Innovative Monitoring and Predictive Maintenance Solutions on Lightweight Wagon Grant Agreement no.: 730863 - S2R-OC-IP5-03-2015 Project Start Date: 01/11/2016 Project End Date: 30/04/2019 DELIVERABLE D1.1 Benchmark and market drivers for an integrated intelligent and lightweight wagon solution Work Package: WP 1 Deliverable type R Dissemination Level: PU Status: Final Leader beneficiary: UNEW Due date of deliverable: 31/03/2017 Actual submission date: 31/03/2017 Prepared by: Cristian Ulianov and Paul Hyde, Newcastle University (UNEW) Contributors: Sian Evans, Newcastle University (UNEW) Liang Cheng, Newcastle University (UNEW) Emmanuel Matsika, Newcastle University (UNEW) Raluca Marin-Perianu, Inertia Technology B.V. (INE) Martin Wischner, Havelländische Eisenbahn AG (HVLE) Daniele Regazzi, Lucchini RS S.p.A. (LRS) Franco Castagnetti, NewOpera Aisbl (NEWO) Giuseppe Rizzi, NewOpera Aisbl (NEWO) David Vincent, Perpetuum Ltd. (PER) Stefano Bruni, Politecnico di Milano (POLIM) Marco Macchi, Politecnico di Milano (POLIM) Dachuan Shi, Technische Universität Berlin (TUB) Philipp Krause, Technische Universität Berlin (TUB) Florentin Barbuceanu, Uzina de Vagoane Aiud S.A. (UVA) Verified by: Cristian Ulianov Deliverable D1.1 Document history Version Date Author(s) Description D1 02/12/2016 Cristian Ulianov [UNEW] Document initiated, draft structure D2 20/12/2016 Cristian Ulianov [UNEW] Document updated, structure and Paul Hyde [UNEW] content proposed D3 24/01/2017 All Update of structure and content D5 23/02/2017 All Content added and revised D6 25/03/2017 All Content added and revised – pre-final version D7 30/03/2017 All Conclusions added and revised D8 31/03/2017 Cristian Ulianov [UNEW] Integration, proof-read, and Sian Evans [UNEW] submission of final version Paul Hyde [UNEW] The INNOWAG project consortium No Partner organisation Short Name Country 1 NEWCASTLE UNIVERSITY UNEW UK 2 INERTIA TECHNOLOGY B.V INE Netherlands HAVELLANDISCHE EISENBAHN 3 HVLE Germany AKTIENGESELLSCHAFT 4 LUCCHINI RS SPA LRS Italy 5 NEW OPERA AISBL NEWO Belgium 6 PERPETUUM LIMITED PER UK 7 POLITECNICO DI MILANO POLIM Italy 8 TECHNISCHE UNIVERSITAET BERLIN TUB Germany UNION DES INDUSTRIES FERROVIAIRES 9 UNIFE Belgium EUROPEENNES 10 UZINA DE VAGOANE AIUD SA UVA Romania 11 VYZKUMNY USTAV ZELEZNICNI VUZ Czech Republic Disclaimer This report was prepared as an account of work funded by Shift2Rail Joint Undertaking. The contents of this document are provided “AS IS”, and no guarantee or warranty is provided that the information is fit for particular purposes. The information, analyses and views set out in this report are those of the author(s) and do not necessarily reflect the official opinion of the European Union. Neither the Community institutions and bodies, nor any person acting on their behalf may be held responsible for the use which may be made of the information contained therein. The user, thereof, uses the information at its sole risk and liability. Copyright notice © 2016 – 2019 INNOWAG Consortium 2 / 169 Deliverable D1.1 Table of Contents Executive Summary ................................................................................................................... 5 List of abbreviations ................................................................................................................ 6 List of figures .......................................................................................................................... 7 List of tables ......................................................................................................................... 10 1. INTRODUCTION ............................................................................................................... 11 2. OVERVIEW OF MARKET DRIVERS AND TRENDS ......................................................... 12 2.1 Freight market drivers ................................................................................................ 12 2.1.1 External freight market drivers ............................................................................. 12 2.1.2 Internal freight market drivers .............................................................................. 14 2.2 Trends and opportunities in railway freight market ..................................................... 18 2.2.1 Global Market Trends .......................................................................................... 18 2.2.2 EU Market trends ................................................................................................ 19 2.3 Concluding remarks ................................................................................................... 26 3. OVERVIEW AND ASSESSMENT OF EXISTING AND EMERGING SOLUTIONS ............ 27 3.1 Sensors ...................................................................................................................... 27 3.1.1 Specific market drivers and trends ...................................................................... 27 3.1.2 Overview of existing and emerging solutions ....................................................... 30 3.1.3 Assessment and recommendations for further work ............................................ 44 3.2 Energy harvesting technologies ................................................................................. 44 3.2.1 Specific market drivers and trends ...................................................................... 44 3.2.2 Overview of existing and emerging solutions ....................................................... 45 3.2.3 Assessment and recommendations for further work ............................................ 51 3.3 Identification and tracing technologies ........................................................................ 52 3.3.1 Specific market drivers and trends ...................................................................... 52 3.3.2 Overview of existing and emerging solutions ....................................................... 54 3.3.3 Assessment and recommendations for further work ............................................ 58 3.4 Data communication technologies .............................................................................. 60 3.4.1 Inside train communication .................................................................................. 60 3.4.2 Outside train communication ............................................................................... 61 3.4.3 Assessment and recommendations for further work ............................................ 65 3.5 Big data management solutions ................................................................................. 65 3.5.1 Specific market drivers and trends ...................................................................... 65 3.5.2 Overview of existing and emerging solutions ....................................................... 66 3.5.3 Assessment and recommendations for further work ............................................ 69 3.6 Design solutions for lightweight vehicles .................................................................... 70 3.6.1 Specific market drivers and trends ...................................................................... 70 3.6.2 Overview of existing and emerging solutions ....................................................... 73 3.6.3 Assessment and recommendations for further work ............................................ 98 3.7 Lightweight materials for vehicle technologies .......................................................... 100 3 / 169 Deliverable D1.1 3.7.1 Specific market drivers and trends .....................................................................100 3.7.2 Overview of existing and emerging solutions .....................................................101 3.7.3 Assessment and recommendations for further work ..........................................108 3.8 Analysis and testing of lightweight railway vehicles ...................................................109 3.8.1 Specific market drivers and trends .....................................................................109 3.8.2 Overview of existing and emerging solutions .....................................................109 3.8.3 Assessment and recommendations for further work ..........................................113 3.9 Simulation tools and predictive models for predictive maintenance ...........................114 3.9.1 Specific market drivers and trends .....................................................................114 3.9.2 Overview of existing and emerging solutions .....................................................115 3.9.3 Assessment and recommendations for further work ..........................................126 3.10 Maintenance management solutions .........................................................................127 3.10.1 Specific market drivers and trends .....................................................................127 3.10.2 Overview of existing and emerging solutions .....................................................128 3.10.3 Assessment and recommendations for further work ..........................................136 4. OVERVIEW AND ASSESSMENT OF INTEGRATED SOLUTIONS .................................137 4.1 Specific market drivers and trends ............................................................................137 4.2 Overview of existing and emerging integrated solutions ............................................137 4.2.1 Condition based maintenance and Condition monitoring