Dear Partners! OKOndt GROUP is continuing to operate in common mode.
We are trying to stay ahead of COVID-19 situation and take the best measures to ensure the safety of our families, friends, customers, partners.

Ultrasonic flaw detectors

UDS2-77 Ultrasonic Single Rail Flaw Detector

UDS2-77 Ultrasonic Single Rail Flaw Detector

REQUEST A QUOTE

 

The UDS2-77 ultrasonic single rail flaw detector is a mechanized trolley intended for the inspection of one rail line.

The flaw detector employs a unique scanning scheme that allows testing the entire rail section, except for foot flanges, by pulse echo, echo-shadow and echo-image techniques.

 

 

The display of the ultrasonic mechanized flaw detector for the inspection of one rail line UDS2-77
  • User-friendly operation

Both mechanics (trolley) and electronics (software) of the UDS2-77 are ergonomically designed, have a user-friendly intuitive interface, as well as are resistant to severe weather conditions that may occur during operation on a railway track.

  • Trolley design

  1. Weight of the trolley is 16 kg only.
  2. Modular design of the trolley consists of a support frame with adaptive rollers; electronic unit for control and visualization; multichannel unit  (MUX); battery pack; couplant (water) tank; probe units; suspension mechanism of the probe units to place them into operation/transportation position; encoder.
  3. The position of the electronic unit for control and visualization can be adjusted along three axes
  4. The probe unit is positioned cross-wise to the rail with the aid of a dedicated control device.
  5. The probe unit can be centered using the adaptive roller
  6. The suspension mechanism of the probe unit ensures a stable coupling if the trolley is tilted for up to 15°
The display of the ultrasonic mechanized flaw detector for the inspection of one rail line UDS2-77
Probe units of the ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77
  • Probe units

The UDS2-77 flaw detector employs contact probe units of conventional type with both standard and specialized probes.

The probe units are made from wear resistant plastic material, with hard-metal inserts on the working surface.

 

The probe units comprise the following probes:

Probe unit №1: Probe unit №2:
0° probe — 4 MHz 4х58°х34° probe — 2.5 MHz
70° probe — 2.5 MHz (Forward) 70° probe — 2.5 MHz (Backward)
4х58°х34° probe — 2.5 MHz 2х45° probe — 2.5 MHz (Forward/Backward)
 

1. One 4 MHz probe, 00 refracted angle is intended for inspection of the entire rail section by height in the web projection, for the presence of internal defects and laminations. This probe enables two testing techniques: pulse echo and echo-shadow.

2. Two 2.5 MHz probes, 700 refracted angle of (one of them emits along, and another — across the trolley movement) are intended for inspection of the central part of the rail head, for the presence of mature transverse defects.

3. Two 2.5 MHz probes, 450refracted angle (one of them emits along, and another — across the trolley movement) are intended for inspection of the entire rail section in the web projection, for the presence of internal defects, as well as for inspection of bolt holes for the presence of star-type defects.

4. Eight 2.5 MHz probes, 580 refracted angle that are turned by 34° in relation to the rail axis. The probes are placed in two cases, with 4 piezoelectric-crystal plates each. These probes enable pulse echo and echo-image techniques and are intended for flaw detection across the entire rail head.

Key features:

  • Representation of test results in the form of A-scan, multi-A-scan, B-scan for all channels;
  • Real-time display of test results in the form of B-scan
  • Data recording and saving (operator’s name, line, direction, track number, left/right position, initial track coordinate, date, time, final track coordinate);
  • Screenshot saving (PrintScreen);
  • Saving of test results in the form of data array (B-scan) to the internal memory;
  • Use of USB flash drive for transmitting test results to PC;
  • Availability of measuring gates in A-scan & B-scan modes;
  • Post-viewing of test result on the flaw detector with the possibility to measure conditional sizes of defects;
  • Possibility to put the track markers (e.g. “Bridge”, “Crossing”, “Bolt hole”, etc.).
  • Suspension mechanism of probe unit

The suspension mechanism is responsible for positioning the probe unit in the rail head cross-section. It also ensures a steady acoustic coupling when the trolley is turned by ±15°.

