Hi-rail vehicle-based rail inspection system

• US 20020065610A1
• Filed: 10/10/2001
• Published: 05/30/2002
• Est. Priority Date: 10/10/2000
• Status: Active Grant

• Current Assignee: Sperry Rail Holdings, Inc.
• Original Assignee: Momentum Data Systems, Inc.
• Inventors: Clark, Robin, Boyle, Jeffery L., LaMacchia, Brewster W., Main, Douglas T. Jr.
• Granted Patent: US 6,600,999 B2
• Time in Patent Office: Days
• US Class Current: 702/35
• CPC Class Codes: B61D 15/00 Other railway vehicles, e.g. scaffold cars; Adaptations of vehicles for use on railways conveyor frames mounted for movement on rail tracks B65G41/02; wheeled machines used in permanent way construction or maintenance E01B
• CPC Class Codes: B61K 9/10 for detecting cracks in rails or welds thereof

Abstract

A railroad rail inspection system is provided for use in conjunction with a non-railbound vehicle having an equipment bay. The system comprises a detector carriage adapted for being propelled over a two-rail railroad track by the non-railbound vehicle. A magnetic induction sensor system adapted for magnetic induction inspection of at least one rail of the track is attached to the detector carriage. The system further comprises a data acquisition system in communication with the magnetic induction sensor system, the data acquisition system including at least one data processor adapted for processing induction data received from the magnetic induction sensor system. The system further comprises a power supply system adapted for supplying electrical power to the magnetic induction sensor system. The data acquisition system and the power supply system are configured for disposition and operation within the equipment bay of the non-railbound vehicle.

Claims

1. A railroad rail inspection system for use in conjunction with a non-railbound vehicle having an equipment bay, the system comprising:

a detector carriage adapted for being propelled over a two-rail railroad track by the non-railbound vehicle;

a magnetic induction sensor system attached to the detector carriage, the magnetic inductor sensor system being adapted for magnetic induction inspection of at least one rail of the track;

a data acquisition system in communication with the magnetic induction sensor system, the data acquisition system including at least one data processor adapted for processing induction data received from the magnetic induction sensor system; and

a power supply system in electrical communication with the magnetic induction sensor system, the power supply system being adapted for supplying electrical power to the magnetic induction sensor system;

wherein the data acquisition system and the power supply system are configured for disposition and operation within the equipment bay of the non-railbound vehicle.

2. A rail inspection system according to claim 1 wherein the non-railbound vehicle is a hi-rail vehicle adapted for use in both highway travel and travel over the two-rail railroad track.

3. A rail inspection system according to claim 1 wherein the magnetic induction sensor system includes

at least one brush assembly in electrical communication with the power supply system, the at least one brush assembly being configured for selectively engaging the at least one rail and for selectively conducting electrical current into the at least one rail to saturate a test portion of the at least one rail and establish a magnetic field around the at least one rail;

and

an induction search unit in communication with the data acquisition system, the induction search unit being configured for sensing perturbations in the magnetic field around the test portion of the at least one rail.

4. A rail inspection system according to claim 3 wherein the magnetic induction system includes first and second brush assemblies in communication with the power supply system, the first and second brush assemblies being adapted for selectively engaging the upper surface of the at least one rail to establish electrical communication therewith, the first and second brush assemblies being positioned in tandem alignment in a spaced apart relationship so that engagement by the first and second brush assemblies with the rail establishes a rail saturation circuit from the power supply system through the first brush assembly, the test portion of the at least one rail, the second brush assembly and back to the power supply system.

5. A rail inspection system according to claim 4 wherein the first and second brush assemblies each comprise:

a bus block in electrical communication with the power supply system;

a bristle holder attached to and in electrical communication with the bus block; and

a plurality of elongate bristle assemblies in electrical communication with the bristle holder, each bristle assembly having a plurality of elongate wire elements each having a proximal end and a distal end configured for contacting the upper surface of the rail, the proximal ends of the plurality of wire elements being collectively secured by a sleeve-like cap;

wherein the bristle holder is adapted for receiving the bristle assemblies and securing the bristle assemblies in place at an angled orientation.

6. A rail inspection system according to claim 5 wherein the elongate wire elements are formed from a beryllium copper alloy.

