阅读说明：本技术 冶金车辆车轴检测装置及检测方法 (Metallurgical vehicle axle detection device and detection method ) 是由 闫涛 陈洁 张娜 徐伟 席翠省 王晓宁 翟烜 郭海龙 戴志强 张宁 刘建涛 刘 于 2021-09-30 设计创作，主要内容包括：本发明公开了一种冶金车辆车轴检测装置,属于车辆检测领域,包括用于与被测车轴相配合的扫查检测机构,和与扫查检测机构电连接的移动工作站,扫查检测机构由与扫查检测机构活动连接的驱动机构驱动。本发明还公开了一种冶金车辆车轴检测方法,包括设备校准、现场准备、设备安装、设备调试、检测的步骤。本发明在不拆卸车体的情况下完成车轴检测,简化了检测步骤,降低了检测难度,提高了检测效率,适用于所有大尺寸轴类工件的检测,尤其适用于冶金车辆的车轴检测。(The invention discloses a metallurgical vehicle axle detection device, which belongs to the field of vehicle detection and comprises a scanning detection mechanism matched with a detected axle and a mobile workstation electrically connected with the scanning detection mechanism, wherein the scanning detection mechanism is driven by a driving mechanism movably connected with the scanning detection mechanism. The invention also discloses a metallurgical vehicle axle detection method, which comprises the steps of equipment calibration, field preparation, equipment installation, equipment debugging and detection. The axle detection device disclosed by the invention can be used for completing the axle detection without disassembling the vehicle body, so that the detection steps are simplified, the detection difficulty is reduced, the detection efficiency is improved, and the axle detection device is suitable for detecting all large-size shaft workpieces, and is particularly suitable for detecting the axles of metallurgical vehicles.)

1. The metallurgical vehicle axle detection device is characterized by comprising a scanning detection mechanism matched with a detected axle and a mobile workstation electrically connected with the scanning detection mechanism, wherein the scanning detection mechanism is driven by a driving mechanism movably connected with the scanning detection mechanism.

2. The axle detecting device for the metallurgical vehicle as claimed in claim 1, wherein the scanning detection mechanism comprises a phased array probe, a wedge block, an encoder and a pressure mechanism for pressing the wedge block to the detected axle, the phased array probe and the wedge block are connected with the pressure mechanism through a fixed clamping mechanism, the pressure mechanism is connected with the driving mechanism through a steering clamping mechanism, and the mobile work station comprises a phased array flaw detector.

3. The axle detecting device for metallurgical vehicle as claimed in claim 2, wherein the pressure mechanism comprises a movable rod and a fixed rod sleeved on the movable rod, the top end of the movable rod is provided with an upper spring seat, the fixed rod is provided with a lower spring seat, a tension spring is arranged between the upper spring seat and the lower spring seat, the lower end of the movable rod is fixedly arranged on the fixed clamping mechanism, the fixed rod is fixedly arranged on the steering clamping mechanism, and the pressure applied to the axle to be detected by the phased array probe and the wedge block is changed by adjusting the height of the steering clamping mechanism.

4. The metallurgical vehicle axle detecting device of claim 3, wherein the steering clamping mechanism comprises a vertical rod connected with a fixed rod, the vertical rod is detachably sleeved on the steering seat, the steering clamping mechanism further comprises a horizontal rod which is connected with the driving mechanism and is perpendicular to the vertical rod, and the horizontal rod is detachably sleeved on the steering seat.

5. The metallurgical vehicle axle detecting device as claimed in claim 4, wherein the steering seat comprises a first adjusting sleeve sleeved on the vertical rod and a second adjusting sleeve sleeved on the horizontal rod, the first adjusting sleeve is vertically and fixedly arranged on the second adjusting sleeve, an opening along the axial direction of the adjusting sleeve is arranged on each of the first adjusting sleeve and the second adjusting sleeve, and an adjusting nut used for adjusting the inner diameter of each of the first adjusting sleeve and the second adjusting sleeve is arranged at the opening.

6. The metallurgical vehicle axle testing device of claim 5, wherein the fixed clamping mechanism comprises an "Contraband" clamping block adapted to the width of the phased array probe, and a clamping screw matched with the groove of the phased array probe is arranged on one side of the clamping block facing the phased array probe.

7. The metallurgical vehicle axle detection device according to any one of claims 2 to 6, wherein the mobile workstation comprises a frame body, the frame body is provided with a phased array flaw detector electrically connected with the phased array probe and the encoder, a transformer electrically connected with the driving mechanism and providing power for the driving mechanism, a peristaltic pump and a water tank which are connected with the phased array probe through a water supply loop and are used for providing coupling agents for the phased array probe, and the frame body is further provided with a mobile power supply which is electrically connected with the phased array flaw detector, the transformer and the peristaltic pump and is used for providing power for the phased array flaw detector, the transformer and the peristaltic pump.

