КАLМАR 32+ consists of a rail bogie with a mechanical scanner to install on a rail, a set of phased array probes, a multi-channel flaw detection unit and a control PC tablet. All functions of controlling and moving the bogie are performed by an operator.
A scanner with PA sensors is installed by the operator in the center of the weld. PA probes mechanically move along the perimeter of the weld and sound the base metal and weld zone in head, web and base flange. The software of the flaw detector includes typical settings for joints welded by aluminothermic, electrocontact and gas-press methods . Average inspection time of one weld joint is 5 min.
Electronic control of ultrasonic beam input angle and analysis of reflected echoes allow to generate a rail contour scan on the flaw detector screen, which enables the operator to control the automatic determination of a reflector coordinate, its origin in the weld cross-section, conditional dimensions and detectability index. Detailed analysis in scan "A" and "S" allows the operator to determine a defect shape index. S-scan does not only provides the operator with visual information about the location and coordinates of defects, but also allows in many cases to measure their real size. The ultrasonic beam generated by a multi-element phased array can be directed at different angles and focused at any depth, which significantly increases the detection reliability of variously oriented defects located at different points of a rail cross-section.
Features and advantages of КАLМАR 32+: