Railway Axle Inspection Systems

STARMANS DIO 2000 Automated Ultrasonic Testing Device for Railway Axles

Advanced Automated Ultrasonic Inspection for Railway Axles

The STARMANS DIO 2000 Automated Ultrasonic Testing Device for Railway Axles delivers comprehensive, fully automated inspection solutions for critical railway safety components. Engineered for continuous four-shift operation, this system provides reliable defect detection in both solid and hollow railway axles, ensuring passenger safety and operational reliability.

Fully Automated Operation

Our advanced inspection system provides complete automated testing with minimal operator intervention, delivering consistent, reliable results for:

• Solid Axles: Complete volumetric inspection of solid railway axles
• Hollow Axles with Borehole: Specialised inspection for hollow axle configurations
• Radial Direction Testing: Circumferential defect detection
• Axial Direction Testing: Longitudinal defect identification

International Standards Compliance

Comprehensive Regulatory Conformity

The STARMANS DIO 2000 Railway Axle Testing Device complies with major international railway axle inspection standards:

International & European Standards:

• ISO 5948: Railway rolling stock materials - Ultrasonic acceptance testing
• EN 13261: Railway applications - Wheelsets and bogies - Axles - Product requirements
• E BN 918 275: Axles for motor wagons - Testing specifications
• DB 907.0101: Deutsche Bahn standard for ultrasonic testing of new hollow wheelset axles

Quality Assurance: Meeting the most stringent requirements for railway safety worldwide.

Revolutionary Geometry-Independent Testing

Unique Adaptive Inspection Technology

No Pre-Programming Required

Game-Changing Advantage:

• Geometry-Independent Operation: Tests axles regardless of specific geometry variations
• No Drawing Input Required: Eliminates need to enter axle drawings before testing
• Universal Application: Single system handles diverse axle designs and configurations
• Rapid Changeover: No setup time for different axle types
• Future-Proof Technology: Automatically adapts to new axle designs without reprogramming

This revolutionary capability significantly reduces setup time, eliminates programming errors, and maximises operational flexibility.

Advanced Inspection Technology

Pulse-Echo Ultrasonic Method

Proven Detection Technique

• Radial Inspection: Complete circumferential coverage detecting transverse defects
• Axial Inspection: Longitudinal examination identifying axial discontinuities
• Multi-Directional Coverage: Comprehensive defect detection from all orientations
• High Sensitivity: Detects minute defects before they become critical failures

Flexible Coupling Options

Optimized for Different Applications

• Immersion Coupling: Full water immersion for optimal ultrasonic transmission
• Water Gap Coupling: Alternative coupling method for specific axle configurations
• Consistent Results: Reliable coupling ensures repeatable inspection performance
• Contamination-Free: Clean water coupling eliminates gel residue

Robust Mechanical Design

Industrial-Grade Construction

Built for Continuous Operation

• Four-Shift Capability: Designed for 24/7 continuous production environments
• Compact Design: Space-efficient footprint for production facilities
• Durable Construction: Robust components ensure long service life
• Stainless Steel Components: All water-contact parts constructed from corrosion-resistant stainless steel

Intelligent Axle Handling

Flexible Fixturing System

• Apex Fixturing: Secure axle positioning with adjustable apex points
• Size Adaptability: Automatic adjustment accommodates various axle dimensions
• Stable Positioning: Precise fixturing ensures consistent inspection geometry
• Quick Loading: Efficient axle placement for high-throughput operation

Advanced Water Management

Efficient Bath System

• Spillway Design: Controlled water level management
• Dual Bath Configuration: Additional bath for water circulation and temperature control
• Pumping System: Automated water transfer between baths
• Water Quality Maintenance: Circulation system maintains optimal coupling conditions

Advanced Control Systems

Siemens PLC Integration

Industrial Automation Excellence

• OptiPanel Operation: User-friendly touchscreen interface for intuitive control
• Network Connectivity: Seamless integration with company information systems
• Automated Operation: Continuous testing with minimal operator intervention
• Real-Time Monitoring: Live system status and inspection results

Comprehensive Software Suite

DIO 2000 Software Platform

User-Friendly Features:

• Settings Management: Easy configuration of inspection parameters
• Real-Time Display: Live visualisation of testing results during inspection
• Data Monitoring: Continuous tracking of system performance and results
• Calibration Mode: Integrated calibration procedures with reference standards
• Intuitive Interface: Minimal training requirements for operators

Advanced Capabilities:

• Automated Defect Detection: Intelligent algorithms identify and classify defects
• Multiple Inspection Modes: Configurable for different axle types and requirements
• Quality Gates: Programmable accept/reject criteria based on standards
• Alarm Management: Visual and acoustic signalisation for defects

Defect Marking & Signalisation

Integrated Marking System

Immediate Defect Identification

• Automatic Marking: Defects marked directly on axle surface
• Precise Location: Accurate defect position identification
• Visual Signalization: Light indicators for inspection results
• Acoustic Alerts: Audible warnings for critical defects
• Operator Notification: Immediate feedback for quality control decisions

Comprehensive Data Management

Advanced Analytics & Documentation

Complete Quality Records

• Automatic Data Recording: All inspection results captured and stored
• Statistical Analysis: Comprehensive quality trends and process control analytics
• Report Generation: Professional documentation for railway certification
• Large Database Capacity: Extensive historical data storage for fleet management
• Custom Report Formatting: Records arranged according to customer specifications
• Print Integration: Professional report output for quality documentation

Enterprise System Integration

Network Connectivity

• Company Network Interface: Direct connection to existing information systems
• Data Export Capabilities: Automated transfer of inspection results
• ERP Integration: Seamless connectivity with production and maintenance management
• Complete Traceability: Inspection history linked to axle serial numbers
• Quality Management: Integration with ISO and railway quality management systems

System Advantages

Operational Excellence

Cost & Time Effectiveness

• Fully Automated Operation: Minimal operator intervention reduces labor costs
• High Throughput: Efficient inspection cycles for production and maintenance facilities
• Geometry-Independent Testing: Eliminates programming time and setup errors
• Four-Shift Capability: Continuous operation maximises equipment utilisation
• Reduced Downtime: Quick axle changeover and minimal maintenance requirements
• Consistent Quality: Automated system eliminates operator variability

Safety Assurance

Critical Railway Component Inspection

• 100% Volumetric Inspection: Complete axle coverage ensures no defects missed
• Multi-Directional Detection: Radial and axial inspection identifies all defect orientations
• Standards Compliance: Meets international railway safety requirements
• Early Detection: Identifies defects before catastrophic failure
• Preventive Maintenance: Data-driven axle replacement and maintenance scheduling

Detection Capabilities

Defect Types Detected

• Internal Cracks: Fatigue cracks and stress-related defects
• Voids and Porosity: Manufacturing defects and material inconsistencies
• Inclusions: Non-metallic inclusions and material contamination
• Seams and Laps: Surface and subsurface manufacturing defects
• Forging Defects: Burst, flow-through, and other forging anomalies
• Service Defects: In-service damage and deterioration

Applications & Industries

Primary Markets

• Railway Axle Manufacturers: Production quality control for new axles
• Rolling Stock Maintenance: Periodic inspection and re-qualification
• Railway Operators: Fleet management and safety assurance
• Wheelset Workshops: Comprehensive axle inspection during overhaul
• Quality Assurance Labs: Independent testing and certification facilities

Axle Types

• Solid railway axles (all configurations)
• Hollow axles with borehole
• Passenger vehicle axles
• Freight car axles
• Locomotive axles
• High-speed train axles
• Metro and light rail axles