Railway Wheel Inspection Systems

STARMANS DIO 2000 Automated Ultrasonic Testing Device for Railway Wheels

Advanced Automated Ultrasonic Inspection for Railway Wheels

The STARMANS DIO 2000 Railway Wheels Testing Device delivers comprehensive, fully automated ultrasonic inspection solutions for critical railway wheel components. Engineered for continuous four-shift operation, this system provides superior defect detection in both new production wheels and re-profiled service wheels, ensuring passenger safety and operational reliability.

Complete Wheel Inspection in Single Cycle

Unmatched Efficiency & Coverage

Our advanced inspection system examines the entire wheel structure in one automated cycle:

• Rim Inspection: Complete rim volume including tread and flange areas
• Disc Inspection: Full disc examination for cracks and material defects
• Hub Inspection: Comprehensive hub bore and mounting surface evaluation
• Single-Cycle Efficiency: Complete wheel inspection without repositioning

Time & Cost Effective: Single-cycle complete inspection significantly reduces testing time and operational costs compared to multi-setup systems.

International Standards Compliance

Comprehensive Regulatory Conformity

The STARMANS DIO 2000 Railway Wheel Testing Device complies with major international railway wheel inspection standards:

Global Railway Standards:

• EN 13262: Railway applications - Wheelsets and bogies - Wheels - Product requirements
• AAR M-101-90: Association of American Railroads - Manual of Standards and Recommended Practices
• UIC 811-1: International Union of Railways - Technical specification for the supply of wheels

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

Superior Detection Technology

Advanced Ultrasonic Performance

Enhanced Defect Sensitivity

Superior Detection Capabilities:

• Improved Defect Sensitivity: Advanced transducer technology detects minute defects
• Enhanced Detection Accuracy: Sophisticated signal processing for reliable defect identification
• Reduced Signal-to-Noise Ratio: Optimized electronics minimise false indications
• High Reliability: Consistent performance across all wheel types and conditions

Result: Better defect detection with fewer false calls, improving both safety and operational efficiency.

Versatile Application Range

New Production & Re-Profiled Wheels

Complete Lifecycle Inspection

New Wheel Production:

• Quality Assurance: 100% inspection of newly manufactured wheels
• Manufacturing Defect Detection: Identifies forging, casting, or heat treatment defects
• Pre-Service Verification: Ensures wheels meet specifications before installation
• Documentation: Complete quality records for certification and traceability

Re-Profiled Wheel Testing:

• Service Life Extension: Validates re-profiled wheels for continued service
• Fatigue Crack Detection: Identifies service-related cracks and defects
• Periodic Re-Qualification: Routine inspection during wheel maintenance cycles
• Safety Assurance: Ensures re-profiled wheels meet original safety standards

Fully Automated Operation

Minimal Operator Intervention

Advanced Automation for Maximum Efficiency

Automated Functions:

• Wheel Loading: Automated or semi-automated wheel positioning
• Inspection Cycle: Fully automatic testing sequence without operator input
• Defect Detection: Intelligent algorithms automatically identify and classify defects
• Result Documentation: Automatic recording and reporting of inspection results
• Accept/Reject Decisions: Automated quality gates based on standard criteria

Benefits:

• Reduced Labor Costs: Minimal operator intervention lowers operational expenses
• Consistent Quality: Eliminates operator variability in test results
• High Throughput: Efficient automated cycles maximise production capacity
• Operator Safety: Automated operation reduces operator exposure to hazards

Robust Mechanical Design

Industrial-Grade Construction

Built for Continuous Operation

Durable Components:

• Four-Shift Capability: Engineered for 24/7 continuous operation in demanding environments
• Compact Design: Space-efficient footprint optimises facility layout
• Rigid Frame Construction: Stable platform ensures consistent inspection geometry
• Long Service Life: Heavy-duty components designed for years of reliable operation

Advanced Wheel Handling System

Precision Positioning & Rotation

Mechanical Features:

