Final Report Summary - I-RAIL (An intelligent on-line high-speed rail condition monitoring system deployed via passenger and freight trains)
Executive summary:
The 'An intelligent on-line high-speed rail condition monitoring system deployed via passenger and freight trains' (I-RAIL) is a Seventh Framework Programme (FP7) project funded under the research for the benefit of small and medium sized enterprises (SMEs) scheme. The consortium consists of 10 partners from five European countries. I-RAIL has focussed in improving the efficiency of rail inspection and minimising the occurrence of catastrophic failures through the implementation of a novel high speed inspection system based on pitch-catch electromagnetic acoustic transducer (EMAT) techniques which can be installed on any type of train. Ultrasonic phased array techniques have been developed and will be used for the verification and quantification of the defects detected by the EMAT system. An intelligent decision support tool has been developed and will be used to build a database of the defects detected and plan appropriate maintenance activities for the network.
Project context and objectives:
The technological advances in train design in recent years have enabled the construction of more high-speed rail lines and the broader use of high-speed trains as an alternative and environmental friendly means of travel, which offers fast and reliable transportation of passengers and goods between hundreds of cities across the European continent. The increasing trend for the industry's business is forecast to continue in the forthcoming years, since rail transport is steadily becoming a more attractive option over other means of transportation for the public. This is due to the fact that train travel is generally cheaper than using a car or an airplane, and very often the fastest option to reach a destination. It is also inherently safer and far more environmentally friendly in comparison to car travel, without compromising passenger convenience.
Rail tracks are increasingly being subjected to high speed heavy load traffic, and defects caused by cyclic loading, corrosion and wear, are of growing concern. Surface breaking cracks often cause more serious threats to structural integrity when compared to defects such as volumetric cavities. In particular, rolling contact fatigue (RCF) leads to crack formation and hence its detection is especially of interest. RCF cracks develop from the surface, and normally initially propagate at a shallow angle to the rolling direction. The cracks can then resurface (causing spalling), or propagate into the rail at a steep angle.
Project results:
The technology developed and implemented within I-RAIL will increase the reliability and efficiency of rail inspection by delivering a high-speed system based on EMAT that can be installed on any type of train. The EMAT system developed and demonstrated within I-RAIL under actual operational conditions in Entrocamento, Portugal with the help of EMEF and REFER, uses a pitch-catch technique that minimises the effect of increasing inspection speed. The system has the capability of detecting as well as quantifying the detected defects based on both signal frequency and amplitude analysis. Techniques based on ultrasonic phased arrays have been employed for verification purposes of the defects detected by the EMAT system. Intelligent decision support tools developed within the project permit the creation of a database for the defects detected. The I-RAIL Intelligent Decision Support tool assists in the planning of the optimum maintenance activities and scheduling. The I-RAIL project has brought together five SME partners from the United Kingdom (UK), namely CIT Ltd and Sonemat Ltd, Greece (PSP S.A.) and Belgium (Akron N.V. and I-Moss N.V.) supported by four research and technological development (RTD) performers from Belgium (D2S), the UK (University of Warwick), Cyprus (Engitec Ltd) and Portugal (ISQ) and an industrial partner from the rail sector in Portugal (EMEF S.A. representing the Portuguese Railways).
The I-RAIL system
The complete I-RAIL system uses an innovative inspection technology based on guided waves produced by EMATs using a pitch-catch technique. A key aspect of the project has been the demonstration of the I-RAIL deliverables on the Portuguese rail network with the support of EMEF and REFER. The demonstration activities will be followed by further improvement of the system prior to subsequent commercialisation.
The developed EMATs were tested in the laboratory before being integrated with the deployment mechanism and installed on the test train used for the field trials and demonstration of the I-RAIL system. The purpose of the ultrasonic phased arrays system has been to evaluate more accurately the defects detected by the high-speed EMAT system. For that purpose a special deployment trolley has been constructed.
The intelligent decision support software can be used to log the data of any defects reported by the high-speed EMAT system and evaluated using the ultrasonic phased array system. The data file can be either imported or created is in 'xml' format. The information that should normally be included includes the defect number, defect code, rail line name, kilometric position on the line, longitude, latitude, rail (left or right), defect type, detection methodology and inspection date. The signal data can be included as a 'dat' file for each of the defect listed. If this is applicable then the name of the signal data file that corresponds for a particular defect should also be included. In order to make a maintenance decision and determine the severity of the defect the user can simply press the 'Make decision' function. Once the user has activated the 'Make decision' function the software will automatically indicate the severity of the defect and will indicate the level of action code, the timescale code and the maintenance recommendation.