8. The metallurgical vehicle axle detection device of claim 7, wherein the drive mechanism comprises a scanning vehicle in operative connection with the scanning detection mechanism.

9. A metallurgical vehicle axle detection method is realized by using the metallurgical vehicle axle detection device as claimed in any one of claims 1 to 8, and is characterized by comprising the following steps which are sequentially carried out,

equipment calibration: firstly, calibrating equipment, wherein the equipment calibration comprises sound velocity calibration, wedge block delay calibration, sensitivity calibration, TCG calibration and encoder calibration;

preparing on site: after equipment is calibrated, carrying out on-site preparation, wherein the on-site preparation comprises on-site environment preparation, vehicle preparation to be detected and wheel axle detection part preparation;

equipment installation: after the on-site preparation, equipment installation is carried out, the scanning detection mechanism is respectively connected with equipment on a mobile workstation, the parameters of the detected vehicle axle are measured and input into the scanning detection mechanism;

equipment debugging: after the equipment is installed, starting equipment debugging, starting a scanning detection mechanism, enabling the scanning detection mechanism to move circumferentially, and observing the working state of the scanning detection mechanism;

and (3) starting detection: after the equipment is debugged, starting detection, adjusting the scanning detection mechanism to the position of the equipment during calibration, starting a detection device, enabling the scanning detection mechanism to rotate at least one circle along the circumferential direction of the tested vehicle axle under the driving of the driving mechanism, and observing the crawling condition of the scanning detection mechanism;

and (4) finishing detection: and after the detection is finished, the detection data is stored, the scanning detection mechanism is closed, the equipment is disassembled and returned, and the detection site is cleaned.

10. The metallurgical vehicle axle detection method of claim 9,

in the equipment calibration step, sound velocity calibration, wedge block delay calibration and sensitivity calibration are carried out on a test block with a standard reflector; TCG calibration is carried out on an ultrasonic flaw detection half shaft sample block; calibrating the encoder, selecting a single line for scanning type, entering calibration, controlling a scanning detection mechanism to move a given distance in the circumferential direction, clicking for calibration, automatically calculating the resolution of the encoder by the instrument, and setting the resolution in the instrument;

in the field preparation step, the field environment preparation comprises the steps of detecting whether the environment can ensure the illumination and power utilization safety or not and ensuring that no dangerous factors influencing the detection activity safety in the field can be generated in the detection process; preparing a vehicle to be detected, wherein the vehicle to be detected is guided by a dispatcher in an empty state and is transferred to a field, wheels are masked to prevent the vehicle from sliding and moving, and warning signs are arranged at front and rear remarkable positions of the vehicle to be detected and are watched by special persons; the preparation of the wheel axle detection part comprises the steps of checking the detection space of the wheel axle, removing dust and dirt on the surface of the wheel axle to enable the dust and the dirt not to influence the stable running of a scanning detection mechanism, polishing a scanning area, and removing a paint layer and iron slag until the surface roughness Ra is less than or equal to 12.5 mu m;

in the equipment installation step, the scanning detection mechanism is respectively connected with the equipment on the mobile workstation, the scanning vehicle is taken out of the mobile workstation, the scanning vehicle is placed at the approximate position of the axle to be measured, a proper amount of water is added into the water tank, and the water tank is connected with the peristaltic pump; placing a mobile power supply on a mobile workstation, and supplying power to a phased array flaw detector, a transformer and a peristaltic pump through a connecting circuit; installing a circuit and a pipeline at the probe end of the phased array, installing the phased array probe, a fixed clamping mechanism and a pressure mechanism, installing a steering clamping mechanism, enabling a horizontal rod to be on an extension line of the diameter of the axle, adjusting the position of a vertical rod to enable the phased array probe to be tightly attached to the axle, applying pressure to the axle through the pressure mechanism, and fixing the steering clamping mechanism; installing lines and pipelines at the end of a mobile workstation, connecting a phased array probe and a coder with a phased array flaw detector, connecting the phased array probe with a peristaltic pump through a silica gel water pipe, connecting a scanning vehicle with a transformer, and keeping enough stroke allowance; measuring and calculating the diameter and the perimeter of the detected axle, inputting the diameter and the perimeter into a phased array flaw detector, and debugging the phased array flaw detector to a working state;

the equipment debugging step comprises the steps of opening a water supply loop to open a circuit, providing a coupling agent for the probe, placing an instrument gate A at the depth position of the bottom surface, monitoring a detected area, controlling a scanning detection mechanism to move in a circumferential direction within a set range, observing the coupling condition of the phased array probe and displaying an instrument image, and if the sensitivity is weak, compensating 3-6 dB gain as scanning gain according to the surface state of a workpiece until the sensitivity reaches a standard;

in the detection starting step, starting the detection device, wherein the peristaltic pump is started to enable the couplant to wet the surface of the axle, the speed of the driving mechanism is adjusted to a proper range, the driving mechanism drives the phased array probe and the encoder to rotate around the axial direction of the axle to scan, and the scanning length is the sum of the circumference of the axle 25 and the allowance of 20-30 mm; observing the crawling condition of the scanning detection mechanism comprises observing whether a signal received by the phased array flaw detector is complete, if clear and complete, enabling the driving mechanism to quickly return to the original position to finish the test, otherwise, reducing the speed of the driving mechanism, reversely scanning and continuously recording until the acquired signal is clear and complete, and finishing the detection.

