PA Axle Safe Pistol

PA Axle Safe Pistol

Phased Array scanner for end-face inspection of solid shafts, without interference from bearing press holes

Axle Safe is the solution developed and patented by IMG Ultrasuoni for the ultrasonic inspection of solid railway axles and field-assembled axles, reducing the typical challenges associated with “end-face” inspection due to the presence of bearing press holes.

In traditional inspection, in fact, when the probe passes near the threaded holes (typically 3 or 4 M18 holes at the ends of the axle), a loss of ultrasonic transmission can occur. This creates shadow zones and an uneven POD across the full 360° of the inspected surface.
Axle Safe was developed to overcome this limitation without requiring any mechanical machining that would affect the axle heads.

Examples of use:

  • Ultrasonic inspection of solid railway axles from the ends
  • Inspection of components installed on-site (axles/wheels), reducing the maintenance load compared to methods that require disassembly

Coverage with no “blind spots”

  • Designed to account for interference from the press-fit bearing holes, which can prevent UT transmission when the probe passes over the hole.
  • The combination of operating modes allows for seamless coverage, maintaining uniform POD across the entire 360°.

Phased Array Inspection Technology (Pulse-Echo + Pitch-Catch)

  • Use a Phased Array probe with elements arranged in at least two columns:
    • central column in reflection (pulse-echo)
    • lateral columns in pitch-and-catch mode (one transmits, the other receives)
  • Configuration:
    • 2 columns: control in 2 scans
    • 3 columns: control in a single scan with recording in a single file

The practical implementation of this technique involves a clear workflow focused on data quality:

  • preparation of the examination surface
  • data acquisition with data validity checks (pairing/speed)
  • traceability of the scan associated with the UN number of the axle
  • scans evaluation