AU674367B2 - Station for controlling railway wheelsets - Google Patents

Description

Our Ref: 498528 P/00/011 Regulation 3:2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT o o c Applicant(s): Address for Service: I-ivention Title: Investigacion Y Asesoramiento Tecnico, S.A.

Invastesa Montalban, 14 28014 MADRID

SPAIN

DAVIES COLLISON CAVE Patent Trade Mark Attorneys Level 10, 10 Barrack Street SYDNEY NSW 2000 Station for controlling railway wheelsets

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The following statement is a full description of this invention, including the best method of performing it known to me:- 5020 Y-II-I-eI II -I I-I' I I I DS\IiWS I'IIit' i 17Y, i3< -2- BACKGROUND OF THE INVENTION The present inventions relates to a station for controlling railway wheelsets, intended to measure parameters of railway wheel profiles, that is to say, diameter, thickness, height, flange angle and distance between active wheelset faces, in order to obtain a control and have a real time information on the condition of wheelset materials incorporated in vehicles under service.

Apart from this, this station for controlling railway wheel sets is capable, through an appropriate connection with a computering service, of carrying out statistical study of all measured parameters with the corresponding evaluation of material exploitation.

FIELD OF THE INVENTION This invention applies to the railway industry in general.

RELATED ART It is known to use a cadenced manual technique to check the condition of some points on the motive parts, this being an operation effected since a relatively few years.

Obviously, a manual operation assisted by an impact tool exercised on the wheels and a visual inspection of the railway vehicle wheelset surfaces did not fully exclude the existence of multiple anomalies.

Of course, there were some potential anomalies detected by the use and utilisation of this technique.

Later on, periodical inspection were carried out on railway vehicles in order to determine possible failures existing on the vehicle itself, or in order to detect a possible damage even before it being caused.

am L Y L__II~L- I':WIDOCS\D)Y SL\P[J(1W .94 -2110196 -3- These operations incorporated a high labour cost, shutdown of the inspected material and, of course, added operations for moving the material to workshops and again moving it to be incorporated into an active service.

Basically, the railway vehicles should be inspected at the area corresponding to their wheelset elements, and this operation should be effected in a rigorously periodical way, with a previously stressed character, and thus once the inspection operation carried out, the firm owning the railway vehicle could get an exhaustive detailed account of the condition of its vehicle, and also have a checking or control sheet showing the operations already made or to be made on it 10 in order to have an absolute certainty on the vehicle itself.

According to the above, the modern trains should be subjected to increased rigorous controls in view of the increasing traffic speeds, and, of course, due to the greater requirements existing at present as regards their safety and comfort.

On the other side, it is also imperative to attain these suitable improvements with a lesser exploitation cost.

An evident solution to this problem would be to provide a fully automatic installation, fitted with a great reliability and, at the same time, offering the possibility of getting a substantial reduction of financial costs, guaranteeing at the same thne a reliable control process ofwheelsets.

Nevertheless, nothing is known, up to date, on the existence of any station for controlling railway wheelsets, such as it has been pointed above.

SUMMARY OF THE INVENTION According to the present invention there is provided an apparatus for measuring selected parameters of railway wheelsets, the apparatus including a guide and support assembly operatively connected to a railway track by which the wheelsets are moved into and out of the apparatus; A-1- A -i v\ i; S; IL U I':\WVI'JO(:S\I)YS\Si'lC11jWJ!'$1 32.924110/96 -4a plurality of parameter measuring gauges operatively connected to said guide and support assembly, each adapted for measuring a selected parameter, at least some of said measuring gauges including one or more feelers responsive to engagement with the wheel of the wheelset being measured; measuring means in operative communication with the measuring gauges for processing the information from the measuring gauges, said measuring means including potentiometers for developing a signal responsive to movement of the feelers, and electronic processing units which process the signals from the potentiometers and transfers the processed information to a central processing unit (CPU); a computer for receiving and analysing data from the measuring means; and a pneumatic control system operatively connected to said gauges, said control system being operable so as to selectively move each gauge between an operative position in which measurements of the wheelset can be effected and a non-operative position.

15 It can be said that the station for controlling railway wheelsets, according a preferred embodiment, has three definite areas, that is: S- A mechanical part An electronic part A computerised part.