Technical Field

The invention belongs to the field of vehicle detection, and relates to an axle detection device and a detection method, in particular to a metallurgical vehicle axle detection device and a detection method.

Background

The metallurgical vehicle is a low-speed rail vehicle used in metallurgical enterprises and comprises special carrying equipment such as a hot metal ladle car, a molten steel ladle car and the like produced by professional metallurgical equipment manufacturers. The metallurgical vehicle bears important production tasks in metallurgical enterprises, continuously works for a long time, has extremely severe use environment conditions, and has serious damage and huge loss if failure occurs. Therefore, maintenance and repair of metallurgical vehicles is very important. Furthermore, the metallurgical vehicle axle is a key part for ensuring the safety of the vehicle, not only bears huge load, but also bears impact caused by turnout, steel rail welding seams, unsmooth lines and the like, has complex stress condition and severe working condition, is easy to generate fatigue cracks, and can break the axle or even cause the derailment of the vehicle if the axle is subjected to fatigue damage and continues to expand. Therefore, the axle is regularly detected, which is the most important content for the metallurgical vehicle inspection.

In the related art, since the press-fitting portion between the wheel and the axle cannot be contacted and the shape of the peripheral region is complicated, the detection can be generally performed only by an ultrasonic method. In the conventional ultrasonic testing, a probe is brought into contact with an end face or a surface of an axle to irradiate ultrasonic waves into the axle, and each reflected wave is observed and analyzed. The main methods include three methods of vertical flaw detection, small-angle flaw detection and oblique flaw detection. The vertical flaw detection is that a longitudinal wave straight probe vertically injects ultrasonic waves from the end face of an axle to detect whether the axle has damage and some material defects in the full length direction. The small-angle flaw detection is carried out on the end face of an axle by using a specific small-angle longitudinal wave probe aiming at the wheel seat, the brake disc seat, the axle diameter and other parts which can be damaged by the axle under the condition of not withdrawing the wheel. Oblique angle flaw detection generally uses transverse wave ultrasonic waves which are injected by a transverse wave oblique probe with a larger angle from the oblique direction of the axle body and the surface of the axle diameter, and the damage of a gear box seat, a brake disc seat and the like can be detected by oblique angle flaw detection.

According to the traditional ultrasonic detection method, detection must be performed from a plurality of detection surfaces for many times, and the vehicle body, the bogie and the axle box must be disassembled before detection, so that the operation is complex, the detection efficiency is low, professional knowledge and experience are required, and the requirement on detection personnel is high.

Disclosure of Invention

In order to overcome the defects in the prior art, the invention aims to provide a metallurgical vehicle axle detection device and a detection method, so that the detection method is simplified, and the detection is carried out under the condition that the end face of an axle is not disassembled, so that the detection efficiency is improved, and the detection difficulty is reduced.

In order to achieve the purpose, the technical scheme adopted by the invention is as follows: the utility model provides a metallurgical vehicle axletree detection device, is used for looking into detection mechanism with the sweeping of being surveyed the axletree complex, and with sweep the removal workstation that the detection mechanism electricity is connected, sweep and look into detection mechanism by with sweep and look into detection mechanism swing joint's actuating mechanism drive.

As a limitation of the present invention: the scanning detection mechanism comprises a phased array probe, an encoder and a pressure mechanism used for enabling the phased array probe to apply pressure to a detected vehicle axle, the phased array probe is connected with the pressure mechanism through a fixed clamping mechanism, the pressure mechanism is connected with the driving mechanism through a steering clamping mechanism, and the mobile workstation comprises a phased array flaw detector.

As a further limitation of the invention: the pressure mechanism comprises a movable rod and a fixed rod sleeved on the movable rod, the top end of the movable rod is provided with an upper spring seat, a lower spring seat is arranged on the fixed rod, a tension spring is arranged between the upper spring seat and the lower spring seat, the lower end of the movable rod is fixedly arranged on the fixed clamping mechanism, the fixed rod is fixedly arranged on the steering clamping mechanism, and the fixed clamping mechanism is used for changing the height of the steering clamping mechanism to apply pressure to the phased array probe through adjusting.

