Periodic Reporting for period 1 - Gearbodies (Innovative Technologies for Inspecting Carbodies and for Development of Running Gear) Reporting period: 2020-12-01 to 2021-12-31 Summary of the context and overall objectives of the project The GEARBODIES project addresses several issues related to the inspection of carbodies and running gear. The project is divided into two distinct workstreams which address particular issues. In this sense, Workstream 1 focuses on reducing the complexity of carbody inspection caused mainly by their complex geometry, high thickness of many composite components currently used for carbody shells and the one-side inspection within a 12-hour period requirement. Workstream 2.1 is focused on improving the durability and LCC of elastomer-based running gear components, which at the time need to be replaced in considerably low time intervals as a result of fast worn out. Short durability is caused by fatigue, friction, wear, and degradation due to ultraviolet radiation. Workstream 2.2 is focused on prolonging the lifetimes of lubricants in an attempt to extend inspection intervals. The aim is to completely rethink the concept of lubrication used in Europe, not only considering their chemical composition but also considering mechanical and material aspects. The final aim is to advance towards new formulas, with the base idea being oil lubrication, which has already been practically applied in high-speed endeavours. The main objective of the GEARBODIES project is to improve the efficiency of rolling stock maintenance. This main goal is set within the greater context of enabling cost-efficient and reliable long-lasting trains to ultimately foster the modal shift towards rail. In order to achieve said goal, the project is focused on extending the overhaul periods and improving maintenance processes. Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far The current report covers the time interval from the project start to M12, this is, from 01/12/2020 to 31/12/2021. During this period work has been performed in both Workstreams as summarised below. With regards to Workstream 1, the project has identified the requirements and specifications for the inspection system that will detect defects/damage on composite and hybrid carbody shells; several Non-Destructive Testing (NDT) techniques were reviewed for future stages; two components based on inputs received from PIVOT2 project and resembled structural sections of the composite carbody prototype to be manufactured under this project have been modelled; ultrasonic modelling and simulations were carried out to test the detectability of defects on the two model components; a calibration sample (without defects) was manufactured; preliminary work has been carried out for the automated recognition software; a preliminary design of the Modular Prototype Platform (MPP) (A technological concept of the prototype has been formulated) and the inspection platform have been prepared; and finally worst- and best-case scenarios of the carbody inspection using different scanning area sizes and times have been developed. With regards to Workstream 2.1 a study analysing different elastomeric polymeric materials was presented in WP1 based in market solutions; a study summarizing requirements and specifications elastomeric polymers selected in was performed together with an analysis of the most significant standards to be consider during further steps of the project involving materials; two different formulations (elastomeric polymeric matrix and all the additives corresponding to the manufacturing process) for the two different elastomeric components pre-selected have been studied in detail; and two elastomer components to be prototyped have been selected considering inputs from WP1 and WP4 as well as from PIVOT2 discussions: conical spring in primary suspension and bushing in swingarm.With regards to Workstream 2.2 and concerning the research in new materials, greases to be researched have been selected and a first preselection of High Entropy Alloys have been carried out. In addition, the effects of geometry variations in cages and rollers have started to be anylised. Concerning the design of a new journal bearing, its design is well under way, with prototyping and validation yet to be started. Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far) The GEARBODIES project intends to go beyond the state of the art in several ways. Specifically, and with regards to the work being performed in Workstream 1, it intends to develop a set of novel technologies to be integrated and applied in an industrial scale manipulator system to inspect a carbody shell in 12 hours or less. The system will be capable of overcoming problems related to the state-of-the-art practices for the inspection of carbodies such as its lack of precision and long inspection time. The system will utilise advanced software algorithms to highlight the detected defects. A number of comprehensive algorithms, a system based on Artificial Intelligence (AI), will be developed for automatic defect recognition. These algorithms will build pattern recognition methods based on statistical models and artificial neural networks. With regards to the work being carried out in Workstream 2.1 it intends to design several elastomer-based running gear components with reduced LCC and longer lifetime which can be manufactured in serial production, based on a new-formulated elastomer and an existing elastomer material. Both materials will have enhanced performance, i.e enriched mechanical properties (higher resistance to abrasion, strength and elongation at break, tear strength), heat resistance, enhanced durability and/or cycle life and will be tested and used for the prototype of several running gear components at TRL4. Finally, and with regards to Workstream 2.2 the intention is to challenge the lubrication concept in Europe, to advance towards oil lubrication and to introduce slightly or radically different roller geometry (abandoning cylindrical and tapered rollers) to significantly lower today’s bearing operating temperatures, thus leading to extreme-long-lifetime lubricant. Stricter tolerances and lower toughness than today’s components, as well as lower shear stresses on the lubricant, will be sought. GEARBODIES concept
