03 dual handwave technical details

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Technical Details (Dual HANDWave) CATER Technical Details Dual HANDWave Ultrasonic Testing System Version: V01 Dated: 15-Jun 2010 Subject: Specifications Copyright 2010, Fairclough Corporation Pty Ltd, Unit 6 / 133 Winton Road, Joondalup Western Australia, 6027 Australia. All rights reserved. This product of documentation is protected by copyright and distributed with restricted use, copying, distribution and decompilation. No part of this product or documentation may be reproduced in any form by any means without prior written authorization of Fairclough Corporation Pty. Ltd. and its licensors, if any. Third-party software is also copyrighted and licensed from the respective companies. 10061500.00 Dual HANDWave Technical Details.odt Commercial-in-Confidence Page 1 of 27

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Page 1: 03 Dual HANDWave Technical Details

Technical Details (Dual HANDWave) CATER

Technical Details Dual HANDWave Ultrasonic Testing System

Version: V01Dated: 15-Jun 2010Subject: Specifications

Copyright 2010, Fairclough Corporation Pty Ltd,

Unit 6 / 133 Winton Road, JoondalupWestern Australia, 6027 Australia.

All rights reserved.

This product of documentation is protected by copyright and distributed with restricted use, copying, distribution and decompilation. No part of this product or documentation may be reproduced in any form by any means without prior written

authorization of Fairclough Corporation Pty. Ltd. and its licensors, if any. Third-party software is also copyrighted and licensed from the respective companies.

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ContentsSection Heading Page

1Introduction...........................................................................................................................3

2Overview...............................................................................................................................4

2.1CATER Dual HANDWave U/T System...............................................................................5

2.2Hardware ...........................................................................................................................5

2.2.1Wheel Probe...................................................................................................................5

2.2.2ULTRAWave Module.......................................................................................................7

2.2.3ULTRAWave Module Power Supply................................................................................7

2.2.4Couplant Supply..............................................................................................................7

2.2.5Frame (Single HANDWave Tester).................................................................................8

2.2.6Notebook or Tablet PC....................................................................................................8

2.3Software ............................................................................................................................9

2.3.1ULTRAWave...................................................................................................................9

2.3.2Operating System..........................................................................................................10

2.3.3Startup and Shutdown...................................................................................................10

2.3.4SETUP Screen..............................................................................................................10

2.3.5A-Scan Viewer..............................................................................................................11

2.3.6C-Scan Viewer..............................................................................................................13

2.3.7C-Scan Functions..........................................................................................................14

2.4Hand Verification..............................................................................................................16

2.4.1Operation Control..........................................................................................................16

2.4.2Channel Control............................................................................................................18

2.4.3Gate Editor....................................................................................................................19

2.4.4Ultrasonic Test Data......................................................................................................20

3Dual HANDWave U/T System Specifications (typical).........................................................23

4Notice..................................................................................................................................27

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1 Introduction

Figure 1 – CATER Dual HANDWave Tester

This document includes a technical description of the Dual HANDWave U/T System, manufactured by CATER

The highlights of the Dual HANDWave U/T Tester are many;• requires only ONE pass to assess the rail using 5 channels/rail simultaneously. There

is no need to change transducers and redo the same rail section.• runs on standard Windows OS Notebooks or Tablet PCs;• has been designed by experienced engineers that have contributed to the design of the

ULTRAWave U/T system currently in use. The particularly successful graphics screens and wheel probes have been refined and incorporated from the larger ULTRAWave Systems.

• The resulting system is so intuitive to use that almost no operator training is required. During recent demonstrations we have noticed that the operators were able to operate and configure ULTRAWave after 30 minutes of training.

• has been designed for use in a modern computer environment in which data-sharing is essential. U/T data can easily be:

− exported to Microsoft Office tools − emailed (small file sizes);− copied to (and restored from) backup media, USB thumb-drives, CDs;

• has been future-proofed. The software running on the PCs and the firmware can be upgraded (“flashed”) on-site if required;

• has been designed in a modular way. Exchange of PC or ultrasonic hardware can be completed in a few minutes;

• allows full interface with the ULTRAWave Systems and any office-based computer system.

