Railway rail damage detection device

Abstract

The application relates to a rail damage detection device, which comprises a vehicle frame, two or more moving wheel groups, two magnetic flux leakage flaw detection devices and two image acquisition devices. The two or more moving wheel groups are oppositely arranged on the two sides of the vehicle frame, and the two magnetic flux leakage flaw detection devices are oppositely arranged on the two sides of the vehicle frame, and the detection ends of the magnetic flux leakage flaw detection devices face the rail surface. The image acquisition device is arranged adjacent to the magnetic flux leakage detection device, and the acquisition end of the image acquisition device faces the rail surface and is suitable for acquiring the image of the rail surface. A control unit is arranged in the image acquisition device. The input end of the control unit is electrically connected with the output end of the magnetic flux leakage flaw detection device and is suitable for receiving the damage signal sent by the magnetic flux leakage flaw detection device. The input end of the control unit is electrically connected with the output end of the image acquisition device and is suitable for controlling the opening of the image acquisition device when the damage signal sent by the magnetic flux leakage flaw detection device is received.

Description

Technical Field

[0001] This application relates to the field of railway rail inspection technology, and in particular to a rail damage detection device. Background Technology

[0002] In the railway facility maintenance system, rail flaw detection is a core and critical link to ensure train operation safety. Magnetic flux leakage (MFL) testing, as an important non-destructive testing technology, has been widely used in the field of rail inspection. When existing MFL testing devices detect rail damage, they can calculate the size of the damage based on sensor data. However, due to the complex and diverse morphologies of rail surface damage, when rail cracks need to be classified according to the damage morphology of the rail surface, it is difficult to accurately determine the damage level based solely on sensor data. Therefore, on-site observation and verification by staff are still required, resulting in a heavy workload and low flaw detection efficiency. Summary of the Invention

[0003] In view of this, this application proposes a rail damage detection device, comprising: a frame, two or more movable wheel sets, two magnetic flux leakage flaw detectors, and two image acquisition devices; Two or more movable wheel sets are arranged opposite each other on both sides of the frame, and two magnetic flux leakage (MFL) flaw detectors are arranged opposite each other on both sides of the frame, with the detection end of the MFL flaw detector facing the rail surface. The image acquisition device and the magnetic flux leakage detection device are set up adjacent to each other, and the acquisition end of the image acquisition device faces the surface of the rail, which is suitable for acquiring images of the surface of the rail; The image acquisition device includes a control unit; the input end of the control unit is electrically connected to the output end of the magnetic flux leakage flaw detection device, and is suitable for receiving the damage signal sent by the magnetic flux leakage flaw detection device. The input terminal of the control unit is electrically connected to the output terminal of the image acquisition device, and is suitable for controlling the start of the image acquisition device when a damage signal sent by the magnetic flux leakage flaw detector is received.

[0004] In one possible implementation, the image acquisition device includes: a housing, a line scan camera, and a power module; The housing is equipped with a partition; the partition is installed vertically in the middle of the housing to divide the internal cavity of the housing into a collection cavity and an operation cavity; The linear array camera is mounted on the partition and located inside the acquisition chamber, while the control unit is mounted on the partition and located inside the operating chamber. The power module is located on the inner wall of the housing, and its output is electrically connected to the input of the line scan camera and the input of the control unit.

[0005] In one possible implementation, the image acquisition device also includes a supplementary lighting device and a light source controller. The supplementary lighting device is installed on the partition and located inside the collection cavity of the housing. The light source controller is located on the side of the partition away from the supplementary lighting device and is located below the control unit. The output terminal of the light source controller is electrically connected to the input terminal of the supplementary lighting device, and the input terminal of the light source controller is electrically connected to the output terminal of the power module.

[0006] In one possible implementation, the supplementary lighting device includes: an auxiliary light source and a clamping member; the clamping member is fixedly mounted on a partition, and the auxiliary light source is mounted on the clamping member.

[0007] In one possible implementation, a spacing adjustment mechanism is also included; The movable wheel set, magnetic flux leakage flaw detection device, and image acquisition device on one side of the frame are all connected to the frame through a spacing adjustment mechanism.

[0008] In one possible implementation, the spacing adjustment mechanism includes: a drive unit, a guide rail assembly, and a support plate; The drive unit is fixedly mounted on one side of the frame, and the output end of the drive unit is fixedly connected to the support plate; The guide rail assembly is arranged adjacent to the drive unit, and both ends of the guide rail assembly are fixedly connected to the frame and the support plate, respectively.

[0009] In one possible implementation, the movable wheel assembly includes: a fixed wheel base, a support wheel, and a lateral wheel; The opening of the fixed wheel seat faces the rail, and the support wheel is rotatably installed inside the opening of the fixed wheel seat; The fixed wheel seat has a connecting part on the side near the frame, and the lateral wheel is mounted on the connecting part, with the lateral wheel in perpendicular contact with the inner wall of the rail.

[0010] In one possible implementation, the magnetic flux leakage detection device includes: a main frame, a sensor module, a first mounting bracket, and auxiliary wheels; The main frame is mounted on the first mounting bracket, and the sensor module is located at the bottom of the main frame; The auxiliary wheels are located at the bottom of the main frame, and are situated on both sides of the sensor module. The odometer encoder is mounted on the auxiliary wheel.

[0011] In one possible implementation, the frame includes: a first body, a second body, and an articulation member; the first body and the second body are hinged together by the articulation member.

[0012] In one possible implementation, a pallet rack is also included; the pallet rack is located at the connection between the first vehicle body and the second vehicle body.

[0013] Beneficial effects of this application This application sets up an image acquisition device to acquire images of the rail surface, thereby obtaining images of the rail surface damage morphology. Based on the image information acquired by the image acquisition device, the staff can classify the rail damage, reducing the need for manual on-site verification, reducing the workload of the staff, and improving work efficiency. At the same time, the control unit controls the image acquisition device to start when it receives the damage signal sent by the magnetic flux leakage flaw detector, avoiding invalid acquisition by the image acquisition device.

[0014] Other features and aspects of this application will become clear from the following detailed description of exemplary embodiments with reference to the accompanying drawings. Attached Figure Description

[0015] The accompanying drawings, which are included in and form part of this specification, illustrate exemplary embodiments, features, and aspects of this application together with the specification and serve to explain the principles of this application.

[0016] Figure 1 This diagram shows the main structure of the rail damage detection device according to an embodiment of this application. Figure 2 A partial structural diagram of the rail damage detection device according to an embodiment of this application is shown; Figure 3 This diagram shows the main structure of the magnetic flux leakage flaw detection device according to an embodiment of this application; Figure 4 An internal view of an image acquisition device according to an embodiment of this application is shown; Figure 5 This application shows a front view of an array camera and a supplementary lighting device according to an embodiment of the present application; Figure 6 This diagram shows the main structure of the guide rail assembly according to an embodiment of this application; Figure 7 This diagram shows the main structure of the movable wheel assembly according to an embodiment of this application; Figure 8 This diagram shows the main structure of the pallet rack according to an embodiment of this application; Figure 9 This diagram shows the main structure of the rail damage detection device according to an embodiment of this application, installed on a rail. Figure 10 This diagram shows the internal structure of the magnetic flux leakage flaw detection device according to an embodiment of this application; Figure 11 This diagram shows the main structure of the sensor module according to an embodiment of this application.

[0017] First vehicle body 110; Second vehicle body 120; Moving wheel set 200; Fixed wheel seat 210; Support wheel 220; Side wheel 230; Support shaft 231; Connecting part 211; Magnetic flux leakage flaw detector 300; Main frame 310; Sensor module 320; First mounting bracket 330; Auxiliary wheel 340; Mileage encoder 350; Image acquisition device 400; Control unit 410; Housing 420; Line array camera 430; Power module 440; Partition plate 450; Second mounting bracket 460; Lighting device 500; Auxiliary light source 510; Clamping part 520; Light source controller 530; Drive device 610; Guide rail assembly 620; Guide rail 621; Sliding support 622; Support plate 630; Pallet frame 700; Support column 710; Pallet 720; First plug-in seat 730; Second plug-in seat 740; Rail 800. Detailed Implementation

[0018] Various exemplary embodiments, features, and aspects of this application will now be described in detail with reference to the accompanying drawings. The same reference numerals in the drawings denote elements that have the same or similar functions. Although various aspects of the embodiments are shown in the drawings, they are not necessarily drawn to scale unless specifically indicated otherwise.

[0019] It should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", and "circumferential" 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 this utility model or 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 this utility model.

[0020] 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.

[0021] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.

[0022] Furthermore, to better illustrate this application, numerous specific details are provided in the following detailed embodiments. Those skilled in the art should understand that this application can be implemented without certain specific details. In some instances, methods, means, components, and circuits well-known to those skilled in the art have not been described in detail in order to highlight the main points of this application.

[0023] This application proposes a rail damage detection device, such as... Figures 1 to 9 As shown, the system includes: a frame, two or more movable wheel sets 200, two magnetic flux leakage (MFL) flaw detectors 300, and two image acquisition devices 400; the two or more movable wheel sets 200 are arranged opposite each other on both sides of the frame, and the two MFL flaw detectors 300 are arranged opposite each other on both sides of the frame, with the detection end of the MFL flaw detectors 300 facing the surface of the rail 800; the image acquisition devices 400 are arranged adjacent to the MFL flaw detectors, with the acquisition end of the image acquisition devices 400 facing the surface of the rail 800, and are suitable for acquiring images of the surface of the rail 800; wherein, the image acquisition device 400 is provided with a control unit 410; the input end of the control unit 410 is electrically connected to the output end of the MFL flaw detectors 300, and is suitable for receiving damage signals sent by the MFL flaw detectors 300; the input end of the control unit 410 is electrically connected to the output end of the image acquisition device 400, and is suitable for controlling the image acquisition device 400 to turn on when a damage signal sent by the MFL flaw detectors 300 is received.

[0024] It should be noted that the rail damage detection device of this application is suitable for detecting the rails 800 of a double-rail system. The chassis is suitable for providing a stable and rigid mounting reference for the overall structure, ensuring that the movable wheel set 200, the magnetic flux leakage (MFL) testing device 300, and the image acquisition device 400 are assembled in preset positions. The movable wheel set 200 is suitable for providing support to the chassis and is adapted to the rails 800 of the double-rail system. The movable wheel set 200 is rotatably mounted on the rails 800 of the double-rail system, so that the movable wheel set 200 rolls along the length of the double-rail system, thereby driving the chassis forward along the rails 800. The MFL testing device 300 is suitable for detecting damage to the rails 800. The movable wheel set 200 drives the chassis and the MFL testing devices 300 on both sides of the chassis to move synchronously. Two magnetic flux leakage (MFL) flaw detectors 300 correspond one-to-one with the rails 800 of the double-rail system. The design of the two MFL flaw detectors 300 allows for simultaneous detection of two rails 800, improving detection efficiency. The moving wheel set 200, the MFL flaw detectors 300, and the image acquisition device 400 are arranged sequentially along the forward direction (i.e., the X direction) of the chassis, with the image acquisition device 400 located behind the MFL flaw detectors. The moving wheel set 200 drives the chassis to move, thereby causing the MFL flaw detectors 300 and the image acquisition device 400 to move synchronously. When the MFL flaw detectors 300 detect damage and transmit the detected damage signal to the control unit 410, the control unit 410 controls the image acquisition device 400 to acquire images of the surface of the rails 800, avoiding invalid acquisition by the image acquisition device 400.

