❱❱ Below: axle bearing come under particularly heavy and varying loads during use on the railway


network; bottom left to right: sensors are built into a complete control and data acquisition environment; the condition monitoring test rig can accommodate complete rail wheelsets; and for testing, axles are loaded onto a powered test rig with sensors attached to a data acquisition and analysis system


SMARTCHECK SENSOR


The compact and modular SmartCheck sensor from Schaeffler, above, can perform online measurements for the decentralised and continuous monitoring of machinery and process parameters. It is particularly


Local public transport with regional rail vehicles


is part of the operator’s core business so low maintenance costs and high train availability are crucial factors for the company. Any downtime or delays can mean considerable costs and fines. In order to ensure the best possible availability,


the gearboxes and wheels of all the wheelsets, including their axle and gearbox bearings, are regularly inspected, overhauled or replaced. The operator needed a system that would ensure reliability and accuracy of checks, while minimising train downtime. With its condition monitoring test rig for railway gearboxes and axlebox bearings, Schaeffler implemented a cost-effective method optimised for the customer’s specific application.


ROBUST SENSORS The system uses Schaeffler SmartCheck sensors. These are simply attached to the components to be monitored using magnets and undertake precise measurements of vibration and temperature without a requirement for further installation outlay. Components monitored include gears in gearboxes, gearbox bearings, wheel axles and axle box bearings. For data acquisition and analysis, the sensors are


connected via a Schaeffler SmartController to the input and output terminals of an acquisition system, such as an HMI touchscreen panel, an external monitor and alarm, and data processing systems. During a test run, an integrated electric motor is


used to drive the axles. As well as monitoring vibration, temperature, speed and bearing end position, the system can also check if the bearings have been correctly mounted, for example, after replacement.


LOWER INVESTMENT For the Asian rail operator, the integrated system for the inspection of gearboxes and wheelsets is an important tool in eliminating unplanned downtime and to avoid malfunctions in rail applications. The investment in the test rig is also significantly lower compared to the cost of complex onboard monitoring systems, which are often used in long distance trains. By adequately planning maintenance intervals during which the monitoring takes place, there is no need for the complexities of constant onboard monitoring. In addition, the rail operator gains benefits


through reliable and very precise monitoring, simple and full integration with its own systems and infrastructure and a user-friendly method of performing the monitoring. The gearboxes can be inspected without


dismantling them or changing the oil and the bearings can be similarly inspected without removing them or having to replace any seals. Once the monitoring is completed, if any bearings are replaced, they can be checked again for correct mounting using the same equipment. Unplanned downtime of trains can always result


in direct and indirect costs for rail operators. The reputation of the operator can also be damaged, particularly in public transport applications. In this particular case, there is an additional significant risk because any downtime or delays in rail traffic is penalised with severe financial penalties stipulated by national regulations. Following the positive experience with Schaeffler’s


test rig, the customer is now planning to use the system at other locations. T&TH


suitable for the early detection of roller bearing damage as well as imbalances and misalignments on motors, vacuum and fluid pumps, ventilators and fans and gearboxes and compressors as well as spindles and machine tools. The sensor has


predefined parameter presets for monitoring and has an integrated bearing database, which can be accessed when using the parameter presets. The presets can be easily adapted to specific monitoring tasks with the aid of assistants. SmartCheck is


Power-over-Ethernet (PoE) enabled so does not need separate power cabling and can use both Fieldbus and Ethernet TCP/IP protocols. With service and maintenance functions rapidly being incorporated into digital Industry 4.0 enterprises, the SmartCheck sensor is compatible with such environments.


December 2019 /// Testing & Test Houses /// 23


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