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Inspection of trains during transit: Digital inspection processes with added value

Trains and rail transport systems are subject to enormous demands. Rough environments as well as the highest speeds in wind and weather put all components under extreme stress. Inspections are essential if consequential damage or even operational disruptions are to be avoided. With digital and automated inspection systems from PSI Technics, inspections of trains are carried out in the shortest possible time with reliable results.

Inspection during transit: Image-processing systems are arranged as camera gates in an inspection facility. They are equipped with high-resolution 2D/3D cameras and high-power LED spotlights and inspect a large number of assemblies on the train. Among other things, images of the side surfaces, in the underfloor area as well as the roof are inspected.
(Video: PSI Technics GmbH)

Local and long-distance passenger trains as well as freight vehicles roll over the rail network 24 hours a day, around the clock. Many trains are in continuous operation and there will be more and more if we really want to tackle climate change. Time for inspections is scarce. But it is precisely the early detection of likely faults that is important in order to avoid consequential damage and disruptions. They must be rectified even before they have an impact on traffic flow.

Inspection during transit

Until recently, trains were usually inspected exclusively by means of a manual inspection by test engineers. This is a time-consuming process that takes around 1.5 hours per train and has to take place in a maintenance hall. In order to automate and digitalize this process, the company PSI Technics from Urmitz In Germany has developed the automated train inspection.

This involves image-processing systems arranged as camera gates in an inspection facility. Each inspection system contains a total of three such camera gates. All are equipped with high-resolution 2D/3D cameras and high-power LED spotlights.

In the first gate, images of the train's side surfaces, windows, pictograms, graffiti and running gear, among other things, are taken to detect faults and defects, for example in window panes, lettering and the running gear.

The second camera gate detects damage in the underfloor area such as brakes, E-tubing, slew ring and underfloor damage.

In the third gate, the roof is inspected. Here, among other things, the roof garden, current collectors, contact strips, antennas, cables, screws and much more are inspected.

In total, more than 96 assemblies are inspected on the train - the results are available to the operating personnel within 10 minutes. In this way, maintenance intervals are optimized and repair work can be initiated quickly. Trains do not have to be dismantled and maintenance halls remain free for their actual tasks.

Inspection down to the last detail

PSI Technics systems are designed for their respective tasks down to the last detail. A special lighting and camera arrangement is available for each assembly so that it can be tested in an individually set up test system. The system is connected to the control system to monitor the processes. Testing operations can thus be coordinated centrally. The camera technology dynamically adapts to the speed of the passing train via speed measurement. The automated train inspection system is designed for 24-hour operation and thus allows a very high throughput.

Artificial intelligence / data mining for more insight

"However, the inspection system not only has high-precision recording technology," explains Karl-Heinz Förderer, Managing Director of PSI Technics. "We use a variety of state-of-the-art methods and algorithms for image evaluation and assessment." In the future, artificial intelligence will make the inspection system much more than a fault detector on passing trains. "The data is stored centrally and is available for highly exciting Big Data applications," says Karl-Heinz Förderer, describing another major added value.

How do weather conditions or dirt affect assemblies? What influence does the distance traveled have? The inspection process not only collects countless data, but also links them to further information - the so-called peripheral data. On this basis, statements about the life expectancy of certain components become possible over time, qualities can be compared and assembly checks can be carried out.

Karl-Heinz Förderer is delighted with the success: "We are demonstrating very clearly here what the digitization of processes can achieve. The result is efficient, targeted and preventive quality control, which helps to expand the competitiveness of rail transport companies."

Author: Dorothee Bönsch, Concept and Text, Darmstadt; Karl-Heinz Förderer, PSI Technics

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