阅读说明：本技术 一种可定位道岔疲劳裂纹的监测方法及其系统装置 (Monitoring method capable of positioning fatigue crack of turnout and system device thereof ) 是由 林俊明 黄凤英 毛昆朋 高东海 沈淮 于 2021-07-27 设计创作，主要内容包括：本发明一种可定位道岔疲劳裂纹的监测方法及其系统装置,用于铁路交通轨道或道岔等的钢轨(1)的裂纹损伤在役监测,通过无线传输电连接于中心处理计算机(2),监测装置包括在钢轨表面涂覆带有沿着轨道纵向方向延伸的若干条导电金属线(13)、电联接于各导电金属线(13)之间阵列分布排列的若干相同电阻值的电阻器(14)、以及检测控制器(3),其特征在于检测控制器(3)包括电源(31)、感应开关(32)、PLC编程控制器(33)、模拟开关(34)、电阻测量仪(35)和数据存储器(36)；其中,PLC编码控制器(33)和模拟开关(34)控制电阻测量仪(35)检测接点与导电金属线(13)节点的接通和断开,切换形成不同的电阻测量电回路。本发明通过分析计算电阻值的变化,实现判定裂纹的具体位置,在粗略检测判定一长段道岔等的钢轨是否存在裂纹缺陷的基础上,实现进一步精确裂纹的具体位置。(The invention relates to a monitoring method capable of positioning fatigue cracks of a turnout and a system device thereof, which are used for in-service monitoring of crack damage of a steel rail (1) of a railway traffic track or the turnout and the like and are electrically connected with a central processing computer (2) through wireless transmission, wherein the monitoring device comprises a plurality of conductive metal wires (13) which are coated on the surface of the steel rail and extend along the longitudinal direction of the track, a plurality of resistors (14) which are electrically connected among the conductive metal wires (13) and have the same resistance value and are distributed in an array manner, and a detection controller (3), and is characterized in that the detection controller (3) comprises a power supply (31), an inductive switch (32), a PLC (33), an analog switch (34), a resistance measuring instrument (35) and a data memory (36); the PLC (33) and the analog switch (34) control the connection and disconnection of the detection contact of the resistance measuring instrument (35) and the node of the conductive metal wire (13), and different resistance measuring circuit loops are formed by switching. The method realizes the judgment of the specific position of the crack by analyzing and calculating the change of the resistance value, and realizes the further accurate specific position of the crack on the basis of roughly detecting and judging whether the steel rail of a long section of turnout and the like has crack defects.)

1. A method for monitoring fatigue cracks of a positionable turnout is characterized in that a plurality of conductive metal wires extending along the longitudinal direction of a track are coated on the surface of a steel rail, and a plurality of resistors with the same resistance value are distributed in an electrically connected array mode among the conductive metal wires, and the specific method comprises the following steps:

a. forming a conductive loop: selecting two conductive metal wires to form a conductive loop;

b. detecting a resistance value: detecting the total resistance value in the conductive loop in the step a;

c. calculating and analyzing resistance value: and b, calculating a total resistance value R0= R/n (n resistors with the same resistance value (resistance value = R) are connected in parallel) by the resistance value detected in the step b through a plurality of resistors connected in parallel, and when the resistance value is larger than the threshold value of the total resistance value R0, reversely calculating the number of the resistors connected with the actual electric connection through the resistance value, and determining the disconnection position of the conductive metal wire.

2. The method for monitoring positionable switch fatigue cracks as claimed in claim 1, wherein said forming conductive loops in step a further comprises sequentially selecting two-by-two arrangements of conductive metal wires to be combined into electrical loops through analog switches of a PLC controller, and said detecting resistance value in step b is sequentially measuring resistance values between all the electrical loops combined in two-by-two arrangements through the PLC controller.

3. The method for monitoring positionable switch fatigue cracks according to claim 2, wherein in the step c, the resistance value is calculated and analyzed, and the switch fatigue cracks are analyzed and judged to be at specific positions of the conductive metal wire and the resistor by comparing the resistance value detected when the same conductive metal wire is compared with two or more other conductive metal wires.

4. The method for monitoring positionable switch fatigue cracks according to claim 3, wherein the calculation and analysis of the resistance value further comprises a crack length determination analysis, and whether the crack penetrates through two or more conductive metal wires is determined by calculating and analyzing the abnormal resistance value of the conductive metal wire beside the abnormal conductive metal wire so as to confirm the length trend of the crack.

5. The method for monitoring positionable switch fatigue cracks of claim 1, wherein a plurality of resistors are distributed in an electric connection array among the conductive metal wires and are thin film resistors coated on the switch surface simultaneously with the conductive metal wires.