• is configured purely through software. Dual HANDWave does not include any physical configuration switches, links, etc.;

• is completely self-sufficient and does not rely/depend on any 3rd party software.The system can incorporate CATER’s perway analysis application, RIPWave at additional cost. This application is used for post run analysis and is capable of importing historical and legacy test data.

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2 OverviewThe CATER Dual HANDWave U/T System is of modular design and consists of the following components:

● Ruggedised Notebook PC, the ultrasonic hardware module specifically designed for HANDWave, power supply (battery), couplant supply bottle, the ULTRAWave software and the adjustable and collapsible frame.

● Wheel Probe with an excellent signal-to-noise ratio and requiring no angle calibration. The specially designed wheel and axle has 5 transducers housed in the one axle.

● Framework with CANT and LATERAL and gauge adjustments The lightweight and collapsible frame is able to be easily carried on and off the rail.

● Comprehensive system documentation, including Operator, Maintenance and Spare Parts Manuals, in printed and electronic formats.

NOTE: Images below of Single Rail HANDWave Tester

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Industrial Notebook PC

Couplant Bottle Wheel Probe

Full Adjustments For

CANT and LATERAL

Gauge adjustmentsCollapsible frame

Battery

ULTRAWave ultrasonic processing Module

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2.1 CATER Dual HANDWave U/T SystemThe Dual HANDWave U/T System is based on a hand-push mobile framework supporting one wheel probe connected to a single Notebook PC.

The overall superiority of the Dual HANDWave tester is in the specially designed Wheel Probe and the simultaneous processing of data in the ULTRAWave on-board Module.

The ultrasonic information from the transducers in the Wheel Probe is processed immediately by the PC. The information can then be recorded and analysed using ULTRAWave and optionally post processed using RIPWave. The export of data from the Dual HANDWave U/T System can be by many forms including via LAN connection, portable media, printed form or copied onto CD/DVD.

The data format generated by a CATER ULTRAWave Systems is completely compatible with HANDWave software, a unique feature of CATER RFD systems. With the exception of a number of configuration files, the software on all three systems is identical allowing the information to be shared between all CATER RFD installation sites.

For protection against vibration, temperature and dust, as is likely the case in the varying conditions of the Dual HANDWave working environment, the transportable Notebook can be of the 'military' or industrial type with a stronger protective casing and screen. The Notebook can be quickly removed for office use, for connection to a LAN or for security purposes.

Explanations of Wheel Probe, ULTRAWave Module, Battery supply, Frame, Notebook PC, ULTRAWave software and Special feature follow this section.

2.2 Hardware

2.2.1 Wheel Probe

Figure 2 – Wheel Probe

The Dual HANDWave Wheel Probe is designed to house 5 transducers.

The typical configuration is for a 0º, 2 x 40º, facing forward and rearward and 2 x 70º, facing forward and rearward. Other configurations are possible .

The 70º is a wide transducer which replaces the traditional smaller and more numerous transducers seen in competitiors' probe arrangements. Our preference is for greater sensitivity (up to 17 times) provided by the larger transducer.

A hand verification channel is also available to connect various hand probes for closer inspection.

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Figure 3 – Transducer Arrangement and Coverage (typical)

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2.2.2 ULTRAWave Module

2.2.3 ULTRAWave Module Power Supply

2.2.4 Couplant Supply

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5 ultrasonic channels are simultaneously processed

by the HANDWave Module. A hand verification mode is used for spot assessment

using hand held probes

Couplant supply is easily refilled

Battery supplies ~8hrs of testing time

via 12VDC, 20 AH battery.

Recharging takes as little as 4 hours

A 10L bottle is optional

for a longertesting session

The battery is rechargeable

or replaceable for long testing sessionsA charger is supplied

Flow is adjustable for economy

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2.2.5 Frame (Single HANDWave Tester)

The lightweight frame can be lifted by one person.

Please Note: Electric CANT and LATERAL alignment is optional on Dual HANDWave

It is collapsible for ease of transport in a regular vehicle.

