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1. Click an item to select or unselect it Selected Items are highlighted in yellow When selecting an item the behaviour of other items on the sort control is as follows e When selecting ascending or descending the next available primary secondary or secondary item becomes selected e When selecting primary secondary or tertiary sort the ascending item becomes automatically selected e When selecting primary and another column is already selected as primary the newly selected column becomes the primary sort and the other column becomes unselected The same applies for secondary and tertiary Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 peee pee cS s am RailBAM Trending Database v5 8 User Manual Page 22 of 61 4 5 2 Data Forms Paging Paging is used to speed up the rendering of all data forms Rather that displaying all the data at once the data is split up into pages of one hundred records The paging control is located in the bottom right hand region of data forms an es H Brel Me eel LC ee Hr in KN E E ibA yli K iH ih i H il ES DI EH H H E LEY 8 LA Fn a D H E i ipg Wiii ME Lig Fi D M E fa Ll AL DR In 7a i H Era H EF Ej CMDS a Pd ET HI ba F LiF a r E i JE HHH i ka UN ZS D La Em ti bi L MCL HR DI GSM PR u tan T A E L LADE Gei Ka thi fri Ki E Weel i D Sa IH AF Es Er d LJ NCOHGGAERL V im JET Bs Li Lre 7 H E
2. To display a particular bearing history enter a 139 then click ial 4 8 4 Wagon passes Depending on the location of RailBAM cabinets and the routing of the traffic not all rolling stock may be scanned by the RailBAM Q systems The wagon passes form lists all known rolling stock and the number of times each side of the wagon has been seen by the RailBAM system Based on this report decisions can then be made to reroute traffic to expose rolling stock to the RailBAM system In Figure 4 12 the form reports that some vehicles have been seen 72 times or more for the period selected in Global Parameter Selection whilst other have been seen 3 times and some not at all Wagon passes Passes Passes Tag L AAR R AAR BWGN 7055 CAR 1503 CAR 1525 CAR 1526 CAR 1539 CAR 3432 EWGN 1910 ACAR 56 CAR 1815 Perini 0 Sep 2010 10 Now2010 Excluding S Fu Show acords 1 100 lage Orphans Untagged Including howing records 1 100 lt gt Page RR Removed Bearings Sites Sitel Stez Operators Op Total number of records 9724 ke Ignore tag class Figure 4 12 Wagon passes In the case of sites with single RailBAM cabinets as opposed to sites with dual RailBAM cabinets Passes L amp Passes R may not always be equal This is because only one side of the vehicle will be measured by the RailBAM system in this configuration Should one side of a vehicle not be exposed enough then decisi
3. e Axles indicates the total number of axles analysed on the train e Vehicles indicates the total number of vehicles including locomotives on the train e Length shows the total length of the train e Km h in out MPH in out shows the speed of the train entering in and leaving out the RailBAM System e Direction shows the direction the train was travelling Refer to RD 1 for definition of directions e Fault Count and Fault2 Count indicate the number of faults on a train that belong to the severity category shown by the drop down options at the bottom of the form Refer to Chapter 3 for a definition of severity categories The Train List form possesses the following controls e 2 Display a summary of that specific train o Faulti Clearlevell Fault ClearLevel2 we Drop down options o Displays a count of specific faults symptoms found in a train o Note Choosing the same type for both categories will double the count when summing the two faults e Refresh data form to populate the Train List as per Parameters selected and Fault1 Count amp Fault2 Count options e E Export data to Microsoft Excel Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 21 of 61 4 5 1 Sorting Data Forms Data forms consist of columns Each column heading contains a sort control Train ID Loco ID The sort control consists of five clickable items
4. Order The unit used on the horizontal axis of RailBAM spectral plots One order one revolution of a wheel Orphan Rolling stock for which an operator has not been assigned See Appendix B 2 Peak Magnitude The magnitude of a peak read from the vertical axis ina RailBAM spectral plot See Section 7 1 Prefix Component of severity classification used to identify noise that may interfere with bearing or wheel fault detection For example Clpd Shrk FBS NOISY See Chapter 3 Roller Pass Frequency Rate at which the rollers pass over a point on the cup and cone raceways Running Surface type of bearing fault See Section 3 1 Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 Op RailBAM Trending Database v5 8 User Manual Page 60 of 61 severity Categories A group of severity classifications See Chapter 3 Severity Classification An identifier for the type and extent of fault development See Chapter 3 Shrieking a strong tonal sound that is removed before bearing and wheel fault analysis See Section 3 4 Spectral Plot A plot showing fault spectra or signatures with peak magnitude on the vertical axis and order on the horizontal axis RailBAM Spectral Plot Tag ID Wagon ID The tag number unique to each wagon See Appendix B 1 Component of severity classification used to identify the most likely type of fault as predicted by the RailBAM System For example
5. ol FNS Lav 52 6 2 Fault Alerts for Replaced Bearings anrenanunnnnnnnnnnnnnunnnnnnnnnennnnnnnnennnnnnnnennnnennnnnnnnennnvennnr 53 7 INTERPRETATION OF TRENDING DATA nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 54 PN PEAK MAGNUS sd 54 FEN 55 7 3 Example Increasing Fault Strength aanxrnnnnonnnnnrnnnnennnnnnnnnnennnnennnnnnnnnnennnnennnnnennnnennnnnen 55 7 4 Example Sudden Decrease in Fault Strength rrnnnrnnnnvvnnnvrnnnuvnnnnvennnunrnnnnennnvennnnennnnner 56 7 5 Direction Dependent Faults cccccsseccsseeeeeeeeseeeseceeeeeeseseaseeeneeoeseseaseoeseeenseneaseoenesons 57 TE y a o EE NE 57 oO ed ad eee en E E EEE E E EE EEEE EREE 58 APPENDIX A IMPORTANT TERMS rerrnnoonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnr 59 APPENDIX B BEARING LOCATION CONVENTION seen 61 BI Tagged Rolling EE te Tei 61 B 2 Orphans and Untagged Rolling Stock ranrerannrnnnnnnnnennnnnnnnennnnennnnnnnnennnnennnnnnnnennnnennnennnnen 61 B 3 Viewing Orphans and Untagged Rolling Stock nrrrnnurnnnennnnennnnnnnnennnnnnnnnnnnnennnnennnennnnen 61 Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 5 of 61 1 INTRODUCTION 1 1 Overview of the RailBAM System Developed by Track IQ the RailBAM System a Bearing Acoustic Monitoring system is designed to detect and rank axle bearing faults provide condition mo
6. 1 cup and Figure 3 2 cone e Brinelling e Water etching See Figure 3 3 e Electrical etching e Corrosion Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 Page 10 of 61 Figure 3 2 H Ac A Nu ken A AE Figure 3 3 Water etching on rollers Spherical Roller Bearings Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 11 of 61 A description of particular Running Surface RS faults can be determined by the roller pass frequency the rate at which the rollers move over the cup and cone raceways Whena description of the fault is clearly identifiable a descriptor is appended to the severity classification For example a severe cup fault would be classified as RS1_p The approximate roller pass frequencies and descriptors for different RS faults are given in Table Cons 125 1 cup tH p 3534 Multiple Any combination of the above Extended Any of the above with additional e S indication of an extended fault Table 3 2 Roller Pass Frequencies and Fault Descriptions of specific running surface faults Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 12 of 61 3 2 Looseness and Fretting LF Faults Faults that generate a more continuous sound rather than the faster pulsing sound generated by Running Surface RS faults are ident
7. DEFINITION Administrator RailBAM A person with permission to change settings of a RailBAM system system Bearing ID The axle number and side for a particular bearing See Appendix B 1 Clpd Clipping caused by saturation of the microphone signal See Section 3 4 dB Trends 1 plots These plots display fault strengths normalised to speed for running surface faults See Section 4 8 1 dB Trends 2 plots These plots display fault strengths normalised to speed for all faults except running surface faults See Section 4 8 1 Descriptor Component of severity classification used to reveal detail about the fault For example p n r M S See Chapter 3 Direction Dependent A bearing wheel fault which is more prominent when the wheel is rotating in a particular direction See Section 7 5 Fault Strength A measure of the strength of a fault that is normalised for wheel speed See Section 7 2 FBS Extraneous noise from Flanging Braking or Slamming that may interfere with bearing and wheel fault analysis See section 3 4 History Plots This displays a spectral plot and a RPM graph See Section 4 8 1 Level Component of severity classification used to identify the severity of the fault For example 1 Severe 2 Moderate or 3 Minor See Chapter 3 Looseness Fretting type of bearing fault See Section 3 2 NOISY Unknown extraneous noise that may interfere with bearing and wheel fault analysis See Section 3 4
8. FO2008 4 58 12 AM emm 40202008 20227 PM emm 1 022008 12 04 56 AM sm 1502 2006 9 57 07 AM ee 2002 2008 20252 AM Figure 7 1 Significant cup fault at different pass by times The peak magnitude is shown in Figure 7 1 where the red dashed line determines the magnitude of a peak from the vertical axis The peak magnitude can be affected by any of the following factors e Bearing deterioration e Wheel speed Section 7 2 e Direction of wheel rotation Section 7 5 e Axle load to a minor extent Section 7 6 An example in which the peak magnitude is used to interpret data is included in Section 7 4 Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 55 of 61 7 2 Fault Strength The normalised fault strength is a more succinct measure for monitoring the development of a fault since it is normalised for speed In other words the fault strength is only affected by the following factors note that wheel speed is no longer applicable e Bearing deterioration e Direction of wheel rotation Section 7 5 e Axle load to a minor extent Section 7 6 As explained in Section 4 8 1 the RailBAM Trending Database contains graphs showing the fault strength for various kinds of bearing and wheel faults To determine whether a RS fault is increasing or decreasing over time the dB Trends 1 graphs should be the primary consideration These graphs show fault strength over time s
