High Speed - Inspection
Work on the Contiunous track
monitoring and advanced
monitoring for switches & crossings
Dr. Gunnar Baumann
Director Infrastructure System Interfaces – I.NVT 8
Gunnar.Baumann@deutschebahn.com
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Aims
Aims



Unplanned and planned non-availability of the track caused by failures or
restrictions are cost-drivers in the networks.
A prediction of failures allows an optimisation of the instant of time, where the
work is economical in a larger part of the track. Larger maintenance sections
reduce the costs and provide usually a better quality !!!
Switches are most critical devices in the network concerning availability and costs.
A reduction of failures are direct noticeable by the passenger or the logistic
company.
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Solutions
Solutions


Monitoring of track alignment by regular sheduled trains during operation to get
„Online“-Information of the track. On this basis a prognosis of the deterioration of
single faults is possible and a maintenance planning for the line is more
economical.
Monitoring and inspection of switches will give an individual information about the
„Health“ of a switch. Maintenance intervention before any faults are possible,
maintenance staff will be equipped with the spare-parts needed. Traffic
interruption caused by switches will be reduced.
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
WP 3 Organisation
WP 3 Organisation



WP 3.1 In-Service Measurement (ISM):
Measurement of the track alignment by an in-service freight locomotive
in the demonstrator. Line will be Rotterdam (Nl) – Dillingen (D). Data
processing for failure prediction and the display to the maintenance staff
(MMI).
WP 3.2 Switch:
Monitoring and inspection of switches by intelligent sensors and failure
prediction by modern algorithms and the display to the maintenance
staff (MMI). Demonstrators are switches in Eslöv (S).
WP 3 Partners:
ProRail, Network Rail, Deutsche Bahn, Trafikverket, Strukton Rail,
Damill, Birmingham Univ., Luleå Tekniska Univ., DLR, Mermec, Vossloh
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
WP 3 Organisation
Delivering of track
recording data
DB / MER
Delivery of switch
data
UoB / DAM
Demonstrators
Algorithms for
failure prediction
DLR / UoB
Development of
Algoritms
UoB
Prediction of opt.
time for Mainten.
DLR / UoB
Development of
Maintenance Prog.
Stru / LTU
Programming of
the MMI
VCSA
Workflow
Input for
WP2, WP4, WP5
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Advantages of ISM
Advantages
 Reduction of service breakdown and delays by early detection of defects
 Measured data are automatically stored in a maintenance database
 Prediction of defect development (more frequently measurements)
 Early maintenance planning due to defect/failure prediction
(Single defect tamping vs. line tamping)
 Verify the quality of repair efforts (close control loop)
 Measurement is a “by-product (spin-off) of train operation”
 Improvement of maintenance management  Reduction of costs (LCC)
 From “Find and Fix” to “Predict and Prevent”
 High Availability of the Freight-Backbones of the ports (Target of FP 7 !)
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Equipment of ISM
Continuous monitoring of track geometry on Freight Loko (BR 189)
Location with GPS
Data transmission by radio
Freight train
Acceleration sensors on axle bearing
Onboard-computer module (IPC)
IMU (Gyroscope)
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Corridor for demonstrator
Ore line Rotterdam - Dillingen
Dillingen/
Saar
Quelle:Verkehrsrundschau.de
Foto: A. Seidel
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Corridor for demonstrator
Ore-line Rotterdam - Dillingen
Decision was done
due to the
automatic coupling
of the lokomotive
 fixed schedule for
the ore-line
Foto: bahn007.startbilder.de
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Processing of the acc.-data
Processing of the acceleration data
 To gain the vertical alignment from the acceleration data, a double integration has
to be carried out. Algorithms were applied to minimize sensor errors. Still,
different measurement runs could not easily be compared, see the Fig. left side.
Fig: Vertical alignment of several measurement runs before (left) and
after (right, zoomed in) filtering
Quelle: DLR
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Defect/Failure prediction
Defect growth prediction
Strecke 1700-1; km 136,1
3-Punkt-Signal - linke Schiene [mm]
Vertical Deviation of track alignment [mm]
12
Predicted exceeding of the
Limit value
Limit value (11 mm)
11
10
In-service measurement
(ISM)
9
Inspection measurement
(Railab)
Mid-October
8
Date of the predicted
exceeding of the
limit value
7
6
Jul07
Jul
Aug07
Aug
Sep07
Sep
Oct07
Oct
Datum
Nov07
Nov
Dec07
Dec
Date
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Monitoring of defects
Sustainable maintenance:
Längshöhe (3Punkt) in mm, beurteilt nach Ril 821.2001, (vzg=200km/h)
11
1
1
11
1
1
2
2
1
8
1
4
1
3
1
3
1
1
2
1
1
01-Jun-2007
1
1
1
1
1
2
1
1
2
3
1
1
3
2
2
1
1
1
3
4
1
2
1
11
1
2
1
1
1
3
1
1
1
1
1
1
3
1
2
5
3
1
1
3
1
2
1
2
2
1
2
1
1
2
1
1
1
4
2
3
1
1
3
1
1
135.81
135.82
km auf Strecke 1700-2
3
2
1
1
2
135.8
3
1
1
1
1
1
1
3
2
5
2
2
135.79
4
2
2
2
2
2
1
01-Jan-2008
1
4
1
1
1
1
01-Dec-2007
1
5
1
1
2
01-Feb-2008
6
3
1
3
1
1
1
01-Oct-2007
Date
1
2
3
1
4
5
2
Datum
01-Sep-2007
7
1
1
1
01-Aug-2007
01-Nov-2007
12
2
1
1
2
1
1
1
2
01-Jul-2007
Vertical Deviation of track alignment [mm]
8594
15
6
11
23
11
2
2
9
1
1
5
3
1
13
2
1
3
1
23
6798
1
7
1
1
1
1
1
10
8 7
2
1
1
109
43
76
17
16 15
54
1
1
18
14
12
10
1
2
43 6 5
423
1
1
1
1
01-May-2007
1
1 2
3
3
4
1
01-Apr-2007
52364
1
01-Mar-2007
135.83
135.84
1
135.85
0
Track position [km]
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Switches & Crossings
SP 3.2 Monitoring & intelligent self-inspection of switches
 Switch inspection with special staff for the signalling and the track part causes a
lot of logistic and economical effort
 Inspections are carried out in fixed time periods
