EC Contract No. FP7 - 234299 D5.1 State of the Art Application to Railways Instrumentation Due date of deliverable: 31/01/2010 Actual submission date: 11/08/2010 Leader of this Deliverable: P Kitson, Corus Reviewed: N Document status Revision Date Description 1 17/5/2010 First issue 2 11/08/2010 Second issue after quality review Project co-funded by the European Commission within the Seven Framework Programme (2007-2013) Dissemination Level Y PU Public PP Restricted to other programme participants (including the Commission Services) Restricted to a group specified by the consortium (including the Commission Services) Confidential, only for members of the consortium (including the Commission Services) RE CO Start date of project: 01/06/2009 Instrument: Small or medium-scale focused research project Thematic priority: Sustainable Surface Transport Duration: 36 months EC Contract No. FP7 - 234299 EXECUTIVE SUMMARY The purpose of this deliverable is to identify the key sensors available to the rail market for use in measuring parameters that can assist in the maintenance of and the prediction of the residual life of components. The key sensors are those that can monitor the required parameters but importantly can withstand the railway environment, giving good reliability and will not result in the current maintenance costs being transferred from the rail infrastructure to the monitoring system. The document outlines the key parameters that can be sensed using different sensors. The applicability of each to the industry is then discussed in its relevance to predictive life and maintenance. It describes the available sensor technology, their function and application to the railway environment. PMI-D-CRS-001-02 Page 2 of 19 11/08/2010 EC Contract No. FP7 - 234299 TABLE OF CONTENTS Executive Summary ...................................................................................................................... 2 List of Figures ................................................................................ Error! Bookmark not defined. List of Tables ................................................................................. Error! Bookmark not defined. 1. Introduction ............................................................................................................................... 4 2. Monitoring using Sensors.......................................................................................................... 5 3. Sensing Technology ................................................................................................................. 6 3.1 Position ............................................................................................................................... 6 3.1.1 Linear Voltage Displacement Transducer (LVDT) .................................................. 6 3.1.2 Eddy Current Transducers ..................................................................................... 6 3.2 Speed ................................................................................................................................. 6 3.2.1 Velocity Transducer ............................................................................................... 7 3.3 Acceleration ........................................................................................................................ 7 3.4 Force, Torque and Load Measurement ............................................................................... 7 3.4.1 Electrical Resistance Strain Gauge ........................................................................ 7 3.4.2 Fibre Optic Strain Gauge ....................................................................................... 8 3.4.3 Vibrating Wire Strain Gauge .................................................................................. 8 3.4.4 Mechanical Strain Gauge ....................................................................................... 9 3.4.5 Torque Measurement............................................................................................. 9 3.4.6 Pressure (Stress) ................................................................................................. 10 3.5 Temperature ..................................................................................................................... 10 3.5.1 Thermocouples .................................................................................................... 10 4. Typical Applications of Monitoring ........................................................................................... 11 4.1 Position ............................................................................................................................. 11 4.2 Acceleration ...................................................................................................................... 11 4.3 Strain Gauges ................................................................................................................... 12 4.3.1 Electric Resistance Strain Gauges ....................................................................... 12 4.3.2 Fibre Optic Strain Gauge ..................................................................................... 12 Appendix 1 Summary of Measurements AND sensors ................................................................ 