Big data for free (almost)

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1 Big data for free (almost) Volker Brundisch Product Manager Mechatronics

2 4.bp.blogspot.com 2017 Bombardier Inc. or its subsidiaries. All rights reserved. Invitation for big data These are some typical pictures from a typical nowadays train. Do You see the opportunity? Big Data is awaiting You! 2 x 20min.ch 2

3 Opportunities & limitations Smartphones/Tablets can provide data for 1. absolute time synchronization, frequency analysis 2. 3-axis accelerations ride comfort, vibration analysis 3. 3-axis rotation rates curvature, roll movements 4. GPS speed, geolocalisation 5. Noise HF vibration analysis Limitations are Normally, data from inside carbody only No analogue filters risk of aliasing Limited sampling rate e.g. up to 100 Hz Care needed when used in normal operation 3

4 Operation Track Vehicle Correlation, Interpretation 2017 Bombardier Inc. or its subsidiaries. All rights reserved. Coverage versus Precision Wheels Bearings Springs Diagnostics systems (FLEXX* Guide) Twist Alignment Ripples Diagnostics systems (FLEXX* Track) Track measurement units Shocks Ride smartphone Indication Vehicle response Track geometry 4 * Trademark(s) of Bombardier Inc. or its subsidiaries.

5 Data handling Present set-up: Sensor app computer for all kind of data management + very flexible + minimum initial investment + know-how re-use Vision: 1 device & 1 app which can cover all steps of the process data server Onboard units Sources Transfer Validation Processing Report Are the data relevant for the question? Test campaigns Smartphones & Tablets Needed investment in chain remains low when: 1. Data from different sources can be handled 2. Processing can be developed / tested / ported 5

6 Modes of sensor operation 1. Expert mode Sensor operation is handed over to the broad public 2. Crew mode 3. Customer mode Perfect for jumping into data collection in a reliable manner but it is not efficient to pay an expert for carrying his mobile at a specific train. Augsburger Allgemeine 2011 Let loco drivers and traveller assistants operate mobiles! (for data collection) Die Welt Guess: how many sensors will board the train soon? Challenge is to organize the data transfer (e.g. automated via bluetooth, web interface for upload, traveller app function, ) 6

7 Validation Comparison with test lab measurements Monitoring(permanent) - Smartphone (temporary) - Tablet (temporary) z..* y..* Assessment of comparison (after low pass filter at 10 Hertz corner frequency): 1) Smartphone provided in y..* and z..* almost identical signals like the monitoring 2) Tablet provided in y..* almost identical, and in z..* very similar but slightly increased, signals, whereby the deviation could potentially be explained with the local structure (wooden plate). 7

8 Accel_Z [m/s2] RMS_Accel_Z [m/s2] Accel_Y [m/s2] RMS_Accel_Y [m/s2] Accel_X [m/s2] RMS_Accel_X [m/s2] Geschwindigkeit V [km/h] Geschwindigkeit V [km/h] 2017 Bombardier Inc. or its subsidiaries. All rights reserved. Validation Comparison with test lab measurements - Data were collected during the Velim tests of ETR1000 TS01 - Smartphone dropped close to comfort sensors from the test lab - comparison were done for low-frequency content (< 1 Hz) and ride comfort values (RMS) Testbild fuer die Beschleunigungen (mit 1 Hz Tiefpass) V [km/h] x..* [m/s²] y..* [m/s²] Fahrkomfort (ISO-gewichtete RMS-Werte ueber5 sec) Zeit T [sec] BLAU = ipad-messung.sd_1121_ auf Versuchsring Velim GRUEN = Referenz-Messung.Velim im Fahrzeug.TI Zug 1 M 6 passiv,.fussboden Wagenmitte z..* [m/s²] BLAU = ipad-messung.sd_1121_ auf Versuchsring Velim GRUEN = Referenz-Messung.Velim im Fahrzeug.TI Zug 1 M 6 passiv,.fussboden Wagenmitte 8

9 PSD (z..*) [(m/s²)²/hz] 2017 Bombardier Inc. or its subsidiaries. All rights reserved. V [km/h] Example: Wheel condition If Campbell plot shows the wheel rotation frequency one wheel is not round Simple rule for 920 mm diameter wheels: V [km/h] = 10 *f [Hz] Wheel condition to be checked T [sec] 9

10 Envelope Noise spectrum 2017 Bombardier Inc. or its subsidiaries. All rights reserved. Example: Wheel flat internal noise In noise measurements, the wheel frequency is not directly visible (too low). After appropriate analysis, the wheel rotation frequency becomes evident. V est [km/h] Wheel rotation and harmonics 10

11 Example: Wheel flat passing noise Listening to wheels in passing vehicles is another potential smartphone application. Not a big thing to do an educated guess which wheelset has had a wheel flat!? Raw data Processed data 11

12 Example: Axle bearing passing noise Finding exact moment when the wheelsets are passing is already done (provided that vehicle s main geometric parameters known) Interpretation of higher energy level as indicator for a damaged bearing is plausible. Still under development: Confirmation through frequency analysis of passing noise sources Bombardier Inc. or its subsidiaries. All rights reserved. Listening to other components in passing vehicles is the next big challenge.

13 Example: Vibrations at some track section (1) 1. short-time heavy lateral vibrations 2. f ~ 7 Hz less stable bogie But where? No GPS available 3. NCA Correlation with another run 4. Location identified and reported Track & Bogies to be checked 13

14 Example: Vibrations at some track sections (2) 1. Vibrations over a longer period 2. GPS available track sections identified 3. Frequency / wavelength known Track & Bogies to be checked 14

15 Example: Vibrations at track sections (3) and (4) 2. GPS available 3. Single local peak: from a switch Track geometry to be checked V [km/h] y..* [m/s²] PSD [(m/s²)²/hz] 1. Different vibration types occurred 4. Quasi-permanent vibrations: at recently built, new track Low Body Motion (1 Hz) at low conicity track Vehicle / track interaction to be checked 15

16 More conventional data sources Not convinced yet? You think it is a toy rather than a professional tool? Go for our solutions developed in line with railway standards! FLEXX Track FLEXX Guide Car body Power Extended Controller Module (1U) Basic Controller Module (2U) Power X1 GPS Solid state PW Ext. Controller disk CAN1 CAN2 CAN3 CAN4 X1 Power Basic Controller CAN1 CAN2 CAN3 CAN4 V24 SPM IN1 IN2 IN3 IN4 X3 X4 X5 X6 X2 X3 X4 X5 X6 X7 X8 X9 X10 2+3S CB Accel 3 (3ax) Bogie 2S 2S 2S X1 X2 X3 PMA Tube SPM Sensor (Vert) SPM1 SPM Sensor (Vert) SPM2 SPM Sensor (Lat) SPM3 Left side of the axle Right side of the axle (not in scope of this presentation they are a little bit more costly ) 16

17 ? Q&A 17

18 Bombardier Inc. or its subsidiaries. All rights reserved.

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