As a further limitation of the invention: the mobile workstation comprises a frame body, be provided with the phased array appearance of detecting a flaw with phased array probe and encoder electricity is connected on the frame body, still be provided with and be connected with actuating mechanism electricity, to the transformer that actuating mechanism provided the power, still be provided with the phased array probe through the peristaltic pump and the water tank that supply water the return circuit and link to each other, be used for providing the couplant to the phased array probe, still be provided with on the frame body with phased array appearance of detecting a flaw, transformer, peristaltic pump electricity are connected for provide the portable power source of power to phased array appearance of detecting a flaw, transformer, peristaltic pump.

As still further limiting the invention: the steering clamping mechanism comprises a vertical rod connected with the fixed rod, the vertical rod is detachably sleeved on the steering seat, the steering clamping mechanism further comprises a horizontal rod which is connected with the driving mechanism and perpendicular to the vertical rod, and the horizontal rod is detachably sleeved on the steering seat.

As still further limiting the invention: the driving mechanism comprises a scanning vehicle movably connected with the scanning detection mechanism.

As a further limitation of the invention: the steering seat comprises a first adjusting sleeve sleeved on the vertical rod and a second adjusting sleeve sleeved on the horizontal rod, the first adjusting sleeve is vertically and fixedly arranged on the second adjusting sleeve, the first adjusting sleeve and the second adjusting sleeve are respectively provided with an opening along the axial direction of the adjusting sleeve, and an adjusting nut used for adjusting the inner diameter of the first adjusting sleeve and the inner diameter of the second adjusting sleeve is arranged at the opening.

As a limitation of the present invention: the fixed clamping mechanism comprises an Contraband-shaped clamping block matched with the width of the phased array probe, and one side, facing the phased array probe, of the clamping block is provided with a clamping screw matched with a groove of the phased array probe.

The invention also discloses a metallurgical vehicle axle detection method which is realized by using the metallurgical vehicle axle detection device and comprises the following steps which are sequentially carried out,

equipment calibration: firstly, calibrating equipment, wherein the equipment calibration comprises sound velocity calibration, wedge block delay calibration, sensitivity calibration, TCG calibration and encoder calibration;

preparing on site: after equipment is calibrated, carrying out on-site preparation, wherein the on-site preparation comprises on-site environment preparation, vehicle preparation to be detected and wheel axle detection part preparation;

equipment installation: after the on-site preparation, equipment installation is carried out, the scanning detection mechanism is respectively connected with equipment on a mobile workstation, the parameters of the detected vehicle axle are measured and input into the scanning detection mechanism;

equipment debugging: after the equipment is installed, starting equipment debugging, starting a scanning detection mechanism, enabling the scanning detection mechanism to move circumferentially, and observing the working state of the scanning detection mechanism;

and (3) starting detection: after the equipment is debugged, starting detection, adjusting the scanning detection mechanism to the position of the equipment during calibration, starting a detection device, enabling the scanning detection mechanism to rotate and detect along the circumferential direction of the tested vehicle axle under the driving of the driving mechanism, and observing the crawling condition of the scanning detection mechanism;

and (4) finishing detection: and after the detection is finished, the detection data is stored, the scanning detection mechanism is closed, the equipment is disassembled and returned, and the detection site is cleaned.

As a limitation of the present invention: in the equipment calibration step, sound velocity calibration, wedge block delay calibration and sensitivity calibration are carried out on a test block with a standard reflector; TCG calibration is carried out on an ultrasonic flaw detection half shaft sample block; calibrating the encoder, selecting a single line for scanning type, entering calibration, controlling a scanning detection mechanism to move a given distance in the circumferential direction, clicking for calibration, automatically calculating the resolution of the encoder by the instrument, and setting the resolution in the instrument;

in the field preparation step, the field environment preparation comprises the steps of detecting whether the environment can ensure the illumination and power utilization safety or not and ensuring that no dangerous factors influencing the detection activity safety in the field can be generated in the detection process; preparing a vehicle to be detected, wherein the vehicle to be detected is guided by a dispatcher in an empty state and is transferred to a field, wheels are masked to prevent the vehicle from sliding and moving, and warning signs are arranged at front and rear remarkable positions of the vehicle to be detected and are watched by special persons; the preparation of the wheel axle detection part comprises the steps of checking the detection space of the wheel axle, removing dust and dirt on the surface of the wheel axle to enable the dust and the dirt not to influence the stable running of a scanning detection mechanism, polishing a scanning area, and removing a paint layer and iron slag until the surface roughness Ra is less than or equal to 12.5 mu m;

