Engineering Commons^™

Optimizing Power Consumption Of Freight Railroad Bearings Using Laboratory Experimental Data, Carlos E. Lopez Iii, Constantine Tarawneh, Arturo A. Fuentes, Harry Siegal

Mechanical Engineering Faculty Publications and Presentations

Based on projected freight truck fuel efficiency, freight railroad and equipment suppliers need to identify, evaluate and implement technologies and/or operating practices to maintain traditional railroad economic competitiveness. The railway industry uses systems that record the total energy efficiency of a train but not energy efficiency or consumption by components. Lowering the energy consumption of certain train components will result in an increase in its overall energy efficiency, which will yield cost benefits for all the stakeholders. One component of interest is the railroad bearing whose power consumption varies depending on several factors that include railcar load, train speed, condition …

Estimating The Inner Ring Defect Size And Residual Service Life Of Freight Railcar Bearings Using Vibration Signatures, Jennifer Lima, Constantine Tarawneh, Jesse Aguilera, Jonas Cuanang

Mechanical Engineering Faculty Publications and Presentations

There are currently two primary wayside detection systems for monitoring the health of freight railcar bearings in the railroad industry: The Trackside Acoustic Detection System (TADS™) and the wayside Hot-Box Detector (HBD). TADS™ uses wayside microphones to detect and alert the train operator of high-risk defects. However, many defective bearings may never be detected by TADS™ since a high-risk defect is a spall which spans about 90% of a bearing’s raceway, and there are less than 30 systems in operation throughout the United States and Canada. HBDs sit on the side of the rail-tracks and use non-contact infrared sensors to …

Optimization Of Railroad Bearing Health Monitoring System For Wireless Utilization, Jonas Cuanang, Constantine Tarawneh, Martin Amaro Jr., Jennifer Lima, Heinrich D. Foltz

Mechanical Engineering Faculty Publications and Presentations

In the railroad industry, systematic health inspections of freight railcar bearings are required. Bearings are subjected to high loads and run at high speeds, so over time the bearings may develop a defect that can potentially cause a derailment if left in service operation. Current bearing condition monitoring systems include Hot-Box Detectors (HBDs) and Trackside Acoustic Detection Systems (TADS™). The commonly used HBDs use non-contact infrared sensors to detect abnormal temperatures of bearings as they pass over the detector. Bearing temperatures that are about 94°C above ambient conditions will trigger an alarm indicating that the bearing must be removed from …

Bibliometric Analysis Of Bearing Fault Detection Using Artificial Intelligence, Pooja Kamat, Rekha Sugandhi Dr.

Library Philosophy and Practice (e-journal)

The new industrial revolution called Industry 4.0 is proliferating at its peak. The time is no longer away when the human race is going to witness a huge paradigm shift. Intelligent machines empowered by Artificial Intelligence (AI)will take over the presence of human workers in the industrial manufacturing sector with the target of achieving 100% automation. With the emergence of cut-throat price competition in the product market, it has become equally important to manufacture goods at minimal costs and with the highest quality. Predicting the decrease in machinery efficiency at an earlier stage to accomplish this objective helps to reduce …

Estimating The Outer Ring Defect Size And Remaining Service Life Of Freight Railcar Bearings Using Vibration Signatures, Joseph Montalvo, Constantine Tarawneh, Jennifer Lima, Jonas Cuanang, Nancy De Los Santos

Mechanical Engineering Faculty Publications and Presentations

The railroad industry currently utilizes two wayside detection systems to monitor the health of freight railcar bearings in service: The Trackside Acoustic Detection System (TADS™) and the wayside Hot-Box Detector (HBD). TADS™ uses wayside microphones to detect and alert the conductor of high-risk defects. Many defective bearings may never be detected by TADS™ since a high-risk defect is a spall which spans more than 90% of a bearing’s raceway, and there are less than 20 systems in operation throughout the United States and Canada. Much like the TADS™, the HBD is a device that sits on the side of the …

Vibration-Based Defect Detection For Freight Railcar Tapered-Roller Bearings, Joseph Montalvo, Constantine Tarawneh, Arturo A. Fuentes

Mechanical Engineering Faculty Publications and Presentations

The railroad industry currently utilizes two wayside detection systems to monitor the health of freight railcar bearings in service: The Trackside Acoustic Detection System (TADS™) and the wayside Hot-Box Detector (HBD). TADS™ uses wayside microphones to detect and alert the conductor of high risk defects. Many defective bearings may never be detected by TADS™ due to the fact that a high risk defect is considered a spall which spans more than 90% of a bearing’s raceway, and there are less than 20 systems in operation throughout the United States and Canada. Much like the TADS™, the HBD is a device …

