Waygate Technologies, a subsidiary of Baker Hughes, has announced the unveiling of the Krautkrämer WheelStar RPS, a new fully automated system designed to modernize and enhance the inspection of train wheels. The system was introduced as part of Waygate Technologies’ ongoing efforts to broaden its portfolio for the rail industry.

According to the company, the Krautkrämer WheelStar RPS utilizes advanced matrix array ultrasonic technology in combination with an industrial robotic assembly, allowing for detailed and rapid train wheel inspections. The new platform is engineered to handle dismantled train wheels and can conduct both initial and follow-up examinations, giving overhaul facilities and train operators a robust tool to meet strict international railway safety and regulatory standards for non-destructive testing.

The system's design features a compact footprint and promises to reduce the complexity of wheelset inspection workflows. The automated WheelStar RPS positions ultrasonic equipment with the help of a robotic arm, while an underfloor unit rotates the train wheels for a comprehensive examination. A key aspect of the system is its ability to compare inspection results with calibrated standards in real time.

Notably, the system achieves processing times as short as six minutes per wheelset—a substantial improvement in speed compared to many conventional methods. This efficiency translates to a reduction in total shift work time for operators between 7% and 23%, with a specific 5% decrease in check and re-check cycles, according to data provided by Waygate Technologies. The methodology aims to ensure both faster and more reliable detection of defects across various wheel geometries and wear profiles, while minimizing false positives and unnecessary interventions.

The Krautkrämer WheelStar RPS offers a simplified workflow via single-screen operation and pre-programmed wheelset profiles, enabling automatic report generation and minimizing operator training requirements. Additionally, the system supports remote service and troubleshooting, reflecting a push toward digitalization and smarter maintenance management in the rail sector.

Availability for order is scheduled for August 2025, according to Waygate Technologies’ announcement on their official website.

The introduction of the WheelStar RPS underlines growing industry demand for automation and precision in rail safety practices, as regulators and operators worldwide seek to maximize train availability while adhering to ever-stricter compliance standards.