[0025] The rail damage detection device of this application moves along the X direction of a double-rail track under motor drive or manual pushing. Magnetic flux leakage (MFL) detectors 300 on both sides simultaneously perform flaw detection on two rails 800. When a damage is found at a certain point on a rail 800, the MFL detector 300 detects a sudden change in the magnetic flux leakage field, generates a damage signal, and sends it to the control unit 410. At this time, the control unit 410 controls the image acquisition device 400 to activate, enabling the image acquisition device 400 to acquire images of the surface of the rail 800. The control unit 410's ability to control the image acquisition device 400 based on the received damage signal is its capability. This application employs conventional technical means in the field; by setting up an image acquisition device 400, the image acquisition device 400 acquires images of the surface of the rail 800 to obtain images of the surface damage morphology of the rail 800. Based on the image information acquired by the image acquisition device 400, the staff can classify the damage of the rail 800, reducing the need for manual on-site verification, reducing the workload of the staff, and improving work efficiency. At the same time, the control unit 410 controls the image acquisition device 400 to start when it receives the damage signal sent by the magnetic flux leakage flaw detector 300, avoiding invalid acquisition by the image acquisition device 400.

[0026] In one possible implementation, a preset distance L is provided between the image acquisition device 400 and the magnetic flux leakage flaw detection device 300, and the value of the preset distance L is 213.5mm.

[0027] In one possible implementation, such as Figures 1 to 3 As shown, the magnetic flux leakage detection device includes: a main frame 310, a sensor module 320, a first mounting bracket 330, and auxiliary wheels 340; the main frame 310 is mounted on the first mounting bracket 330, the sensor module 320 is located at the bottom of the main frame 310; the auxiliary wheels 340 are located at the bottom of the main frame 310, and the auxiliary wheels 340 are located on both sides of the sensor module 320; the odometer encoder 350 is mounted on the auxiliary wheels 340.

[0028] It should be noted that the first mounting bracket 330 is used to fix the main frame 310 to the vehicle frame (or support plate 630). The main body of the first mounting bracket 330 has an L-shaped structure, and the main frame 310 is set inside the opening of the first mounting bracket 330. The top of the main frame 310 is connected to the first mounting bracket 330. The main frame 310 is used to provide an installation positioning reference for the sensor module 320. The sensor module 320 is installed at the bottom of the main frame 310 and above the rail 800. The sensor module 320 detects... The sensor is positioned with its end facing the rail 800 to ensure that it can accurately capture the leakage magnetic field signal generated by defects on the surface of the rail 800, thereby improving detection accuracy. The auxiliary wheel 340 is used to control the distance between the sensor module and the top surface of the rail 800. The auxiliary wheel 340 is rotatably set at the bottom of the main frame 310 and contacts the upper surface of the rail 800, thereby ensuring that the sensor module and the upper surface of the rail 800 maintain a constant lift-off value, avoiding detection errors of the flaw detection device due to fluctuations in the lift-off value, and further improving detection accuracy.

[0029] The mileage encoder 350 is used to detect the mileage of the magnetic flux leakage (MFL) flaw detector 300, thereby assisting in locating the specific position of the damage. The mileage encoder 350 is mounted on the axle of the auxiliary wheel 340, ensuring that the mileage detected by the mileage encoder 350 and the spatial reference of the damage signal detected by the MFL flaw detector 300 are consistent. The mileage encoder 350 rotates synchronously with the auxiliary wheel 340. By detecting the rotation angle of the axle of the auxiliary wheel 340, the mileage encoder 350 calculates the travel distance of the MFL flaw detector 300 (i.e., the mileage data traveled by the MFL flaw detector 300). The output terminal of the mileage encoder 350 is electrically connected to the input terminal of the control unit 410, transmitting the detected mileage data to the control unit 410. The control unit 410 synchronously receives the damage signal from the MFL flaw detector 300 and the mileage data from the mileage encoder 350, calculates the actual damage position of the rail 800, and controls the activation of the image acquisition device 400 based on the calculated actual damage position of the rail 800. Specifically: When a defect is found at a certain point on the rail 800, the magnetic flux leakage detector 300 detects a sudden change in the magnetic flux leakage field, generates a defect signal, and sends it to the control unit 410. Simultaneously, the control unit 410 receives mileage data from the mileage encoder 350 and records the mileage value P1 (i.e., the coordinates of the defect point on the rail 800). The control unit 410 has a preset distance L (i.e., the preset distance L between the magnetic flux leakage detector 300 and the image acquisition device 400). The control unit 410 calculates the target mileage value P2 that should be triggered by the image acquisition device 400 according to the formula P2 = P1 + L. The control unit 410 continuously receives real-time mileage data transmitted by the mileage encoder 350 and compares it with the target mileage value P2. When the received real-time mileage value is equal to the target mileage value P2, the acquisition end of the image acquisition device 400 is directly above the coordinates of the defect point. At this time, the control unit 410 activates the image acquisition device 400 to acquire images of the surface of the rail 800.

