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In the rail industry, the integrity of wheels and tracks is paramount for safe and efficient operations. XMPro’s solution focuses on monitoring wear and tear to prevent derailments and reduce maintenance costs.
Rail systems face significant challenges in maintaining the health of wheels and tracks:
XMPro’s solution for wheel and track wear monitoring leverages advanced sensors and analytics to ensure rail safety and performance. It continuously monitors key parameters like wheel wear, track wear, axle load, and vibration. Using machine learning algorithms, the system predicts issues before they escalate, providing real-time alerts for maintenance teams. Configurable dashboards display critical data such as wheel and track wear metrics, axle loads, and vibration amplitudes. Predictive insights optimize maintenance schedules based on actual conditions rather than fixed intervals. An asset overview map shows the status of trains, tracks, and crossings, with real-time recommendations for immediate attention. This technology enhances safety, operational efficiency, and the lifespan of both wheels and tracks.
XMPRO’s Data Stream Designer lets you visually design the data flow and orchestration for your real-time applications. Our drag & drop connectors make it easy to bring in real-time data from a variety of sources, add contextual data from systems like EAM, apply native and third-party analytics and initiate actions based on events in your data.
Figure 1: Wheel Wear Condition Monitoring Data Stream
This wheel wear condition monitoring data stream ingests real-time data from sensors measuring wheel profile, wheel vibration, track profile, and GPS timestamps. The data is combined with telemetry data and broadcasted for further analysis.Critical thresholds are continuously checked to flag high-risk conditions, generating alerts for the maintenance team. An anomaly detection model identifies subtle issues in the wheel and track wear, while a Predictive LSTM model forecasts wheel component longevity, providing insights into the Remaining Useful Life (RUL) of the wheels.
XMPRO Recommendations are advanced event alerts that combine alerts, actions, and monitoring. You can create recommendations based on business rules and AI logic to recommend the best next actions to take when a certain event happens. You can also monitor the actions against the outcomes they create to continuously improve your decision-making.
Figure 1: Example Recommendation: Wheel Wear Threshold
This wheel wear threshold recommendation identifies an issue with the wheel exceeding predefined safety limits. It provides event data, including wheel wear depth, axle load, vibration amplitude, bearing temperature, timestamp, and wheel ID. Users can add notes, mark the recommendation as solved or a false positive, and create a work request with special instructions if necessary. This recommendation helps ensure timely maintenance actions to address the issue and maintain safe railway operations
Figure 2. Configure With Granular Rule Logic
This example wheel wear recommendation configuration allows users to set up granular rule logic. The interface enables selecting metrics such as wheel vibration, bearing temperature, and spring compression, and setting specific thresholds to trigger alerts. Users can categorize recommendations, enable execution order, and auto-escalate critical issues.
The XMPro App Designer is a no code event intelligence application development platform. It enables Subject Matter Experts (SMEs) to create and deploy real-time intelligent digital twins without programming. This means that SMEs can build apps in days or weeks without further overloading IT, enabling your organization to accelerate and scale your digital transformation.
Figure 1. Real-Time Rail Asset Overview Dashboard
This dashboard provides a real-time view of rail assets with an interactive map that updates GPS coordinates of trains and track issues, offering a clear visual of railway lines. Each asset is marked with a color-coded status icon indicating its operational state, including alerts and error messages. The dashboard shows the overall status of asset categories like trains, crossings, tracks, maintenance vehicles, and substations, and highlights active recommendations from the system’s rule logic, such as exceeded bogie wear thresholds.
This comprehensive view ensures that users have all the necessary information at their fingertips to monitor and manage rail assets efficiently, respond quickly to issues, and maintain optimal operational performance.
Figure 2. Asset Class Drilldown View
The Asset Class Drilldown view provides an in-depth analysis of rail track lines, presenting a comprehensive overview of current track alerts and work order statuses. It features a bar chart displaying the number of track lines with open alerts categorized by severity (high, medium, and no alerts) and a pie chart summarizing the status of current work orders (available, planning, and waiting). The asset list below details individual track lines, showing their last service dates, recommendations, and upcoming service schedules, allowing users to prioritize maintenance needs efficiently. Key metrics for the past 30 days, including new alerts, work requests, work orders, and time to resolution, are displayed for performance tracking.
Key Features:
This dashboard is designed for ease of use, allowing quick access to vital information and efficient management of train assets.