9. Statistics menu Figure 4 6 Statistics EN Figure 4 6 Statistics menu 4 8 1 Bearing History Bearing history can be accessed through the following routes e Train Summary Section 4 5 e Statistics menu Section 4 8 e Most Seen Section 4 8 6 e First Seen Section 4 8 7 Bearing histories are only available for tagged wagons For untagged wagons because the wagon cannot be identified only information for one pass by can be shown Only data from trains that match the parameters entered in the Parameters form Section 4 4 will be displayed Selecting the Bearing History button on the Statistics menu will open the Bearing History form To display a particular bearing history enter the Tag Axle and Side or Wheel depending on the bearing numbering system you are using Tag CAR 4008 Axle 6 Side HR Wheel The Tag may be entered in a number of different ways For example an AAR standard tag XXXX 001234x may be entered completely XXXX 001234x or partially XXXX1234x XXXX 1234x XXXX001234x The actual format is displayed when tab is pressed If multiple wagons match the number entered the desired tag ID can be selected from a list If the exact Axle and Side bearing ID is not known the axle and side spaces can be left empty and the information for all bearings on the vehicle are presented Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Pag
10. default removal status and a Date Format to match the date format in your input file e When you have done the above you should save your settings as a profile so they can be re used at a later time by Entering a profile name and clicking e You can delete profiles by using the DI button Click in the Removed bearings Import Wizard form to import the data into the Removed Bearings form e Click g to open the Bearing Details and Inspection Results section These forms allow you to enter inspection results details Note The data automatically saves as you type into each field ob laaan Tag CAR 000597 Aler Side R Type Date last reconditioned Serial number Last reconditioner Manufacturer Total months in service Was New O Total kilometres run e Type contains a drop down list to select the type of bearing removed e Serial number contains the bearing manufacturer s serial number entered e Manufacturer contains a drop down list of manufacturers to select the manufacturer of the removed bearing e Was New is ticked if the faulty bearing was a new bearing That is it was never reconditioned e Date last reconditioned is the date the bearing was last serviced reconditioned Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 51 of 61 e Last Recondition
11. e WHLFLT1 Wheel Flat of level 1 The severity classification is used wherever individual pass by s are displayed such as the Bearing History form detail Section 4 8 1 and Train Summary form detail Section 4 7 Individual severity classifications are grouped into categories wherever fault summaries are displayed This can be seen in the Train List form Section 4 5 Train Summary form summary Section 4 7 Bearing History form summary Section 4 8 1 Wagon History form Section 4 8 3 Most Seen form Section 4 8 6 and Statistics plots Sections 4 8 9 and 4 8 8 The RailBAM Trending Database comes with a set of pre configured severity categories as defined in Table 3 1 Additional severity categories can be created by RailBAM System administrators The purpose of severity categories is to assign multiple fault types to one easily recognisable label This helps manage and display the numerous fault types Clear Level 1 D DFL m e S Shrk or no prefix Table 3 1 Pre set severity categories Clear Level 2 Dn r m e S Shrk or no prefix Consideration A severity classification may be included in more than one category If these categories are displayed in the same fault summary the total number of faults can include the same fault type more than once 3 1 Running Surface RS Faults Running surfaces include the cup cone and rollers of a bearing Acoustic signatures can be caused by faults such as e Spalling See Figure 3
12. example is shown in Figure 6 1 Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 BS Fw RailBAM Bearing Alert Yersion 6 4 Message HTML File Edit View Insert Format Tools Actions Help Ca Reply G Reply to All 3 Foward G Y EG A As vr AC D From DoNotReply R ailBAM com Uwe Kopke EC Subject FW RailBAM Bearing Alert Version 6 4 Rule 1 Clear Level1 Clear Level2 gt 6 count s Rule 2 Clear Level1 3 count s Page 53 of 61 Sent Tue 05 06 2012 18 16 The list below shows the number of times each bearing satisfied any of the above rule s within 10 pass es and 120 day s from the last pass Check Date 28 05 12 11 03 Undefined CAR 3433 28 05 12 14 48 Undefined CAR 4006 28 05 12 03 42 Undefined CAR 7843 Total number of records 3 Checked Sites Site1 Site2 4 Figure 6 1 Trend Alert Email 6 2 Fault Alerts for Replaced Bearings If this function is activated fault alert emails for bearings that become faulty soon after being removed and replaced see also Section 4 8 5 will be sent to the appropriate operator Refer to RailBAM Importer Configuration RD 2 for details An example is shown in Figure 6 2 RailBAM Removed Bearing Alert Message Plain Text dj Reply to All SE Forward 4 Si dl A x Forv A S t Format Tools Actions Help Extra line breaks in this message were removed From RAILBAM DATA IMPORTER To hearing s
13. large date selection is chosen the spectra can be cluttered To overcome this you have the option to show one pass by at a time in the fault spectrum chart by clicking ona date time at the left of the bottom chart To show all passes again click the Show all passes button Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 31 of 61 e You can stretch the fault spectrum chart in the Y direction entering a Zoom value e g 6 82e5 or by clicking on the magnitude label or by using the slider The three graphs on the dB Trends1 tab Figure 4 9 show Running Surface RS faults by type over the selected time period RS fault types are described in Section 3 1 Bearing history graph CAR 4008 6R a E E E E E Ea E Di Ji OZ 13 4 04 13 15 16 18 15 15 20 ae Z i ZA 23 24 Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 16 iT 17 18 19 20 Z i Kai 24 Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul io 10 10 10 io 10 10 10 10 io 10 17 18 19 19 ZA 2 24 Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul 19 10 10 10 10 10 10 10 10 10 Figure 4 9 Bearing History graph dB Trends1 tab e The top chart in dB Trendst shows Fault Strength of Cone faults over time This particular bearing shows virtually no cone faults there are only a few Fault Strength bars shown in the chart e The middle c
14. number Appendix B 1 e Axle and Side combine to give the bearing ID Appendix B 1 e Operator displays the wagon operator Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 37 of 61 e Fault count indicates the number of times the bearing was seen with a fault belonging to the severity category shown by the fault drop down option Refer to Chapter 3 for a definition of severity categories The Faulty Replaced Bearings form possesses the following controls e Fault ClearLevell v Min 5 The type and number of fault criteria e Show removed bearings faulty within 10 day s or 5 pass es after removal The number of days or passes after removal criteria ir Refresh data form as per Parameters form and fault criteria selection 4 8 6 Most Seen Bearings Selecting Most Seen Bearings from the Statistics menu displays a list of bearings that have been detected with the highest number of fault symptoms for a chosen fault type Fault1 Only wagons that match the parameters entered in the Parameters form and that match Fault1 type are included Fault2 provides a secondary fault count but does not determine the form results Most seen bearings WGN 10449 CAR 1577 CAR 3047 CAR 3763 CAR 2745 CAR 2494 EWGN 2138 CAR 4008 WGN 10259 CAR 2023 CAR 1555 CAR 3111 CAR 4008 CAR 1550 EWGN 1700 CAR 2617 WGN 10407 CAR 3545 CAR 2537 CAR 2035 CAR 3950 CAR 3640 CAR 3058 C
15. or LF bearing faults however it cannot be concluded that these are not true bearing faults For example a flanging noise could be obscuring a bearing fault of any kind For this reason the severity classifications for such wheels are prefixed with Clpd Shrk FBS or NOISY with the potential fault tyoe and ranking shown in brackets e Clpd clipped indicates noise that causes saturation of the data acquisition equipment e Shrk shrieking indicates a strong tone in a high frequency band This tone is removed by the RailBAM System before further analysis but retained in the sound file e FBS indicates the presence of Flanging Braking or Slamming e NOISY indicates an unknown noise For example FBS RS1 indicates a potential RS1 fault associated with extraneous noise from flanging braking or slamming The Play Sound 2 feature in the Train Summary Section 4 7 and Bearing History Section 4 8 1 forms can be useful in determining the nature of a FBS NOISY Clod or Shrk pass It is useful to get a feel for how various fault signatures sound to interpret some RailBAM trending data comprehensively Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 14 of 61 4 DETAILED DATABASE INSTRUCTIONS 4 1 Running the web application The RailBAM Trending Database is a rich web application and has been formulated to run across various web browsers Recommended web brows
16. 05 PM Site2 L 1 ABC 008252 R 558 138 2249 61 63 East T 28 EI 16 03 2008 06 04 17 PM Site2 L 3 ABC 008135 R 566 140 2286 37 58 East 8 11 EI 16 03 2008 04 49 43 AM Gute L 1 ABC 005796 R 526 130 2123 53 51 West 11 14 EI 16 03 2008 12 14 01 AM Site2 L 1 ABC 006610 L 522 129 2104 72 68 East 2 4 EI 15 03 2008 08 09 18 DM Site2 L 1 ABC 005878 L 522 129 2106 81 83 East 6 8 E 14 03 2008 10 24 44 DM Site2 L 1 ABC 006444 R 558 138 2248 59 62 East 10 19 E E 12 03 2008 12 15 35 PM Site2 520 129 2097 58 60 East 6 16 Mar fe ak AN ite Le ala dt A b Period 01 Jan 2008 31 Mar 2008 Including Orphans Untagged Including Removed Bearings Sites Site1 Site2 Site3 Operators Op1 0p2 Total number of records 195 ault1 Clear Levelt Y Fault2 Clear Level2 e Ed Figure 4 4 Train List form Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 20 of 61 The individual columns on the Train List form are e Time the time which the train passed the RailBAM System e Site the site as which the train passed the RailBAM System e Train ID on some systems a Train ID is automatically assigned typically based on a dynamic loco tag containing a Train ID Otherwise this is blank e Loco ID when the tag of the first locomotive is read this is displayed in the Loco ID box o If the tag is missing or is not read correctly the second or third tag will be used
