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Railway Wheel Profile Gauge IKP-5 Series (Model 2016) Manual

Railway Wheel Profile Gauge IKP-5 Series (Model 2016) Manual

Product catalog summary

Safety Precautions and Measurement Conditions: This section outlines the necessary safety measures and conditions under which the Laser Wheel Profilometer should be operated to ensure user safety and accurate measurements.

Electromagnetic Compatibility: Details the device's compliance with electromagnetic standards to prevent interference with other electronic equipment.

Laser Safety: Provides guidelines for safe operation of the laser components, emphasizing the importance of following safety protocols to avoid injury.

General Information: Offers an overview of the device, including its purpose and applications in measuring wheel profiles.

Basic Technical Data: Lists the technical specifications of the IKP-5 Series, including measurement ranges and accuracy.

Device Structure: Describes the main components of the device, such as the digital readout device, laser scanning module, and calibration block, and their respective functions.

Operation Principle: Explains the fundamental working mechanism of the profilometer, detailing how it measures various geometric parameters of wheels.

Geometric Parameters of the Wheel: Covers the specific parameters measured by the device, including flange height, thickness, slope, wear parameters, angle parameters, rim parameters, wheel diameter, and tram wheel parameters.

First Activation and Measurement Procedure: Provides step-by-step instructions for activating the device and conducting initial measurements.

PDA Basic Parameters Setting: Guides users on setting up the PDA, including measurement type, units, date/time, device selection, language, and synchronization with a PC.

Measurement Parameters Setting: Details how to configure calculation methods, select displayed parameters, and set preset parameter values.

Database Parameters, Tolerances, and Measurement Schemes: Discusses how to manage database settings, select reference profiles, form measurement schemes, and set tolerances.

Software Installation and Startup: Instructions for installing the necessary software on a PC, synchronizing with the PDA, and starting the program.

User Settings of the Program: Covers customization options for the software, including parameter settings, database settings, and registration data.

Data Exchange Between PDA and PC: Explains the process of synchronizing data between the PDA and PC using ActiveSync, including transferring database and language files.

Specifications and Procedures: The document outlines the methods for measuring and calculating various parameters of wheel profiles using the IKP-5 Series Laser Wheel Profilometer. Key parameters include flange thickness, flange slope, wear parameters, angle parameters, rim parameters, wheel diameter, and tram wheel parameters. Each parameter has specific methods for calculation, often involving measurements from defined points on the wheel.

Flange Thickness and Slope: Flange thickness is measured horizontally between two points on the flange, with two methods provided for determining these points. Flange slope is calculated using parameters L1 and L3 (or L4), with three methods available: in millimeters, in degrees, or as a pass/fail condition.

Wear Parameters: Wear parameters such as vertical wear, horizontal wear, corner wear, and hollow are calculated automatically. These measurements help assess the condition of the wheel by comparing current measurements to reference values.

Angle and Rim Parameters: Angle parameters include inclination and specific angles (S1 and S2) calculated at preset distances. Rim parameters include rim width and thickness, which are measured vertically between specific points.

Measurement and Activation Procedures: The document details the activation and measurement procedures for the profilometer. It includes steps for charging, turning on the PDA and laser module, and establishing a Bluetooth connection. Two types of measurements are available: rapid measurements without saving results and measurements with saving results to a database.

PDA Settings: The PDA settings include options for measurement type, units of measurement, date/time, device selection, language, and synchronization with a PC. These settings ensure the profilometer operates correctly and data is managed efficiently.

Measurement Parameters Setting: The document describes how to set calculation methods and select displayed parameters. This ensures that the profilometer provides accurate and relevant data during measurements.

Overview: This document provides detailed instructions for operating the Laser Wheel Profilometer, IKP-5 Series, Model 2016. It covers parameter settings, database management, measurement procedures, and software updates.