Figure 3. Wheel Wear Asset Analysis View
The “Asset Analysis – Wheel Wear” view offers a detailed examination of the wheel wear condition for a specific train. Key metrics such as wheel wear depth, axle load, bearing temperature, and vibration amplitude are displayed at the top, providing real-time data and thresholds for quick assessment. The central section features a visual representation of the wheel, highlighting specific issues such as exceeded wear thresholds, with precise identification and error codes for easy response. To the right, the remaining useful life (RUL) prediction graph compares actual versus predicted RUL. Below, the running status of the wheel, including its train type, make, and description, is detailed for comprehensive monitoring.
Key Features:
This Asset Analysis View is designed to provide users with a holistic understanding of Train T001, combining detailed visual models with actionable data and AI-assisted insights for effective asset management.
Experience the transformative power of XMPro’s Intelligent Business Operations Suite (iBOS) – Featuring comprehensive AI capabilities, XMPro iBOS helps to significantly increase product yield, drastically reduce downtime, and ultimately eliminate unexpected business events.
Figure 1: Embedded AI Example – Wheel Wear & Track Wear
Embedding XMPro AI Agents in XMPro Data Streams enables executable AI and machine learning for algorithmic business processes, significantly enhancing the capabilities of operational digital twins. This integration allows for advanced features such as real-time analytics, MLOps, and seamless embedding of AI into core business processes.
In this example of wheel wear condition monitoring, XMPro’s AI Agents empower the data stream to accurately identify and predict potential wheel wear issues. The process begins with the ingestion of real-time sensor data, including wheel profile, wheel vibration, track profile, and GPS timestamps. The data is normalized and contextualized with telemetry and operational information from digital twins.
Machine learning models, including anomaly detection and remaining useful life (RUL) prediction, are applied to detect deviations and forecast maintenance needs. The results are filtered, merged, and broadcasted for further action. The data stream generates actionable insights for maintenance scheduling and resource allocation, ensuring optimal wheel performance and minimizing the risk of failures.
XMPro offers a variety of AI agents to support diverse operational needs, including:
By embedding these powerful AI agents, XMPro transforms AI models into valuable assets that drive business growth and efficiency, bridging the gap between data flow and operational AI.
XMPro’s Intelligent Business Operations Suite (iBOS) is uniquely equipped to address the complexities of Wheel Wear Monitoring in the rail industry, utilizing cutting-edge technology and analytics. Here’s how XMPro iBOS excels in this application:
XMPro iBOS allows users to craft an intelligent digital twin of the bogie components, enabling detailed simulation and analysis. This virtual model is crucial for assessing wear patterns and predicting maintenance needs, enhancing the accuracy of anomaly detection.
Featuring a robust integration library, XMPro iBOS seamlessly incorporates data from various sensors, including vibration and temperature sensors on bogies. This integration is key to transforming raw data into meaningful insights for predictive maintenance.
Utilizing machine learning algorithms, XMPro iBOS analyzes sensor data to identify anomalies that indicate abnormal wear. This approach allows for early detection of potential issues that could lead to derailments or other safety hazards.
By analyzing wear patterns and predicting maintenance needs, XMPro iBOS helps optimize maintenance schedules. This shift from fixed-interval to condition-based maintenance reduces costs and prevents unnecessary downtime.
The system provides instant alerts on emerging bogie issues, coupled with decision support tools. This feature aids maintenance teams in prioritizing actions based on the criticality of the detected anomalies.
XMPro iBOS includes adaptable dashboards that display vital bogie health data, alongside comprehensive reporting features for maintenance planning and compliance purposes.
Designed for scalability and flexibility, XMPro iBOS can be tailored to various rail network sizes and integrates effortlessly with diverse sensor technologies. Its rapid deployment capability ensures a quick realization of value.
By enabling proactive maintenance and early wear detection, XMPro iBOS significantly enhances the safety and operational efficiency of rail systems, reducing accident risks and ensuring reliable service.
Utilize XMPro blueprints, pre-configured for bogie health monitoring, to quickly set up the digital twin dashboard. These blueprints integrate industry best practices, ensuring a swift and effective implementation.
In essence, XMPro iBOS offers a holistic, real-time, predictive, and integrated approach to bogie health monitoring. Its advanced capabilities in digital twin modeling, data integration, machine learning, and configurable dashboards make it an invaluable asset for ensuring the safety and efficiency of rail operations.
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