Fault Detection for Point Machines: A Review, Challenges, and Perspectives
Abstract
:1. Introduction
- We provide a review of fault detection in point machines for research and development personnel, scholars, and engineers, covering the latest data-driven algorithms with comments as well as evaluation metrics.
- We conduct a comprehensive analysis of point machines, including their requirements, inherent features, and external influences.
- We describe the anticipated requirements for an intelligent point machine fault detection system.
- We propose eight urgent issues and possible solutions for future point machine fault detection research which can be of genuine use to infrastructure maintainers and owners, and present a blueprint for intelligent point machine fault detection.
- Which types of data-driven algorithms are employed for point machine fault detection, what are their pros and cons, and what are their specific application scenarios?
- What metrics are appropriate for evaluating the task of fault detection in point machines?
- What are the requirements for an intelligent point machine condition monitoring and fault detection system?
- What future directions can be identified for the advancement of intelligent point machine fault detection?
2. Fundamentals of Turnouts and Point Machines
3. Condition Monitoring and Fault Detection
3.1. Common Failure Modes
3.2. Monitored Parameters
- Motor-related parameters. Studies have revealed that the switching resistance best reflects the condition of the point machine [2,3,8]. However, real-time and reliable switching resistance measurement is not easy to achieve; motor-related parameters are an alternative, as the energy provided by the motor overcomes the resistance between movable parts and the track bed during the switching process. In other words, whether the motor operating parameters are normal or not when there are no faults with the motor is consistent with whether the switching resistance is normal or not. Therefore, the motor current, voltage, and power are extensively monitored in actual condition monitoring. In contrast, the motor output speed and torque are rarely employed in actual railway operation due to the difficulties involved in sensor installation.
- Gap-related parameters. The gap between the lock/detection slide notch and the edge of the lock/detection hammer notch in a point machine is considered an indirect measurement of the gap between a switch point and its adjacent stock rail in the closed position, which is a crucial safety parameter for monitoring the condition of a turnout. Too large a gap may cause disastrous consequences, such as train derailment, human injury, and severe damage to both infrastructure and the environment [9,10]. Because the sensor is installed beside the rails at a point where the train wheel sets often pass through, the direct measurement method results in low reliability. At present, alarms based on a threshold gap are widely used in the railway field [11].
- Other parameters. Fault detection based on other parameters is largely absent, as it is not easy to deploy real-time online monitoring sensors, particularly the switch circuit controller. Nonetheless, these parameters can be beneficial for on-site operations and maintenance.
3.3. Fault Detection in Point Machines
3.3.1. Statistical Analysis-Based Methods
3.3.2. Proximity-Based Methods
3.3.3. Supervised Learning-Based Methods
3.3.4. Unsupervised Learning-Based Methods
3.3.5. Semi-Supervised Learning-Based Methods
3.3.6. Evaluation Metrics
4. Analysis of Point Machines and Monitoring Systems
4.1. Requirements for Point Machines
- High safety and reliability. Because point machines drive the turnout, which is the crucial section of railway track, they involves the operational safety of trains. Any hardware device or software installed in point machines should be reliable and trustworthy, including the sensors, supporting signal processing, and monitoring procedures.
- Long service life. Point machines are designed and manufactured with a focus on a lengthy service life, as replacing the entire machine that works along the trackside requires time and money. Therefore, providers can guarantee high quality, with suppliers typically claiming more than one million throwing movements before machine overhaul.
4.2. Inherent Features for Point Machines
- Electro-mechanical. A point machine is a typical mechanical or electro-mechanical device; it is often driven by an AC or DC motor, and outputs the displacement of the throw slide with the aid of mechanical drive mechanisms. In addition, its structure is non-redundant, that is to say, each component is indispensable to realization of the point machine’s required functions.
- Limited space. The majority of point machines are tailored products. Limited space is a basic attribute, as they need to be convenient for transportation and maintenance. This advantage, however, means that there is limited remaining space inside the point machine, making it challenging to fix and to a certain extent relying on sensing units to determine maintenance needs.
