Ultrasonic testing of train wheels

Abstract

A testing system includes two testing heads, each designed to interact with a separate train wheel mounted on the same axle. These testing heads use ultrasonic transducers to send and receive signals that help assess the condition of the wheels. One or both testing heads include an encoder wheel that rolls along the surface of the train wheel during inspection. This encoding wheel tracks the rotational position of the train wheels, allowing the system to match ultrasonic data with specific locations on the wheel surface. Each head may have its own power source, or they may be powered by a central controller. Alternatively, one head may supply power to the other.

Description

Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WOULTRASONIC TESTING OF TRAIN WHEELSCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. § 119 of United States Provisional Patent Application No. 63 / 685,222, filed on 20 August 2024, entitled “Rail Wheel Compact Tester” the entirety of which is hereby incorporated by reference.TECHNICAL FIELD

[0002] The subj ect matter described herein relates to ultrasonic testing of components, such as train wheels.BACKGROUND

[0003] Train cars must be periodically inspected to ensure safe operations. One aspect of such inspections involves assessing train wheels for wear and fatigue. Such can be performed in a variety of ways, for example, in some instances, ultrasonic testing equipment us used to evaluate train wheels while the train wheels are still attached to the train car. Such inspections can be performed in the field in a garage, or in a train yard. In some cases, the train wheels are removed from the cars and are sent to a lab for testing under controlled conditions.SUMMARY

[0004] This disclosure relates to ultrasonic testing of train wheels.

[0005] A testing system includes two testing heads, each designed to interact with a separate train wheel mounted on the same axle. These testing heads use ultrasonic transducers to send and receive signals that help assess the condition of the wheels.

[0006] One or both testing heads include an encoder wheel that rolls along the surface of the train wheel during inspection. This encoding wheel tracks the rotational position of the train wheels, allowing the system to match ultrasonic data with specific locations on the wheel surface. Power for the testing heads can be supplied in different ways. Each head may have its own power source, or they may be powered by a central controller. Alternatively, one head may supply power to the other.1532158374v.1Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WO

[0007] The controller receives data from both testing heads and from the tracking wheel. It uses this information to evaluate the condition of each train wheel. This may include determining whether a wheel is suitable to remain in service or should be removed.

[0008] The method involves placing each train wheel in contact with its respective testing head, rotating the wheels, and collecting ultrasonic data. The tracking wheel monitors rotation, and the controller processes the data to assess wheel condition. Water may be added to the wheels to improve signal transmission during testing.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations.

[0010] FIG. l is a schematic diagram of an example train wheel testing system;

[0011] FIG. 2 is a side view of an example trail wheel with an ultrasonic testing head coupled to it;

[0012] FIGS. 3 A and 3B are transparent views of example ultrasonic testing heads that can be used as the testing head in FIG. 2;

[0013] FIG. 4 is a block diagram of a controller that can be used with aspects of this disclosure; and

[0014] FIG. 5 is a flowchart of an example method that can be used with aspects of this disclosure.DETAILED DESCRIPTION

[0015] Certain implementations will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the devices and methods disclosed herein. One or more examples of these implementations are illustrated in the accompanying drawings. Those skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting2532158374v.1Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WO implementations and that the scope of the present invention is defined solely by the claims. The features illustrated or described in connection with one implementation may be combined with the features of other implementations. Such modifications and variations are intended to be included within the scope of the present invention.

[0016] Further, in the present disclosure, like-named components of the implementations generally have similar features, and thus within a particular implementation each feature of each like-named component is not necessarily fully elaborated upon. Additionally, to the extent that linear or circular dimensions are used in the description of the disclosed systems, devices, and methods, such dimensions are not intended to limit the types of shapes that can be used in conjunction with such systems, devices, and methods. A person skilled in the art will recognize that an equivalent to such linear and circular dimensions can easily be determined for any geometric shape. Sizes and shapes of the systems and devices, and the components thereof, can depend at least on the anatomy of the subject in which the systems and devices will be used, the size and shape of components with which the systems and devices will be used, and the methods and procedures in which the systems and devices will be used.

