Design and Experiment Research of Oblique Crack Detection System for Rail Tread Based on ACFM Technique

doi:10.3901/JME.2023.14.023

Abstract

Abstract: The oblique crack is the major damage of rail tread surface. When it reaches a certain depth, they will rapidly expand and cause transverse fracture of the rail head. So the detection of oblique cracks on rail treads is of great significance to the railway safe. According to the characteristics of rail tread detection, the rail tread oblique crack detection system is developed and tested based on the alternating current field measurement (ACFM) technique. The ACFM detection model is established by the finite element software COMSOL. The response relationships between the induced electromagnetic field and the oblique cracks are analyzed. And the influences of different scanning paths on the distortion of characteristic signals are explored. The detection probe, scanning frame and detector are designed and the detection software is written to form a complete rail tread oblique crack detection system, and rail tread cracks of different lengths and depths are detected. The simulation and experimental results show that the distortion of the characteristic signal of the center position of the oblique crack is the smallest, and the characteristic signal of the end position is the largest. The detection system can realize the effective detection of the 1mm deep oblique crack on the rail tread. As the depth of the crack increases, the distortion of the crack center characteristic signal increases, and as the length of the crack increases, the distortion of the characteristic signal first increases and then decreases.

Key words: rail tread, ACFM, oblique crack, induced electromagnetic fields, detection system

CLC Number:

U216

ZHAO Jianming, LI Wei, ZHU Yukai, YUAN Xinan, YIN Xiaokang, ZHAO Jianchao. Design and Experiment Research of Oblique Crack Detection System for Rail Tread Based on ACFM Technique[J]. Journal of Mechanical Engineering, 2023, 59(14): 23-32.

