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Industrial Solutions

Wheel Inspection System

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  • Overview
  • Software Features
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Overview

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Introduction to the Olympus Automated Train Wheel Inspection System

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.)

Inspection from both sides of the Hub
Front view of the Wheel and rollers

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

Software Features

RailView Software

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

metal sorting results

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

Resources

Blog

Right on Time: An Efficient and Reliable Train Wheel Inspection System (WIS)

Videos

Introduction to the Olympus Automated Train Wheel Inspection System
FOCUS PX Automated Train Wheel Inspection
Automated Train Wheel Inspection Systems
 Show More

Brochures

Automated Train Wheel Inspection System (WIS)
Automated Train Wheel Inspection Systems
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