UDS2-77 Ultrasonic Single Rail Flaw Detector

 

The UDS2-77 ultrasonic single rail flaw detector is intended for continuous inspection of a rail in track and manual verification of indications caused by rail defects.

Bulk mode testing is done at a speed of 4 km/h.

The unique scanning scheme, employing pulse echo, echo-shadow, and echo-image techniques, enables inspection of the whole rail, excluding its base blades.

 

 

An electronic unit of ultrasonic single rail flaw detector UDS2-77
  • Easy-to-Use

The UDS2-77 is easy to use due to its intuitive interface.

The ‘Hot Keys’ panel gives quick access to all the main settings and functions of the detector.

  • Lightweight, Ergonomic, and Reliable

The UDS2-77 consists of a support frame with adjustable rollers; an electronic unit for control and visualization; a multichannel unit (MUX); a storage battery; a couplant tank; 13 probe units for continuous inspection and 2 probe units for hand testing; a suspension mechanism to place the probe units into an operation or transportation position; an encoder.

All the modules can be easily assembled and disassembled.

The weight of the flaw detector without a storage battery and a couplant tank is no more than 16 kg.

The electronic unit is 3-axis adjustable.

The rollers are adjusted for the size of the rail.

The suspension mechanism guarantees the stability of acoustic coupling, even if the frame is tilted at ±15°.

The flaw detector performs excellently under difficult field conditions common for rail inspection.

Several ultrasonic single rail flaw detectors UDS2-77
Probe units of the ultrasonic single rail flaw detector 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 detection 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 detection 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 detection of internal defects, as well as for inspection of bolt holes for the detection of star-type defects.

4. Eight 2.5 MHz probes, 580 refracted angle that are turned by 340 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 single rail flaw detector UDS2-77. Working position (lever down) of the ultrasonic single rail flaw detector UDS2-77

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

Suspension mechanism of the UT single rail flaw detector UDS2-77. Transport position (lever up) of the ultrasonic single rail flaw detector UDS2-77

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

Adaptive wheels of the ultrasonic single rail flaw detector UDS2-77

Fig. 5 — Adaptive wheels

Electronic unit of the ultrasonic single rail flaw detector 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 single rail flaw detector 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 display of the ultrasonic single rail flaw detector UDS2-77

а) A-scan

Multi A-scan of the ultrasonic single rail flaw detector UDS2-77

b) Multi-A-scan

 
B-scan of the ultrasonic single rail flaw detector UDS2-7

c) B-scan (for all channels)

A-Scan + B-scan of the ultrasonic single rail flaw detector UDS2-77

d) A-scan + B-scan

Fig. 6 — Test result display modes:

 
 

Test result post-viewing mode

 
General menu of the ultrasonic single rail flaw detector UDS2-77

a) Viewing the general menu

Flaw parameters of the ultrasonic single rail flaw detector UDS2-77

b) Measuring flaw parameters

B-scan + A-scan of the ultrasonic single rail flaw detector UDS2-77

c) Viewing B-scan + A-scan

Fig. 7 — Test result viewing mode

Advanced version of the ultrasonic single rail flaw detector UDS2-77

Type#1 (Advanced version)

allows testing central and field faces of the rail head for the detection 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

Modification of the ultrasonic single rail flaw detector UDS2-77 which allows to detect all defects in the rail, according to AREMA requirements

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)

Modification of the ultrasonic single rail flaw detector UDS2-77 for testing the rail head with 70° probes and detection of exclusively horizontal cracks

Type#3 (Indian version)

allows testing the rail head with 70° probes and testing for the 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)

Modification of the ultrasonic single rail flaw detector UDS2-77 for inspection of the rail in the web projection

Type#4 (BASIC)

testing of the 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

Modification of the ultrasonic single rail flaw detector UDS2-77 for the detection of “Star”-type defects

Type#5 (EU)

testing of the rail in the web projection, except for the bolt holes, for the detection of “Star” defects)

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

Modification of the ultrasonic single rail flaw detector UDS2-77 for the detection of “Star”-type defects

Type#6 (Crane version)

Crane rail 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 single rail flaw detector UDS2-77
Ultrasonic single rail flaw detector UDS2-77, view from the operator’s place
Ultrasonic single rail flaw detector UDS2-77
Water tank of the ultrasonic single rail flaw detector UDS2-77
Ultrasonic single rail flaw detector UDS2-77, view from above
 
 
  1. UT techniques: pulse echo, (echo image) and echo shadow.

  2. Number of ultrasonic channels for 100% scanning: 13 for continuous inspection and 2 for manual verification.

  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

12

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

1 pc.

 

13

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

1 pc.

 

14

Calibration block

1 pc.

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

15

Tools and accessories

1 set

 

16

Spare parts

1 set

 

17

USB flash drive

1 pc.

 

18

Application-dependent software

1 set

 

19

Carrying case for transportation and storage

1 pc.

 

20

Operational documentation

1 set

 

21

Case bag

1 pc.

 

 

 

 

 

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