Abstract: A rail testing system comprises a proximal mobile track system and a distal mobile track system. Each of the proximal mobile track system and the distal mobile track system are movable in a horizontal direction and a vertical direction. A carriage is movably coupled to the proximal mobile track system and the distal mobile track system. The system has a sensor pod comprising a roller search unit. The sensor pod is configured to lock to the carriage for testing of a rail. The system includes a sensor array comprising time of flight sensors. The sensor array is usable to maintain an alignment of the roller search unit with the rail.

Abstract: A roller search unit for detecting rail defects with integrated digital circuitry includes a liquid filled tire mounted to an axle assembly with wheels. An ultrasonic transducer array positioned within a housing is positioned within the within the tire and coupled to the axle. The housing contains transducer interface circuitry operable to receive analog signals from the ultrasonic transducer array and contains digital flaw detection circuitry operable to convert the analog signals to digital signals and perform analysis on the digital signals to detect flaws in a rail. The transducer interface circuitry and digital flaw detection circuitry are configured to stack to provide a compact, small footprint assembly. The conversion of the transducer signals from analog to digital within the tire permits transmission of the digitized data without susceptibility to interference and noise.