Waygate Technologies, a Baker Hughes business specialising in non-destructive testing (NDT) solutions, has unveiled the Krautkrämer WheelStar RPS – a fully automated ultrasonic inspection system developed to support the rail industry’s increasing regulatory and operational demands.
The Krautkrämer WheelStar RPS (Radsatz-Prüf-System – or ‘wheelset testing system’) integrates advanced robotics and proprietary phased array matrix ultrasonic technology to deliver precise, reliable, and highly efficient inspection of dismantled rail wheels. It is the first system of its kind to automate the entire ultrasonic testing process for railway wheelsets.
Increased efficiency, reduced downtime
Designed for Maintenance, Repair and Operations (MRO) facilities and train operators, the WheelStar RPS system eliminates the need for manual checks. Wheels are rotated via an underfloor shift-rotate unit while the robotic assembly positions ultrasonic probes, allowing the system to complete inspection of each wheelset in just six minutes. Results are automatically calibrated and validated without operator intervention, drastically reducing cycle time and labour requirements.
By automating check and re-check functions, the system removes the need for manual handling of reference wheelsets, helping reduce total shift work time by up to 23%, according to Waygate Technologies. The streamlined process also supports the growing need for consistent inspection standards in the face of a shortage of trained inspection personnel.
Improved safety and usability
Rail wheel failures pose significant safety risks, prompting strict international standards mandating regular ultrasonic inspection. The WheelStar RPS is engineered to detect defects across varying wheel geometries and wear conditions, while minimising false indications and unnecessary costs. Features such as wheel profile compensation and direct coupling control enhance accuracy and ensure maximum safety.
To simplify operations, the system uses a guided workflow and a single-screen interface. Pre-programmed wheel types and automatic report generation further reduce training time. Remote technical support is available if needed.
Orders open from august 2025
Available for order from August, the WheelStar RPS adds to Waygate Technologies’ legacy of rail inspection systems, which includes axle, track, and wheel solutions such as the Krautkrämer WheelStar UFPE and Solid Axle Mechanized Testers.
The new system builds on over 75 years of experience in ultrasonic testing, offering a next-generation solution that aligns with the rail industry’s goals for safety, reliability, and operational efficiency.
Share on:
