Referentie 1 maart 2020

Condition-Based Monitoring van rollend materieel

“Condition-based monitoring” belooft het onderhoud van spoorvoertuigen efficiënter te maken, zowel in tijd als in kosten. Westfälische Lokomotiv-Fabrik Reuschling GmbH & Co. KG laat zien hoe spoorwegexploitanten conditiebewaking voor hun rollend materieel kunnen implementeren.

De manier waarop locomotieven worden aangedreven, bepaalt hoe snel componenten slijten of bedrijfsmiddelen verouderen. Daarom is het zinvol om spoorvoertuigen continu te monitoren. Dit proces wordt 'condition-based monitoring' genoemd. “Als we weten wat de belasting is,kunnen we de voertuigen dynamisch onderhouden. Maar daarvoor hebben we gegevens nodig ”, legt Udo Pinders, algemeen directeur van Reuschling, uit. Westfälische Lokomotiv-Fabrik staat in heel Europa bekend als een betrouwbare deskundige partner voor onderhoud en modernisering van alle soorten spoorvoertuigen.

Voor effectief service- en toestandsafhankelijk onderhoud vertrouwt dit bedrijf uit Hattingen in Noordrijn-Westfalen op een modulair systeem met een cloudverbinding. De automatiseringstechnologie van WAGO vormt daarbij de interface naar een webgebaseerd systeem voor wagenparkbeheer van rollend materieel - de J.I.M. Portal, wat staat voor "job-based intelligent monitoring". Dat betekent: in plaats van alleen op de bedrijfsuren te letten, maakt condition-based monitoring het mogelijk om slijtagedelen en bedrijfsmiddelen alleen te vervangen als dat echt nodig is.

Condition-Based Monitoring - Hier is hoe Wago u ondersteunt:

Modulair systeem met cloudverbinding: WAGO vormt de krachtige interface naar het webgebaseerde J.I.M portaal.
200 meetwaarden per seconde: Omdat verwerking met CODESYS niet meer mogelijk was, werd de XTR controller geprogrammeerd op basis van Linux®.
Druk, temperatuur, versnelling: Met behulp van "conditiebewaking" kunnen conclusies worden getrokken over het rijgedrag van de machinist.

Hoe condition-based monitoring van rollend materieel werkt

Voor condition-based monitoring krijgt Reuschling eerst toegang tot de gegevens die zijn gegenereerd in de bestaande veiligheidscontroller van de locomotief via Modbus TCP en gebruikt de WAGO XTR-type controller om deze op te nemen. "Dat is echter niet voldoende voor slijtagedetectie", zegt Udo Pinders. Extra sensoren zijn nodig; Reuschling sluit deze direct aan op het WAGO-systeem, dat is goedgekeurd voor spoorwegtoepassingen. De XTR-controllers van het I / O System 750 zijn speciaal ontworpen voor ongunstige omgevingsomstandigheden. Een interferentiebestendige XTR I / O-oplossing is net zo robuust bij extreme temperatuurveranderingen, trillingen of schokken. Dit zijn precies de omstandigheden die het gebruik van een locomotief tijdens goederenvervoer en rangeren kenmerken. Daarom voldoet het systeem aan de eisen van de instantie die verantwoordelijk is voor het onderhoud in het Europese spoorvervoer, de Entity in Charge of Maintenance (ECM).

Condition-based monitoring produceert een digitale vingerafdruk

Voor condition-based monitoring zijn druk, temperatuur en acceleratie de belangrijkste typen sensoren die Reuschling in de machines integreert om oude wisselmotoren te moderniseren. Met kennis over het tijdsverloop van zowel negatieve als positieve acceleratie, "kunnen we bijvoorbeeld het rijgedrag van de machinist afleiden", zegt Michael Lingen, CEO van Ikado GmbH, een bedrijf uit Aken. Zijn IT-systeembedrijf programmeerde de WAGO Controller XTR op basis van Linux® en kreeg ook de opdracht om de J.I.M. portal in samenwerking met Reuschling. "Als we continu de rijparameters registreren die voor ons belangrijk zijn, krijgen we een digitale vingerafdruk in de analyse." Dit onthult de rijomstandigheden, geeft inzicht in hoe voorzichtig of ruw rangeerwerkzaamheden worden uitgevoerd en, samen genomen, kan worden voorspeld wanneer de volgende onderhoudsbeurt moet plaatsvinden.

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Conditie-gebaseerde monitoring - een continu overzicht van activiteiten

Voortdurende conditiebewaking geeft spoorwegexploitanten een ECM-conforme tool om hun spoorweglogistiek op een gebeurtenisgestuurde manier te optimaliseren. Als een locomotief bijvoorbeeld continu wordt overbelast door een te groot aantal zware auto's, treedt mechanische schade onvermijdelijk op op de lange termijn als gevolg van een te grote negatieve versnelling tijdens het duwen. Daarom levert de analyse in dit opzicht waardevolle indicatoren op - zonder welke het overbelastingsgedrag zelfs niet kon worden gedetecteerd - en dit maakt de juiste reactie mogelijk. In een andere situatie kan het alarm voor een acceleratiesensor, dat direct via mobiele communicatie naar een meldkamer wordt gestuurd, wijzen op een ongeval.

Conditiegebaseerde monitoring en spoorwegnormen

“We hebben een bedrijfs- en drijfstrategie nodig. Daarvoor zijn weer data nodig met bijbehorende intelligentie ”, vat Udo Pinders samen. Achter dit alles schuilt het veilige spoorwegbeheer dat vereist is door nationale en Europese normen. De veiligheidsnorm behelst bijvoorbeeld tijdsintervallen voor technische monitoring. Met de extra sensoren aan boord zet Reuschling monitoring op gewenste data om in een continu proces. "We plaatsen een temperatuursensor op een lager en observeren een trend: als het warm wordt, dan is dat voor mij een technische indicatie dat het lager moet worden vervangen", legt de algemeen directeur uit. Metingen, registraties en documentatie van voertuigdata maken het onderhoud flexibel, zonder het vereiste veiligheidsbewijs uit het oog te verliezen.

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