[0017] A system for mobile inspection of two train wheels of one wheel set (one wheel on each side of a train car) in parallel often requires two or more inspectors, each with their own testing equipment. Traditionally, such equipment includes long analog cables that are stiff, not easy to handle, give rise to signal deterioration, and can pick up noise via environmental absorption or electro-magnetic interference. The cables alone make such traditional equipment cumbersome and often requires a dedicated cart to move from wheel to wheel. Such a process is labor intensive and inefficient. This disclosure describes a light-weight system (e.g., can be carried by a single technician for extended periods of time) that includes two, fixed ultrasonic testing heads. Each inspection head is arranged to measure two wheels in each wheel set simultaneously. In addition, the solution described herein includes light-weight components that do not need a full cart to use.3532158374v.1Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WO

[0018] Such a testing system 100 is illustrated in FIG. 1. The system 100 includes a first ultrasonic testing head 102a and a second ultrasonic testing head 102b. Each ultrasonic testing head includes various sensors 103 and microelectronics 104 substantially similar to those described within United States Patent 12,203,889, filed on 11 November 2022, entitled “Inspection apparatus with integrated electronics”, the entirety of which is hereby incorporated by reference. In some implementations, one or both of the ultrasonic testing heads 102 included a power supply, such as a battery 105, to power the sensors 103 and microelectronics 104. The ultrasonic testing heads 102 are communicatively coupled (wired or wirelessly) to a controller 106. Such a controller 106 can include a tablet, phone, laptop, desktop computer, or any other controller. In some implementations, the controller 106 supplies power to one or both of the ultrasonic testing heads 102. In some implementations, a power supply within one ultrasonic testing head 102 can be used to power a second ultrasonic testing head 102b.

[0019] FIG. 2 is a side view of an example trail wheel 202 coupled to the ultrasonic testing head 102. The ultrasonic testing head 102 is roughly triangular shaped with a profile 204 configured to mate with an outer circumferential surface 206 of a train wheel 202. Typically, such a testing head 102 is secured, for example, to a rail 208 upon which the train wheel 202 travels. The testing head 102 can be secured in a variety of ways, for example, with one or more fasteners, adhesives, or magnets. Alternatively or in addition, the testing heads 102 can be mounted and secured separately from the rail 208. In some implementations, the portion of the rail 208 that the testing head is secured to can be movable, for example, to allow a train to move so that a next set of wheels can be tested.

[0020] Moving back to the testing heads themselves, FIGS. 3A and 3B are transparent views of example ultrasonic testing heads (300a, 300b) that can be used as the testing heads 102 in FIGS. 1-2. Each ultrasonic testing head (300a, 300b) includes multiple ultrasonic transducers 302 configured to send and receive ultrasonic signals, for example, into and from the train wheel 202. In the implementation shown in FIG. 3B, an encoder wheel 304 is arranged to roll in unison 4532158374v.1Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WO with a surface 206 of a train wheel 202 when the ultrasonic testing head 102 is in contact with the train wheel 202. In some implementations, the first ultrasonic testing head 102a includes the encoder wheel 304 while the second ultrasonic testing head 102b does not. Accurate measurements can still be taken with such an arrangement as wheels 202 on a single axle can be examined and can be assumed to rotate in unison. Alternatively, both of the ultrasonic testing heads 102 can include the encoder wheel 304. Such arrangements offer a redundancy in the event that an encoder 304 fails. While primarily described as using ultrasonic transducers, other nondestructive testing sensors can be used without departing from this disclosure. For example, in some implementations, eddy current sensors, phased arrays, or other sensors / transmitters can be used.

[0021] FIG. 4 illustrates an example controller 106 that can be used with some aspects of the current subject matter. The controller 106 can, among other things, monitor parameters of the system 100 send signals to actuate and / or adjust various operating parameters of such systems. As shown in FIG. 4, the controller 106 can include one or more processors 450 and non-transitory computer readable memory storage (e.g., memory 452) containing instructions that cause the processors 450 to perform operations. The processors 450 are coupled to an input / output (VO) interface 454 for sending and receiving communications with components in the system, including, for example, the ultrasonic transducers, the encoder wheel 304, or pressure sensors. In certain instances, the controller 106 can additionally communicate status with and send actuation and / or control signals to one or more of the various system components (including, for example, a motor to rotate the train wheels) of the system 100, as well as other sensors (e.g., pressure sensors, temperature sensors, vibration sensors and other types of sensors) that provide signals to the system 100.