in the equipment installation step, the scanning detection mechanism is respectively connected with the equipment on the mobile workstation, the scanning vehicle is taken out of the mobile workstation, the scanning vehicle is placed at the approximate position of the axle to be measured, a proper amount of water is added into the water tank, and the water tank is connected with the peristaltic pump; placing a mobile power supply on a mobile workstation, and supplying power to a phased array flaw detector, a transformer and a peristaltic pump through a connecting circuit; installing a circuit and a pipeline at the probe end of the phased array, installing the phased array probe, a fixed clamping mechanism and a pressure mechanism, installing a steering clamping mechanism, enabling a horizontal rod to be on an extension line of the diameter of the axle, adjusting the position of a vertical rod to enable the phased array probe to be tightly attached to the axle, applying pressure to the axle through the pressure mechanism, and fixing the steering clamping mechanism; installing lines and pipelines at the end of a mobile workstation, connecting a phased array probe and a coder with a phased array flaw detector, connecting the phased array probe with a peristaltic pump through a silica gel water pipe, connecting a scanning vehicle with a transformer, and keeping enough stroke allowance; measuring and calculating the diameter and the perimeter of the detected axle, inputting the diameter and the perimeter into a phased array flaw detector, and debugging the phased array flaw detector to a working state;

the equipment debugging step comprises the steps of opening a water supply loop to open a circuit, providing a coupling agent for the probe, placing an instrument gate A at the depth position of the bottom surface, monitoring a detected area, controlling a scanning detection mechanism to move in a circumferential direction within a set range, observing the coupling condition of the phased array probe and displaying an instrument image, and compensating 3-6 dB gain as scanning gain according to the surface state of a workpiece if the sensitivity is weak; setting the scanning type as single line scanning: the scanning length is the sum of the circumference of the axle and the allowance of 20mm, and a certain coverage of the scanning detection mechanism after one circle of crawling is ensured;

in the detection starting step, starting the detection device, wherein the peristaltic pump is started to enable the couplant to wet the surface of the axle, the speed of the driving mechanism is adjusted to a proper range, and the driving mechanism drives the phased array probe and the encoder to rotate around the axle in a circle in the axial direction; observing the crawling condition of the scanning detection mechanism comprises observing whether a signal received by the phased array flaw detector is complete, if clear and complete, enabling the driving mechanism to quickly return to the original position to finish the test, otherwise, reducing the speed of the driving mechanism, reversely scanning and continuously recording until the acquired signal is clear and complete, and finishing the detection.

Due to the adoption of the technical scheme, compared with the prior art, the invention has the following beneficial effects:

the invention uses the phased array flaw detector to detect, and completes axle detection under the condition of not disassembling the vehicle body, so that the dynamic detection of the metallurgical vehicle axle becomes possible, the overhaul period of the vehicle is greatly shortened, the occurrence of vehicle failure accidents is avoided to the greatest extent, and the smooth production of enterprises is guaranteed; and detection device structure is ingenious, detects easy operation, need not professional knowledge, has reduced the requirement to the measurement personnel, has reduced the detection degree of difficulty and maintenance cost, has improved maintenance speed, can satisfy enterprise's production demand to realize the periodic detection, establish the vehicle and use archives, make axletree cold cut risk reduce, and then the periodic detection inspection business through the metallurgical vehicle of enterprise, provide data support for government department's supervision.

In conclusion, the axle detection is completed under the condition that the vehicle body is not disassembled, the detection steps are simplified, the detection difficulty is reduced, the detection efficiency is improved, and the axle detection device is suitable for detecting all large-size shaft workpieces, in particular for detecting axles of metallurgical vehicles.

Drawings

The invention is described in further detail below with reference to the figures and the embodiments.

Fig. 1 is a schematic structural view of a scanning detection mechanism and a driving mechanism in embodiment 1 of the present invention;

fig. 2 is a schematic structural diagram of a mobile workstation according to embodiment 1 of the present invention;

FIG. 3 is a front view of the scanning detection mechanism in embodiment 1 of the present invention;

FIG. 4 is a right side view of the scanning detection mechanism in embodiment 1 of the present invention;

fig. 5 is a top view of the scanning detection mechanism in embodiment 1 of the present invention.

In the figure: 1-phased array probe, 2-encoder, 3-clamping block, 4-clamping screw, 5-encoder connecting part, 6-fixed rod, 7-movable rod, 8-spring upper seat, 9-spring lower seat, 10-tension spring, 11-vertical rod, 12-horizontal rod, 13-steering seat, 131-first adjusting sleeve, 132-second adjusting sleeve, 133-adjusting lug, 134-adjusting nut, 14-scanning vehicle, 15-forward and backward switch, 16-walking speed adjusting button, 17-frame body, 18-frame body wheel, 19-phased array flaw detector, 20-transformer, 21-peristaltic pump, 22-water tank, 23-mobile power supply, 24-beam tube, 25-axle and 26-wedge block.

Detailed Description

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the metallurgical vehicle axle detection apparatus and method described herein are preferred embodiments, are provided for illustration and explanation only, and are not to be construed as limiting the present invention.

The terms "upper", "lower", "left", "right" and the like in the present invention are used in terms of orientation or positional relationship based on the drawings in the present specification, and are only for convenience of describing the present invention and simplifying the description, and are not intended to indicate or imply that a device or element must have a specific orientation, be constructed in a specific orientation and be operated, and thus should not be construed as limiting the contents of the present invention.

