Integrated Optical Fibre Sensing (OptRail-PRO) to Optimise Rail S&C Maintenance

This SBRI FOAK 2020 “OptRail-PRO” Project will demonstrate the use of Optical Fibre Multi-Sensing for Integrated Condition Monitoring of Rail Infrastructure Switches and Crossings (S&C), through further development, test trial certification and installation of the OptRail prototype solution developed by an rcm2- led consortium funded by Innovate UK and Department for Transport (DfT) under AIR5 during 2018-2019. OptRail achieved Rail Industry Readiness Level Five (RIRL 5) equivalent to Technology Readiness Level Six (TRL 6). Various Intellectual Properties (IP’s) were developed, some of which require further R&D to ensure a robust and cost-effective solution for predictive maintenance of railtrack S&C in particular for void and/or crack growth monitoring, prevention and prediction. A railway infrastructure Switches and Crossing (S&C) system is a safety-critical and high-value asset with moveable track sections that guide trains from one track to another and allow them to cross paths. They have an especially limited lifespan because trains cause wear and deformation when they travel across them. As such an S&C system is at a multi-disciplinary interface between rolling-stock (train load and wheel-rail dynamics), signalling (point machines aka turnout) and track (crossing panel - designed to enable the train wheel “smooth” travel from the wing rail to the nose rail.). Its long-term performance relies on how these elements interact with each other over time, while it is always required to be highly reliable since its failure or downtime can cause system delay or even fatal accidents, such as the Potters Bar accident in 2002 (seven deaths and 76 injuries). Network Rail and rcm2 limited identified Bethnal Green Crossing (BGK), Greater Anglia Route as a practicable and critical location for installation and field trial of the OptRail (Optical Fibre Sensing) Solution for Void/Crack Growth Prediction (V&CGP). The Prototype Demonstration project will build upon and advance innovative elements of OptRail. These vary from improving robustness (optimised sensor configuration, magnetic clamp installation kit) to signal processing and V&CGP algorithms (Edge computing, IoT, AI, Cloud) development and validation. Two crossings at Network Rail's Melton Rail Innovation & Development Centre (RIDC) are identified for field trials. Data collected will be validated against S&C Digital Twin model. OptRail data will be shared through rcm2 Cloud through a web API. The expected outcome is to have demonstrated that OptRail had met and satisfied all the Reliability Readiness Level (RRL6-RRL8) requirements as per NR/L2/RSE/0005 L2 Business Process “Product Design for Reliability".