基于智能巡检机器人系统平台的列车空气泄漏超声波检测装置设计

Design of ultrasonic detection device for train air leakage based on intelligent inspection robot system platform

民众日益增长的交通出行需求,直接推动了列车及其营运线路的开通与增长,也给列车日检工作带来了不断增大的压力。作为保障列车制动安全的重要环节,空气制动管路的密封性检测在列车日检作业中不可或缺。为满足实际需求,弥补当前智能巡检机器人巡检功能短缺,文章以双臂机器人为平台,基于泄漏小孔产生湍流、湍流产生超声波的原理,采用“一板两头”结构型式,设计开发了一套空气泄漏超声波检测装置。从信号采集、信号放大和滤波等预处理功能层面对装置结构和硬件配置展开设计,并基于FFT与Parseval定理设计了气体泄漏检测判断算法。通过模拟检测不同孔径(0.125 mm,0.200 mm,0.400 mm)的小孔在不同工况下的泄漏状况,验证了试验样机在0.3s采集时间内能满足接收与正确判断50°锥角、600mm范围内气体泄漏信号的功能需求。

The increasing demand for transportation by the public has directly promoted the opening and expansion of train services and routes,which has also led to increasing pressure on the daily inspection work for trains.As an important part of ensuring train braking safety,the tightness detection of air braking pipeline is indispensable in daily train inspection.To meet practical needs and address deficiencies in the current capabilities of intelligent inspection robots,this paper introduced a dual-arm robot platform.Based on the principle of turbulence generated by small leakage holes and the subsequent generation of ultrasonic waves,a"one board,two ends"structural design was adopted to design and develop an ultrasonic detection device for air leakage.The design focused on the structure and hardware configuration of the device from the aspects of signal acquisition,signal amplification and filtering preprocessing capabilities.In addition,an algorithm for air leakage detection was designed based on FFT and the Parseval's theorem.By simulating the air leakage conditions of small holes with different diameters(0.125 mm,0.200 mm and 0.400 mm)under different conditions,the experimental prototype was verified to be able to receive and correctly judge air leakage signals within a range of 50°cone angle and 600 mm distance in a 0.3 s acquisition time.