6. A monitoring device capable of positioning fatigue cracks of turnout junctions comprises a plurality of conductive metal wires (13) extending along the longitudinal direction of a track, resistors (14) electrically connected among the conductive metal wires (13) and distributed in an array mode and having a plurality of same resistance values, and a detection controller (3), and is characterized in that the detection controller (3) comprises a power supply (31), an induction switch (32), a PLC (programmable logic controller) (33), an analog switch (34), a resistance measuring instrument (35) and a data storage device (36); the PLC (33) and the analog switch (34) control the connection and disconnection of the detection contact of the resistance measuring instrument (35) and the node of the conductive metal wire (13), and different resistance measuring circuit loops are formed by switching.

7. The switch fatigue crack locatable monitoring device of claim 6, wherein the induction switch (32) of the detection controller (3) turns on the power supply device when detecting that a vehicle passes through, and all the conductive metal wires (13) are connected to form a resistance detection electric loop through the sequential pairwise arrangement and combination of the PLC (33) and the analog switch (34) so as to complete one round of detection and the sequential resistance value detection set by the PLC (33).

8. A monitoring system capable of positioning fatigue cracks of turnout comprises a power supply module (41), an analog switch module (42), a data transmission module (43) and a calculation analysis module (44); the vehicle-mounted power supply is characterized in that the power supply module (41) further comprises an inductive switch module (411) for detecting the passing of a vehicle; the analog switch module (42) comprises a conductive loop combination module (421) for combining conductive metal wires into a loop; the data transmission module (43) comprises a data storage module (431) for storing the detection data and a wireless transmission module (432) for transmitting the data; a crack location analysis module (441).

9. The monitoring system for locating the fatigue crack of the turnout junction according to claim 8, wherein the conductive loop combination module (421) further comprises a PLC programming switch switching module (422) for sequentially switching each loop to perform resistance value detection, so as to cooperate with each loop formed by the conductive metal wires arranged two by two to perform sequentially switching to perform resistance value detection in turn.

10. A system for monitoring positionable switch fatigue cracks according to claim 8 or 9, wherein said calculation and analysis module (44) further comprises a crack size and length analysis module 442, for determining whether the crack penetrates two or more conductive metal wires by calculating and analyzing abnormal resistance of the conductive metal wires beside the abnormal conductive metal wire to confirm the length of the crack.

Technical Field

The invention relates to the technical field of nondestructive testing, in particular to a long-term monitoring and detecting technology for online monitoring of surface cracks of railway switches and the like, and particularly relates to a monitoring method capable of positioning fatigue cracks of switches and a system device thereof.

Background

The method is suitable for long-term monitoring devices of in-service railway tracks and the like, for example, a track surface process with corrosion prevention and monitoring functions and a detection method thereof disclosed in Chinese patent publication CN113030189A, and can be used for long-term in-service monitoring of railway traffic, particularly fatigue cracks of turnouts. However, the method only judges whether the long rail turnout has cracks, and cannot position the specific crack position, and for the railway track, the length of a long section of turnout is generally from 10 meters to hundreds of meters, and if an alarm is given, the crack position is not easy to find. Moreover, most cracks are fine and are likely to be detected only under the condition that a vehicle passes by, the cracks are difficult to visually observe, the occurrence of the cracks is only roughly judged, the defects are far from enough, and further accurate positioning of the specific positions of the cracks and even judgment of the sizes and the shapes of the cracks are very necessary.

Aiming at the problems of the defects, the invention adopts the following technical scheme.

Disclosure of Invention

The invention aims to provide a monitoring method capable of positioning fatigue cracks of turnout and a system device thereof, and the disclosed technical scheme is as follows:

a monitoring method for locating fatigue crack of turnout is used for long-term in-service monitoring of crack damage of steel rails of railway traffic tracks or turnouts and the like, and is characterized in that the surface of the steel rail is coated with a plurality of conductive metal wires extending along the longitudinal direction of the track and a plurality of resistors with the same resistance value are distributed and arranged in an array mode in which the conductive metal wires are electrically connected, and the specific method comprises the following steps:

a. forming a conductive loop: selecting two conductive metal wires to form a conductive loop;

b. detecting a resistance value: detecting the total resistance value in the conductive loop in the step a;

c. calculating and analyzing resistance value: and b, calculating a total resistance value R0= R/n (n resistors with the same resistance value (resistance value = R) are connected in parallel) by the resistance value detected in the step b through a plurality of resistors connected in parallel, and when the resistance value is larger than the threshold value of the total resistance value R0, reversely calculating the number of the resistors connected with the actual electric connection through the resistance value, and determining the disconnection position of the conductive metal wire.