[0030] Furthermore, the control unit 410 integrates a timer, which is used to set time intervals. The control unit 410 controls the image acquisition device 400 to shut down based on these time intervals. Specifically, when the control unit 410 turns on the image acquisition device 400 to acquire images of the rail 800 surface, the timer starts counting. During the counting period, the control unit 410 continuously monitors whether it receives a damage signal from the magnetic flux leakage flaw detector 300 again. If no new damage signal is received from the magnetic flux leakage flaw detector 300 after the preset time has elapsed, the current damage acquisition is considered complete, and the control unit 410 shuts down the image acquisition device 400. If the control unit 410 receives a damage signal again during the counting period, the timer restarts, and the image acquisition device 400 continues to be turned on and in operation.

[0031] In one possible implementation, the control unit 410 adopts an existing model. The controller for CP2E_N14DT_D uses the existing ADK-K3808 encoder for the mileage encoder 350.

[0032] In one possible implementation, such as Figure 10 As shown, the magnetic flux leakage testing device 300 also includes: a height adjustment mechanism; the height adjustment device is disposed within the cavity of the main frame 310, and the bottom of the height adjustment device is connected to the sensor module 320 to drive the sensor module 320 to move in a direction toward or away from the rail 800. Specifically: The height adjustment mechanism includes: a fixed base 361, a movable base 362, a screw 363, and a connecting base 364. One end of the main frame 310 has an opening facing the direction of the rail 800. The main frame 310 is fastened to the top of the fixed base 361, and the movable base 362 is located at the bottom of the fixed base 361. The middle of the connecting base 364 has a threaded hole suitable for connecting with the screw. The connecting base 364 is fixedly mounted on the top of the movable base 362. The screw 363 passes through the main frame, the fixed base 361, the connecting base 364, and the movable base 362 in sequence and is threadedly connected to the connecting base 364. When the screw 363 rotates, the connecting base 364 moves along the length of the screw 363 and drives the movable base 362 to move, so as to realize the vertical movement of the movable base 362 within the main frame, thereby adjusting the height position of the sensor module 320 connected to it.

[0033] Furthermore, a bearing is provided between the screw 363 and the fixed seat 361 to improve the rotational smoothness of the screw 363 compared to the fixed seat 361. The screw 363 is fixedly connected to the inner ring of the bearing, and the outer ring of the bearing is fixedly connected to the fixed seat 361, thereby ensuring that the screw 363 only generates rotational motion and does not generate up-and-down motion.

[0034] In one possible implementation, such as Figure 10 As shown, the top of the fixed base 361 is provided with a clamp 365, and the clamp 365 is sleeved on the screw 363. When the height position of the detection mechanism does not need to be adjusted, the clamp bolt passes through the two threaded holes of the clamp 365 and locks the clamp 365, so that the clamp 365 firmly holds the screw 363 in the middle. When the height position of the detection mechanism needs to be adjusted, the clamp bolt is rotated to loosen the clamp 365, and the clamp 530 loosens the screw 363.

[0035] In one possible implementation, such as Figure 10As shown, the magnetic flux leakage flaw detection device 300 also includes: a height adaptive mechanism; a height adjustment mechanism is connected to the sensor module 320 through the height adaptive mechanism; the height adaptive mechanism is suitable for adjusting the height position of the sensor module 320 to ensure that the sensor module 320 continuously contacts the surface of the rail 800.

[0036] Furthermore, the height adaptive mechanism includes: a first connecting plate 371, a second connecting plate 372, and two elastic hinges 373; the top surface of the first connecting plate 371 is connected to the height adjustment mechanism, the bottom surface of the second connecting plate 372 is connected to the sensor module 320, and the two elastic hinges 373 are arranged opposite to each other between the first connecting plate 371 and the second connecting plate 372; the first connecting plate 371 is connected to the movable seat 362 by a connecting block 375, and hinge seats are provided at the bottom of the first connecting plate 371 and on both sides of the second connecting plate 372; one side of the elastic hinge 373 is hinged to the hinge seat of the first connecting plate 371 by a hinge shaft, and the other side of the elastic hinge 373 is hinged to the hinge seat of the second connecting plate 372 by a hinge shaft. Since the elastic hinge 373 is elastic, it will exert a downward pressing force on the second connecting plate 372, thereby realizing the height adaptive adjustment of the sensor module 320.

[0037] In one possible implementation, the top of the second connecting plate 372 is provided with a limiting post 374, and the first connecting plate 371 is provided with a limiting tube corresponding to the limiting post 374. One end of the limiting post 374 is continuously inserted into the limiting tube, so that when the second connecting plate 372 is pressed tightly by the elastic hinge 373 and undergoes a small-amplitude movement, the detection mechanism will only produce vertical movement and will not produce horizontal sway under the limiting action of the limiting post 374. The bottom of the second connecting plate 372 is provided with a first suspension member suitable for connecting the sensor module 320.