An Analysis Of The Efficacy Of Wayside Hot-Box Detector Data, Constantine Tarawneh, James Aranda, Veronica Hernandez, Claudia J. Ramirez

Mechanical Engineering Faculty Publications and Presentations

Wayside hot-box detectors (HBDs) are devices that are currently used to monitor bearing, axle, and brake temperatures as a way of assessing railcar component health and to indicate any possible overheating or abnormal operating conditions. Conventional hot-box detectors are set to alarm whenever a bearing is operating at a temperature that is 94.4°C (170°F) above ambient, or when there is a 52.8°C (95°F) temperature difference between two bearings that share an axle. These detectors are placed adjacent to the railway and utilize an infrared sensor in order to obtain temperature measurements. Bearings that trigger HBDs or display temperature trending behavior …

Impact Of Hysteresis Heating Of Railroad Bearing Thermoplastic Elastomer Suspension Pad On Railroad Bearing Thermal Management, Oscar O. Rodriguez, Arturo A. Fuentes, Constantine Tarawneh

Mechanical Engineering Faculty Publications and Presentations

It is a known fact that polymers and all other materials develop hysteresis heating due to the viscoelastic response or internal friction. The hysteresis or phase lag occurs when cyclic loading is applied leading to the dissipation of mechanical energy. The hysteresis heating is induced by the internal heat generation of the material, which occurs at the molecular level as it is being disturbed cyclically. Understanding the hysteresis heating of the railroad bearing elastomer suspension element during operation is essential to predict its dynamic response and structural integrity, as well as to predict the thermal behavior of the railroad bearing …

Defect Prognostics Models For Spall Growth In Railroad Bearing Rolling Elements, Nancy De Los Santos, Constantine Tarawneh, Robert E. Jones, Arturo A. Fuentes

Mechanical Engineering Faculty Publications and Presentations

Prevention of railroad bearing failures, which may lead to catastrophic derailments, is a central safety concern. Early detection of railway component defects, specifically bearing spalls, will improve overall system reliability by allowing proactive maintenance cycles rather than costly reactive replacement of failing components. A bearing health monitoring system will provide timely detection of flaws. However, absent a well verified model for defect propagation, detection can only be used to trigger an immediate component replacement. The development of such a model requires that the spall growth process be mapped out by accumulating associated signals generated by various size spalls. The addition …

Radiative Heat Transfer Analysis Of Railroad Bearings For Wayside Hot-Box Detector Optimization, Arthur Mealer, Constantine Tarawneh, Stephen Crown

Mechanical Engineering Faculty Publications and Presentations

The railroad industry utilizes wayside detection systems to monitor the temperature of freight railcar bearings in service. The wayside hot-box detector (HBD) is a device that sits on the side of the tracks and uses a non-contact infrared sensor to determine the temperature of the train bearings as they roll over the detector. Various factors can affect the temperature measurements of these wayside detection systems. The class of the railroad bearing and its position on the axle relative to the position of the wayside detector can affect the temperature measurement. That is, the location on the bearing cup where the …

Hysteresis Heating Of Railroad Bearing Thermoplastic Elastomer Suspension Element, Oscar O. Rodriguez, Arturo A. Fuentes, Constantine Tarawneh, Robert E. Jones

Mechanical Engineering Faculty Publications and Presentations

Thermoplastic elastomers (TPE’s) are increasingly being used in rail service in load damping applications. They are superior to traditional elastomers primarily in their ease of fabrication. Like traditional elastomers they offer benefits including reduction in noise emissions and improved wear resistance in metal components that are in contact with such parts in the railcar suspension system. However, viscoelastic materials, such as the railroad bearing thermoplastic elastomer suspension element (or elastomeric pad), are known to develop self-heating (hysteresis) under cyclic loading, which can lead to undesirable consequences. Quantifying the hysteresis heating of the pad during operation is therefore essential to predict …

Development Of Prognostic Techniques For Surface Defect Growth In Railroad Bearing Rolling Elements, Nancy De Los Santos, Robert Jones, Constantine Tarawneh, Arturo A. Fuentes, Anthony Villarreal

Mechanical Engineering Faculty Publications and Presentations

Prevention of bearing failures which may lead to catastrophic derailment is a major safety concern for the railroad industry. Advances in bearing condition monitoring hold the promise of early detection of bearing defects, which will improve system reliability by permitting early replacement of failing components. However, to minimize disruption to operations while providing the maximum level of accident prevention that early detection affords, it will be necessary to understand the defect growth process and try to quantify the growth speed to permit economical, non-disruptive replacement of failing components rather than relying on immediate removal upon detection. The study presented here …

Integrated Condition Monitoring And Prognosis Method For Incipient Defect Detection And Remaining Life Prediction Of Low Speed Slew Bearings, Wahyu Caesarendra, Tegoeh Tjahjowidodo, Buyung Kosasih, Anh Kiet Tieu