The harmonious cooperation of these three units results in the station for controlling railway wheelsets.

The mechanical part is mounted on the track itself, and it is composed of a plate that, L s

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I_ ,YSLFI'II[:II:\r~l VJ -?IS~b acting as a guide, supports the mechanisms driving potentiometric displacement sensors, by a fixed number of 4 or more per rail, corresponding to the wheel diameter, flange thickness, flange height, angle and distance between active faces.

Said mechanisms are made of high quality, precision machined alloyed steel, and they are superficially protected against aggressive agents normally found on the tracks, such as: Oils Water -Grease and so on.

0 Their dimensioning corresponds to 22 tons per shaft.

15 The electronic part is intended for carrying out measurements, and it is composed of eight potentiometric sensors and, of course, it includes the processing electronics for the signals from S the sensors.

*For processing these signals, there is provided an electronic unit composed of: Feeding bridges, of-15V and Eight units processing and digitizing the signals they send these signals to a CPU, and each of them disposes of a mircroprocessor handling each signal according to a specific program; and A CPU to communicate the electronic measurement unit to a PC.

The computerised part is integrated, in its hardware, by a compatible PC and a printer.

Its software, specifically developed for this application, is basically composed of the I _I is O('D\cSs'.iCiall. 2(.2wM6 -6following parts: A communication program of the electronic measurement unit with a PC, watching the link between the CPU of the electronic unit and the PC.

A program analysing the obtained wheelset parameters, adapting itself to the requirements of the user. This analysis can be modified according to the theorical or experimental data as for the wear of the wheelsets and reprofiles brought by the user.

Files for taking decisions according the analysis made, being organically configured in relation to the user's requirements, and they can be continuously loaded.

9 9 These files contain the denomination listing of the vehicle, its wheelset profile and its tolerances related between wheels on a same shaft, between bogie wheels, vehicle wheels and 15 even branch wheels.

According to these files, the system will take decisions to recommend predetermined operations, which can be validated by the user or modified in accordance with particular circumstances so the automatic decision being cancelled "i The files arranged in the computerised part are designed as a vehicle file, a stencil file and a calibration file, all them being specifically designed for handling a base process.

A program applied to maintenance, that is to say, a program basically foreseen for providing control and information to the Depot Heads or those responsible for the maintenance, and it can be modified according to the requirements of each department.

From the information on the wheelset condition alarms can be obtained for the wheels, the profile of which is within the limi'ts and is necessary to turn on a lathe, turning programming, removal of material which cannot be turned, etc.

I';'%VPDOICSkD)Y SSIT('Ini5J4 112,94-2/51966 -7- A specific application for CNC lathe, intended for realising, once approved, the turning decision on the PC display, proceeding to transmit to the numerical controls the corresponding turning program, and obtaining, through a printer, the configuration listing.

The station for controlling railway wheelsets has a scope based on the following points: A) The passing speed of the vehicle will be lesser than 5 km/ hour, but if no measurement is required, it can run up to 15 km/h.

B) The wheel parameter sensing tolerances are as follows: wheel diameter 1 mm flange height .1 mm *0 flange thickness .1 mm; 15 Qr. .2 mm .e C) Repetition of measurements: wheel diameter .5 mm 0 flange height .05 mm flange thickness .05 mm Qr. .1 mm The system is compatible with the present railway substructure, and it can be installed on any track where the traffic is made at a shunting speed.

Also, the system is compatible with the present electric railway substructure at any line or depot.

Lastly, the system is open, which means that it can accept any additional signal preprocessing or obtained result postprocessing, such as: vehicle identification systems il'liCII J -8generation of local networks linked to a computer managing several PCs.

Information transmit via telephone.

DESCRIPTION OF THE DRAWINGS In order to supplement the present description and to help to a better understanding the features of the invention, the accompanying drawings, which are a part of the specification, will show, in an illustrative and non limitative way, the following: Figure 1 shows a view of the different elements composing the station for controlling railway wheelsets which thanks to their fully harmonious operation, attain the proposed aim of this invention.

Figure 2 shows an elevational side view of the mechanical part or installation.

Figure 3 shows a front elevational detail duly sectioned, viewed by A-B, shown jointly with other elements in Fig. 2.

Figure 4 shows a front elevational detail duly sectioned viewed by C-D of the assembly 20 shown in Figure 2.