Parameter Settings:

Displayed Parameters: To enable display mode, press the "Show param." button. Double-click in the "Show/Hide" column to select or deselect parameters, then press "Save."
L Parameters: Access by pressing the "L Parameters" button. Edit values by double-clicking in the "Value" column and entering new data. Save changes by pressing "Save."
Preset Parameter Values: The document lists default values for L-parameters used in various calculations, such as flange slope, wheel diameter, and wear.

Database and Measurement Settings:

Database Management: Create and manage database files for storing measurement results. Files are named by default with the format "wp_yy_mm_dd.ikp."
Reference Profile Selection: Compare scanned wheel profiles with reference profiles stored in the PDA database. Users can request additional profiles from RIFTEK if needed.
Measurement Scheme: Define sequences for measuring wheels. Users can select, view, or delete schemes, and create new ones using the PDA or a PC program.
Tolerances Setting: Set and manage tolerance groups for geometric parameters. Critical values are highlighted in red, and near-critical values in orange.
Wheel Type Selection: Assign specific measurement schemes, reference profiles, and parameters to different wheel types.

Software Updates: The latest software version can be downloaded from the RIFTEK website. Update procedures are detailed in the manual.

Measurement Procedures:

Types of Measurements: Rapid measurements without saving results and detailed measurements with database maintenance.
Measurement Process: Follow the program's prompts to measure wheels. Results beyond tolerances are highlighted. Users can view profiles and save satisfactory results.
Wear and Defect Measurement: Special procedures for measuring even/uneven wear and defects like slides and cavities.

Integration with Other Devices: Instructions for using the PDA with other devices to store results in a unified database.

Data Filtering and Visualization: To filter data, press the Filter button and set parameters in the window that appears. For example, filtering by the Axle parameter will highlight the field in yellow. To delete a filter, press the delete button. To visualize the wheel profile, press the Profile button to display the scanned wheel profile and the selected reference on the PDA screen. Buttons allow zooming, standard scaling, and browsing profile wear, with wear areas highlighted in green (positive) and blue (negative).

Software Installation and Synchronization: Install the ikp5_DB software for maintaining a wheel sets wear database on a PC by inserting a CD and following the installation wizard. Synchronization between PDA and PC can be done via USB using MS ActiveSync or Mass Storage. For MS ActiveSync, install the necessary software on the PC. For Mass Storage, the device is detected as an external storage device.

Program Startup and User Settings: Start the program via Start > All programs > Riftek, LLC > IKP5_DB > Ikp5_DB.exe. User settings include parameters for wheelset, calculated parameters, L parameters, and measurement methods. Measurement units can be set to metric or English. Database settings allow changing the database path, creating new databases, and importing data. Language settings allow changing the software language and editing terminology.

Registration and Data Exchange: Registration includes adding organizations, operators, series, car/locomotive numbers, tolerances, and reference profiles. Data exchange between PDA and PC is done via ActiveSync or Mass Storage. ActiveSync allows transferring database, language, reference profile, and processing scheme files, as well as updating PDA software. Mass Storage treats the PDA as an external storage device for data transfer.

Working with Profilograms and Wear Calculations: To browse saved profiles, select Database > Profiles. The table of profiles displays identification parameters. Graphical images and geometric parameters can be viewed, and profile coordinates can be accessed by clicking the Profile Values button. Functions include showing/hiding graphs, saving and printing profile images, and calculating geometric parameters.

Selection of Comparison Profile: This section explains how to compare a profile with a reference or another measured profile. Users can select the reference profile from a drop-down list or choose to compare two measured profiles, such as left and right wheels.

Selection of L-Parameters Values: When calculating geometric parameters of wheelsets, users can choose between General parameters, which are default database values, or Profile parameters, which are values saved during measurement. These parameters can be edited and recalculated if necessary.

Geometric Parameters of the Profile: The table displays selected geometric parameters, highlighting those beyond set tolerances in red or orange.

Wear Calculation: Fast wear calculation can be done by selecting a profile and clicking to see coordinate differences. For a comprehensive wear analysis, the Wear button calculates wear at all points, displaying results graphically and in a table format, which can be saved in Excel format.