2.2.6 Notebook or Tablet PC

MS Windows based ruggedised Notebook. Alternatively, supplied with rugged casing and daylight screens if required for use in bright light.

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CANT adjusting arm

LATERAL adjuster moves Wheel Probe sideways

for best echo result

Rugged case for

Notebook protection

Gauge adjusting leg

Gauge adjusting

lock

Pin is quickly removed to fold frame

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2.3 Software The Dual HANDWave U/T System is configured using ULTRAWave for ultrasonic assessment.

The PCs selected by CATER include the most up-to-date components and are able to run the latest version of Windows. We choose PCs from a respected manufacturer that is able to offer an international on-site support, so that problems arising from PC malfunctions can be addressed swiftly.

Communication with the ultrasonic hardware is via USB2.0. The benefit to operators is that they can conveniently backup testing results on USB storage medium.

2.3.1 ULTRAWaveThe ULTRAWave software preloaded on Dual HANDWave U/T System has been designed in a modular way to increase its stability and reliability. The main ULTRAWave modules for HANDWave are:

Operation Control: The Operator Control window allows the operator to control the ultrasonic testing operation.

Channel Control: The Channel Control window allows the operator to set channel-specific parameters.

A-Scan Viewer: The A-Scan Viewer displays the current A-Scan (ultrasonic signal) and replaces the oscilloscopes that are used in older-style U/T systems.

C-Scan Viewer: The C-Scan Viewer displays echo groups (artefacts) and other information recorded by the system.

Hand verification Mode: The spot verification of identified artefacts allows the operator to immediately assess for potential problems by using hand-held probes.

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Operational Control

Channel Control

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2.3.2 Operating SystemULTRAWave runs on the Microsoft OS (e.g. XP) platform.

The Notebooks are pre-configured in our factory to include the user accounts (typically 1 administrator account, 1 operator account, 1 maintenance account of the ULTRAWave software and any other software required by our customer (for example RIPWave, MS Office and Adobe Reader).

The ULTRAWave software is a collection of executable (“.exe”) files that can be installed quickly on any PC.

ULTRAWave does not need (or rely on) any 3rd party software to run and no special tools are required for installation or maintenance.

A number of files are necessary to configure ULTRAWave CATER pre-configures these files in the factory with data supplied by the client. In the case that the configuration needs to change, a simple text editor (for example Notepad) is all that is required.

The RIPWave post run analysis application requires a number of application files and a database containing configuration information. The configuration database can be pre-configured in the factory with data supplied by the client. Database administration tools are provided to allow the client to maintain the database.

2.3.3 Startup and ShutdownThe ULTRAWave software starts automatically after the operator has logged in and is ready for use in less than 1 minute.

The HANDWave Notebook can be shut down at any time without losing any test data.

2.3.4 SETUP Screen

Figure 4 –Dual HANDWave SETUP Screen GUI Screen Layout

The SETUP screen allows the operator to set the testing configurations.

Parameters that can be set are the location, rail type, direction, resolution of testing and number of user defined preferences.

All these are similar to the ULTRAWave system found on the larger RFD carriers.

• Show trip statistics: trip duration, distance travelled and average speed;

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Rail type and location can be

preset in the SETUP

Preferences screen,

as well as many other criteria

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• Start/Stop and Pause a testing run;

• Enter calibration mode. In calibration mode, only A-Scans are displayed which are used by the operators to align the Wheel Probes, or to fine-tune the gain;

• Select district, line and track. CATER will pre-configure ULTRAWave to reflect the client’s track network;

• Select the sampling resolution (nominally 4mm, but selectable between 1mm to 6mm);

• Select the rail type. CATER will pre-configure ULTRAWave to include the local rail type.

• Select counting direction (i.e. travelling forward count up OR travelling forward counts down);

• Select unit orientation (i.e. Wheel Probe side over left rail OR Wheel Probe side over right rail).

2.3.5 A-Scan Viewer

Figure 5 – A-Scan Viewer Window

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Individual Gain adjustment for

4 Ultrasonic channels and Hand Verification

channel

Gate (editable)

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The A-Scan Viewer displays the current A-Scan (ultrasonic signal). It replaces the oscilloscopes that are found in older-style U/T systems.

