EH 2016

EH Powered IoTMonitoring Trains and Track

Roy FreelandPresident – Perpetuum Ltd

Slide 1

IoT Characteristics

Sensor, Microprocessor, Transmitter

Self Powered - Energy Harvester (no batteries)

Wireless Data Transmission to Cloud Server

Information/Alarms anywhere over the internet

Mobile Platform (to make it a little more difficult)

When will see this ?

Slide 2

WARNTRAKWARNS

ENERGYMAN

INNOVATE UK EU FP7/H2020 SME INST

Live Monitoring on Trains

Axle Bearings

Wheels

Gearboxes

Traction Motors

Track

Cows

Perpetuum WSN Features

Totally Autonomous WSN (no wires or batteries)

32 WSN’s per 4 car train transmitting to 1 Data Concentrator (powered) with GPRS link to Cloud Server Vibration & Temperature Sensors

Early Identification of Failure

Wireless Communication

No Wires

Vibration Energy Harvester

No batteries

Robust design for harsh environments

Fast to fit

Trains fitted overnight

Installation

Slide 5

Wireless Sensor Node:Vibration &Temp SensorsEnergy HarvesterMicroprocessorWireless Transmitter

Wireless Sensor Node

Data Concentrator

On Train Communications

Data Download Via Cellular Network

Communications

Bearing Failure !

Slide 7

Simple to Use

Slide 8

Temperature

Raw Vibration

Data

Output:Simple numerical rating of wear:

Bearing/Wheel Health Index (BHI/WHI)

Input:Complex & noisy 3D

Vibration data

Perpetuum’sAlgorithms:

Reduce background noise,Look for Vibration

signatures of bearing & wheel damage

Vibration Data

Slide 9

Good Bearing

Onset of Flat

Degrading Bearing

2 Months

0

10

20

30

40

50

60

70

80

90

100

0 0.5 1 1.5 2 2.5 3

Exte

nt

of

Dam

age

(mm

)

Bearing Health Index (BHI)

Correlation of Damage to BHI

Slide 10

Subsurface Damage Revealed

Slide 11

0.6 mm Cut

Initial inspection shows minimal

damage

Surface removal reveals hidden

damage

Business Case

Extend service intervalMaintain on need not on mileage

Reduce number of major overhauls in franchise period

Improves asset utilisationFleet being monitored while earning revenue

Improves efficiency of maintenance operationsAllows potential failure to be identified in advance &

maintenance planned

Reduces damage by enabling early interventionWheel sets, shock damage etc

Avoids in service breakdownPenalty charges , cost of repair & recovery

Improved Reliability and Safety Slide 12

No Wasteful Bearing Changes

Slide 13

Only spend cash to replace the small % of

bearings that are failing

Use full life of good bearings and don’t waste cash on them

Current Maintenance Plan Extended Life

Use full life of good bearings and don’t waste cash on them

Gearbox Monitoring

Slide 14

Original bearing solution led to wheel solution

Now investigating track solution

> 5 000 sensors already monitor Kent network daily in real-time

Location tagged data using GPS

Going beyond rolling stock …

Sprung & Unsprung measurements

“Noisy” wheels easily removed

Vertical shock & vibration at

wheel/rail (+/- 0.025Grms)

Also lateral and longitudinal forces

WARNTRAK Track Monitoring

Vibration sensors measure the interaction of the rolling stock and the track

The Perpetuum Data Concentrator has GPS capability which enables vibration levels to be correlated with track position

This enables the system to identify locations where there are faults developing

Maintenance teams can then predict the priority areas for maintenance resulting in improvements in safety, reliability and cost

Examples:

Increasing vibration that leads to a track break

Increased vibration associated with poor track bed

Degradation of quality of points over time16

Poor Bed Identified, Remedied

17

Stations (B) & (C)

JunctionPoints around

Tunnel

Distance (Miles)

Instability under track

Each line shows vibration

levels vs distance

Each line represents

data from a week later

than the previous line

Tamping work done and

improvement seen in

vibration data

Degradation of Points

18

Degradation of Points over 6 Month Period

Future: Fully Monitored Train

Slide 19

Rail/Wheel Impact

Gearbox & Traction Motor

Pantograph Impact

Coach Temperature

Door Open & Close

Compressor

Ride Quality

BearingsWheels

Suspension

IoT–Improving Quality of Life

Slide 20

Checking the bearings on

the 12.37 to Brighton

Summary – EH Powered IoT

EH Powered Wireless > Competitive Installation Wireless Condition Monitoring

Adopt new maintenance methodology

Enhanced Safety from real time data

Improve Reliability

Reduce Maintenance Costs

Fast to Fit & Easy to Use with clear actionable information

Early Warning

See bearing degradation 2-3 months ahead

Wheel issues before further damage

Reduce unnecessary speed restrictions

Powerful Evolution Path Gearboxes, Traction Motors, Track condition, Cows

Slide 21

Cow on track – Train in Field

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26/07/2015 21:31 26/07/2015 21:33 26/07/2015 21:34 26/07/2015 21:36 26/07/2015 21:37 26/07/2015 21:38 26/07/2015 21:40 26/07/2015 21:41 26/07/2015 21:43

Vib

rati

on

/G

Time

375703 - Vibration Level over Time

VibrationA

VibrationB