Taking the example that the total length of the switch is 10M and the resistors with the resistance R =10K are placed at intervals of 1 meter, that is, the total number of the resistors is n = 10. When 10K resistors are arranged in an equally spaced array and connected in parallel to the conductive metal lines a1 and a2, the resistance in the measuring loop is 1K Ω, and the system shows normal and the switch has no crack. When the middle metal line is disconnected and only 5 10K Ω resistors are connected in parallel, the measured resistance value is about 2K Ω. Thus, the crack is judged to be in the middle 5M of the turnout. In the detection calculation, the resistance value of the conductive metal wire is only several ohms or tens of ohms, so that the resistance value is ignored by rounding in the calculation analysis.

Further, the step a of forming the conductive loop further includes sequentially selecting two electric loops of the conductive metal wires to be arranged and combined through an analog switch of the PLC controller, and the step b of detecting the resistance value is to sequentially measure the resistance value between all the electric loops to be arranged and combined through the PLC controller.

And in the step c, in the calculation and analysis of the resistance value, the switch crack is analyzed and judged to be positioned on the specific positions of the conductive metal wire and the resistor by comparing the resistance values detected when the same conductive metal wire is compared with two or more other conductive metal wires. Like a conductive metal wire A0 and A2, and A0 and A3 which are arranged in pairs to form an electric circuit, when the detected total resistance values are that A0 and A2 are abnormal and the combination of A0 and A3 is a normal value, the crack is judged to be on the corresponding resistor of the conductive metal wire A2.

Furthermore, the calculation and analysis of the resistance value also comprises judgment and analysis of the crack length, and whether the crack penetrates through two or more conductive metal wires is judged by calculating and analyzing the abnormal resistance value condition of the conductive metal wire beside the abnormal conductive metal wire so as to confirm the length trend of the crack. When it is determined that the conductive metal line a2 is abnormally cracked as described above, the detection values of the conductive metal lines a1 and A3 near a2 are extracted as references, and if the conductive metal line a1 is cracked at the same position, it may be determined that the crack extends on the conductive metal line a2, or if A3 is cracked at the same position, it may be determined that the crack extends on the conductive metal line a2, and it may be determined that the length of the crack is calculated.

The electric connection array among each conductive metal wire is distributed with a plurality of resistors which are thin film resistors coated on the surface of the turnout simultaneously with the conductive metal wires.

The invention also discloses a monitoring device capable of positioning fatigue cracks of the turnout, which is used for monitoring the crack damage of the steel rail (1) of a railway traffic track or the turnout and the like in service and is electrically connected with a central processing computer (2) through wireless transmission, the monitoring device comprises a plurality of conductive metal wires (13) which are coated on the surface of the steel rail and extend along the longitudinal direction of the track, a plurality of resistors (14) which are electrically connected among the conductive metal wires (13) and have the same resistance value and are distributed in an array manner, and a detection controller (3), and is characterized in that the detection controller (3) comprises a power supply (31), an inductive switch (32), a PLC (33), an analog switch (34), a resistance measuring instrument (35) and a data memory (36); the PLC (33) and the analog switch (34) control the connection and disconnection of the detection contact of the resistance measuring instrument (35) and the node of the conductive metal wire (13), and different resistance measuring circuit loops are formed by switching.

When the vehicle is detected to pass through, the power supply device is started by the inductive switch (32) of the detection controller (3), all the conductive metal wires (13) are sequentially connected in a pairwise arrangement and combination mode through the PLC (programmable logic controller) and the analog switch (34) to form a resistance detection electric loop, and one round of resistance value detection in a sequence set by the PLC (33) is completed.

And the detection controller (3) also comprises a data transmission module (37) which is set to be in a wireless data transmission module structure.

The invention also discloses a monitoring system capable of positioning the fatigue cracks of the turnout, which comprises a power supply module (41), an analog switch module (42), a data transmission module (43) and a calculation analysis module (44); the vehicle-mounted power supply is characterized in that the power supply module (41) further comprises an inductive switch module (411) for detecting the passing of a vehicle; the analog switch module (42) comprises a conductive loop combination module (421) for combining conductive metal wires into a loop; the data transmission module (43) comprises a data storage module (431) for storing the detection data and a wireless transmission module (432) for transmitting the data; a crack location analysis module (441).