Compared to old-style oscilloscope technology, the use of a fully digital A-Scan monitor offers many advantages:

• A-Scans can be saved to disk for later reference, in “.csv” (Excel) or “.bmp”/”.jpg” (image) format;

• The A-Scan display can be scaled to suit the operators;

• A-Scans can be “frozen” for close investigation

• Fully digitised A-Scans can be used for automatic lateral/cant Wheel Probe Alignment (in the future);

• Provides a precise visual comparison with the ultrasonic scan and the gates.

• The A-Scan display includes a “peak memory”, it displays the peak amplitude of all previously collected A-Scans. This peak memory function is very useful for echo detail analysis.

The A-Scan Viewer includes the necessary functionality:

• Switch between the 5 simultaneous A-Scans (1 for each transducer)

• Each A-Scan; Entry Echo, Backwall Echo (if applicable), gate and maximum signal level is shown. The operators will find the maximum signal level useful for Wheel Probe Alignment, Gain Control and during maintenance;

• Freeze/Unfreeze display;

• Print the A-Scans on paper for post processing and recording;

• Save A-Scans so that they can be displayed at a later stage;

• Automatically save A-Scans at a pre-determined rate (1Hz … 10Hz) for later processing;

• In the case that an A-Scan should be examined more closely, the A-Scan Viewer includes a window that allows measuring, zooming and printing.

Figure 6 – A-Scan Properties Windows

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Zoomable A-Scan display. Can be copied to Clipboard in numerical and graphical form and “pasted” in MS Word/Excel

Track kilometry details

A-Scan measurement (absolute/relative)

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Figure 7 – A-Scan Viewer Window

2.3.6 C-Scan ViewerFigure 8 – C-Scan Viewer Window

The C-Scan Viewer displays the echo groups recorded by the system.

The CATER C-Scan Viewer is configured to use the same colour coding as other existing CATER RFD viewers and for this reason the operators will find it so easy to use that hardly any training is required.

Each artefact is annotated with track location (kilometry), ID number and with the option of classification (menu setting).

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A-Scan with Peak Memory function

Selectable probe/channel A-Scan Viewer

Coloured dots show artefacts identifed by

Wheel Probe ultrasonics related to channels below

Reports and Tags placed by operator

or by changes to system

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2.3.7 C-Scan FunctionsDuring U/T testing and during replay, the operator can scroll the window using the scroll bar

The C-Scan Viewer includes the necessary functionality to:

• Replay existing C-Scan data;

• Export all/selected parts of the C-Scan data in Microsoft Excel (“*.csv”) or image (“*.bmp” or “.jpg”) formats

• View, modify and print artefacts details :

Figure 9 – C-Scan Properties Window

• Find artefacts, based on some search criteria:

Figure 10 – C-Scan Search Window

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Zoomable C-Scan display. Can be copied to Clipboard in numerical and graphical form and “pasted” in MS Word/Excel

Zoom and echo rendering control. Used to distinguish between strong and weak echo amplitude

Track kilometry details

General artefact details, automatically assigned by ULTRAWave

Classification

Tag

Operator Comments

Search criteria Search parameter

Search direction

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• Measure relative/absolute depths and displacements between two nominated points:

Figure 11 – C-Scan Measure Window

In post processing an operator can

• Print screen dump

• Print all/selected parts of the C-Scan data in summary or detail format

1

2

3

4

5

Summary Report (Header Page) Summary Report Detail Report

Figure 12 – C-Scan Viewer Reports

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C-Scan measurement (absolute/relative), between Point A and B

Point A

Point B

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2.4 Hand VerificationThe Dual HANDWave Module has the facility to process handheld transducer signals. This standalone feature uses various user selected probes to identify and verify potential flaws in the rail. Spot verification is concurrent with regular testing.

