Riftek IDK Series User manual

Wheel diameter measuring gauge, IDK
IDK [Revision 2.2] 4th September 2017
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Contents
1. Safety precautions and measurement conditions .................................................................3
2. Electromagnetic compatibility...............................................................................................3
3. General information..............................................................................................................3
4. Basic data and performance characteristics.........................................................................3
5. Example of item designation when ordering.........................................................................3
6. Complete set to be supplied.................................................................................................4
7. Design..................................................................................................................................4
8. Operation principle...............................................................................................................5
9. Working with the gauge........................................................................................................5
9.1. Gauge turn-on ..............................................................................................................5
9.2. Single measurement.....................................................................................................6
9.3. Measurement with averaging........................................................................................6
9.4. Gauge turn-out .............................................................................................................7
10. Indication parameters setup .................................................................................................7
10.1. Image rotation...............................................................................................................7
10.2. Image brightness set-up ...............................................................................................8
10.3. Millimeters-Inches-Tapes display set-up.......................................................................8
11. Service operation modes......................................................................................................9
11.1. Calibration conditions ...................................................................................................9
11.2. Get into operational modes...........................................................................................9
11.3. Calibration of the sensor zero.......................................................................................9
11.4. Calibration of the device base.....................................................................................10
12. Charging of built-in accumulator battery.............................................................................11
13. Warranty policy...................................................................................................................11
14. Distributors.........................................................................................................................11
15. Annex 1. RIFTEK’s measurement devices for railway transport .........................................14

Wheel diameter measuring gauge, IDK
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1. Safety precautions and measurement conditions
The metering accuracy depends greatly on the wheel surface quality. There-
fore it is necessary to carry out the check and presorting of the wheel surface
roughness and flaws before measuring the diameter.
Prior to place the gauge onto the wheel there is a need to clean the wheel
parts that contact with gauge ball bearings, side supports and measuring tip,
of the mud.
At arranging the gauge, do not allow hitting its supports on the wheel and any
measuring tip side hitting
At arranging the gauge, do not apply strong forcing in the direction of the
measuring tip movement. It can result in the gauge sag, that will bring about
the uncertain metering result
It is necessary to inspect the gauge supports periodically and to cleanse them
To save the battery power the display extinguishes if there were no buttons
pressings for 60 seconds, at that only blinking dot is shown. Pressing any but-
ton just turns on the display and does not act in any other way in this case.
2. Electromagnetic compatibility
The gauge has been developed for use in industry and meets the requirements
of the following standards:
EN 55022:2006 Information Technology Equipment. Radio disturbance char-
acteristics. Limits and methods of measurement.
EN 61000-6-2:2005 Electromagnetic compatibility (EMC). Generic standards.
Immunity for industrial environments.
EN 61326-1:2006 Electrical Equipment for Measurement, Control, and Labor-
atory Use. EMC Requirements. General requirements.
3. General information
Electronic gauge is designed for measuring wheel rolling circle diameter (amount
of wear) of railway, metro and tram in the course of checkup, examination, repair and
formation of wheel sets. Measurements are made directly on rolling stock without wheel
set roll-out.
4. Basic data and performance characteristics
Name of parameter
Value
Measurement range, mm
400…1400 or on request
Measurement error, mm
±0.2
Indication discreteness
0.1mm, 0.01mm * or 0.01 inch **
Position of measurement, S, mm
On request
Distance between axes of ball bearings (base), mm
and diameters measurement range, mm
122±0.5 (400…750 mm) or
200±0.5 (400…950 mm) or
250±0.5 (600…1400 mm) or
300±0.5 (720…1400 mm)
Display
build-in, LED
Operating temperature, 0C
-5…+55
Weigh, kg
<0,5

