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Dred mobile self-propelled system

This recent solution by TVEMA helps to solve a range of tasks to ensure safety of facilities of the city transport infrastructure, railways, metros, and industrial railway enterprises. DRED provides comprehensive diagnostics of short track sections at a speed of up to 20 km/h.

The compactness of the device facilitates easy control, and its versatility ensures the simultaneous solution of several problems. DRED can be operated at ambient temperatures ranging from - 20°С to + 50°С.

Depending on configuration, the system provides the following functions:

- non-destructive (ultrasonic) testing of rails;

- comprehensive inspection and automated evaluation of the track geometry (width, level, alignments, sag);

- inspection of long irregularities in plan and profile;

- inspection of longitudinal profile;

- inspection of longitudinal track profile inclination in the wavelength range above 300 m;

- inspection of short irregularities at the rail tread;

- comprehensive inspection and automated evaluation of the rail geometry (horizontal and vertical wear, cant, and rail tread slope);

- inspection of clearance profiles, including tunnels, bridges, and equipment;

- inspection and automated evaluation of geometrical position (vertical, horizontal) of the conductor rail;

- comprehensive video monitoring of infrastructure facilities;

- rail lubrication;

- treatment of ballast prism with herbicides;

- prompt transportation of track repair crews and required process equipment and tools to the site of scheduled and emergency repair works.

DRED system can be additionally equipped with a trailer which can double the system capacity up to 1000 kg.

DRED provides hardware and software processing of control signals for track sections inspected, their logging and collection for long-term storage and subsequent analysis, as well as registration of travel data.

The system provides diagnostics for rail types R50, R65, R75, UIC54, and UIC60 laid on a wooden or reinforced concrete base in a railway track with 1000, 1435, 1520, 1520, 1676 mm gauge (depending on version).

Skat single-thread ultrasonic ndt analyzers

The main features of SKAT compared to competitor devices in this segment are: its light weight, compactness, long operating time without battery recharge, a powerful processor with flexible user-friendly software, a wide range of signal logging, and its stability with respect to rapid changes in ambient temperature.

This offers convenient and highly reliable application of SKAT at any moment for secondary manual track inspection following mobile inspection and in the sections where application of mobile diagnostic systems is hampered or too expensive, e.g. at switchyard switches and the side tracks or crane tracks of industrial facilities.

SKAT constitutes a classical NDT system of ultrasonic units equipped with a microprocessor, with a control panel and a numerical display. It also has a battery power supply unit and a canister with contact liquid.

During its pedestrian-speed travel, SKAT is sounding the rail thread and logging the signals from any defects detected along the entire length and across the entire width of the rail, excluding rail base plates, rail web areas and rail base under bolt holes. The wide dynamic range of the logged signals increases decoding performance enormously and, with it, inspection reliability.

The device implements the function of acoustic contact monitoring in each channel throughout all transmit/receive cycles. Consecutive energising of transducers prevents spurious signal appearance for any probe transducer configuration. This simplifies the decoding procedure and increases inspection reliability.

The information acquired is displayed online as A or B scans on the microprocessor display and simultaneously recorded to the memory chip for further processing. The handy control panel and the flexible software enable the operator to easily combine piezoelectric transducers in the device's ultrasonic units and to use various ultrasonic checking patterns depending on operating conditions of a particular track section.

SKAT NDT analyzer meets the international standard ISO 12710:2002 "Non-destructive testing - Ultrasonic inspection - Evaluating electronic characteristics of ultrasonic test instruments" and provides for detection of rail defects according to the international index UIC Code 712 R "Rail defects".

Sprut ndt/track geometry inspection bogie

This device designed by TVEMA was awarded the «Quality Mark» for innovative solutions and the Golden medal «For measurement consistency» at the Moscow Forum «Metrology 2008».

The main buyers of «SPRUT» bogie are enterprises having their own side tracks requiring daily inspection and maintenance.

