HITACHI tor sige eo Cas Railway Inspection Systems Rail and Contact Line Inspection Technology for Safe and Reliable Railway Traffic (Releronce Hitachi Review July 20%2: pth hitachi comewarchive2012/2471275_82777 hi) 7/7/2014 Brian Rattray Social Infrastructure Division Hitachi High-Tech Fine Systems Corporation ‘cop 20 taht gh Tech Fine Systs Cap Al pis ened HITACHI Inspire the Next Contents RR SN eS RE SRT Introduction Track Inspection Technology Overhead Conductor Inspection - 9 Bb Railway Inspection Systems Cony 20 tia gh Tch Com Alraueresives 1HITACHI Inspire the Next 1. Introduction ‘Coppi 2010Hach Hn TesnFine Stems Cor. Alighsroered 2. 1-1 Introduction HITACHI Inspire the Next Overview There are a great many factors that affect the performance and stability of railway infrastructure. The only way to ensure safe, reliable and comfortable railway services is regular maintenance. Environment factors: Human/economic factors: + Seasonal temperature changes, + Rain and snow + Lightning strikes * Flooding, earthquakes and a variety of other natural disasters + Higher speed trains + More frequent traffic + Heavier haulage + Ageing/material flaws ‘Coppfah® 20%aHiehiMigh Tach Fine Sysams Corp. Abaphisrecaved 31-2 Product Outline HITACHI Inspire the Next 0 SSS SSS Ht EE 1. Track Inspection 1) Track Geometry Inspection Geometry is the major inspection item to keep safe and reliable ride. It measures relative position of each rail such as longitudinal level, alignment, gauge, cross-level and twist. 2) Rail Profile Rail Profile is an optional track inspection item mainly for analysis purpose. Itgives a 2D image information of rail shape to identify the degree of rail wear. 3) Rail Corrugation Measurement Rail Corrugation Measurement is an optional track inspection item mainly for feedback to grinding regime and noise reduction. Corrugation, wave-shaped- wear, causes vibration and noise. \Copyand 2013Hta6N High Tock Fine Systns Corp Asesinas, 1-2 Product Outline HITACHI Inspire the Next 0 RH SS SSS SEES ESSN 2. Overhead Conductor Inspection 1) Overhead Conductor Inspection Overhead Conductor Inspection keeps safe train operation. It measures stagger, height and wear of conductor. 2) Mast Detection Mast Detection is an optional function of overhead conductor inspection. It counts the number of masts to locate the position of defects. Coprrig® 2013Htsch High-Tech Fie Systane Comp Alrgesresones 51-3 Product menu HITACHI Inspire the Next Standard | Option Track Geometry = Longitudinal Level = Alignment = Gauge -- Cross-Level Track Inspection ojo}ojolojo — Twist Rail Profile Rail Corrugation Measurement Rall Flaw Detection ojo|o Overhead Conductor Inspection -- Stagger Overhead ~ Height Inspection ~ Wear olojojo Crossover Line and Clasp Mast Detection Surveillance Cameras Others olojojo Construction Clearance CConright9 2019!tach ph Tech Fine Syst Cp, Ais ese HITACHI Inspire the Next Puna 2. Track Inspection Technology ‘copy 2013Hteshi Hah Tech Fine Sytons Cop. Alighicesoned 72-1 Railway Track Inspection HITACHI Inspire the Next Primary track geometry inspection items These items alll started off as manual measurements using some simple gauges. { Lonaitudinal Level | (Gage) (cross-level } Distance between gaige lines, Pa Ral ‘Measurement chord Height of right over left (may be negative Rail (L) ‘Alignment (L) at mid-point Rail (R) Copyihe 2013Htact Hah Ten Fine Sytams Cop Alrgnisrsened 8 2-1 Railway Track Inspection HITACHI Primary track geometry inspection items And what made these measurements so critical? Longitudinal Level 1. Maintaining safety margins for drivers Positive (+) 2. Excessive wear on tracks and wheels eS 3. Hunting can lead to catastrophic failure eer Se Se Negative [-) _ i The! heey vigor Ament et freightane exacerbates the efecs Jcauge I i) Alignment ight Rail Corinto 2131S Heh Tech Fie Systems Comp Alas reseedHITACHI Inspire the Next 2-1 Railway Track Inspection Primary track geometry inspection items And what made these measurements so critical? 