[0038] In one possible implementation, such as Figure 10 , Figure 11 As shown, the sensor module 320 includes: a mounting bracket 321, two or more sensors 322, and an excitation device. A bracket 323 is disposed inside the mounting bracket 321. Two or more sensors 322 are sequentially mounted on the bracket 323 with their detection ends facing the rail 800. The excitation device is mounted on the bracket 323. It should be noted that the two or more sensors 322 are arranged in a row along a direction perpendicular to the length of the rail 800 in a horizontal plane. The excitation device is used to magnetize the rail 800 to generate magnetic flux in the shallow region of the rail 800. The multiple sensors 322 detect the leakage of magnetic flux to detect whether the rail 800 is damaged and the size of the damage.

[0039] Furthermore, the sensor 322 is a Hall sensor, with two or more sensors 322 arranged in a row, and the spacing between any two adjacent sensors 322 is the same. The excitation device consists of two permanent magnets 324, which are symmetrically arranged on both sides of a row of sensors 322.

[0040] In one possible implementation, the opposite side walls of the fixing frame 321 are provided with bolt holes for passing through bolts 325, and the opposite side walls of the bracket 323 are also provided with bolt holes for passing through bolts 325. The bracket 323 is placed inside the fixing frame 321 and the two are connected by two bolts 325.

[0041] In one possible implementation, the two opposite outer side walls of the bracket 323 are provided with second suspension members. The second suspension members are provided with bolt holes for bolts 326 to pass through. The two second suspension members of the bracket 323 are opposite to the two first suspension members at the bottom of the second connecting plate 372 and are fixedly connected by bolts 326, thereby realizing the connection between the sensor module 320 and the height adaptive mechanism.

[0042] In one possible implementation, the opposite side walls of the fixing frame 321 are provided with mounting portions 327 for connecting the auxiliary wheel 340, and the auxiliary wheel 340 is connected to the mounting portions 327 of the fixing frame 321 via a connecting shaft.

[0043] In one possible implementation, such as Figure 4 As shown, the image acquisition device 400 includes: a housing 420, a line scan camera 430, and a power module 440; a partition 450 is provided inside the housing 420; the partition 450 is vertically installed in the middle of the housing 420 to divide the internal cavity of the housing 420 into an acquisition cavity and an operation cavity; the line scan camera 430 is installed on the partition 450 and located in the acquisition cavity, and the control unit 410 is installed on the partition 450 and located in the operation cavity; the power module 440 is installed on the inner side wall of the housing 420, and the output terminal of the power module 440 is electrically connected to the input terminal of the line scan camera 430 and the input terminal of the control unit 410, respectively.

[0044] It should be noted that the main body of the housing 420 is a rectangular box structure. The housing 420 is suitable for providing a fixed mounting reference for internal components and isolating them from external environmental interference, thus providing physical protection for the internal components. A partition 450, vertically installed in the middle of the housing 420, divides the interior of the housing 420 into a data acquisition chamber and an operating chamber. The control unit 410 and the line scan camera 430 are positioned opposite each other on the partition 450 to avoid mutual interference between the circuit components of the control unit 410 and the optical components of the line scan camera 430. The power module 440 is installed on the inner wall of the housing 420. The power module 440 is suitable for powering the line scan camera 430 and the control unit 410. 10. Provides stable power support. The acquisition cavity of the housing 420 has acquisition slots on the side facing the rail 800. The line scan camera 430 is installed in the acquisition cavity, and the acquisition end of the line scan camera 430 is set facing the acquisition slots. The line scan camera 430 is suitable for capturing images of the surface of the rail 800, thereby providing clear visual basis for subsequent classification. Through reasonable layout, the internal space of the housing 420 is fully utilized. The line scan camera 430 and the control unit 410 are respectively installed on both sides of the partition 450, which not only ensures convenient electrical connection between the two, but also avoids heat dissipation problems and messy wiring caused by space congestion, thus improving space utilization.

[0045] In one possible implementation, such as Figure 1 As shown, it also includes a second mounting bracket 460. The main body of the second mounting bracket 460 is L-shaped and the opening faces away from the image acquisition device 400. One side of the second mounting bracket 460 is fixedly mounted on the frame (or guide rail assembly 620); the image acquisition device 400 is mounted on the other side of the second mounting bracket 460.

[0046] Furthermore, the opening of the second mounting bracket 460 is provided with reinforcing ribs, which are fixedly connected to the two sides of the second mounting bracket 460 respectively, further enhancing the load-bearing capacity of the second mounting bracket 460.

[0047] In one possible implementation, such as Figure 4 , Figure 5 As shown, the image acquisition device 400 also includes a supplementary lighting device 500 and a light source controller 530. The supplementary lighting device 500 is mounted on the partition 450 and located inside the acquisition cavity of the housing 420. The light source controller 530 is disposed on the side of the partition 450 away from the supplementary lighting device 500 and is located below the control unit 410. The output terminal of the light source controller 530 is electrically connected to the input terminal of the supplementary lighting device 500, and the input terminal of the light source controller 530 is electrically connected to the output terminal of the power module 440.

[0048] It should be noted that the supplementary lighting device 500 is used to provide sufficient and uniform light to the acquisition area of ​​the line scan camera 430, avoiding blurry images and excessive shadows caused by insufficient light, thus improving the quality of the acquired images. The light source controller 530 is used to control the opening and closing of the supplementary lighting device 500. In areas with low light, the operator can turn on the supplementary lighting device 500 through the light source controller 530. At this time, there is a circuit between the power module 440 and the supplementary lighting device 500, thereby supplementing light to the line scan camera 430. In outdoor areas with strong light, the operator can turn off the supplementary lighting device 500 through the light source controller 530. At this time, there is a circuit between the power module 440 and the supplementary lighting device 500, thereby reducing unnecessary energy waste.

