Why is it necessary to test the wheelsets of rail vehicles?
Testing the wheelsets of rail-bound vehicles is crucial for several reasons. These tests make a significant contribution to the safety and reliability of rail transportation by identifying potential problems at an early stage and thus preventing serious accidents. Here are some key aspects:
Safety and reliability:
- Detection of material fatigue:
Wheelsets are exposed to extreme loads that can lead to material fatigue. Regular inspections identify signs of fatigue before they lead to breakage. - Monitoring wear:
Wear on the treads of the wheels and other components of the wheelset can impair driving safety. Inspections enable the timely maintenance or replacement of worn parts. - Detecting cracks:
Cracks in the wheels or axles can have catastrophic consequences. Non-invasive testing techniques such as ultrasonic or magnetic particle testing detect cracks at an early stage. - Check the lubrication:
Insufficient lubrication of the bearings and other moving parts leads to increased friction and wear. Regular checks ensure that all lubrication points are optimally supplied.
Improvements through measurements
- Optimization of design and materials:
By analyzing the measurement data, weak points in the design can be identified and improvements made. This leads to more durable and more efficient wheelsets. - Performance and durability improvement:
Measurements provide important information for improving the durability and performance of wheelsets, which extends component life and reduces operating costs. - Minimization of rolling noise:
Vibration and noise measurements help to develop measures to reduce rolling noise, which increases passenger comfort and reduces environmental impact.
Sensors:
- Strain gauge (350 Ω): For monitoring loads and stresses in the wheelset.
- Temperature sensors: To detect temperature changes that indicate lubrication problems or excessive friction.
- IEPE vibration sensors: For measuring vibrations that indicate imbalances, bearing problems or other mechanical defects.
Power supply:
A stable and battery-supported power supply enables long data recordings. The inductive current and data transmission via a multi-coiled copper wire ensures a reliable connection, even under harsh conditions.
Environmental conditions:
- Protection against splash water, oil, dust: The components must be robust and protected against environmental influences such as water, oil and dust.
- Shock and vibration resistance: Devices and sensors must be able to withstand heavy shocks and strong vibrations.
- Temperature resistance up to 85°C/185°F: The equipment must be able to withstand high ambient temperatures without sacrificing performance or reliability.
Additional challenges:
In order to meet the application conditions for a system in the railroad sector with a shaft diameter of 110 mm at a maximum speed of 1500 rpm, and at the same time to take into account the special challenges in dealing with high voltages and different potentials of the sensors and measuring amplifiers, several aspects must be taken into account. These aspects include mechanical durability, electrical insulation and protective measures as well as data acquisition and signal processing.
Conclusion
Regular and thorough inspections of wheelsets are essential to ensure the safety and reliability of rail transportation. By using the latest measurement technologies and robust system setups, potential problems can be identified and rectified at an early stage, leading to a significant improvement in operational performance and safety.
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