Diagnostics of rolling stock on the train: development and implementation
At the end of October this year, a meeting of the carriage industry section of the Scientific and Technical Council of Russian Railways was held on the topic "Development of diagnostic tools for the technical condition of rolling stock on the train. Development and implementation". During the work of the section, heads of structural divisions and specialists of Russian Railways discussed the most important and interesting diagnostic issues with invited representatives of development organizations and research institutes. We introduce readers to the protocol of this event.
One of the main directions for improving traffic safety and reducing the number of failures of technical means is the development of diagnostic tools for rolling stock. At the same time, in both existing and newly developed diagnostic tools, it is necessary to achieve a level of confirmability of the detected defects that would eliminate the need for wagon inspectors to confirm the readings. This will reduce the influence of the human factor on decision-making.
Currently, a number of diagnostic tools are used on the Russian road network to monitor the technical condition of rolling stock on the train. Including:
- KTSM equipment, which was developed by Infotex AT LLC (Yekaterinburg), is used for thermal control of axle boxes;
- acoustic monitoring systems developed by JSC "GRC named after Makeev" (Miass) have been used since this year to detect a malfunction of the axle box assembly. These systems make it possible to detect defects at the earliest stages, long before the risk of failure and the onset of overheating of the bearing. Acoustic monitoring systems are installed on the Rybatskoye — Izhory section of Oktyabrskaya Road and the Lost station of Severnaya Road.;
- automated diagnostic complexes of KTI (LLC "CNT", Novosibirsk) are used to measure the geometric parameters of wheel sets of wagons on the road network. Subsystems have also been developed for the KTI complex to detect defects on the rolling surface and shift the axle box assembly.;
- There are 334 UZOT devices in operation to charge and test brakes at maintenance points on the road network. UZOT installations are serviced by the NTC Vagon-Brak service centers, which minimizes the time spent inoperable. But with all the positive aspects in the work of the UZOT, there is one serious drawback — with the help of UZOT, it is impossible to detect a delayed release of the brakes. The effectiveness of the diagnostic systems implementation will be increased by creating integrated control centers with the integration of information from various diagnostic methods of rolling stock. At the moment, this work is being carried out by specialists from JSC NIIAS.
As part of the program for equipping network maintenance facilities on roads in the period 2002 — 2004, a number of diagnostic tools were supplied, including automatic control systems for automatic coupling mechanisms SAKMA (developed by the Ural branch of VNIIZHT and NPP Spektr LLC, Yekaterinburg), automated systems for determining negative dynamics of ASOD, defective wheel detectors DDK (developed by JSCVNIIZHT", Moscow). However, almost all systems have been decommissioned due to low confirmability.
At the same time, the equipment was inoperable for a long time due to equipment failure. The costs of developing, implementing and maintaining the equipment do not correspond to the effect of their implementation.
Currently, specialists are upgrading the SAKMA and DDK systems. Two ASODE systems with new laser sensors and updated software are being operated on the North Caucasian Road.
Employees of JSC NIIAS, as part of the research and development plan, are creating a concept for the implementation of technical diagnostics systems for rolling stock on the train. This will allow for a more thorough approach to the placement of equipment on the road network.
The largest number of failures of technical means and cases of traffic safety violations are caused by malfunctions of the braking equipment and the axle box. In order to reduce failures of axle boxes in operation, the management of the Central Directorate for the Repair of Freight Cars of JSC Russian Railways decided to introduce an additional operation — output quality control of repaired axle boxes using vibration diagnostic stands.
Despite the use of vibration diagnostic equipment, the number of disconnections due to malfunctions of the axle box remains unacceptably large. The main influencing factors are:
- the lack of technically justified uniform sensitivity thresholds for each type of equipment, including those that take into account the use of a polyamide separator;
- software deficiencies in obtaining measurement results in absolute terms (currently, only a "normal" or "suspected malfunction" conclusion is issued);
- elimination of the human factor affecting the measurement results (scrolling the same wheelset with changing numbers).
