CN210534071U - Ultrasonic flaw detection scanning device for steel rail - Google Patents

Abstract

The utility model discloses a steel rail ultrasonic flaw detection scanning device, which comprises an installation frame, wherein the top of the installation frame is provided with a top wheel type ultrasonic probe which is contacted with a railhead tread, the side surface of the installation frame is provided with a railhead side wheel type ultrasonic probe which is contacted with the railhead side and a railwaist side wheel type ultrasonic probe which is contacted with a railwaist, and the installation frame is provided with a supporting guide wheel which is contacted with a steel rail and is used for supporting and guiding; the mounting frame is provided with spray heads for spraying coupling agent on the contact surfaces of the top wheel type ultrasonic probe, the rail head side wheel type ultrasonic probe and the rail waist side wheel type ultrasonic probe and the steel rail respectively; the device can realize full-coverage ultrasonic detection of the steel rail longitudinally and transversely, and improves the accuracy and efficiency of detection.

Description

Ultrasonic flaw detection scanning device for steel rail

Technical Field

The utility model relates to a rail detects a flaw and detects technical field, especially relates to an adopt ultrasonic wave to sweep the inside quality of rail and look into device.

Background

With the rapid development and construction of high-speed railways in China and the constantly improved train speed per hour and train density, the speed of the rail for the railway turnout is accelerated in the development of the damage and defects of the whole railway line rail, and due to the particularity and the importance of the railway turnout in the line, the damage of the turnout rail seriously affects the driving safety.

The steel rail for the turnout is subjected to the processing procedures of die forging, profiling, bending, quenching, machining and the like in a manufacturer. Harmful defects often occur in the steel rail due to the influence of a plurality of factors such as defects of steel rail raw materials, processing and manufacturing processes and methods, and the like, and are mainly divided into volume defects and planar defects. In the using process, fatigue defects can be generated under the action of external force. If these defects are not detected in time, the steel rails can be broken, and the safe operation of the train is seriously endangered.

At present, the device for scanning the internal defects of the steel rail is mainly used for detecting on a tread, and the area defects of the parallel steel rail cannot be detected.

SUMMERY OF THE UTILITY MODEL

In order to solve the not enough among the prior art, provide one kind to the ultrasonic detection of rail railhead tread, railhead side and web of a rail side, and realize vertical ultrasonic detection and horizontal ultrasonic detection's rail flaw detection and sweep and look into the device, the utility model discloses the technical scheme who adopts is:

a rail ultrasonic flaw detection scanning device comprises an installation frame, wherein a top wheel type ultrasonic probe in contact with a rail head tread is arranged at the top of the installation frame, a rail head side wheel type ultrasonic probe in contact with a rail head side and a rail web side wheel type ultrasonic probe in contact with a rail web are arranged on the side surface of the installation frame, and a support guide wheel in contact with a rail for supporting and guiding is arranged on the installation frame; and the mounting frame is provided with spray heads for spraying coupling agent on the contact surfaces of the top wheel type ultrasonic probe, the rail head side wheel type ultrasonic probe and the rail web side wheel type ultrasonic probe and the steel rail respectively.

Furthermore, the rail head side wheel type ultrasonic probe and the rail waist side wheel type ultrasonic probe are respectively arranged on one side, and the rail head side wheel type ultrasonic probe and the rail waist side wheel type ultrasonic probe are arranged on the same side of the mounting frame.

Furthermore, the rail head side wheel type ultrasonic probe and the rail waist side wheel type ultrasonic probe are respectively arranged on one side, and the rail head side wheel type ultrasonic probe and the rail waist side wheel type ultrasonic probe are respectively arranged on two sides of the mounting frame.

Furthermore, the rail head side wheel type ultrasonic probe and the rail web side wheel type ultrasonic probe are respectively provided with a pair, and the pair of rail head side wheel type ultrasonic probe and the rail web side wheel type ultrasonic probe are respectively symmetrically arranged or are diagonally arranged on two sides of the mounting frame.

Furthermore, a mounting plate capable of moving towards the steel rail is movably arranged on one side of the mounting frame, the railhead side wheel type ultrasonic probe and the rail web side wheel type ultrasonic probe are mounted on the mounting plate, a driving device for driving the mounting plate to move towards the steel rail is arranged on the mounting frame, and a guide piece for guiding the mounting plate to move is further arranged on the mounting frame.

