Railway axle bearing failure pdf

A wheelset is the wheel axle assembly of a railroad car. The term is derived from the journal bearing trucks used before the mid20th century. An axle journal bearing on the locomotive, which was positioned at the rear of the train, had failed. Failures are typically i caused by restricted lubricant flow or excessive temperatures that degrade the lubricants properties.

Types of failure bearing failures main cause reference failures failure details rolling fatigue flaking. The design of an adequate railway system has developed over a long period of time. Wayside detection of faults in railway axle bearings using time spectral kurtosis analysis on high frequency acoustic emission signals. Rail wheels, axles and bearings are among the most fundamental elements of railroading the very efficiency of railroading depends on how well these elements work together. Ball bearings depend on the continuous presenceof a very thinmillionths of an inchfilm of lubricant between balls and races, and between the cage, bearing rings, i. The assembly of two railway wheels and an axle is commonly called a wheelset, which rotates and is supported by bearings that are called axlebox or journal bearings. It also mentions another seven similar failures occurring between 1998 and 2000. Due to all the factors such as design, installation technology, use conditions and sudden load, it is hard for railway axle bearings to avoid wear, pitting, crack, stripping and abrasion and so on. Ntnsnr played an active role in the 2007 rail speed record. Approximately 220 trackside habd detectors are currently installed in the uk 9. This is a video of a recovery of a boxcar with a failed bearing. Railroad administration axle failure data for the last decade fra, 2001.

Accident causes breakdown 36% 37% 25% 1% infrastructure rolling stock operational failure others environment etc. The immediate cause of the bearing failure could not be determined due to the extensive damage to the bearing, which can occur following substantial overheating and deformation of the material as in this case. The springs used in the bogie suspension of railway coaches are helical compression springs. Pdf defects in railway axle bearings can affect operational efficiency, or cause inservice failures, damaging the track and train. It is fitted with a ball bearing on the axle end for thrust load support. Pdf perspectives on railway axle bearing condition monitoring. In the first case, the failure caused a major destruction of the railway line. Timken bearing damage analysis with lubrication reference. Healthy bearings produce a certain level of vibration and noise, but a bearing with a defect causes substantial changes in the vibration and noise levels. The roller thrust face large end in tapered roller bearings and the corresponding thrust face on the inner ring become smeared with a characteristic torn finish as shown above.

This paper present the analytical method of a railway axle using three different load at a constant speed. Pdf realtime onboard condition monitoring of train axle bearings. Axle bearings are the connecting design elements from the wheelset to the nonrotating parts of the vehicle. Original railroad bearing adapters have gone through modification to house the sensor. A picture of a typical railway bearing shown in figure 1 is provided by the canadian paci. Timken is the global leader in bearing reconditioning for the rail industry. Timken bearing damage analysis with lubrication reference guide. Causes are investigated on the earlier failures of the bearings for china railway freight cars with radial bogie.

Spring is an elastic member whose main function is to deflect or distort under load and to recover its original shape when lo ad is removed. May 02, 2003 a railway axle hub unit of the type comprising an axle box housing 1 for supporting a bearing, is provided with a sensor body 3, 9 containing sensors 4, 5 for detecting vibration in the vertical direction and the horizontal axial direction. Products for railway applications schaeffler group. Pdf railway wheelsets consist of three main components. The railway s major differentiator from other means of transport is a pair of wheels often jointed to a wheelset rotating around a common axis, and supported and guided through a pair of rails. Total axle failures, including bearing related failures, numbered between 59 and 68 for each year. Schaeffler group industrial is, through its brands ina and fag, one of the worlds leading manufacturers of rolling and plain bearings. Provisions of blanket in other railway systems 22 10. In railways, the axle bearings condition monitoring can be made directly onboard or indirectly ontrack and. Skf railway solutions provide superior electrical insulation. Fatigue life estimation of modified railroad bearing adapters. It is a good thing that it was caught when it was as there could have. Roller bearings with spherical rollers are called as spherical roller bearings see fig.

