In-situ wheelset diagnostic unit

The unit is intended for periodic inspection of high-speed train wheelsets within the scope of scheduled examinations, without rolling out the bogies or dismantling the running gear. It detects flange and tread wear, diameter differences between the wheels of one axle, runout and internal defects in axles and discs at an early stage, before the train has to be withdrawn from the timetable for lengthy repair.

The unit is installed in the inspection pit at one of the repair stations. The train is brought onto the station, the operator positions the required axle over the unit, the lifting device raises the wheelset clear of the rails and drive rollers rotate it at a set speed. Laser measuring heads on both sides capture the wheel profile and determine diameter, flange thickness and height, radial and axial runout. Ultrasonic probes brought up to the axle end and the wheel rim scan the metal for cracks and laminations.

The unit comprises a lifting module with two support beams, a roller rotation drive, a measuring gantry with laser heads, an ultrasonic module with automatic couplant supply, a control cabinet and an operator workstation. Measurement results are stored in a database by train and axle number and compared with previous readings, giving a wear trend for every wheel. The unit can be extended with an axle box temperature module and a data link to the depot's repair planning system.