Overview

	Automated Train Wheel Inspection System (WIS) With more than a million kilometers of railway track around the world, trains are an important method of transporting goods and people. Wheel integrity is essential for safe train operation. For use on different railroad networks, train wheels are manufactured with different diameters, profiles, and weights. To help prevent railway catastrophes, manufacturing quality requirements and standards for railway wheels are increasingly demanding.

Automated Train Wheel Inspection System (WIS)

With more than a million kilometers of railway track around the world, trains are an important method of transporting goods and people. Wheel integrity is essential for safe train operation. For use on different railroad networks, train wheels are manufactured with different diameters, profiles, and weights. To help prevent railway catastrophes, manufacturing quality requirements and standards for railway wheels are increasingly demanding.

Fast and Compliant Inspection The Wheel Inspection System’s phased array probes inspect the rim, from the tread and one face, in addition to the hub from both sides in less than one minute. The fully automated system detects the typical defects found in train wheels: Rim face volumetric defects Equivalent to 1 mm–3.2 mm (0.04 in.—0.13 in.) diameter flat-bottom holes (FBHs) with a near-surface resolution of 5 mm–6 mm (0.2 in.—0.24 in.) Rim tread volumetric defects Equivalent to 1 mm–3.2 mm (0.04 in.—0.13 in.) diameter flat-bottom holes (FBHs) with a near-surface resolution of 5 mm–6 mm (0.2 in.—0.24 in.) Hub inner and outer face defects Equivalent to 2 mm (0.08 in.) diameter flat-bottom holes (FBHs) with a near-surface resolution of 5 mm–6 mm (0.2 in.—0.24 in.)

Fast and Compliant Inspection

The Wheel Inspection System’s phased array probes inspect the rim, from the tread and one face, in addition to the hub from both sides in less than one minute.

The fully automated system detects the typical defects found in train wheels:

Rim face volumetric defects
Equivalent to 1 mm–3.2 mm (0.04 in.—0.13 in.) diameter flat-bottom holes (FBHs) with a near-surface resolution of 5 mm–6 mm (0.2 in.—0.24 in.)
Rim tread volumetric defects
Equivalent to 1 mm–3.2 mm (0.04 in.—0.13 in.) diameter flat-bottom holes (FBHs) with a near-surface resolution of 5 mm–6 mm (0.2 in.—0.24 in.)
Hub inner and outer face defects
Equivalent to 2 mm (0.08 in.) diameter flat-bottom holes (FBHs) with a near-surface resolution of 5 mm–6 mm (0.2 in.—0.24 in.)

	Optimized Mechanical platform A complete turnkey inspection station, the WIS is designed to be directly installed in the production line. Wheels are fed into the system horizontally on a rail, rolling at low speed, fully inspected using phased array ultrasonic probes, and then ejected from the system onto a rail. Main components of the system: Adjustable probe holders out of the water Motorized rollers with hydraulic wheel height adjustment out of the water Wheel kickers IN/OUT HUB inspection water wedge with height adjustment (Optional) Automatic Probe Debubbling device Fixed immersion tank with water circulation with filtering

Optimized Mechanical platform

A complete turnkey inspection station, the WIS is designed to be directly installed in the production line.

Wheels are fed into the system horizontally on a rail, rolling at low speed, fully inspected using phased array ultrasonic probes, and then ejected from the system onto a rail.

Main components of the system:

Adjustable probe holders out of the water
Motorized rollers with hydraulic wheel height adjustment out of the water
Wheel kickers IN/OUT
HUB inspection water wedge with height adjustment (Optional)
Automatic Probe Debubbling device
Fixed immersion tank with water circulation with filtering

Versatile and Efficient System

Advantages

Rollers out of the water preventing wearing and simplifying maintenance operation
Hydraulic device with accurate height positioning
Include a full control of the handling to optimize the cycle time
Retaining arms to avoid shocks on the rollers which might create misalignment and frequent mechanical adjustments
On board electronics to limit the probe cable length
Ease-to-use dedicated software
User interface designed to ease the train wheel inspection workflow
Communication OPC to facilitate system upgrade

Manufacturing Inspection

In-service train wheels require periodic reprofiling. During this process, material is removed from the wheel to restore it to its original profile. When reprofiling is completed, the wheel rim is checked from the tread using a linear phased array probe before it goes back into service (Figure 3). Typically, a 5 MHz, 128-element phased array probe is used in this application. A linear scan is performed to cover the area of interest (Figure 4).

Checking the tread using a linear phased array probe. Figure 3

A linear scan. Figure 4

Requirements

Radial Defects:

1.0 mm FBH for high-speed train wheels.
2.0 to 3.2 mm FBH for freight train wheels.
Various depths from the tread surface.

Axial Defects:

3.0 or 5.0 mm FBH in the web section.
Up to 3 defects at different depths.

Performance

Inspection time down to 30 s/wheel for freight train wheels.
- Complete thread and rim area coverage.
Inspection time down to 3 min./wheel for high-speed train wheels.
- In-depth thread, rim, hub, and flange coverage.

Code Compliance

ESR 0331
EN 13262
AAR M107-84

Olympus’ wheel tread inspection solution.

Software Features

RailView Software

RailView acquisition and analysis software is PC based and offers powerful inspection features, advanced analysis tools, and fully customizable displays.

Acquisition and Analysis Software

This software has been designed specifically for train wheel inspection and includes features that ease the entire process.

Special attention has been given to the ergonomics of the interface, providing a human-machine interface (HMI) that optimizes the wheel inspection workflow.

Software Features

User interface designed to ease the train wheel inspection workflow
Multiple beam sets per probe
Assistance for mechanical adjustment of probes, including envelope readouts and water column measurement
Cropping tool to optimize the probe coverage
Calibration assistance tools
Time-corrected gain (TCG)
Communication with level 2 through the OPC
Multiple user levels
Automatic verdict generation (accept, reject, or retest)

Specifications

System Performance

Standard Product Range	Type	Cast steel wheel Forged steel wheel
	Size	24–49 inch (30.5 cm–124.5 cm) wheels
	Speed	Up to 100-200 mm/s
	Coverage	Rim inspection from tread and one face Additional hub inspection (possibility to inspect the web on request) 1 mm FBHs 5-6 mm near-surface resolution
Data Presentation	Real-Time Inspection Results	C-scan, A-scan, B-scan, strip charts, and alarms
Inspection Modes	Typical Inspection Modes	Longitudinal waves
Detection Capabilities for Typical Reference Defects	Repeatability	Volumetric defects: 1 mm-3.2 mm diameter flat bottom hole (FBH) with a typical dead zone of 5 mm-6 mm
	Standards	EN13262, ISO5948, AAR M-107/M-208
Reporting and Data Storage	Report types	Inspection, calibration, and calibration-check user-configurable reports
	Storage	Real-time database inspection data storage