A dead train on the railway line has implications for customer perception, operator and manufacturer reputation, along with large costs from penalties, recovery, train availability and. If one of the axle bearings of an automobile or a railway car breaks down, a serious accident could occur. Pdf wayside detection of faults in railway axle bearings. Bearing failures and their causes bearings are among the most important components in the vast majority of machines and exacting demands are made upon their carrying capacity and reliability. Novel efficient technologies in europe for axle bearing. An experiment test on railway axle bearings was performed in the testrig shown in figure 2. Wayside detection of faults in railway axle bearings. We are the number one choice when it comes to wheel, axle, and journal bearing needs.

Pdf a stress analysis on railway axle with fatigue crack. Rowan a bearing capacity type design procedure for assessing the stability of the track subgrade is presented in this paper. The axle box is locked on a portion of the railway axle, which includes the bearing seat, the shoulder and a part of the axle with wider diameter. Axle bearings are key elements in the integrity of railway wheel sets. Brass is the most preferred cage material for bearing used in railways all over the world. This has led to stringent requirements to remove axles from service when corrosion is present.

A rolling component is typically pressed onto an axle and mounted directly on a locomotive or indirectly on a bogie. Onboard condition monitoring of rail axle bearings. Axle box bearing monitoring systems because of the criticality and importance of railway bearings mounted in the axle box, these components are subject to careful maintenance. Realtime onboard condition monitoring of train axle bearings. Southeastern railway company has fitted more than 5,000 bearing sensors to its electrostar fleet.

Faults can develop on any of the aforementioned components, but the most common are related to wheel and axle bearing defects. In 1959, brenco received conditional aar approval for the product it is known for today throughout the worldwide railroad industry the tapered roller bearing. Attempting to remove such components by cutting the cone inner race may. In passenger coaches of indian railway system, only single bearing type axle box arrangement is used. If you continue browsing the site, you agree to the use of cookies on this website. Pdf premature failure of rail axle bearings causes a significant increase in train operating costs and can impact train safety. Some of the significant steps in progress are described here. Despite the fact that occurrence of axle bearing failures is rare. Onboard detection of railway axle bearing defects using envelope analysis of high frequency acoustic emission signals.

Spherical roller bearings for meter gauge and broad gauge passenger coaches have symmetrical roller design figure 1 bearing components causes and failure pattern of bearings in railway bogies and their remedies dhameliya b. The railway test shop at the fag schweinfurt site is recognised and certified as a test facility for rail vehicle bearing arrangements by the federal german railway authority. The rollingcontact bearing is an element of machinery with a very important role, and is critical to the performance of the machine. Rail accident report passenger train derailment near east langton. We are the sole supplier for multiple class i railroads. Axle bearing, condition monitoring, railway, wayside, onboard.

Our cylindrical roller bearings are fitted to the axles of both passenger and freight trains. The article deals with two cases of failures in freight wagon cylindrical roller bearings and axles. Defects in railway axle bearings can affect operational efficiency, or cause inservice failures, damaging the track and train. The scope of that previous project was to investigate the transmissibility of the vibration signals from the defective bearing to the rails, a transient mechanical path formed by the bearing, the axle, the wheel, the rail, the and accelerometers. The failure parts of railway axle bearings contain outer. Any static overload or severe impact can cause brinelling. This month, providers of wheels, axle and bearing technology share information on whats new as well as tried and true in terms of rail wheel, bearing and related technology. Failures of bearings and axles in railway freight wagons. Bearing capacity approach to railway design using subgrade. Timken rail service trs throughout the world and rail bearing service rbs in north america bring new life to used bearings by replacing worn and damaged parts. Inspection and removing roller bearing with hydraulic. Roller bearing mountingfreight and amtrak passenger car.

Article information, pdf download for perspectives on railway axle bearing condition. The passage of electric current through bearings can lead to premature failure. It follows on from the investigation carried out in 2014 and was aimed at two specific elements. In railway axle bearings, this is quite rare and usually due to poor lubrication. Determining the cause of the failure was a difficult task, as the material was rather deformed by the damage and modified due to high temperatures.

Based on the design of the ap bearing, we engineered the ap2 bearing to minimize journal axle flexure and fretting wear. Observing early stage rail axle bearing damage request pdf. A dead train on the railway line has implications for customer perception, operator and manufacturer reputation, along with large costs from penalties, recovery, train availability and repairs. Faults can develop on any of the aforementioned components.