EXAMPLE 1 axle testing device for Metallurgical vehicle

In the embodiment, as shown in fig. 1 to 5, the axle detection device for the metallurgical vehicle comprises a scanning detection mechanism for being matched with a detected axle 25, and a mobile workstation electrically connected with the scanning detection mechanism, wherein the scanning detection mechanism is driven by a driving mechanism movably connected with the scanning detection mechanism.

The scanning detection mechanism comprises a phased array probe 1, a wedge 26 (the phased array probe 1 is arranged on the wedge 26), an encoder 2 and a pressure mechanism for pressing the phased array probe 1 to a detected axle 25, wherein the phased array probe 1 is connected with the pressure mechanism through a fixed clamping mechanism, the pressure mechanism is connected with a driving mechanism through a steering clamping mechanism, namely the phased array probe 1 is connected with the fixed clamping mechanism, the fixed clamping mechanism is connected with the pressure mechanism, the pressure mechanism is connected with the steering clamping mechanism, and the steering clamping mechanism is connected with the driving mechanism.

Fixed fixture includes "Contraband" shape grip block 3 with phased array probe 1 width looks adaptation, and detachable is provided with voussoir 26 and phased array probe 1 in the opening of grip block 3, is provided with in grip block 3 towards voussoir 26 one side with wedge 26 on recess assorted clamping screw 4, through screwing up clamping screw 4, fixes wedge 26 (and phased array probe 1) on grip block 3. The outer side of the clamping block 3 is also provided with an encoder connecting part 5 which is used for connecting the encoder 2 to the outer side of the clamping block 3 so that the encoder 2 moves along with the phased array probe 1.

The pressure mechanism comprises a movable rod 7 and a fixed rod 6 sleeved on the movable rod 7, an upper spring seat 8 is arranged at the top end of the movable rod 7, a lower spring seat 9 is arranged on the fixed rod 6, a tension spring 10 is arranged between the upper spring seat 8 and the lower spring seat 9, the lower end of the movable rod 7 is fixedly arranged at the center of the outer side of the fixed clamping mechanism, the fixed rod 6 is fixedly arranged on the steering clamping mechanism and moves downwards to the steering clamping mechanism, the fixed rod 6 moves downwards relatively, namely the movable rod 7 moves upwards relatively, so that the upper spring seat 8 arranged on the movable rod 7 moves upwards relatively, the tension spring 10 is stretched, the wedge block 26 applies pressure towards the axle center of the axle 25 to the axle 25, namely the pressure mechanism can change the pressure applied to the axle to be tested by the phased array probe 1 and the wedge block 26 through adjusting the height of the steering clamping mechanism.

The steering clamping mechanism comprises a vertical rod 11 connected with the fixing rod 6, the vertical rod 11 is detachably sleeved in a steering seat 13, the steering clamping mechanism further comprises a horizontal rod 12 which is used for being connected with the driving mechanism and perpendicular to the vertical rod 11, and the horizontal rod 12 is detachably sleeved on the steering seat 13. Turn to seat 13 including cup jointing in the first adjusting collar 131 of vertical pole 11, and cup joint in the second adjusting collar 132 of horizontal pole 12, first adjusting collar 131 sets firmly on second adjusting collar 132 perpendicularly, all be provided with the opening that sets up along the adjusting collar axial on first adjusting collar 131 and the second adjusting collar 132, all be provided with in open-ended both sides and adjust ear 133, be provided with the adjusting nut 134 that is used for adjusting two adjusting ear 133 intervals on adjusting ear 133, adjust two intervals of adjusting ear 133 through adjusting nut 134, and then adjust the internal diameter of first adjusting collar 131 and second adjusting collar 132.

One end of the horizontal rod 12, which is far away from the steering seat 13, is rotatably connected with a driving mechanism, a rod sleeve matched with the outer diameter of the horizontal rod 12 is arranged on the driving mechanism, and the horizontal rod 12 is rotatably connected with the driving mechanism by being sleeved in the rod sleeve. Further, the driving mechanism in the embodiment comprises a scanning vehicle movably connected with the scanning detection mechanism, the structure of the scanning vehicle is the same as that of a walking part in the CG2-11 pipeline cutting machine, and a forward and backward switch 15 and a walking speed adjusting button 16 are arranged on the scanning vehicle for the prior art. The scanning detection mechanism is driven to run on the axle 25 by the running of the scanning vehicle on the axle 25.

