Ultrasonic rail inspection is the most commonly implemented method for detecting internal rail defects. While the conventional ultrasound wheel probe has gained its popularity within rail maintenance community, it suffers from the limited test speeds (25 mph at most). This paper presents the state-of-the-art developments in ultrasonic rail inspection technique that utilizes non-contact receivers and no active transmitters. The transfer function between two points of the rail is reconstructed by deconvolutions of multiple pairs of receivers that sense the acoustics naturally excited in the rail by the running wheels. The deconvolution process eliminates the random effect of the excitation to reconstruct a stable acoustic transfer function of the rail. A fixed bulk delay and frequency selection technique are introduced to facilitate the power spectral density estimation for robust transfer function reconstruction. A multivariate analysis based on selected features extracted from various frequency bands is conducted on the signals recorded by multiple sensor pairs respectively. Furthermore, damage index traces based on data from different sensor pairs provide system redundancy for improved reliability with the voting logic for damage detection. The proposed approach lends itself to extremely high testing speeds (as fast as the service train speed, e.g. 60 mph and above), that would enable the real-time evaluation of rail track integrity at train operational speeds. A prototype based on this passive-only inspection idea has been constructed and tested with the DOTX216 testing vehicle of the Federal Railroad Administration at the Transportation Technology Center (TTC) in Pueblo, CO in September 2016. Test runs were made at various speeds from 25 mph to 80 mph (the maximum speed allowed on the test track). The results show the feasibility of stable reconstruction of the transfer function from the random wheel excitation, as well as the detection of joints and welds present in the track. Some tests were also conducted on TTC Defect Farm showing the potential for defect defection.
In the field of non-destructive evaluation, defect detection and visualization can be performed exploiting different
techniques relying either on an active or a passive approach. In the following paper the passive technique is investigated
due to its numerous advantages and its application to thermography is explored.
In previous works, it has been shown that it is possible to reconstruct the Green’s function between any pair of points
of a sensing grid by using noise originated from diffuse fields in acoustic environments. The extraction of the Green’s
function can be achieved by cross-correlating these random recorded waves. Averaging, filtering and length of the
measured signals play an important role in this process. This concept is here applied in an NDE perspective utilizing
thermal fluctuations present on structural materials. Temperature variations interacting with thermal properties of the
specimen allow for the characterization of the material and its health condition. The exploitation of the thermographic
image resolution as a dense grid of sensors constitutes the basic idea underlying passive thermography. Particular
attention will be placed on the creation of a proper diffuse thermal field, studying the number, placement and excitation
signal of heat sources. Results from numerical simulations will be presented to assess the capabilities and performances
of the passive thermal technique devoted to defect detection and imaging of structural components.
The University of California at San Diego (UCSD), under a Federal Railroad Administration (FRA) Office of Research and Development (R&D) grant, is developing a system for high-speed and non-contact rail defect detection. A prototype using an ultrasonic air-coupled guided wave signal generation and air-coupled signal detection, paired with a real-time statistical analysis algorithm, has been realized. This system requires a specialized filtering approach based on electrical impedance matching due to the inherently poor signal-to-noise ratio of air-coupled ultrasonic measurements in rail steel. Various aspects of the prototype have been designed with the aid of numerical analyses. In particular, simulations of ultrasonic guided wave propagation in rails have been performed using a Local Interaction Simulation Approach (LISA) algorithm. The system’s operating parameters were selected based on Receiver Operating Characteristic (ROC) curves, which provide a quantitative manner to evaluate different detection performances based on the trade-off between detection rate and false positive rate. The prototype based on this technology was tested in October 2014 at the Transportation Technology Center (TTC) in Pueblo, Colorado, and again in November 2015 after incorporating changes based on lessons learned. Results from the 2015 field test are discussed in this paper.
