INVESTIGATION INTO A LOW-COST WAGON BEARING FAILURE PREVENTION SYSTEM

THE MAJORITY OF AUSTRALIAN cane processing factories utilise a rail network and rolling stock (i.e. locomotives and cane wagons) for the transport of sugar cane to the factory. Rolling stock derailments are a significant problem within these transport systems, creating major safety, environment and financial risks to businesses. A significant proportion (in some seasons up to 10%) of these derailments was caused by wagon axle bearing failures. Like most rolling element bearings, the wagon bearings exhibit random failure modes and failure is therefore unpredictable based on service interval. This paper investigates the use of various condition monitoring methods with respect to identifying a cost effective method for on-line bearing monitoring for cane wagon bearings. With Hot axle box detection having been considered before in the Australian sugar industry (Everitt, 1987; Everitt et al., 1997), a number of constraints to the successful use of this technology at this time limited its overall capabilities. Through a review of bearing failure theory and identification of the failure lead indicators, a system was designed. The system design was realised as a prototype system for evaluation as a measurement and data management tool for integration with a wagon identification system. Experimental trials were conducted to evaluate the system components’ suitability for the application and to determine the expected success in developing the system further. The ultimate aim was to achieve a low-cost, stand alone, on-line derailment prevention system that can integrate with current business systems and the rolling stock operational environment.