Automated testing

Magnetic Particle and Ultrasonic Inspection System


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

The line includes:

  • Magnetic particle inspection equipment for in-production testing of 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 wheels according to EN 13262 & AAR M 107/208, GOST 10791, followed by return of tested wheels to the finished product acceptance facility.

The line solves the following tasks:

  • conformity to quality control requirements for wheel products as per GOST 10791-2011, with test productivity of 25 wheels/hour;
  • conformity to quality control requirements for machined wheel centers having a flange, as per TUU 35.2-23365425-640:2009 &TU U 35.2-23365425-643:2009, with test productivity of 20 wheel centers/hour;
  • compliance with quality control requirements for machined locomotive wheels with outer diameter of the rolling circle up to 1350 mm, with test productivity of 10 - 20 wheels/hour, depending on the product size range and specific standard requirements;
  • compliance with quality control requirements for machined freight car wheels of American railways with Ø28"÷ 43" and test productivity of 20 - 25 wheels/hour;
  • test result data communication to a single server 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 wheels axles during production and after repair.

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

This stationary-type system can be either integrated into the workshop process line or operated independently as a stand-alone MT station. Magnetic fluid is made of finely-cleaned degassed water, free from mechanical impurities and 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 railcar wheelsets


Purpose

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

Features

  • The System is used for automated UT, EMAT and ET of railcar wheelsets at 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 detection of the existing flaws of in-service or repair origin in the wheelset axle, wheel disk, remand 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 are smoothly 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 of multiple 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.



The system is intended for the magnetic particle inspection of 55 dimension types of the rail transport 650-1300 mm diameter wheels for the surface and subsurface defects in any direction on all wheel surfaces, except for the hub inner hole surface.The system reset for the wheel specific dimension type is carried out for 30 min. The system is set up for the certain dimension type of the testing wheel by resetting the gibs in direction of the wheel, wheel oiling system, magnetization system and IF illumination system movement.

UMPK-1 is a semi-automated system with advanced technologies which make it possible to perform qualitative testing of the rail transport wheels by the magnetic and luminescent technique. The guaranteed testing efficiency – no less than 40 wheels per hour as long as the wheels are continuously loaded to the testing site. The wheel testing time without taking into account the time of loading-unloading on the testing site - no more than 1,5 min. The system can operate as an independent unit or can be integrated in the existing manufacturing lines of the customers' enterprises.

The system assures detection of the surface defects with the minimal conditional length 2 mm – on the finishing surface and 6 mm – on the roughly machined one (re-machined surfaces), such as "crack" of any direction with the opening width no less than 25 µm.

Main specifications:

  • Wheel magnetic particle inspection techniques are performed in compliance with:
  1. GOST 21105 "Non-destructive testing. Magnetic particle technique".
  2. ISO 6933.
  3. PrEN 13262.
  4. DIN EN ISO – 9934 – 1,2,3.
  5. AAR M 107.
  • testing of 55 dimension types wheels with the diameter from 650 to 1300 mm;
  • system reset time for another dimension type – no more than 30 min.;
  • wheel testing time – no more than 1,5 min.;
  • testing efficiency: 40 wheels per hour;
  • testing results documentation;
  • possibility to integrate video surveillance system for remote control of the testing process.

 The system carries out semi-automated magnetic and luminescent inspection of 55 dimension types wheels with the diameter from 650 mm to 1300 mm and testing velocity up to 40 wheels per hour. The system meets the requirements of such normative documents on magnetic particle inspection as GOST 21105, PrEN 13262, ISO 6933, ААR M107, DIN EN ISO-9934-1,2,3. Sensitivity conditional level of "B" system magnetic particle inspection - according to GOST 21105.

UMPK -1 system of magnetic particle inspection of rail transport wheels

Structurally, "UMPK-1" system consists of the following component parts connected by one control system:

  1. Mechanical part.
  2. Computer system which, in its turn, consists of:
    • - operators remote controls;
    • - computing unit.
  • the system of preparation and oiling with magnetic and luminescent suspension;
  • wheel magnetization and demagnetization system;
  • UV illumination system.

  Main specifications of the system:

  1. Wheel magnetic particle inspection techniques are performed in compliance with:
  • GOST 21105 "Non-destructive testing. Magnetic particle technique";
  • ISO 6933;
  • PrEN 13262;
  • DIN EN ISO – 9934 – 1,2,3;
  • AAR M 107.
  • conditional sensitivity of "В" magnetic particle inspection according to GOST 21105;
  • detection of the surface defects with the minimal conditional length 2 mm and opening width no less than 25 µm;
  • testing of 55 dimension types wheels with the diameter from 650 to 1300 mm;
  • system reset time for another dimension type – no more than 30 min.;
  • wheel testing time – no more than 1,5 min.;
  • testing efficiency: 40 wheels per hour;
  • testing results documentation;
  • possibility to integrate video surveillance system for remote control of the testing process.