17. 2 03 2006 2 17 12 AM eh EEEEEKEECEEEEKECECEEKCEKE ok KM ka kd kd KM kd ka kd kd kd ki eriod 01 Jan 2008 31 Mar 2008 including Orphan s Unta gged Including Removed Bearin gs Sites Site1 Site Site3 Operators Op1 Op2 Total number of records 619 Figure 4 15 First Seen form The following information is displayed on the First Seen Bearings form e Tag is the tag identification number Appendix B 1 e Axle The wagon axle on which the bearing is situated See Appendix B 1 e Side The wagon side on which the bearing is located See Appendix B 1 e Severity indicates the severity classification assigned to the first pass by of the faulty bearing Refer to Chapter 3 for a definition of severity categories e Operator displays the wagon operator e Time of the first reading at this severity for this bearing Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 40 of 61 The First Seen Bearings form possesses the following controls e Launch bearing history Section 4 8 1 e Mark bearing as pending removal from service The bearing is automatically entered into the bearings remove from service form Section 4 9 4 with today s date e You can choose which fault type or group will be used to generate the data using the fault Clear Levell drop down menu Fault S Refresh data form as per Parameters form and Fault Co
18. 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 47 of 61 4 9 3 Assign Tags The Assign Tags form Figure 4 23 can be used by the RailBAM System administrator to assign groups of orphan tags to rolling stock operators Assign tags Matched Tag CAR 006620 Total number of records Tag criteria CAR Assign to Operator 1 Show Misread Assign Misread Figure 4 23 Assign Orphans form To assign orphan tags perform the following steps 1 Type in Tag criteria a tag or part of a tag then click the Search button the form will display a list of all orphan tags that match the Tag criteria 2 Select from the Assign to drop down menu the operator you wish to assign the listed tags to and click the Assign button You can also assign misread tags to a particular operator 1 Click the Show Misread button 2 Select from the Assign to drop down menu the operator you wish to assign the listed tags to and click the Assign Misread button Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 48 of 61 4 9 4 Removed Bearings The Removed Bearings form Figure 4 24 is used for managing and telling the RailBAM System which bearings have been removed from service IMPORTANT NOTE Bearings removed by the maintainer should be entered into this part of the database It Is important that this is done diligently to maximise the effectiveness of the Rai
19. AR 3612 Period 01 Jul 2010 37Jul 2010 Including Orphans Untagged Including Removed Bearings Showing records 1 to 51 APR Page I ial ah won TT e k eo tm fa Ou ow as j armer ee 0 Pir E Fo E a Op 201 20 4 ch P My Bo hs Jeu JJ seer errr rer TT TTT TTT TTT TT Sites Site 1 Site Operators Op1 Op2 Total number of records 51 Figure 4 14 Most Seen Bearings form The following information is displayed on the Most Seen Bearings form e Tag ID The tag identification number Appendix B 1 e Axle and Side combine to give the bearing ID Appendix B 1 Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 38 of 61 e Operator displays the wagon operator e Fault 1 amp 2 count indicates the number of times the bearing was seen with a fault belonging to the severity category shown by the fault drop down options Refer to Chapter 3 for a definition of severity categories e Consistency 1 amp 2 is the percentage value of how consistent the fault readings have been each time the bearing has been measured by the RailBAM System If a fault level is maintained or increases steadily over time then the consistency percentage value will be high If readings are more sporadic then the consistency percentage value will be low e Passes displays the total number of times the bearing has passed a RailBAM System during th
20. N 11432 WGN 11417 Total number Showing records 1 100 i Page 1 of records 169 Figure 4 21 Orphan Tags form You can export the data to Microsoft Excel by clicking E Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 46 of 61 4 9 2 User Tags The User s Tags form Figure 4 22 displays a list of the wagons with identification tags held in the RailBAM Trending Database and the associated wagon operator and bearing type optional It is the responsibility of the RailBAM System administrator to update this table according to information provided by rolling stock operators User tags Operator ID Tag Bearing Type AEPX 003337 AEPX 003342 AEPX 003385 CAR 000501 CAR 000502 CAR 000503 CAR 000504 CAR 000505 P P AE AE AE AE AE Total number of records 3482 Figure 4 22 User Tags form To add a new user tag 1 Type in a new tag into the Tag box 2 Select an Operator from the drop down menu 3 Select a bearing type from the drop down menu optional 4 Click Add To delete a tag or a set of tags 1 Type in a tag into the Tag box or a wild car entry e g CAR would delete all tags starting with CAR 2 Click the Delete button To edit a Tag 1 Click next to the tag you wish to edit 2 Make changes to Tag Operator and bearing type as required 3 Click Save Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence
21. RS LF NOISY WHLFLT See Chapter 3 WHLFLT Wheel defect type of fault See Section 3 3 Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 61 of 61 Appendix B Bearing Location Convention B 1 Tagged Rolling Stock Where rolling stock is tagged the location of a specific bearing on a wagon bearing ID is notated according to the convention selected by the RailBAM System administrator The bearing ID does not change with direction The tag ID refers to the number and letters uniquely assigned to each tagged wagon A tag ID may consist of different combinations of letters and numerals Specific bearing locations cannot be determined for untagged rolling stock B 2 Orphans and Untagged Rolling Stock Rolling stock for which an operator has not been assigned in the RailBAM Trending Database are referred to as orphans Information about which orphans exist is available to all users including history and trending data When the operator of an orphan is identified this information must be added to the Permitted Users Tags table by the RailBAM System administrator as described in Section 4 9 B 3 Viewing Orphans and Untagged Rolling Stock To view untagged and orphan rolling stock click Orphans Tags from the Tags amp Maint section in the application menu Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012
22. Trackside Intelligence Pty Ltd RailBAM Trending Database v5 8 User Manual Document No 51R 05 5656 UMA 239163 10 7 June 2012 ELE tyrseper seretirn W Trackside Intelligence Pty Ltd gE Cassa TEIE mile OG HOLE 17 19 King William Street et ET STi Teri ik Hie CTIE TOTON Kent Town SA 5067 Phone 61 8 8362 5445 Fax 61 8 8362 0793 RailBAM Trending Database v5 8 User Manual Page 2 of 61 RailBAM Trending Database v5 8 User Manual DOCUMENT NO 91R 05 5656 UMA 2391 63 1010 PREPARED BY Trackside Intelligence Pty Ltd 17 19 King William Street KENT TOWN SA 5067 PREPARED BY REVIEWED BY AUTHORISED BY REVISION HISTORY Revision No 1 COON O ao A O N 9 10 LIBRARY CODE B 99 Email railbam Qvipac com au Fax Emmanuel Mouille VA lyn Nick Aschberger died Mirek Vesely Date Issued 19 July 2007 31 October 2007 12 June 2008 29 April 2009 26 July 2010 8 November 2010 10 March 2011 7 June 2012 18 November 201 1 7 June 2012 KEYWORDS RailBAM Trending Database User Manual 61 8 8362 5445 61 8 8362 0793 7 June 2012 Date 7 June 2012 Date 7 June 2012 Date Reason Comments Database v4 0 8 Database v4 1 1 Database v4 2 Database v5 Web version Database v5 2 Database v5 6 Database v5 7 Database v5 8 Changed MostSeen behaviour v5 8 1 Formatting This document contains commercial conceptual and engineering information which is proprietar
23. Trending Database Configuration RD 3 for more details Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 7 of 61 2 APPLICABLE AND REFERENCE DOCUMENTS The following documents form a part of this document to the extent specified herein In the event of any conflict between this document and any applicable document referenced herein such conflict shall be reported to the Quality Manager in the Adelaide office of Trackside Intelligence All documents shall be used at their most current agreed issue 2 1 Applicable Documents Reference to the documents within the text shall be by the following nomenclature AD x where x denotes the reference document number There are no applicable documents 2 2 Reference Documents Reference to the documents within the text shall be by the following nomenclature RD x where x denotes the reference document number RD 1 51R 05 5656 UMA 233002 RailBAM System User Manual RD 2 51R 05 5656 UMA 239163 RailIBAM Importer Configuration RD 3 51R 05 5656 TNT 422500 RailBAM Trending Database Configuration Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 8 of 61 3 FAULT TYPES AND NOTATION Each bearing or wheel that passes a RailBAM system is given a severity classification in the following format PREFIX TYPELEVELDESCRIPTOR PREFIX noise that may
24. ailBAM fault types The severity categories assign multiple fault types to one easily recognisable label The RailBAM Trending Database comes with a set of pre configured severity categories which can be explored as per below Click on Severity categories in the main menu to reveal the pre configured severity categories Seventy categories Clear Levelt gt Running Surface Faults R Level 1 potential e cup p multiple _m cone n extended _e roller es Ls No fault Other Faults LF none WHLELT none Select the other categories for the drop down menu and take a look at what they comprise of To successfully use the RailBAM Trending Database you should be familiar with each severity category Whilst administrators can create new custom categories RailBAM Trending Database comes with the following pre configured severity categories e Clear Level 1 e Clear Level 2 e Potential 1 amp 2 e Wheel Flats See Section 3 and Table 3 1 for more detail Note that the less specific classic fault rankings that were generated by older RailBAM Wayside software before ver 5 effectively encompassed the clear and potential rankings For example the Classic RS1 are now encompassed by RS1 and RS1 e RS1 m RS1 r RS1_n RS1_p The corresponding ranking is therefore very similar to RS1 which is available in the Fault tyoe drop down options Alternatively specific fault categories name
