Practice of NDE 4.0 Concept in Cases of In-service Railway Wheelset Inspection
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International Virtual Conference on NDE 4.0 – 2021 Practice of NDE 4.0 Concept in Cases of In-service Railway Wheelset Inspection More info about this article: http://www.ndt.net/?id=26332 Xiaorong GAO 1, Jianping PENG 1, Yu ZHANG 1, Chaoyong PENG 1 1 Non-destructive Testing Center, Southwest Jiaotong University, Chengdu, China Contact e-mail: gxrr@vip.163.com Abstract The running parts quality is one of the fundamental issues concerning the safety of high- speed railway. With the strategic transition from planning-based maintenance to condition- based maintenance for crucial parts of the trains, a five-level comprehensive inspection system was established to increase inspection functions and detection areas. Based on the concept of industry 4.0 and railway 4.0, the prototypes of NDE 4.0 in railway were introduced to achieve full-life-cycle management for railway assets. In this paper, focusing on in-service railway wheelset inspection, two practical examples for application of NDE 4.0 are discussed. Wheelset lifetime forecasting model and algorithm are analyzed according to wheelset daily inspection data, and suggestions for the maintenance schedules are given by the digital twin model. Similarly, the level of abrasion of the brake pad is studied, and balanced maintenance plans are conducted. With the help of data mining and artificial intelligence, trend analysis and critical threshold evaluation of failures become possible. In this way, traditional NDT methods are empowered to meet both the safety and economic needs of the railway industry. Keywords: wheelset, NDE 4.0, full-life-cycle management, condition-based maintenance 1 License: https://creativecommons.org/licenses/by-nd/4.0/
Practice of NDE 4.0 Concept in Cases of In-service Railway Wheelset Inspection Xiaorong Gao, Jianping Peng, Yu Zhang, Chaoyong Peng Non-destructive Testing Center Southwest Jiaotong University, Chengdu, China April 20 , 2021 Contents 1 Background and Requirements 2 Typical Failures and Inspection System for CRH Wheelset n Typical failures on wheelset n Five-levels comprehensive inspection system for CRH wheelset n NDT techniques and facilities applied in CRH railway wheelset 3 NDE 4.0 Concept in Cases of In-service Railway Wheelset Inspection n Digital twin and condition-based maintenance for in-service wheelset n Case study 1: wheelset lifetime prediction with concept of NDE4.0 n Case study 2: wear trend prediction of brake pad 4 Conclusion
The development achievement of Chinese high-speed railway China high-speed railway construction The plan of high speed railway network in 2035 achievement (by 2020)：operation line more than 3.8×104km ， about 50% railway lines with the designing speed of 350km/h. China 65% Other countries 35% Contribution of Chinese high-speed railway lines in the world 2035: construction scale 7.0×104km High speed railway trains and in-service maintenance n 3500 sets of CRH trains, 20 types in total — 200-250 km/h — 300-350 km/h n Distributed in 18 railway administrations Level I maintenance Application Level II maintenance maintenance Failure maintenance Level III maintenance Heavy Level IV maintenance maintenance Level V maintenance
What Does the Railway Want? CHINA RAILWAY ——The Big A’s Reforming the present maintenance standards n Improve the intelligent level of existing maintenance n Accuracy equipment for CRH trains n Automatic system n Automated algorithms to find defects n Optimize the inspection cycle and techniques for all n Answers — NOT data kinds of maintenance levels n Adapted to all kinds of weather and n Strengthen information construction and big data environments application, promote fault prediction and health n Accessible database management !PHM" n Asset management n Transfer from planned preventive maintenance to digital precise condition-based maintenance Contents 1 Background and Requirements 2 Typical Failures and Inspection System for CRH Wheelset n Typical failures on wheelset n Five-levels comprehensive inspection system for CRH wheelset n NDT techniques and facilities applied in CRH railway wheelset 3 NDE 4.0 Concept in Cases of In-service Railway Wheelset Inspection n Digital twin and condition-based maintenance for in-service wheelset n Case study 1: wheelset lifetime prediction with concept of NDE4.0 n Case study 2: wear trend prediction of brake pad 4 Conclusion