[0049] In one possible implementation, the supplementary lighting device 500 includes an auxiliary light source 510 and a clamping member 520; the clamping member 520 is fixedly disposed on the partition 450, and the auxiliary light source 510 is disposed on the clamping member 520. It should be noted that the clamping member 520 is used to provide an installation base for the auxiliary light source 510. The clamping member 520 is installed on the partition plate 450 and has a reserved opening, so that the clamping member 520 can be easily fitted onto the auxiliary light source 510. The inner wall of the clamping member 520 matches the outer wall of the auxiliary light source 510. The clamping member 520 is fitted onto the auxiliary light source 510, and the emitting end of the auxiliary light source 510 is set towards the rail 800. The bolt passes through the clamping member 520. By tightening the bolt, a fastening force is applied to the clamping member 520 so that the inner wall of the clamping member 520 fits tightly against the outer wall of the auxiliary light source 510, thereby fixing the auxiliary light source 510 onto the clamping member 520.

[0050] Furthermore, a preset angle α is provided between the acquisition end axis of the line scan camera 430 and the axis of the beam emitted by the supplementary lighting device 500. The design of the preset angle α allows the light emitted by the auxiliary light source 510 to illuminate the surface of the rail 800 at an inclined angle, thereby preventing reflected light from directly entering the acquisition end of the line scan camera 430, reducing the reflective area in the acquired image, ensuring the clarity and integrity of the overall image of the rail 800 surface, and improving image quality.

[0051] Furthermore, the preset angle α has a range of 15°.

[0052] In one possible implementation, a spacing adjustment mechanism is also included; the movable wheel set 200, magnetic flux leakage detection device 300, and image acquisition device 400 on one side of the frame are all connected to the frame through the spacing adjustment mechanism; the spacing adjustment mechanism is suitable for driving the movable wheel set 200, magnetic flux leakage detection device 300, and image acquisition device 400 on one side of the frame to move synchronously, thereby adjusting the distance (i.e., wheel gauge) between the movable wheel sets 200 on both sides of the frame. The design of the wheel gauge adjustment device allows the rail damage detection device of this application to flexibly adapt to the gauge deviation in the double-rail track, ensuring that the movable wheel set 200 always maintains good contact with the rail 800, avoiding the jamming or even derailment of the rail damage detection device due to the mismatch between the wheel gauge and the track gauge, ensuring the smooth and continuous operation of the detection work, and at the same time ensuring that the adjusted movable wheel set 200, magnetic flux leakage detection device 300, and image acquisition device 400 are always located on the rail 800 of the double-rail track.

[0053] In one possible implementation, such as Figure 1 , Figure 2 , Figure 6 As shown, the spacing adjustment mechanism includes: a drive device 610, a guide rail assembly 620, and a support plate 630; the drive device 610 is fixedly mounted on one side of the frame, and the output end of the drive device 610 is fixedly connected to the support plate 630; the guide rail assembly 620 is arranged adjacent to the drive device 610, and both ends of the guide rail assembly 620 are fixedly connected to the frame and the support plate 630, respectively.

[0054] It should be noted that the drive unit 610 is suitable for providing moving power for the image acquisition device 400, the support plate 630 and the moving wheel set 200 and the magnetic flux leakage testing device 300 on it. The support plate 630 is suitable for providing a mounting platform for the moving wheel set 200 and the magnetic flux leakage testing device 300 on one side of the frame. The moving wheel set 200 and the magnetic flux leakage testing device 300 on one side of the frame are mounted on the side of the support plate 630 away from the frame. The driving force output by the drive unit 610 is evenly transmitted to the moving wheel set 200 and the magnetic flux leakage testing device 300 on the support plate 630 through the support plate 630, thereby enabling the moving wheel set 200 and the magnetic flux leakage testing device 300 to move synchronously and stably, avoiding damage to the moving wheel set 200 or the magnetic flux leakage testing device due to uneven force. The image acquisition device 400 is mounted on the guide rail assembly 620 and located above the rail 800. When the drive device 610 drives the support plate 630 to move, it simultaneously drives the guide rail assembly 620 to extend and retract, thereby causing the image acquisition device 400 and the magnetic flux leakage detection device 300 on the guide rail assembly 620 to move synchronously. This prevents the moving wheel set 200, the magnetic flux leakage detection device 300, and the image acquisition device 400 from shifting or shaking during the wheel spacing adjustment process. At the same time, the guide rail assembly 620 provides stable support for the image acquisition device 400, the support plate 630, and the moving wheel set 200 and the magnetic flux leakage detection device 300 on it, preventing the spacing adjustment mechanism from deforming or being damaged due to weight or external force, and ensuring the stability of the overall structure.

