Laser-based non-destructive spike defect inspection system
Inventors
Assignees
Publication Number
US-11821848-B2
Publication Date
2023-11-21
Expiration Date
2041-05-27
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Abstract
Described herein are a low-cost, non-destructive, and contact-free intelligent inspection system that is field-deployable on a geometry car, high-rail vehicle, or other types of track inspection platforms to identify broken railway/railroad spikes in real-time.
Core Innovation
The invention provides a low-cost, non-destructive, and contact-free intelligent inspection system deployable on track inspection platforms, such as geometry cars or high-rail vehicles, to identify broken railway or railroad spikes in real-time. The system combines laser excitation, acoustic analysis, computer vision, pattern recognition, and artificial intelligence (AI) to detect structural faults within spikes or screws without physical contact or removal from the railway.
Addressing the issue of manual spike inspection—which is subjective, time-consuming, and labor-intensive—the invention automates structural integrity analysis. A laser source excites a spike, generating internal acoustic waves that are detected by capacitive air-coupled transducers. The acoustic wave analysis determines the presence, location, and extent of faults such as cracks, often hidden under the spike head and undetectable without destructive testing.
To further enhance detection efficiency and accuracy, the system utilizes computer vision to locate and recognize spikes, while an onboard AI module processes acoustic data, referencing a growing database to improve results over time through self-learning. The system is designed to operate in situ, providing real-time decisions about spike health directly from the inspection platform as it moves along the track.
Claims Coverage
There are two independent claims, each covering essential inventive features for non-destructive, real-time detection of structural integrity in railroad spikes or screws using an integrated laser, acoustic, and AI-based system.
Mobile field-deployed intelligent inspection using laser-air hybrid ultrasonic beams
A system that identifies a railroad spike or screw for analysis using a mobile, field-deployed inspection platform with automatic target detection and computer vision. - Employs at least one laser-air hybrid ultrasonic beam to excite the spike or screw, generating internal acoustic waves by heat flux. - Receives the resulting acoustic wave via at least one capacitive air-coupled transducer. - Determines the presence or absence of a structural fault by analyzing the acoustic wave to enable on-site, real-time quantification of crack depth and severity.
Non-destructive, contact-free structural integrity inspection of spikes or screws
A method that includes recognizing an object (railroad spike or screw) via a mobile, field-deployed intelligent inspection system with automatic target detection and computer vision prior to structural analysis. - Determines the location on the object for laser excitation. - Uses at least one laser-air hybrid ultrasonic beam to generate an internal acoustic wave within the object due to heat flux. - Detects the acoustic wave with at least one capacitive air-coupled transducer. - Analyzes the acoustic wave to establish the presence or absence of a structural fault, quantifying its depth and severity in real time, with the object analyzed while remaining in place.
The independent claims cover an integrated, mobile system for non-destructive spike inspection, featuring laser-induced acoustic analysis, computer vision for spike recognition, and AI-driven real-time fault detection and quantification.
Stated Advantages
Greatly improves inspection efficiency and saves inspection costs compared to manual methods.
Provides non-destructive, contact-free, and in-situ spike inspection, eliminating the need for physical removal or manual examination.
Significantly enhances detection accuracy for hidden or sub-head cracks in spikes that cannot be recognized by existing technologies.
Reduces derailment risk, optimizes maintenance strategy, and improves overall track safety.
Facilitates real-time, onsite decision making by using AI and a reference library, increasing operational speed without complicated post-processing.
Integrates onto field-deployable platforms for continuous, automated spike defect evaluation.
Documented Applications
Field-deployable inspection of railroad spikes or screws for broken or cracked conditions in real-time using geometry cars, high-rail vehicles, or other track inspection platforms.
Automated, continuous, and accurate evaluation of spike health to support maintenance and safety management of railway tracks.
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