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,

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

npp@mail.npptec .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

npp@mail.npptec .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

Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4

Pierre MARTYProduct Line Leader, AREVA NDE-Solutions12th July, rolling Stock 3, D4

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