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What is instrumented wheelset technology IWT5?
An Instrumented wheelset is an advanced sensor measuring the dynamic contact forces at the wheel-rail interface. These measurements are crucial for railway safety and efficiency. Through real-time, precise monitoring of train dynamics and track interactions, instrumented wheelsets meet the demand for higher safety and greater efficiency in rail operations.
Instrumented wheelset technology 5 (IWT5) is TÜV SÜD’s fifth-generation technology for this purpose. It uses the vehicles’ existing wheelsets without any destructive modification, so that there is no need to manufacture special testing wheels. This leads to simplified project logistics, compressed schedules, reduced risks, and lower project costs.
Why IWT technology is important
Our advanced IWT technology (IWT5) directly and accurately measures dynamic forces, capturing the complex interactions at the wheel-rail interface. This way, IWT5 helps prevent derailments and excessive rail wear. That contributes to safer and more reliable railway operations.
Furthermore, IWT5 supports the compliance with safety standards and enhances the overall management of rail infrastructure. It helps you comply with different regional rail safety standards such as EN 14363 in Europe and 49 CFR Part 213 in the US.
IWT5 allows to integrate this advanced sensor technology into existing wheelsets without compromising their structural integrity or operational capabilities. By facilitating the effective processing and analysis of large volumes of data, it enables actionable insights.
How TÜV SÜD can help you with IWT technology
TÜV SÜD provides state-of-the-art IWT5 technology, backed by our decades of experience in developing and implementing instrumented wheelset technologies across various international rail networks.
IWT5 offers advanced measurement capabilities and robust data analysis tools such as cutting-edge sensor and telemetry systems. This helps railway operators and manufacturers achieve high safety and performance standards. We can tailor our capabilities to specific operational needs and compliance requirements.
IWT5 enhances traditional measurement techniques by providing comprehensive data on wheel-rail interactions, enabling better track and vehicle maintenance decisions and optimising rail system performance.By allowing the use of existing wheelsets, IWT5 reduces the need for costly specialised equipment. This makes rail maintenance more cost-effective while continuing to ensure safety and performance.
What our IWT technology services include
IWT5 avoids structural integrity issues, as the wheels do not need to be machined. This removes the need for any additional periodic ultrasonic inspection of the instrumented wheelsets.
The IWT5 interface comprises an updated Measuring Wheelset Computer (MWSC), which allows for an innovative and improved user experience. It offers various configuration and diagnostic options while being visual and intuitive, adding to the user experience.
IWT5 provides a multitude of digital output interfaces such as, TCP/IP, EtherCAT and CAN as well as direct integration into Imc CRONOSflex and HBK QuantumX data acquisition systems. Additional interfaces are available on demand.
IWT5 is backwards compatible, allowing legacy instrumented wheelsets to be used for decades to come. As further development of IWT4, IWT5 wheelsets can be calibrated while being mounted in the vehicle, as a newly developed mobile calibration rig enables this.
Track condition monitoring
IWT5 is capable of measuring at high frequencies while using the vehicles’ original wheelset. The high frequencies make it possible to locate track irregularities, both singular and periodical.
Collecting this data enables TÜV SÜD to clearly identify, quantify and classify areas of infrastructure degradation. This is specifically important to identify parts of the tracks that experience high track or wheel wear, corrugation, or poorly performing switches or crossings.
Friction measurement
Friction at the wheel-rail interface is a critical parameter for an effective railway system. By identifying areas of the network with low friction in real-time, operators can drastically reduce wheel flats on their fleet. Measuring high friction also helps operators actively manage lubrication regimes and drastically reduce wheel wear.
Frequently asked questions (FAQs)
Is IWT5 available worldwide?
Yes. Just as we currently do with our legacy instrumented wheelsets, we can truck or fly IWT5 to clients all over the world. We have extensive international experience in the field. To date, our instrumented wheelsets have been used in Germany, in the United States, Canada, Brazil, China, Austria, Switzerland, Poland, Czech Republic, Sweden, Finland, and Norway.
How do I know that IWT5 is robust?
IWT5 is based on our core instrumented wheelset technologies IWT4 and the “Minden technology, improved by PROSE”. Both have been heavily scrutinised by both internal and external parties. For example, the German Railway Authority appointed an independent assessor which conducted an independent review of these technologies.
Furthermore, the independent bodies SWEDAS and SAS have scrutinised the calibration of our technologies as part of ISO17025 laboratory accreditations. Our experience in using instrumented wheelsets in demanding applications ranges from hot, humid, and dusty applications on iron ore cars in Brazil, to harsh Nordic conditions on EMUs and locomotives in Scandinavia. This ensures that IWT5 is a field-hardened technology.
Our laboratory in Berlin is as well accredited by DAkkS as a calibration laboratory for instrumented wheelsets.
Furthermore, the independent bodies SWEDAS and SAS have scrutinised the calibration of our technologies as part of ISO17025 laboratory accreditations. Our experience in using instrumented wheelsets in demanding applications ranges from hot, humid, and dusty applications on iron ore cars in Brazil, to harsh Nordic conditions on EMUs and locomotives in Scandinavia. This ensures that IWT5 is a field-hardened technology.
Our laboratory in Berlin is as well accredited by DAkkS as a calibration laboratory for instrumented wheelsets.
What quantities can IWT5 measure?
IWT5 can measure vertical, lateral and longitudinal forces. At present, longitudinal forces are not easily calibrated in our calibration rig, so this quantity is provided as a scaled but non calibrated signal. IWT5 can also output the lateral position of the contact patch, in other words, the lateral position of where the wheel is meeting the rail.
Can IWT5 use all wheelsets?
IWT5 can use nearly all of them. Instrumented wheelsets rely on strain gauges to sense the deformation of the wheelset when a force is applied. Extremely small wheels with thick webs will be so stiff that the deformation is not measurable, hence these can't be used. That said, we have produced over 150 wheelsets ranging from freight cars, heavy haul ore cars, EMUs, DMUs and locomotives, and all have performed well.
Can IWT5 be used on braked wheelsets?
IWT5 can be operated with axle-mounted disc brakes, or during regenerative/resistive braking from the propulsion system. IWT5 cannot be used with tread brakes (as the tread brake clamping forces will affect the strain measurements in the wheel and hence interpretation of the wheel-rail contact forces) nor wheel-mounted disc brakes (because of the risk of the discs damaging the wheel instrumentation). However, even if brakes are fitted, it is recommended that the brakes be disabled to avoid the risk of wheel flats.
How long can IWT5 operate if it is measuring continuously?
Our latest version of IWT5 is powered by an inductive power transfer system. This is a contact free system, eliminating the need for slip ring devices and battery systems which would require regular maintenance. With the latest IWT5 system, as long as your vehicle is powered up, so is IWT5.
How easy is IWT5 to use?
IWT5 is a highly complex instrumentation item which should be used by measurement technicians with suitable training. Given the system’s intuitive interface and architecture, it is easy to use with the right background and training. Several of our clients are relying on our instrumented wheelset technology while performing the actual testing themselves.
How often do the instrumented wheelsets require calibration?
After initial calibration of an IWT5 wheelset, they should be re-calibrated after they are reprofiled, because the deformation behaviour is changing. Besides of this it is recommended that they are recalibrated every three years.