7. A rail inspection system according to claim 3 wherein the magnetic induction sensor system includes

a first at least one brush assembly in electrical communication with the power supply system and configured for selectively engaging a first rail and for selectively conducting electrical current into the first rail to saturate a first rail test portion and establish a first magnetic field around the first rail;

a first induction search unit in communication with the data acquisition system, the first induction search unit being configured for sensing perturbations in the first magnetic field;

a second at least one brush assembly in electrical communication with the power supply system and configured for selectively engaging a second rail and for selectively conducting electrical current into the second rail to saturate a second rail test portion and establish a second magnetic field around the second rail; and

a second induction search unit in communication with the data acquisition system, the second induction search unit being configured for sensing perturbations in the second magnetic field.

8. A rail inspection system according to claim 7 wherein the magnetic induction sensor system includes

first and second brush assemblies in communication with the power supply system, the first and second brush assemblies being adapted for selectively engaging the upper surface of the first rail to establish electrical communication therewith, the first and second brush assemblies being positioned in tandem alignment in a spaced apart relationship;

and

third and fourth brush assemblies in communication with the power supply system, the third and fourth brush assemblies being adapted for selectively engaging the upper surface of the second rail to establish electrical communication therewith, the third and fourth brush assemblies being positioned in tandem alignment in a spaced apart relationship,

wherein engagement by the first and second brush assemblies with the first rail and engagement by the third and fourth brush assemblies with the second rail completes a rail saturation circuit from the power supply system through the first brush assembly, the first rail test portion, the second brush assembly, the third brush assembly, the second rail test portion, the fourth brush assembly and back to the power supply system.

9. A rail inspection system according to claim 8 wherein the first, second, third and fourth brush assemblies each comprise:

a bus block in electrical communication with the power supply system;

a bristle holder attached to and in electrical communication with the bus block; and

a plurality of elongate bristle assemblies in electrical communication with the bristle holder, each bristle assembly having a plurality of elongate wire elements each having a proximal end and a distal end configured for contacting the upper surface of the rail, the proximal ends of the plurality of wire elements being collectively secured by a sleeve-like cap;

wherein the bristle holder is adapted for receiving the bristle assemblies and securing the bristle assemblies in place at an angled orientation.

10. A rail inspection system according to claim 3 wherein the induction search unit includes

a plurality of inductive coils disposed in a coil housing, each inductive coil being in electrical communication with the data acquisition system.

11. A rail inspection system according to claim 1 further comprising an ultrasonic sensor system attached to the detector carriage, the ultrasonic sensor system being adapted for ultrasonic inspection of the at least one rail of the track.

12. A rail inspection system according to claim 11 wherein the ultrasonic sensor system includes at least one roller search unit comprising a fluid-filled wheel adapted for engaging the upper surface of the at least one rail, the fluid-filled wheel having disposed therein an array of ultrasonic sensors adapted for transmission and reception of ultrasonic beams into and from the at least one rail for detection of defects within the rail, the array of ultrasonic sensors being in communication with the data acquisition system.

13. A rail inspection system according to claim 12 wherein the ultrasonic sensor system includes a plurality of roller search units with at least a first one of the roller search units adapted for ultrasonic inspection of a first rail and at least a second one of the roller search units being adapted for ultrasonic inspection of a second rail.

14. A rail inspection system according to claim 11 wherein the at least one data processor is adapted for processing ultrasonic signal data received from the ultrasonic sensor system.

15. A rail inspection system according to claim 14 wherein the at least one data processor is adapted for correlating and integrating the ultrasonic signal data with the induction data.

16. A rail inspection system according to claim 15 further comprising a graphical user interface in communication with the at least one automatic data processor, the graphical user interface being adapted for visual presentation of the correlated and integrated ultrasonic signal data and the induction data.

17. A rail inspection system according to claim 1 wherein the power supply system comprises

a generator powered by an internal combustion engine;

and

at least one power supply in electrical communication with the generator and having a plurality of switching power supply modules connected in parallel.

18. A rail inspection system according to claim 1 wherein the at least one power supply has an output capacity of at least 3600 amps DC at a voltage in a range of about 0.5 volts to about 3.5 volts.

19. A rail inspection system according to claim 1 further comprising a carriage stowing arrangement adapted for attachment to the non-railbound vehicle, the stowing arrangement including:

a stowing frame adapted for pivotal attachment to a portion of the non-railbound vehicle, for selective extension outward from the railbound vehicle in a carriage attachment position, and for selective retraction to a stowed position adjacent a surface of the non-railbound vehicle;

means for removably attaching the stowing frame to the detector carriage; and

means for pivotably moving the stowing frame between the carriage attachment position and the stowed position.

