Design and Development of Automatic Detection System for Locomotive Wheel Rims RCF Cracks Based on ACFM

After extensive use, rolling contact fatigue (RCF) cracks can develop on locomotive wheels, potentially endangering the safety of locomotive operation. In response to the detection needs of wheel rim RCF cracks, an ACFM detection model for wheel rim RCF cracks using COMSOL simulation software is created. The model focus on examining how important variables like surface cracking angle, vertical cracking angle and cluster structure affected the characteristic signals of the ACFM. An experimental system for the automatic detection of ACFM wheel rim RCF cracks using a robotic arm is built. The system could achieve comprehensive scanning of key positions on the locomotive wheel rims. The outcomes demonstrate that the robotic arm-based ACFM wheel rim RCF cracks automatic detection system significantly enhances the system's portability and integration. It also guarantees the correctness of the detection findings, and increases detection efficiency. With a minimum recognizable cracks depth of 0.2mm, it can automatically identify defects including small cracks, oblique cracks, and cluster cracks. The system can provide technical support for the inspection and maintenance of in-service wheel rims.