Railway Track Inspection Systems

STARMANS Automated Ultrasonic On-Line Railway Defect Detection

Advanced Railway Track Ultrasonic Inspection System

STARMANS has developed a comprehensive ultrasonic inspection system specifically engineered for continuous on-line railway track inspection and defect detection. Successfully deployed on NDT inspection trains worldwide, this integrated system provides real-time detection, localisation, classification, and marking of railway defects at operational speeds.

Proven Performance

Our railway inspection system has been successfully installed as an integral component of hydraulic holder assemblies on NDT inspection trains, delivering reliable defect detection under demanding operational conditions.

Complete Railway Inspection Solution

High-Speed On-Line Detection

Continuous Track Monitoring

• Operational Speed Testing: Inspects both rails simultaneously at speeds up to 60 km/h
• Uninterrupted Service: Continuous scanning without track closure requirements
• Hydraulic Mounting System: Integrated holder ensures consistent probe contact with tracks
• Dual-Rail Coverage: Complete inspection of both track sides in single pass

Comprehensive Defect Detection

Surface & Subsurface Analysis

• Subsurface Defect Detection: Advanced ultrasonic technology identifies internal cracks, voids, and discontinuities
• Surface Defect Imaging: Specialised camera systems with sensitive detectors and image processing algorithms
• Multi-Layer Inspection: Complete evaluation from surface to subsurface structures
• Real-Time Processing: Immediate defect identification during inspection runs

Advanced Technical Capabilities

Multichannel DIO 2000 Platform

Industry-Leading Technology

• Multiple Ultrasonic Probes: Strategically positioned probes in direct contact with rail surface
• Specialised Construction: Purpose-built probe configuration for optimal railway scanning
• Safe Operation: Engineered design ensures reliable detection at inspection speeds
• Hydraulic Integration: Seamless integration with train hydraulic systems

Intelligent Signal Processing

Advanced Software Architecture

• Proprietary Signal Evaluation: Custom-developed software for railway-specific defect analysis
• Variable Parameters: Adaptive processing methods guarantee comprehensive object detection
• Advanced Algorithms: Sophisticated signal processing optimised for railway defect characteristics
• Real-Time Analysis: Instantaneous defect evaluation during inspection

Automated Classification & Analysis

Object Classification System

Intelligent Defect Identification

• Automated Classification: Distinguishes between defects, cracks, holes, and welds
• EN Standards Compliance: Classification according to European railway standards
• Defect Type Separation: Advanced algorithms separate and categorise detected objects
• Severity Assessment: Evaluates defect criticality for maintenance prioritisation

Comprehensive Database Management

Complete Data Recording & Analysis

• SQL Database Storage: All detected objects automatically stored in relational database
• Statistical Analysis: Detailed statistics of defects, holes, and welds present in tracks
• Historical Tracking: Long-term defect progression monitoring
• Automated Reporting: Printable reports of all detected objects and locations

GPS Integration & Localisation

Precision Defect Mapping

GPS-Synchronised Detection

• Real-Time GPS Coordination: Every detected defect tagged with precise GPS coordinates
• Map Visualisation: Defects displayed on interactive track maps
• Accurate Localisation: Pinpoint identification of defect locations for maintenance crews
• Route Planning: Optimize maintenance schedules based on defect locations

Automated Notification System

• Instant Alerts: Real-time notifications for critical defects
• Maintenance Coordination: Automated work order generation for detected issues
• Priority Flagging: Critical defects highlighted for immediate attention
• Service Integration: Seamless communication with maintenance management systems

System Synchronisation & Integration

Dual Detection System

Unified Surface & Subsurface Monitoring

• Full Synchronisation: Ultrasonic and camera systems fully coordinated
• Comprehensive Coverage: Combined detection ensures no defects are missed
• Unified Database: All detection methods feed into single integrated database
• Correlated Analysis: Surface and subsurface data analysed together for complete assessment

Enhanced Safety & Oversight

Railway Safety Advancement

• Proactive Maintenance: Early defect detection prevents catastrophic failures
• Service Optimisation: Maintenance companies gain complete overview of track condition
• Safety Improvement: Continuous monitoring enhances rail transport safety
• Risk Mitigation: Identifies potential failures before they become critical

Technical Specifications

Performance Features

• Platform: Multichannel ultrasonic system DIO 2000
• Detection Speed: Up to 60 km/h continuous operation
• Coverage: Dual-rail simultaneous inspection
• Detection Types: Surface and subsurface defects
• Processing: Real-time automated signal processing and monitoring
• Classification: Defects, cracks, welds, holes per EN standards
• Storage: SQL database with GPS synchronization
• Output: Automated notifications and reports

Detection Capabilities

What the System Detects:

• Internal cracks and fissures
• Subsurface voids and cavities
• Weld quality and discontinuities
• Rail head defects
• Transverse defects
• Longitudinal cracks
• Bolt holes and fastener damage
• Surface irregularities

Applications & Benefits

Railway Operations

• Mainline Railways: High-speed and conventional rail network inspection
• Urban Transit: Metro and light rail system monitoring
• Freight Lines: Heavy-haul track condition assessment
• High-Speed Rail: Critical infrastructure monitoring for passenger safety

Operational Advantages

• No Track Closure Required: Inspection at operational speeds
• Complete Documentation: Comprehensive defect records for regulatory compliance
• Maintenance Optimisation: Data-driven maintenance scheduling
• Cost Reduction: Early detection prevents expensive emergency repairs
• Safety Enhancement: Proactive defect identification prevents accidents