1. Falling off or climbing up the rails Gauge 1 Postivet 2. Speed on curved track (cant deficiency) : Bight alt 3. Atthe right (or wrong) speed, benign defects can pose significant risks such as ‘cyclic top’ leading to derailment Freight train suspension ‘may not offer much ee 10 Reve Te CCopyigh® 201aHiach HighTech Fine Systems Corp Alig rexeied HITACHI Inspire the Next 2-3 Principles of Railway Track Inspection Traditional mid-chord offset techniques for the inspection car Car body can be used as the measurement chord if we know its height above the track <—| Longitudinal Level Q 000 0 0 Measurement chord 1. Measurement ford length 10m __ 1 Referencetine 1 Separation Sm y Separation 5m_.! a ise “Railway te Train wheels follow the level of the rails, so their position relative to the vehicle reference line is a measure of vertical displacement but they cannot be used to measure lateral leight/ Depth at mid-point displacement. Additional sensors are required ; : : to measure Alignment: both contact and Earlier solutions used 3-bogie inspection car non-contact types have been developed. with height measurements at 3 wheel.axles f A 10m mid-chord offset measurement using the differential method | Cony 2012Rach High Tech Fea Systoms Co Alighisesened, 112-4 Modern Implementation of Track Inspection —_ HITACHI Inspire the Next Non-contact mid-chord offset using optical displacement sensors The need for higher inspection speeds ushered in the use of optical sensors, involving no mechanical contact with the rails and were suitable for double bogie vehicles. fell iS oO {__ Sere et \¢_Susetin sm gig Béla i Pay te eet Furthermore, the inherent accuracy of these devices allows us to apply this technique to smaller vehicles and still calculate the required 10m chord data without surement incurring too much error. pn FD Palen Se Des (Coby 201atach Mah-Teen Fie Syste Comp. Alfahisesered 12 2-5 Passenger Car Mounted Track Inspection HITACHI Inspire the Next Distortion in the track causes vibration in the train Measurement of the vibration can yield the displacement of the track...with a little help! The key for a passenger mounted inspection system is that it be small. Inertial geometry systems |offer a compact solution. With the addition of optical displacement sensors and an optical gyroscope i these systems can yield both aplacerent : | vertical and transverse mid-chord sensor & oy ~—__~loffset track geometry data. Taehitorion A compact passenger car mounted overhead cable inspection system has also been developed and is currently being evaluated in the field C Inspection systems fitted to revenue cars means substantial amounts of (data can be obtained continuously with no effect on scheduled train services ‘opto 201saen gh Teoh Fie Systm Ga, A hs esened 32-5 Passenger Car Mounted Track Inspection HITACHI Inspire the Next Mix inertial with differential techniques for high & low speed accuracy Inertial technique works best at speeds above 50km/h, differential can work stationary = = For a passenger car mounted a \ at stations is frequent, the ability to measure at low speeds is required. The addition of a second set of optical displacement sensors can enable vertical and transverse Primary —p tan(83*)-9 [Offset measurements for linear GA SETS speeds all the way down to zero. 2 locations (@ & b), a fixed distance (0) apart Differential measurements dominate low speeds of operation then transition to inertial measurements for the higher speeds with a hybrid operating mid-range. Inspection systems fitted to revenue cars means substantial cost savings compared to purpose specific maintenance inspection vehicles Copyigh 2019HHathi High Tach Fine Systane Corp. Aleghtvatered, 14 2-5 On-board processor BEACH Operation panel Te Transfer status Vehicle setting | Waveforms: Operation pane! Equipment status Inspection date Line a Section Distance eeseeseerr conn 20;acn HpnTaeh Fine Syms Comp Arghisresoned 152-5 On-board processor HITACHI Inspire the Next Waveform display Tee Distance (kn) ‘Speed 1_waveform item ‘Structure ‘Copy 201siaeh gh Tech Fe Systm Corp. Aligisresenved. 16 2-5 On-board processor HITACHI Inspire the Next Excursion List I Select Close Excursion table Color ke) ple|ser| Copy 2013Htseh Heh Teen Fe Systane Comp. Aegis rosoned 17.2-6 Ground-based processor HITACHI Inspire the Next Data base Ccopyigt> 201sHten HpnTech Fie Systems Cop Alighsetered 18 2-6 Ground-based processor aoe Data list records Conyrgto2012HeacHighsTen ine Stans Corp AlNghsresened 192-6 Ground-based processor Ae Waveform chart records Ceayroh 20191tecn Hg Ten Fine Systems Cap. Al his reserved 20 2-6 Ground-based processor (ITACHI. Excursion control settings a6 (0 | tne | mee aban See FFB cae "ee} 50h 34) 0 3 opr 2013ee ph Teen Fine Systane Corp Aegis resewmd 212-7 Rail cross-section profiling AAC The amount of wear of a rail is measured from a profile (or contour) of the rail cross-section generated by a two-dimensional displacement sensor. 2D displacement \\ Arithmetic ‘sensor Processing unit | Measurement method ae Hood 1 ot S| Ba eseuement pote, i Measurement conditions ‘Measurement method | « Non-contact + Night measurement Measuring speed * Max 40km/h Copyright 20a igh Tech Fe Systm Cop Adige rasaved 22 2-8 Rail corrugation measurement HuACH @ Features + Corrugation and joint depression are < en detected by measuring unevenness of the /(_]j() an Oj contact surface ofthe reilhead le an (a\ + High precision measurements realized by Sa I combining a high precision laser ere least re | displacement sensor with an accelerometer based inertial system. + Capable of fine pitch measurement. neat + Position compensation is possible fro une input of cation data. + ‘ Dialcement Sensor Poston Aeeationeensor | | Distance pulse generator 1 | tary encoder) 1 Measurement conditions of rai Cconpig©2019Htach gh Tach Fine Systems Cop. Aighsreseres. 29HITACHI Inspire the Next 3-1 Overhead Conductor Inspection HITACHI Inspire the Next Primary overhead conductor inspection items Inspection can be done manually but is better done under dynamic conditions. above RBitway tie ee Worn depth (Cross-section of conductor) |, contact | surface Cony 201m HGh-TAONFne Sse Cop. Al his exened 253-2 Principles of Overhead Conductor Inspection HITACHI Inspire the Next Using a transverse scanning laser to measure position & width of wire The beam is deflected by a polygon mirror then concave . mirror to form a transverse laser scan directed vertically Overhead up at the sliding surface of the overhead cable (or cables) Cndctor Remaining diameter Polygon Photo ta | sensor Interference filter EEAEtE EAT these eso Solid stat oncave! Light travels back to a photo sensor . laser indicting position and width of reflecting surface 50mm measurement pitch achieved at Shinkansen speeds of up to 275km/h Limited field of view and filtering allows for inspection in daylight conditions Conytah 20Htach HighTech Fine Syst Cor Aighisresanad. 26 3-5 On-board processor HITACHI Inspire the Next Operation panel “ES Sh a = } eouiooJ: TAR Se ae on eile iele ree ame | et a Eee a 8 pu ; Es Tame eS = ———— ‘copii 2013Htaen gh Tesh Fine Stems Corp. A igs xered, 272-5 On-board processor HITACHI Inspire the Next a Waveform display 2-5 On-board processor HITACHI Inspire the Next pm EE Pantograph & cable imagery pire ce Dot rot Conyrshit 2019180 Hh Ten Fne yams Cap. A igs esered 292-6 Ground-based processor HITACHI Inspire the Next Data base €| Ble] eo MBE | fae] axe | mene [on |ae| mone umn] oereem areal Tae | sper [Pol as or see eet ase et Sot rae Copyigh201s!taciHighTe=r Fine Stans Co. Aight recored, 30 2-6 Ground-based processor HITACHI Inspire the Next Data list records \Copyigns 2013tecHah-Tech ine Systoms Gop Algusresenes. 312-6 Ground-based processor Boer Waveform chart records a SS a Er) aw) Ceopyrehae 201shaen High Ten Fine Stems Com. Al gis ronened 32 2-6 Ground-based processor aa LL Excursion control settings 5 ae AR TETE ee 9 a | i AURalatareom (Tia | | etm ao omemtar [HEERSaaTes || erartnacun xartmecea ET FR ‘Toa ea Seals earca 94000) —| ER] ig) 8600 ae lspge| sco _ 4000 Cop 2013Haeh HighTech Fine Systm Corp Age reaned. 333-3 OHE Crossover Inspection ace Measuring irregularities in crossover line and clasps Crossover line Check crossover line height as crossover line approaches from the side Measure the Angle of Clasps holding the overhead conductor Crossover line approach height Interference sensor Crossover in; Angle of Clasps Crossover line sensor Cong 201staen High-Tech Fe Systns Crp Aegis reserved. 