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Die zerstörungsfreie Prüfung von Eisenbahnschienen wird mit Schienenprüfzügen durchgeführt. In den Prüfsystemen liegen alle Messdaten und Ortskoordinaten in digitaler Form vor. Mithilfe einer automatisierten Auswertung und Standardisierung der Datenformate ist eine Einbindung der Prüfergebnisse in Instandhaltungskonzepte möglich, die auf den Ideen von Industrie 4.0 bzw. Bahn 4.0 basieren. Für die Erhöhung der passiven Sicherheit der Komponente Schiene durch die automatisierte Klassifizierung von Anzeigen, deren Bewertung und Verortung kann eine moderne zerstörungsfreie Prüfung einen signifikanten Beitrag leisten. Dieser Grundgedanke wurde bereits bei der technischen Auslegung der Prüfsysteme in den Schienenprüfzügen berücksichtigt. In diesem Vortrag wird dargestellt, welche Möglichkeiten die installierte Technik bereits heute bereitstellt und welche Synergien mit einer automatisierten auf bildgebenden Methoden basierenden Bewertung in Zukunft möglich sind.
High speed ultrasonic axle inspection using a phased array with an electronically rotated beam
(2016)
The ultrasonic testing of the railway axes with a hollow drilling can be realized from the inside of the drill hole without demounting the axes and without dismantling the wheels and the brake discs. Flaws in the outer surface of the hollow shafts, whose orientation lies in the radial-radial plane have to be detected. Common testing systems use scanning in the circumferential direction by mechanical rotation of the probe system in the drilling. The presented phased array probe system carries out the rotation scan by electronically steering of the sound field only. Thereby manipulation of the probe inside the drilling becomes more simple and the inspection time can be shortened significantly. The beam will additionally be focused in the plane vertical to the specimen axis to optimize sound field parameters to different axle geometries.
Increased use of high performance steel (HPS) for demanding applications calls for non-destructive ultrasonic testing methods which is covered by standards like SEP 1927 (1) and ASTM E588 (2). Here, an adaption of standards like increasing sensitivity and resolution of ultrasonic testing may be needed in order to improve determination of steel cleanliness.
Modern requirements on standardization in that field have been evaluated during the INCAFAT project “A novel approach for rating fatigue-initiating inclusions in highly demanding steel” which was funded by the European Commission.
Main results of this research show that an adapted standard should be open to different type of specimen due to the diversity in application. This includes a wide range from bars, rings and plates as well as different inspection sensitivities. An adapted standard should be open to the definition of the volume to be investigated and open to be selected by the user. Furthermore, for enhanced resolution the frequency range should be extended to higher frequencies. The use of focal beam probes shall be mandatory and probes should be selected according to the geometry of the specimen. Therefore, calibration procedures have to be improved significantly to allow proper sizing of indications. Indication height shall be directly transferred into an equivalent disc shaped reflector taking distance amplitude curves as well as signal amplitude distribution and signal travel time into account.
A new standard draft proposal taking all these requirements into account has been filed in the frame of the INCAFAT project and is now on discussion.
Compared to standard ultrasonic testing methods the application of phased arrays offers advantages and flexibility by the electronic steering possibilities to control the transmitted and received sound fields as well as the image based evaluation of the recorded scans. For more than one decade phased array systems have been introduced and used in the railway sector for the inspection of wheelsets in the workshops. Up to the present field applications of phased array systems in rail inspection are rather rare. On the other hand a lot of scientific work on rail testing using phased arrays has been carried out in the recent past.
Mechanized ultrasonic rail inspection poses strong challenges e.g. due to the harsh environment, complex flaw types and high inspection speeds. Different tasks have to be carried out by non-destructive testing ranging from manufacturing inspection of thermite welds to in-service inspection for operational induced flaws in the rail head, rail web and rail foot as well as rolling contact fatigue. This work will give an overview and categorization of different present approaches for rail testing using phased array.
Phased array systems typically offer digital image based inspection results. This make these systems become the perfect candidates to feed inspection data into a modern big data based workflow, using e.g. cloud computing, signal processing and data fusion for recording, positioning and tracking of flaws and artefacts in rails and to gain additional benefit.
Evaluation of promising innovative approaches and solutions for phased array based ultrasonic rail inspection in the frame of “Industry 4.0” will be discussed.
In the last twenty years, components made of fibre-reinforced plastic became a prominently used material in safety-relevant structures. Periodic in-service inspection of these structures using reliable non-destructive testing methods became a relevant issue in the field. The goal of the EMRP-funded project VITCEA (Validated Inspection Techniques for Composites in Energy Applications) aims on the evaluation of the performance of various non-destructive testing methods on the inspection of fibre-reinforced plastics.