A hot box is the term used when an axle bearing overheats on a piece of railway rolling stock. The rollingcontact bearing is an element of machinery with a very important role, and it dominates the performance of the machine. Advanced wayside condition monitoring of rolling stock wheelsets mayorkinos papaelias 1, zheng huang 1. Early warnings for failing train axle bearings based. Bearing failure defects in the appearance of bearings are referred to as bearing failures. The consequences of a roller bearing failure on line are that the section is blocked for the traffic and if. Advanced wayside condition monitoring of rolling stock.

Quality and safety are major emphases at progress rail working safely and efficiently allows us to produce the highest quality products available in the market today. Railway axles are key components of railway rolling stock. This type has an advantage of although has a disadvantage of increasing the number of parts. Premature failure of rail axle bearings generates a. Axle bearings and condition monitoring for railway vehicles. The present study aims to analyses the mechanical stability of greases and temperature of bearings as indicators for conditionbased bearing maintenance. Rail vehicle axle bearings are one of the most important components of railway vehicles regarding transportation safety. The axle bearing is a safety critical component so it is vital that there are zero defects. Onboard detection of railway axle bearing defects using. May 28, 2016 railway component in detail, its failure, prevent to failure and causes of failure slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. The continuous increase in train operating speeds means that failure of an axle bearing can lead to very serious derailments, potentially causing human casualties, severe disruption in the operation of the network, damage to the tracks, unnecessary costs, and loss of confidence in rail. From the opposite side of the axle box cover, the axle, in correspondence with the portion in which it has been sectioned, is connected to a shaft with a smaller crosssection which is actuated by an. Design of railway axle in compliance with the european.

Our experience in the rail industry goes back more than 40 years. Design of railway axle in compliance with the european norms. Spherical roller bearings are critical components whose failure may have catastrophic consequences. The continuous increase in train operating speeds means that failure of an axle bearing can lead to serious derailments, causing loss of life and. Design and dynamic analysis of locomotive wheel axle a. Axle bearing damage with possible catastrophic failures can cause severe disruptions or. Abstract defects in railway axle bearings can affect operational efficiency, or cause inservice failures, damaging the track and train. Defects in railway axle bearings can affect operational efficiency. Almost 60% of all rolling stock accidents were due to wheelset failure, thus accounting for one in five of all railway accidents considered in the study. Investigating rail axle bearing damage engineering. In fact, railways were built before the advent of modern soil mechanics. The axles serve to transmit driving torque to the wheel, as well as to maintain the position of the wheels relative to each other and to the vehicle body.

Volume 2, issue 12, december 20 issn 2319 4847 causes and. Walbo railway moravskoslezsky kra ostrava 702 00 walb 7 private closed or dropped wheel shops posted for shop mark reference only company state. The current phase of the research concentrates on the incorporation of the matric. Table 21 describes bearing failures, first assigning a general term to each type of failure, then adding more detailed classifications. Passenger car, series 25k, sponsored by the ministry of railways, p. Design methodspractice in world railway systems 22 11. Through observing failure objects, checking manufacturing quality, and calculating rolling contact fatigue rcf stresses, it reveals that poor manufacturing quality of bearing outer ring plays a key role to the earlier failures and, in addition, mismatch design of rcf stresses. Rail axle bearing failure is a serious issue that can affect passenger safety and generate large costs for operators from penalties, recovery, reduced train availability and repairs. The axle bearings were housed in a box that used oilsoaked rags or cotton collectively called packing to reduce the friction of the axle against the truck frame. Corrosion fatigue has been the reason for failure of rail axles in a number of accidents. Rail vehicle axle bearing failure is a serious issue often resulting in service delays and potentially fire and derailment, with obvious risks to life. Railway wheelsets consist of three main components. Therefore, the train has to be stopped immediately causing disruptions to passengers and railway traffic. Perspectives on railway axle bearing condition monitoring mani.

The transportation safety board of canada 2 reported one axle failure to have been caused by corrosion pits under the journal bearing. Rail vehicle axle bearing failure is a serious issue which often results in service delays and potential fire and derailment, with obvious risks to life. Unfortunately, numerous bearings suffer early failures due to poor fitting. Healthy bearings produce a certain level of vibration and noise, but a bearing with a defect causes. Roller bearings are named according to the shape of rollers. Very rare case is may be possible, train is running condition then suddenly apply the break and one wheel is stationary condition and second. Cylindrical roller bearings with ribs with this type of bearings which is referred as the uic. Moreover, the immediate stop of the train causes large disturbances in the dense railway network. Bearing capacity approach to railway design using subgrade matric suction pamela sattler, d. Iso bearings are sometimes used, but specially dimensioned bearings are the most common.