[0055] In one possible implementation, such as Figure 6 As shown, the guide rail assembly 620 includes a guide rail 621 and a sliding support 622. One end of the guide rail 621 is fixedly mounted on the frame, and the other end of the guide rail 621 extends toward the support plate 630. A guide groove is provided on the guide rail 621. One end of the sliding support 622 is fixedly connected to the side of the support plate 630 facing the frame, and the other end of the sliding support 622 is embedded in the guide groove. The sliding support 622 can reciprocate along its length within the guide groove. The image acquisition device 400 is mounted on the sliding support 622. The guide groove provides precise guidance for the movement of the sliding support 622. The sliding support 622 is restricted to linear movement along the length of the guide rail 621, ensuring that the moving wheels, magnetic flux leakage testing device 300, and image acquisition device 400 can move smoothly. At the same time, the sliding support 622 cooperates with the guide rail 621 through the guide groove, thereby providing lateral support for the image acquisition device 400, support plate 630, moving wheel set 200, and magnetic flux leakage testing device 300. It should be noted that the sliding direction of the sliding support 622 is parallel to the direction in which the drive device 610 drives the support plate 630 to move, so as to ensure that the drive device 610 and the guide rail assembly 620 work together.

[0056] Furthermore, a limiting hole is provided through the sliding support 622. The driving device 610 drives the support plate 630 and its movable wheel set 200 and magnetic flux leakage detection device 300 to move to a position that matches the target track gauge. At the same time, the movement of the support plate 630 drives the sliding support 622 and its image acquisition device 400 to move above the rail 800. One end of the locking bolt passes through the limiting hole of the sliding support 622 and abuts tightly against the inner wall of the guide groove of the guide rail 621. The relative position of the sliding support 622 and the guide rail 621 is locked by the friction between the locking bolt and the inner wall of the guide groove.

[0057] In one possible implementation, the drive unit 610 is a telescopic cylinder.

[0058] In one possible implementation, two drive units 610 and two guide rail assemblies 620 are provided. The two drive units 610 are arranged opposite each other between the frame and the support plate 630. The two drive units 610 work together to apply a thrust to the support plate 630, thereby ensuring that the support plate 630 is subjected to uniform force during movement and avoiding tilting of the support plate 630 due to single-point force. The two guide rail assemblies 620 are arranged opposite each other between the frame and the support plate 630, and the two guide rail assemblies 620 are located on the opposite side of the drive units 610. The two guide rail assemblies 620 together provide precise guidance for the movement of the support plate 630, ensuring that the support plate 630 moves along a preset direction. At the same time, the arrangement of the two guide rail assemblies 620 increases the connection stability between the support plate 630 and the frame, further improving the reliability and durability of the entire wheelbase adjustment system.

[0059] In one possible implementation, such as Figure 7 As shown, the movable wheel set 200 includes: a fixed wheel seat 210, a support wheel 220, and a side wheel 230; the opening of the fixed wheel seat 210 is arranged facing the rail 800, and the support wheel 220 is rotatably arranged in the opening of the fixed wheel seat 210; a connecting part 211 is provided on the side of the fixed wheel seat 210 near the frame, and the side wheel 230 is arranged on the connecting part 211, and the side wheel 230 is in perpendicular contact with the inner wall of the rail 800.

[0060] It should be noted that the fixed wheel seat 210 is mounted on one side of the frame (or support plate 630) via the connecting part 211. The fixed wheel seat 210 is suitable for providing a mounting base for the support wheel 220. The main body of the fixed wheel seat 210 has a U-shaped structure. The design of the opening of the fixed wheel seat 210 facing the rail 800 makes it less likely for the support wheel 220 to deviate laterally when rolling, thus enhancing the stability of the support wheel 220 when rolling. The support wheel 220 is rotatably mounted in the opening of the fixed wheel seat 210, and the support wheel 220 is in perpendicular contact with the upper side of the rail 800, thereby ensuring full contact between the support wheel 220 and the upper surface of the rail 800. 10 is mounted on the side wall of the frame via a connecting part 211. A support shaft 231 is provided on the connecting part 211. The side wheel 230 is rotatably mounted on the support shaft 231 and is in perpendicular contact with the inner side wall of the rail 800. The side wheel 230 restricts the movement of the moving wheel set 200 from the outside of the rail 800 by rolling contact with the inner side wall of the rail 800. At the same time, the side wheel 230 provides a lateral limit for the spacing adjustment mechanism. When the spacing adjustment mechanism drives the moving wheel set 200 to move, the side wheel 230 moves laterally synchronously with the fixed wheel seat 210, so that the side wheel 230 is always in contact with the inner side wall of the rail 800.

[0061] In one possible implementation, four movable wheel sets 200 are provided; the four movable wheel sets 200 are arranged opposite each other on both sides of the frame; the design of the four movable wheel sets 200 being arranged opposite each other allows the weight of the frame to be evenly distributed on the two steel rails 800 of the double-rail track, avoiding the frame from tilting or shifting its center of gravity due to uneven weight distribution, and the magnetic flux leakage detection device 300 is arranged between the two movable wheel sets 200 arranged on the same side of the frame.

[0062] In one possible implementation, the frame includes a first body 110, a second body 120, and a hinge. The first body 110 and the second body 120 are hinged together by the hinge. It should be noted that a first groove is formed on the bottom side of the first body 110, and correspondingly, a second groove is formed on the bottom side of the second body 120 near the bottom side of the first body 110. When the first body 110 and the second body 120 come into contact, the first groove and the second groove together form a receiving cavity. The hinge is disposed in the receiving cavity, and the first body 110 and the second body 120 can rotate relative to each other around the pivot of the hinge to achieve folding and storage. The folding design of the frame can be more easily loaded onto a transport vehicle, reducing space occupation and transportation costs during transportation.

