Development of an Automated Inspection System for Hollow Railway Axles

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Outline
Reasons for development of the system: Rapid, reliable inspections, Traceable results Improved communication and reporting Challenges: Speed, Speed, Speed Flexibility and Adaptability Enabling technologies Innovative scanner and instruments NDT software development platform

Drivers for Development

Cost: Asset utilization 100% uptime Compliance: Safety regulations, inspection method Communication: report to: asset owner, 3rd parties.

Challenges
For the Inspection Application: Small fleets with diverse needs NDT in regular maintenance shops Remote from in-depth experts For the Development Team Specialized expertise in several fields Time and economic pressure

Detecting Cracks in Rail Axles

Long wave from end of axle Shear wave from outside of axle Shear wave from inside of axle

RapidScan 2 SFD Instrument

Embedded within host PC Designed for Automation 8 Channels Square-Wave Pulser Receiver 100 MHz Digitizer On-Board DAC/TVG Encoder Inputs: pulse on position.

Scanner for Hollow Rail Axles

Connection for UT signals and motors Axial Drive Mounting Collar Probe Head

Rotary Drive

Image courtesy of: F Kontroll AB and Innoveus Engineering AB

Detail of Hollow Axle Scanner

Connection for UT signals and motors Mounting Collar with adapter plate

Axial Drive Rotary Drive Probe Head

Image courtesy of: F Kontroll AB and Innoveus Engineering AB

Testing the Hollow Axle Scanner

Host PC : Windows / Intel UT Instrument: RapidScan 2 Scanner Drive: Galil DMC 4020 Tool storage

Scanner mounted on test axle

Sample axle with EDM notches

Image courtesy of: F Kontroll AB and Innoveus Engineering AB

Axel Scanner Select Configuration

User Interface: Scan Setup

Axle Scanner Scan Display

Axle Scanner : Data Review

Axle Scanner : System Configuration

Summary
We have discussed the design and deployment of a new inspection system for hollow rail axles. 1. A modular (subsystems ) design enables flexibility and adaptability. 2. A cooperative approach enables the best use of available tools and human expertise. 3. The application of Inspection Automation to maximize productivity of the NDT process.

Acknowledgements
We are grateful to our colleagues:
F Kontroll AB Mr. Jan Nordstrm Torpslingan 25D, SE-973 47 Lule, Sweden jan.nordstrom@afconsult.com www.afconsult.com Innoveus Engineering AB Mr. Mrten Landaeus Bjrsbovgen 140, SE-424 91 Olofstorp, Sweden marten@innoveus.se www.innoveus.se Sonatest PLC Dr. Tom Marshall Dickens Road, Old Wolverton, Milton Keynes, MK12 5QQ United Kingdom tom.marshall@sonatest.com www.sonatest.com AB Kontrollmetod Mr. Hkan Andersson Sdra Lngebergsgatan 18, SE-421 32 Vstra Frlunda, Sweden hakan.andersson@kontrollmetod.se http://www.kontrollmetod.se/

THANK YOU

UTEX Scientific Instruments Inc. www.utex.com Dave Seto: dseto@utex.com