High speed operation, heavy dynamic loading, failures on wheels Damper Disk braking n Surface degradation Height adjuster Wheels n Internal defects Frame n Out-of-roundness Second level suspension Wheel set Damper First level Axle box suspension Typical failures on railway in-service wheels Spalling and indentations on wheel tread and flange Circumferential cracks and internal defects in wheel rim
Conventional & Innovated NDT methods for CRH wheelset Conventional NDT Innovative NDT methods Automatic inspection methods methods (manual) (manual and automatic) for railway wheels n Phased array ultrasonic inspection n Phased array ultrasonic n Magnetic particle n Optical inspection & image recognition n Conventional ultrasonic array Testing(MT) n Acoustic diagnosis n Light-section image measurement & 2D/3D image n Ultrasonic Testing (UT) n Pulsed eddy current & eddy current array recognition n Penetrant Testing(PT) n Image-based magnetic particle flaw detection n Acoustic diagnosis n Eddy Current Testing (ET) n Infrared imaging n Acceleration of vibration n Radiographic Testing(RT) n Laser holography n Conventional displacement & laser displacement inspection Five-levels comprehensive inspection system for CRH wheelset No. Phase Inspection parts NDT techniques Requirement & limitation Vehicle- 1 surface defect & polygons Acceleration of vibration Quantitative results are required mounted On the 2 Wheel surface defect Laser/strain measurement defects on wheel-rail contact area mainline Wheel profile Light section imaging method Limited profiles obtained At depot Wheel tread spalling Image monitoring and recognition Complete image of the object 3 entrance line Wheel tread flats Displacement measurement defects on wheel-rail contact area Wheel rim defect Ultrasonic array flaw detection Focus on the severe defects Wheel rim & plate Phased array ultrasonic Fully covered areas Light 4 Error from the deviation of wheel maintenance Wheel polygons Laser/contact measurement center heavy Wheel rim & plate Phased array ultrasonic Fully covered areas 5 maintenance Wheel surface crack Magnetic particle flaw detection Semi-automatic inspection
(1) Inspection of wheelset - Depot entrance line —— Profile Trigger Optical lens Laser CCD image sensor At the depot entrance line n Operation speed: 5!20km/h n Light section image measuring technique n Wheel diameter, flange height, flange thickness, QR value n Acquire the wheel dimension automatically and back-to-back distance (2) Wayside ultrasonic flaw detection at the depot entrance line n Array probes covering 360 wheel circumferential n Operation speed: 5!20km/h n Big-angle probes and dual-crystal straight probes n Radical defects in wheel flange and radial & circumferential defects in wheel rim
(3) Light maintenance inspection for wheel rim & plate P1 P2 P1 P2 Wheel flange Wheel rim Wheel disk Bor e hole Circumferential Radial defect defect n mounted wheelset flaw detection n Phased array in PC & PE mode n Wheel flange, wheel rim and wheel plate n Automatic scanning with programmed robot n Inspection intervals CRH"20!"#!$% (4) Heavy maintenance inspection for Dismounted Wheelset q Scan 0 degr ee PA Later al inspection m ode n Dismounted and lathed wheels n Phased array and conventional ultrasonic n Internal defects and fatigue cracks in wheel rim & plate n Inspection intervals CRH""&#!"#!$%
Contents 1 Background and Requirements 2 Typical Failures and Inspection System for CRH Wheelset n Typical failures on wheelset n Five-levels comprehensive inspection system for CRH wheelset n NDT techniques and facilities applied in CRH railway wheelset 3 NDE 4.0 Concept in Cases of In-service Railway Wheelset Inspection n Digital twin and condition-based maintenance for in-service wheelset n Case study 1: wheelset lifetime prediction with concept of NDE4.0 n Case study 2: wear trend prediction of brake pad 4 Conclusion IoT and intelligent diagnosis for in-service wheelset