- Complexity. The electro-mechanical components make a point machine’s structure complex, comprising many mechanical, electrical and even hydraulic or pneumatic items that can potentially cause diverse fault modes. The include single faults, compound faults, intermittent faults, and NFF (no fault found) failures. Furthermore, the constituent parts can vary quite considerably in terms of their failure probability, and these failure probabilities are normally very low. As a result, gathering all possible fault data is extremely difficult.
- Variety. Point machines come in three main types: electro-mechanical, electro-hydraulic, and electro-pneumatic [53,54]. Each type has unique parameters. For example, electro-mechanical point machines focus on throwing force and motor power, while electro-hydraulic ones mainly consider the hydraulic system pressure.Second, these three types have different failure mode distributions. Electro-mechanical point machines commonly experience wear and transmission component fractures, electro-hydraulic ones are prone to oil leakage, and electro-pneumatic ones often face pneumatic subsystem-related issues.Furthermore, various subtypes exist within each type to meet specific turnout requirements. These subtypes can vary in their motor type, output force, length and displacement distance of the throw slide detection slide, locking mode, etc. For instance, the China Railway Signal and Communication Corporation produces over forty specific subtypes of the ZDJ9 electro-mechanical point machine; among these, the throwing force range is between 2.5 kN and 4.5 kN, the displacement distance of the throw slide ranges from 80 mm to 220 mm, and the same figure for the detection slide varies from 75 mm to 170 mm. It should be noted that these slight discrepancies need to be taken very seriously.
- Individual differences. Even within a subclass, there may be non-negligible differences in point machines due to production errors. More significantly, differences may result from external factors such as action frequency, ambient temperature and humidity, electromagnetic interference, and train impacts with varying speeds. As a result, the switching resistance between individual machines can very. This variation in the duration of point machine movements exists within a specific range. It is important to recognize that every individual point machine has its own unique behavior due to slight individual differences and diverse external impacts.
4.3. External Impacts for Point Machines
- Rolling stock and operational planning. The complete structure and compliant dimensional parameters of the turnout determine the safe and reliable passage of trains. Deviation of the geometry or component damage of a turnout may make the point machine unable to work normally, e.g., rail creeping, alignment of switch rails, and rail wear. Train passage through turnouts can generate significant impact loads, especially during wheel–rail transitions in the switch and crossing zones, resulting in high vertical and horizontal loads [55]. In [56], a numerical investigation reported maximum lateral displacements of up to 5 mm and variations of up to 8 mm in high-speed rail. Table 4 shows the vertical displacement of CRH2 EMU after passing through the turnout at a speed of 250 km/h. In fact, the extent of displacement depends on the condition of the point machine, track, and traffic characteristics such as the speed, axle load, and train formation. Operation plans, including train passing frequencies, influence geometric parameters and turnout frame integrity. Train-related events, encompassing rolling stock and operation plans, provide essential insights into the mechanical system’s stability.
- Service environment. Point machines operate in diverse service environments influenced by geographical factors such as location, latitude, longitude, and ocean currents. These environments can range from extreme heat during the day to sharp temperature drops at night. For instance, Chinese railway regulations require point machines to function in temperatures ranging from −40 °C to +70 °C. A prime example are the CTS2 point machines installed on the Qinghai–Tibet Railway, which operate in cold high-altitude areas.In certain cases, railways traverse challenging environments, such as the Saudi Arabian Railway across desert terrain known for its harsh climate and abrasive sand and wind. Polar regions with heavy snowfall pose challenges for point machines as well. Despite implementing protective measures, extreme climates can accelerate performance degradation. Additionally, point machine adjustments made at night may become inaccurate during the day due to changing conditions.