[0063] In one possible implementation, a pallet rack 700 is also included; the pallet rack 700 is disposed at the connection between the first vehicle body 110 and the second vehicle body 120. It should be noted that the pallet rack 700 is suitable for providing a platform for a computer, allowing operators to directly upload data detected by the magnetic flux leakage testing device 300 and images detected by the image acquisition device 400 to the computer, thus facilitating viewing during testing. The design of the pallet rack 700 being directly installed at the connection between the first vehicle body 110 and the second vehicle body 120 increases the connection strength between the two vehicles, avoids stress concentration at the hinge point, reduces the risk of hinge damage, and extends the service life of the vehicle frame.

[0064] In one possible implementation, such as Figure 8 As shown, the tray frame 700 includes: a support column 710, a tray 720, and a first connector 730. The main body of the first connector 730 is T-shaped. The first connector 730 is fixed to the connection between the first vehicle body 110 and the second vehicle body 120 by bolts. The first connector 730 has a socket that matches the support column 710. One end of the support column 710 is inserted into the socket of the first connector 730. The first connector 730 and the support column 710 are connected by bolts, thereby achieving a stable connection between the first connector 730 and the support column 710. The bottom of the tray 720 is provided with a second connector 740. The second connector 740 is installed on the end of the support column 710 away from the first socket, and the second connector 740 is fixedly connected to the support column 710 by bolts. The computer is placed on the tray 720 for convenient operation by the operator.

[0065] The various embodiments of this application have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or improvement of the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A rail damage detection device, characterized in that, include: The vehicle frame, two or more sets of movable wheels, two magnetic flux leakage flaw detectors, and two image acquisition devices; Two or more of the aforementioned movable wheel sets are arranged opposite each other on both sides of the frame, and two of the aforementioned magnetic flux leakage testing devices are arranged opposite each other on both sides of the frame, with the detection end of the magnetic flux leakage testing device facing the rail surface. The image acquisition device is arranged adjacent to the magnetic flux leakage detection device, and the acquisition end of the image acquisition device faces the surface of the rail, making it suitable for acquiring images of the rail surface; The image acquisition device includes a control unit; the input terminal of the control unit is electrically connected to the output terminal of the magnetic flux leakage flaw detection device, and is suitable for receiving the damage signal sent by the magnetic flux leakage flaw detection device. The input terminal of the control unit is electrically connected to the output terminal of the image acquisition device, and is suitable for controlling the start of the image acquisition device when a damage signal sent by the magnetic flux leakage flaw detection device is received.

2. The rail damage detection device according to claim 1, characterized in that, The image acquisition device includes: a housing, a line scan camera, and a power module; The housing is equipped with a partition; the partition is vertically installed in the middle of the housing to divide the internal cavity of the housing into a collection cavity and an operation cavity; The linear array camera is mounted on the partition and located inside the acquisition cavity, and the control unit is disposed on the partition and located inside the operating cavity; The power module is disposed on the inner side wall of the housing, and the output terminal of the power module is electrically connected to the input terminal of the line scan camera and the input terminal of the control unit, respectively.

3. The rail damage detection device according to claim 2, characterized in that, The image acquisition device also includes a supplementary lighting device and a light source controller. The supplementary lighting device is mounted on the partition and located inside the collection cavity of the housing. The light source controller is disposed on the side of the partition away from the supplementary lighting device and is located below the control unit. The output terminal of the light source controller is electrically connected to the input terminal of the supplementary lighting device, and the input terminal of the light source controller is electrically connected to the output terminal of the power module.

4. The rail damage detection device according to claim 3, characterized in that, The supplementary lighting device includes: an auxiliary light source and a clamping component; The clamp is fixedly mounted on the partition, and the auxiliary light source is mounted on the clamp.

5. The rail damage detection device according to claim 1, characterized in that, It also includes a spacing adjustment mechanism; The movable wheel set, the magnetic flux leakage detection device, and the image acquisition device on one side of the vehicle frame are all connected to the vehicle frame through the spacing adjustment mechanism.

6. The rail damage detection device according to claim 5, characterized in that, The spacing adjustment mechanism includes: a drive device, a guide rail assembly, and a support plate; The drive unit is fixedly mounted on one side of the vehicle frame, and the output end of the drive unit is fixedly connected to the support plate. The guide rail assembly is disposed adjacent to the drive device, and both ends of the guide rail assembly are fixedly connected to the vehicle frame and the support plate, respectively.

7. The rail damage detection device according to claim 1, characterized in that, The movable wheel set includes: a fixed wheel base, a support wheel, and a side wheel; The opening of the fixed wheel seat faces the rail, and the support wheel is rotatably disposed within the opening of the fixed wheel seat; The fixed wheel seat has a connecting part on the side near the frame, the lateral wheel is mounted on the connecting part, and the lateral wheel is in perpendicular contact with the inner wall of the rail.

8. The rail damage detection device according to claim 1, characterized in that, The magnetic flux leakage detection device includes: a main frame, a sensor module, a first mounting bracket, auxiliary wheels, and a mileage encoder; The main frame is mounted on the first mounting bracket, and the sensor module is disposed at the bottom of the main frame; The auxiliary wheels are located at the bottom of the main frame and are respectively located on both sides of the sensor module; The odometer encoder is mounted on the auxiliary wheel.

9. The rail damage detection device according to claim 1, characterized in that, The frame includes: a first body, a second body, and an articulated member; The first vehicle body and the second vehicle body are hinged together by the hinge member.

10. The rail damage detection device according to claim 9, characterized in that, It also includes pallet racks; The tray rack is installed at the connection between the first vehicle body and the second vehicle body.

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