Waygate Technologies, a Baker Hughes business and global leader in non-destructive testing (NDT), has announced the launch of the Krautkrämer WheelStar RPS, a next-generation ultrasonic inspection system designed to automate and streamline railway wheelset inspections.
With increasing regulatory pressure and the ongoing shortage of skilled inspection professionals, the WheelStar RPS (Radsatz-Prüf-System) is set to transform how the rail industry approaches safety, compliance, and maintenance efficiency. The system is the first of its kind to fully automate ultrasonic testing for dismantled rail wheels using advanced robotics and phased array matrix ultrasonic technology.
Automation Meets Rail Safety
Specifically developed for use in Maintenance, Repair and Operations (MRO) environments, the WheelStar RPS automates every stage of the wheelset testing process. Using an underfloor shift-rotate unit, wheels are automatically turned while a robotic arm positions ultrasonic probes. Each inspection is completed in approximately six minutes, with real-time calibration and result validation.
By eliminating the need for manual inspection and handling of reference wheelsets, Waygate Technologies estimates that total shift work time can be reduced by up to 23%. This not only enhances efficiency but also mitigates operational risks associated with inconsistent manual checks.
Addressing Industry-Wide Challenges
Rail wheel integrity is critical to the safety of rail operations. With stringent international standards mandating regular ultrasonic testing, the WheelStar RPS is designed to identify flaws across various wheel geometries and wear conditions while minimising false indications and reducing unnecessary rework.
Equipped with features such as wheel profile compensation and direct coupling control, the system ensures both precision and compliance, making it a timely solution for a sector under pressure to modernise its inspection regimes.
Simplified User Experience
Waygate Technologies has also focused on user accessibility and operational simplicity. The system offers a guided workflow, a single-screen interface, and supports pre-programmed wheel types with automatic report generation, reducing training time and dependency on highly specialised personnel. Remote technical support is also available for ongoing operational assistance.
Orders Open from August 2025
The WheelStar RPS will be available for order starting August 2025, joining Waygate Technologies’ portfolio of rail-focused inspection technologies including the Krautkrämer WheelStar UFPE and Solid Axle Mechanized Testers.
Building on over 75 years of experience in ultrasonic testing, the WheelStar RPS reflects Waygate’s continued commitment to advancing rail safety and operational excellence.
Reference: https://www.railwaypro.com/wp/baker-hughes-unveils-automated-rail-wheel-inspection-system/
