The Revolution in Weight Measurement: Weighing Technology in Rail Transport
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Solutions
Accurately measuring the load of freight wagons has always been a challenge. It is key to optimising wagon utilisation and complying with maximum weight limits. But how can this task be accomplished efficiently and precisely? The answer lies in weighing technology.
The Dangers of Inaccurate Wagon Weight Measurement
Inaccurate weight measurement of freight wagons can have serious consequences. Obviously, overloading wagons can not only lead to damage to the wagons themselves, but also endanger the safety of the entire train. Small but persistent overloads cause long-term damage to infrastructure such as tracks, points, embankments and bridges. In the worst case scenario, overloading can lead to derailments, causing significant material damage and injuries or even fatalities. When that involves environmentally hazardous goods, there may also be long-term consequences for people and the environment. However, underloading wagons is also problematic. It leads to inefficient use of transport capacity and, therefore, unnecessary costs. In addition, uneven loading of the wagons can impair the train's running behaviour and also increase the risk of derailments. Weighing technology offers a solution here. Precise real-time weight measurement allows overloads and underloads, as well as uneven loads, to be reliably detected and avoided. This way, weighing technology contributes to making rail transport safer and more efficient.
What is Weighing Technology?
Weighing technology is an innovative system for weighing freight wagons. It is based on strain gauges mounted on the wagon's bogies. These sensors stretch proportionally to the weight acting on the wagon. By capturing this elongation, the total weight of the load can be determined with high accuracy.
Weighing technology offers several advantages over conventional methods:
- Time savings: Since trips to weighing stations are not required, operational efficiency is significantly increased.
- Cost savings: Significant costs can be saved by reducing journeys and increasing efficiency.
- Accuracy: With a measurement accuracy of less than 2% deviation, weighing technology sets new standards in weight measurement.
This technology is particularly suitable for wagons transporting bulk materials, logs or scrap metal. For weighing liquids, there are other suitable solutions, as these flow slowly into the wagon.
How Does Weighing Technology Work?
At the heart of the weighing technology are the strain gauges. They are temperature-compensated to ensure high measurement accuracy over a wide temperature range. A simple two-point calibration (full/empty) allows fine adjustment of the sensors for even greater accuracy.The sensors communicate wirelessly with the wagon's telematics unit, which is responsible for data transmission and sensor control. A mobile app enables wireless configuration and fine-tuning of the sensors.
In addition to the strain gauges, the system has secondary optional sensors, including a temperature sensor and a three-axis accelerometer. The accelerometer measures acceleration with high resolution (13-bit) at up to ±16 g on all three axes.
Flexible Configurations for Different Accuracy Requirements
Weighing technology offers flexible configuration options to meet specific customer requirements. The accuracy of the weight measurement improves as more sensors are installed:
- One sensor per wagon: This configuration allows simple detection of the loading status (loaded/unloaded).
- Two sensors per wagon: This allows the detection of an even load in relation to the front and rear axles as well as overload detection.
- Four sensors per wagon (two per bogie): The installation of four sensors offers the highest measurement accuracy of less than 2 percent deviation in more than 95 percent of measurements.
Most customers opt for the installation of four sensors to ensure maximum accuracy and safety.
Applications and Target Customers
Weighing technology is suitable for a variety of wagon types used to transport bulk materials, logs or scrap metal. Several companies have already opted for this technology, including Rail Cargo Austria Rail & Sea and the Rhaetian Railway. These companies recognise the added value offered by weighing technology and plan to equip thousands of wagons with the technology in the coming years.
Technical Specifications
The technical specifications of weighing technology are impressive. The main sensor, a strain gauge, has an absolute measurement accuracy of less than 1000 kg with a single calibration and less than 500 kg with periodic calibration or auto-calibration. The maximum supported range on the bogie is 0-50,000 kg.
In addition to the main sensor, the system has integrated secondary optional sensors, including a temperature sensor and a three-axis accelerometer. This accelerometer measures acceleration with high resolution (13-bit) at up to ±16 g on all three axes.
The system uses a wireless multi-protocol sensor interface that supports standards such as IEEE802.15.4, Bluetooth Low Energy and 6LoWPAN. The sensors communicate wirelessly with the wagon's telematics unit, which is responsible for data transmission and sensor control.
Software Architecture
The weighing technology's software architecture consists of two interfaces: the gateway and the web service. The gateway translates communication between the Observer's energy-efficient protocol and Cumulocity's HTTP API. Cumulocity acts as a broker between Observer and the web service, which is responsible for all provisioning matters.
The web service also offers the option of fine-tuning the PrecisionWeight sensors via an external application, to allow for greater accuracy compared to the factory settings.
Conclusion
Weighing technology represents an innovative and forward-looking solution for weight measurement of freight wagons. It delivers high accuracy, cost-effectiveness and ease of use. By providing real-time weight data and data-driven insights, the technology enables improved utilisation, more efficient maintenance planning and a lower risk of derailment. With its flexibility and adaptability to different accuracy requirements, weighing technology is ideally equipped for the challenges of modern rail transport.