Rail fracture monitoring based on ultrasonic-guided wave technology with multivariate coded excitation

•Enriches the theory and methodology of coded excitation.•A method of multivariate coded excitation is proposed to compensate for the shortcomings of traditional binary coding modulation.•The combination of a multivariate coding technology and ultrasonic wave guide improves the excitation energy of the system and helps to identify rail fracture damage.•Simulations and experiments verify the feasibility and superiority of multivariate coded excitation for monitoring rail fracture. Steel lay the basis of railroad train traffic. Rail fracture is the most serious injury to the rail, which should be monitored in time. The conventional mono-pulse exciting ultrasonic guide wave (UGW) has low energy, the conventional Barker code has limited coding sequence length and the orthogonal complementary Golay code has the problem of low monitoring efficiency. This study proposes multivariate coded excitation (MCE) to excite UGW to monitor rail fracture, and the feasibility of coding and decoding the method is theoretically derived and verified. Ideally, the MCE generated based on the 3-bit Barker code (B3: 1,1, −1) and 4-bit orthogonal complementary Golay code (GA4: 1,1,1, −1; GB4: 1,1, −1,1) is calculated to have a main-lobe power level (MPL) gain of 8.1020 dB, which is significantly higher than the MPL of Barker and Golay codes. For the proposed method, finite element modeling simulation and experimental study are carried out respectively. Analyze and process the data, and calculate the gain of the difference in amplitude (DIA) between the amplitude of echo caused by rail fracture and the amplitude in the healthy rail. The gain of the DIA of the echoes in the MCE is above 50 dB (experimental data, the value of simulation data is 5 dB) under different degrees of rail fracture, while the gain of the DIA of the echoes caused by the other three excitation methods is below 40 dB (experimental data, the value of simulation data is 1 dB). Simulation and experimental results show that the MCE makes up for the shortcomings of the conventional Barker code and Golay code, improves the excitation energy of the monitoring system, and the high gain of the DIA of the echoes is more conducive to the identification of rail fracture damage.