Condition Monitored Maintenance for Rail
Real-time track condition monitoring using passenger train
mounted accelerometers
Justin Southcombe – 29 October 2015
Agenda
• The past
• The present
• The future?
DATA
The past
INFORMATION
KNOWLEDGE
Southeastern railway project to monitor wheel bearings
Issue = Wheel
bearing failing
early and
unpredictably
Aerospace
High downtime
and cost (LT) for
LSER
LSER lead
experience
decision to move
to CBM
High short term
cost for RS OEM
Issue solved as
bearing CBM is
successfully rolled
out at LSER
LSER align
processes to
match new
capabilities
LSER production
and engineering
staff get trained
New information
adopted by
trained staff with
correct tools
LSER develop
single source info
management
Performance spec
written for
innovative
wireless solution
Aerospace
experience
Product and
information
supplied to LSER
New product &
algorithm
innovated by
Perpetuum
The Wireless Sensor Node – from this …
The Wireless Sensor Node – … to this
Data and Information Communications
Wireless Condition Monitoring Process
Remote Website
Communication
GPS Data
Monitoring
Data Concentrator
Wireless Sensor Node
Live data from around the network
DATA
INFORMATION
The present
KNOWLEDGE
Wheel Bearing Health Index (BHI) algorithm delivered
>5 Months
News on BHI with Southeastern
• 100% Safety record - 0 bearings have failed in service
• 20 bearings have been successfully identified by the Perpetuum
system ahead of any other methods
• L2 alarm damage awareness improved10 fold
• Production team trained and using BHI information on overhauls
• Evidence of 6 nearly months of prediction
Wheel Health Index (WHI) algorithm delivered – organic innovation
24 mm Cut
Initial inspection
shows minimal
damage on lathe
Surface removal
reveals hidden
damage
Slide 12
News on WHI with Southeastern
• 0 monitored wheels have triggered a
WILD alarm without a WHI alert;
numerous have pre-empted alarms
• All L2 wheels have been corrected
and reduced to L1 or less
• Wheel turning now based on WHI
score as “inspection” is automated
• Diagnostics - RCF diagnosed 2
months ahead
Track Health Index (THI) algorithm delivered – organic innovation
Why change?
Daily/weekly
trending without
loss of paths …
Measurement at
line speed …
Measurement on
all diagrams …
Filtering out of
outliers
Why the SouthEast region?
Kent:
• >5000 equipped wheels
• >150 equipped trainsets
Sussex:
• >500 equipped wheels
• >40 equipped trainsets
Perpetuum track monitoring programme
1. Exploration phase – research data and verify
the concept
2. Monitoring phase – work alongside TRE
teams and develop Beta version frontend
tool; no change to formal processes
3. Deployment phase – use tool formally as part
of new operational process; involve 3rd parties
September 2015 - Network Rail contract, phase 2
Calibration with the Track Recording Vehicle
Orange = TRV
Red = Perpetuum
Untangling the data – “track mapping”
Route specific analysis and calibration
Track Monitoring Example
Points either
side of tunnel
Station (A)
Level
Crossing
Tamping
work
required
Station (B)
Hastings
Junction
Station (C)
Red Line:
Processed Data
Blue Trace:
Raw Data
Correlation against track improvements - Supporting data
Track Processing Location Accuracy at full line speed
Correlation against track degradation - Supporting data
Track tool video
DATA
INFORMATION
The future
KNOWLEDGE
Predict and prevent
Diagnostics and root causes: Dip angles
Diagnostic opportunities for track
Parameter #2
Wheel/rail management: Chicken or the egg?
WHI
THI
Next steps
1. Track Diagnosis, as well as condition monitoring
2. Robust interrogation of congested track layouts
3. Wheel flange analysis
• Higher track resolution
• Data Concentrator accelerometer integration
• New DC design already incorporates this functionality
• Activation of Differential GPS
• Current system is compatible with proven DGPS systems
• Linear interpolation of geographical and vibration archives
• Use of unique databases – ongoing
• Wheel flange monitoring
Thank you

0% false alerts
 >6 000 assets being monitored
 >1 800 000 data points per day
 >1 000 000 000 sensor km data base
 >10 fleets in 5 countries, 3 continents
 Bearings, wheels, gearbox, motor, track, ride …
 EMU/DMU/Loco/Coach
 Urban/Commuter/HST/VHST/Freight
Slide 33
Please visit
or email
www.perpetuum.com
info@perpetuum.com