WS3 – Wheel Set Scan System

The requirements for railway maintenance are continually increasing. According to DIN EN 13262, wheels should have tangential compressive residual stresses in the rim after manufacture. During operation, tread braking subjects the running surfaces to high thermal loads. Over time, this can gradually transform the originally desired compressive residual stresses into tensile residual stresses that promote cracking. This effect is further intensified by the continuous reduction in diameter caused by wear, turning and wheel reprofiling.

Continuous monitoring of the residual stress state is therefore crucial for detecting damage such as lateral thermal cracks at an early stage and preventing component failure. These tests must be carried out reliably, traceably and cost-effectively – often under considerable time pressure.

Drawing on many years of experience in non-destructive testing (NDT) in railway workshops, W.S. Werkstoff Service GmbH therefore developed a new testing concept for ultrasonic testing of wheelsets: the Wheel Set Scan System – WS3.

The aim: faster testing with greater reliability and complete digital traceability.

Key features and advantages of the WS3 system

The Wheel Set Scan System is a semi-automatic testing system for freight wagon wheelsets based on modern phased-array ultrasonic testing (PAUT). The system was developed to make wheelset testing procedures significantly more efficient, reproducible and future-proof.

The use of standard PAUT instruments keeps the system particularly flexible and future-proof. Unlike proprietary specialist solutions, existing testing instruments can continue to be used. Newly purchased instruments can also be used for other testing tasks.

Phased-array technology for faster and more reliable testing

WS3 includes specially adapted scanning devices for testing wheelset axles and wheel rims. A PAUT instrument reliably covers all relevant test areas.

Imaging ultrasonic testing offers decisive advantages: the simultaneous display of ultrasonic indications and component geometry facilitates the evaluation of test results, reduces adjustment times and increases the information obtained from the test. This makes testing procedures not only faster, but also more traceable and reproducible.

Reproducible testing conditions and complete data security

A central part of the system is flowing-water coupling combined with probe positions that remain constant over time. This creates stable and reproducible testing conditions. In addition, continuous coupling monitoring ensures that probe function is permanently monitored. The test data thus remains reliable and verifiable – even after testing has been completed.

A further advantage is that data acquisition and data evaluation can take place at different times. This considerably increases flexibility in the testing process. Thanks to complete raw data storage, all data remains available for later analyses or reassessments.

The future of wheelset testing is digital, fast and reliable

With WS3, we have developed a modern testing system that makes railway wheelset testing significantly more efficient and digital. The combination of phased-array ultrasonic technology, reproducible testing conditions, complete data documentation and a practice-oriented training concept makes WS3 a powerful solution for maintaining freight wagon wheelsets – and an important step towards the next generation of non-destructive testing in the railway sector.