TRAINWHEELS

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

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 Obiettivo del progetto (Objective)

'The European rail network is getting more and more important in the transportation sector: it hosts high speed-trains, higher loads of more passengers or goods, with increased frequency. This determines a higher mechanical load for the moving parts of the carrier involved: therefore, increasing inspection and maintenance are required in order to guarantee safety and well-being of trains. One of the biggest concerns about transportation safety is broken wheels due to internal cracks. Frequent accidents and regular breakdowns have been registered in the latest years due to this failure. Three testing methods have been investigated to identify cracks or problems on the surface or near the surface of the wheel: Magnetic Particle Inspection, Dye Penetrant Inspection, and eddy current testing. These methods show the following drawbacks: MPI and DPI generates high amount of hazardous waste and none of them is automatable, while the eddy current system is sensitive to lift-off variations and probes need to be positioned at a constant distance. In conclusion a new, more efficient, automated and faster method is needed to detect surface cracks. TRAINWHEELS face the challenge of optimizing thermography in order to use it as an automated train wheel crack detection method, meeting all European Safety Standards. Using thermography for train inspection would result in a big improvement compared to previously quoted methods: thermography is an automated and faster approach; it is as well cleaner and cheaper. At the moment, there is no better way of controlling the train wheel surface than with the use of thermography. Our aim is to improve train circulation safety by enhancing the effectiveness of non-destructive tests on wheels, in order to identify cracks as soon as possible. For this reason, we believe that a coupling between an existing method – the Ultrasound testing – and the proposed one, will suit the purpose of delivering a complete and self-consistent detection method'

Introduzione (Teaser)

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

Descrizione progetto (Article)

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 http://www.trainwheels.eu (TRAINWHEELS) project is optimising infrared thermography, an advanced inspection tool successfully being used in other sectors to detect overheating joints and sections.

Based on the thermography crack detection method, the new system will automatically locate cracks on or near the surface. An infrared camera captures a change in temperature for a crack, and this heat map is fed back to an image processing system that performs an evaluation. The accompanying software is easy to use, and the results are generated quickly on screen for the operator.

During the first reporting period, the focus was on validating the TRAINWHEELS technology. The team characterised various features of wheel sets and surface cracks. They also carried out electromagnetic simulations to develop an induction system for train wheel heating.

Existing thermography methods were assessed in order to come up with a design for an optimal and efficient inspection system.

Researchers are developing algorithms and a software system that will identify failures and allow operators to understand and group results of the thermography system.

TRAINWHEELS intends to deliver 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.