface of the protective cover (7) is provided with a handle (72).

10. The railway track breakage detection device as described in claim 1, characterized in that: It also includes an operating lever (8), one end of which is hinged to one end of the base plate (1) along its length. A lifting arm (81) is provided at one end of the operating lever (8) near the base plate (1). One end of the lifting arm (81) is fixedly connected to the bottom surface of the operating lever (8) in the radial direction, and the other end is used to contact the top surface of the rail. The length of the lifting arm (81) is greater than or equal to the vertical distance from the top surface of the rail to the hinged end of the operating lever (8).

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