zentrak Modular Diagnostic System
A modular diagnostic system for a scalable and cost efficient structuring of wayside monitoring systems.
Benefits
- Diagnostic and Monitoring Functions for Rolling Stock Monitoring
- Wide range of temperature
- Expandable structure of functions
- Low power consumption
- Redundancy for high availability
- Use of identical hardware and software components for different functions
- Easy combination and correlation of monitoring functions
By combining sensor technologies, we offer a wide range of functions like zentrak Hot Box Detection, zentrak Visual Train Analysis, zentrak Wheel Defect Detection etc. The diagnostic and monitoring functions can be complemented with a variety of options and components to fit to specific conditions.
zentrak Modular Diagnostic System Series:
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The condition analysis of rail vehicles and the visual support of maintenance personnel (especially wagon inspectors) is an increasingly important economic and safety factor. The detection of missing bolts or the measurement of wheel and brake wear in combination with precise wagon/container identification helps to optimize processes and save costs. To support this, the Visual Train Analysis function (VTA) was developed. Using low-maintenance industrial cameras, defective components can be detected at an early stage, allowing the utilization of wagons and tracks to be optimized through preventive measures. Consistent quality is ensured during the day and at night by infrared light sources that are invisible to the human eye, so that there is no interference on or beside the track. Due to the well-known modular design of the zentrak system, VTA is able to complement and visually support already existing systems, significantly increasing the value of the checkpoint for the customer. A wide range of additional visual functions is available for this purpose.
Possible detection functions include
- UIC number recognition
- QR code and data matrix code capture
- Inspection/revision data detection
- Determination of the rim thickness
- Panorama images and much more
In addition, new use cases are constantly being defined and the functions are being further developed accordingly - also using machine learning methods.
Benefits:
- Image recording during day and night
- No influence of train traffic due to infrared lighting
- Modular design for a wide range of application scenarios
- Easily expandable
- Low maintenance
- Fully integrated into the zentrak Modular Diagnostic System such as zentrak Wheel Defect Detection (WDD) and zentrak Weighing In Motion (WIM)
- No influence on track maintenance
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Train Profile Surveillance
Slipped loads due to improper fastening or travelling vibrations of train vehicles are major issues in railway transport. Objects sticking out of a train's reference profile can cause serious injury to persons and can lead to extensive damage to railway infrastructure.
The PVS is designed to detect reference profile violations on passing train vehicles. This precise and reliable surveillance system protects persons and railway infrastructure and avoids accidents with passing trains. Event based image recording allows the operator to verify the alarm and identify the severity of the profile violation.Benefits:
- Safety management of railway operations
- Human and asset protection
- Surveillance of train reference profile
- Alarming at violation of reference profile
- Horizontal and vertical clearance gauge verification
- Customer specific definition of reference profile
- No sensor installation near rail necessary
- Maintenance during train operations
- Object recognition for train speed up to 250km/h
- Event image recording at day and night
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Detection of Dragging Equipment
Train parts such as couplings, chains or hoses can be dragged under a train and damage the infrastructure. The DED function protects people next to the track, important installations such as switches, level crossings, ETCS balises or signals from such damage. In case of dragged parts on the train, the sensor generates an alarm in real time, which is reported to the control center or sent directly to the train driver to prevent consequential damage. Potential alarm thresholds can be influenced via mechanically adjustable components. The DED automatically returns to its initial position, which can be ensured by continuous monitoring of the sensor. Thus, it is ready for the next impact to report further hanging parts of a train. Optionally, the system can be equipped with a camera, which transmits reliable images of an impact both during the day and at night.
Benefits:
- Protection for important infrastructure assets and increase of safety in railroad operations
- Detection of dragging parts
- Continuous monitoring of paddle position to ensure functionality
- Increased availability by reducing consequential damage
- Low maintenance, robust construction
- Installation on wooden, concrete and steel sleepers possible
- No influence on track maintenance
- Suitable for all track profiles
- Optional: image recording of the impact during day and nights
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Intelligent Rolling Stock Monitoring
Hot wheels and hot boxes are a major threat for any railway operation, as are malfunctioning brakes. A hot box can lead to fractures of axle journals that might cause a derailment. Remarkable operational hazards are caused by locked brakes, due to overheated loosened wheel rims as well as broken wheel disks. A locked brake can cause fire and is one of the main reasons for the formation of flat spots. Additionally, not functional brakes can lead to very dangerous situations and significant wear and tear.
The Hot Box Detection, Hot Wheel Detection, Cold Wheel Detection and Sliding Wheel Detection are solutions to decrease the mentioned faults to guarantee a safe railway operation. Monitor reliably the temperature of axle bearing boxes, wheel rims and brake discs of passing trains up to 450km/h.Benefits:
- Safety management of railway operations
- Mitigating risks and asset protection
- Improving operational performance by reducing train interruption
- Performance monitoring
- Condition based maintenance
- Modular design for simple and fast mounting without any adjustment
- Up to eight multi-beam scanners per sleeper cover a wide range of wheelset designs
- Low power consumption
- Scanners can be clustered for redundancy
- Self-calibration, self-diagnostic and health monitoring
- No influence on regular track maintenance
Multi-Beam Technology
The configurable sensors are mounted in a hollow steel sleeper in the track. Up to 8 scanners are integrated as a modular plug-in unit and let the customer freely decide the scanning areas of bearings and brakes. The core piece of the sensor is a multi-beam infrared detector. The self-cleaning optic of the scanner unit guarantees a clear view all the time. The integrated high performance processing unit converts fast and exactly each measurement result to determine the temperature profile.
A 3D thermographic image of the scanned axles, wheels and/or discs is generated. With an adapted temperature measurement level, cold wheels are also detected. The sensor output signal is transmitted from the track to the electrical cabinet. Depending on the customer specified tolerance levels the operator will be alarmed directly. The transmission can be realized over several connections like modem, LAN, or GSM.
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Diagnosis of Wheel Defects and Vehicle Weights
Growing rail traffic worldwide requests higher safety standards and lower maintenance costs at the same time. An essential aspect is a continuous, trustworthy monitoring of wheel-rail interaction forces.
Wheels of rail vehicles are exposed to high wear and tear. This may result in geometric wheel defects. The functions WDD and WIM measure on a continuous basis every wheel of the fleet and check for any deviating force levels during normal train operation.
Besides detecting wheel defects the functions are used as a dynamic rail scale at the same time; vehicle weight and load distribution are monitored during every passage and an unbalance or overload can be recognized in time. Assistance for optimal payload usage is available as well.
Benefits:
- Coverage of the complete circumference of the wheel
- Unparalleled ease of installation
- Clamp-on sensors: no drilling/welding/gluing required
- 100% electromagnetic compatible in any railway environment
- No electromagnetic interference
- Self-calibration, self-diagnostic and health monitoring
- No influence on regular track maintenance
- Applied in various climate zones, in tunnel environment and on high speed tracks
- Energy efficient module in compact design
- Flexibility to add sensors
zentrak Wheel Defect Detection (WDD)
- WDD sensors measure increased wheel-rail interaction forces coming from running surface defect of passing wheels.
- Running surface defects create higher wear and tear of both vehicles and infrastructure leading to higher derailment risks. In addition they reduce travel comfort and create an increase in noise and vibration.
zentrak Weighing In Motion (WIM)
- WIM sensors automatically measure the vertical wheel forces of passing vehicles.
- In addition derived quantities such as axle load, asymmetric loading, overloading, vehicle weight and train weight are determined.