Project of on-board acoustic emission diagnostics system of passenger carriage 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) with account of installation and personnel training is included in the contract.

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 diagnostics 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

OOO METKATOM technical director: V.S. Potapenko
Candidate of Science {Engineering}: D.V. Fedorov