Furthermore, the mounting frame both sides all activity be equipped with can move the mounting panel towards the rail, railhead side wheeled ultrasonic transducer and rail web side wheeled ultrasonic transducer install on the mounting panel, the mounting frame on be equipped with the drive arrangement that the drive mounting panel moved towards the rail, still be equipped with the guide piece that plays the guide effect to the mounting panel removal on shown mounting frame.

Furthermore, the driving device is a motor and a screw rod or a knob and a screw rod; the guide piece is a guide sliding column or a guide rail.

Furthermore, the driving device is a motor and a screw rod or a knob and a screw rod; the guide piece is a guide sliding column or a guide rail.

Furthermore, the device also comprises an encoder wheel which can collect the moving distance of the flaw detection scanning device; two ends of the mounting frame along the length direction of the steel rail are respectively provided with a support guide wheel; and a group of balance supporting wheels which are contacted with the top of the rail bottom are also arranged on the mounting frame.

Furthermore, a cleaning brush contacting with a steel rail is arranged at one end of each supporting guide wheel far away from the installation frame, and a roller for supporting and moving the flaw detection scanning device is also arranged on the installation frame.

The utility model has the advantages that: the top wheel type ultrasonic probe realizes longitudinal ultrasonic detection from the tread of the rail head, the rail head side wheel type ultrasonic probe realizes transverse ultrasonic detection from the side face of the rail head, and the rail web side wheel type ultrasonic probe realizes transverse ultrasonic detection from the side face of the rail web, so that the equipment can realize full-coverage ultrasonic detection on the steel rail longitudinally and transversely, and the detection accuracy and efficiency are improved.

Drawings

Fig. 1 is a schematic structural view of embodiment 1 of the present invention;

fig. 2 is a schematic structural view ofembodiment 2 of the present invention;

fig. 3 is a schematic structural view ofembodiment 3 of the present invention;

fig. 4 is a schematic structural view ofembodiment 4 of the present invention;

fig. 5 is a schematic structural view of the wheel-type ultrasonic probe of the present invention, wherein a is a three-probe structure, and B is a two-probe structure;

fig. 6 is a schematic view of the scanning principle of the present invention.

Detailed Description

The technical solution proposed by the present invention is explained in detail below with reference to several embodiments shown in the attached drawings:

the flaw detection scanning device comprises an installation frame 1, wherein a cross beam is arranged at the top of the installation frame 1, a top wheel typeultrasonic probe 2 is installed on the cross beam at the top of the installation frame 1, the top wheel typeultrasonic probe 2 is directly contacted with a rail head tread of a steel rail, longitudinal ultrasonic scanning is realized on the steel rail from the rail head tread downwards, a rail head side wheel typeultrasonic probe 3 and a rail web side wheel typeultrasonic probe 4 are arranged on the side surface of the installation frame 1, the rail head side wheel typeultrasonic probe 3 is contacted with the side surface of the rail head to perform ultrasonic scanning on the rail head from the transverse direction, and the rail web side wheel typeultrasonic probe 4 is contacted with the rail web to perform ultrasonic scanning on the rail web from. Still be provided withsupport leading wheel 5 on installation frame 1,support leading wheel 5 is placed on the rail and is played a supporting role to installation frame 1 and can make installation frame 1 advance along the rail during operation, generally asupport leading wheel 5 cooperates wheeledultrasonic probe 2 in top and just can play a supporting role to this scanning device, but for more firm reliable, further preferred scheme is that be equipped withsupport leading wheel 5 respectively along rail length direction's both ends on installation frame 1, reach the effect of better direction and support through twosupport leading wheels 5, make this scanning device can move along the rail throughsupport leading wheel 5, implement the inspection.

