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Fully automated UT inspection systems for High Speed train wheels (UFPE & AURA)
Dr. Pierre MARTY
Product Line Leader, AREVA NDE-Solutions
12th July, D4 Rolling Stock,
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
AREVA NDE-Solutions Global Organization with 700 people
AREVA NDE-Solutions Nord America
AREVA NDE-Solutions France, Intercontrôle
AREVA NDE-Solutions Germany, intelligeNDT
Systems & Services
AREVA NDE-SolutionsSeat: Paris
Global Industry Product line (Testing Machines)
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
AREVA NDE-Solutions Market segmentation
� Products & System solutions for Industrial Market
• e.g. Trains: Automated Wheels & Axles inspections
� Nuclear Services
• e.g. Automated SG and Tube Inspection (ET, UT, Special)
• e.g. Automated Vessel, Nozzle, and Piping Inspection (UT,RT,ET, Special)
� Development of new inspection techniques
• Dedicated NDE Technical Center - NETEC
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
AREVA NDE-SolutionsNorth America
BeniciaLynchburg Charlotte
Perform NDE inspections since 80’s3 main offices, 2 laboratories, 2 machines shop and 1 training centerMore than 200 employees
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
Inspection of Train Wheels Light (UFPE) & Heavy Maintenance (Aura)
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
History
� After the catastrophic accident of wheel rim fracture in 1999, DB AG reacted in a large field of safety-relate dtechnological areas, among them :
� Automated Nondestructive Testing of the Wheel-Sets• Wheels (AURA and UFPE)
- Rim incl. Flange + Disc (Web)
- Periods:
� China has a program for several units for all CHR high speed trains• Periodicity is higher (360.000km btw heavy maintenance)
0 km 250.000 km 750.000 km500.000 km 1‘000.000 km
UFPE AURA UFPE AURA UFPE
1‘250.000 km
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
History
� (AURA 1) in 2001 & (UFPE 1 ) in 2002 @ DB
• Periodic inspection of wheel sets, dismantled, after reprofiling
• utilizing conventional ultrasonic techniques
• Supplier: Institute of Nondestructive Testing(IzfP) of Fraunhofer Gesellschaft
• 6 AURA + 6 UFPE
• Advantage: Relatively short delivery
• Disadvantage: Large, bulky probe systemswith short lifetime, 28hours per train
AURA 1
UFPE 1
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
A-PAUT for Maintenance of train wheel
Wheels inspections can be Automated with PAUT :
• AURA : Stationary Wheel Set inspection system
• UFPE: Under Train Wheel Inspection Systems
• RWI: New wheels
Advantages of A -PAUT
• Reliability of detection and classification (advanc ed analysis)
• Traceability
• Repeatability
• Productivity
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
Phased Array
0°beam 0°beam focused
45°beam
array with 112 elements
direction of synthetic aperture
scanning
Vertical Sweep Horizontal Sweep
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
Probe Systems: Using Phased Array
Inspection times:
AURA 2: 6 Minuten
UFPE 3: < 15 Minuten
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
AURA Complete unit
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
UFPE
DB AG:7 UFPE 2
Siemens Russland:1 UFPE 3 Komplettsystem
China M.O.R.1 UFPE 3 (for 4 different trains)
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
UFPE - 2nd Generation inspecting under the ICE 3
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
� 1 Probe Holder for the 4 different trains (8 wheel prof iles)
• Bombardier
• Kawasaki (Shinkansen)
• Siemens Velaro
• Alstom (TGV)
� Inspection
• Rolling band
• Disc
UFPE 3
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
4 V-path & PE PA-Probes
Inspection in the discPatented V-Path Phased Array Technique
V-Path distance determines Probe System Length:
3D view of the V-Path with the T/R probes
Sound intensity isshown in colors
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
[email protected] .ruwww.npptec .ru
Main functions of the Unit
Dimensions LxWxH, mm 1400x1500x2700
Weight, kg less then 7000
Consumed power, kWt 30
Water supply to UT-probes local spraying
Warranty, month 24
Life duration, years 10
- Detection of the internal wheel defects
- Displaying data of the UT-measurements
- Computer registration (traceability), archiving and storage
of measurements done found defects
Technical characteristics
Pic. 1 UT-system for railway wheels
RWI: New Wheels in Production
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
[email protected] .ruwww.npptec .ru
UT System: 1minute/wheel
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
Automated inspection
� 100% coverage of all safety relevant areas
� Extremely short down time due to multi-probe system
� Enhanced reliability and repeatability of detection with phased array & V-Path technique
� Improvement of safety and availability
Ability to adapt to up to 8 different wheel profiles :
• TGV Alstom
• ICE & Velaro, Siemens
• Shikansen Kawasaki
• Bombardier
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
UFPE + AURA References
End User Specifications QTY User's Coments
DB AG, Dortmund
UFPE 2 fully automated procedure
2 customer fully satisfied,
DB AG, München
UFPE 2 fully automated procedure
2 customer fully satisfied,
DB AG, Frankfurt
UFPE 2 semi automated procedure
2 customer fully satisfied
DB AG, Berlin
UFPE 2semi automated procedure
1 project on time
Siemens, Russia
UFPE 3fully automated procedure
1 Delivered, reaching end of warranty
M.O.RBeijing
UFPE 3fully automated procedure
1 Project on going
DB AGAURA
Phased Array4
customer fully satisfied, consequence: 5th order
DB AGAURA
Phased Array1 project started
Total: 14
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
ConclusionAutomated UT inspection techniques is used very sucesfully for all
wheel-sets inspection cases
With key benefits:
• Improved detectability
• Improved reliability of inspection
• Higher productivity
• Adaptability to many different profiles
AREVA NDE-Solutions however still continue to further develop thetechnology with:
• Simulation / New probe / SAFT
In order to provide more efficient solutions: higher detectability, simpler & cheaper methods, refined analysis for better evalution
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...Thank youfor your kind attention
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
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Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4
Any reproduction, alteration or transmission of this document or its content to any third party or its publication, in whole or in part, are specifically prohibited, unless AREVA NP has provided its prior written consent.
This document and any information it contains shall not be used for any other purpose than the one for which they were provided.
Legal action may be taken against any infringer and/or any person breaching the aforementioned obligations.