4.4. Requirements for Point Machines Condition Monitoring & Fault Detection System
- Req. 1: Trustworthiness. Any software and hardware equipped with point machines should be trustworthy. Data-driven models, while achieving impressive results, pose difficulties in terms of understanding their internal mechanisms, as most data-driven models function as “black box” models. However, commercialization necessitates clear explanations about how the models learn, what knowledge they acquire, their decision-making rationale, and the level of trustworthiness they offer. Hence, it is highly recommended that point machine fault detection systems be built on a trustworthy foundation, including both software and hardware. The most important thing is to ensure the interpretability of AI models and the trustworthiness of their outcomes.
- Req. 2: Handling multi-source data. Because a single modality provides incomplete insights into the overall condition of point machines [7], even though the force and the current and power signals can best reflect the point machine’s states [2,3], it is highly suggested that point machine fault detection systems effectively integrate data from various sensors in order to comprehensively monitor the state of point machines in terms of Req. 1 and IF 1 of point machines. In addition, certain special scenarios such as sensor failure and parameter offset need to be considered.
- Req. 3: Designing and deploying sensors. Due to the Req. 1, IF 2, and EI 2, reliable, high-accuracy, compact, and interference-free sensors should be favored in point machines, particularly non-intrusive and “plug and play” (easily and quickly interchangeable) types. Thus, it is highly recommended to design suitable sensors and to use a reasonable layout.
- Req. 4: Handling imbalanced data. In light of IFs 3 and 4, practical point machine fault detection problems face extremely imbalanced datasets (i.e., with over 99% normal samples and less than 1% abnormal). Furthermore, abnormal data contain a variety of fault types. Because imbalanced datasets are detrimental to model training for data-driven methods [58,59], leading to bad performance on fault detection, this is an urgent and critical requirement.
- Req. 5: Handling unseen and complex fault modes. Rethinking IFs 3 and 4 of point machines, there are theoretically a number of different fault types for point machines. It is almost impossible to gather all the fault data, as not all faults occur during real operations, especially for new railway lines without historical data. Despite this, unrecorded or unseen faults can affect the determination of the classification boundary between normal and abnormal data. As a result, it is suggested that the system be able to handle both unseen and complex fault modes, even though this is a difficult task.
- Req. 6: Handling part-level fault modes. Considering IF 4 of point machines in combination with the literature survey, electro-pneumatic point machines, which are commonly used in turnout areas and marshaling yards, have received limited attention from researchers. Moreover, scholars have overlooked fault detection for specific parts, such as the retarder, throw rod, and switch circuit controller [60]. However, every part within a point machine is crucial, as all lack redundancy. Previously, researchers have mistakenly taken the current, power, or other condition monitoring parameters as an overall performance indicator for point machines. To enhance precision, there is a need to shift focus towards detecting faults at the part level, such as hydraulic cylinders [61] and bearings [62] under daily loads.
- Req. 7: Universality, generalization, and robustness. Based on IFs 4 and 5 and EIs 1 and 2, developing a model with high universality, generalization, and robustness is recommended. More precisely, a highly universal model can operate on different types and models of point machines without the need for individual model training in each case, which reduces the costs of system deployment and maintenance while allowing the model to be used across a wider railway network. Strong generalization capabilities imply that the model performs well even when facing new and previously unseen fault patterns or environmental conditions. In addition, a robust model maintains stable performance when dealing with noise, interference, sensor failures, and changes in environmental conditions. This means that the model can reliably perform fault detection even in complex real-world operating environments, thereby reducing the and .
- Req. 8: Maintaining fault detection performance over time. Considering Req. 2, IFs 4 and 5, and EIs 1 and 2, more and more observations (e.g., unanticipated fault modes, numerical accumulations) need to be collected throughout the whole life cycle of a point machine while accounting for the changing service environment and imposed time-dependent operation plans. Hence, it is of great importance to ensure that the fault detection model remains effective over time until it can be replaced with a new one.