Alignment and Superposition of Profiles: Profiles can be aligned by selecting the Alignment button and adjusting the profile position. Multiple profiles can be superimposed by selecting them in a table, with each displayed in different colors.

Rescaling: Users can change the image scale by marking parts of the image or using Increase, Decrease, and Show all buttons.

Minimum Wheel Truing Function: This function allows analysis of wheel profiles to minimize truing depth. Users can perform automatic analysis or select a specific reference profile for analysis.

Scanning and Editing of Data: Data can be scanned, sorted, filtered, grouped, and edited. Users can add, delete, or edit data entries and prepare reports in various formats, including Excel, RTF, and PDF.

Taking Measurements Under PC Control: The laser scanning module can be controlled directly by a PC. Calibration and measurement procedures are outlined, including setting up Bluetooth connections and saving measurement data.

Annex 1: Charging Procedure: Details the steps for charging the PDA and laser module, emphasizing the sequence of actions.

Annex 2: Program for Making Measurement Schemes: Describes the use of SchemeBuilder.exe to create measurement schemes, including entering parameters and saving schemes.

Testing and Calibration: The document outlines the procedures for testing and calibrating the IKP-5 Series Laser Wheel Profilometer. It includes the use of an RF432.10 calibration-wheel simulation unit and RF505C calibration program for periodic testing and self-calibration. The process requires setting up a Bluetooth connection between the laser scanning module and a PDA, as detailed in the user manual.

Preparation for Testing/Calibration:

Install the RF505Calibr program on a PC.
Establish a Bluetooth connection between the scanning module and PC.
Place the profilometer on the calibration unit and run the RF505Calibr program.
Select the required port for Bluetooth connection to identify the device and read calibration parameters.

Testing:

Automatic testing involves specifying the number of measurements (5-10) and ensuring deviations from reference values do not exceed 0.1 mm.
If deviations exceed permissible values, calibration is necessary.

Calibration:

Select a reference profile, perform measurement, and execute auto-calibration.
Save parameters if results are positive; otherwise, restore factory settings and recalibrate.

Warranty Policy: The Laser Profilometer comes with a 24-month warranty from the date of operation and a 12-month shelf-life warranty.

Distributors: The document lists distributors across various countries, including Australia, Benelux, Brazil, China, and more, providing contact details for each.

RIFTEK’s Measurement Devices for Railway Transport:

Laser Wheel Profilometer (IKP Series): Measures wheel flange height, thickness, slope, and performs full profile scanning without wheel set roll-out.
Portable Laser Rail Profilometer (PRP Series): Provides cross-section profile information and visualizes railhead profiles.
Wheel Diameter Measuring Gauge (IDK Series): Measures wheel rolling circle diameter directly on rolling stock.
Back-to-Back Distance Measuring Gauge (IMR Series): Measures back-to-back distance of wheels contactlessly.
Disc Brakes Profile Gauge (IKD Series): Measures disc brakes profile parameters and visualizes profiles.
Automatic Real-Time System: Measures geometrical parameters of railway wheels using 2D laser scanners.

Catalog excerpts

LASER WHEEL PROFILOMETER IKP-5 Series, Model 2016 Year User's manual [email protected] www.riftek.com

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year IKP-5 Series, Model 2016 Year [Revision 3.0.0] 04.01.2016

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year IKP-5 Series, Model 2016 Year [Revision 3.0.0] 04.01.2016

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year Safety precautions and measurement conditions · Prior to mounting the profilometer onto the wheel, areas of contact of the side supports with the wheel surface should be thoroughly cleaned from dirt. · When mounting the module on the wheel, do not allow heavy shocks of its support against the wheel. · The output window of the profilometer and profilometer supports must be carefully inspected and cleaned. · Do not use laser module in locations close to powerful light sources. Electromagnetic compatibility The profilometer have been developed...

