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.

Abstract: An apparatus for detecting defects in a railway rail mounted on a test vehicle. The apparatus includes a transducer assembly with one or more arrays of ultrasonic transducers directed toward the running surface of the rail. Beams transmitted by the one or more arrays of ultrasonic transducers may be dynamically adjusted to compensate for the varying profile of the rail head and running surface. A laser profiler mounted on the test vehicle in combination with a linear encoder provide profile data, which is communicated to a system controller to dynamically adjust the focal laws for the one or more arrays of transducers to steer the transmitted beams to produce the ideal inspection beam sets while the test vehicle is in motion.

Abstract: A method for detecting defects in a railway rail including a search unit and preferably a roller search unit (“RSU”) mounted on a test vehicle and in rolling contact with the running surface of the rails to inspect each rail. The RSU includes a tire filled with a liquid and a transducer assembly mounted within the tire. The transducer assembly includes one or more arrays of ultrasonic transducers directed toward the running surface of the rail. A laser profiler mounted on the test vehicle in combination with a linear encoder provide profile data which is communicated to a system controller to dynamically adjust the focal laws for the one or more arrays of transducers to dynamically steer the transmitted beams to produce the ideal inspection beam sets while the test vehicle is in motion.

Abstract: A method for detecting defects in a railway rail including a search unit and preferably a roller search unit (“RSU”) mounted on a test vehicle and in rolling contact with the running surface of the rails to inspect each rail. The RSU includes a tire filled with a liquid and a transducer assembly mounted within the tire. The transducer assembly includes one or more arrays of ultrasonic transducers directed toward the running surface of the rail. A laser profiler mounted on the test vehicle in combination with a linear encoder provide profile data which is communicated to a system controller to dynamically adjust the focal laws for the one or more arrays of transducers to dynamically steer the transmitted beams to produce the ideal inspection beam sets while the test vehicle is in motion.

Abstract: An apparatus for detecting defects in a railway rail includes a search unit and preferably a roller search unit (“RSU”) mounted on a test vehicle and in rolling contact with the running surface of the rails to inspect each rail. The RSU includes a tire filled with a liquid and a transducer assembly mounted within the tire. The transducer assembly includes one or more arrays of ultrasonic transducers directed toward the running surface of the rail. A laser profiler mounted on the test vehicle in combination with a linear encoder provide profile data which is communicated to a system controller to dynamically adjust the focal laws for the one or more arrays of transducers to dynamically steer the transmitted beams to produce the ideal inspection beam sets while the test vehicle is in motion.

Abstract: An apparatus for detecting defects in a railway rail includes a search unit and preferably a roller search unit (“RSU”) mounted on a test vehicle and in rolling contact with the running surface of the rails to inspect each rail. The RSU includes a tire filled with a liquid and a transducer assembly mounted within the tire. The transducer assembly includes one or more arrays of ultrasonic transducers directed toward the running surface of the rail. A laser profiler mounted on the test vehicle in combination with a linear encoder provide profile data which is communicated to a system controller to dynamically adjust the focal laws for the one or more arrays of transducers to dynamically steer the transmitted beams to produce the ideal inspection beam sets while the test vehicle is in motion.

Abstract: An apparatus for detecting defects in a railway rail includes a search unit and preferably a roller search unit (“RSU”) mounted on a test vehicle and in rolling contact with the running surface of the rails to inspect each rail. The RSU includes a tire filled with a liquid and a transducer assembly mounted within the tire. The transducer assembly includes one or more arrays of ultrasonic transducers directed toward the running surface of the rail. A laser profiler mounted on the test vehicle in combination with a linear encoder provide profile data which is communicated to a system controller to dynamically adjust the focal laws for the one or more arrays of transducers to dynamically steer the transmitted beams to produce the ideal inspection beam sets while the test vehicle is in motion.

Abstract: An apparatus for detecting defects in a railway rail includes a search unit and preferably a roller search unit (“RSU”) mounted on a test vehicle and in rolling contact with the running surface of the rails to inspect each rail. The RSU includes a tire filled with a liquid and a transducer assembly mounted within the tire. The transducer assembly includes one or more arrays of ultrasonic transducers directed toward the running surface of the rail. A laser profiler mounted on the test vehicle in combination with a linear encoder provide profile data which is communicated to a system controller to dynamically adjust the focal laws for the one or more arrays of transducers to dynamically steer the transmitted beams to produce the ideal inspection beam sets while the test vehicle is in motion.