基于电涡流热成像的钢轨滚动接触疲劳裂纹动态检测研究

doi:10.3901/JME.2021.18.086

机械工程学报 ›› 2021, Vol. 57 ›› Issue (18): 86-97.doi: 10.3901/JME.2021.18.086

• 特邀专栏：高速铁路钢轨检测监测与应用 • 上一篇下一篇

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基于电涡流热成像的钢轨滚动接触疲劳裂纹动态检测研究

苗玲¹, 高斌¹, 石永生², 李浩然¹, 黎潇枫¹, 吴同乐¹, 张喜源¹, 田贵云^1,3

1. 电子科技大学自动化工程学院成都 611731;
2. 中国国家铁路集团有限公司铁路基础设施检测中心北京 100081;
3. 纽卡斯尔大学电气与电子工程学院纽卡斯尔NE17RU英国

收稿日期:2020-12-29 修回日期:2021-06-09 出版日期:2021-09-20 发布日期:2021-11-30
通讯作者: 高斌(通信作者),男,1983年出生,博士,教授,博士研究生导师。主要研究方向为电磁多物理传感无损检测,非监督/监督机器学习。E-mail:bin_gao@uestc.edu.cn
作者简介:苗玲,女,1991年出生,博士研究生。主要研究方向为电涡流热成像检测。E-mail:miaoling@std.uestc.edu.cn
基金资助:
国家自然科学基金（61971093，61527803，61960206010）、四川省科技厅（2019YJ0208，2018JY0655，2018GZ0047）和中央高校基本科研业务费专项资金（ZYGX2019J067）资助项目。

Research on Dynamic Detection of Rail Rolling Contact Fatigue Crack Based on Eddy Current Thermography

MIAO Ling¹, GAO Bin¹, SHI Yongsheng², LI Haoran¹, LI Xiaofeng¹, WU Tongle¹, ZHANG Xiyuan¹, TIAN Guiyun^1,3

1. School of Automation Engineering, University of Electronic Science and Technology, Chengdu 611731;
2. Railway Infrastructure Inspection Center, CHINA RAILWAY, Beijing 100081;
3. School of Electrical and Electronic Engineering, Newcastle University, Newcastle NE17RU, UK

Received:2020-12-29 Revised:2021-06-09 Online:2021-09-20 Published:2021-11-30

摘要/Abstract

摘要： 针对钢轨滚动接触疲劳裂纹检测挑战，提出了新型传感结构下的多物理电涡流热成像技术。通过COMSOL Multiphysics有限元仿真软件，分析了圆柱形磁芯结构、弧形磁轭结构和U形磁轭结构的电磁场特性，并研究了在不同传感架构下对疲劳裂纹的检测效果。针对实际应用条件，在U形磁轭结构的基础上研制了L形磁轭和梭形磁轭结构并集成开发了感应激励源系统。静止状态下铣平钢轨试块缺陷检测试验表明自主研制的系统对钢轨表面微小缺陷的检测灵敏度高，能实现0.5 mm宽缺陷的定量分析，且最小能识别钢轨表面0.2 mm宽的缺陷。通过圆盘缺陷检测试验对速度效应下疲劳裂纹的检测进行了研究，提出的鲁棒低秩张量裂纹分解算法极大地消除了原始热图像的背景噪声并提升缺陷检测分辨率。最后搭建并集成了钢轨低速巡检试验平台，验证了对钢轨踏面复杂滚动接触疲劳裂纹检测的有效性。

关键词: 滚动接触疲劳裂纹, 电涡流热成像, 传感架构, 定量检测, 巡检

Abstract: In response to the challenge of rail rolling contact fatigue crack detection, a multi-physics eddy current thermography technology under new sensor structures is proposed. Through COMSOL Multiphysics finite element simulation software, the electromagnetic field characteristics of the cylindrical magnetic core structure, the arc-shaped yoke structure and the U-shaped yoke structure are analysed, and the detection effect of fatigue crack under different sensing architectures is studied. According to actual application conditions, the L-shaped yoke and the shuttle-shaped yoke structures are developed based on the U-shaped yoke structure, and the induction excitation source system is integrated and developed. Defect detection experiment of milled rail test blocks in the static state shows that the self-developed system has high detection sensitivity for small defects on the rail surface. It can realize quantitative analysis of 0.5 mm wide defects and identify defects with a minimum width of 0.2 mm on the rail surface. Through the defect detection experiment of disc, the fatigue crack detection under speed effect is studied. The proposed robust low-rank tensor crack decomposition algorithm greatly eliminates the background noise of the original thermal image and improves the defect detection resolution. Finally, the low-speed rail inspection experimental platform is built and integrated to verify effectiveness of complex rolling contact fatigue crack detection on rail treads.

Key words: rolling contact fatigue crack, eddy current thermography, sensor architecture, quantitative detection, low-speed inspection

中图分类号:

TG156

苗玲, 高斌, 石永生, 李浩然, 黎潇枫, 吴同乐, 张喜源, 田贵云. 基于电涡流热成像的钢轨滚动接触疲劳裂纹动态检测研究[J]. 机械工程学报, 2021, 57(18): 86-97.

MIAO Ling, GAO Bin, SHI Yongsheng, LI Haoran, LI Xiaofeng, WU Tongle, ZHANG Xiyuan, TIAN Guiyun. Research on Dynamic Detection of Rail Rolling Contact Fatigue Crack Based on Eddy Current Thermography[J]. Journal of Mechanical Engineering, 2021, 57(18): 86-97.

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基于电涡流热成像的钢轨滚动接触疲劳裂纹动态检测研究

Research on Dynamic Detection of Rail Rolling Contact Fatigue Crack Based on Eddy Current Thermography

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