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Referenz 1. März 2020

„Condition Based Monitoring“ im Rolling Stock

Die Instandhaltung von Schienenfahrzeugen soll effektiver, zeitsparender und kostengünstiger werden – all das verspricht „Condition Based Monitoring“. Wie Bahnbetreiber die Zustandsüberwachung ihrer Fahrzeuge auf der Schiene realisieren können, zeigt die Westfälische Lokomotiv-Fabrik Reuschling GmbH & Co. KG.

Die Fahrweise einer Lok im Betrieb ist entscheidend dafür, wie schnell Bauteile verschleißen oder Betriebsstoffe altern. Daher ist es sinnvoll, den Zustand von Schienenfahrzeugen permanent zu überwachen. Dieser Vorgang wird auch „Condition Based Monitoring“ genannt. „Wenn wir die Belastungen kennen, können wir die Fahrzeuge dynamisch warten. Dafür brauchen wir aber Daten“, erklärt Udo Pinders, Geschäftsführer bei Reuschling. Die Westfälische Lokomotiv-Fabrik ist europaweit bekannt als kompetenter und zuverlässiger Partner bei der Instandsetzung und Modernisierung von Schienenfahrzeugen jeglicher Art.

Für einen effektiven Service und eine zustandsorientierte Wartung setzt das Unternehmen aus Hattingen auf ein modulares System mit Cloud-Anbindung. Dabei bildet Automatisierungstechnik von WAGO die Schnittstelle zu einem webbasierten System für das Flottenmanagement auf der Schiene – dem J.I.M-Portal. Es steht für „Jobbased Intelligent Monitoring“. Das bedeutet: Statt nur auf die Betriebszeiten zu achten, ermöglicht das „Condition Based Monitoring“, Verschleißteile und Betriebsstoffe erst dann zu wechseln, wenn es wirklich notwendig wird.

Condition Based Monitoring – so unterstützt Sie WAGO:

Modulares System mit Cloud-Anbindung: WAGO bildet die leistungsstarke Schnittstelle zum webbasierten J.I.M-Portal.
200 Messwerte pro Sekunde: Weil die Verarbeitung mit CODESYS nicht mehr möglich war, wurde der Controller XTR auf Basis von Linux^® programmiert.
Druck, Temperatur, Beschleunigung: Mit Hilfe des „Condition Based Monitorings“ lassen sich etwa Rückschlüsse auf das Fahrverhalten des Lokführers ableiten.

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So funktioniert das „Condition Based Monitoring“ im Rolling Stock

Für das „Condition Based Monitoring“ greift Reuschling im ersten Schritt die in der vorhandenen Sicherheitssteuerung der Lok erzeugten Daten über Modbus TCP ab und lässt diese vom WAGO Controller, vom Typ XTR, aufnehmen. „Für die Verschleißerkennung reicht das aber noch nicht aus“, sagt Udo Pinders. Notwendig sei zusätzliche Sensorik, die Reuschling direkt auf das für Bahnanwendungen zugelassene WAGO System aufschaltet. Die XTR Controller aus dem I/O-System 750 sind speziell für widrige Umgebungsbedingungen konzipiert. Entsprechend robust verhält sich eine störungsunempfindliche XTR-I/O-Lösung gegenüber extremen Temperaturwechseln, Vibrationen oder Stößen. Genau diese Bedingungen sind es, die den Betrieb einer Lok im Güterverkehr und Rangierbetrieb ausmachen. Das System erfüllt daher die Vorgaben der für die Instandhaltung zuständigen Stelle im europäischen Schienenverkehr, der Entity in Charge of Maintenance (ECM).

„Condition Based Monitoring“ erzeugt digitalen Fingerabdruck

Beim „Condition Based Monitoring“ sind es im Wesentlichen Druck-, Temperatur- und Beschleunigungssensoren, die Reuschling für die Modernisierung alter Rangierloks in die Maschinen integriert. Liegen zum Beispiel Kenntnisse über den zeitlichen Verlauf negativer wie positiver Beschleunigungen vor, „können wir daraus das Fahrverhalten des Lokführers ableiten“, verdeutlicht Michael Lingen, Geschäftsführer der Ikado GmbH aus Aachen. Sein IT-Systemhaus hat den WAGO Controller XTR auf Basis von Linux^® programmiert und ebenfalls im Auftrag und Zusammenarbeit mit Reuschling das J.I.M-Portal konzipiert und umgesetzt. „Wenn wir die für uns wichtigen Fahrparameter kontinuierlich aufzeichnen, bekommen wir in der Analyse einen digitalen Fingerabdruck.“ Dieser macht Fahrsituationen deutlich, eröffnet Einblicke, wie sanft oder ruppig rangiert wird und lässt in Summe Prognosen zu, wann der nächste Service ansteht.

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Condition Based Monitoring – den Betrieb kontinuierlich im Blick

Bahnbetreiber bekommen mit der kontinuierlichen Zustandsüberwachung ein ECM-konformes Werkzeug an die Hand, ihre schienengebundene Logistik ereignisgesteuert zu optimieren. Wird eine Lokomotive beispielsweise durch zu viele schwere Wagons dauerhaft überlastet, kommt es aufgrund zu hoher negativer Beschleunigungen beim Anschieben unweigerlich auf der Langstrecke zu mechanischen Schäden. Die Analyse gibt an dieser Stelle also wertvolle Hinweise, dieses Überlastverhalten überhaupt zu erkennen – um dann richtig zu reagieren. In einem anderen Fall kann der umgehend per Mobilfunk an eine Leitwarte übertragene Alarm eines Beschleunigungssensors Indiz für einen Unfall sein.