The defect location can be automatically highlighted by placing a marker on the exact defect position. Provided the defect signal data is also saved and available then the user can plot it by selecting the 'Plot data' function.
I-RAIL system demonstration
The demonstration of the complete I-RAIL system was carried out on the Portuguese rail network in Entrocamento, Portugal, with the help of EMEF and REFER. The results of the tests have been assessed by REFER, the infrastructure managing company in Portugal. The field trials and overall demonstration of the I-RAIL technology was successfully completed at the end of October 2012.
The successful demonstration of the complete I-RAIL system is a key step prior to its commercialisation. The demonstration results have shown that the I-RAIL technical deliverables have the capacity of delivering a step-change in existing inspection procedures and increase substantially the competitiveness of rail transport against other less environmentally friendly modes.
Potential impact:
The technology developed and implemented within I-RAIL will increase the reliability and efficiency of rail inspection by delivering a high-speed system based on EMAT that can be installed on any type of train. The EMAT system developed and demonstrated within I-RAIL under actual operational conditions in Entrocamento, Portugal with the help of EMEF and REFER, uses a pitch-catch technique that minimises the effect of increasing inspection speed. The system has the capability of detecting as well as quantifying the detected defects based on both signal frequency and amplitude analysis. Techniques based on ultrasonic phased arrays have been employed for verification purposes of the defects detected by the EMAT system. Intelligent decision support tools developed within the project permit the creation of a database for the defects detected. The I-RAIL intelligent decision support tool assists in the planning of the optimum maintenance activities and scheduling. The I-RAIL project has brought together five SME partners from the UK (CIT Ltd and Sonemat Ltd), Greece (PSP S.A.) and Belgium (Akron N.V. and I-Moss N.V.) supported by four RTD performers from Belgium (D2S), the UK (University of Warwick), Cyprus (Engitec Ltd) and Portugal (ISQ) and an industrial partner from the rail sector in Portugal (EMEF S.A. representing the Portuguese Railways).
Project website: http://www.i-railproject.eu
E-mail: a.vanleuven@d2sint.com
The 'An intelligent on-line high-speed rail condition monitoring system deployed via passenger and freight trains' (I-RAIL) is a Seventh Framework Programme (FP7) project funded under the research for the benefit of small and medium sized enterprises (SMEs) scheme. The consortium consists of 10 partners from five European countries. I-RAIL has focussed in improving the efficiency of rail inspection and minimising the occurrence of catastrophic failures through the implementation of a novel high speed inspection system based on pitch-catch electromagnetic acoustic transducer (EMAT) techniques which can be installed on any type of train. Ultrasonic phased array techniques have been developed and will be used for the verification and quantification of the defects detected by the EMAT system. An intelligent decision support tool has been developed and will be used to build a database of the defects detected and plan appropriate maintenance activities for the network.
Project context and objectives:
The technological advances in train design in recent years have enabled the construction of more high-speed rail lines and the broader use of high-speed trains as an alternative and environmental friendly means of travel, which offers fast and reliable transportation of passengers and goods between hundreds of cities across the European continent. The increasing trend for the industry's business is forecast to continue in the forthcoming years, since rail transport is steadily becoming a more attractive option over other means of transportation for the public. This is due to the fact that train travel is generally cheaper than using a car or an airplane, and very often the fastest option to reach a destination. It is also inherently safer and far more environmentally friendly in comparison to car travel, without compromising passenger convenience.
Rail tracks are increasingly being subjected to high speed heavy load traffic, and defects caused by cyclic loading, corrosion and wear, are of growing concern. Surface breaking cracks often cause more serious threats to structural integrity when compared to defects such as volumetric cavities. In particular, rolling contact fatigue (RCF) leads to crack formation and hence its detection is especially of interest. RCF cracks develop from the surface, and normally initially propagate at a shallow angle to the rolling direction. The cracks can then resurface (causing spalling), or propagate into the rail at a steep angle.