25. ata form as per Parameters form e ll percentage data can be exported to Excel to form the data set for an Excel graph Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 43 of 61 4 8 9 Monthly Statistics The Monthly Statistics buttons on the Statistics Figure 4 6 displays the monthly statistics graphs Figure 4 18 and Figure 4 19 by severity category There are two variations of the Overall Statistics graph By passes In this variation of the graph each bearing measurement seen by the system is considered The graph shows a monthly breakdown of the percentage of bearing measurements at a selected severity divided by the total number of bearing measurements in that month Monthly Statistics Clear Levelt Potentiall amp 2 Clear Level Wheel Flats RSTl e RS1 m Hait RS1 n RS1_p RS1 RS e 0 80 0 60 RS2 m RSZ r 0 40 3 RSZ n 3 RS2 p BB VB Ma VM OE eee 0 20 Jar UD Feb Up Clear Levelt Potential1 amp 2 E Clear Level Vvheel Flats Sites Site1 Site Site3 Operators Op1 Op2 Based on 340832 bearing passes Figure 4 18 Monthly Statistics By passes graph The total number of bearings that passed the selected sites is displayed at the bottom right hand corner of the form The total number of bearing passes for each individual month is not displayed but is factored
26. ata form as per Parameters form and fault types selected Restore fault types to default selection and Refresh data form as per Parameters form e EO percentage data can be exported to Excel to form the data set for an Excel graph Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 45 of 61 4 9 Tags and Maintenance The Tags and Maint menu Figure 4 20 offers the following functions e Orphan tags e User Tags e Assign Tags e Removed bearings Tags amp Maint The User tags and Assign Tags functions are available to Trend and Administrator logins only Figure 4 20 Tags and Maintenance menu The Tags and Removed Bearings functions are used by RailBAM System administrators to assign tag ownership and by rolling stock maintainers for entering removed bearings 4 9 1 Orphan Tags The Orphan Tags form Figure 4 21 displays a list of tags that have been read by a RailBAM System but are not listed in the Permitted User s Tags list Section 4 9 2 This may be due to the tag being misread or not yet assigned to the list of operators wagons It is the responsibility of the RailBAM System administrator to resolve orphan tags by assigning tags from this list to rolling stock operators as described in Section 4 9 3 Orphan tags WGN 15003 WGN 11439 WGN 11438 WGN 11437 WGN 11436 WGN 11435 WGN 11434 WGN 11433 WG
27. base v5 8 User Manual Page 16 of 61 4 3 Menu After the login has been accepted and access is gained into the database the application menu Figure 4 2 is displayed The menu is divided into four sections Main Statistics Tags amp Maint Window 2 Ys Statistics NA Tags amp Maint y Statistics Tags amp Maint A Window X Figure 4 2 Main menu Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Each menu section contains the following functions 1 Main o Parameters o Train list o Severity categories 2 Statistics o Bearing history o Wagon history o Faulty replaced brgs o Most seen bearings o First seen bearings o Overall statistics o Monthly statistics o Wagon passes O O O O O Section 4 4 Section 4 5 Section 4 6 Section 4 8 1 Section 4 8 3 Section 4 8 5 Section 4 8 6 Section 4 8 7 Section 4 8 8 Section 4 8 9 Section 4 8 4 Page 17 of 61 Tag Class Filter A drop down list populated by tag classes When selected the tag class acts as a filter over all functions contained in the Statistics section 3 Tags amp Maint Orphan tags User tags Assign tag Removed bearings 4 Window o A drop down list of the currently opened windows Selecting from the drop down list brings the selected window to the front This is useful when there are many windows opened at the sa
28. d say Classic RS1 Classic RS2 and Classic RS3 could be created The definition of Classic RS1 would be similar to that of Clear Levelt shown above but with potential ticked and ers _s unticked Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 24 of 61 4 7 Train Summary The Train Summary can be launched in the following ways e Click onthe Train List form Section 4 5 e Click onthe Bearing History form Section 4 8 1 Train summary Mast t Slave Cabinet i Train Whi dia A Bearing Wheel A Bearing Wheel ee FE sanser KS CBR ds Severity gne 4R No uD BWGN 8146 1107 4L RS3 WHLFLT1 BWGN 8146 B End Leading 1076 3R BWGN 8146 B End Leading 1078 2R BWGN 8146 B End Leading 1077 1R BWGN 8138 B End Leading 1067 WHLFLT1 6R WHLFLT1 BWGN 8138 B End Leading 1067 WHLFLT1 6R WHLFLT1 BWGN 8138 B End Leading 1067 WHLFLT1 6R WHLFLT1 BWGN 8138 B End Leading 1067 WHLFLT1 6R WHLFLT1 BWGN 8138 B End Leading 1069 5R BWGN 8138 B End Leading 1069 4R BWGN 8138 B End Leading 1064 3R BWGN 8138 B End Leading 1067 2R BWGN 8138 B End Leading 1059 1R EWGN 1939 A End Leading 986 8L EWGN 1939 A End Leading 981 7L EWGN 1939 A End Leading 987 6L EWGN 1939 A End Leading 982 DL EWGN 1939 A End Leading 971 AL EWGN 1939 A End Leading 967 3L EWGN 1939 A End Leading 967 2L EWGN 1939 A End Leading 972 AL CAR 3253 A End Leading 942 E amp E a
29. display a fault count for each severity category The most severe fault is at the top of each list Wagon History Fault Cnt Clear Level 1 Plain R51 1 GAR 000531 MRD ART ISR Ar TI Fault Cnt Fault Cnt Fault Cnt Fault Cnt Clear Levelt 6 Plain R51 6 C remove C remove C remove Plain R51 Wheel Flats w o CAR 000530 o 0 CAR 000532 Clear Level1 e Clear Level2 ep Tag FO ae EDER S Figure 4 11 Wagon History form The Wagon History form possesses the following controls Da e Click 3 to add ticked bearings wheelsets as pending removal from service The bearings wheelsets are automatically entered into the bearings remove from service form Section 4 9 4 with the current date Clear Level e Clear Level The Fault counter displays fault counts e Plain R51 we for up to four types of fault or fault NFAILIAA o Select from the drop down menu and the fault count automatically updates o Note Choosing the same type for both categories will double the count when summing the two faults Refresh data form as per Parameters form and fault counter selection ip aa m O CRL OG Display previous next non orphan wagon In Alphabetical tag order Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 35 of 61 e Selecting the Wagon History on the Statistics menu will open the Weg History form
30. e 28 of 61 P Click refresh 3 to display the bearing history information as shown in Figure 4 7 Bearing history Train direction Severity Removed 24 07 2010 20 00 52 RS1 p CAR 4008 23 07 2010 21 36 24 RS1 p CAR 4008 23 07 2010 13 29 44 RS2 p CAR 4008 22 07 2010 13 00 48 RS1 p CAR 4008 22 07 2010 03 28 01 RS1 p CAR 4008 20 07 2010 17 15 11 RS1 p CAR 4008 19 07 2010 21 22 22 RS2 p CAR 4008 19 07 2010 02 50 20 RS1 p CAR 4008 18 07 2010 18 33 37 RS1 p CAR 4008 17 07 2010 17 55 19 Shrk RS1 p CAR 4008 17 07 2010 08 05 16 RS1 p CAR 4008 16 07 2010 04 14 52 RS1 p CAR 4008 15 07 2010 19 06 20 RS1 p CAR 4008 13 07 2010 19 48 49 RS1 p CAR 4008 4 07 2010 22 41 07 RS1 p CAR 4008 4 07 2010 09 06 55 RS1 p CAR 4008 3 07 2010 07 14 41 RS1 m CAR 4008 2 07 2010 22 42 02 RS1 p CAR 4008 1 07 2010 17 52 34 RS1 p CAR 4008 1 07 2010 06 49 48 RS1 p CAR 4008 E VW VW E E VW VW E E VW wW E E E E E VW W E E oO on Oo o Oo o Oo o Oo o Oo o Oo o Oo 000505 On 2 2029 2 3 2 3 20 129 20 129 2 129 o 129 029 2 7 2 a m ja a ja a a a fem fe fe le fem lem le je pe jem je a 6666666666685 Period 01 Jul 2010 31 Jul 2010 Including Orphans Untagged Including Removed Bearings Showing records 1 20 AP Page 1 v Sites Site1 Site2 Operators Op1 0p2 Total number of records 20 Tag CAR 4008 d m meet See EZ Clear Levell Y 17 Clear Level2 vw 2 Axle 6 Side R Wheel gt Sr lt a al Wheel Flats 0 Potentiali a
31. e period in the Parameters form The Most Seen Bearings form possesses the following controls e Launch bearing history Section 4 8 1 e Mark bearing as pending removal from service The bearing is automatically entered into the bearings remove from service form Section 4 9 4 with today s date e You can choose which fault type or group will be used to generate the data using the fault 1 amp 2 drop down menus Fault ClearLevell se Fault Clear Level se o Note Choosing the same type for both categories will double the count when summing the two faults e You can specify the maximum number of axles to be included The axles with the most fault counts will be included Max axles 50 e You can filter the set of vehicles show in this list by Passes and Consistency1 amp 2 filter controls Passes gt Consistency o Consistency gt o o Click Ea to activate filter o Entering a value in Passes will filter out any result with less passes than the value entered o Entering a value in Consistency1 will filter out any result with less Consistency than the value entered o Entering a value in Consistency2 will filter out any result with less Consistency1 than the value entered Za Refresh data form as per Parameters form and Fault1 Count S Fault2 Count options Note Upon opening the form refresh must be pressed in order to see the data e E Export data to Microsoft Excel Ref 51R 05 5656 UMA 239163 10 Com
32. er is the company who reconditioned the bearing e Total months in service is the total number of months the bearing was in use before removal e Total kilometres run is the total distance km run by the bearing before removal Tag CAR 000597 Axle 1 Side R SWR edge SWR bore Cone Cone back Cup defect Seal defect wear wear Cone defect defect size face wear Cup defect size Roller defect Outboard k 3 Inboard vi sl Comments Backing ring defect Fitted Bench end play Assesment v EI e Outboard contains specific details about faults found on each component of the outboard bearing assembly e Inboard contains specific details about faults found on each component of the inboard bearing assembly e Information relating to the entire bearing assembly is found in Backing ring defect Fitted and Bench end play e Assessment contains the bearing inspector s conclusion on the inspection e Comments contain additional information such as faults found or a reference to an inspection report Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 52 of 61 5 AUTOMATIC IMPORTER When the RailBAM Server detects new train data on a connected remote RailBAM Wayside computer the measurements are automatically downloaded from the wayside computer using the application AutoF TP An alternative conf