Condition Based Monitoring und Bahnnormen

„Wir brauchen eine Betriebs- und Fahrstrategie. Dafür bedarf es wiederum Daten mit entsprechender Intelligenz“, fasst Udo Pinders zusammen. Dabei schwebe über allem die in nationalen und europäischen Normen vorgeschriebene sichere Eisenbahnführung. Aus dem Sicherheitsanspruch heraus resultieren dann zum Beispiel Zeitintervalle für die technische Überwachung. Mit der zusätzlichen Sensorik an Bord überführt Reuschling die Stichtagsüberprüfung in einen kontinuierlichen Prozess. „Wir platzieren einen Temperatursensor an einem Lager und sehen einen Trend: Wird es warm, ist das für mich die technische Indikation, das Lager zu tauschen“, erklärt der Geschäftsführer. Messungen, Aufzeichnungen und Dokumentation von Fahrzeugdaten machen die Wartung flexibel, ohne dabei den geforderten Sicherheitsnachweis aus den Augen zu verlieren.

Condition Based Monitoring fordert hohe Rechenleistung

Das XTR-System von WAGO verwendet Reuschling – parallel zur Sicherheitssteuerung der Lok – zum Einsammeln der Signale sowie zur Vorverarbeitung mit entsprechenden Algorithmen. Das „Condition Based Monitoring“ im Schienenfahrzeug fordert nach Auskunft des IT-Experten Michael Lingen eine hohe Rechenleistung. Allein die verwendeten Beschleunigungssensoren bringen es pro Sekunde auf 600 interne Messungen in allen drei Achsen. „Davon lesen wir 200 Messwerte pro Sekunde ein“, führt Michael Lingen aus. Die Verarbeitung sei mit dem in der Automation weit verbreiteten CODESYS nicht mehr möglich – weshalb sein IT-Systemhaus die WAGO XTR-Steuerung mit Linux^® betreibe. Übertragen werden die vom I/O-System gebündelten und vorverarbeiteten Daten per LTE – versehen mit exakten Zeitstempeln und GPS-Koordinaten. Erkannte Ereignishäufigkeiten sind damit auch örtlich zuzuordnen. Von dieser Navigationshilfe profitiert nicht nur die Streckeninstandhaltung, sondern auch das Leasinggeschäft. Der Hintergrund: Temporär vermietete Loks sind auf dem Gelände großer Verteilzentren und Rangierbahnhöfe besser zu lokalisieren.

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„Condition Based Monitoring“ ist erst der Anfang

Udo Pinders und Michael Lingen sind sich einig: Die Datenanalytik und das J.I.M-Portal mit dem aktuellen Funktionsumfang zum „Condition Based Monitoring“ sind im Zuge der Digitalisierung erst der Anfang für eine Reihe neuer Anwendungsmöglichkeiten. Höhere Effizienz und Betriebsverfügbarkeit in der schienengebundenen Logistik lassen sich ebenfalls erreichen, indem die Lokführer über die Cloud wertvolle Hilfestelle im Betrieb und bei der eigenständigen Behebung kleinerer Störungen erhalten. Schon jetzt ist es mit J.I.M möglich, die Visualisierung der Lokbedienung mit minimalem Zeitverzug in die Cloud zu übertragen.

Condition Based Monitoring: Modulares System wächst mit den Aufgaben von morgen

Angesichts der noch längst nicht ausreizten Möglichkeiten, schätzen beide Unternehmen die Flexibilität des WAGO I/O Systems 750 in der Ausbaustufe XTR. „Als das Projekt startete, haben wir kurz darüber nachgedacht, ein eigenes geschlossenes System zu entwickeln – also die Hardware selbst zu bauen. Hier wären wir aber schnell an Funktionsgrenzen gelangt“, fasst Michael Lingen zusammen. Die Modularität des WAGO I/O Systems eröffne hier den Weg, neue Aufgaben ECM-konform durch einfache Kombination weiterer Standardmodule in den Verbund erledigen zu können.

Text und Fotos: Thorsten Sienk

Embedded Linux

Offene Automatisierung mit WAGO

Wir bringen zusammen, was zusammengehört – und kombinieren hochleistungsfähige WAGO Hardware mit dem zukunftsfähigen Betriebssystem Linux^®.

Das beste Betriebssystem für Ihre Automatisierung

Das Linux^®-Betriebssystem, Basis unserer Controller PFC100 und PFC200 sowie der Control Panels, bietet unschlagbare Vorteile: Es ist schlank, sicher und gewährt Ihnen die Flexibilität, die Sie für Ihr Automatisierungsprojekt brauchen. Dank „Open Source“ können Sie jederzeit den Quellcode auf Ihre individuellen Anforderungen anpassen. Zudem zeichnet sich Linux^® durch seine hohe Stabilität aus und wird permanent durch die aktive Open-Source-Community optimiert. Damit sind Sie auch für künftige Anforderungen – vor allem hinsichtlich Security – bestens gerüstet.

Ihr Ansprechpartner bei WAGO

Weitere Serviceangebote:

WAGO I/O SYSTEM 750 XTR

Das System für extreme Umgebungsbedingungen

XTR – dieses Kürzel im Systemnamen steht für extremen Schutz vor klimatischen Einflüssen, Schwingungen, Erschütterungen und Überspannungen

WAGO I/O SYSTEM 750 XTR

Automatisierungssysteme, die extremen äußeren Witterungsverhältnissen ausgesetzt sind, benötigen häufig zusätzliche platzraubende und kostspielige Schutzmaßnahmen im bzw. am Schaltschrank/Schaltkasten, um den klimatischen und mechanischen Kräften zu trotzen. Das WAGO I/O System 750 XTR kommt hier ohne zusätzliche Maßnahmen aus und zeichnet sich durch weitere praktische Feinheiten aus, wie beispielsweise einen erweiterten Temperaturbereich von -40 °C bis +70 °C.

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