Vision Based Wheel Condition Monitoring Kambiz Nayebi Beena Vision - - PowerPoint PPT Presentation

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Vision Based Wheel Condition Monitoring Kambiz Nayebi Beena Vision - - PowerPoint PPT Presentation

Jun 07, 2023 16 likes •480 views

Vision Based Wheel Condition Monitoring Kambiz Nayebi Beena Vision Systems, Inc. Y O U R L O G O Beena Vision Systems Inc. 1 Condition Based Maintenance Benefits for the Industry High Availability of Rolling Stock Optimum use of

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Y O U R L O G O

Vision Based Wheel Condition Monitoring

Kambiz Nayebi Beena Vision Systems, Inc.

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Condition Based Maintenance

Benefits for the Industry

  • High Availability of Rolling Stock
  • Optimum use of personnel for Maintenance
  • Preventative Maintenance
  • Need Based Maintenance vs Time based Maintenance
  • Minimizing Timely and Unscheduled Maintenance to Prevent Adverse Impact on Operation
  • Monitoring Leading Indicators
  • General Fleet Weakness and Failure Point Detection
  • Cost Savings
  • Reduce Risk to Personnel / Increased Safety
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Industry Expectations from TCM systems

Reduced Cost with Higher Reliability, Freight vs Passenger

Operations Consideration

  • Painless Operation
  • Reliability
  • Availability
  • Verifiability
  • High Enough Accuracy
  • High Data Quality
  • Actionable Information

Business Considerations

  • Inspection of Rolling Stock Using Technology
  • Predict and Prevent Failures
  • Move Hard Decision Away from the

Maintenance Crew

  • Minimize Depot Maintenance Visits
  • Use Labor to Repair
  • Drive Planning and the Supply Chain through

CM

  • Prevent Disasters
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Main Wayside Detector Types

From 40’s to 2101’s and Future

Wayside Detectors have been deployed since early 1950’s with first talkers at 60’s

 GEN 1: Hotbox/Hot Wheel (1950’s with IR Detectors)  GEN 2: WILD and Acoustic Bearing Detectors (1980’s)  GEN 3: Wheel Profile Measurement (Early 2000’s)  GEN 4: Brake Shoe and simpler Image Based Systems (2000’s)  GEN 5: Vision Based Inspection Systems (2010’s)  Next Generation: Full Vision Inspection along with Multispectral/Thermal/3D aligned with other non‐ contact sensing technologies There has been some attempts to bring Ultrasonic, EMAT, X‐Ray, Thermal, Radar, Lidar and other NDT techniques to mainline wayside detection systems.

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Characteristics of Vision Based Systems

Cameras to Improve Inspector Eyes

  • Versatility: Cameras see a Whole Lot
  • Fast: Sophisticated Inspections at Speed
  • Easy Verification: Verification is Usually Very Easy with Access to Images
  • Data Presentation: Intuitive with Combination of Data and Images
  • Processing Categories: Measurements vs. Inspections (Detection)
  • System Categories: Component Specific to Area Specific Imaging
  • Capabilities: Complex and Accurate Measurements/Inspections
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Characteristics of Vision Based Systems

Complexities of Vision Based Systems

  • High Computational Complexity: Demand for High Computational Power
  • Development Time: Sophisticated Vision Algorithms Takes Time to Mature
  • Large Data Volume: GBytes of Data per Train
  • Power: Some Systems are Power Hungry
  • Availability: Keeping Systems Fully Operational 24/7
  • Ambient Light is the Main Enemy: Only a Well Designed System Can do the Job
  • Not as Easy as it may Look!
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Usually Multiple Sensors are Installed in One Location

In this site systems that are installed listed from left to right: Coupler Inspection System, Undercarriage Inspection System, Wheel Profile Measurement, Brake Shoe Measurement, and Truck Inspection Systems

A Typical US Vision Detector Site

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Usually Multiple Tracks are Equipped with Detectors

This is a double track site with several systems installed on each track.

A Typical Western Australian Site

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A Typical Passenger Train Inspection Site

A Typical Successful Example

Helsinki, Finland Passenger Train Operation

  • Wheel Profile and Brake Pad Units Installed
  • Painless Operation for 5 years
  • Very Reliable
  • More than 99.9% Availability
  • Yearly Verification
  • Accuracy to the Level of 0.2mm
  • High Quality Data
  • Replaced Manual Measurement for Daily

Maintenance

  • Operates on Different Types of Rolling Stock
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Different Vision System Types (1)

Laser Based Systems

Wheel Profile Measurmet Total Wheel Inspection Brake Pad/Shoe Measurement

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Different Vision System Types (2)

Pure Image Based Systems

Brake Shoe Measurement Bogie (Truck) Inspection Undercarriage Inspection

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Different Vision System Types (3)

Laser/3D/Image/Thermal Imaging Based Systems

Pantograph Inspection Total Train Inspection Brake Disk Measurement

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Typical Images from Different Systems

Real Images from Real Systems

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US/Australia /Europe Sites

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Complete Optical Wheel Inspection

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Full Wheel Inspection Station

Static and Dynamic Wheel Measurements

STATIC

  • Wheel Profile
  • Wheel Diameter
  • Wheel Equivalent Conicity
  • Wheel Surface Defect
  • Wheel Plate Inspection
  • Broken Wheel Sections
  • Externally Visible Cracks
  • Internal Defects and Cracks