33. ers BROWSER OVERALL PERFORMANCE Google Chrome ee 100 Internet Explorer 7 or 8 SSS 96 Mozilla Firefox 3 and above Ss 80 The following web browsers can be used but are not recommended due to known issues in the browser BROWSER OVERALL PERFORMANCE RN soy Windows cannot be dragged Internet Explorer 6 E ene IE6 is an obsolete browser that does not support e Modern HTML and CSS standards Several bugs with rich applications Minimum system requirements e Windows 2000 XP VISTA 7 e 2Ghz CPU Recommended system requirements e Windows 2000 XP VISTA 7 e 2 4Ghz CPU or Dual Core 1 2Ghz Open the RailBAM Trending Database Web application in your chosen browser by following the URL provided by your I T Department e g httos RailBAM UITIER Main aspx Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 15 of 61 4 2 Log On After following the provided URL the Logon form is displayed as in Figure 4 1 Each user can be given an individual logon ID and password allowing access to permitted information only User name Password Figure 4 1 Logon form Ticking the Remember me checkbox checked will cause the login box to remember the user name up to 8 hours so that you only have to enter login details once per day Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Data
34. ervicing domain com LC Subject RailB mM Removed Bearing Alert Date 25 07 2008 2 36 04 PN On 25 07 2008 RailBiM detected the following bearing faults on after removal or 30 days after removal ignoring passes older than 300 days The following rule was used to generate the listing Rule 1 Clear Levell 1 REMOVAL DATE Sent Fri 25 07 2008 2 36 PM removed replaced hearings within 10 passes Figure 6 2 Trend Alert Email for Replaced Bearings Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 54 of 61 7 INTERPRETATION OF TRENDING DATA Tagging of wagons is essential to enable the consistent identification of rolling stock and hence the compilation of bearing fault trends over time Each time a particular wagon passes any RailBAM system the spectra of faulty bearings wheels only are retained and can be overlaid as in Figure 7 1 from the Bearing History form Section 4 8 1 Each pass by of the bearing is plotted in a different colour to represent the date the spectrum was captured The following examples show how the trended data can be used to interpret the deterioration of a bearing over time 7 1 Peak Magnitude Figure 7 1 shows the spectral plot of a cup fault with changing peak magnitude over time 9 59E 05 8 53 05 1 zen Ai Peak ges TT TE 5 76E 05 4 80E 05 4 3 54E 05 2 58E 05 Order ss ANDES 1 47 25 DM emm
35. hand corner of the form Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 Eesen P H le Bech RailBAM Trending Database v5 8 User Manual Page 42 of 61 Unique In this variation of the graph each individual bearing is only counted once i e is unique regardless of the number of passes The percentage is calculated as the number of faulty bearings at a selected severity divided by the total number of bearings in the system As this report is based on individual tags untagged wagons cannot be not included in the graph Orphans can be included depending on Parameters form selection Overall Statistics Clear Levelt Potential1 amp 2 Clear Level Wheel Flats RS1_e RS1 m Hait RS1 n RS1_p RS1 R52 e RS2 m RS r RS2 N RS2 p 4 00 2 00 0 00 E H E T ep Si a Si TN GH T3 Fe E gi HI op T ma T hI hI Sites Site1 Site Site3 Operators Op1 0p2 Based on 27824 bearing passes Figure 4 17 Overall Statistics Unique graph The total number of unique bearings that have passed the selected sites is displayed at the bottom right hand corner of the form The Overall Statistics form possesses the following controls Clear Levelt CS Plain R amp S1 e Fault Selector I Tick the faults types to include in the graph L Refresh data form as per Parameters form and fault types selected Restore fault types to default selection and Refresh d
36. hart in dB Trendst shows Fault Strength of Cup faults over time For this example the cup fault has recorded an above High severity level on all days except the second pass on 19 Jul 2010 where a Medium severity level was recorded e The bottom chart in dB Trends1 shows Fault Strength of Roller faults over time This particular bearing has spurious roller Fault Strength bar in the representation e The values read from the vertical axes are Fault Strength derived from the Peak Magnitude Figure 4 8 The Fault Strength is normalised to a typical running speed of a wheel to enable easy comparisons between bearing passes at different speeds The direction of wheel rotation is identified by the colour of the Fault Strength bar presented The blue bar indicates that the wagon was travelling in a positive direction in relation to the tag CAT end leading and the burgundy bar indicates that the wagon was travelling in the Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 TraCHk IN RailBAM Trending Database v5 8 User Manual Page 32 of 61 negative direction B end leading This helps to determine if the fault is direction dependent Section 7 5 The direction of wheel rotation should be taken into consideration when observing the change in Fault Strength over time to determine the amount of bearing deterioration Further details on using these values to interpret data are included in Chapter 6 2 At the top of t
37. he form you can use the check boxes to add remove clear fault types This is useful to highlight clear faults and to examine fault trends without a clear fault spectrum Jas Fsultsin e LI RS muttipleim Rs Extentedie RS Extendedis For example if we tick RS Faults n p r RS Faultsfn p r Then the clear cup fault passes RS1_p are all highlighted except for the multiple fault pass RS1 m on 3 Jul 2010 1 1 18 19 13 j Kai Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul 10 10 10 10 10 19 19 10 19 19 19 19 19 10 19 19 10 10 10 19 oe Jul If we un tick RS Faults n p r and tick RS Mulitiple m Flas Faults n p r RS Multiple m Then multiple fault pass RS1 m on 3 Jul 2010 is highlighted 65 E cup E cup E 3 Cear High Medium Low M mh SZ 04 04 13 15 16 17 iT 18 19 13 Al ES ES 23 ZA 24 Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul 19 19 10 10 19 10 19 19 19 19 19 19 19 19 19 19 10 10 19 10 E 9 Roller E 9 Clear E Roller EA Cear High Medium Low m amp mh 13 15 16 17 17 18 19 19 20 Ke 22 24 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 33 of 61 The dB Trends2 tab uses the same format as dB Trends1 to show all remaining pote
38. i E hH fin d ICT KR ih en LAG hhk Ka LH oi ka H Fan H ET i IE Pe Tir LL SE Re Ha i Bt H H Leg J E E ua d che AEN Ge mg LE DE Seth A ka LA iin i E Cir d rt 5 IA AE dd TH f MA Lig Je Ka Hi Fra i H EN ad irr L 1 A STAR Li LE JEU 1 H Yri T I E Hi T L LSC ee Ri un bk Cir Li HA COM ER EN Bl P nd LEE tll LA E LN Fra D E R me ei IEN KU r LI e hd HE H 74 k H Lg E p My In the example above there is a total of 108 records e Page 1 will show records 1 to 100 e Page 2 will show records 101 to 108 4 5 3 Data Forms Row Highlighting This function is available to Mozilla Firefox amp Google Chrome users not Internet Explorer users Clicking on a data row highlights it in yellow This is useful for quickly referring to a previously clicked row or cross referencing information between forms Train summary Removed Wheel from Operator Diameter Service imm Wagon Train Wage direction vehicle Severity X 021256 bs B End Leading E X 021240 1 A End Leading No a E E X 021256 A End Leading No X 021256 A End Leading No 675 E x 021240 Se J B End Leading No z 678 Ei E Note The highlighter disappears if the form refreshed or closed Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 23 of 61 4 6 Severity Categories The purpose of severity categories is to help manage and display the numerous R
39. icates whether the bearings in the axle have been removed from service and identified by the operator as described in Section 4 9 4 Both Master Cabinet and Slave Cabinet columns contain the following sub columns WHhIID wheel bearing identification axle number amp side such as 1L or wheel number such as W1 Bearing Severity Bearing severity measurement Wheel Severity Wheel severity measurement The Train Summary form possesses the following controls ke Play bearing sound Launch bearing history Section 4 8 1 arm Launch wagon history Section 4 8 3 Faults Only L Tick or un tick to hide or show passes with no faults 0 Garret O Show previous next train summary Clear Levelli Clear Level e The Fault counter displays fault counts PlgainRSi Wheel Flats v for up to four types of fault or fault AVFALL INA o Select from the drop down menu and the fault count automatically updates Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 26 of 61 o Note Choosing the same type for both categories will double the count when summing the two faults e 5 Refresh data form as per Parameters form e E Export data to Microsoft Excel Refer to Section 3 for a definition of severity categories Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 27 of 61 4 8 Statistics The
40. ified by RailBAM as Looseness and Fretting LF faults The types of faults identified as LF include e Looseness e Fretting e Seal wear e Back face wear Figure 3 4 e Loss of clamp e Misalignment Worn Back Face W a p i Figure 3 4 Severe back face wear identified as Looseness Fretting i Other contributing factors can also be identified as LF faults These include e New seals breaking in e Equipment rubbing on wheel axle e Flanging and Noisy Wheels Section 3 4 e Badly tracking bogies e Wheel flats Section 3 3 As these factors are not bearing faults LF faults are flagged as potential LF related bearing faults Before removing a bearing identified as an LF fault the above factors should be checked Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 13 of 61 3 3 Wheel Flat WHLFLT Faults Wheel flats produce peaks in the spectrum at one order since the flat part of the wheel strikes the rail once per wheel rotation The RailBAM System distinguishes this from bearing faults and uses separate ranking thresholds to determine the severity of the wheel flat An example of a wheel flat is shown in Figure 3 5 Figure 3 5 Mature wheel flat resulting from a small skid defect 3 4 Extraneous Noise Wheels that emit flanging squealing and other extraneous noises have a potential to produce peaks that may appear like those of RS
