Rail flaw detection: the evolution from “brainless computer” to “digitalization”
Rail flaw detection
Ten years ago, the rail flaw detection equipment was old, and the flaw detector was bulky, slow, and the accuracy was not high. Now, intelligent flaw detectors and rail flaw detection vehicles have appeared one after another, and the flaw detection efficiency and accuracy are getting higher and higher. Freed from heavy labor.
During the production process of the steel rail, there will be metal inclusions and defects, as well as air bubbles or white spots, etc., which will be damaged by external impact during use, so that under the repeated load of the train, the source of damage will continue to develop, and it is easy to cause rail damage. break off. Therefore, rails need regular flaw detection.
Rail flaw detection mainly adopts the combination of rail flaw detector and manual inspection, and regularly conducts “physical examination” on the rails to find out the small cracks on the rail surface, internal flaws, and the damage above the millimeter level on the part of the rail covered by the splint, so as to prevent damage The source is constantly evolving. At present, the rail flaw detectors mainly used include single-track rail flaw detectors, double-rail rail flaw detectors, and rail flaw detectors.
In the past, A-type display ultrasonic flaw detectors were used for flaw detection operations. This kind of flaw detector does not have the function of automatically recording detection signals and information processing. The workers jokingly called it a “brainless machine”. The “brainless machine” weighs dozens of kilograms, and the speed of the single-strand rail is less than 3 kilometers per hour. Each operation team needs 7 people, and the daily workload is only 7 or 8 kilometers. On-site detection also requires personnel to manually record and judge the waveform signal on the display screen. After the damage is found, it is necessary to rely on manual calculations to calculate the location of the damage. The detection results are greatly affected by human factors, which can easily lead to false positives and false negatives of damage, and it is difficult to guarantee the quality of flaw detection.
With the continuous improvement of flaw detection technology, Type 10 and Type 11 rail flaw detectors have appeared, which have initially realized the intelligence and digitalization of flaw detection. This kind of flaw detector has been upgraded from the original single A-mode display mode to A-mode + B-mode image display at the same time, which can directly read the horizontal distance and vertical depth of the damage, and can accurately locate rail defects without calculation. . At the same time, the B-ultrasound image is clear at a glance, and the operator can intuitively see the abnormal waveform, which effectively improves the accuracy and efficiency of flaw detection.
rail ultrasonic flaw detectors
In recent years, with the addition of dual-track rail ultrasonic flaw detectors, rail flaw detection has undergone a qualitative leap. This kind of flaw detector not only takes into account all the functions of the AB-type flaw detector but also adopts the overall frame structure. It only needs simple disassembly and assembly on-site to go on and off the line, and personnel can sit in the car to carry out control operations. The car body is driven by electricity, and the operation team only needs 4 workers, the labor intensity is reduced, and the operation speed is increased to 13 km/h, which greatly improves the work efficiency.