Furthermore, the conductive circuit combination module (421) further comprises a circuit formed by sequentially arranging and combining the conductive metal wires in pairs, and the analog switch module (42) further comprises a PLC programming switch switching module (422) for sequentially switching the circuits to detect the resistance value, so that the circuits formed by the conductive metal wires arranged in pairs are sequentially switched to detect the resistance value in turn.

Further, the calculation and analysis module (44) further includes a crack size and length analysis module 442, which determines whether the crack penetrates through two or more conductive metal lines by calculating and analyzing the abnormal resistance of the conductive metal line beside the abnormal conductive metal line, so as to determine the length of the crack.

According to the technical scheme, the invention has the following beneficial effects:

the invention discloses a monitoring method capable of positioning fatigue cracks of a turnout, which is characterized in that strip-shaped metal wires are distributed and coated on the special key positions of the turnout, such as the rail bottom, the rail bottom corner and the rail waist, a resistor (a common resistor or a printed resistor) is arranged on each strip-shaped metal wire at intervals, the resistance value between the metal wires is measured, the specific position of the crack is judged by analyzing and calculating the change of the resistance value, and the specific position of the crack is further accurately realized on the basis of roughly detecting and judging whether the rail of a long turnout and the like has crack defects;

secondly, the technical scheme of the invention also analyzes and judges the concrete positions of the turnout cracks on the conductive metal wire and the resistor by comparing the resistance values detected when the same conductive metal wire is compared with two or more other conductive metal wires, thereby realizing more accurate judgment of which conductive metal wire the crack is positioned on;

and thirdly, the technical method judges whether the crack penetrates through two or more conductive metal wires by calculating and analyzing the abnormal resistance value of the conductive metal wire beside the abnormal conductive metal wire, so as to realize more accurate analysis and confirm the size, the length and the trend of the crack.

Drawings

FIG. 1 is a schematic flow chart of a method according to a preferred embodiment of the present invention;

FIG. 2 is a schematic diagram of a circuit structure of a method flow according to the preferred embodiment of the present invention;

FIG. 3 is a schematic diagram of a circuit structure of a method flow according to the preferred embodiment of the present invention;

FIG. 4 is a schematic diagram illustrating a usage status of the preferred embodiment of the present invention;

FIG. 5 is a schematic diagram of a detection controller according to a preferred embodiment of the present invention;

FIG. 6 is a system diagram of the preferred embodiment of the present invention;

FIG. 7 is a schematic process flow diagram of the preferred embodiment of the present invention.

Detailed Description

The invention is further described with reference to the following drawings and detailed description.

As shown in the flow chart of the method in fig. 1, a monitoring method for locating fatigue cracks of a turnout is used for long-term in-service monitoring of crack damage of a steel rail of a railway traffic track or the turnout and the like, and is characterized in that the surface of the steel rail is coated with a plurality of conductive metal wires extending along the longitudinal direction of the track, and a plurality of resistors with the same resistance value are distributed and arranged in an array mode in which the conductive metal wires are electrically connected, and the specific method comprises the following steps:

a. forming a conductive loop: selecting two conductive metal wires to form a conductive loop;

b. detecting a resistance value: detecting the total resistance value in the conductive loop in the step a;

c. calculating and analyzing resistance value: and b, calculating a total resistance value R0= R/n (n resistors with the same resistance value (resistance value = R) are connected in parallel) by the resistance value detected in the step b through a plurality of resistors connected in parallel, and when the resistance value is larger than the threshold value of the total resistance value R0, reversely calculating the number of the resistors connected with the actual electric connection through the resistance value, and determining the disconnection position of the conductive metal wire.

As shown in the circuit configuration in fig. 2, taking a resistor with a resistance value R =10K, a total switch length of 10M, and 1 resistor placed at intervals of 1 meter as an example, that is, n =10 resistors are placed in total. When 10K resistors are arranged in an equally spaced array and connected in parallel to the conductive metal lines a1 and a2, the resistance in the measuring loop is 1K Ω, and the system shows normal and the switch has no crack. When the middle metal line is disconnected and only 5 10K Ω resistors are connected in parallel, the measured resistance value is about 2K Ω. Thus, the crack is judged to be in the middle 5M of the turnout. In the detection calculation, the resistance value of the conductive metal wire is only several ohms or tens of ohms, so that the resistance value is ignored by rounding in the calculation analysis.

Further, the step a of forming the conductive loop further includes sequentially selecting two electric loops of the conductive metal wires to be arranged and combined through an analog switch of the PLC controller, and the step b of detecting the resistance value is to sequentially measure the resistance value between all the electric loops to be arranged and combined through the PLC controller.

