Hollow axle tests
Hollow axle tests
The hollow railway axle testing system we have developed is based on the CUD BO WiFi flaw detector. This system allows for testing of axles without their prior disassembly – the entire test is carried out from the front side of the journal. Therefore, it is enough that the axle box covers are removed in preparation for the test. This is a system used, among others, by Alstom Konstal when testing polish Pendolino vehicles. Hollow axles are tested with probes profiled to the diameter of the hole. Calibration is performed on a control standard with 2 mm deep nochtes perpendicular to the axle axis.
Some features and capabilities of the system:
acceleration of tests and reduction of their costs as a result of automation and mechanization of all basic activities,
possibility of performing tests of non-dismounted axles,
reliability of tests by making the test result as independent as possible from the subjective assessment of the operator,
recording of the test progress and its archiving,
possibility of using the device at the test stand and in any other conditions,
the degree of complexity of the tests does not exceed the requirements of the 1st and 2nd degree certificate according to or EN ISO 9712,
possibility of expanding the system at any time,
selection and arrangement of probes and the course of the test in accordance with the instructions presented by the Purchaser,
holes with a diameter below 40 mm must have a separate mechanical system for each diameter. Holes above 40mm may have replaceable heads with probes,
due to the lack of a European equivalent, the test instructions are based on the German requirements of the DIN 27201-7 standard,
calibration blocks and instructions approved by a person with a level 3 certificate in the railway maintenance sector in accordance with EN ISO 9712,
length of the system – 2.70m.
The testing system consists of the following elements:
digital Ultrasonic Flaw Detector CUD WiFi (can also be used for testing full axles from the front side of the journal),
laptop computer,
software for controlling and archiving,
head with ultrasonic probes,
mechanical system for automatic rotation and movement of head with probes,
system for automatic oil feeding and pumping out.
View of the profiled head with ultrasonic probes.
Presentation of momentary results during the test
During the test, the screen is divided into a number of fields corresponding to the head of the probes used and shows the current status of the test. The upper part of the screen shows two current defectoscopic courses (ScanA images – two probes). Below is a longitudinal section of the axle. The oblique sections indicate the places of testing the axle with the probe “forward” and the probe “backward”. In the lower right corner of the screen on the cross-section, the section indicates the angular positions of these temporary test places. The areas not yet tested are marked in grey.
Presentation of the collective results at the end of the test