15 5. References ............................................................................................................................. 18 PMI-D-CRS-001-02 Page 3 of 19 11/08/2010 EC Contract No. FP7 - 234299 1. INTRODUCTION Railways and tramways have many different track components all of which require periodic inspection, regular maintenance and have a finite life. The aim of work package 5 is to allow automatic inspection and the ability to predict the residual life of the different track components by application of sensor technologies. The track components being investigated include: Switch blades Stretcher bars Fishplated and insulated joints Expansion joints The purpose of this document is to identify the key sensors that are currently available to the rail market for use in measuring parameters, which will assist in the prediction of residual component life. The key sensors are those which can be used in the environment, will give good reliability and will not simply result in the current maintenance costs being transferred from the rail infrastructure to the monitoring system. The document outlines the key parameters that can be monitoried using different sensor technology. The applicability of each is then discussed in its relevance to predictive life and maintenance. The next part investigates available sensor technology, their function and application to the railway environment. Finally there is a summary of all the sensor technologies covered giving details of accuracy repeatability and frequency response. PMI-D-CRS-001-02 Page 4 of 19 11/08/2010 EC Contract No. FP7 - 234299 2. MONITORING USING SENSORS Sensors can be used to measure a range of operating conditions for monitoring the duty and condition of track components. The concept is to use intelligent analysis of the output from sensors fixed to track components to predict when maintenance is required and the residual life of those components. Under normal operating conditions the sensors will produce a “signature tune” it is only when the operation of the component deviates from this signal that the system highlights that it is starting to deteriorate and maintenance is required. Such a system reduces and potentially eliminates manual inspection being replaced by continuous monitoring of the component that highlights when maintenance is required before a failure occurs. The information provided by the sensors can also be used to predict the remaining life of the component. The fundamental measurements that can be made using sensors in their various forms can be split into the following groups Position, speed and acceleration Force, torque, stress, pressure Temperature Electrical current/voltage Material property measurements Surface profile (wear) Of these a number are more significance to the monitoring of in service railway equipment. Position, speed and acceleration Force and stress Temperature Surface profile and wear The systems for monitoring wear and surface profile are actually specialist developments of the measurement of position, speed and acceleration and have been well researched and reported therefore will not be covered in detail. Work is ongoing in WP1 in developing these systems for tramway and metro systems. PMI-D-CRS-001-02 Page 5 of 19 11/08/2010 EC Contract No. FP7 - 234299 3. SENSING TECHNOLOGY 3.1 POSITION A range of sensors are available to determine position and displacement, these include Linear Voltage Displacement Transducers (LVDT), laser range finders, eddy current sensors, and capacitance sensors. 3.1.1 Linear Voltage Displacement Transducer (LVDT) A LVDT Displacement Transducer comprises 3 coils: a primary and two secondaries. The transfer of current between the primary and the secondaries of the LVDT displacement transducer is controlled by the position of a magnetic core called an armature. Typically the two transducer secondaries are connected in opposition. At the central position of the measurement stroke, the two secondary voltages are equal but because they are connected in opposition the resulting output from the sensor is zero. As the armature moves away from centre, the result is an increase in one of the position sensor secondaries and a decrease in the other. This results in an positive or negative output from the measurement sensor depending on which way the armature has moved with the magnitude of the output being proportional to the distance moved. The advantage of the LVDT sensor is that there is no electrical contact across the transducer position sensing element which means clean data, infinite resolution and a very long life. 3.1.2 Eddy Current Transducers Eddy current transducers consist of a driver and a probe body. The probe head typically contains two coils an active coil (main) and a balance coil. This uses the effect of eddy (circular) currents to sense the proximity of non-magnetic conductive materials. A typical eddy current transducer contains two coils: an active coil (main coil) and a balance coil. The active coil senses the presence of a nearby conductive object and the balance coil is used to balance the output bridge circuit and for temperature compensation 3.2 SPEED Speed measurement is usually measured using a velocity transducer. Laser technology is available in the form of laser vibrometers. PMI-D-CRS-001-02 Page 6 of 19 11/08/2010 EC Contract No. FP7 - 234299 3.2.1 Velocity Transducer A velocity transducer consists of a fixed cylindrical coil, in which a permanent magnet is suspended by means of a spring. When the casing is subject to vibration there is relative motion between the magnet and the coil producing an induced voltage in the coil proportional to the velocity across the coil. The advantages of the transducer are that it gives a high signal output and can transmit its signal over long distances (typically up to 300 m). The disadvantage of the system is that due to the internal damping forces accuracies are limited to ±5% in the frequency range of 20 to 1500 Hz. 3.3 ACCELERATION The standard method of sensing acceleration is by use of an accelerometer. An accelerometer typically consists of a piezoelectric crystal between a mass and a rigid bass. The term piezoelectric refers to the crystals property of generating an electric charge when it is stressed. Thus when an accelerometer is subject to vibration perpendicular to its base, inertial forces caused by acceleration of the mass act on the crystal producing a charge proportional to the mass’s acceleration. Coupling the crystal to a charge amplifier (internal or external to the accelerometer) a voltage proportional to acceleration is produced. Accelerometers give a linear response over a wide frequency range 1 Hz to greater than 5 kHz. Single and double integration of signals to obtain velocity and displacement respectively is possible although not advised without the addition of additional high pass filters due to charge drift issues. 3.4 FORCE, TORQUE AND LOAD MEASUREMENT The measurement of load, force and torque measurement relies on the use of strain gauges in their various forms. The strain gauge cannot give an absolute measure, of load, torque and force but can be built into a measurement system that can be designed and calibrated. There are various forms of strain gauges including: acoustic, capacitive, inductive, mechanical, optical, piezo-resistive and semi-conductive. 3.4.1 Electrical Resistance Strain Gauge The electrical resistance strain gauge can be considered as a mature technology dating back to the 1930’s. It is formed by a resistance element attached to a backing. The resistance element is normally in the form of a grid, however for high temperature applications it can be formed from a wire. The strain gauge must be bonded to the component to be monitored, the bond being a critical part of the measurement system as it is via this interface that strain is transferred from the component to the strain gauge. PMI-D-CRS-001-02 Page 7 of 19 11/08/2010 EC Contract No. FP7 - 234299 The strain in the component can then be measured knowing the initial resistance of the strain gauge, the gauge factor and the change in resistance due to the applied strain. The strains measured are typically small (microstrain) with similar small changes in gauge resistance, these small changes being measured using a Wheatstone bridge and suitable amplification. In installations where the principal direction of strain is known a single gauge can be applied however in most applications the principal strain direction is not known and three gauges must be applied in a rosette formation where the angles between the three gauges are known, thus allowing the principal direction to be calculated. 3.4.2 Fibre Optic Strain Gauge A fibre optic strain gauge consists of a fibre optic with a Bragg grating formed within its core by a modulation of the refractive index of the fibre. As light is passed through the fibre optic the Bragg grating reflects light at wavelengths associated with the grating spacing. As the fibre is strained the spacing of the Bragg grating is changed and hence the wavelength of the reflected light is changed. By passing a broad spectrum of light and monitoring the frequency of the reflected light the strain in the fibre can be determined. A series of Bragg gratings can be formed at discrete positions along the length of the fibre optic. By selecting the spacing of the gratings appropriately the reflected light from one grating does not interfere with any other on the same fibre. Therefore a single fibre can be used to measure at a number of discrete locations. The limitations of fibre optic strain gauges are the fixed equipment and associated cost of the optical measuring system and the signal processing required. The fibre optic strain gauge has similar installation requirements to that of the electrical resistance strain gauge, it has to be bonded to or embedded within the component to be monitored. It can only measure in a single direction therefore it also needs to be attached in rosette formation if the principal stress direction is not known. The sensing elements can be small less than ten millimetres but the patch to which they have to be attached for protection can be large in comparison e.g. a hundred millimetres. The disadvantage of the optical gauge is that the fibre Bragg grating is sensitive to temperature therefore it is critical to measure temperature at the same time so as to compensate for thermally induced strains, there are a range of methods that can be employed. The advantage of the optical gauge method is that a number of fibre Bragg gratings can be etched into a fibre optic, thus one fibre can be used to measure at a number of discrete locations. 3.4.3 Vibrating Wire Strain Gauge The vibrating wire strain gauge uses the principle that a tensioned wire, when plucked, vibrates at a frequency that is proportional to the strain in the wire. The gauge is constructed so that a wire is held in tension between two fixed points. An electromagnet is used to pluck the wire and measure PMI-D-CRS-001-02 Page 8 of 19 11/08/2010 EC Contract No. FP7 - 234299 the frequency of vibration. Strain is then calculated by applying calibration factors to the frequency measurement. Installation of this type of sensor is normally undertaken in large concrete structures when they are installed, either directly to any reinforcing cage or directly into the concrete after pouring. As with other strain gauges the principal stress direction must be known or multiple gauges have to be used. These type of gauges are not suitable for use in high frequency measurements. 3.4.4 Mechanical Strain Gauge The mechanical strain gauge commonly referred to as a demountable mechanical strain gauge (DEMEC) is designed to enable strain measurements to be made at different parts of a structure using a single instrument. It consists of a dial gauge attached to an Invar metal bar. A fixed conical point is mounted at one end of the bar, and a moving conical point is mounted on a knife edge pivot at the opposite end. The pivoting movement of this second conical point is measured by the gauge giving a reading of strain. In a typical application pre-drilled stainless steel discs are attached to a structure. To take a measurement the conical points of the gauge are inserted into the holes in the discs and the change in reading on the dial gauge from the installed reading can be converted to the strain in the structure. The gauge has been designed so that only minor temperature corrections are required for changes in ambient temperature, and an Invar reference bar is provided for this purpose. 3.4.5 Torque Measurement The measurement of torque is typically achieved by the application of strain gauges in a particular arrangement directly on to a component or by the addition of a discrete measurement system. The main issues associated with torque measurement, not already covered in the section dealing with strain gauges, is the transmission of data from a rotating component. The two common methods are by the use of slip rings or by telemetry. The use of slip rings has advantages in that it allows power to be supplied and the data transmitted continuously but has the disadvantage that it has components that wear and require maintenance. The use of telemetry based systems avoid the use of components that wear, but require the transducers to be powered by batteries or by use of induction. Both alternatives have limitations, batteries have to be changed at regular intervals, inductively powered systems require small air gaps between rotor and stator. PMI-D-CRS-001-02 Page 9 of 19 11/08/2010 EC Contract No. FP7 - 234299 3.4.6 Pressure (Stress) The monitoring of pressure is normally associated with fluid systems, however in the context of measurement transducers, the measurement of the pressure between two components whilst difficult to monitor continuously can be measured. Pressure measurement between components is typically achieved by placing a pressure sensitive membrane between the two objects loading the system and then removing the membrane. Typically the membranes change colour depending on the pressure applied, devices of this type do not carry out continuous measurements but record the maximum values. 3.5 TEMPERATURE Temperature measurement for continuous monitoring is normally carried out by using thermocouples or pyrometers. 3.5.1 Thermocouples Thermocouples are formed by the junction of two dissimilar metals that produce a potential which is related to the temperature at which the junction is. All thermocouples are referenced to zero degrees Celsius, however for practical measurement systems electronic cold junction compensation is made to compensate for variations in the temperature of the instrumentation system. PMI-D-CRS-001-02 Page 10 of 19 11/08/2010 EC Contract No. FP7 - 234299 4. TYPICAL APPLICATIONS OF MONITORING 4.1 POSITION Measurement of position is typically restricted to knowing if a device or component has reached an operating position, it is not normally used to determine condition. Typically eddy current or capacitance sensors are used. Within the railway environment position sensing is important for the correct operations of switches. To ensure that the switch is in the correct position a sensor is used, the output from which is interlocked with the signalling system to confirm that the correct route is set before the protecting signal can be cleared to allow the train to proceed. The output from interlocking sensors combined with monitoring of the drive motor parameters has been used to understand the performance of switches in track to be able to carry out maintenance when the system is starting to degrade and not when a severe fault has occurred. Recent research in this area was carried out within WP3.3 of Innotrack (www.innotrack.eu) 4.2 ACCELERATION Acceleration measurement are routinely used for investigations of both track and wheel condition and can frequently be associated with noise measurements. There are many examples of acceleration measurements being used for the identification of damage resulting from rolling stock defects such as wheel flats and out of round wheels. Commercial systems are available and in use such as Gotcha® and WheelChex™. Most system have a significant signal processing component to process the time waveforms, into frequency spectra, cepstrum and wavelets. The use of cepstrum analysis has been demonstrated to be particularly useful as it allows the discrimination of wheelflats independently from the presence of other defects, even when their effects are hidden in globally high acceleration levels due to heavy rail corrugation. Systems are also available that use acceleration fitted to vehicle or trolleys that measure the longitudinal profile of the rail to identify the location and severity of corrugation. One well proven system is Rail Measurement’s Corrugation Analysis Trolley (CAT) and Rail Corrugation Analyser(RCA) . Acceleration measurements have also been used to validate numerical predictions on squat growth by way of field monitoring, measurement and survey. The predictions concern a postulated squat growth process, the relation between the dynamic contact force and the corrugation-like wave pattern that often follow squats, the high frequency wheel/rail interaction related to squats and the influence of tangential force on squat growth. The validated results have proven the feasibility for detection of early squats by identification of their signature tunes. Show the necessity to include dynamic wheel/rail interaction in the analysis of squats, and provide evidence for the relation between squats initiation, growth and rolling stock performance. PMI-D-CRS-001-02 Page 11 of 19 11/08/2010 EC Contract No. FP7 - 234299 4.3 STRAIN GAUGES In the following sections the application of electrical resistance strain gauges and Fibre Optic Strain Gauges is discussed, greater emphasis has been given to the fibre optic gauges, this is the result of it being a newer technology and is therefore a significant topic for research. 4.3.1 Electric Resistance Strain Gauges There are few major references to the use of electrical resistance strain gauges in application to railway systems. This is mainly the result of the electrical resistance strain gauge being seen as a low cost item and a standard component in engineering investigations and monitoring. The references mainly focus on them as a tool and a source of data. An example is the comprehensive track investigations in to Rolling Contact Fatigue(RCF) in the United Kingdom following the Hatfield derailment. It adopted a practical and scientific approach to understand the occurrence of RCF and the behaviour of the railway as a system. The objectives of the project were to monitor a total of 27 stretches of track providing essential information on the development of RCF cracks under different conditions. At each site, multiple strain gauges were attached in single and rosette formation to the rail to give data to validate the models. 4.3.2 Fibre Optic Strain Gauge There are a number of examples of the use of fibre optic strain gauge systems in the railway industry, these have included: investigations into vehicle/track interaction, pantograph/catenary interaction, train detection, weight and speed monitoring and infrastructure monitoring Vehicle/Track Interaction and Track Condition Monitoring The modal characteristics of the rail and sleepers have been investigated using fibre optic sensors to allow the identification of signatures that indicate the presence of damage or defects1,2,3,4. Fibre optic sensors have been used to characterise the dynamic effect of cracks in pre-stressed concrete sleepers based on their vibration signatures5. Fibre Bragg gratings (FBG) bonded to the rails have been used to monitor local deformation of the rail in response to the loading by a passing train6 and to monitor switch arms during transitions7. In Hong Kong, an optical fibre sensor system is deployed as a structural health monitoring system on a passenger rail system, with sensors attached to the rail and to the underside of carriages, measuring temperature and static and dynamic strain at critical locations. The system provides information on the loading of the passenger cars, deformation of the rails and of the carriages, temperatures of axles and brakes, and axle vibrations allowing assessment of corrosion and bearing wear8. PMI-D-CRS-001-02 Page 12 of 19 11/08/2010 EC Contract No. FP7 - 234299 The detection of wheel flats has been investigated using multimode fibre optic sensors by monitoring the temporal changes in the speckle pattern at the output of the fibre 9. FBG sensors mounted on a Maglev guideway have been used to facilitate the determination of local changes in curvature and vertical deflection in response to the passing vehicle10. The frequency components within the FBG sensor measurements matched those of an accelerometer for trains passing at speeds of up to 40km/h, and the deflection and curvatures determined from the measurements match theoretical predictions. Pantograph – Catenary Interaction The measurement of the contact forces between the pantograph and catenary is an application in which the electromagnetic interference immunity of fibre optic sensors offers a significant advantage. Measurement of the dynamic loads in the vertical and horizontal directions between the pantograph and catenary on a high speed tracks and in mountainous regions has been achieved using FBG sensors embedded within the composite carbon/aluminium collector strip11. Integrating FBG sensors into the current collectors was considered to turn the pantograph into a 3 point bending sensor in direct contact with the overhead cable, with a concomitant reduction in sensitivity of the measurements to inertial forces introduced by the pantograph suspension structure. Using an interrogation system with a 500 Hz update rate, measurements undertaking on a TGV duplex train between Paris and Vendome, with a speed of 320 km/h offered a spatial resolution of better than 20 cm. The FBG measurements allowed the contact forces and current collector temperature to be computed in real time12 Train Detection, Weight and Speed Monitoring FBG sensors have been deployed to detect trains13,14, count train axles15,16 and to measure velocity17, acceleration17 and weight distribution1,17. An array of FBG sensors installed on a short span railway bridge was found to be capable of onmotion determination of train speed and weight distribution17. The FBG were mounted in a weldable package that was spot welded to the track. Sensors were configured such that at each measurement location two FBG were mounted on the track, with one on the neutral axis and the other displaced vertically from the neutral axis to allow separation of the effects of the track deformation from the total deflection of the deck. The deflection of the deck was measured separately using an FBG mounted of the deck surface. From the combination of the measurements made by the FBG sensors it was possible to determine speed, acceleration and weight distribution of a passing train17. PMI-D-CRS-001-02 Page 13 of 19 11/08/2010 EC Contract No. FP7 - 234299 Infrastructure Monitoring FBG sensors have been widely deployed in the monitoring of civil engineering structures, including many bridges18 and tunnels19. The Como railway bridge in Australia has been instrumented with FBG sensors, measuring strain induced by passing trains at a bandwidth of 16 Hz, with a 1με resolution20. Geotechnical applications include the use of FBG sensors integrated into geosynthetic sheets used in the reinforcement of railway platform subject to localised sinkholes, making it possible to accurately measure the strain of the geosynthetic reinforcement and to validate analytical calculations used in the design of the platform21. The use of both distributed fibre optic sensors and multiplexed arrays of FBG sensors to monitor the temperature of the permafrost roadbed temperature in the Qinghai-Tibet railway has been reported22,23. PMI-D-CRS-001-02 Page 14 of 19 11/08/2010 EC Contract No. FP7 - 234299 APPENDIX 1 SUMMARY OF MEASUREMENTS AND SENSORS Parameter to be Measured Position Instrumentation (Velocity) Advantages LVDT Measurement of deflection / Standard piece of instrumentation movement Eddy Current Measurement of small deflection. Capacitance Measurement of small deflection. (Displacement) Speed Application High accuracy but requires Distance measurement calibration for the environment proportional to size of (material) transducer, small displacements Laser Displacement Measurement Absolute measurement from a fixed Can only measure point. perpendicular to a fixed surface Velocity Transducer Constant regardless of frequency Range limited between 10Hz and 2KHz Laser Vibrometer Non Contact Measurements are in line with laser. Non Contact Measurement Acceleration Accelerometer Measurement of rail or wheel Range >0Hz and 400kHz vibration Strain Electrical Stress analysis of PMI-D-CRS-001-02 Disadvantages Relatively low cost, item common in Preparation of Surface Critical to Page 15 of 19 31/01/2010 EC Contract No. FP7 - 234299 Parameter to be Measured Instrumentation Advantages Disadvantages Resistance Strain components. Gauges Sensing element in manufactured transducers e.g. load cell use in a wide range of applications Fibre Optic Strain Structural Component Gauges Monitoring. Electrical Power Lines Many sensing elements can be formed in a single fibre. Preparation of Surface Critical to the performance. Not affected by electromagnetic interference. Require specialist equipment to analyse the data and convert to a signal suitable for monitoring. the performance. Physical protection and water proofing required. Interference from electrical sources Vibrating Wire Strain Gauge Structural Component Monitoring Not suitable for high speed dynamic measurements DEMEC Developed by British Cement Minimal Installation Costs. and Concrete Association Access required to measurement location. Demountable Mechanical Strain Gauge Load Application Accuracy requires a skilled operator Load Cell Must be put into the load path (Typically strain gauges) PMI-D-CRS-001-02 Page 16 of 19 31/01/2010 EC Contract No. FP7 - 234299 Parameter to be Measured Temperature Instrumentation Thermocouple Application Advantages Disadvantages Standard piece of instrumentation can be linked to various monitoring equipment Table 1: Summary of Measurements and Sensors PMI-D-CRS-001-02 Page 17 of 19 31/01/2010 EC Contract No. FP7 - 234299 5. REFERENCES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 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Zhang W., Shi B., Suo W., Cai Y., Wu Q., An experimental study on thermal state monitoring for permafrost roadbed of Qinghai-Tibet Railway using DTS, 2nd International Conference on Structural Health Monitoring of Intelligent Infrastructure, 573-576, 2006 PMI-D-CRS-001-02 Page 19 of 19 31/01/2010