Railway wheelset digital twin diagnostic system n Corrective Maintenance n Plan-based Maintenance n Condition-based Maintenance Case study 1: Wheelset lifetime prediction based on NDE4.0
Case study 1: Wheelset lifetime prediction based on NDE4.0 ELM（Extreme Learning Machine）： single hidden layer feedforward neural network The output function of the No. i hidden layer f! x" = ∑!#$% β#ϑ w"x" + b" = t " , j = 1, ⋯ , N. (1) Formula (1) rewritten as Hβ = T (2) h(x%) ϑ(w%x% + b%) ⋯ ϑ(w!x% + b!) H= ⋮ = ⋮ ⋯ ⋮ h(x&) ϑ(w%x& + b%) ⋯ ϑ(w!x& + b!) &×! β%( t%( Regularization coefficient η is introduced β= ⋮ , T= ⋮ β = H ((HH *+ηI)+%T (4) β(! !×) t( & &×) Output function of ELM =ℎ β= H *T (3) (5) The output weight matrix Case study 1: Wheelset lifetime prediction based on NDE4.0 KELM: Kernel Extreme Learning Machine The Kernel matrix is defined as, • N:training sample datasets (x! , t ! )∈ R " ×R # Q ,!- = HH ( (6) • L: number of hidden layer nodes of ELM • ϑ : excitation function Its element is, • β$ : weight vector between the No. i hidden Q ,!- i, j = h x# @ h x" = K(x#, x") (7) • layer node and the output layer node With the formula ( ) = ℎ( ) , the network output, • w, b : input weight and offset K x, x% ( of the hidden layer node y x = ⋮ (ηI + Q ,!-)+%T (8) K x, x& • H : output matrix of hidden layer nodes • β : output weight matrix Kernel function K(x#, x") which is radial basis function is chose • T : objective matrix as the type of kernel function, # • H % : generalized inverse of H K x#, x" = exp(− ) (9) .! +." /# • I : identity matrix
Case study 1: Wheelset lifetime prediction based on NDE4.0 Case study 1: Wheelset lifetime prediction based on NDE4.0 Entropy Weight Method Variable Weight ) Constant Weight B∑(X) = T x#: ， 0 < α ≤ 1 .&' +)#1(.& ) #$% x#"0 = or )#1(.& )+)#1(.& ) w# x%, … , x) x#"0 = (10) )4. .! +.!" ) = w# x # W T w# x;:+% (13) )#1(.! )+)#1(.! ) 9 :+% 9 .$!" y#" = ∑' (11) ;$% .$!" • x# : the state score of the No. i index !%& e# = −k @ ∑) #$% y#" × ln y#" , = ∑ ( + ) + (12) • α : equilibrium coefficient of variable weight • x#" : the No. i indicator of the No. j state • B∑(X) is ∑ Type equilibrium function • x#" can be converted into x#"0 as the No. i indicator of • w# is the constant weight coefficient of (9) the No. j state by normalization processing the No. i index • k is a constant, and k = 1/ln m • w#(x%, … , x)) is the variable weight • m : the number of evaluation indicators coefficient of the No. i index
Case study 1: Wheelset lifetime prediction based on NDE4.0 Case study 2: Wear trend prediction of brake pad
Contents 1 Background and Requirements 2 Typical Failures and Inspection System for CRH Wheelset n Typical failures on wheelset n Five-levels comprehensive inspection system for CRH wheelset n NDT techniques and facilities applied in CRH railway wheelset 3 NDE 4.0 Concept in Cases of In-service Railway Wheelset Inspection n Digital twin and condition-based maintenance for in-service wheelset n Case study 1: wheelset lifetime prediction with concept of NDE4.0 n Case study 2: wear trend prediction of brake pad 4 Conclusion Conclusion n Innovated NDT techniques are showing their advantages, ultrasonic testing and optical measurement are the most widely used methods in the railway industry for wheelset to measure the profile dimensions and find defects in wheelset. n With the concept of NDE4.0, the digital twins network establishes the mapping between the actual wheelset and virtual model. The virtual digital model is improved and updated on the basis of the actual situation from the NDT inspection results of the wheelset. n With the help of technologies such as artificial intelligence, machine learning, from the two case studies, some maintenance decisions and guiding suggestions are provided back to the actual wheelset, which transforms the wheelset maintenance strategy from the existing Plan-based Maintenance to the Condition-based Maintenance.
Practice of NDE 4.0 Concept in Cases of In-service Railway Wheelset Inspection Xiaorong Gao, Jianping Peng, Yu Zhang, Chaoyong Peng Non-destructive Testing Center Southwest Jiaotong University, Chengdu, China Email: gxrr@vip.163.com 14
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