41. iguration is also allowed in which the RailBAM Wayside computer uploads the measurements using AutFTPut and FTPFetchAndProcess applications If the download upload has been successful the data is then automatically imported into the RailBAM Trending Database Note e f an automatic download upload is unsuccessful an email is sent to the RailBAM System administrator In this case the automatic import process cannot occur the new train data will not appear in the database e In addition the import process could fail if there is a problem with the measurement content or file corruption Again in this case the system administrator will be notified The system administrator should attempt to re report the train and download data manually to the database server o Refer to the RailBAM System user manual RD 1 for details e The import process will automatically import the re processed data during the next run 6 AUTOMATED MESSAGES The Importer DataChecker can be configured to automatically send email alerts If this is enabled the DataChecker scans the history of each newly imported bearing and checks these against rules 6 1 Fault Alerts If this option is activated rules that scan for trends that may indicate bearing deterioration are applied and fault alert emails are sent to the appropriate operator for individual bearings showing dangerous trends Refer to RailBAM Importer Configuration RD 2 for details An
42. interfere with bearing or wheel fault detection see Section 3 4 e Clod Clipped signal e Shrk Tonal noise removed before bearing analysis e FBS Flanging Braking Slamming e NOISY Unknown extraneous noise Note If there is no interfering noise the prefix will not be present TYPE type of fault Sections 3 1 3 2 and 3 3 e RS Bearing Running Surface fault e LF Bearing Looseness Fretting e WHLFLT Wheel Flat Note each pass by can receive one bearing type RS or LF classification and one wheel type WHLFLT classification LEVEL severity of the fault e 1 Severe fault e 2 Moderate fault e 3 Minor fault e 4 No fault identified Note A fourth fault level is used at sites that analyse very quiet rolling stock and level five indicates no fault in these cases Similarly wheel flats are identified by two fault levels with level three indicating no wheel flat DESCRIPTOR detail about the fault Section 3 1 e _r clear roller fault e p clear cup fault e _n clear cone fault e m multiple faults e e extended fault e s extended fault Note Descriptor is only applicable to RS type faults Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 9 of 61 Examples of severity classification are given below e RS2r Clear Running Surface Roller fault of level 2 e NOISY LF3 Looseness Fretting of level 3 with noise
43. into the calculation Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 44 of 61 Unique In this variation of the graph each individual bearing is only counted once i e is unique regardless of the number of passes The graph shows a monthly breakdown of the percentage of faulty bearings divided by the total number of bearings As this report is based on individual tags untagged wagons cannot be included Orphans can be included depending on Parameters form selection gt Clear Level Potential1 amp 2 Clear Level Wheel Flats RS1e RS1 m RS1 r Rain RS1 p RS1 RS2 e R52 m RS2 r RS2 n RS2 p DD lt Feb 06 Clear Level Potential142 E Clear Level Yvheel Flats Period 01 Jan 7008 31 Mar 2008 Including Orphans Untagged Including Removed Bearings Sites Site1 Site Site3 Operators Op1 0p2 Based on 67776 bearing passes Figure 4 19 Monthly Statistics Unique graph The total number of total number of bearing that passed the selected sites is displayed at the bottom right hand corner of the form The total number of bearing passes for each individual month is not displayed but is factored into the calculation The Monthly Statistics form possesses the following controls Clear Level 5 Plain RS1 e Fault Selector Tick the faults types to include in the graph e Refresh d
44. lBAM System s The import facility described below will aid with this Removed bearings Removal date 1 07 2010 1 07 2010 1 07 2010 1 07 2010 1 07 2010 1 07 2010 1 07 2010 1 07 2010 1 07 2010 1 07 2010 1 07 2010 1 07 2010 C 10850 C 10850 C 10850 C 10850 C 10850 C 10850 C 10850 C 10850 C 10850 C 10850 C 10850 C 10850 C 10850 NO On On Om P P GANN gn Ga ak i amp Wheelset Removal status Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Completed Comoleted severity RS3 RS2 LF3 RS3 LF3 FBS LF3 RS3 FBS RS2 LF3 FBS RS2 LF3 FBS RS1 RS3 Roller Rank POM RO Of OM OP PM E 63 S ZZ ZZ ZZ ZZ Z bb 1 07 2010 d Pending v v Period 01 Jul 2010 31 Jul 2010 Including Orphans Untagged Including Removed Bearings Sites Site1 Site2 Operators Op1 Op2 Showing records 1 100 lt gt Page Total number of records 2910 Figure 4 24 Removed Bearings form The following information is displayed on the Removed Bearings form e Removal date is the date the bearing was removed from service e Tag is the tag ID of the wagon that contained the bearing Refer to Appendix Bil e Axle is the wagon axle number from which the bearing was removed e Side is the side of the wagon from which the bearing was removed R or L e Wheelset is the unique number assigned to each wheel set e Removal stat
45. lete web page comparable to the Bearing History form itself Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 30 of 61 4 8 2 Bearing History Graph The Bearing History graph is launched from the Bearing History form Section 4 8 1 by clicking There are three kinds of charts that can be viewed by selecting the tabs along the top of the form The tabs are History Figure 4 8 dB Trends1 Figure 4 9 and dB Trends2 Figure 4 10 Bearing history graph CAR 4008 6R Krem Py ren 01 Jul 10 06 49 48 e 01 Jul 10 05 52 34 02 Jul 10 10 42 02 03 Jul 10 07 14 41 04 Jul 10 09 06 55 04 Jul 10 10 41 07 13 Jul 10 07 48 49 15 Jul 10 07 06 20 16 Jul 10 04 14 52 17 Jul 10 08 05 16 17 Jul 10 05 55 19 18 Jul 10 06 33 37 19 Jul 10 02 50 20 19 Jul 10 09 22 22 Show all passes Figure 4 8 Bearing History graph RPM amp Spectrum tab e The top chart illustrates the RPM and direction of the wagon for the bearing s being viewed All readings are based on the location and or side information of the tag so train travel direction and wagon orientation are accounted for See Appendix B 1 for definitions of wagon ends and direction labels e The bottom chart illustrates the fault spectrum acquired for each pass by of the bearing Each pass by is plotted in a different colour with a legend relating it to that colour at the base of the chart If a
46. lude e Bearing History plots where bearing deterioration on tagged rolling stock can be monitored over time e Wagon History form where the histories of all bearings on a wagon are displayed e Train List form where all selected trains are listed e Train Summaries showing all faults on a particular train and relevant information such as train length vehicle count train speed direction of travel and location e Most Seen Bearings First Seen Bearings and Faulty Replaced Bearings forms to aid in prioritising bearings for maintenance e Monthly Statistics and Overall Statistics e Parameters form which enables the current data selection to be changed at any point in the database e Records of removed bearings wagon owners bearing types and orphan rolling stock rolling stock for which an owner has not been identified Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 6 of 61 e Security options to protect rail operators confidentiality e Remote access for all authorised users e SQL server data storage for quick retrieval of data Optionally the Importer DataChecker can issue various automated messages This is not an actual function of the web interface but examples will be shown in this doc For more details refer to RailBAM Importer Configuration RD 2 Database settings can be configured by users with administrator privileges Refer to RailBAM
47. me time Ref 51R 05 5656 UMA 239163 10 Section 4 9 1 Section 4 9 2 Section 4 9 3 Section 4 9 4 Available to Trend and Administrator logins only Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 18 of 61 4 4 Parameters The Parameters form Figure 4 3 selects the range of information to be displayed across all database functions Q January 2008 Oo Su wo Tufwe m Fr s Parameters Date from 01 07 2010 Date to 31707 2010 DEN 27lejeede Orphans Untagged N 8 This month enoved bearings Permitted operators Select all Select none g 2008 oO Op1 Operator 1 Su mo Tu we Tn Fr sa spre GIS p Operator 2 Le IC elle folie raske amagada Permitted sites 27 28 29 30 laaf Site1 Site 1 Site Site 2 Figure 4 3 Parameter form e The Date From and Date To fields limit the date range o E Select a date using the calendar date picker icon e The Orphans Untagged tick box shows or hides orphaned and untagged bearings e The Removed bearings tick box shows or hides bearings removed from service e The Permitted operators tick boxes filters the information by wagon operator e The Permitted sites tick boxes filter the information by RailBAM site of pass by Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 T TACA LG RailBAM Trending Database v5 8 User Manual Page 19 of 61 4 5 Train Li
48. mercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 39 of 61 4 8 7 First Seen Bearings Selecting First Seen Bearings from the Statistics menu displays the first reading of each bearing fault at a severity in the selected category Only bearings that match the parameters entered in the Parameters form are included First seen bearings Tag WGN 002556 WGN 003014 CAR 096566 CAR 0965538 CAR 098586 PSG 043093 CAR 006740 CAR 000584 PSG 022760 WGN 002546 WGN 003738 PSG 027620 WGN 003251 WGN 002159 PSG 221110 CAR 098563 CAR 002533 WGN 003261 WGN 003491 WGN 003795 WGN 003053 WGN 002407 WGN 002462 WGN 002116 WGN 002122 a P 2 3 4 2 4 4 3 3 4 2 3 3 1 P GA oa b M bo LA Severity RS1 e RS1 n Hie RS1 e RST m RS1 np RS1 n Hie RS1 n Hie RS1 e Hie Hie RS1 n Hie RS1 n Hie RS1 e RS1 e RS1 m RS1 m Hie R51 e shrk RS1_e Hie 31 03 2008 2 12 44 PM 31 03 2008 2 12 44 PM 31 03 2008 4 19 55 AM 31 03 2008 4 19 55 AM 31 03 2008 4 19 55 AM 30 03 2008 7 11 48 AM 29 03 2006 7 22 56 PM 29 03 2008 7 22 56 PM 26 03 2008 10 29 34 AM 26 03 2008 9 16 45 AM 26 03 2008 9 16 45 AM 25 03 2008 3 12 52 PM 24 03 2008 10 06 26 PM 24 03 2008 10 06 26 PM 24 03 2008 4 26 52 AM 23 03 2006 1 35 16 PM 23 03 2006 1 35 16 PM 22 03 2008 2 17 12 AM 22 03 2008 21712 AM 22 03 2008 2 17 12 AM 22 03 2008 2 17 12 AM 22 03 2008 2 17 12 AM 22 03 2008 2 17 12 AM 22 03 2008 2 17 12 AM 2
