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Condition Monitoring of Train Wheels Using a Cost-Effective Smart Rail Pad
Condition Monitoring of Train Wheels Using a Cost-Effective Smart Rail Pad
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Condition Monitoring of Train Wheels Using a Cost-Effective Smart Rail Pad
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Condition Monitoring of Train Wheels Using a Cost-Effective Smart Rail Pad
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Condition Monitoring of Train Wheels Using a Cost-Effective Smart Rail Pad
Condition Monitoring of Train Wheels Using a Cost-Effective Smart Rail Pad
Dissertation

Condition Monitoring of Train Wheels Using a Cost-Effective Smart Rail Pad

2022
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Overview
Sensing instrumentation plays an important role in measuring both the performance and the condition of the railway track. Data on how the various components of a railway track respond to a passing train in terms of acceleration, displacement, and loading are necessary for condition monitoring of the railway track. Measuring these parameters from within a rail pad can enable a new condition monitoring system for wheel defects and provide information about the wheel load distribution on the track structure.In this study, a smart rail pad was fabricated utilising 3D printing technology and instrumented with low-cost sensing instrumentation. Initial material testing was conducted to determine the best suited 3D printing material, considering Polylactic Acid (PLA), Polyethylene Terephthalate modified with Glycol (PETG) and Thermoplastic Polyurethane (TPU), to protect the instrumentation and to withstand the typical forces of a real rail pad. The material testing results showed that the best suited material was PETG, and it was subsequently used for the final design. Various laboratory tests were done using a hydraulic actuator on two different prototypes to determine the response within a 3D printed rail pad. Similar laboratory tests were done on the final designed smart rail pad before it was tested in the field on a railway line to determine its performance in operational conditions.The developed smart pad system was able to automatically detect an oncoming train and turn the Razor microcontroller on to start logging the data from the smart rail pad. The smart rail pad was able to identify more than 60 % of the wheel defects on average. This was not as accurate as expected because of the major limiting factor being the low sampling rate of the system when all three instruments are logging data. The strain gauge could also be used to detect wheel defects as do the accelerometers. The smart rail pad showed excellent signal response to the variations in the loading magnitude of the tested trains. The measured wheel loads were in good agreement with the control wheel load measurements. The smart rail pad can therefore be used for wheel load sensing measurements and act as an axle counter.