Faculty of Engineering and Information Sciences - Papers: Part B

This paper presents an application of multivariate state estimation technique (MSET), sequential probability ratio test (SPRT) and kernel regression for low speed slew bearing condition monitoring and prognosis. The method is applied in two steps. Step (1) is the detection of the incipient slew bearing defect. In this step, combined MSET and SPRT is used with circular-domain kurtosis, time-domain kurtosis, wavelet decomposition (WD) kurtosis, empirical mode decomposition (EMD) kurtosis and the largest Lyapunov exponent (LLE) feature. Step (2) is the prediction of the selected features' trends and the estimation of the remaining useful life (RUL) of the slew bearing. In …

Heat Generation In The Railroad Bearing Thermoplastic Elastomer Suspension Element, Oscar O. Rodriguez, Juan Carbone, Arturo A. Fuentes, Robert E. Jones, Constantine Tarawneh

Mechanical Engineering Faculty Publications and Presentations

The main purpose of this ongoing study is to investigate the effect of heat generation within a railroad thermoplastic elastomer suspension element on the thermal behavior of the railroad bearing assembly. Specifically, the purpose of this project is to quantify the heat generated by cyclic loading of the elastomer suspension element as a function of load amplitude, loading frequency, and operating temperature. The contribution of the elastomer pad to the system energy balance is modeled using data from dynamic mechanical analysis (DMA) of the specific materials in use for that part. DMA is a technique that is commonly used to …

Temperature Profiles Of Railroad Tapered Roller Bearings With Defective Inner And Outer Rings, Constantine Tarawneh, Luz Sotelo, Anthony A. Villarreal, Nancy De Los Santos, Ryan L. Lechtenberg, Robert Jones

Mechanical Engineering Faculty Publications and Presentations

In the railroad industry, monitoring the condition of key components such as bearings and wheels is vital to ensure the safe transport of goods and commodities. Bearing seizures are amongst the most dangerous types of failures experienced by trains because they occur unexpectedly and may lead to costly derailments. Current bearing health monitoring techniques include tracking the temperature and acoustic emissions given by the bearings. Although temperature histories of railroad tapered roller bearings are readily available, the literature does not provide information relating the temperature profiles to the severity of the bearing defect. The study presented here investigates the correlation …

Fatigue Life Estimation Of Modified Railroad Bearing Adapters For Onboard Monitoring Applications, Alexis Trevino, Arturo A. Fuentes, Constantine Tarawneh, Joseph Montalvo

Mechanical Engineering Faculty Publications and Presentations

This paper presents a study of the fatigue life (i.e. number of stress cycles before failure) of Class K cast iron conventional and modified railroad bearing adapters for onboard monitoring applications under different operational conditions based on experimentally validated Finite Element Analysis (FEA) stress results. Currently, freight railcars rely heavily on wayside hot-box detectors (HBDs) at strategic intervals to record bearing cup temperatures as the train passes at specified velocities. Hence, most temperature measurements are limited to certain physical railroad locations. This limitation gave way for an optimized sensor that could potentially deliver significant insight on continuous bearing temperature conditions. …

Tracking Of Spall Deterioration On Tapered Roller Bearings, Amy Gonzalez, Constantine Tarawneh, Ping Hu, Joseph A. Turner, Brent Wilson

Mechanical Engineering Faculty Publications and Presentations

Fatigue spall initiation is one of the major modes of premature bearing failure. The spall initiation is often exacerbated by the presence of impurities in the near-surface region (∼400 μm) of the bearing raceways. Once a spall initiates, it can propagate rapidly, leading to abnormal bearing operation and possible catastrophic failure if not detected early. Testing performed at the University of Texas-Pan American (UTPA) has focused on ultrasonically scanned tapered roller bearings found to have inclusion content within 400 μm of the surface of the raceways. These bearings undergo accelerated service life tests in which spall initiation is detected and …

Energy Harvesting Potential Of Terfenol-D For On-Board Bearing Health Monitoring Applications, Raul Estrada, Heinrich D. Foltz, Constantine Tarawneh, Rene Moreno

Electrical and Computer Engineering Faculty Publications and Presentations

One of the limiting factors in on-board bearing health monitoring systems is the life of the batteries used to power the system. Thus, any device that can extend the life of the battery, or entirely replace it, is a notable improvement on any currently available systems. Existing on-board monitoring systems, not optimized for low power, are designed to run on approximately 300 mW of power. Current bearing health monitoring systems have proven effective with as few as one reading every four minutes. The environment under which railroad bearings operate is a harsh one, making most forms of energy harvesting very …

Structural Integrity Of Conventional And Modified Railroad Bearing Adapters For Onboard Monitoring, Joseph Montalvo, Alexis Trevino, Arturo A. Fuentes, Constantine Tarawneh