Figure 13 – Hand Verification Screens from Dual HANDWave

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Settings can be

saved as Presets

Adjustable Gate

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2.4.1 Operation Control

Figure 14 – Operation Control Window

The Operation Control Window allows the operator to control the ultrasonic testing operation

The window includes the necessary functionality to:

• Set and adjust the current track location (kilometry) :

Figure 15 – Change Track Location

• Monitor the current speed. Together with the current vehicle speed, the speed limit applicable to the selected rail type is shown. The speed limit for a heavier rail (e.g. UIC60) is lower than the speed limit for a lighter rail (e.g. 41kg). The ultrasonic signal path for a heavier rail is longer than for a lighter rail, and for that reason it takes the signal longer to traverse the rail, slowing down the maximum testing speed.

• Enter operator’s comments during ultrasonic testing operation. Comment’s entered by the operators appear on the C-Scan Viewer

Figure 16 – Operators' Comments

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Enter new track location

Operator Comment shown in C-Scan Viewer

(real time, replay, fault history)

Enter Operator's Comments

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• Modify any operational settings:

General Settings Maintenance Settings Wheel Calibration Settings

Figure 17 – Operation Control Settings

2.4.2 Channel Control

Figure 18 – Channel Control Window

The Channel Control window allows the operator to set channel-specific parameters

The window includes the necessary functionality to:

• Adjust the gain for each channel (ultrasonic transducer);

• Disable or enable a channel. In the case that a channel develops a fault, the channel in question can be disabled and rail testing can be completed without this channel.

• Monitor the health and activity of each ultrasonic channel;

• Set Entry Echo parameters.

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2.4.3 Gate EditorThe Gate Editor assists the operator in fine-tuning the ultrasonic gates.

Figure 19 – Gate Editor Main Window

The main window shows the timing sequence of all gates used for a particular rail (in the above example 60K rail, Class 1).

By selecting one particular gate, the operator can inspect its properties See Figure 19 below

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Figure 20 – Gate Editor Window

This window includes the necessary functionality to:

• Modify the shape of the gate (mouse click & drag);

• Modify whether the gate is used to detect the “loss” of signal (in the case of Loss-of-54°), if the transducer operates in “pitch-catch” or “pulse-echo” mode, and whether Backwall Echo (BWE) should be detected; [ 54° not used in HANDWave ]

• Modify the BWE parameters. BWE parameters are indicated by dotted red lines). The max. expected rail wear (Rail Height Tolerance, displayed as “RH Tol.” in the figure above) is computed automatically from the BWE Start and BWE End parameters (RH Tol = BWE End – BWE Start);

• Modify transducer transmit characteristics. These settings are for advanced applications and do not need to changed normally.

All settings are pre-configured and confirmed in our factory.

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2.4.4 Ultrasonic Test DataUltrasonic test data is stored in “flat” files that contain binary information. These files can be read using CATER tools (C-Scan Viewer or the CATER RIPWave product). Double-clicking on a file will automatically open the ULTRAWave C-Scan Viewer in replay mode, greatly reducing the time required for reviewing test data. Opening a file in replay mode is very efficient. A few seconds are enough to display an average-sized test data file.

In order to be able to share ultrasonic test data with Microsoft Word/Excel or imaging tools (Microsoft Paint), they must be opened with the CATER tools provided and then exported as “.csv”, “.bmp” or “.jpg”.

Ultrasonic test data are stored in a hierarchical way, grouped by year, month, day of testing. The file name is composed of district, line, track, kilometry and operator comment (note that the naming of district, line and track is read from the relevant configuration files and changes from customer to customer).

Figure 21 – Ultrasonic Testing Data

The grouping/naming of files enables the operator to quickly find test results, either by date (browse directory tree) or by file name (e.g. search all *-211d-* files).

A file is automatically created each time the operator starts a testing run (i.e. each time the operator presses the Start ► Button). During a test run, test data is continuously generated and saved to disk so that any interruption (power failure, software crash) greatly minimises the loss of data. The maximum loss possible is one artefact each for left and right side.

Figure 22 – Start Button

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Year Month Day Test Data Files

District Line Track Kilometry Operator Comment

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Each typical ultrasonic test data file includes the information shown in the table below. When using the “.csv” export function, all of the information shown below is written to the “.csv” file.

