Design And Implementation Of Corrugation Inspection Car Based On Chord Measurement Theory

Rail corrugation is rail top surface along the longitudinal distribution of periodic similar wave characteristics of irregularity phenomenon, and becomes a major form of orbital damage. In recent years, with the vigorous development of high-speed rail, subway and light rail transport sector, corrugation problem has become more serious. Due to unavoidable of corrugation has an enormous impact on wheel-rail vibration and noise, we need more testing equipment to detect and analyze the corrugation to give enough preparation for the prevention and service. Therefore, this paper aims to design a convenient hand-push corrugation inspection car, mainly to complete the quality inspection after maintained and polished the rail.Compared the commonly used corrugation detection method at home and abroad, this paper introduced the two methods, based on the inertial reference method and chord measuring method. Paper chose the chord measuring method for providing basic algorithm to the detection car, based on its simple little affected by speed and reduced deficiency by advanced sensor technology.The overall design was completed in the paper that met the various functions by analyzed inspection tasks and developed measurement programs, according to the demands of the general performance, including three systems: mechanical systems, measurement system, data analysis and display system. Corrugation car was designed to be a H-type structure, having two track continuous measurement. At the same level of 160 rolls with specific interval contacting with the rail were installed in the bottom of the corrugation car, which was equivalent to a reference orbit and walking wheels. Every components of the corrugation car modelled all in Pro/E5.0 software were designed in detail, and carried out static strength analysis and modal analysis by ANSYS software in order to ensure the strength of the body at the same time to consider the impact of the vibration. According to the theory of chord measurement method, the paper developed the test scheme for the car, mainly to complete the measurement of the rail corrugation parameters. In the process of measuring the car, the displacement sensors and the rotary encoders installed in the car can measure amplitude and distance of corrugation in real time and pass the data to the host computer. The host computer can display and store the real-time and historical data through having several control functions by developed LabVIEW software.