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5. Example of item designation when ordering
IDK-S/B-MIN/MAX-X
Symbol
Description
S
Position of measurement, mm
В
Base, mm
MIN
Bottom of measuring range, mm
MAX
Up of measuring range, mm
Х
Position of indication. А – Indication is at the side of side supports (figure А), В
–Indication is at opposite side (figure В)
Example: IDK-70/250-850/1260-А. Position of measurement –70 mm; base of the gauge –
250 mm; bottom of measuring range –850 mm; up of measuring range –1260 mm; po-
sition of indication –А.
Fig.А
Fig.В
6. Complete set to be supplied
Name
Quantity
Weight, kg
Wheel diameter measuring gauge IDK series
1 piece
0,5
Charger
1 piece
0,2
Manual
1 piece
Case
1 piece
Calibration tools (option)
on request
Flat block RF510.11.000 (fig.2)
-
Reference wheel block for calibrating RF510.11.XXXX (fig.3)
-
7. Design
Electronic gauge contains two ball supports to place the gauge onto the roll sur-
face, two side supports to base the gauge to the wheel edge and a measuring tip.
There are a digital numeric display and control buttons on the front panel of the
gauge. “Charge” connector for charging device connection is situated on the top panel of
the gauge. Accumulator batteries (two AAA 1,2V) are a source of power supply. The ac-
cumulator batteries are easy to change too.

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Figure 1
Figure 1.1
8. Operation principle
The measurement of the diameter is performed according to the “three points”
technique, without the complete wheel coverage. The measurement method is based on
the diameter calculation by the known length of the segment chord (the distance be-
tween the ball bearings centers), which is obtained at placing the gauge onto the wheel.
The suggita of the segment is measured by means of the displacement converter. Video
presentation is placed here: https://youtu.be/pMienHfBizg
9. Working with the gauge
9.1. Gauge turn-on
Press Red button to turn on the power. The display shows “ErrP” message if the ac-
cumulator battery voltage became lower then the control level. In this case the short-term
work is possible after pressing any key.

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9.2. Single measurement
To perform measurement, it is necessary to:
turn the power on (press Red button). The display shows “- - - - -”;
place the gauge onto the wheel;
make sure the ball supports are tight against the roll surface and side sup-
ports are adjacent to the edge of the wheel;
press Green button.
in a 1 second the display will show the value of the wheel diameter.
For viewing the result of measurement with indication discreteness of 0.01mm (it
is accessible only in a mode of direct indication) it is necessary to press Blue button,
thus displayed result will be shifted to the left on one digit. Next pressing Blue button will
lead to return of indication to a starting position:
9.3. Measurement with averaging
The program of the wheel diameter calculation contains an averaging algorithm
that allows eliminating the surface defects influence on the diameter measuring result.
All the results of metering, performed after the Red button pressing, are averaged. The
measurement is meant to be Green button pressing.
To carry out measurements it is necessary to
turn the power on (press Red button). The display shows “- - - - -”;
place the gauge onto the wheel
make sure the ball supports are tight against the roll surface and side sup-
ports are adjacent to the edge of the wheel;
press Green button;
display shows the value of pressing counter “n x”, where x–quantity of av-
eraged values;
in a 1 second display shows an average value over the set of metering (over
the quantity of Green button pressings)
move the gauge to a new position and repeat the measuring.
(The total quantity of measurements averaged in this way can run up to 9999.)

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Press Red button to reset averaging result at switching to another wheel.
For viewing the result of measurement with indication discreteness 0.01mm (it is
accessible only in a mode of direct indication) it is necessary to press Blue button, thus
displayed result will be shifted to the left on one digit. Next pressing Blue button will lead
to return of indication to a starting position.
9.4. Gauge turn-out
The gauge turn-out occurs automatically. The display extinguishes if there were
no buttons pressings for 60 seconds, at that only blinking dot is shown. If there were no
button pressings for 4 more minutes, the gauge is turned out completely. You can turn
the gauge off by long pressing Red button (more then 3 sec.).
10. Indication parameters setup
10.1. Image rotation
To rotate the image it is necessary to:
turn the power on (press Red button);
press Blue button and keep it pressed for more than three seconds;
display will show “Up”;
by the pressing of Green button turn over the image: the message “Up” will
be turned over 1800;
to save the changed parameters press Red button. The display shows
“SAUE” message, press the Green button to confirm saving and Red to can-
cel saving of the changed parameters;
Image rotation function allows observing the result in the way comfortable for the
operator regardless of the gauge placement direction.
Notes:
- indication discreteness of 0.01mm is accessible only in a mode of direct indica-
tion;