Artefact:

• Shaft encoder location

• DGPS location

• Date and time

• Rail side

• Severity

• ID Number

• Classification

• Rail type

• Rail class

• Status (tag)

• Rail height

• Horizontal size

• Vertical size

• Sampling Resolution

• Speed• Echoes• Comments

Event: • Shaft encoder

location• DGPS location

• Date and time• Rail side

• Action type• ID Number

Operator Action:• Shaft encoder

location• DGPS location

• Date and time• Rail side

• Action type• ID Number

Operator Comment:• Shaft encoder

location• DGPS location • Rail side

• Date and time• Operator comment

Header:

• Operator name

• Description of test run

• Start date & time

• Vehicle name

• Company name

• District ID

• Line ID

• Track ID

• Start location

• Travel direction

• Count direction

• Orientation

Footer:• End location • End date & time

The size of ultrasonic test data files is difficult to estimate but is in the range of approximately 100kB per km. Files are easily copied/backed up using functions offered by the Microsoft Operating system (for example copy files to USB thumb drive, CD, etc).

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3 Dual HANDWave U/T System Specifications (typical)These specifications are typical and subject to change, depending on model variations and configurations and if it there is a conflict between a specification stated here and a specification stated in previous sections, the specification stated in the previous sections have precedence. Performance figures are from CATER Laboratory Tests (see CATER Document “UW Detection Test 030526.01.ppt”) on artificial artefacts.

ULTRAWave, Detection Performance

DP1 Dead Zone 0°: 8mm40°: 5mm70°: 3mm

DP2 Coverage 0°: rail surface to foot40°: rail surface to foot70°: rail headHand Probes for rail head

DP3 Loss of Backwall Recorded for 0° channels

DP4 Rail Corrosion Recorded for 0° channelsRail Corrosion is detected by a special filtering algorithm developed by CATER

DP5 Resolution:- Longitudinal (location)- Depth - Rail Height

1.0mm0.1mm0.1mm

DP6 Accuracy:- Longitudinal (location)- Depth - Rail Height

+/- 5 m / km+/- 0.5mm+/- 0.5mm

DP7 Minimum Detectable Defect Size (at 4mm resolution)

2mm diameter hole in rail head, simulating a horizontal/vertical crack1.6mm (W) x 5mm (H) slot on gauge side corner of rail head, simulating a transverse defect2mm diameter hole in rail foot, simulating rail foot defects (i.e. corrosion) For details, please request a copy of the CATER document “UW Detection Test 030526.01.ppt”.

ULTRAWave, Ultrasonic Modules for Dual HANDWave

UM1 Configuration 2 HANDWave Ultrasonic Modules (UWUM), 5 channels per module simultaneously

UM2 Sampling Resolution 1mm-10 mm (selectable in 1mm steps)

UM3 Gain 255 stepsManual selection for each channelPreset gain values for each rail type/rail class

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UM4 Gate / Threshold Configurable, in steps of:-- 0.1% (amplitude)- 0.5µs (time of flight) Separate for each rail type/class

UM5 Rail 22kg/m … 68kg/m,

UM6 Max. Echoes per scan (how many echoes can be recorded simultaneously, per scan)

8 per channel

UM7 C-Scan Display Fully digital

UM8 A-Scan Display Fully digital

UM9 Configuration Fully automatic, no calibration requiredDownloaded from ULTRAWave System Controller

UM10 Communication with Controller USB 2.0 high speed communication

UM11 Cooling Natural convection, no fans required

UM12 Air Filtration Not applicable

UM13 Power Consumption 10W (max.), 5W (typically), per module

UM14 Mounting Fit inframe holder

ULTRAWave, Channel Configuration (per side)

CC1 Arrangement 5 channels for each rail (10 channels in total):

- 0° channel operating in Pulse-Echo mode;

- 40° channel (x2, front and rear), forward and reverse facing, operating in Pulse-Echo mode;

- 70° channel (x2, front and rear), forward and reverse facing, operating in Pulse-Echo mode;

- Hand verification probes with transducers operating in Pitch-Catch mode

CC2 Frequency 2.25MHz

ULTRAWave, System Controller

SC1 Operating System Standard Notebook PC, MS Windows

SC2 Performance Intel Core™ 2 Duo, 2.33GHz, 1GB RAM, 160GB HD, or better

SC3 Monitor Notebook screen (typically)

SC4 Keyboard Standard, US layout

SC5 Mouse Pen (touch) type

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SC6 C-Scan Viewer- Technology- Display Areas- Colour CodingModes

- Scrolling

- Synchronisation

- Tool Suite

- PC based- Left rail, right rail, status- Per ultrasonic channel.