The scanning detection mechanism comprises a phased array probe 1, a wedge block 26 and an encoder 2, so that the scanning detection mechanism further comprises a mobile workstation electrically connected with the scanning detection mechanism. During testing, the scanning detection mechanism is driven by the driving mechanism to detect, and the workstation provides power supply and couplant for the scanning detection mechanism and collects detection signals. The mobile workstation includes the support body 17 on four layers, support body 17 is provided with the support body wheel 18 that makes things convenient for support body 17 to remove towards ground one end, phased array flaw detector 19 with phased array probe 1 and encoder 2 electricity connection has been placed on the top layer of support body 17, the second floor at support body 17 has been placed and has been connected with actuating mechanism electricity, transformer 20 to the actuating mechanism power supply, bottom at support body 17 is the fourth layer and has still been placed and pass through the silica gel water pipe with phased array probe 1 and link to each other and form the water supply return circuit, a peristaltic pump 21 and a water tank 22 for providing the couplant to phased array probe 1, place on the third layer of support body 17 with above-mentioned phased array flaw detector 19, transformer 20, peristaltic pump 21 electricity is connected, a portable power source 23 for providing the power to phased array flaw detector 19, transformer 20, peristaltic pump 21. The above-mentioned lines for electrical connection, as well as the water supply circuit piping, are covered by the bundle pipe 24.

Embodiment 2 axle detection method for metallurgical vehicle

The embodiment is a metallurgical vehicle axle detection method, which is realized by using the metallurgical vehicle axle detection device in the embodiment 1 and comprises the following steps which are carried out in sequence.

Equipment calibration: firstly, calibrating equipment, wherein the equipment calibration comprises sound velocity calibration, wedge block delay calibration, sensitivity calibration, TCG calibration and encoder 2 calibration;

the method comprises the following steps of carrying out sound velocity calibration, wedge block delay calibration and sensitivity calibration on a test block with a standard reflector, placing probes at different parts of the certified standard test block, and adjusting a reflected signal to a specified position to finish calibration;

TCG calibration is carried out on the ultrasonic flaw detection half shaft sample block: after setting sound, placing a gate A1 of a phase control array probe at a bottom wave position, moving the probe to find a near-end grooving defect, entering a calibration interface, selecting a calibration TCG, axially moving the probe back and forth to make all fan-swept angles strike the near-end grooving defect, automatically recording the maximum amplitude of each angle striking the defect by an instrument, displaying the maximum amplitude on an instrument screen in an envelope line mode, clicking for calibration when the amplitude of each angle is not changed, automatically compensating the amplitude of each angle by the instrument at the moment, and setting the reflected wave height of the defect of each angle after calibration to be 80% +/-5%;

verification of TCG in calibration mode: after calibration, the probe was moved axially back and forth to see if the envelope fluctuated within a threshold (80% ± 5%). If so, indicating that the calibration result is good and acceptable, and carrying out the next step of work;

calibrating the encoder 2, selecting a single line for scanning type, presetting the encoder 2 as 10-14 steps/mm, entering calibration, controlling the scanning detection mechanism to move for a given distance in the circumferential direction, clicking for calibration, automatically calculating the resolution of the encoder 2 by the instrument, and setting the resolution in the instrument;

it should be noted that, during the detection of multiple groups, the sound velocity calibration and the calibration of the encoder 2 are performed only once, and each of the wedge delay calibration, the sensitivity calibration and the TCG calibration needs to be performed separately, in this embodiment, the encoder 2 is preset to 12 steps/mm, and of course, other values within the range may also be selected according to actual situations, such as 10 steps/mm, 14 steps/mm, and the like.

Preparing on site: after equipment is calibrated, carrying out on-site preparation, wherein the on-site preparation comprises on-site environment preparation, vehicle preparation to be detected and wheel axle detection part preparation;

the field environment preparation comprises the steps of detecting whether the environment can ensure the illumination and power utilization safety or not, and ensuring that no dangerous factors influencing the detection activity safety are generated in the field in the detection process; the preparation of the vehicle to be detected comprises the steps that the metallurgical vehicle to be detected unloads a hot metal ladle, iron slag on the surface of a vehicle body is cleaned, the metallurgical vehicle is transferred to a maintenance site (namely a detection site) under the command of a dispatcher in an empty vehicle state, wheels are covered to prevent the vehicle from sliding and moving, and warning signs are arranged at the front and rear remarkable positions of the vehicle to be detected and are watched by special persons; the preparation of the wheel axle detection part comprises the steps of checking the detection space of the wheel axle 25, removing dust and dirt on the surface of the wheel axle 25 to enable the dust and the dirt not to affect the stable running of a scanning detection mechanism, polishing a scanning area, and removing a paint layer and iron slag until the surface roughness Ra is less than or equal to 12.5 mu m.