In combination with the structure given above, the present invention will be further described in detail with respect to various embodiments, such as embodiment 1 shown in fig. 1, in which the railhead-side wheeledultrasonic probe 3 and the railwaist-side wheeledultrasonic probe 4 are respectively provided one, and the structure given in fig. 1 is that the railhead-side wheeledultrasonic probe 3 and the railwaist-side wheeledultrasonic probe 4 are located on the same side of the mounting frame 1, in which case the whole device is difficult to balance after being placed on a rail, and can realize support balance by providing a counterweight on the other side of the mounting frame 1 or installing wheels at the corresponding position, and in short, it is enough to provide a conventional support scheme to balance the mounting frame 1. On the basis of the embodiment, in order to better achieve the balance effect, the rail head side wheel typeultrasonic probe 3 and the rail web side wheel typeultrasonic probe 4 can be respectively arranged on two sides of the mounting frame 1, so that a certain balance effect is achieved.

Because the wheel-type ultrasonic probe needs to be in close contact with the steel rail in the flaw detection scanning process, the top wheel-typeultrasonic probe 2 can be tightly attached to the rail head tread of the steel rail by means of the self-gravity of the device, but the rail head side wheel-typeultrasonic probe 3 and the rail web side wheel-typeultrasonic probe 4 which are positioned on the side surface of the mounting frame 1 need a transverse force to enable the rail head side wheel-type ultrasonic probe and the rail web side wheel-type ultrasonic probe to be in close contact with the steel rail, the simple solution is that the positions of the rail head side wheel-typeultrasonic probe 3 and the rail web side wheel-typeultrasonic probe 4 are positioned to be proper positions according to the overall dimension of the steel rail, so that the rail head side wheel-typeultrasonic probe 3 and the rail web side wheel-typeultrasonic probe 4 are naturally in close contact with the steel rail when the flaw detection. Therefore, amounting plate 7 capable of moving towards the steel rail can be arranged on the side surface of the mounting frame 1, the railhead side wheel typeultrasonic probe 3 and the railweb side wheel typeultrasonic probe 4 are mounted on themounting plate 7, and in the initial position, the railhead side wheel typeultrasonic probe 3 and the railweb side wheel typeultrasonic probe 4 are spaced from the steel rail enough to facilitate the scanning device to enter the steel rail. After entering the steel rail, themounting plate 7 starts to move towards the steel rail, so that the rail head side wheel typeultrasonic probe 3 and the rail web side wheel typeultrasonic probe 4 are pressed on the steel rail to realize close contact. In order to facilitate the movement of themounting plate 7, aguide 9 and a driving device 8 are arranged on the mounting frame 1, the driving device 8 drives themounting plate 7 to move along theguide 9 toward the rail, the driving device 8 can be driven by a motor and a lead screw in a matching manner, or by an adjusting knob and the lead screw in a matching manner, or by an air cylinder, and the like, and theguide 9 can be a guide rail or a guide column for guiding themounting plate 7. As the embodiment shown in fig. 2, in the case that the railhead side wheel typeultrasonic probe 3 and the railweb side wheel typeultrasonic probe 4 are respectively arranged one by one and respectively arranged at both sides of the mounting frame 1, themounting plate 7 is also arranged two by two and respectively arranged at both sides of the mounting frame 1, the railhead side wheel typeultrasonic probe 3 and the railweb side wheel typeultrasonic probe 4 are respectively arranged at themounting plate 7 at both sides, the driving device 8 in the embodiment is a motor and a screw rod matched real-time driving, and the guidingmember 9 is a guiding column. If wheeled ultrasonic probe ofrailhead side 3 and wheeled ultrasonic probe ofweb side 4 all are in installation frame 1 with the same side when then only need set upmounting panel 7 in mounting bracket one side can, the opposite side adopts the wheel support that the above-mentioned embodiment mentioned can, because the rubber tyer does not survey the original paper, need not consider the problem with the hard contact damage of rail, but in order to make the better entering of equipment, also can installmounting panel 7 simultaneously in installation frame 1 both sides under this condition, will support the wheel of balanced usefulness and also install onmounting panel 7.

Because the wheel-type ultrasonic probe has a near field area, namely, a steel rail close to one side of the ultrasonic probe cannot be detected within a certain depth range, if the near field area is to be overcome, the near field area can be eliminated by increasing the distance between the ultrasonic probe and the steel rail, and therefore when only one rail head side wheel-typeultrasonic probe 3 and one rail waist side wheel-typeultrasonic probe 4 are arranged, if a blind zone is eliminated as much as possible, the size of the wheel-type ultrasonic probe needs to be large enough, but the integrity and the balance of equipment are influenced.