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- the separation point is indicated at the top side of the screen in the reverse indica-
tion regime.
10.2. Image brightness set-up
To change the display brightness it is necessary to:
turn the power on (press Red button).;
press Blue button and keep it pressed for more than three seconds;
display will show “Up”;
press Blue button again than “brt X” message appears on the display;
choose the necessary brightness value by Green button pressings;
to save the changed parameters press Red button the display shows “SAUE”
message, press the Green button to confirm saving and Red to cancel saving
of the changed parameters;
At brightness choosing one should take into account that increased brightness
enhances power consumption and decreases the period till battery recharge moment.
10.3. Millimeters-Inches-Tapes display set-up
To change the mode it is necessary to:
turn the power on (press Red button).;
press Blue button and keep it pressed for more than three seconds;
display will show “Up”;
press Blue button again until the either “SI” or “Inch” message appears on the
display. “SI” –measuring results will be shown in mm, “Inch” –measuring re-
sults will be shown in inches, “Tape”;
choose the necessary value by Green button pressings;
to save the changed parameters press Red button the display shows “SAUE”
message, press the Green button to confirm saving and Red to cancel saving
of the changed parameters

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11. Service operation modes
This section contains the description of the modes for the check of device effi-
ciency and calibration. As erroneous actions in this mode can lead to invalid measure-
ment results, only specially trained personnel should perform such operations.
11.1. Calibration conditions
Calibration of the device is not necessary in the current work. It is neces-
sary only after producing, repairing and also after checking with negative result.
To perform calibration the following means are necessary:
Calibration plate with the deviation from flatness less then ±0,5 um for 250
mm length (or Flat block RF510.11.000, figure 2);
Johansson gauge;
reference wheel of the known diameter (or Reference wheel block
RF510.11.ХХХХ, figure 3)
11.2. Get into operational modes
To get into the operational modes it is necessary to turn-off the device (press
Red button more then 3 seconds).
Keeping Green button in pushed position turn-on the device (press Red but-
ton).
Display shows “CLbr.0” message (the mode of calibration of the sensor's "0").
To get into this mode it is necessary to press Green button (see. p. 11.2).
For transition to next mode it is necessary to press Blue button.
Display shows “CLbr.b” message (the mode of device base calibration).
To get into this mode press Green button (see. p.11.3).
To get out the mode of calibration press Red button.
11.3. Calibration of the sensor zero
Zero calibration mode being enabled, the display shows the Johansson gauge
value used for calibration in increments of 0.5 µm.
If editing of the Johansson gauge value is not required, go to the next step. To
edit the Johansson gauge value, press the Blue button, and the digit to be ed-
ited starts blinking. Changing over between the digits is made by pressing the
Blue button while changing of values is made by pressing the Green button.
When editing is finished, press the Red button and confirm or cancel saving of
the parameter by pressing the Green button or Red button, respectively.
Press the Green button, and the Johansson gauge value starts blinking,
which means that the device must be placed onto a flat plate and a Johans-
son gauge with nominal value of the previous step must be placed under the
measuring tip. The Johansson gauge must be tightly fitted to the flat plate and
supports and balls of the device must be firmly forced against the plate.
Press the Green button, and the display shows current reading of the sensor
in its own coordinate system. By moving the device, assure that repeatability
of measurement results is obtained.

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RF510.11.000
Figure 2
If readings of the sensor are sufficiently stable, press the Blue button. Sensor
zero position is calculated in the device coordinate system, and prompt ap-
pears to save calibration results. Press the Green or Red button to confirm or
cancel saving of the results, respectively.
11.4. Calibration of the device base
Device base calibration mode being enabled, the display shows the value of refer-
ence diameter used for calibration.
If editing of the diameter value is not required, go to the next step. To edit the di-
ameter value, press the Blue button, and the digit to be edited starts blinking.
Changing over between the digits is made by pressing the Blue button while
changing of values is made by pressing the Green button. When editing is fin-
ished, press the Red button and confirm or cancel saving of the parameter by
pressing the Green button or Red button, respectively.
Press the Green button, and the reference diameter value starts blinking, which
means that the device must be placed onto a gage with the diameter value set at
the previous step. The device supports must be firmly forced against the reference
block.
Press the Green button, and the display shows current reading of the sensor in
the device coordinate system. By moving the device, assure that repeatability of
measurement results is obtained.
If readings of the instrument are sufficiently stable, press the Blue button. Device
base value is calculated, and prompt appears to save calibration results. Press the
Green or Red button to confirm or cancel saving of the results, respectively.

