Initial work analysed the market drivers and trends in the areas of the project and benchmarked existing and emerging solutions; performance indicators and technical specifications were defined. Further research focused on the development of innovations in three macro-areas, from concept to laboratory and real environment testing. Specific challenges in these essential areas were tackled separately by the INNOWAG work streams.
Work Stream 1: CARGO CONDITION MONITORING
Scope: Development of an autonomous self-powered sensor system for cargo tracing and condition monitoring of key parameters for critical types of freight, such as perishable goods, high value sensitive goods and dangerous goods, by integrating novel technologies and solutions.
Activities and results
• Definition of potential sensor system architectures and design of solutions dedicated to the defined cases
• Analysis of energy consumption and design of energy harvesting solutions (vibration energy harvester, radio frequency based energy harvesting and transfer, and solar cells)
• Analysis of communication solutions and design of different communication hub concepts, integrating GPS for tracking, GPRS for remote data transmission and either Bluetooth or RFID for communication with sensors
• Implementation of energy harvesting and Cargo Condition Monitoring System prototypes
• Preliminary testing of prototypes in laboratory (TRL 3-4)
• Testing and demonstration of prototypes in controlled environment (TRL 5) and/or in rail freight operation (TRL 6-7).
Work Stream 2: WAGON DESIGN
Scope: Development of a novel concept of modular and lightweight wagon.
Activities and results
• Analysis and selection of materials
• Design of five different lightweight concepts for three different technologies (using advanced materials along with optimised design):
- Lightweight Y25 bogie (17% mass reduction)
- Lightweight 60' container wagon (22% mass reduction)
- Lightweight cereals hopper wagon in 3 versions (mass reduction between 21-27% and 13.3% capacity increase for 1 design)
• Modelling and analysis of lightweight structural solutions to support refinement of design concepts and validate the solutions
• Implementation and testing of samples and prototypes, including:
- Full scale prototypes (bogie frame and composite panel for hopper side walls)
- Different relevant samples (hybrid joints steel - composites, impact testing and abrasion testing of composites).
Work Stream 3: PREDICTIVE MAINTENANCE
Scope: Development of an integrated predictive maintenance approach to enable efficient use of both remote condition monitoring and historical data, and further support the implementation of predictive models and tools in rolling stock maintenance programmes.
Activities and results
• RAMS and LCC analyses based on sets of real data from maintenance activities and components failure data
• Definition of Prioritisation List of critical Y25 bogie components in terms of their relevance for predictive maintenance
• Development of data processing methods for the structural health monitoring of bogie components
• Study on the detection of short-size wheel flat and its propagation to a large size by means of analytical models, simulation and field data
• Definition of a guided procedure for a predictive maintenance policy for Y25 bogies based on available historical data, condition monitoring data and maintenance costs
• Software tool “Wizard tool for maintenance policy optimisation” synthesising the procedure for predictive maintenance; the tool was tested through two case studies.
An investigation of the opportunities for integration and complementarity was also carried out and showed that there are significant opportunities across the INNOWAG concepts to deliver an integrated, cost effective and low risk lightweight smart freight wagon solution.
