Evolution of Railway Track Crack Detection System

Pranav Lad Mansi Pawar

Production and Industrial Engineering Electronics and Instrumentation Engineering
VIT University VIT University
Vellore, India Vellore, India
ladpranav.pratap2013@vit.ac.in pm.shailendrasingh2013@vit.ac.in

Abstract— In this paper, we have established into certain proportion of the signal energy propagates
use and operation of the integration of ultrasonic crack over to the other medium, at the same time the
detection method and complete station for eternal remaining energy gets reflected back. The calculated
railway track geometry surveying system. This system speed of the sound wave in the material to be tested is
comprises of GPS module, GSM modem, IR sensor, PIR
5790 m/s. As the mentioned the speed of the sound
sensor to bring into operation the crack detection,
communication purpose and identification of any living wave in the particular material density, after getting
being crossing the railway track. The GPS module and the reflected signals we can measure the properties
GSM modem contribute in identification and such as time difference of arrival (TDOA). By using
transmission of railway geometric parameter of crack this time arrival we can calculate the thickness and
detection to the nearby railway station. This paper also the flaws in the material. The flaws create gaps in the
explains the summation of an ultrasonic-based non- material and make it appear as another medium due
destructive testing (NDT) and wireless sensor networks to which the waves get reflected back.
(WSNs) to keep in a continuous record the material
without interruption in nobility during run-time. The II. LITERATURE
PIR sensor is executed to keep away manual patrolling
and finding of living beings across the tracks. This can A. Existing system
operate during the night as well as the daytime. The Every portion of Permanent Way inspected daily
summation of both the technologies WSN and NDT will on foot. The types of patrolling are Gang patrol
form various advanced and trending applications to during abnormal rainfall, night patrolling during
make wireless material scanning more cost-effective in monsoon, hot weather patrolling for welded track,
real-time.
security patrolling, watchmen at vulnerable locations
Keywords—Non-destructive testing; NDT; WSN;
and cold weather patrolling. The impact of gang
Equipment Monitoring; GPS module; GSM modem; patrol during rainfall is on the length which should be
Ultrasonic distance meter. likely to be affected. It is independent of other
patrolling. Meteorological department issues
I. INTRODUCTION telegrams of warning of storms/heavy rainfall.
Watchmen and Gang mates are extra vigilant and are
The presented system helps to detect the flaws in
prepared to introduce patrolling. Security patrolling is
the rail track using ultrasound testing method. When
done to protect train against tampering with track and
the crack is detected, respective coordinates are sent obstruction on the line. Hot weather patrolling is
to the nearest station. This recording and sending of supposed to be done when rail temperature reaches td
coordinates are done by GPS and GSM module. + 20 or above in Welded Rail Sections.
Ultrasonic technique is the most effective method
which detects minor cracks and also calculates the
growth rate of the crack. The growth rate can be
detected at regular intervals. Non-destructive system
for crack detection is implemented. One of the
processes which help in the examination of material
without causing any harm is non-destructive testing
technique. NDT is a widely used method for material
maintenance without dealing with the principles of
the material. In this method, the ultrasound-waves are
extensively used, due to the various behaviors as
ultrasound waves displays in various material
properties. When ultrasound wave signal propagates Fig.1. Manual method: Keyman’s daily patrol
from one medium to another distinct medium, a
B. Proposed system
The presented system helps to detect the flaws in
the rail track using ultrasound testing method. When
the crack is detected, respective coordinates are send
to the nearest station. This recording and sending of
coordinates is done by GPS and GSM module.
Ultrasonic technique is the most effective system it
even detects minor cracks and also calculates the
growth rate of the crack. The growth rate can be
detected after several observations at regular
intervals. One of the processes which help in
examination of material without causing any harm is
non-destructive testing technique. NDT is widely
used method for material maintenance without
dealing with the principles of the material. In this
method Ultrasound-wave are extensively used, due to
the various behaviors as ultrasound waves displays in
various material properties. When ultrasound wave
signal propagates from one medium to another
distinct medium, a certain proportion of the signal-
energy propagates over to the other medium, at the
same time the remaining energy gets reflected back.
The calculated speed of sound wave in material to be
tested is 5790 m/s. As the mentioned speed of sound
wave in the particular material density, after getting
the reflected signals we can measure the properties
such as time difference of arrival (TDOA). By using
this time arrival we can calculate the thickness and
the flaws in the material. The flaws create gaps in the
material and make it appear as another medium due
to which the waves get reflected back.
III. DESIGN
Fig.2 Front View of Model Design in Solid works
Fig.3 Inside view of model design in Solid Works
As you can see the Solid works design is the real-
time robot, designed according to the respective
parameters. The locomotion of the robot is such that
it runs parallel. The locomotion is designed in such a
manner that the centre of gravity is parallel to the
railway tracks. Setting the center of gravity near to
the ground increases the stability and more
aerodynamic, that makes the robot move easily
cutting the air resistance. For making the robot's
frame we have used a light weight ‘Aluminium alloy
7075' with good strength, in which zinc as the basic
alloying substance. The length between the two
parallel railway tracks is about 5ft 6in (1,676 mm).
This measurement length between tracks is noted
from the broad gauge railway tracks.
A. Mechanism
The given mechanical system is designed in solid
works 2014 software. There are 12 wheels mounted
on each side of the rail. This results in consistency in
speed for systematic observation. The axis of the
wheel is perpendicular to the ground which gives a
hold on the rail with a larger area of observation. The
motors attached to each wheels act as actuators.
B. Components
a) DC motor
DC motors are selected depending upon the
weight and speed of the robot. In this project, we
have used the motors of 150 rpm and 2kg-cm torque.
No load current value equals to 60mA (max) and
Load current equals to 300mA. In its common mode
of operation, DC motors can be driven
simultaneously, both in forward and reverse direction.
L293D is a dual H-bridge motor driver integrated
