Тел./факс: 8 (812) 449-88-19
E-Mail: info@metkatom.com
Санкт-Петербург
ул. Олеко Дундича, 40

On-board acoustic emission diagnostics system of bearing units

FUNCTION

On-board acoustic emission diagnostics system of bearing units is intended for the constant control monitoring of axle boxes and operating generator bearing units condition; it allows to:

  • control bearing units condition in the real-time mode;
  • quickly inform the train crew and wagon depot workers about incipient malfunctions and generate guidance on further operation;
  • save current parameters for condition database storage with the purpose of residual life prediction and generating guidance on maintenance.

ADVANTAGES

  • on-line control of bearing units operating condition;
  • immediate data communication to train and locomotive crew;
  • possibility to switch to periodic scheduled work performance based on the results of diagnosis;
  • possibility of lubricating workload reduction and lubricant saving;
  • possibility of overhaul life increase;
  • possibility of efficient use in international and high-speed traffic.

ON-BOARD DIAGNOSTICS SYSTEM STRUCTURE

  • acoustic emission sensors set -12 it.;
  • communication lines;
  • modem -1it.;
  • junction boxes;
  • central analytic unit – ARP-11/4 - 3 sets;
  • color graphic terminal -1it.;
  • nonvolatile memory card -1it.;
  • adapter module -1it.

DEVELOPMENT CENTRE, BASE ADOPTION ENTERPRISE

Developer: OOO METKATOM.
System blocks delivery, personnel training, technology of diagnosis.

DELIVERY DATE

System delivery and installation is performed within three months.

SYSTEM COST

The cost of on-board 12-channel system (for a passenger carriage with an undercar electricity generator) and system cost in case of equipping carriage pilot batch is specified at the contract conclusion.

ON-BOARD CONTROL SYSTEM STRUCTURE CHART

COST EFFECTIVENESS CALCULATION OF ON-BOARD ACOUSTIC EMISSION DIAGNOSTICS SYSTEM OF PASSENGER CARRIAGES BEARING UNITS ADOPTION

PRESENT CARRIAGE PREVENTIVE MAINTENANCE SYSTEM ON-BOARD DIAGNOSTICS SYSTEM ADOPTION FOR PASSENGER CARRIAGES
Periodic preventive maintenance and repair work costs with present maintenance system TO-3→TR→DR→KR are ≈ 600,000 roubles per carriage a year, out of which 10-15 % (≈ 90,000 roubles) are wheelpairs and undercar gears maintenance costs. On-board diagnostic system allows to reduce unreasonable expenses, thereby units maintenance estimated expenditures according to their actual condition will be ≈ 20-25 % (≈ 20,000 roubles). Hereby annual saving rate will be SR= 90-20 = 70,000 roubles per equipped carriage.
Lubricant costs with the present lubricating system (at the cost of 1 kg of BUKSOL lubricant 50 roubles) are ≈ 30,000 roubles per carriage a year. Bearing units lubrication according to their actual need allows to reduce unreasonable operations of lubricant final squeezing and reduce lubricant consumption by 45-50 % ( ≈ 15,000 roubles per carriage a year). Hereby annual saving rate will be SR = 30-15 = 15,000 roubles per equipped carriage.
Preventive maintenance costs according to structure TO-3→TR→DR→KR with the existing norms of overhaul life are ≈ 945,000 roubles per carriage a year. On-board diagnostics system of bearing units adoption allows to increase overhaul life by 20-25 % of the existing norms (≈ 750,000 roubles per carriage a year). Hereby annual saving rate will be SR = 945-700 = 245,000 roubles per equipped carriage.

TOTAL ANNUAL SAVING RATE

Per equipped carriage SR= 70+15+245=331,000 roubles
Per wagon depot (with the average rolling stock of 300 carriage units) SR=331 х 300=99,300,000 roubles
Per wagon depots network (8-10 wagon depots) SR=99,3 х 10=993,000,000 roubles