49. mp amp D D D amp S DE E E DE 8L p Showing records 1 100 lt 4 Page 1 el Total number of records 949 Date Time 10 11 2010 09 34 53 Speed in 69Km h Clear Level1 e 3 Clear Level2 v 1 Faults only F E Direction West Speed out 68Km h e Loco ID L 1 X7057R Axles 946 Vehicles 119 Wheel Flats w 9 Potential18 amp 2 v 29 OGG Figure 4 5 Train Summary form The bottom left of the Train Summary form Figure 4 5 displays the general train information e Date Time the time which the train passed the RailBAM System e Site the site as which the train passed the RailBAM System e Train ID on some systems assignment of a Train ID is done automatically based on a dynamic loco tag containing a Train ID Otherwise this is blank e Loco ID when the tag of the first locomotive is read this is displayed in the Loco ID box In some cases the first tag may not have been read correctly or the loco may be untagged In this case the second or third tag will be used e No Axles indicates the total number of axles analysed on the train e No Vehicles indicates the total number of vehicles including locomotives on the train e Direction reveals the direction the train was travelling Refer to RD 1 for definition of directions e Speed in Speed out reveals the speed of the train entering in and leaving out the RailBAM System Ref 51R 05 5656 UMA 239163 10 Commercial i
50. mp 2 w 0 Total number of passes 20 Show faults only v Hide WHLFLT Figure 4 7 Bearing History form The following information is displayed on the Bearing History form e Site The RailBAM System site at which the bearing passed e Track Side shows which side RailBAM cabinet detected the bearing fault e Train Direction displays the direction in which the train was travelling when it passed e Time The local time at which the train passed the RailBAM System site e Severity The severity classification of the fault for this particular pass by Refer to Chapter 3 for a definition of severity classification e Tag The tag identification number Appendix B 1 e Axle The wagon axle on which the bearing is situated See Appendix B 1 e Side The wagon side on which the bearing is located See Appendix B 1 e Axle and Side combine to give the bearing ID Appendix B 1 o Note To cater for some numbering systems when side displays a W then the axle column displays the wheel number instead of axle number e Removed Indicates if the bearing has been removed from service Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 29 of 61 The Bearing History form possesses the following controls ke Play bearing sound Launch Train Summary Section 4 7 providing information on the whole train This is useful for viewing the bearing in relation to
51. n Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 25 of 61 The individual columns on the Train Summary form are Tag The vehicle identification tag Train axle Number of the axle in train The axle count begins at the first locomotive of the train unless the system was interrupted e g if the train came to a stop in front of the sensor In this case the axle count begins from the first axle seen after system start up Train vehicle Location of vehicle in train C_number relates to the wagon car number starting from the first wagon Similarly L_number is used for locomotives R_number is used for road railer trailerail bogies Severity indicates the severity classification of the fault Refer to Chapter 3 for definition of severity classifications Wagon dir refers to the direction in which the wheel was rotating A End Leading means the wagon is travelling forward B End Leading means the wagon is travelling backwards Refer to Appendix B 1 Operator displays the wagon operator Operators of untagged wagons cannot be identified and a blank is displayed in this column Refer to Appendix B 2 Whi dia mm or Inches shows the diameter of the wheel measured by the RailBAM System s wheel sensors Master Cabinet Bearing measures from Master cabinet side See section below for detail Slave Cabinet Bearing measurements from Slave cabinet side See section below for detail Rmvd ind
52. ngth readings when the wheel was rotating in the other direction this is potentially a cause for the example in Section 7 4 Cases such as this should be closely monitored to determine whether the fault is consistently direction dependent If the fault in this example is not consistently direction dependent it is likely the bearing fault has become very developed 7 6 Axle Load Research has shown that the fault strength of RS faults is not significantly influenced by axle load The tare weight of a wagon Is sufficient to create a fault signature that is easily detectable Changes in fault strength for some types of LF faults may be caused by axle load If a wagon is seen with a particularly large or small load this may cause one high or low reading of fault strength however it is consistent trends over time that best show bearing deterioration Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 58 of 61 SUPPORT For further information on the use of the RailBAM Trending Database please ask your demonstrator or contact Track IQ railoam vipac com au Track IQ M is committed to the continuing development of products and training Suggestions are appreciated and can be emailed to railbam Qvipac com au Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 59 of 61 Appendix A Important Terms TERM
53. nitoring reports and advance warning of potential bearing failure The RailBAM System is located in trackside cabinets suitable for harsh environments e g desert tropical cold wet amp snow freezing with one installation serving several thousand kilometres gt one thousand miles of track An entire network can be monitored with only a few strategically located RailBAM systems As a train approaches wake up sensors trigger and e The shutters protecting the acoustical sensors open e The data acquisition process begins including measurement of Sound signatures emitted by bearings and wheels Train speed and wheel diameter Tag data Sampled real time data is analysed by a computerised data acquisition and analysis unit during and immediately after the train has passed the RailBAM System The RailBAM system extracts bearing fault and wheel flat signatures from extraneous noise enabling fault identification and severity classification Data for individual bearings is stored in the RailBAM Trending Database Further information regarding the RailBAM System can be found in the RailBAM System User Manual RD 1 1 2 Overview of the RailBAM Trending Database Data from trains analysed by RailBAM is imported into the RailBAM Trending Database where reports and graphs for bearing and wheel faults can be viewed Different functions are interlinked through a user friendly web interface Features of the database inc
54. ntial bearing faults those which are not RS faults Bearing history graph CAR 4008 6R WHLFLT EE wurr High Medium 15 16 iT iT 18 15 19 20 ae Kai 2 23 24 Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul 10 10 10 10 10 10 10 10 10 10 10 10 10 E or E r High Medium Low 18 tr tr 18 19 13 20 Ke 22 23 23 24 Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul 10 10 10 10 10 10 10 10 10 10 10 10 Figure 4 10 Bearing History graph dB Trends2 tab e The top chart in dB Trends2 shows the Fault Strength of potential Wheel Flats WHLFLT In this example there are no wheel flats are recorded for this wheel e The bottom chart in dB Trends2 shows the Fault Strength of potential Looseness Fretting LF faults In this example there is no looseness fretting detected Section 3 2 explains faults signatures related to rubbing on the wheel or axle Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 el A HH egene H ln R i ben RailBAM Trending Database v5 8 User Manual Page 34 of 61 4 8 3 Wagon History The Wagon History form Figure 4 11 displays summaries of fault readings for each bearing on a vehicle Only bearings passes that match the parameters entered in the Parameter form are included in the lists Bearings with faults identified in the selected severity categories are displayed in and bearings without are displayed in Wee The fault lists
55. o deterioration can be seen easily Similarly the dB Trends 2 graphs should be used for LF and WHLFLT faults Examples in which the fault strength is used to interpret trending data are included in Section 7 3 and Section 7 4 7 3 Example Increasing Fault Strength Figure 7 2 shows the dB Trends 2 plot for a significant Looseness Fretting LF fault The fault strength has grown consistently since the first reading Current evidence suggests that consistent increases in the fault strength can indicate deterioration of the bearing for any fault type LoosenessjFretting LoosenessjFretting bek T CO el O2 Feb Ui Feb 09 Feb 11 Feb 15 Feb 20 Feb Figure 7 2 Increasing fault strength for a bearing with an LF fault Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 56 of 61 7 4 Example Sudden Decrease in Fault Strength An example of the worst type of bearing deterioration is shown in Figure 7 3 The peak magnitude reduces over time after a very high reading on 2 02 2008 2 2 2008 1 47 25 PM cme 1502 2008 93 57 01 AM 7002 2008 4 58 12 AN eee 93008 20227 PM 11022008 12 04 56 AM Figure 7 3 Peak magnitude reducing after a very high reading This could be due to reduced wheel speed so RPM should also be considered O2 Feb OF Feb 09 Feb 11 Feb 15 Feb Figure 7 4 Fault strength reducing after a very high reading The fault s
56. ons can be made to re orient vehicles within the train consist to enable exposure Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 36 of 61 Refreshes data form as per Parameters form Note Upon opening the form refresh must be pressed in order to see the data The Ignore tag class check box is to cater for a specific case of vehicle tagging convention In the event that all coupled vehicles share the same vehicle number this tick box enables counting of the coupled vehicles as if they were one 4 8 5 Faulty Replaced Bearings Selecting Faulty Replaced Brgs from the Statistics menu displays tagged bearings that have developed fault symptoms soon after being replaced Figure 4 13 Only wagons that match the parameters entered in the Parameters form are included Faulty replaced bearings ual Te Fault Removal Date Count 01 Feb 2008 CAR 099674 01 Feb 2008 CAR 098516 Period 01 Feb 2008 29 Feb 2008 Including Orphans Untagged Including Removed Bearings Sites Site1 Site Sites Operators Op1 Op2 Total number of records 2 Fault Clear Levelli Min 5 Show removed bearings faulty within 10 day s or 5 pass es after removal Figure 4 13 Faulty Replaced Bearings form The following information is displayed on the Faulty Replaced Bearings form e Removal Date The date the bearing had been removed from service e Tag The tag identification