And as shown in fig. 3, in the calculation and analysis of the resistance value in the step c, the switch crack is analyzed and judged to be located at the specific position of the conductive metal wire and the resistor by comparing the resistance value detected when the same conductive metal wire is compared with two or more other conductive metal wires. Like a conductive metal wire A0 and A2, and A0 and A3 which are arranged in pairs to form an electric circuit, when the detected total resistance values are that A0 and A2 are abnormal and the combination of A0 and A3 is a normal value, the crack is judged to be on the corresponding resistor of the conductive metal wire A2.

Furthermore, the calculation and analysis of the resistance value also comprises judgment and analysis of the crack length, and whether the crack penetrates through two or more conductive metal wires is judged by calculating and analyzing the abnormal resistance value condition of the conductive metal wire beside the abnormal conductive metal wire so as to confirm the length trend of the crack. When it is determined that the conductive metal line a2 is abnormally cracked as described above, the detection values of the conductive metal lines a1 and A3 near a2 are extracted as references, and if the conductive metal line a1 is cracked at the same position, it may be determined that the crack extends on the conductive metal line a2, or if A3 is cracked at the same position, it may be determined that the crack extends on the conductive metal line a2, and it may be determined that the length of the crack is calculated.

The resistors are thin film resistors which are coated on the surface of the turnout simultaneously with the conductive metal wires.

As shown in fig. 4 and fig. 5, the invention also discloses a monitoring device for locating fatigue crack of turnout, which is used for monitoring crack damage of steel rail 1 of railway traffic track or turnout, etc. in service, and is electrically connected with the central processing computer 2 through wireless transmission, the monitoring device comprises a plurality of conductive metal wires 13 which are coated on the surface of the steel rail and extend along the longitudinal direction of the track, a plurality of resistors 14 which are electrically connected with the conductive metal wires 13 and are distributed in array and arranged with the same resistance value, and a detection controller 3, and is characterized in that the detection controller 3 comprises a power supply 31, an inductive switch 32, a PLC programmed controller 33, an analog switch 34, a resistance measuring instrument 35 and a data memory 36; the PLC 33 and the analog switch 34 control the connection and disconnection between the detection contact of the resistance measuring instrument 35 and the node of the conductive metal wire 13, and different resistance measuring circuit loops are formed by switching.

When the inductive switch 32 of the detection controller 3 detects that a vehicle passes through, the power supply device is turned on, and all the conductive metal wires 13 are sequentially connected in pairs through the PLC 33 and the analog switches 34 to form a resistance detection electric loop, so that one round of resistance value detection in a sequence set by the PLC 33 is completed.

And, the detection controller 3 further comprises a data transmission module 37 configured to wirelessly transmit data.

As shown in FIG. 6, the invention also discloses a monitoring system capable of positioning fatigue cracks of turnout, wherein the monitoring system 4 comprises a power module 41, an analog switch module 42, a data transmission module 43 and a calculation analysis module 44; the power module 41 is characterized by further comprising an inductive switch module 411 for detecting the passing of the vehicle; the analog switch module 42 includes a conductive loop combination module 421 for combining conductive metal wires to form a loop; the data transmission module 43 comprises a data storage module 431 for storing the detection data and a wireless transmission module 432 for transmitting the data; crack location analysis module 441.

Further, the conductive loop combination module 421 further includes a PLC programming switch switching module 422 for sequentially switching each loop to perform resistance value detection, so as to sequentially switch each loop formed by the conductive metal wires arranged and combined in pairs to perform resistance value detection in turn.

Further, the calculation and analysis module 44 further includes a crack size and length analysis module 442, which determines whether the crack penetrates through two or more conductive metal lines by calculating and analyzing the abnormal resistance of the conductive metal line beside the abnormal conductive metal line, so as to determine the length of the crack.

In the rail surface coating treatment of turnout and the like, in the D0, the rail 1 is not surface-treated, a first anticorrosion insulating layer 111 is sprayed on the rail bottom and rail web parts of the rail which are most prone to crack breakage in the D1 process, the elongated conductive metal wires 112 and the resistors 113 which are arranged in pairs and electrically connected with each other and have the same resistance value are transversely distributed and sprayed on the anticorrosion insulating layer 111 in the D2 process, and a second anticorrosion insulating layer 114 is sprayed on the surface of the rail with the conductive metal wires 112 and the resistors 113 in the D3 process in a covering mode.

The above is one embodiment of the present invention. Furthermore, it is to be understood that all equivalent or simple changes in the structure, features and principles described in the present patent concepts are included in the scope of the present patent.