The compactness of the device facilitates easy control, and its versatility ensures the simultaneous solution of several problems. While measuring track gauge and level, SPRUT at the same time detects defects in both rail threads along the entire length and across the entire width of the rail (excluding rail base plates, rail web areas, and rail base under bolt holes) and is logging the coordinates of each defect.

The precise referencing of these measurements is provided by a GPS receiver installed on the inspection bogie in the equipment mix. The inspection bogie is a frame chassis with wheels and travel handles.

The inspection bogie hosts a microprocessor with a display and a control unit, a battery power supply unit, a canister with contact liquid, a maintenance kit box, and a probe skid. Sensors measuring total travel, level and track gauge are mounted on the frame. The data being acquired from sensors is on-line displayed and simultaneously recorded on the memory chip for further processing.

An advantageous feature of SPRUT is acoustic contact monitoring in each channel throughout all measuring cycles. The wide dynamic range of the logged signals increases decoding performance enormously and, with it, inspection reliability.

Consecutive energising of transducers prevents spurious signal appearance for any probe transducer configuration. This simplifies the decoding procedure and increases inspection reliability.

«SPRUT» is available in the several versions: with 1520, 1435, 1676 mm track gauge with English user interface of the electronic unit software.

The electronic unit can operate as a standalone (without the bogie) single-channel NDT analyzer. «SPRUT» NDT/track geometry inspection bogie meets the international standard ISO 12710:2002 «Non-destructive testing - Ultrasonic inspection - Evaluating electronic characteristics of ultrasonic test instruments» and provides for detection of rail defects according to the international index UIC Code 712 R «Rail defects».

«PT-7МК» and «AKNOP» track geometry inspection bogies

Railway traffic safety is directly related to proper track geometry. Therefore, monitoring the parameters of track geometry is indispensable in railway operations. There exist various devices for this purpose, but the most practical are budget-friendly and robust manual geometry inspection bogies, which are especially popular with facilities having their own side track and repair tracks requiring daily inspection and maintenance.

«PT-7МК» and «AKNOP» computerised geometry inspection bogies manufactured by TVEMA became one of the most popular in the diagnostics of such tracks in various regions of Russia and CIS states. This is due, first of all, to their robust and simple design, which ensures operation in all climatic conditions, as well as to their comprehensive and flexible software.

By measuring the track geometry parameters and processing them in the same format as used by inspection vehicles, «PT-7МК» provides full-scale analysis of the current track condition, as well as it forecasts its future behaviour and possible malfunctions.

When moved manually along the rails, the sensors of «PT-7МК» inspection bogie automatically measure rail track level, gauge, and the track coordinate.The information is logged and displayed on the indicator display. The acquired results are stored in the built-in microprocessor's non-volatile memory for further transmission via the communication adapter to the enterprise computer of the track facilities.

Because the inspection bogie operates on track in continuous mode irrespective of weather and illumination, it is vital to take care of its operators' safety. Therefore, for better visibility it is painted in bright yellow or orange colour and is equipped with a holder for a warning flag or disk.

The upgraded option of the track geometry inspection bogie produced by the Company is an Automated System for Field Track Inspection (AKNOP), which differs from «PT-7МК» by higher automation and computerisation. Specifically, «AKNOP» is equipped with a Pocket PC communicating via dedicated software with the geometry inspection bogie's electronic unit. Thanks to this, more accurate signal processing and rail track parameter decoding are performed in real time.

High battery capacity facilitates operation of the system's electronic equipment in completely standalone mode for several hours. This provides for automated execution of a number of typical operations envisaged by the geometry inspection bogie operator's workflow and a considerable expansion of system capabilities.

On option inspection bogies are manufactured for track gauges 1520 mm, 1435 mm and 1067 mm.

Long experience in application of «PT-7МК» and «AKNOP» has set a sort of standard for business rivals from third party vendors. These designs became a generic model for designing a number of promising railway track inspection and diagnostic systems.