The University of California at San Diego (UCSD), under a Federal Railroad Administration (FRA) Office of Research and Development (R&D) grant, is developing a system for high-speed and non-contact rail defect detection. A prototype using an ultrasonic air-coupled guided wave signal generation and air-coupled signal detection, paired with a real-time statistical analysis algorithm, has been realized. This system requires a specialized filtering approach based on electrical impedance matching due to the inherently poor signal-to-noise ratio of air-coupled ultrasonic measurements in rail steel. Various aspects of the prototype have been designed with the aid of numerical analyses. In particular, simulations of ultrasonic guided wave propagation in rails have been performed using a Local Interaction Simulation Approach (LISA) algorithm. The system’s operating parameters were selected based on Receiver Operating Characteristic (ROC) curves, which provide a quantitative manner to evaluate different detection performances based on the trade-off between detection rate and false positive rate. Results from the first field test of the non-contact air-coupled defect detection prototype conducted at the Transportation Technology Center (TTC) in Pueblo, Colorado, in October 2014 are presented and discussed in this paper. The results indicate that the prototype is able to detect internal cracks with high reliability.
The University of California at San Diego (UCSD), under a Federal Railroad Administration (FRA) Office of Research
and Development (R&D) grant, is developing a system for high-speed and non-contact rail integrity evaluation. A
prototype using an ultrasonic air-coupled guided wave signal generation and air-coupled signal detection, in pair with a
real-time statistical analysis algorithm, is under development. Experimental tests results, carried out at the UCSD Rail
Defect Farm, indicate that the prototype is able to detect internal rail defects with high reliability. Extensions of the
system are planned to add rail surface characterization to the internal rail defect detection.
The University of California at San Diego (UCSD), under a Federal Railroad Administration (FRA) Office of Research and Development (R&D) grant, is developing a system for high-speed and non-contact rail integrity evaluation. A prototype using an ultrasonic air-coupled guided wave signal generation and air-coupled signal detection in pair with a real-time statistical analysis algorithm has been realized. This solution presents an improvement over the previously considered laser/air-coupled hybrid system because it replaces the costly and hard-to-maintain laser with a much cheaper, faster, and easier-to-maintain air-coupled transmitter. This system requires a specialized filtering approach due to the inherently poor signal-to-noise ratio of the air-coupled ultrasonic measurements in rail steel. Various aspects of the prototype have been designed with the aid of numerical analyses. In particular, simulations of ultrasonic guided wave propagation in rails have been performed using a LISA algorithm. Many of the system operating parameters were selected based on Receiver Operating Characteristic (ROC) curves, which provide a quantitative manner to evaluate different detection performances based on the trade-off between detection rate and false positive rate. Experimental tests have been carried out at the UCSD Rail Defect Farm. The laboratory results indicate that the prototype is able to detect internal rail defects with a high reliability. A field test will be planned later in the year to further validate these results. Extensions of the system are planned to add rail surface characterization to the internal rail defect detection.
Continuous Welded Rail (CWR) is used in modern rail construction including high-speed rail transportation. The
absence of expansion joints in these structures brings about the risk of breakage in cold weather and of buckling in warm
weather due to the resulting thermal stresses. The University of California at San Diego (UCSD), under a Federal
Railroad Administration (FRA) Office of Research and Development (RandD) grant, is developing a system for in-situ
measurement of the rail Neutral Temperature in CWR. Currently, there is no well-established technique able to
efficiently monitor the rail thermal stress, or the rail Neutral Temperature (rail temperature with zero thermal stress), to
properly schedule slow-order mandates and prevent derailments. UCSD has developed a prototype (Rail-NT) for
wayside rail Neutral Temperature measurement that is based on non-linear ultrasonic guided waves. Numerical models
were first developed to identify proper guided wave modes and frequencies for maximum sensitivity to the thermal
stresses in the rail web, with little influence of the rail head and rail foot. Experiments conducted at the UCSD Largescale
Rail NT Test-bed indicated a rail Neutral Temperature measurement accuracy of a few degrees. The first field tests
of the Rail-NT prototype were performed in June 2012 at the Transportation Technology Center (TTC) in Pueblo, CO in
collaboration with the Burlington Northern Santa Fe (BNSF) Railway. The results of these field tests were very
encouraging, indicating an accuracy for Neutral Temperature measurement of 5°F at worst, on both wood ties and
concrete ties.
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