Wheel diameter measuring gauge, IDK
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RF510.11.XXXX
Figure 3
NOTE: Video-help for calibration procedure you can find here
www.riftek.com/resource/video/idk_calibr.avi
12. Charging of built-in accumulator battery
To charge accumulator battery it is necessary to connect charging devise to the
power grid 85-250V and to a battery compartment on the top panel of the gauge.
The period of charging is 15 hours.
13. Warranty policy
Warranty assurance for the Wheel diameter gauge - 24 months from the date of
putting in operation; warranty shelf-life - 12 months.
14. Distributors
AUSTRALIA
Applied Measurement
Australia Pty Ltd
RAILWAY INSTRUMENTS ONLY
Thornton Plaza, Unit 5,
27 Thornton Crescent, Mitcham
VIC 3132, Australia
Tel: [phone]
Fax: [phone]
[email protected]
www.appliedmeasurement.com.au
AUSTRALIA
XN Innovation
LG Centre, Suite 1, Level M, 55 Par-
ramatta Rd, NSW, 2141,
Lidcombe, Australia
Tel: [phone]
Fax: [phone]
[email protected]
BENELUX
Altheris B.V.
Vlietweg 17a
2266KA Leidschendam
The Netherlands
Tel: [phone]
Fax: [phone]
[email protected]
www.altheris.com

Wheel diameter measuring gauge, IDK
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BULGARIA, HUNGARY
RMT Ltd.
R Zahradni 224
739 21 Paskov, Czech Republic
Tel: [phone]
Fax: [phone]
[email protected]
www.rmt.cz
BRAZIL
CAPI Controle e Automação Ltda
Rua Itororó, 121, CEP 13466-240
Americana-SP, Brazil
Tel: [phone]
Tel: [phone]
[email protected]
www.capicontrole.com.br
CHILE
Verne SpA
Apoquindo 2818, oficina 31,
Las Condes, Santiago, Chile
Tel: [phone]
[email protected]
[email protected]
www.verne.cl
CHINA
Zhenshangyou Technologies
Co.,Ltd.
Rm 2205-2210, Zhongyou Hotel
1110 Nanshan Road, Nanshan
District 518054 Shenzhen, China
Tel: [phone]
Fax: [phone]
[email protected]
www.51sensors.com
CHINA
Shanghai micron-metrology
com., Ltd.
Room 602 unit 4, lane 399,
Mudan road, Pudong New district
Shanghai, China
Tel: [phone]
[email protected]
www.micron-metrology.cn
CHINA
JRKtech Co., Ltd.
1F, Building 9, 100 Xianlie Rd.,
Guangzhou, China
Tel: [phone]/
[phone]
Fax: + 86 755 85267190
[email protected]
www.jrktech.com
CZECH REPUBLIC
RMT Ltd.
Zahradni 224
739 21 Paskov, Czech Republic
Tel: [phone]
Fax: [phone]
[email protected]
www.rmt.cz
FINLAND
TERÄSPYÖRÄ-STEELWHEEL OY
RAILWAY INSTRUMENTS ONLY
Juvan teollisuuskatu 28
FI-02920 ESPOO, Finland
Tel: [phone]
Fax: [phone]
[email protected]
www.teraspyora.fi
FRANCE
DB Innovation (ALTHERIS
France)
26, avenue de la Mediterranee
34110 Frontignan France
Tel: [phone]
Fax: [phone]
[email protected]
www.altheris.fr
GERMANY
Disynet GmbH
Breyeller Str. 2
41379, Brueggen
Tel: [phone]
Fax: [phone]
[email protected]
www.sensoren.de
GERMANY
BIP-Industrietechnik GmbH
RAILWAY INSTRUMENTS ONLY
Am Elisabethhof 22,
D-14772 Brandenburg
D-41379 Brueggen, Germany
Tel: [phone]
Fax: [phone]
[email protected]
www.bip-industrietechnik.de
GERMANY
Finger GmbH & Co. KG
OPTICAL MICROMETERS ONLY
Sapelloh 172,
31606 Warmsen, Germany
Tel: [phone]
Fax: [phone]
[email protected]
www.finger-kg.de
GERMANY
Hylewicz CNC-Technik
SHTRIKH-2 ONLY
Siemensstrasse 13-15,
47608 Geldern, Germany
Tel: [phone]
Fax: [phone]
[email protected]
www.cnc-step.de
INDIA
Pragathi Solutions
#698, 5th Main, 8th Cross,
HAL 3rd Stage,
New Tippasandra Road,
Bangalore, 560075, India
Tel: [phone]
Tel/fax: [phone]
Mobile: [phone]/
[phone]
[email protected]
[email protected]
www.pragathisolutions.in
INDIA
BPI (India)
RAILWAY INSTRUMENTS ONLY
63,Civil Lines, Near Bhagirathi
Colony,
Roorkee, 247667, India
Tel: [phone]
Tel: [phone]
[email protected]
www.bpi-india.in

