Automated Rail Flaw Detector

• MEDUSA Ltd -- ADS-02, An Automated Rail Flaw Detector

By Alexander M. Reyman

Rail fractures account for 30% of damages and wrecks in rail track facilities, as the picture shows. To avoid these damages, the rails can be inspected using several methods, all with their own advantages and problems, as shown in the table.

Because of the robustness and ease of operation, rails are usually inspected using the linear multi-directional ultrasonic method. There are two types of systems used, portable and mobile.

The ADS-02 Automatic Rail Flaw Detector

The portable systems have the advantage of on-line rail inspection, finding more than 92 % of the flaws and the inspection is without traffic interruption. There are drawbacks, however. The inspection speed is low (<8 km/day), a large staff is needed causing safety problems, and there is usually no record of the proceedings.

Mobile systems, on the other hand, provide high inspection speed and high specific productivity, is comfortable and safe, and there is the possibility to make records of the measurents. Unfortunately, their flaw detection quality is not that good, especially at high speeds.

The ADS-02 was developed to take advantage of the high productivity while, at the same time, to improve detection capability.

The basic idea used in ADS-02 was to make electronics as simple and reliable as possible. This problem can be solved in different ways, but the simplest is to make the embedded computer able to implement basic functions of data acquisition, analysis, display and storage.

MEDUSA Ltd chose PC/104 due to its simple open structure, reliability and productivity. The mechanical and electrical assembling method was successfully tested for operation in Russia-oriented rugged climatic and shock/vibration conditions. This experience of exploitation confirmed the validity of chosen solutions and the high reliability of PC/104 platforms.

Medusa chose LiPPERT's Cool RoadRunner II as the heart of the system because this proven PC/104-Plus module is available in an extended temperature version of -40° ... +85°C and, due to its small size, is very well suited for harsh environments.

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