1 Scope
This document specifies the conditions of use of the rail flaw detection car. Technical requirements, inspection and test methods, inspection rules, marking, packaging and transport of the machine.
This document applies to the design, manufacture and inspection of rail flaw detection vehicles (hereinafter referred to as "flaw detection vehicles") using ultrasonic technology for use on 1435 mm gauge railways. The flaw detection vehicle of non-standard gauge railways may refer to the implementation.
2 normative reference documents
The content of the following documents through the normative references in the text and constitute the essential provisions of this document. Among them, note the date of the reference document, only the date of the corresponding version applies to this document; do not note the date of the reference document, its latest version (including all the revision of the list) applies to this document.
GB/T17426 Assessment and test methods for the dynamic performance of special railway vehicles and track machinery
GB/T 25336-2018 Inspection and test methods for railway large road maintenance machinery
GB/T 25337-2018 General technical conditions for railway large road maintenance machinery
3 Terminology and definitions
The following terms and definitions apply to this document.
3.1
Rail flaw detection vehicle
Installed with rail flaw detection device, can detect and record rail defects in operation of large road maintenance machinery.
3.2
Echo pattern
ultrasound echo B_ scan pattern
B-shaped graphical display of ultrasound echo formation.
3.3
Detection of dection
Artificial or natural injuries are identified.
3.4
fixed ultrasound echo B_ scan pattern
A repeatable pattern of non-manual injury echoes at a location on the test line.
3.5
false alarm
A pattern of non-manual or unnatural injury echoes, other than fixed echoes, that is identified.
3.6
Artificial damage detection rate detetion rate
The ratio of the number of manual injuries detected to the number of manual injuries actually set in a test line.
False alarm rate
Ratio of the number of false alarms to the actual number of manual injuries set for a test line.
4 Conditions of use
4.1 Environmental conditions
4.1.1 Ambient temperature: -15 C to +50 C, low temperature areas require -25 C to +50 C.
4.1.2 Altitude 2500 m and below, high altitude areas require altitude 5100 m and below.
4.1.3 Relative humidity should not be greater than 95% (monthly average minimum temperature of 25 C).
4.1.4 There shall be wind, sand, rain and snow.
4.1.5 It shall be possible to meet the requirements of day and night operations.
4.2 Line conditions
4.2.1 Maximum line height: 180 mm.
4.2.2 Maximum line gradient: 33%.
4.2.3 Minimum passing curve radius: 180 m.
4.2.4 Minimum working curve radius: 250 m.
5 Technical requirements
5.1 Complete vehicle requirements
5.1.1 Comply with the provisions of 5.1~5.18.5.22.5.23 in GB/T 25337-2018.
5.1.2 The maximum self-running speed and the maximum attachment speed shall not be less than 120 km/h.
5.1.3 The maximum speed of flaw detection on flat lines shall not be less than 60 km/h.
5.1.4 The dynamics of the whole vehicle shall conform to the provisions of GB/T 17426.
5.1.5 Meet the needs of 50kg/m~75kg/m in-service rail flaw detection operation.
5.1.6 It can be driven and inspected in both directions.
5.1.7 shall be equipped with monitoring devices to ensure operational safety, such as wireless train regulation. Locomotive signal, operation monitoring device. Axle temperature alarm device, etc.
5.1.8 The requirements of high-altitude rail flaw detection vehicle shall conform to the provisions of Chapter 7 of GB/T 25337- 2018.
5.2 Vehicle system (components) technical requirements.
5.2.1 Power transmission system
5.2.1.1 Shall comply with the provisions of 6.1 in GB/T 25337-2018.
5.2.1.2 Two sets of power systems shall be used as a backup to each other.
5.2.1.3 The capacity of the fuel tank should meet the needs of continuous operation of 1200km or 24h, and be equipped with a refuelling pump and an easily observable fuel level display device.
5.2.2 Traveling system
It shall comply with the provisions of 6.2 in GB/T 25337-2018.
5.2.3 Hydraulic system and pneumatic system.
5.2.3.1 The hydraulic system shall comply with the provisions of 6.3 in GB/T 25337-2018.
5.2.3.2 The pneumatic system shall comply with the provisions of 6.5 in GB/T 25337-2018.
5.2.3.3 The pneumatic system shall meet the operational requirements of the operating device.
5.2.4 Air braking system
Shall comply with the provisions of 6.4 in GB/T 25337- 2018.
5.2.5 Electrical system
Shall comply with the provisions of 6.6 in GB/T 25337-2018.
5.2.6 Vehicle body
Shall comply with the provisions of 6.7 in GB/T 25337-2018.
