SmartPlug Rail Force Monitoring Device
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1 SmartPlug Rail Force Monitoring Device Presented by: John Kidd QinetiQ North America Technology Solutions Group June 14,
2 Thermal Loads in Welded Rail Continuous Welded Rail (CWR) Thermal expansion of rail steel Welded rail constrained (no bolted/expansion joints) Develop longitudinal forces in rail Rail Neutral Temperature (RNT) High rail temperatures cause compression Low temperature tension Rail neutral temperature occurs in the transition between tension/compression, when the rail has no force
3 Monitoring Status of CWR Track RNT changes with time (daily, seasonally, etc.) SmartPlug captures RNT value SmartPlug Monitors changes in RNT and rail temperature High rail force can cause track failure SmartPlug calculates rail force (using RNT and rail temperature) SmartPlug sends alert for track failure or high risk of failure
4 Data Measurement Changes in RNT and rail force are calculated from measured parameters (longitudinal strain and rail temperature) Attaching strain gages to rail with strain gage welder Measuring rail strain with strain gage indicator
5 RNT Determination at Rail Cut Actual value of RNT is determined by measuring the strain while the rail is cut (no tension/compression) Gap is cut into rail and rail is pulled together prior to weld to elevate RNT Rail Cut / Rail Gap SmartPlug measures rail temperature SmartPlug calculates proper gap for target RNT
6 De-Stressing Operations during Field Weld Prototype Sensor Units Hydraulic tensors pull rail together to elevate RNT Field Weld (Cooling) SmartPlug measures changes in strain and rail temperatures Hydraulic Tensors SmartPlug calculates RNT (post-weld) and monitors changes in RNT
7 Proof of Concept Prototypes (Wayside Access) Includes strain and temperature sensors Printed circuit board with processor and local memory for data storage Short range RF communications(15-50 feet range for wayside application)
8 Prototype Data (collection) Rail Force/RNT Data Collection Field Weld/De-Stress Operations
9 Rail Temperature and RNT (F) Prototype Data Rail Temp RNT Time (Hrs)
10 RNT and Rail Temperature (Degrees (F)) Prototype Data (Rail Temp and RNT prior to field weld) 160 February 25 - April 7 (Bolted w/joint bars untill April 5, then De-stressed & Welded) RNT shoots up while de-stressed with tensors, then welded 140 Slight drop in RNT when tensors are released 120 New stress (tension) is distributed locally into undisturbed rail with rail traffic, causing RNT to taper off to "equilibrium" 100 Prior to weld, RNT is free to increase w/rail temp (due to slop in bolted connection) RNT Rail Temp Time (Hours after installation)
11 Tr & RNT (degrees), strain (microstrain) Prototype Data (Rail Temp, RNT, Rail Force) DATA - POST WELD RNT Rail Force Rail Temperature Time (hours)
12 New SmartPlug (Specifications) System Specifications Dimensions: Weight: Battery Life: Power Usage: Range: 1.2 x3 x14 6 Lbs. 1 year 26 mamp seconds 1 mile Operating Frequency: MHz Strain Gages: 350 Ohm Operating Temperature: -40F to 180F Zero Calibration: Performed at rail cut, maintained after battery replacement Data Storage: 6 months data storage at 1 hour data collection frequency Installation: Magnetic, non-destructive Sensor Unit Mounts on Rail Performance Specifications Calculates recommended rail gap and displays Real-Time graph of RNT during destressing operations Monitors for track failure at 10 Minute intervals sends message immediately Sends dailey data for track status
13 New SmartPlug Communications Schematic Established long range communication path for data Chain of sensors perform condition and failure monitoring Data is sent to tower Tower uploads data to web accessible database Query data for location, rail force, high rail temperatures, etc
14 New SmartPlug Data Paths to GIS Database
15 Field Testing for Communications Range Field tested long range communications signal Achieved > 1 mile range on both tangent and curved track Develop webaccessible GIS and database for all sensor data Graphical display of sensor and calculated data for maintenance prioritization and risk analysis Tangent track range test Curved track range test Monitor for track failures and send and phone calls to emergency contacts
16 SmartPlug Database/GIS (Specifications) Database for all SmartPlug data will work off of a GIS platform Web accessible Sort and Query functions Graphical Display Data (rail temp., RNT, rail force versus time) Lat/Lon GPS and milepost locations Data from track charts and other site data Google-Earth type birds eye views Current and forecasted site weather data Uploads data from sensors and data dump from roving collector units Auto-send alert function (phone/ ) for track failure conditions
17 SmartPlug Thank You
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