Therefore, referring to the embodiment of fig. 3, a preferable structure is provided, two rail head side wheeledultrasonic probes 3 and two rail web side wheeledultrasonic probes 4 are respectively provided, and one rail head side wheeledultrasonic probe 3 and one rail web side wheeledultrasonic probe 4 are respectively provided on both sides of the mounting frame 1, and the rail head side wheeledultrasonic probe 3 and the rail web side wheeledultrasonic probe 4 are arranged diagonally, so that the rail head side wheeledultrasonic probe 3 or the rail web side wheeledultrasonic probe 4 on any side forms a blind zone in the near field area, and the rail head side wheeledultrasonic probe 3 or the rail web side wheeledultrasonic probe 4 on the other side corresponding thereto can complete scanning, thereby eliminating the blind zone, although the top wheeledultrasonic probe 2 has a certain blind zone in the rail head longitudinal direction, but obtains overall coverage in the lateral direction, and the steel rail detection standard requirement only needs to reach more than 70 percent of coverage, so the structure edge can realize comprehensive coverage. Meanwhile, the rail head side wheel typeultrasonic probe 3 and the rail waist side wheel typeultrasonic probe 4 can also have a balance effect on the installation frame in a diagonal layout mode, so that the device can be better balanced. In the structure, the railhead side wheel typeultrasonic probe 3 and the rail web side wheel typeultrasonic probe 4 can be directly positioned according to the specification of the steel rail, and the railhead side wheel typeultrasonic probe 3 and the rail web side wheel typeultrasonic probe 4 are tightly contacted with the steel rail after the equipment is pushed into the steel rail. It is also possible to use a construction as shown in fig. 3, withmounting plates 7, drive means 8 andguides 9 on both sides of the mounting frame 1. The railhead side wheel typeultrasonic probes 3 and the railweb side wheel typeultrasonic probes 4 on the two sides of the installation frame 1 are respectively installed on theinstallation plate 7, the railhead side wheel typeultrasonic probes 3 and the railweb side wheel typeultrasonic probes 4 are kept to have certain gaps with the steel rail at the initial position so as to be convenient for the device to enter, and after entering, theinstallation plate 7 is driven by the driving device 8 to move towards the steel rail along theguide piece 9, so that the railhead side wheel typeultrasonic probes 3 and the railweb side wheel typeultrasonic probes 4 are in close contact with the steel rail, and the clamping effect is achieved.

On the basis of all the above embodiments, some auxiliary measures are further provided to make the device more optimized. As described with reference to the embodiment shown in fig. 4 in conjunction withembodiment 3, a set of balance support wheels 11 is provided on the mounting frame 1, the balance support wheels 11 can contact with the top surface of the rail bottom of the steel rail, and a four-corner support is formed on the top surface of the rail bottom on both sides of the steel rail by the balance support wheels 11, so that the flaw detection scanning device achieves a better balance and support. Because the surface of the steel rail has dust and impurities during field detection, which affects the detection of the wheel type probe, the two ends of the mounting rack can be provided withcleaning brushes 12 for cleaning in advance. When the flaw detection is carried out manually, each flaw detection position needs to be marked on the steel rail, the equipment can also be marked in the mode, but the marking efficiency is low, and the equipment is compact in structure and is troublesome to mark, so that anencoder wheel 10 can be further arranged on the flaw detection scanning device, theencoder wheel 10 is used for collecting the walking distance of the flaw detection scanning device on the steel rail, the position with the flaw can be marked in a coordinate mode by combining a wheel type ultrasonic probe, and the position with the flaw on the steel rail can be directly read from external data processing software, so that the detection speed is accelerated, the detection accuracy is improved, the distance from the flaw position to the initial position can be directly read from the software, and a maintainer can conveniently and quickly find the position of the flaw. Theencoder wheel 10 may be provided separately and installed on the mounting frame 1 and contacted with the rail, or thesupport guide wheel 5, the balance support wheel 11, or any one of the wheel type ultrasonic probes may be combined with the encoder as theencoder wheel 10. For convenience of carrying and moving,rollers 13 are mounted on the mounting frame 1, and the equipment can be transported on the ground by means of therollers 13.

