1. Wayside Acoustic Detection Device
RailBAM
Wayside Acoustic Detection Device
For Vehicle Condition Monitoring
CORE 2004
This presentation provides an introduction to VIPAC’s automated acoustic sensing bearing fault detection system, RailBAM®, and current & evolving operational practices.
Supported by Australian National (1993) – Whyalla trials
With extensive trials at Pueblo (TTC) in 1996, system placed in field in 1998, upgraded with ARTC support in 2000, operational since 2001 and a recent upgrade in May 2004 to new acquisition system and faster processor.
Key elements:
Trackside cabinets
Optical wheel sensors to measure diameter and speed
Wakeup sensors at +/- 40m
Wayside Hut with Comms (128kbaud) and Power (500W)
Malcolm Owens (ARTC) &
Mirek Vesely (Vipac Engineers & Scientists Ltd)
Vipac Engineers

2. Wayside Acoustic Detection Devices
Objectives:
To improve operational safety by reducing maintenance costs & derailments
Fundamental Principle:
To reliably identify developing bearing faults of rolling stock
So the developing faults can be monitored and bearing removal planned with minimal impact on train scheduling
To spot prematurely failing bearings
Improved maintenance strategies through SAFELY maximizing bearing life
14th IWSC 2004

3. Australian Acoustic Installations
RailBAM
Australian Acoustic Installations
CORE 2004
Darwin
Sydney
Perth
Adelaide
Existing RailBAM units
Proposed RailBAM units
TTCI
BHPB – 1 RailBAM
WestNetRail 5 RailBAM’s
We are in all of the same office locations that our big customers are…so we can have strong alliances, strong service.
yet no one client coy “ownes” more than 5% of our turnover…we are very independent.
ARTC – 1 RailBAM
14th IWSC 2004
Vipac Engineers

4. Future Acoustic Bearing Detectors
At Nov 2004:
Australia – 7 RailBAM units operational
China – 1 RailBAM unit operational
By June 2005:
USA – 1 RailBAM unit operational
Australia – 3 more RailBAM installations
12 total installations operating
14th IWSC 2004

5. Single & Dual Track Installation
RailBAM
CORE 2004
Single & Dual Track Installation
Speed Sensor
Wayside Hut
Trackside Cabinets
Single and dual tracks configurations
Mixed gauge installation
Slim-line cabinet design for closely spaced tracks incorporating new shutter mechanisms that is also suitable for freezing rain / snow conditions: environmental testing is to commence in July.
Mixed Gauge
14th IWSC 2004
Vipac Engineers

6. Hampton Installation Tag Reader
RailBAM
CORE 2004
Hampton Installation
Trackside Cabinet – open shutter collecting data
Tag Reader
14th IWSC 2004
Vipac Engineers

7. Fault Types in Package Bearing Units
Running Surface Faults
- Cups & Cones
- Rollers
Looseness / Fretting Faults
- Wear
- Corrosion
- Maintenance errors
14th IWSC 2004

8. Running Surface Faults Identified
RailBAM
Running Surface Faults Identified
CORE 2004
Cup & Cone Faults
14th IWSC 2004
Vipac Engineers

9. Cup fault precedes roller fault
Comparison of Acoustic Signal Levels for Cup and Roller Faults in an E-class PBU
Cup fault precedes roller fault
Increasing richness of bearing faults indicates increasing failure risk.
Note-: Hot Box detectors range is 20 to 50 kms from detection to derail.
14th IWSC 2004

10. Looseness / Fretting in Package Bearing Units
Small axle flexure leads to wear on internal bearing surfaces and results in looseness and fretting
Rubbing & wear generates axial & radial looseness
Looseness / fretting results in heat generation and overheated bearings
14th IWSC 2004

11. Looseness / Fretting Faults Identified
RailBAM
CORE 2004
Looseness / Fretting Faults Identified
Looseness / Fretting
Examples of fretting of material from cone inner surface associated with cone slipping on journal, prior to initiation of a spun cone.
Cone back face material wear
14th IWSC 2004
Vipac Engineers

12. Bearing Fault Statistics
Tapered Roller Package Bearings - mostly removed due to:
Spalling on raceways
Fretting wear on the cone back face, backing ring or seal wear ring.
Axle Box Bearings - mostly removed due to:
Excessive wear or looseness.
Algorithm enhancements an on-going process and may be bearing type specific.
Note Hot Box detectors can only alert after there is a total failure within the bearing and the thermal run away has escalated the external bearing temp 60 degree above normal temps.
14th IWSC 2004

13. Bearing Faults Preceded by Wheel Faults
Wheel fault noted early April (A)
Acoustic “wheel flats” in May (B)
High “Looseness and Fretting” early June (C)
No evidence of bearing running surface fault
Rapidly worsening wheel defect during this time
Wheels and bearings pulled (350kN impact)
TBOGI/ WheelSpec?
14th IWSC 2004

14. False Economy (cont’d)
Looseness
Noisy
Fretting A B C
6 months
(A) Wheel skid (loading)
(B) Impacts >200 kN
(C) Looseness/Fretting seen
Continued High level Looseness, Acoustic Wheel Flats, Impacts
Not repaired because of “useful” life remaining in vehicle
(D) Vehicle left in service until derailment - $$$
False Economy
14th IWSC 2004

15. Damage Potential Model
RCF
Creep Forces
14th IWSC 2004

16. ARTC Plans for Wayside Detection
Integrated Sensors across network, with data trended by Vehicle Monitoring System.
Data available to all operators
Two Supersites (RailBAM, WCM, AoA & Wheel Profile)
Located on North-South & East-West corridor
Co-located Sensors (RailBAM, WCM, AoA)
Located on
Melbourne-Adelaide
Adelaide-Perth
Sydney-Port Pirie
Melbourne-Sydney-Brisbane
14th IWSC 2004

17. Proposed Wayside Sensor Locations
RailBAM
Proposed Wayside Sensor Locations
CORE 2004
Darwin
Sydney
Perth
Adelaide
WestNetRail 5 RailBAM’s
RailBAM
WCM
Existing Sensors
Proposed Sensors
Wheel
Profile
AoA & TP
RailSQAD
We are in all of the same office locations that our big customers are…so we can have strong alliances, strong service.
yet no one client coy “ownes” more than 5% of our turnover…we are very independent.
14th IWSC 2004
Vipac Engineers

18. Reduced Number of Derailments
Installation of Wheel Impact Detector and RailBAM Systems
14th IWSC 2004

19. Evolving Benefits Summary
Freight Operators:
Optimised Bearing Maintenance based on bearing condition, via trending and targetting worst condition bearings.
Extended Bearing Life & hence improved asset utilisation
Reduced Train Stops & hence improved asset utilisation
14th IWSC 2004