circuit (IC). Motor drivers proceed as current
amplifiers because they capture a low-current control
signal and supply a higher current signal. This higher
current signal operates to drive the motors.
b) Wheels
Selection of wheel is an important part, as the
torque and rpm of the motor may vary depending
upon the dimensions of the wheel. The selected motor
dimensions are 68mm in diameter and weight equals
to 200gm. The core material of the wheel is steel
alloy and the outer part (grip) is rubber. Using rubber
on the outer side increases traction with rail.
c)GPS
GPS stands for Global Positioning system. Global
Positioning System tracking is a method of working
out where exactly the robot is. In the same way, it
tells where exactly the crack is. It also tracks the
movement of the vehicle at the same time. When a
crack is detected by the sensor the vehicle stops at
once, and the GPS receiver triangulates the position
of the vehicle to receive the Latitude and Longitude
coordinates of the vehicle position, from satellites.
Many systems will preserve the data in the GPS
tracking system itself while some send the
information to a centralized database or system by
use of a modem within the GPS system unit or 2-Way
GPS.
d)GSM IV. RESULTS
Mobile messages are sent with the help of GSM.
GSM module provides high range, wireless
communication for integrating the system. It is used
to establish communication between a computer and
a GSM module. An embedded system is used because
the control is completely dedicated towards the
device or the system it controls.
e)Passive Infrared Sensors
(PIR sensors) are electronic devices which
measure infrared light radiating from objects in the
field of view. This sensor is made up of pyroelectric
sensor. This sensor is used to detect the levels of
infrared radiation. This basically acts as a motion
detecting device, helps to detect human presence or
any animal presence on the railway track. Fig4. Flaw
C. Ultrasound testing
In pulse-echo the transducer installed in a pro
The basic principle of ultrasonic testing of performs both the sending and the receiving of the
materials is the propagation and reflection of sound ultrasonic pulse on the computer monitor the
waves. For example, consider a cylindrical intensities being planted upwards on the y-axis and
workpiece. The positions of atoms in it are extremely the time towards the right on the x-axis with a probe
magnified and simplified as a single crystal. To begin at a place free from defects only two signals which
with, a rigid unyielding stop is attached to the right are seen on the monitor i.e. the transmission pulse
front end of the cylinder. At the left front end, a disc and the echo resulting from the lower surface of the
is installed which is used to transmit and receive workpiece turned back wall echo. Moving the probe
sound waves. Pushing and pulling briefly at the disc towards the right leads to an additional echo created
causes a longitudinal sound wave to propagate by the defect. Even further towards the right, only the
through the cylinder. When the sound waves reach to defect echoes are visible from the transmission parts.
the rigid right side it is reflected and runs back
towards the disc which now serves as a receiver. A
free end is also able to reflect a wave. In this case,
however the tents outside run ahead in the reflected
wave and finally deflect the receiver to the right. The
reflected wave is even reflected again and travels
back for several times across the length of the
cylinder. Therefore if a sound wave is generated at
one end of a workpiece, it will travel through the
material with its speed of sound. At the free end of
the workpiece the sound wave is reflected and it
returns to the transmitter which then acts as a
receiver. For ultrasonic testing of a work piece a large
transmitter is used in most cases but a rather compact
one generates a short ultrasonic pulse and a place free
from defects, the ultrasonic pulse travels to the right
front end also termed back wall the pulse is reflected
and reflected again as an echo. When the transmitter
is moved a little downward the cavity reflects a part
of the wave. That part arrived earlier at the Fig.5 Black dots are flaws which are shown in square (marked in
transmitter than the rest of the sound wave. Even red).
further downwards the cavity reflects the complete
ultrasonic pulse. For material testing, the echo of a This experiment is tested on a cylinder to be
defect can be utilized. This is the pulse echo mode on found. It contains artificial defects which are invisible
the phenomenon that hardly any sound waves pass from the outside. To track down the defects the
through the imperfection. This is called the through material tester uses the pulse echo method. A probe is
transmission mode. used for this purpose. A bright well played pioneer
of the electric disc is installed. It can transmit and
receive ultrasonic pulses. A computer operates the
probe a plug-in charger and power electronics. On the
monitor, the intensities plotted upwards and the time
is plotted to the right. After placing the probe on the
top of the cylinder, initially, at all may be seen on the
monitor. The reason for this is the too small contact
area between the probe and the workpiece. Only with
the use of a gel also called as a couple and the
ultrasonic pulses can get into the workpiece and can
also go back into the probe. Now the back wall turns
up on the monitor. The material tests are spread out
the gel evenly on the top surface. That way it is
doable to the entire cylinder. Using the velocity of
sound in the material one can plot the calculated
depth on the monitor to the right instead of time a
very useful feature. With the help of so-called trigger
gates which may be set on the computer with the
echoes mouth, the depth of the defect can easily be
read off at the lower left hand of the corner of the Fig.8 Control Signal
monitor.
Signal details:
1-9.3 divisions: Reflection from axle end.
1-8.7 divisions: Reflection from the inner groove.
3-2.8 divisions: Delayed reflection from wheel seat
inner fillet.
4-2.3 divisions: Delayed reflection from wheel bent
inner fillet.
5-1.7 divisions: Reflection from wheel seat inner
fillet.
6-1.4 divisions: Delayed reflection from near and
groove.
7-0.5 divisions: Reflection from near and groove.
Fig.6 Ultrasonic Test Report
Note: Sometimes signal at 9.0 may appear due to
The cylinder back wall lies in a depth of about delayed reflection from wheel seat out fillet.
200 millimeters below the probe. So the cylinder has
a height of 200 millimeters. The material tester scans The following Fig. 8 and 9 shows scan for Low angle
the upper front end of the cylinder with a probe and and high angle scan respectively. Low angle scan has
observes the monitor. A defect echo appears on the longitudinal wave while high angle scan has the shear
monitor. This echo is located at the depth of 130 wave.
millimeters below the surface. Another echo indicates
the defects in the depth of 87 millimeters. Second
smaller echo at 174 millimeters is caused by double
reflection on the same imperfection.
A. Graph and Simulations:

