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Cracked Rail Spike Detector

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. Introduction and Project Goals Background Design Specifications Final Product

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Cracked Rail Spike Detector

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  1. 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

  2. Overview • Introduction and Project Goals • Background • Design Specifications • Final Product • Future Improvements • Budget

  3. Introduction & Project Goals • 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

  4. Introduction & Project Goals • Project Goals • Design a device to find cracked spikes • Low cost • Portable • Accurate

  5. Ultrasonic Testing Overview • Non-Destructive Testing • Piezoelectric Ultrasonic Transducer • Piezoelectric Crystal • Electrical Energy Mechanical Energy • Short Wavelength • Exceptional Penetration

  6. Time Response • Flaw Detection Length (111.45 mm) • Sound Velocity = 5,890 m/s • Time Range • 10μs 50μs

  7. Design Specifications • Detect Cracks ¼” and Larger • Lightweight and Ergonomic • Easily Interpreted Results • Rechargeable Battery Life > 4 Hours • Weatherproof • Low Cost

  8. Final Product • Proof of Concept Testing • Coupling • Flattened surface • Appropriate amplitude spikes

  9. Final Product • Display • Generated appropriate light with appropriate input • Generated audible sound with input

  10. Final Product • Pulser Generator • 100 volt spike of 20 µsec width • 10 spikes 40 µsec apart • Comparative software • Compare reflected signal to reference • Determine crack probability

  11. Final Product • Receiver filter and amplifier • Unable to amplify signal for analysis • Better amplification circuit needed

  12. Future Improvements • Better amplification to analyze signal • Weatherproof casing • Bubble coupling capsule • Level indicators • Position markers

  13. Budget

  14. Review • Device to detect cracks in spikes • Ultrasound • Results • Future improvements

  15. Demonstration

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