57. other information from nearby wheels E Export data to Microsoft Excel er ita The Fault counter displays fault counts ks BY l kl py d i Fa Clear Level e 17 Clear Level2 D 2 for up to four types of fault or fault Wheel Flats x 0 Potential1 amp 2 x 0 Groups o Select from the drop down menu and the fault count automatically updates o Note Choosing the same type for both categories will double the count when summing the two faults Wagon history A diagrammatic representation of a summarised history of all the bearings in the wagon where the bearing originates S C Mark bearing as pending removal from service The bearing is automatically entered into the bearings remove from service form Section 4 9 4 with today s date al Launch the Bearing History graphs plots of various aspects of the historical bearing measuremenis Launch email function to send the bearing history data along with the sound files Type in your Mail to address and optional Cc address and click Send Email bearing history Subject Bearing history for CAR 4006 6R Wav file s e 941 2010 07 18 10 33 wav L 941 2010 07 17 09 55 wav R 32 2010 07 04 14 41 wav R 925 2010 07 04 01 06 wav L 32 2010 07 02 14 42 wav L 925 2010 07 02 23 14 wav R 925 2010 06 30 22 49 wav R 32 2010 07 01 09 52 wav R 32 2010 07 13 11 48 wav R 941 2010 07 15 11 06 wav The data is sent as a RAR archive containing sound file plus a comp
58. s Import wizard E sprogfldt NNDS osv E Sprngfldi Mics L dap l 18 sornafldi mat_htm _png_csy rar ad Sprngfldi Mics D My Besar ad ana_paras Ej Sprngfldi Mics R dap Documents ad ana stat L el TMR 2008 03 16 06 47 him Ten E ana stat H BSL TENTEL 2008 03 16 06 47 05v Le Z analysis log gd tyvects F EE AXLTBL 2008 03 16 D6 47 c5v gl tvects N ELJBRGTBL 2008 03 16 06 47 c5v 23 whidets ve el msg 2008 03 16 06 50 45 13 htm el win 2008 03 16 06 50 42 55 htm E SPES 2008 03 16 06 47 htm WS wenSNSR_2008 03 16_06 50 43 05 htm raw L 2008 03 16 06 47 dat EE raw D 2008 03 16 06 47 dat a ad rawres L 2008 03 16 06 47 ag ad rawres H 2008 03 16 06 47 he ad Sprngfldimics L Mu Computer w File name SEI DW cay My Network Files of type All Files K Cancel Desktop Navigate to the file of your choice and click Open The Wizard automatically detects the column headers fields within the CSV or TXT file Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 50 of 61 T SQL transformation Import with removal status as Date format dd mm yyyy Select existing import profile D Save profile as f e For each Field select a RailBAM equivalent description from the dropdown list e Optionally you can declare an SQL statement to additionally process each field to conform to the RailBAM data format e You can also specify a
59. st Selecting the Train list function from the Main section in the application menu displays a list of train passes as shown in Figure 4 4 The train passes are displayed as per the selected criteria in the Parameters form Train list Time Site Train ID Loco ID Axles Vehicles otto re h Direction rom am E 31 03 2008 02 12 44 PM Site2 L 1 ABC 008017 R 562 139 2267 64 East 8 f E 31 03 2008 04 19 58 AM Site2 L 1 ABC 007128 L 518 128 2089 63 65 East 11 11 EI 29 03 2008 07 22 58 PM Gute 516 128 2084 62 63 East 5 5 E 26 03 2008 12 19 00 DM Site2 L 1 ABC 006699 L 558 138 2250 30 23 East 14 E 26 03 2008 09 16 45 AM Site2 L 1 ABC 007214 L 566 140 2281 65 67 East 6 32 EI 24 03 2008 10 06 26 PM Site2 L 1 ABC 005655 L 558 138 2248 65 68 East 7 17 E 23 03 2008 04 51 11 PM Site2 L 1 ABC 007202 L 512 127 2067 54 60 East 2 7 EI 23 03 2008 01 35 16 PM Gute L 1 ABC 007256 L 520 129 2100 63 62 East 14 33 E 22 03 2008 02 17 12 AM Site2 L 2 ABC 006173 L 558 138 2247 76 68 East 12 26 E 20 03 2008 05 02 07 AM Site2 L 1 ABC 006663 R 520 129 2100 18 58 West 2 4 EI 19 03 2008 12 50 40 DM Gute 480 119 1935 82 83 East 4 2 E 18 03 2008 10 52 27 AM Site2 L 2 KCS 004020 L 520 129 2099 29 43 East 12 E 17 03 2008 11 56 26 DM Site2 L 1 ABC 005886 L 526 130 2120 62 59 West D 13 E 17 03 2008 08 06 11PM Site2 L_1 ABC 006663 L 520 129 2097 80 81 East 6 17 EI 17 03 2008 04 18 14PM Gute L 1 ABC 008103 R 554 137 2235 63 64 East 3 9 E 16 03 2008 09 04
60. trength also shows a very high reading followed by lower readings indicating this is potentially a well developed fault As a fault becomes well developed a lot of metal is removed from running surfaces The rollers pass over deteriorated areas that are sufficiently large to avoid an impact That is the rollers become either airborne or the entry exit of the fault has rolled out to form a gentle slope Both effects make the fault silent and therefore undetectable by acoustic means Often the mistake is made to assume that the bearing has healed since there is no longer a peak in the spectrum However the bearing now has debris within the grease making failure more likely Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 57 of 61 7 5 Direction Dependent Faults Some faults are direction dependent meaning the fault is more prominent when the wheel is rotating in one direction rather than the other The example in Figure 7 5 clearly shows an LF fault that is consistently direction dependent since higher fault strengths are always seen with the wheel rotating in the negative direction O2 Feb OF Feb 15 Fe Figure 7 5 Direction Dependent fault more prominent in negative direction If a fault is direction dependent and a high fault strength was recorded with the wheel rotating in one direction followed by low fault stre
61. unning the web applicatiOn n ranuennnvnnnnennnnnnnnnnnnnennnnnnnnennnnnnnnnnnnnennnnnnnnennnnnnnnennnvennnunnn 14 Beie el E 15 Me 4 16 5 Kee 18 ATT SE ENN NE NE NE NE Re 19 Sorting Data FOrmS 4 see 21 Data FMS PINE 22 Data Forms Row Highlighting s vanevnnennnvnnnennnennnennnennnvnnnvnnnvnnnennnnnnnennnennnennnennnennnennnennner 22 JENAS ene 23 EECHER 24 SELEN 27 Bearing TE de Ve V r 27 Bearing SON GADH EE 30 Wagon History scsi cate cree cece cts ce cee ence e specie nine tien cantctintcannetiendaneccieccanaesmedantcsencansesmedanseseacansctuades 34 Wagon EEN 35 Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 4 of 61 405 Taully R eplaced BEAINGS ssis S 36 4 8 6 Most SEEN Bearings nsccscncsvcscssspessenssrcessnewonsnaussevecenetevanauetsreconstenantwetenesonsnewesimetenecosaneeesaxs 37 48 7 First eC ii Beal e assise aE EE 39 4008 Overall SUA SUCS Luse 41 4 8 9 Monthly Statisties Jesse 43 4 9 Tags and E Ela Tuer 45 10 ONAN Kl E 45 492 US TAOS xecrescicecncaceecsseacsqesn cen seccpeccsqccy sec eeccpcccseesycecgucepeccseecneescaus wasn eteiceecneccneccnenexensseuaseccee 46 19 3 ASSION En E 47 4 9 4 Removed Bearings ax rannennnunnnnnnnnnnnnnnnnnnennnnnnnnennnnennnnnnnnennnnrnnnennnnennnnnnnnennnnnnnnennnnennnnnnnnen 48 5 AUTOMATIC IMPORTER sccssssnssssnonrsase nEn EN aen ENPO EENEN REENER ENEKEN E ENEON E ENEKEN S Eann 52 6 AUTOMATED MESSAGES Lunde 52
62. unt amp Fault2 Count options e E Export data to Microsoft Excel Ref 51R 05 5656 UMA 239163 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 41 of 61 4 8 8 Overall Statistics The Overall Statistics buttons on the Statistics menu Figure 4 2 displays the overall statistics graphs Figure 4 16 and Figure 4 17 by severity category Only information that matches the parameters entered in the Parameters form is plotted There are two variations of the Overall Statistics graph selectable by tabs By passes In this variation of the graph each bearing pass measured by RailBAM is considered The fault percentage is calculated as the number of faulty bearing measurements at a selected severity divided by the total number of bearing measurements in the system Selected bearings will include Orphan and Untagged wagons if that checkbox is ticked in the Parameters form Overall Statistics Clear Levelt Potential1 amp 2 Clear Level Wheel Flats Hie RS1 m Hait RS1 n RS1_p RS1 RS2 e RS2 mM RS2 r RS2 n RSZ p Masala 0 69 0 50 OOOOOOOOOGOOOODOERRRE 0 00 O H O T i T Du CH Du bet gt ON Eg ae is mi co mi Ka Ka T po m P o M J Sites Site1 Site Site3 Operators 0p1 0p2 Figure 4 16 Overall Statistics By passes graph The total number of bearings that have passed the selected sites is displayed at the bottom right
63. us states the current status of the bearing Pending or Completed e Due to PM is used to indicate if bearings were removed due to Periodic Maintenance e Fault Severity Cone Cup Roller amp L F rank are used to store information concerning the fault type and fault levels The Removed Bearings form possesses the following functions The delete button Ed is used to remove selected entries Select all Select an individual entry Ref 51R 05 5656 UMA 239163 10 i ep ff P E AAA ao Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 49 of 61 e The data entry bar is used to add new removed bearings D Pending wv O m vi sl si aa Fill in each column and click Add e The same data entry bar is used to edit a removed bearings entry 1 Click on the line you wish to edit 2 Make your changes 3 Click Save Note Once a bearing has been saved with Removal Status completed all history for that bearing is flagged so that only the new bearing passes are shown To view passes prior to the removed bearing date the Include Bearings Removed from Service box must be ticked on the Parameters form e To export data to Microsoft Excel click E e To import data from a CSV or TXT file click L to open the Removed Bearings Import Wizard form When you click the import button you will be prompted with a Windows dialogue box to select a file to import Removed bearing
64. y to Trackside Intelligence Pty Ltd We specifically state that inclusion of this information does not grant the Client any license to use the information without Trackside Intelligence s written permission We further require that the information not be divulged to a third party without our written consent Ref 51R 05 5656 UMA 2391 63 10 Commercial in Confidence 7 June 2012 RailBAM Trending Database v5 8 User Manual Page 3 of 61 1 1 1 2 2 1 2 2 3 1 3 2 3 3 3 4 4 1 4 2 4 3 4 4 4 5 4 5 1 4 5 2 4 5 3 4 6 4 7 4 8 4 8 1 4 8 2 4 8 3 4 8 4 TABLE OF CONTENTS INTRODUC TION WE 5 Overview of the RailBAM System rserusvrnnvnnnvnnnvnnvnnnennnvnnnennnennennnennnennnennennnennnennnennnennen 5 Overview of the RailBAM Trending Database r mrsvrsvnnnnnnvnnvnnvrnvnnnnnnennvnnvnnnennesnessesnenns 5 APPLICABLE AND REFERENCE DOCUMENTS nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 7 PANIC A TH DOCUMEN EC 7 Reference DOES ee 7 FAULT TYPES AND NOTATION snnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 8 Running Surface RS Faults rnnnannnnnnnnnnnnnennnnnnnnennnnnnnnnnnnnennnnnnnnennnnnnnnnnnnnennnnnnnnennnnennn 9 Looseness nd Felling LF Faults LL munesamsnsmmen dnvevaessendeaddanned 12 Wheel Flat WHLFLT FUGL 13 EXIKANCOUS NOISE Lassen 13 DETAILED DATABASE INSTRUCTIONS nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 14 R

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