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The effectiveness of railway fault inspection has remained challenging. Conventional techniques are still functionally limited and unable to meet the increasing demand of railway diagnosis. To mitigate the variety of rail fault detection problems, this paper proposes a dynamic railway inspection system based on multi-physical coupled electromagnetic and thermography sensing. It further shows the development and construction of a new inverted L-type magnet yoke abreast with volumetric coils array. The novel structure can not only significantly enhance the sensitivity and detectability of the region of interest (ROI), but also effectively detect the subsurface defects with the compensation of coils array due to the coupled electromagnetic field. Furthermore, the theoretical analysis of the coupled physical fields has been derived and proved to be consistent with the numerical simulation results. A rail test sample with various defects is carried out to verify the feasibility of the proposed system. Additionally, a metric learning post-processing algorithm has been conducted for distilling eddy current signals and thermograms to improve the accuracy of the detection results. On-site experimental and contrast results with various levels of performance validation have demonstrated that the integrated system is well suited for dynamic rail inspection on near-surface cracks at speed of 1 km/h.

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