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| Fully-computerized ultrasonic inspection systems for the production line and refurbishment shop of train wheel. |  |
PRODUCT DESCRIPTION |
| Introducing the AS-220 Series The AS-200 Series Wheel Inspector is a fully computerized ultrasonic inspection machine for train wheels. It includes an easy-to-use operator interface for application-specific tasks, with system mechanics and flexible programming capability to accommodate a wide range of wheel sizes and shapes. |
| Wheel sizes From 660mm (26in) to 1050mm (42in) in diameter. |
| Inspection technique Contact-type with forced water coupling, recirculation and filtering. |
| AS-200p for the production line Parts are inspected without interruption at the rate of up to one wheel per minute or less, independent of wheel size or tape, in single or batch loads. Selection of three inspection modes: fully automatic interfaced to a host or external PLC; semi-automatic operation with operator-loaded inspection parameters per batch; or inspection with full manual override. |
| AS-200r for the refurbishment shop Ultrasonic inspection generally precedes all re-machining operations. Wheels are inspected in sets, each set comprising a pair of wheels and the connecting axle. Automatic compensation for wheel-to-wheel variations in detection sensitivity. |
| AS-200p mechanics Column-supported multi-channel inspection head with drive and idler rollers, coupling water circulation and filtration unit. Installed in the inspection cell on the production line. Optional parts sorter for PASS/FAIL. |
| AS-200r mechanics Gantry-based, dual multi-channel inspection heads, coupling water circulation and filtration unit, and elevator platform with integrated rolls for raising and rotating the wheel set. |
| Multi-probe inspection head
Accommodates automatically to wheel diameter and tread shape for simultaneous inspection from tread and rim. Independently suspended, stainless-steel bubbler and wear shoe for each probe, ensuring smooth contact for all wheel shapes and sizes. |
| Ultrasonic electronics
upi-50 rack-mount ultrasonics, including a remote-mounted RPP2 or RPP4 tunable square-wave pulser preamplifier for each channel. Up to16 channels for AS-200p and up to 32 channels for AS-200r. One or two hardware gates per channel. |
| Ultrasonic instrument software
ScanMaster production-line software with easy-to-program set-up screens and screen-displayed alarms for flaw indications. Two programmable alarm thresholds per gate, programmable alarm duration and number of counts for alarm, and up to 8 programmable digital output ports. |
| Control console
Environment-proof rack-mount cabinet with 17" VGA monitor and pullout tray for mouse and keyboard provide full control of system ultrasonics. MAC Windows NT-based programmable process controller for integration into the production line. |
SUMMARY INSPECTION SPECIFICATIONS |
| Suitable wheel sizes From 660mm (26in) to 1050mm (42in) in diameter. |
| Inspection technique Contact-type with forced water coupling, recirculation and filtering. |
| Number of inspection channels Up to sixteen channels for AS-200p, up to thirty-two channels for AS-200r. One or two hardware gates per channel, with one or two operator-selected threshold levels per gate. |
| Transducers Type TDN or T2DN 4 and 5MHZ normal beam probes. Type RSA 2, 2.25, 4 and 5MHz shear wave probes. Detection sensitivity to KSR 0.8 (No.2 flat-bottom hole) or equivalent. |
| Inspection coverage Full coverage of wheel rim and tread. |
| Inspection resolution Flaw detection to American Association of Railroads Manual of Standards and Recommended Practices, or as otherwise required by the customer. |
| Rim thickness Optional detection of wheel rim thickness. |
| Inspection rates To less than 60 sec per wheel for AS-200p, 180 sec for AS-200r. |
| Number of set-up files in memory Virtually unlimited in number of wheel sizes and tapes. |
| Set-up recall time from upi-50 files' directory Typically five seconds with command from host computer. Typically 20 to 30 seconds if done manually. |
| Ultrasonic attenuation compensation Automatic gain compensation for attenuation deviation from calibration standards. (AS-220r only) |
| Mechanical set-up time for new wheel dimension Inspection head accommodates automatically to each wheel diameter and tread profile. |
| I/O interface Programmable digital output ports for audio-visual alarms, paint spray and process control. |
| Flaw marking type and marking accuracy Type: waterproof paint marking. Accuracy: +/- 10mm (1/2") along wheel circumference. |
| Report documentation Optional inspection report, individual or batch reporting. Records channel, signal amplitude, equivalent flaw size,and depth. |
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Safety Standards and Approvals The AS-220 systems are fully compliant with the most stringent safety standards. The AS-220 systems are CE certified for safety and electro-magnetic compliance. |