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year installing the profilometer. The version with very short handle is specially designed to measure wheels of Ansaldo Breda low floor trams with very limited space for profilometer installing. This super short profilometer version has separate battery block, connected by cable with laser module. Basic technical data Name of parameter Measurement range flange height, mm flange thickness, mm flange slope, mm rim thickness, mm diameter (calculation method), mm Measurement error flange height, mm flange thickness, mm flange slope, mm rim thickness,...

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year Example: IKP-Т – standard magnets; standard support plates; presence of the rim measurement rod. IKP-F-I – reinforced magnets; custom support plates. IKP-Short-T – the shorten handle; presence of the rim measurement rod. Digital readout device (PDA) Laser scanning module Charging device 9V 3.0A for laser module Data cable Bluetooth adapter Packing case Database management system (CD) User's manual Ca libra tion tools (option): RF505.11 Calibration block Calibration software The profilometer comes in the special case that protects the device...

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year Device structure Basic components of the device and their functions Fig. 1 shows basic components of the device: (1) Digital readout device (personal digital assistant, PDA) (2) Laser scanning module (3) Calibration block (4) Charging device (5) Data cable Digital readout device Digital readout device (PDA) is designed for control of the laser scanning module, data reception from the scanning module, indication of measurement results, parameter input, and data storage. Fig. 2 indicates: (1) Turn-on button (2) Charging indication, red/blue...

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year Overall dimensions of PDA are shown in figure 3: Laser scanning module The module is intended for laser scanning of the wheel surface. Fig. 4 indicates: (1) Turn ON button (2) Indicator of turn ON (red LED) (3) Indicator of Bluetooth connection (blue LED) (4) Charging device connector (5) Support for mounting of the device on the wheel flange IKP-5 Series, Model 2016 Year [Revision 3.0.0] 04.01.2016

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year (6) Magnetic support for mounting on the wheel side surface (7) Charging indication, red/green LED (8) Output window (9) Rim measurement rod Overall dimensions of the standard scanning module are shown in figure 5. Overall dimensions of the scanning module with the shortened handle are shown in figure 6. Overall dimensions of super short scanning module and battery block are shown in figure 6.1. IKP-5 Series, Model 2016 Year [Revision 3.0.0] 04.01.2016

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year Calibration block Calibration block is intended for calibration and tests of the profilometer. Calibration block is a metal imitator of the part of wheel with a definite profile. Overall dimensions of calibration block are shown in figure 1A of paragraph 30.3. Also possible is supply of a unit with a profile made to the customer’s drawings. Operation principle Operator mounts the laser scanning module onto the wheel to be measured. Having received a command from PDA or PC, the laser module performs non-contact scanning of the wheel surface....

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year 10. Geometric parameters of the wheel under control Geometric parameters of the wheel are calculated automatically after laser scanning of the wheel is completed. To calculate geometric parameters, use is made of reference points on the wheel profile. Location of the reference points is defined by L- and P-parameters. Values of L- and P-parameters preset in PDA are given in paragraph 14.4. and can be changed by the user. Calculation of the flange height is determined by parameter L2. The flange height is calculated as a distance measured...

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year Method 2 Point 1 is defined by parameter L3. Point 2 is the intersection point of a horizontal line and the flange surface. Note: Both calculation methods can be performed simultaneously. Flange slope, qR Calculation of the flange slope is determined by parameters L1 and L3 (or L4). Height L1 is measured vertically downward from the flange top and determines Point 3 on the flange surface. Height L4 is measured vertically upward from a point of the wheel rolling surface, the position of which is defined by parameter L2 (wheel rolling circle),...

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Laser Wheel Profilometer. IKP-5 Series, Model 2016 Year * Red color indicates the worn profile Hollow is calculated as the difference between the maximum and minimum values within the specified limits. The search limits: - parameters of the minimum value [P7_1..P7_2] - parameters of the maximum value [P8_1..P8_2] dD is calculated as the difference between diameter at point D1 and diameter at point D2. Even wear is the maximum vertical wheel wear selected from several measurements. Uneven wear is the difference between the maximum wheel wear and the minimum wheel wear (selected from several measurements)....

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.

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