Automated testing

Magnetic Particle and Ultrasonic Inspection System


Automated line for magnetic particle and ultrasonic testing of railway wheel rim, hub, disk andflangeto be integrated into the wheel inspection station.

The line includes:

  • Magnetic particle inspection equipment for in-production testingof railway wheels for the presence of surface defects by fluorescent-magnetic technique in accordance with EN 13262, ISO 6933, ААR M107, DIN EN ISO-9934-1,2,3, GOST 10791.
  • Ultrasonic testing system ensures inspection of wheelsaccording to EN 13262 & AAR M 107/208, GOST 10791, followed by return oftested wheelsto the finished productacceptance facility.

The line solves the following tasks:

  • conformity to quality control requirementsfor wheel products as perGOST 10791-2011, with test productivity of 25 wheels/hour;
  • conformity to quality control requirements for machined wheel centers having a flange, as perTUU 35.2-23365425-640:2009 &TU U 35.2-23365425-643:2009, with test productivity of 20 wheel centers/hour;
  • compliance with quality control requirementsfor machined locomotivewheels with outer diameterof the rolling circle up to 1350 mm, with test productivity of 10 - 20 wheels/hour, depending on theproduct size range and specific standard requirements;
  • compliance with quality control requirements for machined freight carwheels of American railways with Ø28"÷ 43" and test productivity of 20 - 25 wheels/hour;
  • test result data communication to a singleserver of the inspection station, followed by generation of test reports.




Wet fluorescent magnetic particle testing of railway axles


UMPKOS-38 system is designed for magnetic particle inspection of railcar wheelset axlesduring production and after repair.

The system is able to detect both longitudinal and transverse surfaceflaws (‘B’ sensitivity level as perGOST 21105) in accordance with EN 13261, GOST 31334, RD 32.144-2000, by wet fluorescent magnetic particle technique, using AC combinedmagnetizing (circular, polar). The system provides 100% inspection of the entire axle surface, except forends.

This stationary-type system can be either integrated into the workshop process lineor operated independently as a stand-alone MT station. Magnetic fluid is made of finely-cleaned degassed water, free from mechanical impuritiesand fat inclusions

Test object specifications:

Axles with the below parameters are subject to testing by the system:

  • maximum diameter – 390 mm;
  • minimum diameter of axle journal – ... mm;
  • maximum length – 2500 mm;
  • minimum length – 1500 mm;
  • temperature of test object: +3 °С to +45 °С.



SNK KP-8 automated system for integrated nondestructive testing of railcarwheelsets


Purpose

  • The System is intended for detection of both surface andinside flaws infreight railcar wheelsets, as well as for measurement of flaw depth and coordinates;
  • Automated inspection is performed on the wheelsets with new machined wheels and repaired axle.

Features

  • The System is used for automatedUT, EMAT and ETof railcar wheelsetsat repair plants that assemble and examine the newly formed wheelsets;
  • Inspections of the freight railcar wheelsets performed by the System are aimed at confirmatory testing or detectionof the existing flaws ofin-service or repair originin the wheelset axle, wheel disk, rimand flange, as well as at determining the flaw locations;
  • The System carries out ultrasonic and eddy current inspection of used wheelset components to be further examined or repaired;
  • Testing productivity is no less than ten (10)wheelsets/hour provided that they aresmoothly fed to the test position.

Benefits

The use of automated wheelset inspection System allows increasing the testing productivity and reliability by several times due to simultaneous operation ofmultiple channels. Not only detected flaws but also all process data are fully recorded by the System during inspections. This helps to avoid NDT inspector’s mistake or negligence,and enables to make a detailed analysis of test results at any time.





Uniscan Luch OS-4 system for automated ultrasonic inspection of railway axles during production


Purpose

  • Main purpose of the system is to find all kinds of defects in railway axle body according to RD32.144-2000, EN 13261, М101, DSTU 31334 & BN 918275;
  • The system is able to examine machined or semi-machined axles during their production.

Features

  • Ultrasonic testing is automatically performed from the radial surface by immersion technique;
  • Axle to be tested is fully placed into the immersion tank, where it is rotated by central clamping devices, and scanning is performed during linear motion of UT scanner along the axle;
  • The system estimates equivalent sizes and depths of the defects;
  • Axle is inspected along its entire length, except for dead zones in center and bolt holes;
  • Testing facility has its own closed-circuit system of immersion liquid intake, supply and purification.

Benefits

  • Design of the system is compact and ergonomic;
  • The system can be either integrated into the production line or operated as a stand-alone inspection station;
  • Metal structure test is also provided to check the structure conformity to applicable standards;
  • High productivity of the system is due to absence of multiplexing schemes in eight scanning modules. Time required for inspection of one axle is up to 8 min.




PSh-11 ERW system for nondestructive testing of pipes


Purpose

  • The system performs a comprehensive automated ultrasonic inspection of welds in longitudinally welded small-diameter pipes during their production;
  • Inner and outer longitudinal defects, as well as residual inside and outside flash are subject to detection in accordance with API Spec 5CT, GOST R 52203-2004, TU 14-3R-27-2000, TU 14-3R-28-2001, TU 14-3R-29-2002, TU 14-3R-31-2005.

Features

  • The system is to be installed immediately downstream the ERW mill and flash trimmer before the local weld zone heat treatment station;
  • It comprises a fusion- and near-weld zone flaw detection module, as well as pipe profile measurement module in heat-affected area;
  • Pipes are supplied to the inspection station at a linear speed up to 1 m/s.

Benefits

  • Heavy-duty equipment capable of operating in harsh industrial environment, such as high temperatures up to 250 °С in test area, and ample scaling;
  • Availability of flaw marker for defective pipe sections, and sending of ‘Reject’ alarms to the production line;
  • Fully automated inspection process, practically unattended by operator.