In all the embodiments, thespray heads 6 for spraying the couplant need to be installed, and at least onespray head 6 should be installed on the corresponding top wheel typeultrasonic probe 2, rail head side wheel typeultrasonic probe 3 and rail web side wheel typeultrasonic probe 4 according to the number of the wheel type ultrasonic probes in the flaw detection scanning device, because the ultrasonic waves are quickly propagated and attenuated in the air, in order to avoid influencing flaw detection scanning, thespray heads 6 need to spray the couplant on the contact part of each wheel type ultrasonic probe and the steel rail, so that the air gap between the ultrasonic probes and the contact surface of the steel rail is eliminated, and the scanning precision is improved. If only onespray head 6 is arranged on each ultrasonic probe, the spray heads need to be arranged at the front end of the advancing direction of the ultrasonic probe, and because local reciprocating scanning is needed in actual scanning, the spray heads are preferably arranged at the two ends of each ultrasonic probe, so that the couplant is sprayed more uniformly. When the couplant is sprayed, thespray head 6 in the device can be externally connected with a water pump and a water tank to implement work.

The layout of the wheel type ultrasonic probe adopted in the utility model is shown in figure 5: because the contact parts of the top wheel typeultrasonic probe 2 and the rail waist side wheel typeultrasonic probe 4 with the steel rail have larger areas, three ultrasonic probes a (shown as A in figure 5) need to be arranged, and the three ultrasonic probes are arranged in a delta shape, and the ultrasonic probe a in the middle is overlapped with the ultrasonic probes on the two adjacent sides so as to avoid an undetected area; since the two side areas of the railhead are smaller, two ultrasonic probes a (as shown in B in fig. 5) are arranged in the railhead side wheel typeultrasonic probe 3 for scanning the part, and the two ultrasonic probes a have overlapped parts to avoid the missed detection area. The wheel type ultrasonic probes comprise a wheel axle b and a tire c, the ultrasonic probes a are fixed on the wheel axle b, the wheel axle b is hollow and leads out wires of the ultrasonic probes a, the tire c is movably arranged on the wheel axle through a bearing, the ultrasonic probes a are arranged in the inner cavity of the tire c, the tire c is filled with coupling agent, the tire c rotates around the wheel axle b during working, the wheel axle b and the ultrasonic probes a are stationary, and the ultrasonic probes a are kept facing the steel rail all the time for scanning detection.

When the scanning device ofembodiment 4 is used for flaw detection scanning of a steel rail, as shown in fig. 6, a top wheel typeultrasonic probe 2 forms a longitudinal scanning from a rail head tread downwards, a rail head side wheel typeultrasonic probe 3 forms a transverse scanning from a rail head side, and a rail web side wheel typeultrasonic probe 4 forms a transverse scanning from a rail web side, so that an ultrasonic scanning network forms a scanning effect of transversely and longitudinally crossing, and the rail head and the rail web are fully covered, compared with the prior art that only the longitudinal scanning is performed from the rail head tread, the scanning coverage area of the device is large, the scanning precision is higher, some defects exist longitudinally in the rolling process of the steel rail, the defects form a small gap longitudinally, the defect area is larger from the transverse direction, therefore, feedback signals are weak and easy to be ignored when the longitudinal scanning is performed, and the device not only has the longitudinal scanning but also has the transverse scanning, the conditions of signal weakening and missed detection caused by the fact that the defect tends to be consistent with the scanning direction are reduced.

The top wheel typeultrasonic probe 2, the rail head side wheel typeultrasonic probe 3 and the rail web side wheel typeultrasonic probe 4 in the scanning device are all single crystal probes, an A-type pulse reflection type ultrasonic flaw detector with a single receiving and sending function can be in butt joint with any probe of the scanning device, and A-type display scanning of the part where the probes are connected can be achieved. The ultrasonic flaw detector with multiple channels (13 channels) can be in butt joint with all probes of the scanning device to complete scanning detection of the steel rail at one time. The flaw detector can be matched with theencoder wheel 10 to perform B-display detection display, can be matched with corresponding software to perform whole-course recording on the steel rail detection process, can accurately record detailed information such as detection length, defect position, horizontal position, sound path (depth), defect indication length, defect equivalent and the like, and can also draw a detection schematic diagram.

Claims (10)

1. The utility model provides a rail ultrasonic inspection scanning device, includes installation frame (1), its characterized in that: the top of the mounting frame (1) is provided with a top wheel type ultrasonic probe (2) contacted with a rail head tread, the side surface of the mounting frame (1) is provided with a rail head side wheel type ultrasonic probe (3) contacted with the side surface of a rail head and a rail web side wheel type ultrasonic probe (4) contacted with a rail web, and the mounting frame (1) is provided with a supporting guide wheel (5) contacted with a steel rail for supporting and guiding; and the mounting frame (1) is provided with a spray head (6) for spraying a couplant on the contact surface of the top wheel type ultrasonic probe (2), the rail head side wheel type ultrasonic probe (3) and the rail web side wheel type ultrasonic probe (4) with the steel rail respectively.

2. A rail ultrasonic flaw detection scanning apparatus according to claim 1, wherein: the rail head side wheel type ultrasonic probe (3) and the rail waist side wheel type ultrasonic probe (4) are respectively arranged one by one, and the rail head side wheel type ultrasonic probe (3) and the rail waist side wheel type ultrasonic probe (4) are arranged on the same side of the mounting frame (1).

3. A rail ultrasonic flaw detection scanning apparatus according to claim 1, wherein: the rail head side wheel type ultrasonic probe (3) and the rail waist side wheel type ultrasonic probe (4) are respectively arranged one by one, and the rail head side wheel type ultrasonic probe (3) and the rail waist side wheel type ultrasonic probe (4) are respectively arranged on two sides of the installation frame (1).

4. A rail ultrasonic flaw detection scanning apparatus according to claim 1, wherein: the rail head side wheel type ultrasonic probe (3) and the rail web side wheel type ultrasonic probe (4) are respectively provided with a pair, and the rail head side wheel type ultrasonic probe (3) and the rail web side wheel type ultrasonic probe (4) are respectively symmetrically arranged or diagonally arranged at two sides of the mounting frame (1).

5. A rail ultrasonic flaw detection scanning apparatus according to claim 1 or 2, wherein: the rail-mounted ultrasonic probe is characterized in that a mounting plate (7) capable of moving towards a steel rail is movably arranged on one side of the mounting frame (1), the rail head side wheel type ultrasonic probe (3) and the rail web side wheel type ultrasonic probe (4) are mounted on the mounting plate (7), a driving device (8) for driving the mounting plate (7) to move towards the steel rail is arranged on the mounting frame (1), and a guide piece (9) for guiding the movement of the mounting plate (7) is further arranged on the mounting frame (1).

6. A rail ultrasonic flaw detection scanning apparatus according to any one of claims 1 to 4, wherein: installation frame (1) both sides all the activity be equipped with can move mounting panel (7) towards the rail, railhead side wheeled ultrasonic probe (3) and rail web side wheeled ultrasonic probe (4) install on mounting panel (7) installation frame (1) on be equipped with drive arrangement (8) that drive mounting panel (7) removed towards the rail, still be equipped with on shown installation frame (1) and remove guide (9) that play the guide effect to mounting panel (7).

7. A rail ultrasonic flaw detection scanning apparatus according to claim 5, wherein: the driving device (8) is a motor and a screw rod or a knob and a screw rod; the guide piece (9) is a guide sliding column or a guide rail.

8. A rail ultrasonic flaw detection scanning apparatus according to claim 6, wherein: the driving device (8) is a motor and a screw rod or a knob and a screw rod; the guide piece (9) is a guide sliding column or a guide rail.

9. A rail ultrasonic flaw detection scanning apparatus according to claim 1, wherein: the flaw detection scanning device also comprises an encoder wheel (10) which can collect the moving distance of the flaw detection scanning device; two ends of the mounting frame (1) along the length direction of the steel rail are respectively provided with a supporting guide wheel (5); and a group of balance supporting wheels (11) contacted with the top of the rail bottom are also arranged on the mounting frame (1).

10. A rail ultrasonic flaw detection scanning apparatus according to claim 1 or 9, wherein: and one end of each supporting guide wheel (5) far away from the installation frame (1) is provided with a cleaning brush (12) contacted with a steel rail, and the installation frame (1) is also provided with a roller (13) for supporting and moving the flaw detection scanning device.

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