5.2.7 Driver's room and flaw detection operation room
5.2.7.1 The driver's room shall comply with the provisions of 6.8 in GB/T 25337-2018.
5.2.7.2 The noise level of the flaw detection operation room shall be less than 78 dB(A) during flaw detection operations.
5.2.8 Hook buffer device
Shall comply with the provisions of 6.9 in GB/T 25337-2018.
5.2.9 Lighting device
Shall comply with the provisions of 6.10 in GB/T 25337- 2018.
5.2.10 Water supply installations
5.2.10.1 Working and domestic water tanks shall be set up separately. The capacity of the working water tank shall be not less than 2.5 m°. A one-way valve should be provided to replenish the domestic water supply to the working tank.
5.2.10.2 The water tank and pipework shall be rust-proof, leak-free, washable and meet the requirements of the station water supply, and shall be equipped with a water level indication device. The water supply system shall meet the needs of winter operation and life.
5.3 Operating devices (components) requirements
5.3.1 Probe support mechanism
5.3.1.1 To meet the needs of safe operation at the highest self-propelled speed, the highest detection speed and the highest hanging speed, and to pass the turnout safely during detection.
5.3.1.2 A locking device shall be provided to ensure that the manning position is reliable when retracted.
5.3.1.3 The lifting and locking can be controlled through the workbench, and there is a video monitoring equipment.
5.3.1.4 The coupling water and rim water spraying functions should be available. The coupling water spraying should evenly wet the rail surface to provide good coupling for the probe, and the rim water spraying should cover the whole rim area.
5.3.1.5 should have the probe emergency lifting function. Support mechanism should have anti-disengagement device.
5.3.2 Probe alignment system
5.3.2.1 There shall be a probe alignment adjustment function, which can be operated manually and automatically.
5.4 Safety and alarm devices
Shall comply with the provisions of 6.11 of GB/T 25337-2018.
6 Inspection and test methods
6.1 Appearance inspection
Appearance inspection shall be carried out in accordance with the appearance inspection methods specified in chapter 5 of GB/T 25336-2018.
6.2 Structural inspection
The outline dimension inspection, limit inspection, weighing inspection, hook inspection, curve passing performance inspection, barrier inspection, lifting performance inspection and body rain test shall be carried out in accordance with the methods specified in GB/T 25336-2018.
6.3 Performance inspection
6.3.1 Vehicle performance inspection and test
6.3.1.1 Diesel engine inspection, static strength test, travel system test, hydraulic system test, brake system test, pneumatic system test, noise inspection, driver's cab operation condition inspection, cooling and heating effect inspection, alarm device and safety device inspection, headlight inspection according to the method specified in GB/T 25336-2018.
6.3.1.2 Electrical system tests are carried out in accordance with the methods specified in GB/T 25336-2018. And visual and manual operation to check the multi-channel video monitor, power output interface and all related control functions.
6.3.2 Water supply device performance check
Using visual and manual operation, check the water level of the working water tank and the living water tank, and check the coupling water heating function.
6.3.3 Performance check of operating equipment
6.3.3.1 Inspection of the probe support mechanism
Check in accordance with the following methods:
a) Visually and manually check the lifting function of the probe support mechanism;
7 Inspection rules
7.1 The inspection is divided into type inspection and factory inspection.
7.2 Each mass-produced flaw detection vehicle shall be factory inspected, and the inspection and test items shall be carried out according to the items with the "S" symbol in Table 1.
7.3 GB/T 25337-2018 in accordance with the case of 8.2, inspection and test items in accordance with Table 1 with the "T" symbol of the project.
8 Marking, packaging and transport of the whole machine
8.1 Marking
The nameplate indicating the main performance of the product and other technical parameters related to transport, such as "no humping", "no fireworks", "no sliding", "no climbing", etc. "No climbing", etc., shall be in accordance with the product drawings and technical documents.
8.2 Packaging
8.2.1 It shall conform to the requirements of GB/T 25337-2018.
8.2.2 The probe shall be removed from its supporting mechanism.
8.2.3 The probe support mechanism shall be placed in the stowed position and tied securely.
8.2.4 The following components shall be protected:
a) the monitoring camera of the vehicle's external flaw detection system shall be wrapped and protected
b) Bolts affecting the long-distance attachment and return should be tightened;
c) axle gearboxes, bearing boxes etc. should be filled with lubricant according to the required grade and quantity.
8.3 Transport
shall comply with the provisions of GB/T 25337-2018.
Appendix A (informative) test line manual injury damage layout and dimensions
1 Scope
2 normative reference documents
3 Terminology and definitions
4 Conditions of use
5 Technical requirements
6 Inspection and test methods
7 Inspection rules
8 Marking, packaging and transport of the whole machine
Appendix A (informative) test line manual injury damage layout and dimensions
