The Development Of An Automatic Ultrasonic Flawdetetecting System For Wheel-Sets

The bogies of freight railway vehicles play a vital role for the running performance. Shaft is a key components, and the features of its quality affect the operation of the railway’s safety. Taking effective means in the process of vehicle manufacture, overhaul shaft defects and processed in a timely manner, which to improve the quality of truck manufacturing, maintenance, ensure the safety of transportation,it plays a key role. With the rapid development of railway, new models, the new shaft type continuously using, wheel and axle inspection in vehicle maintenance link appears more important. At present, the detection of vehicle axle means mainly rely on manual ultrasonic testing, this way of flaw detection efficiency is low, the operator working strength is large, and also poor reliability. For the existing shaft automatic ultrasonic flaw detector, exist in the process of inspection application actual design unreasonable, poor detection accuracy, and many other problems.This paper has been developed for axle of wheel seat insert, journal roots, large shaft body crack and so on to realize automatic ultrasonic flaw detection equipment, hope to effectively address the shortcomings of the current detection means, improve the efficiency and reliability of wheel shaft of ultrasonic flaw detection.Stiffness and strength in terms of mechanical system, to choose a higher profile for structural design, improve the stability. Wheel mechanism adopts the mechanical buffer stable, conform to the requirements of the relevant regulations. Probe movement adopts high precision servo, stepper motor drive screw, to ensure reliability and detection precision, use small Angle probe to enhance detection coverage.In the aspect of control system and electrical control, select the DMC motion control card detection motion control, error compensation PID control method by error compensation, feed forward repetitive positioning based on the analysis on the positioning error, high stability, positioning accuracy can reach 0.005mm, in the probe and the axle contact portion coupled liquid automatic control spray in the inspection process the probe, reduce wear, testing process can be automatic flaw detection or manual inspection choice, reduce labor intensity, improve work efficiency of inspection personnel. The design of electrical system, through the shielding processing, electric control cabinet noise reduction measures of overall planning, transmission line for placing the layout of each part of the equipment, reduces the system noise and compiled the control software program, coordination realize parallel operation, coordination management, function module, response type operation, realize the information management of operation personnel, ultrasonic data curve display, internal cracks found calculation alarm, crack location, self-test, wheel flaw detection result storage, access, print and other functions.Testing machine developed by debugging, commissioning and overall performance testing machine of the automated testing process, manual automatic conversion; User login and user information management, parameter setting, self-check, performance, defect waveform analysis and judgement, inspection results, record, store and print functions such as operations meet the design requirements, ensure detection efficiency of the process, the veracity and reliability of testing results.