Equipment installation: after the on-site preparation, equipment installation is carried out, the scanning detection mechanism is respectively connected with equipment on a mobile workstation, the parameters of the axle 25 to be detected are measured and input into the scanning detection mechanism, and the scanning detection mechanism can be installed only under the condition of ensuring enough detection space and safety;

wherein, the connection of the scanning detection mechanism and the equipment on the mobile workstation respectively comprises that the driving mechanism, namely the scanning vehicle, is taken out from the mobile workstation, the scanning vehicle is placed at the approximate position of the axle 25 to be measured, a proper amount of water is added into the water tank 22, and the water tank 22 is connected with the peristaltic pump 21; a mobile power supply 23 is placed on a mobile workstation and supplies power to the phased array flaw detector 19, the transformer 20 and the peristaltic pump 21 through a connecting line; installing a circuit and a pipeline at the end of the phased array probe 1, installing the phased array probe 1, a fixed clamping mechanism and a pressure mechanism, installing a steering clamping mechanism, enabling the horizontal rod 12 to be on the extension line of the diameter of the axle 25, adjusting the position of the vertical rod 11 to enable the phased array probe 1 to be tightly attached to the axle 25, applying pressure to the axle 25 through the pressure mechanism, and fixing the steering clamping mechanism; installing lines and pipelines at the end of a mobile workstation, connecting a phased array probe 1 and an encoder 2 with a phased array flaw detector 19, connecting the phased array probe 1 with a peristaltic pump 21 through a silica gel water pipe, connecting a scanning vehicle with a transformer 20, and keeping enough stroke allowance; the diameter and the perimeter of the tested vehicle axle 25 are measured and calculated, and are input into the phased array flaw detector 19, and the phased array flaw detector 19 is debugged to be in a working state.

Equipment debugging: after the equipment is installed, starting equipment debugging, opening a water supply loop to provide a coupling agent for the probe, preventing severe abrasion of a wedge block 26 caused by dry friction in the debugging process, placing an instrument gate A at the depth position of the bottom surface, monitoring a detected area, controlling the scanning detection mechanism to move in a circumferential direction within a set range, observing the crawling condition of the scanning detection mechanism, the coupling condition of the phased array probe 1 and the display of an instrument image, if the sensitivity is weaker, compensating 3-6 dB gain as scanning gain according to the surface state of a workpiece until the sensitivity reaches a standard, and completing the setting to prepare for starting detection; .

And (3) starting detection: after the equipment is debugged, the detection is started, the safety state of the vehicle to be detected is confirmed again, after the vehicle to be detected is communicated with a person specially monitoring the peripheral situation, the detection person enters a detection post to check whether the connection of the equipment is correct or not and whether the performance is normal or not, the scanning detection mechanism is adjusted to the position when the equipment is calibrated, the detection device is started, the scanning detection mechanism is driven by the driving mechanism to rotate in the circumferential direction of the axle 25 to be detected for at least one circle, and the crawling situation of the scanning detection mechanism is observed;

the starting detection device comprises a peristaltic pump 21, a coupling agent is started to wet the surface of an axle 25, the scanning type is a single-line scanning, the speed of a driving mechanism is adjusted to the lowest gear, a forward and backward switch 15 is turned on to start a scanning vehicle, the speed is adjusted to a proper range, the driving mechanism drives a phased array probe 1 and an encoder 2 to rotate axially around the axle 25 to scan, the scanning length is the sum of the circumference of the axle 25 and the allowance of 20-30 mm, and the scanning detection mechanism is guaranteed to have certain coverage after crawling for one circle; observing the crawling condition of the scanning detection mechanism comprises observing whether a signal received by the phased array flaw detector 19 is complete, if clear and complete, enabling the driving mechanism to quickly return to the original position to finish the test, otherwise, reducing the speed of the driving mechanism, reversely scanning and continuously recording until the acquired signal is clear and complete, and finishing the detection;

further, in the present embodiment, the scanning length is the circumference of the axle 25 plus a margin of 20mm, but other values within the range may be selected according to actual conditions, for example, the margin may be adjusted to 25mm or 30 mm.

And (4) finishing detection: after the detection is finished, the peristaltic pump 21 is closed, the detection data of the phased array flaw detector 19 are stored for later inspection, the scanning detection mechanism is closed, the equipment is disassembled and returned, and the detection site is cleaned;

wherein, the equipment is disassembled and returned, and the repeated reverse operation of the step of respectively connecting the scanning detection mechanism with the equipment on the mobile workstation is realized.

The invention uses the phased array flaw detector to detect, and completes axle detection under the condition of not disassembling the vehicle body, so that the dynamic detection of the metallurgical vehicle axle becomes possible, the overhaul period of the vehicle is greatly shortened, the occurrence of vehicle failure accidents is avoided to the greatest extent, and the smooth production of enterprises is guaranteed; and detection device structure is ingenious, detects easy operation, need not professional knowledge, has reduced the requirement to the measurement personnel, has reduced the detection degree of difficulty and maintenance cost, has improved maintenance speed, can satisfy enterprise's production demand to realize the periodic detection, establish the vehicle and use archives, make axletree cold cut risk reduce, and then the periodic detection inspection business through the metallurgical vehicle of enterprise, provide data support for government department's supervision.