Discussion on top frame and key technologies of intelligent heavy-duty train

This paper presents the development of artificial intelligence in the countries of the world and the intelligent monitoring of heavy haul trains in China and abroad. The intelligent monitoring top frame of heavy haul trains is designed from the perspectives of internet of things and big data, and the whole monitoring system is divided into four sections, as on-board monitoring system (heavy haul car), ground monitoring system, car and ground data transmission system (car to ground) and ground data processing center, of which the formation, working principle and key technologies have been explained respectively. It is necessary to monitoring the conditions of heavy trains, such as hunting performance, braking system, bottom door mechanism and couplers, from the view of operation safety and maintenance cost. The last part of the paper presents that BHP company using ore car maintenance model to optimize the maintenance period and apply conditionbased maintenance based on big data, which have practical significance for maintenance cost reduction of condition-based maintenance. unmanned technology and on-board monitoring technology for heavy haul trains and applied onboard intelligent monitoring technology together with QRRS on the 40-ton axle load stainless steel ore cars developed by QRRS. At the end of 2018, Rio Tinto officially launched the "automatic driving + condition monitoring" automatic drive intelligent train. The on-board monitoring content includes the track condition, train longitudinal force and other parameters, which shall match the bearing temperature and acoustic signals, the temperature and defects of the wheel, the thickness of the brake shoe and the state of the pins collected by the ground monitoring system to serve the safe operation of the trains. In 2013, the Shift2Rail project presented the idea of sustainable and attractive European freight transportation technology. In May 2018, DB began to use tracking, monitoring and remote information equipment on freight cars. So far, DB has used intelligent monitoring systems on more than 1,000 railway freight cars. The on-board system on the freight car mainly includes the on-board GPS system and various types of sensors. The monitoring content is the loading status of the freight cars (load carried, unbalance loading, etc.), the internal temperature of the refrigerated cars, etc., which can more accurately predict the arrival time of the goods and improve the efficiency of time arrangement. 1.2 Current status of intelligent heavy haul cars in China In China, the intelligent monitoring is mainly based on ground monitoring. The former Ministry of Railways had applied a number of information systems such as Railway Freight Car Technology Management Information System (HMIS) and 5T Railway Vehicle Operation Safety Monitoring System to realize the dynamic monitoring, networked operation, remote monitoring, and information sharing of the ground system for passenger and freight cars to improve the safety and security protections of railway vehicles. In 2017, the Railway Corporation (former Ministry of Railways) proposed the project of developing braking performance monitoring technology against the weak point of braking performance monitoring on the freight car running on Daqin railway line (project number: 2017J004-H). In early December 2018, on-board brake system monitoring system were installed on 66 C80B open top wagons on Daqin railway line for a trial test of 6 month to mainly focus on train pipe pressure, pressure of auxiliary air reservoir and brake cylinder pressure. 2 TOP FRAME DESIGN OF INTELLIGENT HEAVY HAUL FREIGHT TRAIN The intelligent heavy haul freight train is accomplished through a system platform, namely: Intelligent Monitoring and Health Management Platform (IMHM), which is mainly composed of on-board monitoring systems, vehicle data transmission systems, ground data processing systems and existing ground monitoring system and shall realize the status monitoring, health assessment, fault diagnosis, fault warning, fault prediction and operation and maintenance plan of the train, so as to achieve the goal of health management of railway freight cars. From the view of data flow, the platform can be divided into two categories: “freight car as the monitoring unit” and “freight train as the monitoring unit”, and the principles of ground monitoring system first, minimum energy consumption of on-board monitoring system first, modular unit design of onboard monitoring system first, advance and reliable on-board monitoring system shall be followed. 2.1 Top frame 1 (freight car as monitoring unit) Intelligent Monitoring and Health Management Platform (IMHM) is mainly composed of on-board monitoring systems, vehicle data transmission systems, ground data processing systems and existing ground monitoring system, as shown in the following Figure 1: Figure 1. HMHM platform and working procedure 2.1.1 On-board monitoring system The on-board monitoring system is part of the IMHM platform and mounted on each car of the freight train, and mainly consists of vehicle wireless sensor unit (WSN), vehicle gateway (WGW), and GPS or Beidou positioning system module. Vehicle Wireless Sensor Unit (WSN): mainly consists of sensors, pre-processing modules, storage units, wireless communication modules,and batteries,etc. and responsible for collecting data, storing a small amount of data and pre-processing data (single parameter model data), and regularly exchanged data with the vehicle gateway (WGW) via wireless technology in the form of automatic reporting or passive searching according to the requirements of “Monitoring Data Transmission Protocol”; Vehicle Gateway (WGW): mainly consists of wireless communication module, pre-processing module (multiple parameter model data), storage unit, microwave data transmission module, and battery, etc. and is responsible for automatically receiving data, pre-processing data (multiple parameter model data) and storage data according to the requirements of “Monitoring Data Transmission Protocol”. Early warning, alarm, and fault data are sent to the ground data processing center in 4G form, and the original data is sent to the ground data processing center in the form of microwaves. GPS or Beidou positioning system module: mainly composed of GPS or Beidou positioning system and battery and be responsible for vehicle positioning, running mileage calculation and running speed detection.