Project results:
The technology developed and implemented within I-RAIL will increase the reliability and efficiency of rail inspection by delivering a high-speed system based on EMAT that can be installed on any type of train. The EMAT system developed and demonstrated within I-RAIL under actual operational conditions in Entrocamento, Portugal with the help of EMEF and REFER, uses a pitch-catch technique that minimises the effect of increasing inspection speed. The system has the capability of detecting as well as quantifying the detected defects based on both signal frequency and amplitude analysis. Techniques based on ultrasonic phased arrays have been employed for verification purposes of the defects detected by the EMAT system. Intelligent decision support tools developed within the project permit the creation of a database for the defects detected. The I-RAIL Intelligent Decision Support tool assists in the planning of the optimum maintenance activities and scheduling. The I-RAIL project has brought together five SME partners from the United Kingdom (UK), namely CIT Ltd and Sonemat Ltd, Greece (PSP S.A.) and Belgium (Akron N.V. and I-Moss N.V.) supported by four research and technological development (RTD) performers from Belgium (D2S), the UK (University of Warwick), Cyprus (Engitec Ltd) and Portugal (ISQ) and an industrial partner from the rail sector in Portugal (EMEF S.A. representing the Portuguese Railways).
The I-RAIL system
The complete I-RAIL system uses an innovative inspection technology based on guided waves produced by EMATs using a pitch-catch technique. A key aspect of the project has been the demonstration of the I-RAIL deliverables on the Portuguese rail network with the support of EMEF and REFER. The demonstration activities will be followed by further improvement of the system prior to subsequent commercialisation.
The developed EMATs were tested in the laboratory before being integrated with the deployment mechanism and installed on the test train used for the field trials and demonstration of the I-RAIL system. The purpose of the ultrasonic phased arrays system has been to evaluate more accurately the defects detected by the high-speed EMAT system. For that purpose a special deployment trolley has been constructed.
The intelligent decision support software can be used to log the data of any defects reported by the high-speed EMAT system and evaluated using the ultrasonic phased array system. The data file can be either imported or created is in 'xml' format. The information that should normally be included includes the defect number, defect code, rail line name, kilometric position on the line, longitude, latitude, rail (left or right), defect type, detection methodology and inspection date. The signal data can be included as a 'dat' file for each of the defect listed. If this is applicable then the name of the signal data file that corresponds for a particular defect should also be included. In order to make a maintenance decision and determine the severity of the defect the user can simply press the 'Make decision' function. Once the user has activated the 'Make decision' function the software will automatically indicate the severity of the defect and will indicate the level of action code, the timescale code and the maintenance recommendation.
The defect location can be automatically highlighted by placing a marker on the exact defect position. Provided the defect signal data is also saved and available then the user can plot it by selecting the 'Plot data' function.
I-RAIL system demonstration
The demonstration of the complete I-RAIL system was carried out on the Portuguese rail network in Entrocamento, Portugal, with the help of EMEF and REFER. The results of the tests have been assessed by REFER, the infrastructure managing company in Portugal. The field trials and overall demonstration of the I-RAIL technology was successfully completed at the end of October 2012.
The successful demonstration of the complete I-RAIL system is a key step prior to its commercialisation. The demonstration results have shown that the I-RAIL technical deliverables have the capacity of delivering a step-change in existing inspection procedures and increase substantially the competitiveness of rail transport against other less environmentally friendly modes.
Potential impact:
The technology developed and implemented within I-RAIL will increase the reliability and efficiency of rail inspection by delivering a high-speed system based on EMAT that can be installed on any type of train. The EMAT system developed and demonstrated within I-RAIL under actual operational conditions in Entrocamento, Portugal with the help of EMEF and REFER, uses a pitch-catch technique that minimises the effect of increasing inspection speed. The system has the capability of detecting as well as quantifying the detected defects based on both signal frequency and amplitude analysis. Techniques based on ultrasonic phased arrays have been employed for verification purposes of the defects detected by the EMAT system. Intelligent decision support tools developed within the project permit the creation of a database for the defects detected. The I-RAIL intelligent decision support tool assists in the planning of the optimum maintenance activities and scheduling. The I-RAIL project has brought together five SME partners from the UK (CIT Ltd and Sonemat Ltd), Greece (PSP S.A.) and Belgium (Akron N.V. and I-Moss N.V.) supported by four RTD performers from Belgium (D2S), the UK (University of Warwick), Cyprus (Engitec Ltd) and Portugal (ISQ) and an industrial partner from the rail sector in Portugal (EMEF S.A. representing the Portuguese Railways).
Project website: http://www.i-railproject.eu
E-mail: a.vanleuven@d2sint.com
