Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to the field of inspection and scanning systems and equipments. In particular, the present disclosure relates to an apparatus for testing welded joints of a rail.

BACKGROUND
[0002] As conventionally known in the art, the inspection of weld joints is general performed using conventional ultrasonic testing, especially for the weld joints of a rail.
[0003] Further, these conventional ultrasonic testing systems and methods rely on manual testing or limited mobility scanners. This often leads to inconsistent inspection results due to human error or inadequate coverage.
[0004] Thus, the current systems being the mechanized inspection systems lack the adaptability for a full rail profile scanning and suffer from limited automation in challenging on-site conditions.
[0005] Therefore, there is a need to address this poor scan repeatability, coverage limitations, and operator skill dependency of the present weld joint inspection systems and methods.
[0006] Hence, there is a long pending need to provide a more affordable, integrated, and reliable automated solution for testing weld joints of the rail.

OBJECTS OF THE PRESENT DISCLOSURE
[0007] A general object of the present disclosure is to provide an apparatus for testing welded joints of a rail that obviates the above-mentioned limitations of existing equipments/devices.
[0008] An object of the present disclosure is to provide an apparatus for testing welded joints of a rail with a combination of a chain-driven transverse track with a phased array integration and dual-axis scanning.
[0009] Yet another object of the present disclosure is to provide an apparatus for testing welded joints of a rail for a simultaneous inspection of the welded joints along both sides of a rail profile.
SUMMARY
[0010] Aspects of the present disclosure generally relate to the field of inspection and scanning systems and equipments. More particularly, the present disclosure relates to an apparatus for testing welded joints of a rail.
[0011] An aspect of the present disclosure relates to an apparatus for testing one or more welded joints of a rail. The apparatus may include a frame to be mounted securely onto the rail.
[0012] The frame may further include a drive mechanism and a set of inspection probes. Further, the drive mechanism may be mounted transversely onto the frame between a first frame member and a second frame member such that the drive mechanism is configured to allow a linear motion of the frame along a longitudinal length of the rail.
[0013] Furthermore, the set of inspection probes may be operatively coupled to the frame and may inspect the one or more welded joints along the longitudinal length and a transverse length of the rail.
[0014] In another aspect, each inspection probe among the set of inspection probes may be mounted at the first frame member side and at the second frame member side.
[0015] In an aspect, the frame may be a rigid and lightweight frame configured to be mounted onto the rail using a set of adjustable clamping arms. The set of adjustable clamping arms may position the frame securely onto a rail profile for any type of geometry of the one or more weld joints.
[0016] In another aspect, the drive mechanism may be a closed-loop chain drive mechanism and is driven by a motor.
[0017] In an aspect, the each inspection probe among the set of inspection probes may be a two phased array ultrasonic probe for performing a phased array ultrasonic testing (PAUT) of the one or more welded joints from both sides of the rail.
[0018] In another aspect, the each inspection probe among the set of inspection probes may be housed in a set of inspection arms, respectively, such that each inspection arm among the set of inspection arms the arm may be operatively coupled to the both sides of the rail.
[0019] In another aspect, the set of inspection probes may perform a simultaneous inspection of the one or more welded joints on the both sides of the rail.
[0020] In an aspect, the simultaneous inspection of the one or more welded joints may determine one or more faults in the one or more welded joints, and wherein the one or more faults is selected from a group comprising transverse flaws, longitudinal cracks, volumetric inclusions, lack of fusion or penetration, and heat-affected zone (HAZ) defects.
[0021] In another aspect, the drive mechanism may move the set of inspection probes across the rail profile comprising a rail head, a rail web and a rail base along an axis of the one or more weld joints of the rail such that the set of inspection probes perform the inspection of the one or more welded joints at a plurality of angles and depths during a single pass across the one or more welded joints.
[0022] In an aspect, the apparatus may further include a control module in communication with the drive mechanism and the set of inspection probes. The control module may: perform a real-time inspection of the one or more welded joints of a rail; generate, a plurality of inspection scan views of the one or more welded joints, wherein the plurality of inspection scan views comprises A-scan, B-scan, S-scan, and C-scan views for the one or more faults; map, the one or more faults with one or more positional coordinates of the one or more welded joints; and record, the one or more mapped faults of the one or more joints of the rail.
[0023] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0025] FIGs. 1A and 1B illustrate exemplary schematic representations of an apparatus 100 for testing welded joints of a rail 200, in an isometric view and a side view respectively, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0026] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosures as defined by the appended claims.
[0027] For the purpose of understanding of the principles of the present disclosure, reference will now be made to the various embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the present disclosure is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the present disclosure as illustrated therein being contemplated as would normally occur to one skilled in the art to which the present disclosure relates.
[0028] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the present disclosure and are not intended to be restrictive thereof.
[0029] Whether or not a certain feature or element was limited to being used only once, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, “there needs to be one or more” or “one or more elements is required.”