5. Urgent Problems and Challenges
6. Blueprint
7. Conclusions
- Compared to traditional machine learning, deep learning-based algorithms exhibit the capability to autonomously learn features from massive datasets and efficiently detect faults. Notably, they have demonstrated remarkable potential for point machine fault detection. There is considerable room for further exploration of deep learning in point machine fault detection direction. Moreover, the diverse nature of the relevant datasets mandates flexibility in selecting appropriate fault detection algorithms. While supervised learning methods excel when abundant labeled data are available, scenarios involving data scarcity or incompleteness can benefit from the utilization of semi-supervised and weakly supervised learning approaches. These techniques make efficient use of limited labeled data and abundant unlabeled data, thereby enhancing model performance. This flexibility empowers practitioners to choose the most suitable method based on the characteristics of the available data, ultimately achieving enhanced fault detection outcomes.
- Concerning evaluation metrics, the traditional accuracy metric is unsuitable for the imbalanced datasets inherent to the point machine fault detection task. Instead, emphasis is placed on other vital metrics such as the precision, recall, score, false alarm rate, and missed detection rate. These metrics provide a more accurate assessment of model performance, ensuring precise and reliable fault detection in practical railway applications.
- In the context of developing an intelligent point machine condition monitoring and fault detection system, it is imperative that the system exhibit trustworthiness, robustness, and a high degree of generalization and transferability. While there are eight essential requirements that need to be addressed, they come with varying degrees of priority. The core essence of most of these requirements is to effectively address the challenges posed by limited training data in diverse and complex operational scenarios.
- In terms of future directions, the field of point machine fault detection confronts several urgent challenges and opportunities. These encompass the application of trustworthy artificial intelligence methodologies to enhance model safety and reliability as well as the exploration of multi-sensor data fusion techniques to elevate detection precision. Moreover, imbalanced datasets, the presence of unseen and complex fault modes, and the need for fault detection at the device level remain critical challenges that researchers must tackle. Techniques such as data augmentation, transfer learning, and zero-shot learning hold promise for addressing these challenges and building robust models that can effectively detect various fault scenarios. In addition, building fault detection models with high generalization ability is necessary. Models must be capable of adapting to changing environments, accumulating data over time, and maintaining their performance throughout the long service life of point machines.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Designation | Description |
---|---|
Power supply | DC and AC electric motor, hand (rarely), etc. |
Transmission mechanism | Mechanical, hydraulic, and pneumatic drives. |
Throwing/reversing force | A broad range, typically up to 9 kN. |
Retaining force | A wide variety. |
Throwing time | Slow action: over 6 s; medium: 3 s to 6 s; fast action: not more than 0.8 s. |
Stroke | Approximately ranging from 30 mm to 300 mm. |
Product lifetime | Normally over one million throwing movements. |
Locking system | External lock, internal lock. |
Installation configuration | Track center and beside the tracks (right-hand or left-hand layouts); stock rail fixation and sleeper fixation (in-tie or on-tie). |
Trailability | Trailable and non-trailable. |
Environmental conditions | Operating temperature: −40 °C to +80 °C; humidity: up to 95%. |
Degree of protection | Resistance to sand, dust, dirt, snow, meltwater, humidity, and flood water. |
Weight & profile | Diversity. |
Electrical interface | Various interlocking systems, e.g., single-drive (four wires, five wires) and multi-drive technology. |
Turnout interface | No limitation on the types of turnouts. |
No. | Part | Failure Mode | Effect | Safety Impact |
---|---|---|---|---|
