integrated high----speed system speed system speed system ...interailproject.eu/files/workshop/06 -...

Progress meeting #4

REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011

Workshop 2013Copyright INTERAIL Consortium 2013

Development of a Novel Integrated Inspection System for

the Accurate Evaluation of the Structural Integrity of Rail

Tracks

SCP8 – GA-2009-234040

WorkshopWorkshopWorkshopWorkshop

Integrated highIntegrated highIntegrated highIntegrated high----speed system speed system speed system speed system –––– UT UT UT UT

modulemodulemodulemodule

Channa Nageswaran and Nikolaos TsopelasChanna Nageswaran and Nikolaos TsopelasChanna Nageswaran and Nikolaos TsopelasChanna Nageswaran and Nikolaos Tsopelas

Progress meeting #4



Aims• Ultrasonic inspection of the full rail:

– Foot– Web– Head

• Inspection at high speed • Robust mechanical solution

– Data integrity– Operational conditions– Survivability– Simplicity

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The Options• Sled design - rejected

– Mechanically complex to maintain contact at high speed, coupling issues and protection of sensitive components

• The wheel design – chosen– Inherent suspension without loss of contact– Simple, yet robust– Maintenance and replacement– Protection of active components: transducers

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The Concept & the Prototype

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Development

• Tested through laboratory tests:– Static tests on representative flaws

– Dynamic test to prove capability for all flaw types at 75kph

• Field tests:– Focussed on mechanical robustness

– Ultrasonic data integrity

– High speeds > 80kph

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The Tyre

• Strong, flexible polyurethane

• At pressure gives natural damping/suspension

• Protects the active probes from environment

• Commercial availability

• Potential to improve

• Survivability

• Mass production

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The Probes

• Three probes:– 0deg for the foot

– 35deg for the web

– 70deg for the head

• Frequency: 3.5MHz

• Standard probes:– 2 x standard immersion Panametrics

V382-SU (3.5MHz, 13mm)– 1 x Accuscan Paintbrush Panametrics A331S-SU (3.5MHz,

38mmx6mm)

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Optimisation through Simulation

• CIVA platform (validated by TWI)

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Probe Assembly

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Coupling Liquid in Wheel

• Mix of water and propylene glycol (40%)

• Reasons:– Sound velocity really close to membrane material

(~1722m/s)

– Temperature usage (down to -40 C and up to >100 C)

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Effect of Temperature

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Laboratory Testing

• Static tests on rail samples

• Dynamic tests – At TWI on spinning wheels installed

on a lathe (speed up to 75kph)• Side drilled holes

• Slots

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Laboratory Testing Results: 75kph

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Field Trials: REFER Test Train

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Integration of UT module

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Testing of UT module with the deployment system

• Calibration with reference rail piece

• Inner pressure of the tyre

• Position of the wheel on the track

• Pneumatics

• Irrigation

• Communication with system developed by MISTRAS

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Testing of UT module with the deployment system

UT acquisition module by MISTRAS used for field trials(courtesy of MISTRAS)

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• Results generated from UT wheel with UT system developed by MISTRAS

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• Example of a good A-scan from channel 1 (00 probe)

Interface Echo

Irrelevant Indication from rail head

2nd Interface Echo

Back Wall Echo

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• Transverse crack verification in a thermic weld by the 700

probe of the UT module

00 probe 700 probe

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Future

• Further field trials on test trains:– Establish working ranges of wheel system

– Establish survival capabilities

– Establish environmental influences on data & system

• Automated flaw assessment system:– Distances involved not suitable for manual

assessment

– Neural network methods may be better suited

Progress meeting #4



Thank You

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