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An existing Ultrasonic Broken Rail Detection System installed in South Africa on a heavy duty railway line is currently being upgraded to include defect detection and location. To accomplish this, an ultrasonic piezoelectric transducer to strongly excite a guided wave mode with energy concentrated in the web (web mode) of a rail is required. A previous study demonstrated that the recently developed SAFE-3D (Semi-Analytical Finite Element – 3 Dimensional) method can effectively predict the guided waves excited by a resonant piezoelectric transducer. In this study, the SAFE-3D model is used in the design optimization of a rail web transducer. A bound-constrained optimization problem was formulated to maximize the energy transmitted by the transducer in the web mode when driven by a pre-defined excitation signal. Dimensions of the transducer components were selected as the three design variables. A Latin hypercube sampled design of experiments that required a total of 500 SAFE-3D analyses in the design space...

Optimal design of a piezoelectric transducer for exciting guided wave ultrasound in rails