Implementering av IoT på kurvsmörjningsapparatur

Sammanfattning: In addition to various switch and track materials, Vossloh Nordic Switch Systems AB have a wayside lubrication device, Clicomatic© in their product range. Clicomatic© is a lubricator intended for fixed installation to mainly lubricate the railway track at exposed sections. Its purpose is to apply grease in the active interface between the vehicle and the track. Clicomatic© was developed decades ago to improve the lubrication process and thereby minimize the wear on the track as well as on vehicles. Underlying theory determines that the lubrication requirement in curves varies greatly depending on the prevailing weather and climate, the unit’s existing control systems therefore lubricate too much during autumn and winter. The Internet of Things (IoT) aims to modernize the industry through increased use of sensors as well as widespread communication between machines and devices. Due to the expansion of IoT, Vossloh sees an opportunity to develop the Clicomatic© further and provide it with an adaptive control system that adjusts the level of lubrication according to need. This development requires a study of what parameters should be registered as well as whether detection should occur at a local level on individual devices or if a few transducers can provide a number of devices with information via a network connection. Furthermore, a survey of already commercially available control systems that could be implemented on existing units is needed, as well as of the potential added value a product development would lead to. This study will constitute as a preliminary study to base any further development of the Clicomatic© lubrication system. Designing an operational Clicomatic© control system falls outside of the purpose of this study and may be addressed by Vossloh at a later stage. Initially, underlying theories about wear, lubrication and the influence of weather and climate on the friction ratio of the wheel and rail contact are presented as an introduction to why lubrication is needed. This is followed by the requirements for lubrication devices and the existing set up and basic layout of the Clicomatic©. This will indicate what upgrades are in demand. The introduction also gives an insight into the concept of IoT as well as a list of commercially available control systems for this type of product. For this part Assalub, SKF, Jörgensen Industrielektronik and V-teknik Elektronik, Phoenix Contact and also ABB were contacted. Only the last two have complete system applications for IoT-implementation. ABB’s system is designed for operation of large-scale industry while Phoenix Contact’s is adaptive based on the present conditions. The study shows that for further development work, the two suppliers’ systems should be evaluated more thoroughly. In addition to a railway engineering education a literature study in lubrication techniques and IoT, interviews, lectures and study visits will be used as a basis for determining which parameters should be considered and how a system should be designed. Vehicle detection parameters, controlling current ratio, hit indicator and level control are listed with pros and cons and will be used to finally determine appropriate technology layers for current purposes. Vehicle detection should be performed with a vibration sensor, current condition could be recorded with temperature sensors and a hygrometer, precision of aim and distribution of grease can be determined with an UV-indicator in the lubricant and the remaining amount of grease is measured with a load cell. IoT-implementation on Clicomatic© is proposed initially only in the form of remote operation and alarm monitoring via cloud-based data storage and analysis. In the future, self-learning algorithms can be implemented in the system. Due to the fact that current lubrication needs are clearly linked to geographical phenomena, all units are initially assigned to selected sensors. In the future, communication with external sensors can be allowed as the sensor density in society and infrastructure increases. The system will therefore primarily work at local level, but all logged values will be stored in a database for future evaluation and adjustment of lubricant application. A detailed picture of the intended system structure is found in Chapter 3.4 and Figure 14. An optimized control system will mean a simplified process of maintenance. All current maintenance plans can be replaced since the units will provide data on when maintenance or refill is required. This also changes the current business model where a product is sold to the end customer. After IoT has been implemented on devices, instead, a value in the form of curve noise below XX decibel or guaranteed friction of up to XX can be offered to the customer. The customer receives carefree ownership while allowing the supplier to increase the revenue per sold unit, which means that all parties benefit. An improved lubrication method will also have the effect of minimizing the grease consumption. In conclusion, in addition to appropriate parameters, the registration and system structure determines that IoT-implementation on devices in the form of non-safety lubricating grease lubricators such as Clicomatic© may be a starting point for development in other railway engineering equipment. Based on current positive effects and prospects, it is recommended that Clicomatic© will be provided with modern control systems for further empirical studies in real operating conditions and environments.