WS3 - Next generation wheelset testing

Wheel Set Scanning System

Modern maintenance has to fulfil many tasks - and yet always has too little time availabe. Which opportunities would an inspection system offer that allows both better results and faster inspections?

Based on our experience in the field of NDT in railway workshops, we have developed an inspection concept for semi-automatic ultrasonic testing of wheelsets - WS3 (Wheel Set Scan System)

WS3 - a next-generation inspection system - offers the following advantages:

Significant reduction in inspection time
More flexible design of the test sequences
Increased reliability of the inspection
Complete recording and documentation of test data
Automatic generation of electronic test reports

You can find more information about the inspection system below. For more detailed questions or a demonstration, please contact us.

WS3 in detail:

Scope of delivery

Two scanning devices for shaft testing (adapted to shaft and shank diameters)
Two scanning devices for testing the wheel rim
High-end PAUT device (32:128) with online and offline software
Encoder and splitter
Reference wheel set
Training of the inspectors
Online and offline support

WS3 works semi-automatically. This means:

WS3 guides PAUT probes precisely on the test surface using guidance aids
Encoders record probe positions and end the scan automatically
Test data is also recorded automatically
Probe positions and inspection data are linked

The result: Comprehensive and precise information about the component condition.

Optimum configuration

The choice of PAUT probes (number of elements, element sizes, pitch, frequencies, ...) is the result of an optimisation of:

High signal stability
High signal-to-noise ratio
Sound field geometry
POD

Optimised for geometry

Consistent utilisation of the imaging capabilities of PAUT
PAUT inspection of the shaft seat with probe position on the shaft
UT displays from the geometry and flaw signals can be visualised
Overlaying the UT displays with the shaft geometry improves ...
... the display interpretation and thus
... the reliability of the test considerably

Quantitative coupling check

Checking the correct coupling of the probe
Monitoring of the function of the probe itself
This enables temporal separation of test data acquisition and test data evaluation

Detection limit and evaluation threshold

Detection limit in the interference fit wheel-shaft

Half ellipse with a depth of 1.0 mm and a length of 2.5 mm
2.5 mm corresponds to the indicator length that would be found in a magnetic particle inspection

Maximising information through different types of presentation

Possibilities of maximising information through different types of presentation

1st image (above): Setup of the scan
2nd image: C-scan of both probes - very good defect detection
3rd image: D-scan of both probes supports size assessment (length and depth)
4th image: C-scan of the coupling control of both probes

Superposition of the sound field with the wave geometry

Comparison with component geometry

PAUT's imaging signal visualisation also works with wheelset shafts with significantly more contours and worse accessibility than regular freight wagon wheelset shafts.

Reference wheelset

The benefits of a reference wheelset (instead of individual reference bodies) are manifold:

Sensitivity adjustment for wheel and shaft
For the shaft incl. interference fit wheel-shaft
TCG/ACG adjustment
Validation of the test system
Training of the NDT personnel
Demonstration of the performance of the test system to customers

Modular structure

Focus on medium-sized and smaller workshops with high testing result significance
Modular design (automation options from mobile manual testing to test bench)
Example: testing the shaft with 4 probes simultaneously
Test time (time for moving the probes) for all four probes approx. 60 sec

Comprehensive training

Extensive training courses are part of the WS3 package. These include

Creation of setups
Carrying out the scans
Evaluation of the test data
Saving the raw data

Image and link to the flyer WS3 (German) in a new window

Picture and link to the flyer WS3 (English), opens in a new window

Interested? We would be happy to advise you. On the left side you will find the brochure for the WS3 testing system in German or English as a direct link. Do you have questions about the testing system and its implementation in your company? We would be happy to advise you personally on site, via video conference (Zoom/Teams), by telephone or by email. We are looking forward to your contact!
You can find your contact person here.

You can find further services from our RailwayCenter here:

Are you looking for further training opportunities in materials testing and materials technology? Then we would be happy to inform you about the services of our certified TrainingCenter.