[0022] The controller 106 can be implemented with various levels of autonomy. In some implementations, the controller 106 performs a test and provides raw data to an inspector. In some implementations, the controller 106 alerts the operator that a parameter is out of specification or may be out of specification, for example, a train wheel may include a fracture that is longer than 5532158374v.1Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WO is generally acceptable. In such arrangements, the operator evaluates the result and can then decide if the wheel remains in service or not. In some instances, the controller 106 determines a condition of a train wheel, and updates a status of the train wheel. In instances where a wheel must be removed from service, the controller can perform tasks to initiate replacing the wheel, for example, by producing a workorder or ordering a new train wheel. In operation, the controller sends signals to the first ultrasonic testing head and the second ultrasonic testing head to begin testing (e.g., emitting and receiving ultrasonic signals as the train wheels rotate). The controller subsequently receives signals characterizing a respective train wheel from each testing head. In some implementations, data characterizing the position of each wheel during the scan is also received from one or more encoder wheels 304.

[0023] Once all of the signals and data are received, data characterizing the first train wheel, the second train wheel, and the rotational position of the first train wheel and the second train wheel are provided by the controller 106. Providing such data can include saving the data to a file, displaying the data, or otherwise transmitting the data to be stored for later review. As previously discussed, in some implementations, the controller is further configured to determine a condition of the train wheels 202, such as a determination of whether the wheel should stay in service or be removed from service based at least in part on the data.

[0024] FIG. 5 is a flowchart of an example method 400 according to some example implementations. Aspects of the method 500 can be performed by the controller 106 all or in part. At 502, a first train wheel is received by a first ultrasonic testing head. At 504, a second train wheel is received by a second ultrasonic testing head. The second train wheel and the first train wheel are on the same axle. The ultrasonic testing heads 102 are secured such that ultrasonic testing heads 102 are static relative to the respective train wheels. In some instances, the train wheels are wetted (e.g., have water poured or sprayed on them by the inspector) to improve ultrasonic coupling compared to non-wetted train wheel.6532158374v.1Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WO

[0025] At 506, the first train wheel and the second trains wheel are rotated relative to the first ultrasonic testing head 102a and the second ultrasonic testing head 102b respectively. In some implementations, the ultrasonic testing heads 102 can move around static train wheels 202 without departing from this disclosure. During rotation, at 508, an encoder 304 measures a rotational position of the train wheels 202. The encoder 304 can be on the first ultrasonic testing head 102a, the second ultrasonic testing head 102b, or both. In some implementations, a first signal is sent from the controller 106 to the first ultrasonic testing head 102a, and a second signal is sent from the controller 106 to the second ultrasonic testing head 102b. Such signals cause, at 510, ultrasonic signals to be transmitted by the first ultrasonic testing head. Subsequently, at 512, reflected ultrasonic signals are received by the first ultrasonic testing head 102a. Similarly, at 514, ultrasonic signals are transmitted by the second ultrasonic testing head 102b responsive to receiving the signal from the controller 106. Subsequently at 516, reflected ultrasonic signals are received by the second ultrasonic testing head 102b. It should be noted that sending and receiving the ultrasonic signals can occur simultaneously with each wheel / testing head pair.

[0026] At 518, a signal characterizing a position of each train wheel 202 is transmitted to the controller 106 from the encoder 304. At 520, signals characterizing the first train wheel are sent to the controller 106 from the first ultrasonic testing head 102a. At 522, signals characterizing the second train wheel are sent to the controller 106 from the second ultrasonic testing head 102b. In some implementations, the transmission, receiving, and sending steps can be performed simultaneously for both ultrasonic testing heads (102a, 102b). At 524, a condition of the first train wheel and the second train wheel is determined. Such a condition can include, for example, determining that one or both the train wheels should remain in service or should be removed from service.

[0027] While this disclosure contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features specific to particular implementations of particular inventions. Certain features that are 7532158374v.1Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WO described in this disclosure in the context of separate implementations can also be implemented in combination or in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

[0028] Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. Moreover, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together into a single product or packaged into multiple products.

[0029] Thus, particular implementations of the subject matter have been described. Other implementations are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results.

[0030] ... Other implementations can be within the scope of the following claims.8532158374v.1

Claims

Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WOWhat is claimed:

1. An ultrasonic testing system comprising: a first ultrasonic testing head comprising: a first plurality of ultrasonic transducers configured to send and receive ultrasonic signals; and an encoder wheel arranged to roll in unison with a surface of a train wheel when the first ultrasonic testing head is in contact with the train wheel; a second ultrasonic testing head comprising: a second plurality of ultrasonic transducers; and a controller coupled to the first ultrasonic testing head and the second ultrasonic testing head.

