Intelligent Automation Comes to Rail Wheel Ultrasonic Inspection
Waygate Technologies, a leader in nondestructive testing (NDT) solutions for industrial and energy infrastructure inspection, has expanded its advanced inspection solutions portfolio for the rail industry with the introduction of the Krautkrämer WheelStar RPS*. A fully automated ultrasonic testing system that is combined with proprietary matrix technology, the Krautkrämer WheelStar RPS ensures precise results and cost reductions in the inspection process of dismantled train wheels, helping train operators and Maintenance, Repair & Operations (MRO) facilities keep up with growing regulatory requirements, as well as increase reliability and maximize train utilization.
Robotics Combined with Matrix Ultrasonic Technology
WheelStar RPS uses a robotic assembly to position the ultrasonic mechanics on the train wheels. As part of a fully automated process, the wheel is rotated by an underfloor shift-rotate unit while the inspection is facilitated using proprietary Waygate Technologies phased array matrix probe technology, which allows a very compact design and ensures reduced complexity at the same time. Results are then compared with calibration data. Once the first wheel has been inspected, WheelStar RPS moves on to the second wheel without any need for manual intervention, resulting in a cycle time of just six minutes per wheelset.
Check and re-check are performed automatically, eliminating the need to manually handle reference wheelsets. The combination of innovative matrix technology and highly efficient industrial robots paves the way for intelligent and fast inspections of wheels in service, completed within a reduced time frame.
Addressing Customer Key Pain Points
Rail wheels are one of the most critical safety components of rolling stock. A failure can lead to catastrophic events resulting in high material damage and personal injury, or even fatalities. Therefore, international railway standards require non-destructive inspection by means of ultrasound testing (UT) on a regular basis.
With its advanced features, the new system optimizes defect detection across varying wheel geometries and wheel wear conditions. It ensures precise inspections, minimizes false indications, and reduces avoidable costs while offering wheel profile compensation and direct coupling control for maximum safety.
During the development of WheelStar RPS, Baker Hughes’ Waygate Technologies engineering team also focused on addressing the shortage of highly trained inspection personnel, a long-standing challenge in the industry. The result is a workflow principle that makes the new solution exceptionally easy to use. The user is guided throughout the inspection process and can operate the system via a single screen. By using pre-programmed wheelset types and profiles, along with automatic report generation, training times for inspectors are significantly reduced compared to other solutions in the market. Depending on the actual setting the total shift work time can be reduced by 7 – 23 percent, including the check/re-check time that goes down by 5 percent itself. In case of failures or if any sort of assistance is needed, remote service is available on demand.
*RPS stands for German ‘Radsatz-Prüf-System’ which translates to ‘wheel set testing system’.
For more information: www.bakerhughes.com/waygate-technologies
