Krautkrämer WheelStar
Ultrasonic under-car rail
wheel inspection system• High return on investment• Superior performance• Reliable automated process• Trusted by customers, auditorsand operators

Innovation starts here.

Rail travel has experienced continuousand accelerating growth with everincreasing demands for safety.

Overnight wheel inspection
made easy

Today’s demands on trains are high. High-speed passenger trains operating at speedsin excess of 250km/h, regional trains covering huge distances on a daily basis,and the increase in heavy freight loads are taxing the limits of rolling stock. To
ensure that no compromises are made on the safety of rail components,
rail operators, manufacturers and maintenance facilities areconstantly seeking increased productivity and improved quality
using nondestructive testing solutions.

The under-car version of the Krautkrämer WheelStar marks
the optimum in productivity when testing train wheels
in service. Without removing the wheelset from the train,
it is lifted and turned during the test by the integrated
mechanics. This whole inspection cycle only takes 15
minutes per complete wheelset. High-end ultrasoundsignal processing is applied from probes to evaluation.
A combination of conventional and phased arraytransducers ensures ideal adaptation to the inspectedareas: WheelStar inspects the tread, face, flange and(straight) web areas of the wheel and visualizes the results
in a projection view including automatic defect recognition
for easy interpretation by the operator.
Operation commands and the UT signals are transferred
via an industrial wireless connection to the operator station
for maximum flexibility whilst minimising cables. The
test mechanics are moved from wheelset to wheelset byintegrated, battery powered drive motors.

WiFi antenna
Wheelset lifting /turning mechanics
Scissor lift

Train wheels are one of the most safety critical elements ofrolling stock as they are exposed to high stress, particularly
due to increasing speeds, loads and distances. Global
railroad standards require these assets to be ultrasonicallyinspected during maintenance on a regular basis.

 aximizedMproductivity- 15 minutes cycle time
per wheelset- 90 seconds net testingtime per wheel- No wheelset removal
required- No time-consuming
prepositioning- Reduction of work
preparation due topre-programmed
wheel types

Best results- Fully automatedinspection with highest
reproducibility andtraceability- L ess false calls due
to elimination ofgeometric echos andautomated defectrecognition– Intelligent highlightingof relevant incident
increase inspection
quality

Easy operation- Short operator training–S traightforward
operating workflow withintegrated PLC
control- Battery powered andcable-free operation- Wireless data transfer- Compliant to specificrequirements of users
around the world- Automated reporting

Drive battery
Operator stationDrive remote control

Industry proven- L ong lifetime, highquality design-M odular system withintegrated high-end
Krautkrämer USIP
electronics-P rofessional project
execution, trusted byindustry leadersWheelStar software istrusted by operators•	Easy to operate, only short operator introduction
required•	Guided workflow, from stored wheel type toautomated data transfer and reporting• PLC control fully integrated•	Easy result interpretation and fewer false calls
thanks to automated defect recognition andgeometry echo suppression

Specifications•	USIP high-end electronics with modulararchitecture•	8 phased array probes, 6 conventional probes,
2 - 4 MHz•	Phased array: Radial and axial angle sweep•	Cable-free, battery powered, movable test
mechanics, length ~ 4.5 m•	Wireless data transmission between test
mechanics and operator workstation: Industrial
Wi-Fi 802.11 g/n•	Workflow based software with integrated PLC
control and stored wheel types•	Optional: Store ultrasound A-Scans for easy
drill-down•	15 minutes per complete wheelset. 90 seconds
net scan time per wheel

Flaw detectability• Volumetric flaw: FBH >= 2 mm

• Surface flaw: Crack >= 5 mm length, >= 1 mm depth•	Inspected area: Tread, face, flange, web (planar).
Realized by set of conventional and phased arraytransducers•	Complies: DIN 27201-7, other specifications on request

For more detailed information, please visit our website or contact us.

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BHHK60028 (04/2021)