- Online (during testing operation) and replay (office)

- Scrollable to view complete test run, both in “online” and “replay” mode

- 2 modes, synchronise to current vehicle location, or synchronise with other window

- Property Inspector, measuring, search, selections, printing, data export, annotation of artefacts, etc.

SC7 A-Scan Viewer- Technology- Refresh Rate- A-Scan Display- Scaling

- Save of A-Scans

- Extras

- PC based- 10 Hz, user configurable- 4 (single rail tester)- Amplitude in %, depth in mm, time of flight

(TOF) in µs- Manual and automatic, in CSV format- Display of Entry Echo (EE), Backwall Echo

(BWE), gate, maximum A-Scan amplitude, rail outline

SC8 Operation Control Run start and stopCalibration start and stopDisplay of current track location and speedChange track location Change rail type/classDisplay of overall system status

SC9 Channel Control Adjust gain (per channel)Manually disable individual channels

SC10 Classification Bolthole (BH), Bondhole (bh), Rail End (RE) and Weld (W), Misalignment (MA)

SC11 Output One file per test runGrouped by date of test run

SC12 Output file format Native or CSV (Microsoft Excel)

SC13 Output file size Approx. 100kB per kilometre (main line, bolted rail)Approx. 500kB per kilometre (local line, bolted rail)

SC14 Reports Graphical (summary and detail)

SC15 Backup Responsibility of the operatorsUse of Windows XP backup softwareWe suggest the use of DVDs or USB Flash Drive.

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Wheel Probes

WP1 Diameter 165mm (nominal)

WP2 Tyre Polyurethane, flexible, with excellent wear characteristics

WP3 Fluid (Type) Glycol / Water mix

WP4 Fluid (Pressure) 30kPa (typical)

WP5 Calibration- Rotational- Transverse- Longitudinal

- Fixed, no calibration required- Fixed- Fixed

WP6 Weight 6kg (approx)

WP7 Wearable Parts Ball bearing, seal, easily exchanged during maintenance

Location Tracking

LT1 Resolution 1mm

LT2 Accuracy +/-1m per 1000m

LT3 Track Measuring Range -2000km … +2000km

Documentation and Manuals

DOC1 Format Electronic, Printed

System Power Requirements

PWR1 Input Voltage for charger 90…264VAC, 50…60Hz

PWR2 Power Consumption 20W (all inclusive)

PWR3 Battery 12 VDC, 20AH

PWR4 Recharge Time ~ 4 hours

Environmental Conditions

ENV1 Operating Temperature Operator Area (external) 5°C … 40°C

NV2 Storage Temperature -10°C … 65°C

ENV3 Humidity Up to 99% relative humidity (in storage)

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4 NoticeThe CATER Dual HANDWave U/T System has been developed specifically to increase the usefulness and functionality of the ULTRAWave Rail Flaw Detection System.

For customer issues, CATER will investigate a reported problem and respond with a suggested workaround or software upgrade. Software upgrades are sent via e-mail and can easily be installed by the rail operators and maintenance personnel.

Hardware is available from CATER for all CATER developed components and from other sources.

CATER is continuously improving its products from feedback we receive from staff and customers. New software is released to our customers after it has passed rigorous testing with our test facilities on track in Perth.

We would be pleased to organise a demonstration of our Dual HANDWave U/T System (as described in this document) to any interested parties.

Note:

The product described in this document is a typical Dual HANDWave configuration. Exceptions can be configured by the individual client. Please feel free to discuss personalised requirements with CATER.

The ULTRAWave and RIPWave software that will actually be installed on a Dual HANDWave U/T System will include all the functions described in this document plus any developed by CATER in the mean time.

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