双轨式钢轨超声检测系统的设计与应用

Design and application of double rail ultrasonic testing system

当前的钢轨焊缝检测一般采用便携式超声检测仪进行人工检测,检测效率低,劳动强度大。受钢轨的工字型结构及轨底扣件的影响,钢轨焊缝的自动化检测一直难以实现。为了实现对钢轨焊缝的自动化检测,首先在双轨式钢轨超声检测系统中增加了串列式扫查功能,采用轮式探头取代人工焊缝检测中的串列式扫查,可以和钢轨母材检测同时进行;其次,研发了一种采用机械臂的轨底扫查设备并将其安装于双轨式钢轨超声检测仪上,同样采用轮式探头可实现对焊缝轨底的快速检测,利用轮式探头的良好耦合性实现了对钢轨焊缝的全断面自动化检测,并在现场检测作业中验证了检测效果。结果表明,所设计的自动检测系统可取代人工焊缝检测,显著提高劳动效率。

The current detection of rail welds is carried out manually using portable ultrasonic detectors,which have low detection efficiency and high labor intensity.Due to the influence of the I-shaped structure of the steel rail and the fasteners at the bottom of the rail,automated detection of rail welds has always been difficult to achieve.In order to achieve automated detection of rail welds,a serial scanning function was added to the dual rail ultrasonic detection system.A wheeled probe was used instead of the serial scanning in manual weld detection,which can be carried out simultaneously with the detection of the rail base material.Secondly,a rail bottom scanning equipment using a robotic arm was developed,which also used a wheeled probe and was installed on a dual rail ultrasonic detector.It can achieve rapid detection of the weld seam rail bottom.By utilizing the good coupling of the wheeled probe,the full section automatic detection of the rail weld seam was achieved,and the detection effect was verified in on-site inspection operations.The results showed that the designed automatic detection system can replace manual weld seam detection and significantly improve labor efficiency.