1 | Actuator | Short circuit or open circuit | Unable to move the turnout | No |
Aging | Reducing operational efficiency | No | ||
2 | Drive mechanism | Wear and tear, slight deformation & jam (increased resistance) | Reducing operational efficiency | No |
Mechanical fracture, significant deformation & complete jam | Unable to move the turnout | No | ||
3 | Switch circuit controller | Wear and tear, slight deformation & jam (increased resistance) | Reducing operational efficiency | No |
Mechanical fracture, significant deformation & complete jam | Unable to move the turnout/train derailment | Possible | ||
Short circuit or open circuit | Unable to move the turnout | Hardly | ||
4 | Throw slide | Wear and tear, slight deformation & jam (increased resistance) | Reducing operational efficiency | No |
Mechanical fracture, significant deformation & complete jam | Unable to move the turnout/train derailment | Possible | ||
5 | Detection or locking slide | Wear and tear, slight deformation & jam (increased resistance) | Reducing operational efficiency | No |
Mechanical fracture, significant deformation & complete jam | Train derailment | Yes | ||
6 | Housing | housing damage | Reducing operational efficiency/unable to move/train derailment | Low |
Monitored Devices | Monitored Parameters | Type of Point Machines |
---|---|---|
Motor | Current, voltage, power, speed, torque | All motor-driven point machines |
Gap | size | All |
Throw rod | Throwing force, displacement, position, speed | All |
Indication/detection rod | Displacement, position, speed | All |
Locking rod | Gap size, locking depth, locking force | point machines equipped with internal locking devices |
External locking devices | Gap size, locking force | point machines armed with external locking devices |
The whole machine | Switching resistance, sound, vibration, temperature humidity, throwing time, change of movement direction | All |
Switch circuit controller | Contact depth, rotation angle, contact pressure, contact resistance, opening thickness of stationary contact, thickness of movable contact ring, angular displacement/real-time angle/angular velocity of movable contact | Most of point machines made and used in China (ZD6, ZD(J)9, ZYJ7, ZK4) |
Hydraulic device | Oil pressure, oil level, electro valve | Hydraulic transmission type point machines |
Pneumatic device | Pneumatic pressure, electro valve | Pneumatic transmission type point machines |
China Technical Turnout in Wuhan-Guangzhou Test Section | German Technical Turnout in Wuhan-Guangzhou Test Section | French Technical Turnout in Hefei-Nanjing Railway | |||
---|---|---|---|---|---|
Sleeper No. |
Vertical Displacement |
Sleeper No. |
Vertical Displacement |
Sleeper No. |
Vertical Displacement |
10 | 0.62 mm | −3 | 0.84 mm | −3 | 0.33 mm |
28 | 0.76 mm | 10 | 0.46 mm | 13 | 0.37 mm |
37 | 0.65 mm | 27 | 0.99 mm | 27 | 0.1 mm |
47 | 0.44 mm | 44 | 0.96 mm | 50 | 0.56 mm |
Point Machines | Condition Monitoring & Fault Detection System | ||||
---|---|---|---|---|---|
Req. | IF | EI | Req. | Difficulty | Suggested Priority Level |
1 | Trustworthy | Hard | High | ||
1 | 1 | Handling multi-source data | Easy | High | |
1 | 2 | 2 | Designing and deploying sensors | Moderate | High |
3, 4 | Handling imbalanced data | Moderate | Critical | ||
3, 4 | Handling unseen and complex fault modes | Hard | Medium | ||
4 | Handling part-level fault modes | Moderate | Medium | ||
4, 5 | 1, 2 | Universality & generalization and robustness | Moderate | Medium | |
2 | 5 | 1, 2 | Maintaining fault detection performance over time | Hard | Medium |
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Share and Cite
Hu, X.; Tang, T.; Tan, L.; Zhang, H. Fault Detection for Point Machines: A Review, Challenges, and Perspectives. Actuators 2023, 12, 391. https://doi.org/10.3390/act12100391
Hu X, Tang T, Tan L, Zhang H. Fault Detection for Point Machines: A Review, Challenges, and Perspectives. Actuators. 2023; 12(10):391. https://doi.org/10.3390/act12100391
Chicago/Turabian StyleHu, Xiaoxi, Tao Tang, Lei Tan, and Heng Zhang. 2023. "Fault Detection for Point Machines: A Review, Challenges, and Perspectives" Actuators 12, no. 10: 391. https://doi.org/10.3390/act12100391
APA StyleHu, X., Tang, T., Tan, L., & Zhang, H. (2023). Fault Detection for Point Machines: A Review, Challenges, and Perspectives. Actuators, 12(10), 391. https://doi.org/10.3390/act12100391