In order to ensure the quality control of repairs during exit control, 992 diagnostic stands for braking equipment are operated in the carriage repair depots.
In order to improve the quality of repair of braking equipment and wagons in general, it was decided to have 100% output control of the braking equipment of the repaired wagon. During the output control, there is a malfunction of the braking devices previously tested on the automatic transmission stands.
Summing up the results, the Scientific and Technical Council, chaired by A.V. Vorotilkin, Vice-President of Russian Railways, in particular, decided:
- consider it advisable to replicate freight train maintenance technology on the Russian road network with enhanced monitoring of braking equipment while fully testing the brakes;
- consider it advisable to create comprehensive diagnostic centers on the road network;
- consider it inappropriate to develop on-board diagnostic systems for rolling stock.
In addition, specific instructions were given to scientific developers and heads of various structural divisions of the Company, including: - research and design organizations, before the end of the year, to consider the possibility of developing diagnostic tools that identify defects on the rolling surface, malfunctions of auto-braking equipment, automatic coupling device, cracks in the elements of the chassis of wagons, mismatch of slide gaps, overestimation of the friction wedge;
- developers of diagnostic tools should continue working to improve the reliability of the readings of the equipment;
- D.N. Losev, Head of the Department of Wagon Management, to monitor the introduction in 2010 of automated systems for determining the negative dynamics of freight wagons (two devices on West Siberian and one on Trans-Baikal roads);
- Acting General Director of JSC "VNIIZHT" K.P. Schoenfeld (as agreed):
- prepare a conclusion on the expediency of changing the service life of freight car parts (depending on the amount of restoration work performed);
- in 2010, to develop scientifically based requirements for the quality of parts, indicating the minimum sizes of defects of various types to be detected by non-destructive testing (NC) methods in the manufacture and repair of components and parts of wagons;
- after carrying out work on the modernization of the DDK system at the Kresty Moskovskaya Road station, submit a notice of readiness for trial operation to the Department of Wagon Management;
- to the Head of the Department of Technical Policy of JSC Russian Railways, A.S. Nazarov, Acting General Director of JSC VNIIZHT, K.P. Schoenfeld (by agreement) to develop a set of standards of JSC Russian Railways regulating the requirements for NK systems of parts and assemblies of freight wagons during their manufacture, repair and operation, taking into account the level of their potential danger;
- to the director of NPP Spektr LLC, V.F. Barabanshchikov (by agreement), after work on the modernization of the SAKMA system at the Kresty station of the Moscow Road, submit to the Department of Carriage Facilities a notification of readiness for pilot operation, including the system for preventing the derailment of rolling stock;
- In 2010, the head of the Central Directorate for the Repair of Freight Wagons, N.A. Bochkarev, together with representatives of manufacturers of NC equipment, developed a program for the creation of unified mechanized and automated NC equipment that minimizes human involvement in the control process. To develop a system for automated documentation of the results of the NC of the most critical parts and monitoring of their technical condition based on the results of the NC;
- N.A. Bochkarev, Head of the Central Directorate for the Repair of Freight Wagons, and M.S. Sokolovsky, Director of the Central Design Bureau, together with scientists from JSC VNIIZHT, will test the upgraded stand in the first quarter of 2010. If the test results are positive, release an installation batch of wheelsets with axle boxes controlled using a new vibration diagnostic technique. To organize controlled operation together with the Department of Carriage Facilities. If the test results of the wheelsets are positive, make a decision on the modernization of vibration diagnostic stands.;
- to the head of the Central Directorate for the Repair of Freight Wagons, N.A. Bochkarev, together with manufacturers of vibration diagnostics installations, until 02/01/2010, to consider the experience of the Gorky DRV in remote monitoring of vibration diagnostic installations for its subsequent implementation in all car repair depots;
to the head of the Central Directorate for the Repair of Freight Wagons, N.A. Bochkarev, Director of the Design Bureau, M.S. Sokolovsky, together with manufacturers of vibration diagnostic equipment:
06.03.2023, 12:56
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