The restoration of heavily damaged or worn-out railway tracks can cost anywhere between ₹8 crores to ₹12 crores per kilometer (over $1,501,000 per mile). This restoration process can include significant repair or complete replacement of the track. Can you imagine what that would cost beyond monetary expenses?
Poor wheel-track interface inflicts the highest cost of maintenance on railway tracks and trains. Early identification of wheel profile faults and proactive maintenance not only prevents significant damage, but it also increases asset availability while lowering the cost of repairs, downtime. Most importantly, the risk of mishaps is minimized. This underscores the critical role of a Wheel Profile Monitoring System (WPMS), which allows preventive maintenance. The result is enhanced safety, efficiency, and longevity of railway assets.
The Shift to Condition-Based Maintenance
The Indian Railways (IR) and metro corporations are rapidly transitioning fixed, time-based maintenance out in favor of condition-based, preventive maintenance. As part of this shift, railway and metro systems are collaborating with advanced diagnostic product and Condition Monitoring Systems (CMS) providers. However, this initiative is linked to the government’s “Make in India” push, where indigenously manufactured solutions are being prioritized. If you too are looking for a powerful WPMS, while supporting domestic manufacturers of such specialized systems, there are quite a few to choose from. But not all WPMS are created the same.
The first difference to consider is whether you want a manual or automated (wayside) wheel profile measurement system. Manual WPMS, whether contact or no-contact portable, is human dependent. This makes the process slow and the data prone to human error. Plus, they might require individual set ups for each wheel while providing limited data analytics. Can you imagine how long railway assets will be unavailable with a manual system?
On the other hand, an automated or wayside WPMS ensures continuous monitoring, data gathering and analysis. This is far better suited to the shift to condition-based monitoring. An automated wheel profile measurement system allows preventive diagnostics. Early detection of possible future defects means that issues can be addressed before they become a problem.
Another key consideration is whether the WPMS or AWPMS is customized to Indian operating and weather conditions. Even today, the vast majority of wheel profile measurement systems available in India are manufactured via European joint ventures. This means that the WPMS is better suited for European conditions and tends to give inaccurate results in Indian circumstances.
IntelliRail’s wayside wheel profile measurement systems wins over the rest in several aspects. Here’s a look.
A Peek into IntelliWPMS
IntelliRail’s AWPMS uses cutting-edge technology to measure wheel profiles of moving trains. It uses Machine Vision to automate the continuous measurement of various wheel parameters, including the wheel profile, wheel diameter, wheel width, and back-to-back gauge. Designed to work efficiently under Indian weather and operating conditions, the standout features of the automated wheel profile measurement system include:
Contactless, Laser-Based System
IntelliWPMS employs six modules that are strategically placed on the track. Each module is equipped with a high-precision line scanner and camera. The line scanner projects a laser beam onto the wheel surface, while the camera captures thousands of images in the reflected light. This data is used to create a detailed profile of the wheel’s parameters.
Extra Scanner Modules
Traditional systems are equipped with 4 cameras, whereas IntelliWPMS has 8 cameras. The additional module measures the wheel diameter, a critical metric overlooked by many rail monitoring systems.
Train Detection Sensors
Three trigger sensors are also placed along the track to detect the presence of a train. The sensors turn the scanner systems ON when a train arrives and OFF after the last coach passes. The timestamp recorded by the trigger sensors is used to correlate the collected data with the specific wheelset of the detected train.
Air Compressor
IntelliRail’s AWPMS uses a compact air compressor, replacing traditional compressors that could be so large as to need an entire room. This saves space, energy, and manual effort. The compressor is installed on the wayside and provides steady airflow for system cooling and dust removal.
Control Unit
A control unit is also placed on the wayside to manage data processing and transmission. It uses Edge Computing for real-time data analysis, so that only high-quality and relevant images are sent to the cloud (IntelliCloud). It also has an RFID reader that maps the wheels to the train.
Wheel Profile Analysis Dashboard
This allows administrators to access data of all trainsets associated with their respective login details. It offers a comprehensive view of the entire rolling stock inventory. The data is then broken down into axle-wise wheel profile details for each trainset. Axle-wise trend analysis can be used to study the rate of change in the parameter values. Users can download detailed reports for management review.
Access on a Mobile App
IntelliRail has pioneered a mobile app so that the WPMS can send both emails and SMS alerts if any wheel parameter is outside the safety thresholds. In addition, the IntelliWPMS dashboard can also be viewed on the mobile app, allowing administrators to check stats and download reports from anywhere, at any time from their Android smartphones.
Make in India, Make for the World
IntelliRail’s automated WPMS is an embodiment of the Make in India, Make for the World vision. Developed using world-class hardware and cutting-edge laser triangulation and machine vision technology, it offers contactless measurements in moving trains to minimize the risk of micro-cracks developing in the wheels, tracks, and measuring equipment itself. The system can measure wheel profiles of trains moving as fast as 120 kmph with an accuracy of 0.5 mm to 1 mm.
Request a quote now or drop an email at info@intellirail.in to learn more about the cutting-edge solution that is making India’s railways and metros future ready.