References

[1] 贾昕昱. 基于轮轨瞬态滚动接触模型的钢轨接触疲劳伤损研究[D]. 北京:中国铁道科学研究院,2020. JIA Xinyu. Research on contact fatigue damage of rail based on wheel-rail transient rolling contact model[D]. Beijing:China Academy of Railway Sciences,2020.
[2] 邢丽贤. 提速条件下钢轨伤损特点及钢轨伤损分类的研究[D]. 北京:中国铁道科学研究院,2008. XING Lixian. Research on defect characteristics and classification of higher speed rails[D]. Beijing:China Academy of Railway Sciences,2008.
[3] ZERBST U,LUNDéNR,EDEL K O,et al. Introduction to the damage tolerance behaviour of railway rails:A review[J]. Engineering Fracture Mechanics,2009,76(17):2563-2601.
[4] 周清跃,张建峰,郭战伟,等. 重载铁路钢轨的伤损及预防对策研究[J]. 中国铁道科学,2010,31(1):27-31. ZHOU Qingyue,ZHANG Jianfeng,GUO Zhanwei,et al. Research on the rail damages and the preventive countermeasures in heavy haul railways[J]. China Railway Science,2010,31(1):27-31.
[5] SHEN J,ZHOU L,ROWSHANDEL H,et al. Prediction of RCF clustered cracks dimensions using an ACFM sensor and influence of crack length and vertical angle[J]. Nondestructive Testing & Evaluation,2020,35(1):1-18.
[6] 田贵云,高斌,高运来,等. 铁路钢轨缺陷伤损巡检与监测技术综述[J]. 仪器仪表学报,2016,37(8):1763-1780. TIAN Guiyun,GAO Bin,GAO Yunlai,et al. Review of railway rail defect non-destructive testing and monitoring[J]. Chinese Journal of Scientific Instrument,2016,37(8):1763-1780.
[7] 李国厚,黄平捷,陈佩华,等.涡流检测在钢轨裂纹定量化评估中的应用[J]. 浙江大学学报,2011,45(11):2038-2042,2049. LI Guohou,HUANG Pingjie,CHEN Peihua,et al. Application of eddy current testing in the quantitative evaluation of the rail cracks[J]. Journal of Zhejiang University,2011,45(11):2038-2042,2049.
[8] Lao J,Lu C. Application of portable ultrasonic phased array instrument for rail welds ultrasonic inspection[J]. Advanced Materials Research,2013,717(1):384-389.
[9] 高运来,王平,田贵云,等. 钢轨裂纹高速漏磁巡检中的动态磁化及速度效应分析[J]. 无损检测,2013,35(10):53-58. GAO Yunlai,WANG Ping,TIAN Guiyun,et al. Velocity effect analysis of dynamic magnetization in high speed detection for rail crack using MFL method[J]. Nondestructive Testing,2013,35(10):53-58.
[10] ANTIPOV A,MARKOV A. Evaluation of transverse cracks detection depth in MFL rail NDT[J]. Russian Journal of Nondestructive Testing,2014,50(8):481-490.
[11] YU H,LI Q,TAN Y,et al. A coarse-to-fine model for rail surface defect detection[J]. IEEE Transactions on Instrumentation and Measurement,2019,68(3):656-666.
[12] 李天骥,石永生,陈峰,等. 基于超声相控阵全聚焦DAC图谱的钢轨缺陷定量方法[J]. 机械工程学报,2021,57(18):32-41. LI Tianji,SHI Yongsheng,CHEN Feng,et al. Quantitative method of rail flaws based on ultrasonic phased array and total focusing DAC mappings[J]. Journal of Mechanical Engineering,2021,57(18):32-41.
[13] 李骏. 基于时频空特征的钢轨探伤识别研究[D]. 广州:华南理工大学,2017. LI Jun. Research on rail flaw detection based on time-frequency and space feature[D]. Guangzhou:South China University of Technology,2017.
[14] 马旺宇,刘栋,赵文博. 应用于钢轨检测的便携式涡流探伤仪的研制[J]. 机械设计与制造,2010(2):88-90. MA Wangyu,LIU Dong,ZHAO Wenbo. A portable eddy current flaw detection for railway testing[J]. Machinery Design&Manufacture,2010(2):88-90.
[15] 李宁. 基于机器视觉的钢轨表面缺陷检测系统研究[D].北京:北京交通大学,2021. LI Ning. Research on rail surface defect detection system based on machine vision[D]. Beijing:Beijing Jiaotong University,2021.
[16] ZHAO J,LI W,GE J,et al. Coiled tubing wall thickness evaluation system using pulsed alternating current field measurement technique[J]. IEEE Sensors Journal,2020,20(18):10495-10501.
[17] SHEN J,ZHOU L,ROWSHANDEL H,et al. Determining the propagation angle for non-vertical surface-breaking cracks and its effect on crack sizing using an ACFM sensor[J]. Measurement Science and Technology,2015,26(11):1-11.
[18] 袁新安,李伟,殷晓康,等. 基于ACFM的奥氏体不锈钢不规则裂纹可视化重构方法研究[J]. 机械工程学报,2020,56(10):27-33. YUAN Xinan,LI Wei,YIN Xiaokang,et al. Visual reconstruction of irregular crack in austenitic stainless steel based on ACFM technique[J]. Journal of Mechanical Engineering,2020,56(10):27-33.
[19] NICHOLSON G,DAVIS C. Modelling of the response of an ACFM sensor to rail and rail wheel RCF cracks[J]. NDT & E International,2012,46(1):107-114.
[20] Rowshandel H,Nicholson G L,Shen J L,et al. Characterisation of clustered cracks using an ACFM sensor and application of an artificial neural network[J]. NDT & E International,2018,98:80-88.
[21] Shen J,Liu M,Dong C,et al. Analysis on asymmetrical RCF cracks characterisation using an ACFM sensor and the influence of the rail head profile[J]. Measurement,2022,194:111008.
[22] ChacOn Muñoz J M,García Márquez F P,Papaelias M. Railroad inspection based on ACFM employing a non-uniform B-spline approach[J]. Mechanical Systems and Signal Processing,2013,40(2):605-617.
[23] 葛玖浩,杨晨开,胡宝旺,等. 交流电磁场检测技术钢轨表面裂纹高速检测研究[J]. 机械工程学报,2021,57(18):66-74. GE Jiuhao,YAN Chenkai,HU Baowang,et al. High-speed detection of surface crack on rail using alternating current field measurement technique[J]. Journal of Mechanical Engineering,2021,57(18):66-74.