Investigation and research in bearing failures in the railway has been an area of. Typical railway wheelsets consist of wheels, axle and axle bearings. These merely scratch the surface of all the wear and tear your bearings go through on a given day. Design of a test rig for railway axleboxes sciencedirect.

The failure parts of railway axle bearings contain outer ring faults, cage faults and pin roller faults. The axle end side of the ball bearing is sometimes fitted with coned disc spring or rubber buffers to absorb shock loads. Maintenance handbook for roller bearing on axle and tm july99 chapter 1 introduction roller bearings are a vital part of the traction system. In this paper author describes the roll of spherical roller bearings in railway bogie wheels. Onboard detection of railway axle bearing defects using envelope. The consequences of a roller bearing failure on line are that the section is blocked for the traffic and if roller bearing seizes, then the locomotive can not be moved until the axle of the locomotive is lifted. If one of the bearings breaks or seizes, not only the machine but also the assembly line may stop. The most common failure in rail axle bearings is due to rolling contact fatigue rcf of the. Nonjournal related freight car axle failures, coded as brokenbent axle between wheel seats, are displayed. Perspectives on railway axle bearing condition monitoring. The shorter axle journal design provides a longer and stiffer dust guard, which, in turn, reduces stress at the crucial axle fillet area.

Advanced wayside condition monitoring of rolling stock wheelsets. University of birmingham perspectives on railway axle bearing. Healthy bearings produce a certain level of vibration and noise, but. A two axle bogie of a railway freight wagon containing two side frames with axle openings, a nadressornoj beam, a central thrust bearing seat, side bearings, wheel pairs with axle boxes on bearings, a brake linkage with suspended triangles and brake pads with oneway pressing, and also spring suspension with springs and friction dampers, characterized in that the nadressornoj beam and side. Rail vehicle axlebearing failure is a serious issue often resulting in service delays and potentially fire and derailment, with obvious risks to life. A bearing that is creating sufficient heat to trigger an habd will already be in full failure mode. Most bearing damage can be linked back to the six main modes as well as their. Carboni, maraxil project effect of coldrolling onto axle life prediction, esis tc24 workshop, milano, italy, 30 march, 2012. Faults diagnostics of railway axle bearings based on imfs confidence index algorithm for ensemble emd. The inner ring of the bearing is provided with a cylindrical bore. Faults diagnostics of railway axle bearings based on imfs. Each characteristic is described in detail and is shown in diagram form, accompanied by a color photograph.

The frame assembly beneath each end of a car, railcar or locomotive that holds the wheelsets is called the bogie or truck in north america. To avoid trouble, every bearing manufacturer should make efforts to assure the highest quality for each bearing, and should emphasize that the user carefully handle and maintain all bearings. Design and dynamic analysis of locomotive wheel axle. Failure modeling and life predcition of railroad wheels by venkata sasidhar sura dissertation submitted to the faculty of the graduate school of vanderbilt university in partial fulfillment of the requirements for the degree of doctor of philosophy in civil engineering december, 2011 nashville, tennessee approved. The modifications to the railroad bearing adapters include the removal of material to accommodate the sensor. Most north american freight cars have two bogies with two or three wheelsets, depending on the type of car. By removing the seal wear ring in the timken design, axle grooving and the resulting scrapping or expensive repairs of the axle can be reduce axle fillet damage by. China 1 cylindrical roller bearings uiccompliant rotation test equipment for railway axle box bearings based on uic5155o standard.

Our railway specific products and services help you obtain lower life cycle costs by letting you use bearings to their full potential. The roller thrust face large end in tapered roller. Bogie suspension design is a complex and difficult science which has evolved over many years. Severe brinell marks can cause premature fatigue failure. Each railway bearing is composed of two cone assemblies containing roller bearings, a spacer ring, a cup and. Premature failure of rail axle bearings causes a significant increase in train operating. Figures 2 and 3 show, respectively, the nonmodified and modified bearing adapterswithout the elastomer padliner and sensor. Failure analysis on bearings of railway freight cars with. Bearing failures and their causes bearing, linear motion.