Post on 10-Mar-2020
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
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
Aims• Ultrasonic inspection of the full rail:
– Foot– Web– Head
• Inspection at high speed • Robust mechanical solution
– Data integrity– Operational conditions– Survivability– Simplicity
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
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
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
The Concept & the Prototype
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
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
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
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
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
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)
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
Optimisation through Simulation
• CIVA platform (validated by TWI)
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
Probe Assembly
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
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)
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
Effect of Temperature
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
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
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
Laboratory Testing Results: 75kph
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
Field Trials: REFER Test Train
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
Integration of UT module
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
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
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
Testing of UT module with the deployment system
UT acquisition module by MISTRAS used for field trials(courtesy of MISTRAS)
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
• Results generated from UT wheel with UT system developed by MISTRAS
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
• Example of a good A-scan from channel 1 (00 probe)
Interface Echo
Irrelevant Indication from rail head
2nd Interface Echo
Back Wall Echo
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
• Transverse crack verification in a thermic weld by the 700
probe of the UT module
00 probe 700 probe
Progress meeting #4
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
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
REFER, Lisbon, 29th-30th September 2011@Copyright INTERAIL Consortium 2011
Workshop 2013Copyright INTERAIL Consortium 2013
Thank You