The Client
Problem Statement
In keeping with its mission to modernize the metro network in the MMR, MMMOCL sought to transition to condition-based maintenance. BEML was chosen to provide the complete package of diagnostic systems, along with their trainsets for the Charkop and Mandale depots. A key component was upgrading wheel profile measurement to an automated or wayside system. IntelliRail’s wayside wheel profile measurement system was selected based on the quality of the product and the government’s “Make in India” mandate.
- Transitioning to condition-based monitoring of metro assets.
- Implementing an automated wheel profile measurement system for continuous measurement.
- Increasing efficiency and reducing human error in maintenance of metro assets.
- Ensuring passenger comfort, minimizing costs and maximizing lifespan of wheels and tracks.
The Challenge
MMMOCL is in the process of transitioning to condition-based maintenance (CBM), with plans to launch Unmanned Train Operations (UTO). Both initiatives require continuous, automated monitoring of tracks, wheels, trains, etc., to ensure seamless operations with minimal human intervention.
For this, IntelliRail’s WPMS needed to be installed at Charkop Depot for Line 2A and 7 of the Mumbai Metro. The key challenges faced during the process were:
- Difficult operating conditions of heavy Mumbai rain and high humidity.
- Tracks with X-degree slope.
- Movement of shunting locomotives with tyres that infringe SOD.
- Meeting tight deadlines to ensure timely rollout of the WPMS.
The Solution: IntelliWPMS
IntelliRail’s wayside wheel profile measurement system was installed under the guidance of DMRC. The IntelliWPMS team worked closely with representatives from MMMOCL to deliver a solution that furthered the organization’s mission. With a no-contact, automated wheel profile measurement system, we were able to ensure maximum coverage with minimal human dependency. We set up:
- A machine vision-based system to capture wheel profile, diameter, and gauge data.
- RFID for mapping train numbers with the measurement data.
- Train entry and exit sensors to ensure that the system becomes available as soon as the train approaches and goes into hibernation when there’s no movement. This saves power and increases life of WPMS components.
- Edge computing-based controller to pre-process and optimize data for uploading to the Cloud.
- Cloud-based data reporting to ensure near real-time availability of downloadable reports for authorized users.
- Next-generation features, including trend analysis via a graphical view of the regular wear and tear of each wheel.
Every element of the wayside wheel profile measurement system has been carefully integrated to support critical decisions, such as which wheel to turn on the lathe. This is the key to efficient preventive maintenance.
The Results
IntellRail’s wayside wheel profile measurement system allows authorized personnel to access reports directly on their smartphones (Android and iOS) or laptops. SMS and email alerts are sent when a defect is identified. IntellWPMS was successfully installed, with:
- Zero to minimal civil work required for installation.
- Real-time dashboard available to Mumbai Metro to view the health of wheels.
- Data presented in graphical form for easy identification of wear and tear.
- Continuous data collection for early detection of the rate of wear.
Contact us to learn more about IntelliWPMS.
