Waygate WheelStar: Automated Train Wheel Inspection for Railway Efficiency

Waygate Technologies Launches Automated Train Wheel Inspection System

In a move poised to revolutionize railway maintenance, Waygate Technologies, a Baker Hughes business, has unveiled its Krautkrämer WheelStar Radsatz-Prüf-System (RPS). This innovative system promises to significantly enhance the efficiency and accuracy of train wheel inspections. The WheelStar RPS, announced on July 4, 2025, utilizes cutting-edge matrix technology and industrial robotics to automate the inspection of dismantled train wheels. This allows for quicker turnaround times and improved reliability. The core aim of the WheelStar RPS is to empower train operators and maintenance, repair, and overhaul (MRO) facilities to meet stringent regulatory demands, boost train utilization rates, and ultimately, reduce operational costs through advanced automation and defect detection.

Automated Wheel Inspection: A New Era in Railway Maintenance

The WheelStar RPS addresses the critical need for efficient and reliable wheel inspection in the railway industry. The system employs a fully automated ultrasonic testing system, combining Waygate Technologies’ proprietary phased array matrix probe technology with industrial robots. The RPS uses a compact design that houses the robotic assembly, which accurately positions the ultrasonic mechanics on the train wheels. This design allows for a consistent and precise inspection process. The system operates by rotating the wheel using an underfloor shift-rotate unit. The WheelStar RPS is designed to inspect a wide variety of wheel geometries and conditions, detecting defects with high accuracy. The results are then compared with calibration data, enabling a rapid cycle time of just six minutes per wheelset.

Enhanced Efficiency and Reduced Downtime

One of the most significant benefits of the WheelStar RPS is the considerable reduction in inspection time. The automation streamlines the entire process, minimizing the need for manual intervention, previously necessary with reference wheelsets. By automating both initial checks and subsequent verifications, the system significantly cuts down on overall inspection time. In practice, the total shift work time is reduced by 7-23%, including a 5% reduction in check/re-check time. This automation not only enhances efficiency but also guarantees consistency and reliability in the testing process, which is critical for ensuring the safe operation of trains.

Technological Advancements: Matrix Technology and Robotic Integration

The Krautkrämer WheelStar RPS leverages advanced matrix technology and robotic integration to deliver high-quality inspection results. The matrix probe technology provides a more comprehensive and detailed analysis of wheel integrity compared to traditional methods. Industrial robots facilitate precise probe placement and movement, further enhancing the accuracy of the ultrasonic testing. The system minimizes false indications, reducing the risk of unnecessary costs associated with the removal and replacement of wheels that are, in fact, serviceable. Operators benefit from a user-friendly interface that guides them through the process on a single screen, including preprogrammed wheelset types and profiles, plus automatic report generation. Furthermore, remote service support is available to promptly address any technical issues that may arise, ensuring minimal disruption to operations.

Availability and Market Impact

The Krautkrämer WheelStar RPS is set to be available for order next month. This will meet the increasing demands of the railway industry and the need for more efficient and accurate wheel inspection processes. The introduction of this automated system underscores Waygate Technologies’ commitment to innovation and to providing solutions that meet the evolving needs of the global railway sector.

Conclusion

The launch of the Waygate Technologies Krautkrämer WheelStar RPS marks a significant step forward in railway maintenance technology. This automated system promises to revolutionize how train wheels are inspected, offering substantial improvements in efficiency, accuracy, and cost-effectiveness. The ability to reduce inspection times by up to 23%, while maintaining high standards of defect detection, positions the WheelStar RPS as a crucial tool for railway operators and MRO facilities seeking to optimize operations and meet increasing regulatory requirements. By automating critical inspection processes, Waygate Technologies is also contributing to enhanced safety and reduced operational downtime. The future of wheel inspection is undoubtedly heading toward increased automation and data-driven analysis, and the WheelStar RPS is well-positioned to lead this transition. We can expect to see more integrated and intelligent solutions that enable proactive maintenance strategies and optimize the lifespan of railway assets.

Company Summary

Waygate Technologies, a Baker Hughes business, is a global leader in industrial inspection solutions. It offers a wide range of technologies for non-destructive testing, including ultrasonic, X-ray, and eddy current inspection systems. Their expertise lies in providing advanced solutions for industries like aerospace, power generation, and, importantly, the railway sector. Waygate’s railway solutions are designed to meet the demanding requirements of railway operators, including high-performance, reliable systems for critical inspections.