Wagon 4.0
Towards inclusion of the freight rail system in the industrial internet of
things
Prof. Dr. Raphael Pfaff
Prof. Dr.-Ing. Bernd D. Schmidt
Prof. Dr.-Ing. Manfred Enning
Aachen University of Applied Sciences
[email protected]
www.raphaelpfaff.net
@RailProfAC
April 25, 2017
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Driving forces in the industry
The context of Industry 4.0 provides plenty of concepts useful also for freight rail.
Self organisation
Mass Customisation
Updated value generation and value proposition
Enablers:
Quelle: Christoph Roser
at AllAboutLean.com
Internet of Things (IoT)
Cyber Physical Systems
Ubiquitous Computing
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Driving forces in the industry
Logistics 4.0: Amount of freight moved1
Coal
Metals
Construction
Petrochemicals
International
Intermodal
Other
106 tkm
20
10
1
2014
2012
2010
2008
2006
2004
2002
2000
1998
0
ORR statistics table 13.7
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Competitive position and desirable use cases
Autonomous lorries
Alternative fuels
10
106 tkm
Logistics of high value
goods becomes more just
in time and granular
Road transport is working
hard to overcome
challenges:
5
Construction
Intermodal
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
2015
2010
2005
2000
0
International
Other
April 25, 2017
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Competitive position and desirable use cases
Logistics of high value
goods becomes more just
in time and granular
Road transport is working
hard to overcome
challenges:
Autonomous lorries
Alternative fuels
Rail freight may become
more competitive:
Smart wagons
Autonomous operation
Integration into
factories of the future
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Drivers’ and Enablers’ effect on freight rail
New value proposition, new market position
Contextualisation
Right information at the right
time
Value proposition
Cheap wagon becomes
valuable, integrated
production medium
Knowledge based
Cooperative functions
Self configuration
Choose settings according to
train
Security
Against inappropriate
operation
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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What are the main ingredients of the Wagon 4.0?
Use of service proven subsystems, added value by extension.
Cyber Physical Systems
Digital representation of
vehicle
Internet of things
Communication
Affordable electronics
Wearables:
Intuitive Interface
Ubiquitous Computing
Non-noticeable computer
assistance
Brake system acc. to UIC/TSI
WAG
Robust, fit for railway usage,
safe
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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The concept of the Wagon 4.0
Power Supply: Sufficient power to allow online monitoring
Data Network: Connection to sensors, actuators and between wagons
Connectivity: Shared 3G/5G for all elements installed
Localisation: Galileo/GPS as standard equipment
Operating System: open source extendable operating system
WagonOS
Cloud infrastructure: Containing cyber representation of fleet and
algorithms
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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The concept of the Wagon 4.0
Power Supply: Sufficient power to allow online monitoring
Data Network: Connection to sensors, actuators and between wagons
Connectivity: Shared 3G/5G for all elements installed
Localisation: Galileo/GPS as standard equipment
Operating System: open source extendable operating system
WagonOS
Cloud infrastructure: Containing cyber representation of fleet and
algorithms
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Application example: automatic pneumatic brake system
By using the Wagon 4.0 infrastructure, it is possible to gain significant advantages
through automation of the brake system
Mass Customisation for freight rail:
Single Wagon Load economically feasible
New value propositions
Towards Whole-Life-Service
Intralogistics use cases: new customer base
X-as-a-service
“Ad hoc”-train preparation
Significant reduction of preparation time
Noise reduction
Pneumatic noise
Cloud based proximity brake
Further apps from independent developers
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Safety concept
During mainline operation, the brake system of the Wagon 4.0 is as safe as the UIC
system.
All states bistable
Deactivation of actuators
During mainline operation
In case of errors
Potential exception: ep-assisted
brake
Not considered in braked
weight
Additionally Geofencing possible
State change only in e.g.
shunting yard
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Necessary manual operations
Wagon handling during train formation and handling required plenty of manual
operations.
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Necessary manual operations
Wagon handling during train formation and handling required plenty of manual
operations.
Brake:
Buff and draft gear:
Connect and Disconnect BP
Brake Mode
Load
Quick Release
Detect brake state
Operate parking brake
Pfaff, Schmidt, Enning (Aachen UAS)
Connect and disconnect
wagons
Vehicle
Wagon 4.0: IoT for freight rail
Technical wagon assessment
April 25, 2017
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Economic and operational effects of manual operations
Long dwelling time
of ready trains
Makes single
wagon load
expensive
Requires
infrastructure
investments
Error-prone
Personnel
increasingly difficult
to find
Wagon < 4.0
Wagon 4.0
1
Train preparation
39.5
10
Fill Brake Pipe
40
Condition Assessment
1
Tightness
1
1
1
1
1
33.2
Apply brakes
Check brake application
33.2
2
2
1
Release brakes
Check release
33.2
0
20
40
Time / min
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Brake assesment and condition monitoring
By help of IoT and Big Data-techniques can generate rich information from few, robust
and cheap sensors.
