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钢轨焊缝探伤37°双向传播 SV-EMAT优化设计

Optimization Design of 37° Dual-Propagation SV-EMAT for Rail Weld Flaw Detection

  • 摘要: 为满足钢轨焊缝无人化检测需求,本文提出采用非接触式37°双向传播剪切波电磁超声换能器(SV-EMAT),解决探头耦合不良与检测换向难题。首先,分别建立37°双向与单向传播SV-EMAT有限元仿真模型,对比声束扩散角、指向性、声波强度等核心特性,验证双向传播 SV-EMAT 更适用于钢轨焊缝探伤。然后,以声波指向性、强度及检测盲区为优化指标,采用正交试验法对探头线圈匝数、高度、宽度等结构参数展开优化。结果表明:线圈匝数对声波指向性影响最大;提离高度对回波强度和检测盲区影响最显著,提离高度越大,回波强度越弱,检测盲区越小。优化后,SV-EMAT 传感器声波传播指向性角度为37°,回波强度为3.92×10−3mV,检测盲区为6.35 mm。在满足指向性要求的前提下,增强回波强度,减小检测盲区。

     

    Abstract: To meet the demand for unmanned inspection of rail welds, this paper proposes a non-contact 37° bidirectional-shear-wave electromagnetic acoustic transducer (SV-EMAT) to address the problems of poor probe coupling and cumbersome inspection commutation. First, finite element simulation models of the 37° bidirectional- and unidirectional-propagating SV-EMATs were established to compare core characteristics—including sound beam divergence angle, directivity, and wave intensity. The results verify that the bidirectional-propagating SV-EMAT is more suitable for rail weld flaw detection. Next, taking acoustic directivity, echo intensity, and detection blind zone as optimization objectives, an orthogonal experimental design was adopted to optimize structural parameters of the probe coil—namely, number of turns, height, and width. Results indicate that the number of coil turns exerts the greatest influence on acoustic directivity; lift-off distance has the most significant impact on both echo intensity and detection blind zone: larger lift-off leads to weaker echo intensity but a smaller detection blind zone. After optimization, the SV-EMAT achieves a shear-wave propagation directivity angle of 37°, an echo intensity of 3.92 × 10−3 mV, and a detection blind zone of 6.35 mm. Under the constraint of satisfying the required directivity, the optimized design enhances echo intensity and reduces the detection blind zone.

     

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