DYNAMIC

  • Wheel Hunting
  • Angle of Attack
  • Back to Back
  • Wheel Surface Temperature
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Wheel Profile Measurement

WheelView

Standard Measurements

  • Flange Height
  • Flange Thickness
  • Flange Slope
  • Tread Hollow
  • Rim Thickness
  • Back‐to‐Back
  • Tread Rollover
  • False flange
  • Tracking Position
  • Wheel Diameter (Option with WV‐F/I/D)

Typical Accuracy

  • Flange Height, Thickness, Hollow:

 General accuracy: ±0.5mm  Low speed depot: ±0.3mm

  • B2B: ±1.0mm
  • Rim Thickness: ±1.0mm
  • Diameter: ±2.5mm
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Wheel Profile Measurement

Raw Images from WVF

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Measure Wheel Profile

Full End to End Profile

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Wheel Profile Measurement

Flange Thickness Measurement

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From Wheel Profile and Impact to Wheel Condition

  • Wheel profiles are measured at one or few points on the wheel.
  • In wheel profile measurement systems, inherent assumption is that wheel wear is uniform.
  • Impact measurement systems have an inherent assumption that the contact patch is on

the defective part of the wheel and impact measurement can detect it.

  • Even so, many condemnable wheel defects may not have significant wheel impact.
  • Impact measurement requires a minimum speed of travel.
  • Many catastrophic wheel failures do usually either start with small surface defects or

demonstrate themselves as an anomaly on the wheel surface.

  • Optical Wheel Surface Inspection has turned out to be a viable solution that can fill in the

gaps.

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Wheel Surface Scanning Operation

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TreadView and WheelView

This site was developed to evaluate the performance of a fully automated wheel condition monitoring system. This site sees up to 60 trains a day.

A Wheel Inspection Station

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Wheel Inspection in a Freight Track

TreadView

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BNSF Installation of TreadView

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Full Surface Condition Monitoring

Static Wheel Measurements

  • Wheel Surface Defects

 Shelling  Spalling  Dents  Flats  Fatigue Cracks  Out of Round  Built‐up tread  Grooves  Broken and Separated Sections  Externally Visible Cracks  Shattered Rim  Wear Variation along the wheel surface  Significant Spread Rim  Vertical Split Rim

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Sample Wheel Defects

Detectable with TreadView

Dent Shelled Built‐up Shattered Spalled Skid Flat

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More Defective Wheels

Built‐up and Broken Rim

Built‐Up Tread Broken Rim

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TreadView and WheelView

With this station, the task of Wheel Inspection is completely eliminated from the shop floor. Wear, Tread, and Plate condition monitoring are all performed automatically.

A Full Vision Based Wheel Inspection Station

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Full Wheel Inspection System

TreadView

Standard Measurements

  • Shelled/Spalling/RCF Wheel
  • Flat Wheel (Skid, Localized Collapse,

Polygonazation)

  • Built‐up Tread
  • Wheel Profile Variation
  • Wheel OOR
  • Missing/Broken/Shocked Flange/Tread
  • Tread Groove
  • Angle of Attack and Wheel Hunting

Typical Accuracy

  • Out of Round : ±0.25mm
  • Wheel Surface Defects:

 Lateral : ±0.1mm  Longitudinal: ± 1mm  Depth: ±0.2mm

  • Longitudinal for low speed depot:

±0.3mm

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Perfect Wheel

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Hollow Wheel

Measured Across the Whole Wheel

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Flat Wheel

Size and Depth are Measured

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A Sample 3D Map of a Defective Wheel

Shelling

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TreadView Surface Defect

A Detected Shell Example

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3D Wheel Surface Data

A Shell is detected on the wheel surface

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Another Wheel Surface Defect

Shelled/Spalled/Built‐up Tread Wheel Detection

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Wheel Surface Imaging

Visual Inspection

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Visual Inspection of Wheel Flats

Automatic Detection and Size Evaluation

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Out of Round Measurement

23 mm 76 mm 137 mm

Depth – 0.37 mm Depth – 0.61 mm

68 mm

OOR Graph From Manual measurements

35 mm length 139 mm length 80 mm length 68 mm length

OOR Graph From TRDV

0.46 mm depth 0.50 mm depth

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Broken Wheel and its Detection Model

Rendering

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Wheel Surface Representation

Color Depth Display

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Cracked/Broken Wheel Plate

Use Wheel Plate Images

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Conclusion

Wayside Detectors and Vision Based Condition Monitoring Systems,

  • Role of Wayside Condition Monitoring Systems in the Railroad Industry has become

pronounced in the last two decades

  • Vision Based Inspection Systems is now playing a significant role in this sector
  • Wheel Inspection technology has reached to a mature state where a full inspection
  • f the wheel is possible at full track speed.
  • Vision Based CM systems are irreversibly changing railroad maintenance
  • perations worldwide.
  • Acknowledgements: BNSF Railway
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Thank You / Questions

www.beenavision.com Kambiz Nayebi

Beena Vision Systems Inc.

Phone: +1 (678) 597‐3156 E‐Mail: knayebi@beenavision.com