Wheel diameter measuring gauge, IDK
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INDONESIA
PT. DHAYA BASWARA SANI-
YASA
Botanic Junction Blok H-9 NO. 7
Mega Kebon Jeruk, Joglo
Jakarta 11640, Indonesia
Tel: + 62 21 29325859
[email protected]
IRAN
Novin Industrial Development
Grp.
Tel: [phone]
Fax: [phone]
Mobile: [phone]
[email protected]
www.novinid.com
ISRAEL
Nisso Dekalo
Import Export LTD
1 David Hamelech Street
Herzlia 46661 Israel
Tel: [phone]
Fax: [phone]
[e-mail]
www.fly-supply.net
www.aircraft-partsupply.com
ITALY
FAE s.r.l.
Via Tertulliano, 41
20137 Milano, Italy
Tel: [phone]
Fax: [phone]
[email protected]
www.fae.it
LATVIA, ESTONIA
SIA "SOLARTEX"
RAILWAY INSTRUMENTS ONLY
Duntes 15a, 5th floor, office B7
Riga, Latvia
Tel.: [phone]
[email protected]
MALAYSIA
OptoCom InstruVentures
H-49-2, Jalan 5, Cosmoplex
Industrial Park, Bandar Baru Salak
Tinggi, Sepang, Malaysia
Tel: [phone]
Fax: [phone]
[email protected]
www.optocom.com.my
NORWAY
Salitec AS
PB 468,
N-1327 Lysaker
Tel.: [phone]
Fax: [phone]
[email protected]
www.salitec.no
PERU
Verne Perú S.A.C
Las Codornices 104,
Surquillo, Lima, Peru
Tel/fax: [phone]
[email protected]
[email protected]
www.verne.cl
POLAND
MTL ASCO Sp. z o.o.
RAILWAY INSTRUMENTS ONLY
ul. Wielowiejska 53
44-120 PYSKOWICE, Poland
Tel: + 48 32 230 45 70
Fax: + 48 32 332 70 14
[email protected]
www.ascorail.pl
PORTUGAL
UltraSens
Qt. da Portela, Lt. 22.1, Ap. 152
3030 - 502 Coimbra, Portugal
Phone [phone]
Fax: [phone]
[email protected]
www.ultrasens.com
RUSSIA
Sensorika-M LLC
Dmitrovskoye shosse 64-4
127474, Moscow, Russia
Tel: [phone]
Fax: [phone]
[email protected]
www.sensorika.com
RUSSIA
Diesel-test-Komplekt LLC
620030, Karjernaya St, 16
Ekaterinburg, Russia
Tel/fax: [phone]
Tel/fax: [phone]
[email protected]
www.d-test.ru
SERBIA, SLOVAKIA
RMT Ltd.
Zahradni 224
739 21 Paskov, Czech Republic
Tel: [phone]
Fax: [phone]
[email protected]
www.rmt.cz
SOUTH AFRICA
Ratcom Enterprise Pty Ltd
CSIR BUILDING 35, Office 78 Meiring
Naude Road, Brummeria
Pretoria, 0084 South Africa
Tel: + 27 12 841 2032
Fax: + 27 86 225 0650
[email protected]
www.ratcom.co.za
SOUTH KOREA
PROSEN. CO., LTD
M-1001, Songdo techno park IT
center, 32, Songdogwahak-ro,
Yeonsu-gu,
Incheon, 21984, Republic of Korea
Tel: [phone]
Fax: [phone]
[email protected]
www.prosen.co.kr
SPAIN
Iberfluid Instruments S.A.
C/ Botanica, 122
08908 L'Hospitalet de Llobregat,
Barcelona
Tel: [phone]
Fax: [phone]
[email protected]
www.iberfluid.com
SWITZERLAND
ID&T GmbH
Gewerbestrasse 12/a
8132 Egg (Zurich), Switzerland
Tel: + 41 44 994 92 32
Fax: + 41 44 994 92 34
[email protected]
www.idtlaser.com
SWEDEN, DENMARK
BLConsult
Ryssbält 294,
95 291 KALIX, Sweden
Mobile: [phone]
[email protected]
www.blconsult.se

