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Web of Detectors

““Never Stop A Train For Never Stop A Train For

Mechanical Failure”Mechanical Failure”

Dale Cassels ACACSO May 2013

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Joint Wayside Diagnostic System - JWDSJoint Wayside Diagnostic System - JWDS

Goal – Proactive identification of mechanical risks to minimize line of road stops— Eliminate mechanical-caused line of road stops and

derailments— Reduce the stress state of our Railroad — Centralized repository for ALL detector data— Identifies and prioritizes conditions we want to know— Enables car inspectors to move from finders to fixers

CSX, UP and NS share software and rules logic through the JWDS Consortium.

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Joint Wayside Diagnostic System - JWDSJoint Wayside Diagnostic System - JWDS

Before JWDS, we were

REACTIVE

to what the detector was telling us.

Now… we are

PROACTIVE

as to what the equipment is telling us.

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Web of Detector AcronymsWeb of Detector Acronyms ABD – Acoustic Bearing

— Listens to passing trains for bearing & locomotive gear defects – early warning AEI - Automated Equipment Identification

— Radio Frequency based system that reads car and locomotive tags Allows us to piece the defect information to the car and position on the car in JWDS

HBD/WTD – Hot Bearing – Wheel Temperature— HBD measures the temperature of roller bearings and reports defects as an axle count

from head end of train— WTD measures heat on wheels to see cars in trains that are in braking and should not

be or cars not braking that should – Effective Braking & overheating wheels OGD – Optical Geometry - Truck Performance

— Laser/Vision system to measure the relationship between the wheel flange and the rail gauge

WILD – Wheel Impact Load, Hunting Truck & Overload-Imbalanced Load— Measure wheel impacts in both horizontal and vertical directions to determine the degree

of wheel impacts and loading conditions of cars WPD – Wheel Profile

— Laser/Vision System to measure wheel profiles thresholding for AAR/FRA defects such as: High Flange, Thin Rim or Thin Flange, Hollow Worn etc.

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Combined Wheel & Bearing TemperatureCombined Wheel & Bearing Temperature

BearingDetector

Hot Wheel

Deflector

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Hot Wheel Detector – data displayedHot Wheel Detector – data displayed

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Damage from Dragging BrakesDamage from Dragging Brakes

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Hot Bearing Detector - CyberScanHot Bearing Detector - CyberScan

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Networked Hot Bearing Detector DataNetworked Hot Bearing Detector Data

Bearing Temp Rising

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What are the benefits of Trended Temp Data?What are the benefits of Trended Temp Data?

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Wheel Profile Detector – Hump InstallationWheel Profile Detector – Hump Installation

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Wheel Profile Detector – Line of RoadWheel Profile Detector – Line of Road

1313 1313

Wheel Profile Detector Lasers & CamerasWheel Profile Detector Lasers & Cameras

WPD Threshold Settings (in 16ths)Rim Thickness: LT 12/16 - 14/16 (33”/36”)Flange Thickness: LT 14/16Flange Height: GT 24/16

WPD Threshold Settings (in 16ths)Rim Thickness: LT 12/16 - 14/16 (33”/36”)Flange Thickness: LT 14/16Flange Height: GT 24/16

FRA Condemning (in 16ths)Rim Thickness: LT 11Flange Thickness: LT 14Flange Height: GT 24

FRA Condemning (in 16ths)Rim Thickness: LT 11Flange Thickness: LT 14Flange Height: GT 24

IEM WISE®

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Machine Vision - Brake Shoe – at HumpMachine Vision - Brake Shoe – at Hump

Light Sources

Camera

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Notification of Worn Brake ShoesNotification of Worn Brake Shoes

“We got a thin brake shoe on the R3

wheel of this car!”

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Dragging Equipment DetectorDragging Equipment Detector

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Optical Geometry Detector Optical Geometry Detector

OGD

Wheel Sensors

181818

0

20

40

60

80

100

120

140

0 128 255 383 510

Distance along the rail, mm

Dis

tan

ce t

o t

he

su

rfa

ce o

f th

e

wh

ee

l, m

m

OGD: Principle of OperationOGD: Principle of Operation

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OGD, Conditions Measured:OGD, Conditions Measured:

2020

Acoustic Bearing Detector – south of WaycrossAcoustic Bearing Detector – south of Waycross

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Acoustic Bearing Detector Acoustic Bearing Detector

Microphones

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Cup

Bearing Faults from Acoustic DetectorsBearing Faults from Acoustic Detectors

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More Bearing Faults from Acoustic DetectorsMore Bearing Faults from Acoustic Detectors

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Wheel Impact Load DetectorWheel Impact Load Detector

Strain Gages to measure vertical &

lateral forces

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WILD WheelsWILD Wheels

This wheel was measured with 153,000 pounds of force banging on the rail with every rotation. This wheel shows initial flat

spots developing.

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Automatic Equipment Identification Reader - AEIAutomatic Equipment Identification Reader - AEI

AntennaProcessor

2727

Our Supersites have co-located equipment Our Supersites have co-located equipment

WILD & Hunting Truck

Optical Geometry

AEI

AcousticAcoustic

WheelProfile

Hot Bearing

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CSX SystemApproximately850 hot bearing detectorsToday, 706 HBD’s

are networked and trending, and we are adding more as we replace older equipment….

The Web of DetectorsThe Web of Detectors

Hague, GA

Carson, VA

Springfield, PA

Sleepy Creek

MD

Lowell, WV

Johnson City, TN

Cartersville, GA

Self Creek, AL

Locations MP 4 wk Unique 8 wk Unique 12 wk UniqueSpringfield QD 108.6 53,015 83,055 108,002 Hague ANA611.0 45,524 70,142 90,633 Cartersville 0WA47.4 38,931 65,329 86,942 Sleepy Creek BA 118.7 40,057 63,366 82,623 Self Creek 000371.8 32,538 52,145 68,499 Carson A33.8 30,996 49,453 65,727 Lowell CA345.1 17,243 24,567 30,779 Johnson City Z125.5 16,221 22,310 26,889 Total Unique Cars 274,525 430,367 560,094

Grafton, Ohio

Pendleton, IN

Walthourville, GA

Supersites

WILD Only

Selkirk, NY

Queensgate, OH

Waycross, GA

Wheel Profile

Test Site

Voorheesville, NY

2929

Testing Out New TechnologyTesting Out New Technology

What’s in the pipeline?— Using Thermal Imaging

Cameras to find Hot Wheels/Hot Bearings

— Acoustic monitoring for locomotive bearings

— Machine Vision for coupler securement

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Thermal Wheel Imaging – Prototype Thermal Wheel Imaging – Prototype

Hot WheelHot Bearing

Thermal Wheel Imaging – Prototype Thermal Wheel Imaging – Prototype

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Questions?