Session 12 Inspection and Detection Systems

Session 12
INSPECTION AND DETECTION
SYSTEMS
Coenraad Esveld
TU Delft

TU Delft, Railway Engineering

Session 12 Inspection and Detection Systems

QUALITY CONTROL

Define quality

measurements

on-line analysis

store results

analyze results

prepare maintenance plan

feed back/test
was maintenance effective?
adjustment of decision algorithm?

maintenance/
renewal

TU Delft, Railway Engineering

Session 12 Inspection and Detection Systems

MEASUREMENTS
1.
2.
3.
4.
5.

Track geometry
Rail defects
Mechanical properties
Clearance gauge
Catenary
a.
b.
c.
d.

Continuous recording cars

Continuous manual equipment
Point measurements
Visual inspection

TU Delft, Railway Engineering

Session 12 Inspection and Detection Systems

TRACK GEOMETRY

quasi-static

dynamic

periodic phenomena

peak values
various wavebands

Interaction vehicle/track
How does train respond to track?
TU Delft, Railway Engineering

Session 12 Inspection and Detection Systems

RAIL DEFECTS
Ultrasonic inspection
horizontal fissures
vertical fissures
star cracks

Eddy current
surface defects

TU Delft, Railway Engineering

Session 12 Inspection and Detection Systems

CONVENTIONAL ASSESSMENT
OF TRACK QUALITY
Track geometry via track recording car

strip charts (graphical)

or QI per 200 m section
exceedances

NS standards
cant:
< 1.0 mm
level:
< 1.5 mm
alignment
< 1.0 mm
TU Delft, Railway Engineering

Session 12 Inspection and Detection Systems

TU Delft, Railway Engineering

Session 12 Inspection and Detection Systems

TU Delft, Railway Engineering

Session 12 Inspection and Detection Systems

TU Delft, Railway Engineering

Session 12 Inspection and Detection Systems

TRANSDUCERS

8 mm
70

70

70

TEST AREA
0

CRACK

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Session 12 Inspection and Detection Systems

Gain
Transmission pulse

Time
2nd Backwall echo
Defect area
1st Backwall echo
Defect area
Water interface
Transmission
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Session 12 Inspection and Detection Systems

RELEVANT WAVEBANDS

PHENOMENON

MONITORING

1 - 30 cm

corrugations

axle box acc

1 - 100 cm

poor welds

axle box acc

poor wheels

rail accelerations

2-3m

rolling defects

axle box acc/displ

3 - 25 m

medium waves

conventional

25 - v/f m

long waves

stabilized platform

70 - m

design geometry

quasi static

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Session 12 Inspection and Detection Systems

measured amplitude
|H| =
actual amplitude
3 - points
(Mauzin AL)

2
Mauzin
level

inertia (NS)

[m]
2.5

5
NS

10

20

50

100

3dB 70 m
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Session 12 Inspection and Detection Systems

TU Delft, Railway Engineering

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Session 12 Inspection and Detection Systems

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Session 12 Inspection and Detection Systems

~ 4

4
T

1
2
= y ( t )dt
T 0
2

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Session 12 Inspection and Detection Systems

PSD (Power Spectral Density) =

energy per wave length 2 /

i
= r 2 = e
i a

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Session 12 Inspection and Detection Systems

DIGITAL ANALYSIS
Cant
Level
Alignment
Gauge

On-line Off-line
Sampling
at
0.25 m

200 m

Twist

Exceedences
Level-1 Maintenance
Level-2
Safety

TU Delft, Railway Engineering

Planning
Data
per
5-10
km
MAINS

Session 12 Inspection and Detection Systems

PDP 11/53
Rail
Geometry
System

B
M
S

Evaluation
- bad welds
- corrugations

Bad
Welds

Corrugations
A
Track
Recording
System

B
M
S

1
VRA

FFT
VRA

Evaluation Track
Quality
Indices
Evaluation Reactions

Transfer
Functions

Vehicle response AP 500

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Session 12 Inspection and Detection Systems

..
zB

V
h

ztrack

z = z B + c1t + c2 h
TU Delft, Railway Engineering

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Session 12 Inspection and Detection Systems

High Pass filtering to remove :

constants
offsets
non-linearities
and to create selected wavebands:
Integration

Time

Filtering

Length ()
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Session 12 Inspection and Detection Systems

d
ps er
las

vel
a
r
t
f
o
on
directi

tion
a
l
u
g
n
a
tri
distance

or
r
r
i
m
g
n
rotati

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Session 12 Inspection and Detection Systems

ORION Rail Profile Measuring System

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Session 12 Inspection and Detection Systems

Rail Profiles

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Session 12 Inspection and Detection Systems

Image Recognition

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Session 12 Inspection and Detection Systems

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Session 12 Inspection and Detection Systems

TU Delft, Railway Engineering

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Session 12 Inspection and Detection Systems

Data transfer to a
central computer

Modem
Software: peak, RMS
per wheel
Electronic equipment
Wheel triggers
Accelerometers

7 bays (wheel circumference)

TU Delft, Railway Engineering

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Session 12 Inspection and Detection Systems

LEVEL

1.4
1.1
0.8

GT
M
0
0
1
/
0.6 mm

2.4

0.5

T
G
M
0
0
/1
m
m

SNCF : Bordeaux - Ste Line

40

tamping

tamping

1.7

tamping

BMS [mm]

50

tonnage borne [MGT]

60

70

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Session 12 Inspection and Detection Systems

LEVEL
ballast cleaning

BMS [mm]

weld treatment
all sections
tamped + stabilized

1.0

track renewal

1.5

welds straightened + ground

track ground in 3 passes
welds straightened + ground
welds straightened

0.5

tonnage

welds not treated

20

40

60

TU Delft, Railway Engineering

80

[MGT]
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Session 12 Inspection and Detection Systems

DETERIORATION
Influence axle load, tonnage and speed

E = kT P V
Phenomenon
Rail fatigue
Surface defects
Fatigue of other components
Rail geometry

3
1
3
1

3
3.5
3
3

TU Delft, Railway Engineering

Session 12 Inspection and Detection Systems

Renewal
70 %

TOTAL MAINTENANCE AND

RENEWAL COST ON NS
250 million per year
for 4.500 km track
Price level 2006

Manual
maintenance
20 %

Mechanical
Maintenance 10 %
TU Delft, Railway Engineering

Session 12 Inspection and Detection Systems

Inspections

Measurements

Planning

Infrastructure

MAINS

Work carried
out

Costs

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Session 12 Inspection and Detection Systems

INFRA DATA

type of rail, manufacturer, date of laying;

type of sleeper, manufacturer, date of laying;
type of fastening;
type of pad, renewal date;
type of ballast, renewal date, cleaning date;
CWR or jointed;
traffic type, ie passenger, freight, mixed;
speed spectrum;
annual tonnage;
accumulated tonnage.
TU Delft, Railway Engineering

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Session 12 Inspection and Detection Systems

INFORMATION PER MAINS

maintenance history;
vertical geometry;
lateral geometry;
short-wave rail geometry;
infra data

TU Delft, Railway Engineering

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Session 12 Inspection and Detection Systems

Analyses

Long wave defects

Short wave defects
Rail defects
Maintenance

DATA BASE

Regression
Correlation
Plotting

costs

''

..............

''

..............
Central Data Base
for Infrastructure

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