Track geometry cars no longer plain: Sophisticated data-collection systems permit gathering information, even at high speeds, to detect trouble spots and help plan m/w programs

Railway Track and Structures, Dec, 2001 by Tom Judge

High-tech tools have helped rail-roads record track geometry data for decades. These tools are getting more sophisticated and are being complemented by software to help sort through the reams of data collected.

ENSCO: New tools

"Twenty years ago the challenges for automated track inspection technology were accuracy and reliability," said Kevin Kessler, manager rail programs. "While still important today, advancements in sensor, electronics and computer technology have made these requirements much easier to meet with off-the-shelf technology. Today's challenges are more focused on getting the most value for the mountains of automated track inspection data acquired and getting more automated inspection systems in use to enable more frequent coverage of high-density routes.

"The most significant of these technical innovations include the introduction of low-cost wireless data communications, Global Positioning Systems, Geographical Information Systems or computer-based mapping tools, low-cost hand-held computers such as the Palm Pilot and Video-Based Track Inspection Systems," Kessler pointed Out.

The new products and tools that ENSCO now offers include:

* DigiSystems--Palm Pilot-based tools for track inspectors that can download exception data from track geometry cars and use GPS coordinates to navigate to the defect (no more looking for paint marks or measuring distances from mileposts).

* Remote Ride Quality Monitoring Systems--Low-cost, low-power sensors and computers combined with improved cellular data communications have enabled ENSCO to provide remote ride-quality measurement systems to help pinpoint priority surface, line and curve problems long before they present a risk to rolling stock, passengers and lading.

* Low-Cost and Remote Track Geometry Measurement Systems--To help railroads cope with the reduction in track time available for track inspection and the limited supply/high cost of full-sized track geometry inspection vehicles, ENSCO will be introducing a cost-reduced, simple-to-operate-and-maintain gauge and crosslevel measurement system to enable more rail vehicles and hi-rail vehicles to conduct automated track inspections.

* Video-based Inspection Systems (VIS)--When Amtrak needed a way to improve the productivity and reliability of walking track inspections on the Northeast Corridor, ENSCO developed a system that takes a video "slice" of the track bed every 1/8 of an inch at speeds up to 50 mph.

* Automated Track Geometry Inspection Pushcart--This system measures and records gauge, crosslevel, profile and alignment at walking speeds. It is designed as a supplement to automated track inspection cars and as a quality assurance tool behind track maintenance gangs.

Holland: TrackSTAR(r)

Holland Company has developed and delivered a "heavy hi-rail" testing vehicle called TrackSTAR(r) to the rail industry. Built on a dual-axle, 52,000-pound truck format and capable of testing speeds to 30 mph, TrackSTAR is designed to offer convenient and cost-effective track testing.

TrackSTAR is capable of delivering three key track testing systems: Full track geometry measurement is delivered with an inertial based non-contact optical measurement system; track strength measurement using loaded split-axle technology with non-destructive 10,000-pound lateral and 15,000-pound vertical loading; and full rail profile measurement using optical laser camera technology.

Holland's TrackSTAR testing service provides strip-chart and exception reports for immediate delivery to following track crews of the track gauge and geometry exceptions. Rail profile data are processed and delivered in electronic and hard-copy format for rail planning purposes.

All geometry and track strength collected data are also distributed in electronic format for office viewing and evaluation. Statistical tie-exception summary reports are used for planning and comparison purposes.

On-board software systems deliver curve summary evaluation reports. The operating system allows zoom and scrolling features for quick and focused review while testing data continues to be collected.

KLD: Years of experience

The staff at KLD Labs, Inc., has been developing and integrating systems measurement systems for track geometry cars for about 20 years. KLD provides systems directly to railways and to suppliers such as Plasser American Corp. and ENSCO. The company has integrated a wide variety of systems on track geometry vehicles operating throughout the world, testing the track at speeds up to 160 mph.

The latest technology developed by KLD, the High Speed Gage Measurement System, uses high-speed video cameras and high-powered lasers to measure the gauge point. Gauge measurements can be sampled at exactly one-foot intervals at speeds up to 160 mph and higher. Each measurement sampled corresponds to the exact location of the measurement.

KLD has also developed a system called High Speed Rail Measurement System. This system combines all the benefits of KLD's HSGMS as well as the benefits from its Optical Rail Inspection & Analysis or ORIAN system. The ORIAN system is a full rail-profile measurement system that collects detailed rail profile data and rail wear information.