• Testing Tank: Purpose-built immersion tank for water-coupled ultrasonic inspection
• Precision Rollers: Controlled wheel rotation for complete circumferential coverage
• Movable Transducer Holders: Adjustable probe positioning for different wheel geometries
• Stainless Steel Construction: All water-contact parts manufactured from corrosion-resistant stainless steel
• Optimal Coupling: Immersion design ensures consistent ultrasonic transmission

Advanced Control Systems

Siemens PLC Integration

Industrial Automation Excellence

Control Features:

• OptiPanel Operation: User-friendly touchscreen interface for intuitive system control
• Network Connectivity: Seamless integration with company information systems
• Automated Sequences: Pre-programmed inspection cycles for different wheel types
• Real-Time Monitoring: Live system status and inspection progress display
• Remote Access: Network-based system management and diagnostics

DIO 2000 Software Platform

Comprehensive Control & Visualisation

Software Modes:

• Settings Mode: Easy configuration of inspection parameters for different wheel specifications
• Measuring Mode: Real-time ultrasonic signal display and analysis during inspection
• Monitoring Mode: Continuous tracking of system performance and inspection results
• Calibration Mode: Integrated calibration procedures with reference standards

User-Friendly Interface:

• Intuitive Design: Minimal training requirements for operators
• Visual Feedback: Clear graphical representation of inspection results
• Easy Operation: Simplified controls for routine testing operations
• Quick Setup: Rapid parameter adjustment for different wheel types

Comprehensive Data Management

Advanced Analytics & Documentation

Complete Quality Records & Analysis

Data Capabilities:

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

Enterprise System Integration

Seamless Network Connectivity

Integration Features:

• Company Network Interface: Direct connection to existing information systems
• Data Export: Automated transfer of inspection results to central databases
• ERP Integration: Connectivity with production and maintenance management systems
• Complete Traceability: Inspection history linked to wheel serial numbers and heat codes
• Quality Management: Integration with ISO and railway quality management systems

Complete Wheel Inspection Coverage

Defect Types Detected

Rim Defects:

• Subsurface cracks and fissures
• Shelling and spalling precursors
• Tread defects and discontinuities
• Flange cracks and material separation

Disc Defects:

• Radial and circumferential cracks
• Spoke/web cracking
• Fatigue-related defects
• Manufacturing discontinuities

Hub Defects:

• Bore cracks and defects
• Mounting surface irregularities
• Material voids and inclusions
• Heat treatment anomalies

System Advantages

Operational Excellence

Efficiency Benefits:

• Single-Cycle Inspection: Complete wheel testing without repositioning saves time
• High Throughput: Rapid inspection cycles for production and maintenance operations
• Four-Shift Operation: Continuous 24/7 capability maximises equipment utilisation
• Automated Operation: Minimal operator intervention reduces labor costs
• Reduced Downtime: Quick wheel changeover and minimal maintenance requirements

Quality Assurance:

• 100% Wheel Coverage: Complete volumetric inspection ensures no defects missed
• Enhanced Sensitivity: Superior detection of critical safety defects
• Standards Compliance: Meets international railway wheel inspection requirements
• Consistent Results: Automated system eliminates operator variability
• Documentation Ready: Complete records for certification and regulatory compliance

Applications & Industries

Primary Markets

Wheel Manufacturers:

• New wheel production quality control
• Final inspection before delivery
• Manufacturing process monitoring
• Quality certification and documentation

Railway Operators:

• Periodic wheel inspection programs
• Preventive maintenance scheduling
• Fleet safety assurance
• Service life optimisation

Maintenance Facilities:

• Re-profiled wheel re-qualification
• In-service inspection programs
• Wheelset overhaul operations
• Safety verification testing

Independent Testing Labs:

• Third-party wheel certification
• Quality assurance verification
• Standards compliance testing
• Forensic analysis

Wheel Types & Applications

Compatible Wheel Categories

• Passenger vehicle wheels (high-speed and conventional)
• Freight car wheels (standard and heavy-haul)
• Locomotive wheels (diesel and electric)
• Metro and light rail wheels
• Tram and streetcar wheels
• Maintenance-of-way equipment wheels