– The condition of the individual switch is not respected
– Sudden defects will be undetected until the next inspection or produced a
failure
 Prediction of development of defects is difficult
 Monitoring is different than Self-Inspecting
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Modular Self-Inspecting
Infrastructure – Switches
Condition monitoring
Automatic inspection
Orientated on the fault and it can
do:
- fault detection: a system is able
to detect a fault which is
happening
- fault diagnosis: a system is able
to diagnose the fault
- fault prediction: the system is
able the predict a fault a certain
amount of time before it will
happen
Focussed on inspecting the asset
according to inspection
standards and it can:
- identify the assets that do not
meet the standards
- carry out inspections specified
in inspection standards
- carry out the inspections in a
way that satisfies the inspection
requirements (e.g. precision of
measurement)
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Modular Self-Inspecting
Infrastructure – Switches
Condition monitoring
1.
2.
3.
Measures parameters that
reveal faults in the system.
Analyse the data and
identify the faults or predict
potential faults.
Develop a cost effective
system. The drive is to use
the smallest number of
sensors to identify the
largest number of faults.
Automatic inspection
1.
2.
3.
Measure parameters
specified by inspection
standards.
Parameters must be
measured must be in line
with the standards.
The drive is to eliminate the
need for maintenance
personnel to inspect
switches in person.
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Summary of self inspecting switch:
Review of inspection tasks
Shape, size, gauge and
position of rails
Potential solution
Laser measurements
Visual inspection
Potential solution
Video train
Point machine
inspection
Potential solution
Improved CM
Cracks in rails and
crossing
Potential solutions
???
Switch rail fittings
(bolt loosening, cracks)
Potential solution
???
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Architecture of the MMI
(Man-Machine-Interface)
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
MMI data flow
Used in WP6 for demonstration
Track data (scenario 1)
MERMEC/UoB system
Maintenance workers
Track data (scenario 2)
DLR/DB system
MTN Task
Switch data (scenario 3)
UoB system
RailML + HTTPS
MMI
Vossloh
Infrastructure
managers
Scheduling Tool (WP5)
SNCF
Switch data (scenario 4)
Damill system
Switch data (scenario 5)
Struckton system
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
MMI architecture
Used in WP6 for demonstration
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Maintenance
task definition
The MMI is a
“task management
system”. The level of data
managed by the MMI is a
maintenance task. From
ISO13374-1:2003
(Condition monitoring and
diagnostics of machines —
Data processing,
communication and
presentation — Part 1:
General guidelines) the
level of data for a
maintenance task is
defined as a recommended
action.
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Maintenance task process
Maintenance
task process
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
RailML data standard
 www.railml.org
 Since 2001: The railML.org Initiative was founded against the background of the
chronic difficulty of connecting different railway IT applications.
 Its main objective is to enable heterogeneous railway applications to
communicate with each other.
 Today, the connection of various railway software packages is beset with
problems. The purpose of the railML.org Initiative has been to find, discuss and
present systematic, XML-based solutions for simplified data exchange between
railway applications.
 First step in european standardisation for maintenance IT-tools
 MERMEC has already provided lists of standard defects and standard
measurements.
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
RailML data standard
 State of the art in AUTOMAIN
 The RailML schema was agreed by all partners
 The level of data is “the maintenance task”. Every demonstrator has to
decide the way of communication:
 The monitoring inspection systems must send a maintenance task to the MMI
 The monitoring inspection systems send a failure to the MMI, and a “translation table”
validated by the maintenance will match the tasks in relation to the failure produced.
 Every system must send a message to confirm the system is alive
 A draft of a XML schema exists to understand
 The RailML standard will be a data schema file (XSD file). When it is mature
(approved by demonstration), it will be proposed to the official RailML
organization.
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Map for Tasks
The assets have colours and description for the flag:
 No flag if no task
 RED Flag: Needing corrective maintenance.
 ORANGE Flag: Needing preventative maintenance
 For the scheduled maintenance, the asset will be “orange” when it’s time to do it and red when it’s too late.
 For the conditional maintenance, the asset will be “orange” when it appears (alarm from a system, expert
report...)
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
Specifications
 MMI main features





1 unique access for all the systems monitoring assets (through Internet)
1 unique level of data : maintenance task
Map with the status of the maintenance tasks for several assets
Table with the status of the maintenance tasks for several assets
Inspection report on site (questionnaire on site to perform the maintenance
task )
 MMI administration
 Import/export infrastructure RailML data
 RailML “maintenance tasks ” exchange between applications
 Send emails, SMS, etc... to the maintenance team when a task needs it
 Allow confirmation by maintenance to take the work in charge
 Monitors the availibility of the systems (message to know if each system is still alive)
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission
… 18 months left
Thank you for your attention!
www.automain.eu
A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission