IntelliWPMS
IntelliRail’s Wheel Profile Measurement System
IntelliRail’s Wheel Profile Measurement System (IntelliWPMS) is a state-of-the-art product for measuring the wheel profiles of moving trains. It uses a combination of camera and laser technologies to capture accurate and reliable data on various wheel parameters, including flange height, flange thickness, wheel diameter, back-to-back gauge measurement and more for each wheelset.
This advanced automated wheel profile measurement system offers several benefits for railways, such as:
- Automating wheel measurement and inspections, reducing the need for manual interventions and eliminating human error.
- Saving time and money by allowing the rolling stock to stay in service for longer and avoiding unnecessary maintenance.
- Operating in harsh environments and weather conditions, ensuring consistent performance and safety.
- Providing a digital record of the wheel data, which can be easily accessed and analyzed across different departments and functions.
- Alerting the operators and maintenance personnel of any critical issues or deviations from the standards, enabling timely corrective actions.
IntelliWPMS is a trusted product for enhancing the efficiency, reliability, availability, and safety of railway assets.
In the News
IntelliRail successfully delivers the first Make in India AWPMS for Mumbai Metro to support efficient and accurate condition-based maintenance.
How IntelliWPMS Compares with Others
| IntelliWPMS | Other WPMS |
|---|---|
| High accuracy 0.5mm for wheel profile 1mm for wheel diameter and gauge |
Lower accuracy 1 mm for wheel profile 2 mm for wheel diameter and gauge |
Minimal installation time
|
High installation time
|
| Customized for Indian weather and operating conditions | Customized mostly for Europe, leading to inaccurate readings in Indian conditions. |
| Active customer support via Defect Link Period (DLP) and Comprehensive Annual Maintenance Contract (CAMC) | Active customer support is unavailable |
| Measurements based on parameters approved by the Indian Research Designs and Standards Organisation (RDSO) | Not designed for RDSO compliance |
| Trend analysis available | No trend analysis facility |
Cloud-based data storage and transfer
|
Most are not supported by the Cloud |
How IntelliRail’s Wheel Profile Measurement System Works
IntelliRail’s Wheel Profile Measurement System is an automated wayside system that leverages lasers and cameras to provide accurate data on wheel parameters, including flange height, flange thickness, wheel diameter, back-to-back gauge measurement and more for each wheelset.
Machine Vision helps grab and interpret thousands of images of the wheel’s surface to create a visual profile of the wheel. The control panel placed on the wayside is powered by proprietary edge computing software for real-time data analysis of visual information. IntelliWPMS frees you of human dependency, while accelerating the entire process and eliminating human error.
Images that meet the quality and relevance standards are sent to the IntelliCloud for further processing. This reduces the cost of data transmission to the cloud and prevents data lags and delays. The analyzed data is presented in a graphical form, which gives you an easy way to identify variations from the standard wheel parameters at a glance.
IntelliRail’s automated WPMS ensures early identification of regular wear and tear or damage to the wheels, enabling proactive repair or replacement. This extends the life of one of the most expensive railway assets while ensuring maximum asset availability and meaningful cost savings.
IntelliRail’s Wayside Wheel Profile Measurement System Stands Apart from the Rest.
- No-contact measurement to ensure safety of the train and equipment.
- High accuracy measurements of ~0.5 mm for wheel profile and 1mm for wheel diameter and gauge.
- High-speed data capturing and real-time processing for immediate alerts.
- Zero to minimal civil work required for installation.
- Proprietary edge computing-based data analysis for rapid measurements.
- Cloud-based reporting for fast, easy and real-time updates of your rolling stock.
Case Studies: IntelliWPMS in Action
Check out how IntelliWPMS is working to ease condition-based maintenance, minimize costs, and maximize the lifespan and availability of railway assets.
IntelliRail Helps Mumbai Metro Transition to Condition-Based Monitoring
IntelliRail has successfully deployed IntelliWPMS at Charkop depot for line 2A and 7 of the Mumbai Metro. This is the first Make in India AWPMS installed in India.
Where Does IntelliWPMS Stand in the Industry?
IntelliRail’s Automated WPMS scores over manual gauges and portable profilometers.
| Feature | Manual Contact Gauges | Portable Laser/Digital Profilometers | Automatic Wheel Profile Measurement Systems (AWPMS) |
|---|---|---|---|
| Measurement Method | Physical contact and tracing (Mechanical) | Non-contact (Laser triangulation/scanning) | Non-contact (Laser scanners and high-speed cameras) |
| Operation Mode | Manual, hand-held | Portable, operator-mounted (Magnetically attached) | Stationary, installed alongside the track (Wayside) |
| Use Case | Quick checks, final reprofiling validation, simple wear parameters (flange height/thickness) | Detailed profile acquisition, pre/post-reprofiling checks, depot inspections | Continuous, real-time monitoring of running trains at line speed |
| Speed of Measurement | Slow (Several minutes per wheel) | Fast (A few seconds per profile) | Very Fast (Measures entire train at line speed, up to 120 kmph) |
| Data Output | Manual reading, paper logging (Prone to human error) | Digital display, data logging, Bluetooth/USB transfer to PC/App | Real-time data to central server, automated alerts (SMS/Email) |
| Accuracy / Repeatability | Lower accuracy, dependent on operator skill and gauge wear | Higher | High-precision, no-contact measurement, suitable for high-speed analysis |
| Key Advantage | Low initial cost, simplicity, no power required | High accuracy, portability, full profile capture, digital data management | Fully automated, continuous 24/7 monitoring, real-time wear trend analysis, safety-enhancing |
| Key Disadvantage | Slow, labor-intensive, less accurate, limited data analysis | Requires manual setup for each wheel | Requires wayside installation |
| Typical User in India | Railway depots, maintenance technicians | Metro depots, Indian Railway depots, reprofiling shops | Indian Railways, Major metro corporations |