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A novel technology for detecting train wheels surface cracks by non destructive testing based on thermography

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Novel technology to better detect surface cracks on train wheels

Concerns about safety continue to grow as trains become faster and carry more passengers and goods than ever before. An EU initiative developed an innovative inspection and maintenance system to reduce accidents.

Industrial Technologies icon Industrial Technologies

Broken wheels resulting from internal cracks are a major concern for the railway transport industry. These defective wheels lead to mechanical failure, derailments and accidents. Existing techniques that perform tests on wheels to identify cracks early on have several drawbacks. A faster, cleaner method is needed that will automatically detect surface cracks, and that will not cause any damage to materials and components or produce waste. Thanks to EU funding, the TRAINWHEELS (A novel technology for detecting train wheels surface cracks by non destructive testing based on thermography) project sought to optimise infrared thermography, an advanced inspection tool successfully being used in other sectors to detect overheating joints and sections. Early work centred on the creation of a prototype to validate the TRAINWHEELS technology that conforms to all European safety standards. To this end, hardware, software and electrical parameters were modified in order to maximise the detection of cracks. Project partners successfully demonstrated the system's suitability in detecting surface defects via a speedier automated solution. They also demonstrated its overall potential as a surface crack detection system for train maintenance and transportation companies. The TRAINWHEELS solution has the capacity to replace existing visual inspection and other surface inspection technologies, leading to a reduction in inspection times and a boost in productivity. In addition, it can identify cracks early on, allowing for repairs or enhancements. Wheel manufacturers can expect to save up to 25 %. The system runs efficiently and keeps operating costs to a minimum thanks to controlled heating and feedback by the infrared camera and developed software. TRAINWHEELS delivered a time- and cost-efficient, environmentally friendly alternative to railway maintenance companies and train wheels manufacturers. This state-of-the-art train wheel detection technology will raise safety and security standards for both travellers and freight.

Keywords

Cracks, train wheels, TRAINWHEELS, thermography, surface crack detection

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