22. A rail inspection system according to claim 1 wherein the means for performing magnetic induction inspection includes

brush means for selectively conducting electrical current into the at least one rail to saturate a test portion of the at least one rail and establish a magnetic field around the at least one rail, the means for selectively conducting being in electrical communication with the means for supplying electrical power;

and

induction sensor means for sensing perturbations in the magnetic field around the test portion of the at least one rail, the induction sensor means being in communication with the means for processing induction data.

23. A rail inspection system according to claim 22 wherein the means for performing magnetic induction inspection includes first and second brush assemblies in communication with the means for supplying electrical power, the first and second brush assemblies being adapted for selectively engaging the upper surface of the at least one rail to establish electrical communication therewith, the first and second brush assemblies being positioned in tandem alignment in a spaced apart relationship so that engagement by the first and second brush assemblies with the rail establishes a rail saturation circuit from the means for supplying electrical power through the first brush assembly, the test portion of the at least one rail, the second brush assembly and back to the means for supplying electrical power.

25. A rail inspection system according to claim 24 wherein the means for performing ultrasonic inspection includes at least one roller search unit comprising a fluid-filled wheel adapted for engaging the upper surface of the at least one rail, the fluid-filled wheel having disposed therein an array of ultrasonic sensors adapted for transmission and reception of ultrasonic beams into and from the at least one rail for detection of defects within the rail, the array of ultrasonic sensors being in communication with the means for processing ultrasonic data.

26. A rail inspection system according to claim 25 further comprising means for correlating and integrating the ultrasonic data with the induction data, the means for correlating and integrating being in communication with the means for processing induction data and the means for processing ultrasonic data.

30. A method according to claim 29 further comprising:

receiving the magnetic induction data at the data processor; and

processing the magnetic induction data using the at least one data processor.

20. A railroad rail inspection system for use in conjunction with a non-railbound vehicle having an equipment bay, the system comprising:

a detector carriage adapted for being propelled over a two-rail railroad track by the non-railbound vehicle;

means for performing magnetic induction inspection of at least one rail of the track, the means for performing magnetic induction inspection being attached to the detector carriage;

means for processing induction data received from the means for performing magnetic induction inspection; and

means for supplying electrical power to the means for performing magnetic induction inspection, the means for supplying electrical power including means for generating power sufficient to establish a magnetic field around the rail for use by the means for performing magnetic induction inspection;

wherein the means for processing induction data and the means for supplying electrical power are configured for disposition and operation within the equipment bay of the non-railbound vehicle.

21. A rail inspection system according to claim 20 wherein the non-railbound vehicle is a hi-rail vehicle adapted for use in both highway travel and travel over the two-rail railroad track.

24. A rail inspection system according to claim 20 further comprising means for performing ultrasonic inspection of the at least one rail of the track, the means for performing ultrasonic inspection being attached to the detector carriage and means for processing ultrasonic data received from the means for performing ultrasonic inspection.

27. A rail inspection system according to claim 20 wherein the means for supplying electrical power comprises:

a generator powered by an internal combustion engine; and

at least one power supply in electrical communication with the generator and having a plurality of switching power supply modules connected in parallel.

28. A rail inspection system according to claim 20 further comprising means for stowing the detector carriage onboard the non-railbound vehicle, the means for stowing being adapted for attachment to the non-railbound vehicle and including:

a stowing frame adapted for pivotal attachment to a portion of the non-railbound vehicle, for selective extension outward from the railbound vehicle in a carriage attachment position, and for selective retraction to a stowed position adjacent a surface of the non-railbound vehicle;

means for removably attaching the stowing frame to the detector carriage; and

means for pivotably moving the stowing frame between the carriage attachment position and the stowed position.

29. A method of performing magnetic induction inspection of a two-rail railroad track using a non-railbound vehicle having an equipment bay, the method comprising:

providing a detector carriage adapted for being propelled over the two-rail railroad track by the non-railbound vehicle, the detector carriage having attached thereto a magnetic induction sensor system adapted for magnetic induction inspection of at least one rail of the track;

installing in the equipment bay of the non-railbound vehicle a data acquisition system in communication with the magnetic induction sensor system, the data acquisition system including at least one data processor adapted for processing induction data received from the magnetic induction sensor system; and

installing in the equipment bay of the non-railbound vehicle a power supply system in electrical communication with the magnetic induction sensor system, the power supply system being adapted for supplying power to the magnetic induction sensor system for application of a saturating current to the at least one rail of the track;

propelling the detector carriage along a two rail railroad track using the non-railbound vehicle; and

obtaining magnetic induction data for the at least one rail of the track using the magnetic induction sensor system.