Mechanical Engineering Faculty Publications and Presentations

This paper presents a detailed study of the structural integrity of conventional and modified railroad bearing adapters for onboard monitoring applications. Freight railcars rely heavily on weigh bridges and stations to determine cargo load. As a consequence, most load measurements are limited to certain physical railroad locations. This limitation provided an opportunity for an optimized sensor that could potentially deliver significant insight on bearing condition monitoring as well as load information. Bearing adapter modifications (e.g. cut outs) were necessary to house the sensor and, thus, it is imperative to determine the reliability of the modified railroad bearing adapter, which will …

Detailed Seismic Evaluation Of Bridges On And Over The Parkways In Western Kentucky, Jian Xie, Issam E. Harik, Tong Zhao

Kentucky Transportation Center Research Report

This report outlines a rating system and details an evaluation procedure for the seismic evaluation of highway bridges. These processes are later used to investigate the structural integrity of selected highway bridges on and over the parkways in Western Kentucky. A total of 349 bridges were rated with the bridge ranking system, and 17 were selected for detailed seismic evaluation.

The capacity/demand ratio method developed by the Federal Highway Administration is employed for the detailed evaluation of bridges. The evaluation involves creating three-dimensional finite element models for all 17 bridges. Dynamic analysis is performed for a projected 250-year event. Among …

Vibration Event Detection: A Monitoring Method For Slow Speed Bearings, Craig Moodie, A. K. Tieu, S. Biddle

Faculty of Engineering - Papers (Archive)

Traditional signal analysis methods appear to fail in their ability to provide consistent meaningful information when presented with data from large slow moving slew bearings. A number of reasons for this are presented. Statistics obtained from vibration data collected from a large Coal Reclaimer and an experimental test-rig is discussed. The Coal Reclaimer rotates at 4.3 rpm about two vertically mounted, large, slew bearings. The experimental test-rig rotates at 1 rpm in the horizontal plane. These statistics are compared to the results obtained using a simple event detection algorithm. The event detection algorithm is detailed and its strengths discussed relative …

Symmetry Methods Applied To The Condition-Monitoring Of Slow Speed Slew Bearings, Craig Moodie, A. K. Tieu, Simon Biddle

Faculty of Engineering - Papers (Archive)

All data has symmetry and anti-symmetry embedded in it. This paper discusses various aspects of symmetrical transformations that can be applied to data to give machine condition information. These transformations lead to novel views of the information. Combining these symmetrical transformations with the more traditional methods of Eigenvalue/vector and Fast Fourier Transform analyses provides views of the source and extent of the problem. To illustrate the various views of the vibration information, results from a large (4.2m diameter) Coal Reclaimer slow speed (4rpm) slew bearing are presented. Many of the transformations are also currently being evaluated on an experimental test-rig …

Detailed Seismic Evaluation Of Bridges Along I-24 In Western Kentucky, Ching Chiaw Choo, Issam E. Harik, Peng Yuan

Kentucky Transportation Center Research Report

This report presents a seismic rating system and a detailed evaluation procedure for selected highway bridges on/over I-24 in Western Kentucky near the New Madrid Seismic Zone (NMSZ). The rating system, based upon structural vulnerability, seismic and geotechnical hazards, and socioeconomic factors, was used to rank 127 (82 on and 45 over I-24) bridges on/over I-24. A total of 14 bridges were selected and subsequently evaluated using a capacity/demand ratio method outlined in the Seismic Retrofitting Manual for Highway Bridges by the Federal Highway Administration. The focus was on four bridge components; namely the expansion joints, bearings, columns, and footings. …

A Compliant Contact-Aided Revolute Joint, Jessie R. Cannon, Larry L. Howell

Faculty Publications

This paper presents the compliant contact-aided revolute (CCAR) joint, a planar mechanism capable of performing the functions of a bearing and a spring. The pseudo-rigid-body model is used to predict the behavior of the CCAR joint, and this model is validated through the use of finite element analysis and prototype testing. The CCAR joint is shown to have high maximum rotation and lateral stiffness. A case study is presented, and manufacturing considerations are discussed for the macro, meso, and micro scales.

A Compliant Contact-Aided Revolute Joint, Jessie R. Cannon, Larry L. Howell

Faculty Publications

This paper presents the compliant contact-aided revolute (CCAR) joint, a planar mechanism capable of performing the functions of a bearing and a spring. The pseudo-rigid-body model is used to predict the behavior of the CCAR joint, and this model is validated through the use of finite element analysis and prototype testing. The CCAR joint is shown to have high maximum rotation and lateral stiffness. A case study is presented, and manufacturing considerations are discussed for the macro, meso, and micro scales.