Continuity
C-Pressure values of train
Brake apply/release:
C-Pressure of wagon
Brake mode
Feedback changeover
Time-behaviour of C-Pressure
Load dependent brake
Comparison
C-/BP-Pressure/Smart Load
Braking performance
Accelerometer data
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Self configuration example: Brake mode
Brake mode depends on train length and mass.
Actuation by servo motor
Control
Self configuring
Backup: control via cloud
Prerequisites:
Train setup
Wagon list
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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App example: Immobilisation brake
Depending on context, immobilisation brake can be used for parking, proximity or for
shunting of powered wagons.
Electrical operation with feedback
Control via cloud, train bus or wearable
Cooperative behaviour allows implementation of proximity brake
function
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Cooperative feature: ep-assisted brake
An ep-assisted brake can be implemented with control from cloud or cooperative function.
Indirect ep-Brake
Reduces influences
Mixed brake setting
Block train operation
Control:
Cooperative
Cloud
Radio Train Bus
Signal running times negligible
compared to filling time
Not to be considered for braked
weight
Individual failures acceptable
due to indirect operation
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Brake Operation in Freight Train 4.0
Most operation are commanded from the cloud while the wagons is part of a freight train
4.0.
Split trains:
Quick release: Command from Cloud
Brake pipe end cocks:
Cloud control
Pneumatic Display
Used as uncoupling instruction
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Brake Operation in Freight Train 4.0
Most operation are commanded from the cloud while the wagons is part of a freight train
4.0.
Train preparation:
Brake mode, load selection, brake activation: Cooperation with train,
cloud
Braked weight, Brake assessment: Cloud commanded
Security:
Cloud protects against inappropriate operation
Alternatively: Authorisation using Wearables or Smart Devices
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Brake Operation in Freight Train < 4.0
During migration, fall back to wearables and smart devices allows local control of
functions.
Split trains:
Quick release: Control with wearable Wearable/Smart Device
Identification of wagon using NFC chip on common installation position
Brake pipe end cocks:
Via Cloud from uncoupling list
Alternatively: Using Wearable/Smart Device (e.g. dedicated glove)
Pneumatic Display
GP 0/1
Pfaff, Schmidt, Enning (Aachen UAS)
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P 86
Wagon 4.0: IoT for freight rail
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Brake Operation in Freight Train < 4.0
During migration, fall back to wearables and smart devices allows local control of
functions.
Train preparation:
Brake mode, brake activation: Control via Wearable/Smart Device
Load selector: Control via smart load or cloud
Braked weight, brake effectivity: Pneumatic displays
Security:
High security level due to absence of manual controls
Feedback of state change into cloud
GP 0/1
Pfaff, Schmidt, Enning (Aachen UAS)
0
P 86
Wagon 4.0: IoT for freight rail
April 25, 2017
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Application example: the powered wagon
The inclusion of a powered version of Wagon 4.0 in the modular approach helps to gain
new customers.
Cost comparison to road traffic
setting:
10.000 Euro additional cost
economically feasible
Requirements:
Tractive force: 21 kN
Tractive power: 15 kW
Energy consumption: 1 kWh
System to be disconnected
during mainline operation
Use of COTS parts, e.g.:
Forklift motor
Disk brake wheelset
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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Conclusion and perspective
Using appropriate automation allows to gain mass customisation for freight rail and
competitive advantages over road transport.
The Wagon 4.0...
...uses current concepts.
...provides advantages for all
stakeholders:
Wagon owners,
Mainline operators and
Shippers.
...opens the freight rail system for
future developments, such as
1
Train preparation
39.5
10
Fill Brake Pipe
40
Condition Assessment
1
Tightness
1
1
1
1
1
33.2
Apply brakes
Check brake application
Apps,
X-as-a-service or
Automation of knowledge work.
Perspective:
33.2
2
2
1
Release brakes
Check release
33.2
0
20
40
Time / min
Hardware development
AI usage for technical inspection of
trains
Pfaff, Schmidt, Enning (Aachen UAS)
Wagon 4.0: IoT for freight rail
April 25, 2017
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