34 3-4 Mast detection principle (EACH Support structure (catenary clasp, damper etc.) , Reflection Hi Measurement conditions sensor Measurement metned | - Non-contact Vehicle + Daytime measurements Sar Measuring speed | ~ Operating speed Copy 20:3Het Hpy-Teat Fine Stone Cap. Al us enedHITACHI Inspire the Next 0 RR RTE 4. Railway Inspection Systems Coprihto 20 3tect High Tech Fre Systems Com Allotiacesenad 36, 4.1 Railway Inspection Product Lineup HITACHI Inspire the Next a Doctor Yellow Inspection Car Sedu alee ay Erectus These inspection cars for use on Shinkansen lines provide world-class high-speed, real-time processing, They are of the same dual-bogie configuration as the actual Shinkansen, so a laser beam is used as the reference line rather than the car body. Track Geometry Inspection eens Inspection Items @ Longitudinal Level @ Alignment @ Cable wear: 0.2mm (contact surface) & Accuracy @ Gauge @ Cross-Level 6) Twist @ Displacement: 10mm © Other measurements @ Height: 10mm Repeatability within 0.3mm (std. dev.) @ Other measurements Measurement Pitch 25cm Sem This type of equipment combines a total of 38 measurements, conducting frequent and regular inspections at the same speed as revenue trains Copyrint 20aHtacn High-Tech Fine Spars Corp Allis esanedHITACHI Inspire the Next 4.2 Vehicle installation 1. Road-rail vehicles (one example) HITACHI Inspire the Next 4.2 Vehicle installation 2. Rail-bound maintenance vehiclesHITACHI Inspire the Next END © SSS SSS ESTES] Railway Inspection Systems Rail and Contact Line Inspection Technology for Safe and Reliable Railway Traffic 7ITI2014 Brian Rattray Social Infrastructure Design Dept. Hitachi High-Tech Fine Systems Corporation Copyght© 201siacn Heh Tech Fine Seams Core Al ghisresred 40 HITACHI Inspire the NextSurveillance cameras HA LS Forward and rear facing video camera systems Cameras can be mounted internally or externally on fixed or movable stages Automated panttilt stage can move the camera to the desired field of view according to railway structure, e.g. tangent or curved track. “IHigh-Tec Fine Sytem Cor. Aishis reseed, 42 HITACHI Construction clearance Inspire the Next Tunnel Cross-Section Inspection Car Structural Clearance Inspection Car Structure Kinematic envelope’ Beam rotation gauges. \ JLoading gauge i (Wehicle Limit) direction cross-section Toavoid contact with structures or vegetation, clearance must be maintained between the vehicle and construction limits _\Laser Displacement Performance Performance ‘Sensor Measurement method | « Non-contact contact + Daytime measurements Measurement method Measuring speed | « Operating speed Mocaling spect * Operating speed Copii 20a igh Tech Fine Syston Corp. Al ight soredRail flaw detection equipment ee. @ Features + Ultrasonic wheel probe technology measuring reflections from defects inside the head, web and foot ofthe rail + High precision measurement is realized by combining a high precision laser displacement sensor with an accelerometer based inertial system, = Capable of fine pitch measurement + Data can be compared to historical records. I Equipment composition (typical) @ Wheel probes (3 types) 6 units (3 per rail) @ US channel 14 total (470', @® Test carriage 1 set @® Control Unit 1set ® Ground-based processor 1 set i Measurement conditions Measurement ich | «mm (pica) Measuring speed | » Max S6krvh (@émm phy cenieno 201 Hon Teen Fn Stns Cor Ah eine i i HITACHI Rail flaw detection equipment resp nee Ned @ Specifications @® Measurement items and precision Reticneca eeeticnontene) Detection method Pulse-echo (lateral channel operates in pitch-catch mode) Measurement direction _both forward and reverse Measurement pitch 4mm (adjustable in range 1~9mm) ‘Water usage 6 litersikm approx. @ Measurement speed capability 0~36km/h (std. configuration) OR max.80km/h (5 wheel probe configuration) @® Environmental conditions Temperature of surroundings: 0~55°C (external equipment) 10~55°C (external equipment) Relative humidity: 35~85% (no condensation) Applicable standards: Js ‘Copyaht® 2019Hkaeh Heh Tech Fino Systm Com Al ghieeeoned 45HITACHI Inspire the Next Rail flaw detection equipment @ Detection characteristics Rail Foot Corrosion & Corresponding UltraWave C-scan rem Dead Zone: 9, Sm 40, mm (0 Copii 2013Hiochi High Tach Fine Systen Cop Alig saree, 46.