[0030] Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements of the present disclosure. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.
[0031] Use of the phrases and/or terms including, but not limited to, “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment,” “additional embodiment” or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.
[0032] Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the proposed disclosure.
[0033] The terms “comprise,” “comprising,” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by “comprises... a” does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.
[0034] Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.
[0035] The present disclosure in general, relates to the field of inspection and scanning systems and equipments. Specifically, the present disclosure relates to an apparatus for testing welded joints of a rail.
[0036] In an embodiment of the present disclosure, the present disclosure relates to a chain track-guided scanner with transverse and longitudinal scanning capabilities, ensuring complete weld zone evaluation. The proposed apparatus/system minimizes manual intervention, accommodates varied weld geometries, and integrates defect visualization tools. By employing phased array ultrasonic technology in place of conventional single-element probes, the proposed system offers superior flaw detection sensitivity, faster data acquisition, and real-time imaging with greater coverage per scan. Phased array also enables electronic beam steering and focal depth control, allowing inspection of complex geometries without mechanical probe repositioning, thereby enhancing precision and repeatability while reducing overall inspection time.
[0037] In an embodiment, the present disclosure relates to a mechanized ultrasonic scanner apparatus or system for inspecting welded joints in railway rails using phased array ultrasonic testing (PAUT). The proposed system is engineered to ensure complete volumetric coverage of the weld zone including the rail head, web, and base, by employing a chain-guided transverse scanning mechanism and two PAUT probes positioned on opposite sides of the weld, facing each other.
[0038] In an exemplary embodiment of the present disclosure, the proposed mechanized ultrasonic scanner apparatus may comprise the following components:
[0039] Mechanical Scanner Frame: The proposed scanner consists of a rigid, lightweight frame that mounts securely over a single rail. Adjustable clamping arms ensure stable positioning during inspection, accommodating various rail profiles and weld geometries.
[0040] Chain Track Scanning Mechanism: A closed-loop chain drive is mounted transversely across the scanner frame. The chain is tensioned over precision guide rails and driven by a stepper or servo motor, enabling controlled lateral movement of the probe carriage. This mechanism ensures repeatable, high-resolution scanning across the weld cross-section, independent of operator skill.
[0041] Dual PAUT Probe Configuration: Two phased array ultrasonic probes are mounted on either side of the weld, facing each other. Each probe is housed in a spring-loaded or articulated arm to maintain consistent coupling with the rail surface. The opposing configuration allows simultaneous inspection from both sides, enhancing detection of: transverse flaws, longitudinal cracks, volumetric inclusions, lack of fusion or penetration and heat-affected zone (HAZ) defects.
[0042] Scanning Motion and Coverage: The transverse chain scan moves the probes across the rail profile (from base to head), to move the entire scanner along the weld axis. The phased array probes use electronic beam steering and focusing, allowing inspection at multiple angles and depths during a single pass.
[0043] Data Acquisition and Visualization: The system interfaces with a PAUT flaw detector and control tablet. Real-time A-scan, B-scan, S-scan, and C-scan views are generated. Defects are automatically mapped, and recorded with positional coordinates.
[0044] Thus, the proposed scanner configuration not only improves inspection speed and reliability but also ensures consistent, high-resolution detection of all critical defect types in rail welds.
[0045] Various embodiments of the present disclosure will be explained in detail with respect to FIGs. 1A and 1B.
[0046] Referring to FIGs. 1A and 1B, exemplary schematic representations of an apparatus 100 for testing welded joints of a rail 200, in an isometric view and a side view are illustrated respectively, in accordance with an embodiment of the present disclosure
[0047] In an embodiment of the present disclosure, the apparatus 100 for testing one or more welded joints of a rail 200 can include a frame 110 to be mounted securely onto the rail 200.
[0048] The frame 110 can further include a drive mechanism 120 and a set of inspection probes 130a and 130b. Further, the drive mechanism 120 can be mounted transversely onto the frame 110 between a first frame member 110a and a second frame member 110b such that the drive mechanism 120 is configured to allow a linear motion of the frame 110 along a longitudinal length of the rail 200.
[0049] Furthermore, the set of inspection probes 130a and 130b can be operatively coupled to the frame 110 and can inspect the one or more welded joints along the longitudinal length and a transverse length of the rail 200.
[0050] In another embodiment, each inspection probe among the set of inspection probes 130a and 130b can be mounted at the first frame member 110a side and at the second frame member 110b side.
[0051] In an embodiment, the frame 110 may include a frame handle 110c operatively attached between the first frame member 110a and at the second frame member 110b such that the frame 110 may be lifted completely using the frame handle 110c. Further, the frame handle 110c may include a spring mechanism integrated within the frame handle 110c to allow easy handling and enable a quick engagement and/or disengagement of the frame 100 from the rail 200.
[0052] Further, the each inspection probe among the set of inspection probes 130a and 130b may be housed in a spring-loaded or articulated arm to maintain consistent coupling with the rail surface of the rail 200.
