Project of on-board acoustic emission diagnostics system of locomotive wheel-motor blocks

FUNCTION

On-board acoustic emission diagnostics system of wheel-motor blocks is intended for the constant complex control of operating electric locomotive wheel-motor blocks condition; it allows to:

control wheel-motor blocks elements condition in the real-time mode;
quickly inform the locomotive crew and wagon depot workers about incipient malfunctions and generate guidance on movement, maintenance and monitoring;
store monitoring results for detailed analysis and database formation;
perform long-term prediction of operating conditions.

ADVANTAGES

on-line control of operating condition;
immediate data communication to operating personnel;
possibility to switch to periodic scheduled work performance based on actual condition;
possibility of lubricating workload reduction and lubricant saving;
possibility of overhaul life increase and downtime for repairs reduction.

ON-BOARD DIAGNOSTICS SYSTEM STRUCTURE

acoustic emission sensors set;
channels of communication;
switching centers;
central analytic information processing unit;
color graphic terminal;
communication system;
data storage system.

DEVELOPMENT CENTRE, BASE ADOPTION ENTERPRISE

Developer: OOO METKATOM.
System blocks delivery, personnel training, technology of diagnosis.

DELIVERY DATE

System delivery and installation is performed within three months.

SYSTEM COST

The cost of on-board 36-channel system (for a 6-axle electric locomotive) with account of installation and personnel training is included in the contract. System cost in case of equipping locomotive pilot batch is specified at the contract conclusion.

ON-BOARD CONTROL SYSTEM STRUCTURE CHART

COST EFFECTIVENESS CALCULATION OF ON-BOARD ACOUSTIC EMISSION DIAGNOSTICS SYSTEM OF PASSENGER CARRIAGES BEARING UNITS ADOPTION

PRESENT LOCOMOTIVE PREVENTIVE MAINTENANCE SYSTEM	ON-BOARD DIAGNOSTICS SYSTEM ADOPTION FOR LOCOMOTIVES
Periodic preventive maintenance and repair work costs with present maintenance system TO-3→TR-1→TR-2→TR-3→SR are ≈ 1,600,000 roubles per locomotive a year, out of which 35-40 % (≈ 640,000 roubles) are KMB and TED elements maintenance costs.	On-board diagnostic system of bearing units allows to reduce unreasonable expenses, thereby units maintenance estimated expenditures according to their actual condition will be ≈ 20-25 % (≈ 130,000 roubles). Hereby annual saving rate will be SR= 640-130 = 510,000 roubles per equipped locomotive.
Lubricant costs with the present lubricating system (at the cost of 1 kg of BUKSOL lubricant 50 roubles) are 65,000 roubles per locomotive a year.	Bearing units lubrication according to their actual need allows to reduce unreasonable operations of lubricant final squeezing and reduce lubricant consumption by 45-50 % ( ≈ 35,000 roubles per locomotive a year). Hereby annual saving rate will be SR = 65-35 = 30,000 roubles per equipped locomotive.
Preventive maintenance costs according to structure TO-3→TR-1→TR-2→TR-3→SR with the existing norms of overhaul life are 2,205,000 roubles per locomotive a year.	On-board diagnostics system of bearing units adoption allows to increase overhaul life by 25-30 % of the existing norms (≈1,545,000 roubles per locomotive a year). Hereby annual saving rate will be SR =2205 -1545 = 660,000 roubles per equipped locomotive.
TOTAL ANNUAL SAVING RATE
Per equipped locomotive	SR= 510+30+660=1,200,000 roubles
Per locomotive depot (with the average rolling stock of 150 locomotive units)	SR=1,2 х 150=180,000,000 roubles

OOO METKATOM technical director : V.S. Potapenko
Candidate of Science {Engineering}: D.V. Fedorov