Figure 5 shows a front elevational detail duly sectioned viewed by E-F of the assembly shown in Figure 2.

Figure 6 shows finally the measurement equipment.

DETAILED DESCRIPTION OF TI-E PREFERRED EMBODIMENTS From these figures, it can be seen that the station for controlling railway wheelsets proposed by the invention is constituted by a mechanical part 1, from which some connections 2, 3, 4 and 5 emerge, which connect a common communication 6, so being possible on a side, ':\Wl)OCS)YSS\'USp[CII I 132.9 2 ".'96 -9to communicate with a pneumatic installation 7 and with a measurement equipment 8, which, in turn, is connected to a computer 9 by means of a connection 11, the computer 9 having the relevant keyboard 10, the computer and the keyboard being connected t( te, ch other by means of a connection 11.

Also, the station for controlling railway wheelsets has a series of elements 12, 13 and 14, which constitute the mechanical subsystem whereby measurement of the flange thickness, flange height and flange angle is effected there being provided an element -micd 24 that forms the rolling tread diameter measuring device.

The station incorporates a measurement equipment having an indicator LED 15, with a voltage adjuster 16, as well as a second indicator LED 17, also incorporated in a voltage adjuster 18.

Under the reference 19, it is shown the voltage indicator LED +5V; under the reference 20, the general zero setting pushing; under reference 21, the communication link with a PC, while the references 22 correspond to connections to sensor, and the reference 23 correspond to connections to the measurement indicator LEDs.

Summing up, it can be said that, for obtaining the railway wheel profile, there are several geometric standards which are used in a conventional manner by the different railway authorities.

Nevertheless, in all of them, it is necessary to keep a series of geometric parameters within values which are considered fully necessary for obtaining a traffic safety.

When these parameters are within their tolerance limit, it is necessary to specifically recover the profile.

The measurement, that is to say, the control, is periodically performed in order to check these parameters.

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I'^\WPI)OCSU)YS\Sl'Cia~ia 2'516 Parameters normally controlled are: flange thickness flange height flange angle rolling tread diameter To obtain the control these parameters, an installation has been provided, such as above described, capable of measuring with the vehicle running at a maximum speed of 5km/h, all and every above-mentioned parameters for all wheels integrating the vehicle or the railway composite.

Flange thickness is the flange size measured 10mm under the rolling tread.

Flange height is the geometric measure from the lower edge of the flange to the rolling thread, measured on a wheel diameter.

Flange angle is the inclination of the active face of flange itself, measured as the distance between the measuring point of the flange thickness on the active face and a point on the active face 2 mm from the lower edge of the flange.

Finally, diameter of the rolling tread is the wheel diameter measured on a plane parallel to the inner face of the wheel and 70mm from this latter.

It is easily deducted that the installation is composed of three subdivisions and an application software.

The subsystems are as follows A) Mechanical B) Pneumatic C) Electronic 11 W PIM, S I WS Sill Cll- I J4 '196 11 The mechanical subsystem is divided, in turn, into two groups: 1. Wheelset support and guide 2. Measurement gages Both the supporting and guiding of the wheelset is made through a steel plate providing a continuity to the track head.

This support acts as rolling track, and, in turn, presents two guides, one outer and i inner for centering the shaft, the wheels of which are to be measured.

The inner guide is a counter track which is displaced from the shaft transversely to track, within the wheelset tolerances and acting on the inner face of wheel.

The outer guide is a 45 0 ramp, which, acting on the outer face of wheel wheelset bevel S. avoids an excess displacement of shaft, due to the inner centering.

These two centerers are stiffly fastened to the wheelset support by means of bolts.

20 The measurement gages are stiffly anchored to the wheelset supported by means of bolts.

These measurement gages when in rest position do not act on the wheel, so allowing the traffic of vehicles at a shunting speed that, as above-mentioned, will never exceed Once pneumatically activated, the gages are placed in a condition for measuring.

The gages used are those intended for measuring the thickness, height, flange angle and diameter of the rolling tread of the wheel, The thickness gage is composed of a series of mechanical tempered steel feelers contacting the rolling treads and the inner and outer faces of the flange, and being placed, through horizontal and vertical motions in a plane which is perpendicular to the track axle in the 11 VIII)MIr~ htll~LC~l ('11 W I" V I "mmol 12position appropriate for measuring the thickness.