[0053] In an embodiment, the frame 110 may support a single-person handling of the apparatus 100 for quicker and efficient engagement and/or disengagement of the frame 110 to the rail 200 for testing the one or more welded joints of the rail 200.
[0054] In an embodiment, the frame 110 can be a rigid and lightweight frame configured to be mounted onto the rail 200 using a set of adjustable clamping arms 112a and 112b. The set of adjustable clamping arms 112a and 112b can position the frame 110 securely onto a rail profile for any type of geometry of the one or more weld joints.
[0055] In an embodiment of the present disclosure, the apparatus 100 may be a mechanized ultrasonic scanner apparatus 100 that may be managed using one or more magnets or ON/OFF magnets. Further, in an embodiment, the one or more magnets or ON/OFF magnets may be integrated with the set of adjustable clamping arms 112a and 112b for positioning the apparatus 100 securely onto the rail profile for any type of geometry of the one or more weld joints.
[0056] In another embodiment, the drive mechanism 120 can be a closed-loop chain drive mechanism and is driven by a motor.
[0057] Further, the each inspection probe among the set of inspection probes 130a and 130b can be a two phased array ultrasonic probe for performing a phased array ultrasonic testing (PAUT) of the one or more welded joints from both sides 200a and 200b of the rail 200.
[0058] In another embodiment, the each inspection probe among the set of inspection probes 130a and 130b can be housed in a set of inspection arms 140a and 140b, respectively, such that each inspection arm among the set of inspection arms the arm 140a and 140b can be operatively coupled to the both sides 200a and 200b of the rail 200.
[0059] In another embodiment, the set of inspection probes 130a and 130b can perform a simultaneous inspection of the one or more welded joints on the both sides 200a and 200b of the rail 200.
[0060] Furthermore, the simultaneous inspection of the one or more welded joints can determine one or more faults in the one or more welded joints, and wherein the one or more faults is selected from a group comprising transverse flaws, longitudinal cracks, volumetric inclusions, lack of fusion or penetration, and heat-affected zone (HAZ) defects.
[0061] In another embodiment, the drive mechanism 120 can move the set of inspection probes 130a and 130b across the rail profile comprising a rail head 210, a rail web 220 and a rail base 230 along an axis of the one or more weld joints of the rail 200 such that the set of inspection probes 130a and 130b perform the inspection of the one or more welded joints at a plurality of angles and depths during a single pass across the one or more welded joints.
[0062] In an embodiment, the apparatus 100 can further include a control module in communication with the drive mechanism 120 and the set of inspection probes 130a and 130b. The control module can: perform a real-time inspection of the one or more welded joints of a rail 200; generate, a plurality of inspection scan views of the one or more welded joints, wherein the plurality of inspection scan views comprises A-scan, B-scan, S-scan, and C-scan views for the one or more faults; map, the one or more faults with one or more positional coordinates of the one or more welded joints; and record, the one or more mapped faults of the one or more joints of the rail 200.
[0063] In an exemplary embodiment of the present disclosure, the components of the proposed apparatus 100 for testing the one or more welded joints of the rail 200 may include the following working range:
[0064] Inspection Probes 130a and 130b Frequency: 2 MHz to 5 MHz
[0065] Drive Mechanism 120 - Chain Track Width: 200 mm to 500 mm
[0066] Longitudinal Scan Length of the Apparatus 100: 500 mm
[0067] Operating Temperature of the Apparatus 100: 0°C to 55°C
[0068] Therefore, the present disclosure provides the proposed apparatus 100 for testing the one or more welded joints of the rail 200 with a combination of a chain-driven transverse track with phased array integration and dual-axis scanning in a ruggedized portable frame.
[0069] In this application, unless specifically stated otherwise, the use of the singular includes the plural and the use of “or” means “and/or.” Furthermore, use of the terms “including” or “having” is not limiting. Any range described herein will be understood to include the endpoints and all values between the endpoints. Features of the disclosed embodiments may be combined, rearranged, omitted, etc., within the scope of the disclosure to produce additional embodiments. Furthermore, certain features may sometimes be used to advantage without a corresponding use of other features.
[0070] While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The scope of the disclosure is determined by the claims that follow. The disclosure is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the disclosure when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE PRESENT DISCLOSURE
[0071] The present disclosure provides an apparatus for testing welded joints of a rail that obviates the above-mentioned limitations of existing equipments/devices.
[0072] The present disclosure provides an apparatus for testing welded joints of a rail with a combination of a chain-driven transverse track with a phased array integration and dual-axis scanning.
[0073] The present disclosure provides an apparatus for testing welded joints of a rail for a simultaneous inspection of the welded joints along both sides of a rail profile.
[0074] The present disclosure provides an apparatus for testing welded joints of a rail with a longitudinal drive unit for rail-axis scanning.
[0075] The present disclosure provides an apparatus for testing welded joints of a rail with a guided transverse inspection probe motion.
, Claims:1. An apparatus (100) for testing one or more welded joints of a rail (200), the apparatus (100) comprising:
a frame (110) to be mounted securely onto the rail (200) and comprising:
a drive mechanism (120) mounted transversely onto the frame (110) between a first frame member (110a) and a second frame member (110b) such that the drive mechanism (120) is configured to allow a linear motion of the frame (110) along a longitudinal length of the rail (200); and
a set of inspection probes (130a, 130b) operatively coupled to the frame (110) and configured to inspect the one or more welded joints along the longitudinal length and a transverse length of the rail (200).

