The Krautkrämer WheelStar UFPE delivers fully automated, under‑carriage ultrasonic inspection of rail wheelsets without wheelset removal—slashing inspection times to just 15 minutes per wheelset (≈ 90 seconds net scanning per wheel). With industry-leading reproducibility, traceability, and intelligent defect highlighting, WheelStar boosts safety and productivity for train operators, OEMs, and maintenance depots worldwide. Its cable-free, battery-powered design with wireless data transmission enables seamless integration into overnight inspections and tight maintenance windows.
Equipped with premium USIP modular electronics, WheelStar combines 8 phased-array probes and 6 conventional probes operating in the 2–4 MHz range. It performs both radial and axial angle sweeps, capturing defects in the tread, face, flange, and straight web through a blend of phased-array and conventional transducers. The system’s movable 4.5 m long test mechanics interface seamlessly with integrated PLC controls and industrial Wi‑Fi (802.11 g/n). Automated workflows, wheel-type preselection, geometry-echo suppression, and real-time defect recognition ensure fewer false calls and faster operator throughput.