«PT-10» track geometry inspection bogies

The computerised track geometry inspection bogies of «PT» series manufactured by TVEMA became one of the most popular in the diagnostic industry in Russia and CIS states. This is due, first of all, to their robust and simple design, which ensures operation in all climatic conditions, as well as to their comprehensive and flexible software.

When moved manually along the rails, the sensors of «PT-10» inspection bogie automatically measure rail track level, gauge, and the track coordinate.The information is logged and displayed on the touch screen. The acquired results are stored in the built-in microprocessor's non-volatile memory for further transmission via the communication adapter to the enterprise computer of the track facilities.

Because the inspection bogie operates on track in continuous mode irrespective of weather and illumination, it is vital to take care for its operators' safety. Therefore, for better visibility it is painted in bright yellow or orange colour and is equipped with a holder for a warning flag or disk.

High battery capacity facilitates operation of the bogie's electronic equipment in completely standalone mode for several hours. The bogie can be employed the track sections equipped with automatic interlocking or without it. On option inspection bogies are manufactured for railway tracks with 1520, 1435, 1067 and 1676 mm gauge.

RDK «PT-12M» Manual diagnostic system

RDK «PT-12M» Manual Diagnostic System is designed for automated inspection of the metro track facilities.

RDK «PT-12M» Manual Diagnostic System is an advanced version of the track geometry inspection bogies of PT series and provides a wider range of the track geometry measurements. Apart from the measurement of the track gauge, elevation of the external rail and the length travelled, the system can additionally measure the following parameters:

- track sags, wave wear and camber of rail thread with respect to the chord, track longitudinal profile with possibility of obtaining the curve cards;

- long and short irregularities on the rail tread in plan and in profile;

- 3D scanning of the metro infrastructure facilities, including clearances of bridges, tunnels, and clearance profiles;

- automated evaluation of geometric position of conductor rail (vertical and horizontal);

- comprehensive video monitoring of the track condition;

- inspection of horizontal wear;

- referencing to the track coordinates based on reference marks.

RDK «PT-12M» is used on the rail track sections (rail types Р50, Р65, Р75) equipped with automatic interlocking or without it.

The system comprises:

- assembly of non-self-propelled track geometry inspection bogie;

- data acquisition and pre-processing system;

- software and hardware suite — laptop computer with system and application SW which ensures operation during the inspection run;

- computer workstation with application SW;

- battery pack, power supply module and charger.

During inspection of the railway track, the operator and his assistant can easily lift and remove the device from the track. The system design provides for its quick removal and re-installation without disturbing sensors and their settings.

RDK «PT-12M» application SW ensures performance of the following functions:

- measurement of specified parameters with less than 0.2 m increment along the track;

- processing of acquired data to detect deviations of the measured parameters from maintenance standards;

- storage of acquired information with qualitative evaluation of the track facilities condition;

- generation of output report forms according to requirements;

- export of acquired data to the analytical center and maintenance departments. The system ensures reliable operation in the ambient temperature range from -20 °С to +50 °С and relative air humidity up to 80% at +25 °С.

The battery pack ensure up to 8 hours of the system operation before recharge.

The mean time between failures of the RDK «PT-12M» components is not less than 3000 km (provided the established routine maintenance and repair intervals are observed). The average life of the measurement, logging and computer hardware, as well as the measurement equipment is not less than 5 years. The overhaul life of the measurement equipment is not less than 10000 km.

«ECHO-PULSE» portable ultrasonic flaw detectors

«ECHO-PULSE» is a single-channel device for ultrasonic non-destructive testing of an object for defects with contact ultrasonic coupling. In this manner, it is possible to assess the acoustic characteristics of material, to measure the thickness and the extent of structure corrosion, as well as to use the flaw detector for secondary inspection. The device ensures precise measurement of defect depth and location.

The flaw detector records A- and B-scans on removable media and also transmits the acquired data via Bluetooth, Wi-Fi, or IR-port links.