Suspension mechanism of the ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77

Fig. 3 — Suspension mechanism. Working position (lever down)

Transport position (lever up) of the ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77

Fig. 4 — Suspension mechanism. Transport position (lever up)

Adaptive wheels of the ultrasonic mechanized flaw detector for  inspection of one rail line UDS2-77

Fig. 5 — Adaptive wheels

Electronic unit of the ultrasonic mechanized flaw detector for te inspection of one rail line UDS2-77
  • Electronic unit of UDS2-77

1 — Control Knob to change operation modes and parameter values in the software interface;

2 — Connector for headphones;

3 — Connector for USB-drive;

4 — Connector for Encoder;

5 — Connector for Multichannel (MUX).

  • Keypad

Keypad of UDS2-77 flaw detector consists of two navigation panels that are used for browsing through the menu items, modifying the parameter values, and calling for various operation modes with the aid of ‘hot’ keys.

Keypad of the ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77
 

The UDS2-77 features a simple menu structure for setup and calibration, as well as setting of software functions/modes. The device is furnished with the Hot Keys panel to get an immediate access to main operation modes, such as display (А-scan/B-scan), correction of track coordinate, generation of test report, On/Off button for test result saving mode.

 
A-scan of the ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77

а) A-scan

Multi A-scan of the ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77

b) Multi-A-scan (Indian version)

 
B-scan of the ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77

c) B-scan (all channels)

A-Scan + B-scan of the ultrasonic mechanized flaw detector for  inspection of one rail line UDS2-77

d) A-scan + B-scan

Fig. 6 — Test result display modes:

 
 

Test result post-viewing mode

 
A general menu of the ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77

a) Viewing the general menu

Measuring flaw parameters of the ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77

b) Measuring flaw parameters

Viewing B-scan + A-scan of the ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77

c) Viewing B-scan + A-scan

Fig. 7 — Test result viewing mode

Version of UT flaw detector UDS2-77 intended for testing central and field faces of the rail head

Type#1 (Advanced version)

allows testing central and field faces of the rail head for the presence of internal and surface defects (head checking, Squat):

  • Probe Unit 1 (Central Line):
    • 0°-4 MHz
    • 70°-2.5
    • 4x58°x34°-2.5 MHz
  • Probe Unit 2 (Central Line):
    • 4x58°x34°-2.5 MHz
    • 70°-2.5
    • 2x45°-2.5 MHz

Version of UT flaw detector UDS2-77 for detection all defects in the rail, according to the requirements of AREMA

Type#2 (AREMA)

allows to detect all defects in the rail, according to the requirements of AREMA.

  • Probe Unit 1 (Central Line):
    • 0°-4 MHz
    • 70°-2 MHz (Forward Central head)
    • 70°-2 MHz (Backward Central Head)
  • Probe Unit 2 :
    • 2x45°- 2 MHz (Forward / Backward Central head)
    • 2x50°- 2 MHz (Side looking)
  • Probe Unit 3 (Gauge side):
    • 70°-2 MHz (Forward Gauge face head)
    • 70°-2 MHz (Backward Gauge face head)
  • Probe Unit 4 (Field side):
    • 70°-2 MHz (Forward Field face head)
    • 70°-2 MHz (Backward Field face head)

Version of UT flaw detector UDS2-77 for detection of exclusively horizontal cracks

Type#3 (Indian version)

allows to carry out testing of the rail head by the 70 degr. probes and testing for detection of exclusively horizontal cracks)

  • Probe Unit 1 (Central Line):
    • 0°-4 MHz
    • 70°-2 MHz (Forward Central head)
    • 70°-2 MHz (Backward Central Head)
  • Probe Unit 2 (Gauge side):
    • 70°-2 MHz (Forward Gauge face head)
    • 70°-2 MHz (Backward Gauge face head)
  • Probe Unit 3 (Field side):
    • 70°-2 MHz (Forward Field face head)
    • 70°-2 MHz (Backward Field face head)

Version of UT flaw detector UDS2-77 for testing of a rail in the web projection

Type#4 (BASIC)

testing of a rail in the web projection

  • Probe Unit 1 (Central Line):
    • 0°-4 MHz
    • 70°- 2 MHz
  • Probe Unit 2 (Central Line):
    • 70°- 2 MHz
    • 2x45°- 2 MHz