2. The apparatus (100) as claimed in claim 1, wherein each inspection probe among the set of inspection probes (130a, 130b) is configured to be mounted at the first frame member (110a) side and at the second frame member (110b) side.

3. The apparatus (100) as claimed in claim 1, wherein the frame (110) is a rigid and lightweight frame configured to be mounted onto the rail (200) using a set of adjustable clamping arms (112a, 112b), wherein the set of adjustable clamping arms (112a, 112b) are configured to position the frame (110) securely onto a rail profile for any type of geometry of the one or more weld joints.

4. The apparatus (100) as claimed in claim 1, wherein the drive mechanism (120) is a closed-loop chain drive mechanism and is driven by a motor.

5. The apparatus (100) as claimed in claim 1, wherein the each inspection probe among the set of inspection probes (130a, 130b) is a two phased array ultrasonic probe for performing a phased array ultrasonic testing (PAUT) of the one or more welded joints from both sides (200a, 200b) of the rail (200).

6. The apparatus (100) as claimed in claim 5, wherein the each inspection probe among the set of inspection probes (130a, 130b) is configured to be housed in a set of inspection arms (140a, 140b), wherein each inspection arm among the set of inspection arms the arm (140a, 140b) is configured to be operatively coupled to the both sides (200a, 200b) of the rail (200).

7. The apparatus (100) as claimed in claim 1, wherein the set of inspection probes (130a, 130b) are configured to perform a simultaneous inspection of the one or more welded joints on the both sides (200a, 200b) of the rail (200).

8. The apparatus (100) as claimed in claim 7, wherein the simultaneous inspection of the one or more welded joints determines one or more faults in the one or more welded joints, and wherein the one or more faults is selected from a group comprising transverse flaws, longitudinal cracks, volumetric inclusions, lack of fusion or penetration, and heat-affected zone (HAZ) defects.

9. The apparatus (100) as claimed in claim 3, wherein the drive mechanism (120) is configured to move the set of inspection probes (130a, 130b) across the rail profile comprising a rail head (210), a rail web (220) and a rail base (230) along an axis of the one or more weld joints of the rail (200) such that the set of inspection probes (130a, 130b) perform the inspection of the one or more welded joints at a plurality of angles and depths during a single pass across the one or more welded joints.

10. The apparatus (100) as claimed in claim 8, comprising:
a control module in communication with the drive mechanism (120) and the set of inspection probes (130a, 130b), and configured to:
perform a real-time inspection of the one or more welded joints of a rail (200);
generate, a plurality of inspection scan views of the one or more welded joints, wherein the plurality of inspection scan views comprises A-scan, B-scan, S-scan, and C-scan views for the one or more faults;
map, the one or more faults with one or more positional coordinates of the one or more welded joints; and
record, the one or more mapped faults of the one or more joints of the rail (200).