Fig 9. Low angle scan

Fig.7 Far end scan trace pattern

Note: All the dimensions are in mm. This sketch is
made for ultrasonic test purpose only.

Fig.10 Low angle signal
Signal details: (longitudinal)
1-4.6 divisions: Reflection from wheel seat fillet
2-5.1 divisions: Reflection from wheel boss
3-6.0 divisions: Delayed reflection from wheel seat
inner fillet.
Fig.11 High angle scan
Fig.12 High angle signal
Signal details: (Shear wave)
1-4.2 divisions: Reflection from wheel seat inner
fillet.
2-6.6 divisions: Reflection from wheel seat outer
fillet.
The Signal at 7.5 divisions may appear from collar
fillet.
B. Ultrasound measurement using WSNs
Currently available ultrasound predicated Non-
Destructive testing equipment is mostly too
immensely colossal, power-intensive, and sumptuous
for wireless sensor network. Graphically presenting
quantified data on a colored exhibit in authentic-time
is a potency intensive process that needs very high
sampling analog to digital converters and refined
graphical exhibit technology. For wireless sensor
network, such operation data is not required since
unprocessed data is directly recorded back to a server
where it is exhibited only when necessary. The
origination of ultrasound waves and its timely
receiving is the only desired part of a Non-
Destructive Testing system in the ultrasound front
end. This somewhat reduces the amount, utilization
and cost of wireless sensor network based Non-
destructive system. For thickness based Non-
Destructive testing high-speed analog to digital
converter would not be needed, which could
somewhat minimize power load on the system.
Application of a wireless sensor network based Non-
Destructive solution would be advisable for low-cost
supervision of material examination in a static and
isolated environment. The system planning for a
wireless sensor network based Non-Destructive
Testing solution frames upon wireless network
platform. This platform is modular wireless sensor
network platform that permits up to four
characteristic modules to be linked naturally
identified.
V. CONCLUSION
The idea can be implemented in large scale to
facilitate better safety standards for railway tracks in
future. This autonomous vehicle will have a great
impact on the safety and maintenance of tracks. This
vehicle will help in preventing train accidents. This
can be carried out without any human intervention. In
this paper, we have shown the flaw detection using a
USFD machine. The detectable size of the flaw
depends on the wavelength of the ultrasonic wave.
Normally a flaw size of λ/2 is reliably detectable. The
velocity of a particular wave in a medium is constant.
It does not give any false output and has an accurate
detection. The transmitting signals are immediately
transferred.
VI. FUTURE WORK
We have presented the system design and the
locomotion to be achieved by the vehicle. As
mentioned before, tier’s axis is perpendicular to the
ground and during the cross section of the track the
same mechanism it makes it difficult to move from
one track to other. Better locomotion could be
achieved. The system is designed in such a manner
that the vehicle should not engage the train routine
and should work on empty tracks. In case of train
arrival, such mechanisms should be developed so that
the vehicle should get fold between the tracks without
disturbing the train’s routine. There can be an
addition of solar panel which will help in conserving
the power resource.
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