Version of UT flaw detector UDS2-77 for testing of a rail in the web projection, except for the bolt holes, for detection of the “Star”-type defects

Type#5 (EU)

testing of a rail in the web projection, except for the bolt holes, for detection of the «Star”-type defects)

  • Probe Unit:
    • 0°-4 MHz
    • 70°-2 MHz
    • 70°-2 MHz

Version of UT flaw detector UDS2-77 for crane rails testing

Type#6 (Crane version)

Crane rails testing

  • Probe Unit 1 (Central Line):
    • 0°-4 MHz
    • 70°-2 MHz (Forward Central head)
    • 70°-2 MHz (Backward Central Head)
  • Probe Unit 2 (Gauge side):
    • 70°-2 MHz (Forward Gauge face head)
    • 70°-2 MHz (Backward Gauge face head)
  • Probe Unit 3 (Field side):
    • 70°-2 MHz (Forward Field face head)
    • 70°-2 MHz (Backward Field face head)

Ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77
Ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77, view from the operator’s place
Ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77
Water tank of ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77
Ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77, view from above
The bottom of the ultrasonic mechanized flaw detector for inspection of one rail line UDS2-77
 
 
  1. UT techniques: pulse echo, (echo image) and echo shadow.

  2. Number of ultrasonic channels for 100% scanning: 13.

  3. Nominal test frequency: 1 to 6 MHz.

  4. Distance between probe pulse sendings: 1 mm at motion speed up to 5 km/h.

  5. Variation range of receiving path gain: 0 to 100 dB, with a step of 1 dB.

  6. Memory capacity for data storage: not less than 8 Gb.

  7. Weight of the flaw detector without battery and couplant: up to 16 kg.

  8. The flaw detector is powered by an independent power source (battery) with the rated voltage from 10.8 to 14.6 V and rated capacity of no less than 18 А·h.

  9. Time of operating mode setup: up to 15 sec.

  10. Time of continuous operation of the flaw detector with a fully-charged battery: no less than 8 hours.

  11. Protection rating: IP 64.

  12. The following alarms are generated during flaw detection: light – separate for every rail and common (via all test channels); sound – separate for every rail and common (for a group of channels); visual, on the screen – separate for every rail and every channel.

  13. GPS system is used to determine defect location coordinates on the track.

Description Q,ty, pcs. Notes

1

Trolley

1 pc.

Composition according to specification

2

System of couplant supply to probe units

1 set

Included as a part of trolley

2.1

- tank

1 pc.

 

2.2

- tubes

1 set

 

2.3

- distributors

1 set

 

3

Electronic unit

1 pc.

Included as a part of trolley

4

Multichannel unit (MUX)

1 pcs.

Included as a part of trolley

5

Power switching unit

1 pc.

Included as a part of trolley

6

Probe unit

2 pcs.

Included as a part of trolley

7

Battery pack

2 pcs.

1 pc. included as a part of trolley

8

Charger

1 pc.

 

9

Manual probe TSD4-20

1 pc.

Manual testing

10

Manual probe TAB2-45-14x14

1 pc.

Manual testing

11

Manual probe TAB2-70-14x14

1 pc.

Manual testing

13

Connecting cable from multichannel unit (MUX) to probe
(BNC-2xBNC)

1 pc.

 

14

Connecting cable from multichannel unit (MUX) to probe
(BNC-2x238)

1 pc.

 

15

Calibration block

1 pc.

Type of calibration block according to applicable regulatory documents or Customer’s requirements

16

Tools and accessories

1 set

 

17

Spare parts

1 set

 

18

USB flash drive

1 pc.

 

19

Application-dependent software

1 set

 

20

Carrying case for transportation and storage

1 pc.

 

21

Operational documentation

1 set

 

22

Case bag

1 pc.

 

 

 

Related Products:

About OKOndt GROUP™

"OKOndt GROUP™" represents a group of companies with more than 25-year experience in research, development and manufacture of NDT products for industrial clients all over the world, who endeavor to ensure high-level operational safety, quality, and reliability.

Need help?

CONTACT US

Search