2. The ultrasonic testing system of claim 1, wherein the encoder wheel is a first encoder wheel, wherein the train wheel is a first train wheel, wherein the second ultrasonic testing head comprises a second encoder wheel arranged to roll in unison with a surface of a second train wheel when the first ultrasonic testing head is in contact with the second train wheel.

3. The ultrasonic testing system of claim 1, wherein the first ultrasonic testing head comprises a power supply.

4. The ultrasonic testing system of claim 1, wherein the second ultrasonic testing head comprises a power supply.

5. The ultrasonic testing system of claim 1, wherein the first ultrasonic testing head is powered by the controller.9532158374v.1Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WO6. The ultrasonic testing system of claim 1, wherein the second ultrasonic testing head is powered by the controller.

7. The ultrasonic testing system of claim 1, wherein the first ultrasonic testing head or the second ultrasonic testing head is powered by a power supply of the other ultrasonic testing head.

8. A method comprising: receiving a first train wheel by a first ultrasonic testing head; receiving a second train wheel by a second ultrasonic testing head, the second train wheel and the first train wheel having a same axle; rotating the first train wheel and the second trains wheel relative to the first ultrasonic testing head and the second ultrasonic testing head; measuring, by an encoder on the first ultrasonic testing head, a rotational position of the first and the second train wheel; transmitting ultrasonic signals by the first ultrasonic testing head; receiving reflected ultrasonic signals by the first ultrasonic testing head; transmitting ultrasonic signals by the second ultrasonic testing head; receiving reflected ultrasonic signals by the second ultrasonic testing head; transmitting a signal characterizing a position of each train wheel to a controller from the encoder; sending signals characterizing the first train wheel to a controller from the first ultrasonic testing head; sending signals characterizing the second train wheel to a controller from the second ultrasonic testing head; and determining a condition of the first train wheel and the second train wheel.10532158374v.1Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WO9. The method of claim 8, further comprising: sending a first signal from the controller to the first ultrasonic testing head; and sending a second from the controller to the second ultrasonic testing head.

10. The method of claim 8, further comprising: wetting the first train wheel to improve ultrasonic coupling compared to a nonwetted train wheel; or wetting the second train wheel with water to improve ultrasonic coupling compared to a non -wetted train wheel.

11. The method of claim 8, wherein determining a condition of a train wheel is done by the controller.

12. The method of claim 8, wherein determining a condition of a train wheel comprises determining that the train wheel should remain in service or should be removed from service.

13. A system comprising: a first ultrasonic testing head configured to receive a first train wheel, the first ultrasonic testing head comprising: a first plurality of ultrasonic transducers configured to send and receive ultrasonic signals; and an encoder wheel arranged to roll in unison with a surface of the first train wheel when the first ultrasonic testing head is in contact with the first train wheel; a second ultrasonic testing head configured to receive a second train wheel, comprising: a second plurality of ultrasonic transducers; a controller coupled to the first ultrasonic testing head and the second ultrasonic11532158374v.1Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WO testing head, wherein the controller is configured to: receive a first signal from the first ultrasonic testing head, the first signal characterizing the first train wheel; receive a second signal from the second ultrasonic testing head, the first signal characterizing the second train wheel; receive a third signal from the encoder wheel, the third signal being indicative of a rotational position of the first train wheel and the second train wheel; and provide data characterizing the first train wheel, the second train wheel, and the rotational position of the first train wheel and the second train wheel based on the received first signal, second signal, and third signal.

14. The system of claim 13, wherein the encoder wheel is a first encoder wheel, wherein the second ultrasonic testing head comprises a second encoder wheel.

15. The system of claim 13, wherein the first ultrasonic testing head includes a power supply.

16. The system of claim 13, wherein the second ultrasonic testing head includes a power supply.

17. The system of claim 13, wherein the first ultrasonic testing head is powered by the controller.

18. The system of claim 13, wherein the second ultrasonic testing head is powered by the controller.

19. The system of claim 13, wherein the first ultrasonic testing head or the second ultrasonic testing head is powered by a power supply of the other ultrasonic testing head.12532158374v.1Atty. Dkt. No.: 43UT-511000-WO-2 / 866001 WO20. The system of claim 13, wherein the controller is further configured to determine a condition of the first train wheel and the second train wheel based on the received first signal, second signal, and third signal.532158374v.1

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