In this talk the results of the comparison of different ultrasonic testing methods will be discussed. There are two challenges for the ultrasonic inspection of fibre-reinforced plastics. Firstly, different material properties of the fibre and the resin cause anisotropic acoustical behaviour of the material. Secondly, the physical layout of fibre layers leads to complex structures of fibre-reinforced plastic parts, and thus to a complex acoustical response. Both result in a reduction of the signal to noise ratio and make interpretation of measurement results rather extensive.
During the VITCEA project, the acoustical behaviour of fibre-reinforced plate materials has been simulated. Specimens with artificial flaws for the evaluation of the detection thresholds have been designed and manufactured.
Various mechanized ultrasonic testing methods including phased-array sensors, air-coupled transducers, immersion tank testing and contact technique have been evaluated on the specially designed specimen. Laboratory scale tests and a round robin test have been carried out. The probability of detection and the detection thresholds for each method have been estimated.
Die Ultraschall Phased-Array Technik bietet durch die variable elektronische Steuerung des Schallfeldes gegenüber konventioneller Prüftechnik Vorteile bei vielen Prüfaufgaben, sowohl bei der Datenaufnahme als auch der bildhaften Bewertung. Die mechanisierte Schienenprüfung stellt sehr hohe Anforderungen an die Prüftechnik insbesondere durch die hohen Prüfgeschwindigkeiten von bis zu 20 m/s.
Im Rahmen dieses Vortrags wird evaluiert, welche Lösungsansätze auf Basis der Ultraschall Phased-Array Technik vielversprechend erscheinen für einen Einsatz im Umfeld von Bahn 4.0.
Increased speed, heavier loads, altered material and modern drive systems result in an increasing number of rail flaws. The appearance of these flaws also changes continually due to the rapid change in damage mechanisms of modern rolling stock. Hence, interpretation has become difficult when evaluating non-destructive rail testing results. Due to the changed interplay between detection methods and flaws, the recorded signals may result in unclassified types of rail flaws. Methods for automatic rail inspection (according to defect detection and classification) undergo continual development. Signal processing is a key technology to master the challenge of classification and maintain resolution and detection quality, independent of operation speed. The basic ideas of signal processing, based on the Glassy-Rail-Diagram for classification purposes, are presented herein. Examples for the detection of damages caused by rolling contact fatigue also are given, and synergetic effects of combined evaluation of diverse inspection methods are shown.
Die Simulation von Ultraschallausbreitung ist ein wesentliches Hilfsmittel zur Optimierung von Prüfanordnungen und wird zunehmend in der Prüfvorbereitung eingesetzt. Eisenbahnschienen sind Bauteile mit komplexer Geometrie und im eingebauten Zustand eingeschränkter Zugänglichkeit. Bei der Prüfung im Feld entstehen aus der Schienengeometrie komplexe Echosignale mit Formanzeigen, die schwer zu interpretieren sind.
Für das bessere Verständnis der Schallausbreitung in der Eisenbahnschiene wird diese in einem ersten Schritt mit Hilfe verschiedener Ansätze modelliert. Hierbei werden Finite Elemente Methoden und semi-analytischen Modelle verwendet. In einem zweiten Schritt werden die Ergebnisse der Simulationsmodelle einander gegenübergestellt und mit Messungen an realen Schienen verglichen.
Ziel dieser Untersuchungen ist die Validierung von Simulationsverfahren mit Hilfe von Messdatensätzen und Überprüfung der Anwendbarkeit bei der Bewertung von Ergebnissen der Schienenprüfung.
Since 1999 there has been a continuous development of non-destructive head check inspection. Especially in case of modern rail inspection systems, high demands on a fast, detailed detection and classification of defects called for improved testing methods. Due to the large amount of different rail types and profiles, the adaptation and optimization of algorithms is still in progress. Additional data analysis is under devel-opment for combined eddy current and ultrasonic inspection methods. This presentation gives an over-view of further enhancement and linking of testing systems as well as data processing. Main foci of the development are an improved sensitivity and an increased reliability of the testing results. Also, addi-tional information can be obtained like determination of local hardness and roughness of the rail as well as an enhanced resolution for locating of defects which will be part of the presented work.
Im EMRP-Projekt VITCEA werden komplementäre ZFP-Verfahren zur Prüfung von Faserverbundwerkstoffen weiterentwickelt und validiert. In diesem Beitrag werden Ergebnisse verschiedener Techniken der aktiven Thermografie und des Ultraschalls vorgestellt. Die Nachweisempfindlichkeiten bezüglich künstlicher und natürlicher Fehler mit unterschiedlichen lateralen Ausdehnungen und in verschiedenen Tiefen werden miteinander verglichen.