The Fraunhofer IZFP is an internationally renowned research and development institute focusing on “sensor and data systems for safety, sustainability, and efficiency” with headquarters in Saarbrücken.
Material inspection of railway wheelsets is an integral part of safe rail transport. Currently, ultrasonic inspection of railway wheelsets is carried out in large workshops using the AURA system, which has been in use since 1999. In smaller workshops, it is usually carried out manually. Due to the volatility of the data, storage – and thus possible traceability of the inspection results – was and is not possible.
The goal was to develop a compact inspection system for smaller workshops that is equally efficient, offers long-term data storage, and reduces the “human factor” to a minimum, thereby reducing the error rate of manual inspection. This was achieved by combining three hand-held scanners for inspecting the wheel shaft, wheel flange, and tread.
“PASAWIS” (Phased Array Semi-Automated Wheelset Inspection System) is the first system to enable complete storage of test data during manual inspection, thus ensuring long-term traceability and reproducibility. The locally stored data can be transferred to central storage locations via multiple interfaces. Direct upload to cloud-based document management systems is also possible.
Inspection parameters such as inspector, inspection date, signal amplification, and inspection areas are documented in DICONDE format (Digital Imaging and Communication for Nondestructive Evaluation) in accordance with ASTM E2633 14 US. This open standard, with attached PACS (Picture Archiving and Communication System), meets the highest requirements and enables images and digital data from industrial material inspection to be displayed, transmitted, and stored.
Inspection results are automatically saved in customized test reports as PDF files and contain the graphical results for the individual wheelset, such as A-scan, sector scan, and C-scan, as well as metadata such as calibration date, instrument serial number, name of the inspector, or workshop. Only minimal manual input is required for report generation. The test report is provided with a secure digital signature, thereby guaranteeing a high level of security.
PASAWIS consists of an ultrasonic unit with customized software. The system can be operated by one person and is mobile for use in production. This inspection assistance and the visualization of the inspection procedure ensure greater safety for wheelsets. All test data is recorded and stored in full. Since the tread, wheel shaft, and wheel flange are now tested using ultrasound, inspectors do not need any additional qualifications. The acquisition and maintenance costs are moderate.
PASAWIS offers the following advantages:
· Meets the requirements of VPI-EMG 09
· Time-efficient automated inspection reports
· Digital signature
· Complete wheelset inspection
· Short inspection times of approximately 10 minutes per wheelset
· Individually configurable
· Automatic transfer correction
Fraunhofer Institute for High Frequency Physics and Radar Techniques FHR
