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Final Report for Public Distribution WHEEL INSPECTION SYSTEM ENVIRONMENT QUALIFICATION AND VALIDATION Final Report for Public Distribution Prepared for: THE NEW YORK STATE ENERGY RESEARCH AND DEVELOPMENT AUTHORITY AND THE NEW YORK STATE DEPARTMENT OF TRANSPORTATION Albany, NY Prepared By: INTERNATIONAL ELECTRONIC MACHINES CORPORATION 850 River Street Troy, NY 12180 Zack Mian Project Manager NYSERDA Project #9816 NYSDOT Project #C-06-31 Final Report March 20, 2009 0 Notice This report was prepared by International Electronic Machines Corporation in the course of performing work contracted for and sponsored by the New York State Energy Research Development Authority and the New York State Department of Transportation (hereafter the “Sponsors”). The opinions expressed in this report do not necessarily reflect those of the Sponsors or the State of New York, and reference to any specific product, service, process, or method does not constitute an implied or expressed recommendation or endorsement of it. Further, the Sponsors and the State of New York make no warranties or representations, expressed or implied, as to the fitness for particular purpose or merchantability of any product, apparatus, or service, or the usefulness, completeness, or accuracy of any processes, methods, or other information contained, described, disclosed, or referred to in this report. The Sponsors, the State of New York, and the contractor make no representation that the use of any product, apparatus, process, method or other information will not infringe privately owned rights and will assume no liability for any loss, injury, or damage resulting from, or occurring in connection with, the use of information contained, described, disclosed, or referred to in this report. Disclaimer The contents of this report reflect the view of the author who is responsible for the facts and accuracy of the data presented herein. The contents do not necessarily reflect the official views or policies of the New York State Department of Transportation, the United States Department of Transportation, or the Federal Highway Administration. This report does not constitute a standard, specification, regulation, product endorsement, or an endorsement of manufacturers. i DOT Form 1700.7 1. Report No. 2. Government Accession 3. Recipient's Catalog No. No. C-06-31 4. Title and Subtitle 5. Report Date Wheel Inspection System Environment Final Report November 18, 2008 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report Zack Mian, Project Manager No. 9.Amy Performing Lehman Organization Name and Address: 10. Work Unit No. International Electronic Machines Corporation 11. Contract or Grant No. 850 River Street Troy, NY 12180 12. Sponsoring Agency Name and Address 13. Type of Report and Period Final Report NYS Department of Transportation Covered: 50 Wolf Road Albany, NY 12232 14. Sponsoring Agency Code 15. Supplementary Notes: Project funded in part with funds from the Federal Highway Administration 16. Abstract International Electronic Machines Corporation (IEM) has developed and is now marketing a state-of-the-art Wheel Inspection System Environment (WISE). WISE provides wheel profile and dimensional measurements, i.e. rim thickness, flange height, flange thickness, flange angle, diameter, reference groove; brake pad thickness measurements; and flags out-of-round wheels and flat spots. WISE provides modules for: wheel profile, crack detection, flat spot detection and brake pad management system. It easily integrates with existing way-side equipment and works seamlessly with existing railroad rolling stock management systems. During this project, IEM has completed the successful installation of the WISE modules for wheel profile, crack detection and brake pad management at the CSX Transportation hump yard in Selkirk, NY. This report details the thorough testing and validation of these modules through the project that was funded jointly by NYSERDA and NYSDOT. IEM is in advanced talks with Class 1 railroads regarding WISE, and has been selected to install WISE in the new transit system in Sydney, Australia. 18. Distribution Statement 17. Key Words Non-contact wheel measurements, Wheel profile, EMAT, Wayside system 19. Security Classif. (of this report) 20. Security Classif. (of 21. No. of Pages 22. Price Unclassified this page) 23 Unclassified Form DOT F 1700.7 (8-72) ii Abstract International Electronic Machines Corporation (IEM) has developed and is now marketing a state-of-the- art Wheel Inspection System Environment (WISE). WISE provides wheel profile measurements, i.e. rim thickness, flange height, flange thickness, flange angle, diameter, reference groove; brake pad thickness measurements; and crack detection. WISE provides modules for: wheel profile, crack detection, flat spot detection and brake pad management system. It easily integrates with existing way-side equipment and works seamlessly with existing railroad rolling stock management systems. During this project, IEM has completed the successful installation of the WISE modules for wheel profile, crack detection and brake pad management at a freight hump yard in Selkirk, NY. This report details the thorough testing and validation of these modules through the project that was funded jointly by New York State Energy Research Development Authority and New York State Department of Transportation. IEM is in advanced talks with Class 1 railroads regarding WISE, and has been selected to install WISE in the new transit system in Sydney, Australia. Keywords Non-contact wheel measurements, Wheel profile, EMAT, Wayside system iii Table of Contents Notice ............................................................................................................................................................. i Disclaimer ...................................................................................................................................................... i DOT Form 1700.7 ......................................................................................................................................... ii Abstract ........................................................................................................................................................ iii Table of Contents ......................................................................................................................................... iv List of Figures ............................................................................................................................................... v List of Tables ................................................................................................................................................ v Executive Summary ...................................................................................................................................... 1 Introduction ................................................................................................................................................... 2 Identification of the Transportation Problem ............................................................................................ 2 The WISE Solution ................................................................................................................................... 2 Benefits ..................................................................................................................................................... 3 Environmental Benefits......................................................................................................................... 3 Economic Benefits ................................................................................................................................ 4 Safety Benefits ...................................................................................................................................... 4 Installation of the WISE System ................................................................................................................... 5 WISE Modules .............................................................................................................................................. 5 Wheel Profile Module ............................................................................................................................... 5 Testing Profile ....................................................................................................................................... 5 Adjustments of False Positives ................................................................................................................. 6 Brake Pad Management System ............................................................................................................... 7 Testing BPMS ....................................................................................................................................... 8 Crack Detection System ............................................................................................................................ 8 Testing Crack ........................................................................................................................................ 9 Marketing WISE ......................................................................................................................................... 12 Summary ....................................................................................................................................................
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