Cracked Rail Spike Detector Design Team 4: Chad Church: Team Manager Ron Fox: Webmaster Matt Hamm:...
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Cracked Rail Spike Detector Design Team 4: Chad Church: Team Manager Ron Fox: Webmaster Matt Hamm: Lab Manager Geoff Brigham: Presentation Prep John Vogel: Documentation Prep
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Transcript of Cracked Rail Spike Detector Design Team 4: Chad Church: Team Manager Ron Fox: Webmaster Matt Hamm:...
Cracked Rail Spike Detector
Design Team 4:Chad Church: Team Manager
Ron Fox: Webmaster
Matt Hamm: Lab Manager
Geoff Brigham: Presentation Prep
John Vogel: Documentation Prep
Overview
o Introduction and Project Goals
o Background
o Design Specifications
o Final Product
o Future Improvements
o Budget
Introduction & Project Goals
o Introduction• Fully loaded freight trains generate enormous
amounts of pressure on the rails• Cracked rail spikes cannot be detected visually• Broken rail spikes cannot be fully removed without
damaging the rail tie
Introduction & Project Goals
o Project Goals• Design a device to find cracked spikes
o Low costo Portableo Accurate
Ultrasonic Testing Overview
o Non-Destructive Testing
o Piezoelectric Ultrasonic Transducero Piezoelectric Crystalo Electrical Energy Mechanical Energy
o Short Wavelengtho Exceptional Penetration
Time Response
o Flaw Detection Length (111.45 mm)
o Sound Velocity = 5,890 m/s
o Time Rangeo 10μs 50μs
Design Specifications
o Detect Cracks ¼” and Larger
o Lightweight and Ergonomic
o Easily Interpreted Results
o Rechargeable Battery Life > 4 Hours
o Weatherproof
o Low Cost
Final Product
o Proof of Concept Testing• Coupling• Flattened surface• Appropriate amplitude spikes
Final Product
o Display• Generated appropriate light with appropriate
input• Generated audible sound with input
Final Product
o Pulser Generator• 100 volt spike of 20 µsec width• 10 spikes 40 µsec apart
o Comparative software• Compare reflected signal to reference• Determine crack probability
Final Product
o Receiver filter and amplifier• Unable to amplify signal for analysis• Better amplification circuit needed
Future Improvements
o Better amplification to analyze signal
o Weatherproof casing
o Bubble coupling capsule
o Level indicators
o Position markers
Budget
Item Description Mfg Part Number Quantity Cost Per Unit Line Item TotalTransducer, Sensor A106S-RB 1 $249 $249.30BNC to BNC cable BCB-58-6 1 $32.40 $32.40*Student Discount ($28.17) ($28.17)TRANSFORMR 115/230VAC 10VCT 90MA 160D10 3 $6.19 $18.57High Voltage Switch Mode DC-DC Converter 2 $19.99 $39.98RELAY SSR SPST 400V 120MA 4DIP G3VM-401A 3 $3.16 $9.48MOSFETs 400V Dual N-Ch QFET FQS4901TF 3 $0.83 $2.49MOSFETs 100V 20A 38.2mOhm FDPF3860T 3 $1.10 $3.30IC AMP 14-DIP *Suggested LM359N/NOPB 1 $2.88 $2.88Dual Transducer, 5 MHz, 0.25" Element Diameter DHC711-RM 1 $316.00 $316.00Cable. Dual for DHC XDCR - BNC to MICRODOT BCMD-316-5F 2 $74.00 $148.00
Total Cost $794.23
Review
o Device to detect cracks in spikes
o Ultrasound
o Results
o Future improvements
Demonstration
