Investigation into a fleet bearing monitoring system

Abstract

The Australian Sugar Industry is a significant economic contributor along the Queensland and Northern New South Wales coastlines. The majority of cane processing factories utilise a rail network and rolling stock (i.e. locomotives and cane wagons) for the transport of the sugar cane to the factory for processing. Rolling stock derailments are a significant problem within these transport systems. These derailments create major safety, environment and financial risks to businesses like Sucrogen, the industry partner for this project. A significant proportion (in some seasons up to 20%) of these derailments is root 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 dissertation 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. Through a review of bearing failure theory and identification of the failure lead indicators, selection of a system design layout was achieved. 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. Using the prototype system components, experimental trials were conducted to evaluate the system components’ suitability for the application. This testing identified the system to be successful in the application. Future direction for the research was presented based on the findings of the experimental testing. This will allow the development of the system further to achieve a stand alone, on-line derailment prevention system.