A major breakthrough is the development of a flaw detector version operating in Android OS environment with all its associated benefits including: instant sending of the inspection report via MMS or e-mail; use of GPS/GLONASS data for inclusion in the report; display of the inspection documents; display of previously saved inspection reports; sending video file showing transducer travel.

The software which controls the operation of the flaw detector perfectly combines with other applications installed on the device. For instance, when using the microphone it is possible to perform the inspection and make a phone call at the same time to inform the other person about some nuances of the inspection or to ask for advice. Alternatively, the operator can simultaneously perform the inspection and make phone calls via the Internet including video calls and conference calls. Moreover, it is possible send the current display that the operator observes (A or B scan) via the Internet. In complicated situations with interpretation of the inspection results, this will help to evaluate the results and make a correct collective decision.

The flaw detector provides an electric pulse generator for adjustment. Employment of a logarithmic amplifier in the device's receiving channel considerably expands the range of displayed echo signals, while the adaptive threshold conditioning circuit, operated at the noise level, drastically increases inspection reliability, especially in conditions of poor acoustic contact.

«ECHO-PULSE» flaw detector meets the international standard ISO 12710:2002 «Non-destructive testing - Ultrasonic inspection - Evaluating electronic characteristics of ultrasonic test instruments». The flaw detector provides ultrasonic inspection in compliance with technologies adopted in various industries. For example, as concerns the railway industry, «ECHO-PULSE» provides for implementation of technologies stipulated in the following European standards: EN 13674 «Railway applications - Track - Rail - Part 4: Rail Inspection»; EN 14587 «Railway applications - Track - Flash butt welding of rails. Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plant»; and EN 14730 «Railway applications - Track - Aluminothermic welding of rails - Part 2: Qualification of aluminothermic welders, approval of contractors and acceptance of welds».

Ultrasonic transducers

The principle of resonance transformation of electric oscillation into acoustic oscillation underlies all ultrasonic testing devices, including those employed for railway track inspection. Therefore, the quality of piezoelectric transducers directly influences the inspection-reliability of components and assemblies of various structures.

According to an expert appraisal, transducers manufactured by TVEMA belong to the most reliable articles.They are highly competitive with the world's best equivalents. This is due not only to our long experience in production, but also to strict quality control.Each article is tested in the TVEMA laboratory and is supplied with a compliance certificate indicating the test results.

Piezoelectric transducers (PZT) developed and commercially manufactured by TVEMA are intended both for manual control and for use in acoustic units of mechanized and automated ultrasonic testing systems. Their characteristic operating features are high sensitivity and high signal to noise ratio, which is complemented by a low failure level and enhanced wear resistance. They operate fail-safe in a temperature range of -40°С to +50°С.

Another feature of the company's transducers is their electro-acoustic and geometrical compatibility with all cutting-edge devices for ultrasonic rail inspection, ranging from inspection carriages and railcars to portable one- and two-thread flaw detectors.

Depending on the purpose, TVEMA manufactures various lines of transducers.

Series 001T is intended for inspection of parts, which have surfaces of high harshness and/or corrosion. They possess a steel body PZT with CP50-73 vertical connector (BNC) and a large-size piezoelectric crystal of cylindrical shape (12 mm in diameter) (except for the P121-2.5-42°-001T). The working area is 16x23 mm and overall dimensions are 23x16x40 mm (without connector).

Series 002T is intended for inspection of articles having small and medium thickness. This series of transducer possesses a body of aluminium alloy with a horizontal connector (Lemo 00) and a round piezoelectric crystal 12x12 mm in diameter. The body material provides uniform wear of the entire contact surface, thereby enhancing inspection reliability. The working area is 20x29 mm. Overall dimensions are 31x20x26 mm.

Series 003T articles have the same purpose as 002T. These transducers feature minimized rise and dead-zone, and they possess a rectangular 8x9 mm working element. Otherwise they are identical to the 002T series.