The feelers act mechanically on a potentiometer, whose duly processed signal will give the thickness measure.

The height gage is composed of a series of mechanical feelers as well, made of tempered steel, contacting the outer face of the wheel, the rolling tread and the lower part of the flange, and being placed through horizontal and vertical motions in a plane which is perpendicular to the track axle in an appropriate position to measure the flange height.

The mechanical feelers act on a potentiometer whose duly processed signal will give the height of the flange measured.

The flange angle gage is also composed of a series of mechanical feelers, made of 15 tempered steel as well, acting in contact with the outer face of the wheel, the inner face and the lower part of the flange, being located, through hurizontal and vertical motions, at a plane which is perpendicular to the track axle in the appropriate position to measure the flange angle.

The linear feelers act on a potentiometer whose duly processed signal will give the flange 20 angle measurement.

Lastly, the rolling tread diameter gage is composed of a steel fork with hard metal contacts which, in contact with the lower part of the flange, define a chord on a circle contained in a plane which is parallel to the rolling tread and passes over the lower part of the flange.

A feeler entered with the contacts measures the sagging corresponding to that chord.

The system is basically in the wheel running sense to keep in touch three measurement points with the wheel as long as possible.

The sagging measurement results in a displacement of a potentiometer whose duly 1, 1 111 W) I'l 94 Pi/A 13 processed signal will give the rolling tread diameter.

According to the above-mentioned statement, it is clear that both the thickness gage and height gage form a direct measurement, while the flange angle gage and the tread diameter gage form indirect measurements.

The pneumatic subsystem configures as follows: All the deactivated gages do not carry out any measure on the wheels and allow the vehicles to run over the installation at a shunting speed.

The activation of the gages consists in elevating these so that, on passing the wheel, the i contact the feelers.

15 This is obtained thanks to pneumatic cylinders with a 6 kg/-cm 2 pressurized air, sliding ~vertically the gages.

Each gage has two pneumatic cylinders.

20 The station has a flexible pneumatic piping with distributors carrying the compressed air from the pneumatic station to the cylinders.

The pneumatic station is composed of a main compressed air intake, a reducer lowering the compressed air pressure from the real position to a 6 kg/cm 2 a pressure gauge, and an electrovalve allowing the air to pass to the cylinders, and commanded, at operator's will, from the control station of the system, or automatically upon passing a vehicle.

All these devices are housed in a watertight protecting metal closet.

Finally, the electronic subsystem is formed by the so-called measure unit.

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V AVIIPOVSW YMS III VII M. I I I? V4 M/96 -14- The measure unit is composed on an electric control for the pneumatic system and a connection to the mains of the whole system.

The installation counts on the use of electronic cards, which have the following units: Signal collecting and digitizing unit.

Control and communication unit with a PC.

Control and feeding unit for the electrovalves.

Analogic measuring cards.

Feeding sources.

Process control unit.

The signal collecting and digitizing unit performs the corresponding sensor polarization and receives a signal from said sensor, the amplitude of this signal being proportional to the wheel parameter amplitude to be measured.

The sensor polarization is 10 volts, and it is dependent for each sensor.

Aside from the amplitude of the signal provided by the sensor, it can, therefore, oscillate between 0 and 10 volts.

i: The digitized information of the signal is transferred to the control and communication unit.

Each collecting unit occupies a Eurocard typed car connectable to a standard bus on its upper side.

On the front side of the card, the connection to the sensor plus a luminous informative device are found.

The feeding of each of the collecting units, as well as the information transfer with the control unit, is performed through the back bus.

!3 ill Will)()(11 li)Nnlilluclltiii'l I/iNt.

The luminiscent diode or luminous indicator has the function of remaining normally on, blinking slightly when a new measure is produced.

The diode does not light up if the card is not in a condition of carrying out a measure or if there is a general fault in the circuit.

Finally, the signal collecting and digitizing unit has an appropriate adjustment for positioning the sensor in a rest condition. It is a sliding potentiometer fed with 10 volts, having voltage between ends and a tolerance similar to 0.1 per cent, while the voltage between cursor and ground is 1.5 volts, and its tolerance is constituted with a maximum 10 per cent.

The control and communication unit with a PC performs the following functions: It carries out a communication with the collecting units, performing the communication 15 via parallel through the bus card.

In this case, the digitized value of the signal given by the sensor is direct transferred; this value can very between 0 and 3 FFH.

20 Moreover, each collecting unit energizes a flag before a measure, which is read periodically by the CPU.

Communications with a central computer are performed from the information given by different collection units, being transmitted to a PC by means of the SDT protocol via series.

The units feeding and controlling the electrovalves consist ofa +5V FA3 source, a 2V FA2 source, a -12V FAI source, electrovalve feeding and back panel.

Also, the equipment has a main switch feeding the following devices: Measuring unit -Personal. computer I' >W I'MI IY.Sil, l lJ 1 NV ,/v 16- Printer Electrovalves Each analogic measurement cards incorporates 32 Kbyte data memory, and 8 Kbyte program memory, as well a inlet analogic signal treatment step into the microcontroller.

The microcontroller includes the function of analog-digital converter.

It is about, consequently, measuring, in a dynamic way, a series of wheel parameters by means of fully mechanical devices and sensors, constituted as linear potentiometers, which are mounted on the track.

The impulse-shaped signal, which is proportional to the parameter to be measured, is introduced through the front connector on the card, and the first analogic step is produced.

After a filtering and amplification process, the signal arrives at a analog-digital converter, and through a measuring algorithm the maximum value of the signal is detected.

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a a *a a a oa a a a a. :2 S"120 ooo ooo. I* This capture is performed with a 10-bit resolution.

After, this information is transferred to the CPU.

The front LED diode shows the status of the card: ON indicates waiting condition BLINKING indicates measure moment.

Each number is assigned a wheel parameter, and the position of each of the cards in the frame is indifferer..

The station has three feeding sources, two of them of-12V, which have a rectification and filtering step, in addition to a linear voltage regulator.

4 4 I:~iI)('SIf~lrI~~I2.9.1 -17- The outlet voltage is 12V, although it is possible a fine fit by means of a potentiometer located at the front side of the card.

Both sources are fed at 18V AC and can provide an outlet current of 1.5 amperes at 12V.

This voltage stems from a transformer located at the back panel of the equipment.

Since the 18V voltage is floating, it is possible to obtain, through two identical feeding sources, outlet voltages on the order of+12V and -12V.

+12V, -12V voltages are necessary in the 100M measuring unit equipment for feeding the analog steps.

Said steps have, in general, a low consumption and they perform so sensitive tasks as to 15 handle analog signals, sensor impulse amplification, analog-digital conversion, and so on.

The analog step feeding must perform a series of requirements for a correct and accurate operation of same: Feeding voltage with low curly level.

S: 20 Possibility of a separation of ground potentials (digital, analog).

Quick responses at temporary consumptions.

C C The third feeding source is a feeding source with 5VDC 4A outlet.

In fact, it is a regulating step of the 5V source, since the transformer, rectifier and filter condenser are housed in the back panel.

This source receives a 35V direct voltage and reduces them to 5V by means of a switched circuit.

The whole switching electronics is integrated in a module which allows to obtain 11, %WN)m IMO 1111VI IM i I V 94 PSIM -18percent performance and a low thermic dissipation.

The front LED diode shows the presence of 5V outlet voltage.

This equipment requires a 5V for feeding all the digital circuits, both in analog cards and center CPU.

These digital elements are: microprocessors, memory, inlet/outlet buffer, etc., bearing in mind that, in the equipment, 9 microprocessors operate simultaneously with their respective data memory and program, and the common feeding source should have characteristics such as: Overdimensioned nominal outlet power.

S. Low loss index, that is to say, a high performance.

Possible separation of ground potentials (analog/digital).

S.i 15 A high performance, both electric and thermic, is obtained by switched source system.

The ground potential separation is possible by the use of a separate transformer provided g: for said switched source system.

Lastly, the station comprises a process control unit incorporating the microcontroller, a RAM memory, a program memory, inlet/outlet circuits, and, also, a serial communication channel.

Its task is to perform a control function of each of the analog measuring channels, collecting and centralizing the obtained measures and sending them later to a PC.

The data transfer between analog channels and CPU is performed via parallel through a bus located at the rear backplane.

The serial communication with the PC is performed according to standard RS232 through Ill ('11!iSI112.1 4 VV96 19the connector located at the front side of the card.

The operating mode is, basically, as follows: The central CPU checks sequencially the status of the analog channels, and if a card has performed some valid measurement, then, a validation signal is activated which is identified by the CPU.

Once the data referring to a measure have been obtained, the process of the analog channels is energized again.

S. This process is cyclic and ends upon arriving at the number of shafts programmed by the

PC.

15 The CPU identifies each of the analog cards by a preestablished number from 0 to 7.

It is not considered necessary to extend more this description for an expert in the art to understand the scope of the invention and the advantages derived from it.

20 The materials, shape, size and arrangement of the elements will be open to variation, provided that it doe not imply any alteration to the essence of the invention as claimed.

The terms under which this specification has been described should be taken in an ample and non limitative sense.

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Claims (8)

1. Apparatus for measuring selected parameters of railway wheelsets, the apparatus including a guide and support assembly operatively connected to a railway track by which the wheelsets are moved into and out of the apparatus; a plurality of parameter measuring gauges operatively connected to said guide and support assembly, each adapted for measuring a selected parameter, at least some of said 10 measuring gauges including one or more feelers responsive to engagement with the wheel of 10 the wheelset being measured; measuring means in operative communication with the measuring gauges for processing the information from the measuring gauges, said measuring means including *potentiometers for developing a signal responsive to movement of the feelers, and electronic processing units which process the signals from the potentiometers and transfers the processed information to a central processing unit (CPU); a computer for receiving and analysing data from the measuring means; and a pneumatic control system operatively connected to said gauges, said control system being operable so as to selectively move each gauge between an operative position in which measurements of the wheelset can be effected and a non-operative position.

2. Apparatus according to claim 1, wherein each of the electronic processing units has a microprocessor handling each signal in accordance with a specific program, and the CPU unit communicates the information with the computer.

3. Apparatus according to claim 1 or claim 2 wherein said guide and support assembly includes a plate which is in general alignment with the railway track and serves as a support and guide, said plate acting as a wheelset track and, at the same time, having two guides, one outer and one inner, for centering the shaft carrying the wheels to be measured, the inner guide being a counter track which displaces the shaft transversely to the track within the wheelset tolerance, and which acts on the inner face of the wheel. i. it iA V ^J^jy NM:\ I'DOMM MITCH M5112.9lW132.4 21110/96 -21

4. Apparatus according to claim 3, wherein said outer guide is a 450 ramp which, acLA.g on the outer face of the wheel wheelset bevel avoids an excess displacement of the shaft due to the inner centering, both centering guides being stiffly fastened to the wheelset support by means of bolts and the measuring gauges being stiffly anchored to the wheelset support likewise by means of bolts, the gauges in the inoperative position not acting on the wheel and permitting the traffic of vehicles at a shunting speed, while, once pneumatically activated, they are placed in an operative position.

5. Apparatus according to any preceding claims, wherein the measuring gauges 10 include a series of mechanical feelers which in the operative position contact the areas for which they are previously detennined, and act on the potentiometers the signals of which, duly treated, will give the measure of the required parameters.

6. Apparatus according to claim 5, wherein the measuring gauges each have 15 associated therewith two pneumatic cylinders which are operable to cause elevation and S retraction of the gauges between their operative and inoperative position.

S S7. Apparatus according to any preceding claims, further including a signal collecting :and digitizing unit, a unit for control and communication with the computer, several electrovalve feeding and controlling units, analog measuring cards, three power supply units and a process control unit.

8. Apparatus for measuring selected parameters of railway wheelsets substantially as herein described with reference to the accompanying drawings. Dated this 24th day of October, 1996 INVESTIGACION Y ASESORAMIENTO TECNICO, S.A. INVASTESA By its Patent Attorneys DAVIES COLLISON CAVE \cc 7. \v oyc~ ABSTRACT A station for controlling railway wheelsets consisting of a equipment the object of which is to measure profile parameters of railway wheels, that is to say, diameters, thickness, height, flange angle and distance between active wheelset faces, for con- trolling and reporting in a real time the condition or status of de wheelset material under service, and carrying out a statistical survey of all measured parameters with the corresponding evalua- tion, said station being configurated by a mechanical equipment located on the track itself, an electronic equipment and a com- puterized insert. S* *oo oo'