OKOndt GROUP Launched Ultrasonic Rail Inspection System for Metro in Italy

May 2025, Poviglio, Italy

The OKOndt GROUP team carried out the commissioning process and provided training on how to operate the high-speed ultrasonic metro rail testing System integrated to the Geismar Track Motor Car (inspection locomotive). This work was carried out as part of a joint project between OKOndt GROUP and Geismar, a French company that is one of the largest global manufacturers of equipment and services for railway construction and maintenance.

According to the project plans, Geismar designed and manufactured the Track Motor Car and a trolley for ultrasonic rail inspection, which was installed under the underframe of this Track Motor Car. In turn, OKOndt GROUP manufactured and installed a set of electronic measuring instruments for the high-speed ultrasonic rail testing System, along with software designed for non-destructive (NDT) rail testing, data analysis, and report generation.

OKOndt GROUP specialists verified the operability of the System on a railway track section at the Italian production facility in Geismar during commissioning and final testing. The configuration of OKOndt GROUP electronics, the settings of the immersion wheels, the density of their contact with the rail surface, the centring mechanism along the rail axis, and the encoder were all checked during setup.

OKOndt GROUP trained NDT-specialists to work with the Ultrasonic Rail Testing System

Training on how to operate the Ultrasonic Rail Testing System was conducted for the NDT specialists who will be using it. During the training, OKOndt GROUP specialists:

• trained the NDT specialists to use the software of the System and electronic measuring equipment;
• instructed them about the rail sounding schemes used by the System;
• taught them how to interpret ultrasonic testing results of the rail inspection;
• informed the NDT specialists about the features of the ultrasonic (immersion) wheel.

Features of ultrasonic testing of rails with OKOndt GROUP System

The ultrasonic high-speed rail testing trolley is mounted underneath the Geismar track inspection locomotive. There are two OKOndt GROUP immersion wheels, one on each side, positioned between the support wheels of this trolley.

These immersion wheels detect rail cracks and other defects as the locomotive moves along the tracks. This design provides an assessment of the condition of both metro line rails simultaneously, except the electric rail.

The operator is located in the cabin of the motorcar. Using the stepper electric drives of the Ultrasonic Rail Testing System, he can remotely control the immersion wheels to adjust their angle of inclination, lifting height and transverse movement. This allows the System to adapt to the curvature of the rails while the motorcar is moving.

The signals from the ultrasonic probes on each immersion wheel are shown on the displays of the System, which are located inside the locomotive cabin. The System automatically records and saves information about all rail defects detected by the ultrasonic probes, along with their geolocation.

At any time, the operator can send the saved rail testing data to a remote workstation for review by another NDT specialist. This saves time on data interpretation and thereby enhances the safety of metro train operations.

Advancing Safety and Efficiency in Light Rail Transit

OKOndt GROUP has over 30 years' experience in researching, developing and producing NDT solutions. The company provides effective rail flaw detection equipment that are tailored to the requirements of light rail systems worldwide. This joint project demonstrates the company's commitment to improving the reliability and safety of modern urban rail transport using advanced NDT technologies.