Web of Detectors

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Web of Detectors
“Never Stop A Train For
Mechanical Failure”
1
Dale Cassels
ACACSO
May 2013
Joint Wayside Diagnostic System - JWDS
 Goal – Proactive identification of mechanical risks to
minimize line of road stops
— Eliminate mechanical-caused line of road stops and
derailments
— Reduce the stress state of our Railroad
— Centralized repository for ALL detector data
— Identifies and prioritizes conditions we want to know
— Enables car inspectors to move from finders to fixers
 CSX, UP and NS share software and rules logic
through the JWDS Consortium.
2
Joint Wayside Diagnostic System - JWDS
Before JWDS, we were
REACTIVE
to what the detector was telling us.
Now… we are
PROACTIVE
as to what the equipment is telling us.
3
Web of Detector Acronyms



ABD – Acoustic Bearing
—
AEI - Automated Equipment Identification
—


4
Radio Frequency based system that reads car and locomotive tags
 Allows us to piece the defect information to the car and position on the car in JWDS
HBD/WTD – Hot Bearing – Wheel Temperature
—
—

Listens to passing trains for bearing & locomotive gear defects – early warning
HBD measures the temperature of roller bearings and reports defects as an axle count
from head end of train
WTD measures heat on wheels to see cars in trains that are in braking and should not
be or cars not braking that should – Effective Braking & overheating wheels
OGD – Optical Geometry - Truck Performance
—
Laser/Vision system to measure the relationship between the wheel flange and the rail
gauge
WILD – Wheel Impact Load, Hunting Truck & Overload-Imbalanced Load
—
Measure wheel impacts in both horizontal and vertical directions to determine the degree
of wheel impacts and loading conditions of cars
WPD – Wheel Profile
—
Laser/Vision System to measure wheel profiles thresholding for AAR/FRA defects such
as: High Flange, Thin Rim or Thin Flange, Hollow Worn etc.
Combined Wheel & Bearing Temperature
Bearing
Detector
Deflector
Hot
Wheel
5
Hot Wheel Detector – data displayed
6
Damage from Dragging Brakes
7
Hot Bearing Detector - CyberScan
8
Networked Hot Bearing Detector Data
Bearing Temp Rising
9
What are the benefits of Trended Temp Data?
10
Wheel Profile Detector – Hump Installation
11
Wheel Profile Detector – Line of Road
12
Wheel Profile Detector Lasers & Cameras
IEM WISE®
13
WPD Threshold Settings (in 16ths)
Rim Thickness: LT 12/16 - 14/16
(33”/36”)
Flange Thickness: LT 14/16
Flange Height: GT 24/16
FRA Condemning (in 16ths)
Rim Thickness: LT 11
Flange Thickness: LT 14
Flange Height: GT 24
13
Machine Vision - Brake Shoe – at Hump
Light
Sources
Camera
14
Notification of Worn Brake Shoes
“We got a thin brake
shoe on the R3
wheel of this car!”
15
Dragging Equipment Detector
16
Optical Geometry Detector
OGD
Wheel
Sensors
17
Distance to the surface of the
wheel, mm
OGD: Principle of Operation
140
120
100
80
60
40
20
0
0
128
255
383
510
Distance along the rail, mm
18
18
OGD, Conditions Measured:
19
Acoustic Bearing Detector – south of Waycross
20
Acoustic Bearing Detector
Microphones
21
Bearing Faults from Acoustic Detectors
Cup
22
More Bearing Faults from Acoustic Detectors
23
Wheel Impact Load Detector
Strain Gages
to measure
vertical &
lateral forces
24
WILD Wheels
This wheel was measured with
153,000 pounds of force banging on
the rail with every rotation.
25
This wheel shows initial flat
spots developing.
Automatic Equipment Identification Reader - AEI
Antenna
26
Processor
Our Supersites have co-located equipment
Hot
Bearing
AEI
WILD &
Hunting
Truck
Acoustic
Acoustic
Wheel
Profile
Optical
Geometry
27
The Web of Detectors
Selkirk,
NY
Voorheesville, NY
Springfield,
PA
Grafton,
Ohio
Sleepy
Creek
MD
Pendleton,
IN
Lowell,
WV
Self Creek,
AL
Supersites
WILD Only
Wheel Profile
Test Site
Carson,
VA
Queensgate,
OH
Walthourville,
GA
Johnson
City, TN
HagueApproximately
706
HBD’s
CSX
System
, GA 850Today,
hot
bearing
detectors
are networked and
Locations
MP
4 wk Unique 8 wk Unique 12 wk Unique
Springfield
QD 108.6
53,015
83,055
108,002
Hague
ANA611.0
45,524
70,142
90,633
Cartersville
0WA47.4
38,931
65,329
86,942
Sleepy Creek
BA 118.7
40,057
63,366
82,623
Self Creek
000371.8
32,538
52,145
68,499
Carson
A33.8
30,996
49,453
65,727
Lowell
CA345.1
17,243
24,567
30,779
Johnson City
Z125.5
16,221
22,310
26,889
Total Unique Cars
274,525
430,367
560,094
28
Cartersville
, GA
Waycross,
trending, and we are
GA
adding
more as we
replace older
equipment….
Testing Out New Technology
 What’s in the pipeline?
— Using Thermal Imaging
Cameras to find Hot
Wheels/Hot Bearings
— Acoustic monitoring for
locomotive bearings
— Machine Vision for
coupler securement
29
Thermal Wheel Imaging – Prototype
Hot Bearing
30
Hot Wheel
Thermal Wheel Imaging – Prototype
31
Questions?
32
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