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THAILAND
Advantech Solution Co.,Ltd.
20/170 Motorway Rd.,
Kwang Pravet, Khet Pravet,
Bangkok, Thailand 10250
Tel: [phone]
Fax: [phone]
[email protected]
www.advantechsolution.com
TURKEY
TEKMA Mühendislik A.Ş.
Cevizli Mh. M. Kemal Cd.,
Hukukçular Towers,
A-Blok, No: 66-A/39
Kartal –Istanbul
Tel: [phone]
Tel: [phone]
[email protected]
www.tekma.eu
UKRAINE
KODA
Frunze st 22
61002, Harkov, Ukraine
Tel/fax: [phone]
[email protected]
www.koda.com.ua
UNITED KINGDOM, IRE-
LAND
Ixthus Instrumentation Ltd
The Stables, Williams' Barns
Tiffield road, Towcester, Northents
Tel: [phone]
Fax: [phone]
[email protected]
www.ixthus.co.uk
USA, CANADA, MEXICO
International Electronic Ma-
chines Corporation
RAILWAY INSTRUMENTS ONLY
850 River Street, Troy,
New York, USA
Tel: [phone]
Fax: [phone]
[email protected]
www.iem.net
USA, CANADA, MEXICO
Acuity Products of Schmitt
Industries, Inc.
2765 NW Nicolai Street
Portland, OR, 97210, USA
Tel: [phone]
Fax: [phone]
[email protected]
www.acuitylaser.com
15. Annex 1. RIFTEK’s measurement devices for
railway transport
Laser wheel profilometer. IKP Series
A laser profilometer is designed for the measuring of:
wheel flange height;
wheel flange thickness;
wheel flange slope;
full profile scanning and analyze of wheel rolling surface;
maintaining of electronic wear data base;
control of tolerances and sorting in the course of checkup,
examination, repair and formation of railway wheel sets;
Measurements are made directly on rolling stock without
wheel set roll-out.
Portable laser rail profilometer. PRP Series
The main functions of PRP are:
obtaining the information on the cross-section profile
of the working railhead surface;
full profile scanning and analyze of the railhead act-
ing face;
visualization of the combined graphical images of
actual and new cross-section railhead profiles on the dis-
play of system unit.

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Wheel diameter measuring gauge. IDK Series
Electronic gauge is designed for measuring wheel rolling cir-
cle diameter of railway, metro and tram wheel sets.
Measurements are made directly on rolling stock without
wheel set roll-out.
Back-to-back distance measuring gauge. IMR Series
Gauge is designed for contactless measuring of back-to-back
distance of railway, metro and tram wheels in the course of
checkup, examination, repair and formation of wheel sets.
Measurements are made directly on rolling stock without
wheel set roll-out.
Back-to-back distance measuring gauge. IMR-L Series
Gauge is designed for contactless measuring of back-to-back
distance of railway, metro and tram wheels in the course of
checkup, examination, repair and formation of wheel sets.
Measurements are made directly on rolling stock without
wheel set roll-out.
Disc brakes profile gauge. IKD Series
Laser disc brakes profilometer IKD Series is designed for
disc brakes profile measuring.
The main functions of IKD are:
obtaining the information on the profile parameters
of the working disc brakes surface;
full profile scanning and analyze of the disc brakes
acting face;
visualization of the combined graphical images of
actual and new disc brakes profiles on the display of sys-
tem unit.
Automatic real-time system for measurement of wheel-
sets geometrical parameters
The system is designed for contactless automatic measure-
ment of geometrical parameters of railway wheels and uses a
combination of 2D laser scanners, mounted wayside in the
track area.
The system can be easily installed at any type of rail infra-
structure.