Challenges and solutions for integrating simulation into a transportation device

The transportation area has seen an influx of condition monitoring devices in the last 5 years. A condition monitoring device typically has one or more sensors that it uses to measure the state of a component, analyse the measurement and provide a notification if the measurement is outside its normal operating tolerance. However, what happens if the component can’t be readily measured directly, like rolling contact, or when the device is operating in extreme environmental conditions? It can’t just be ignored. This is where simulation has a significant role to play. This paper explores the challenges in integrating a multi-body simulator into an on-board field device installed on a self-powered railway passenger vehicle. The device uses local sensors such as GPS to provide input to a simulator that calculates wheel-rail contact and L/V ratio. The L/V ratio is used as a derailment risk indictor in the rail sector. Wheel-rail contact is a good example of an area that can’t be directly measured, especially in the context of a tractive vehicle. The paper will also describe the use of simulation to verify and validate the device before installation in the field. The study findings show that, while on the cutting edge of available industrial computer technology, it is possible to integrate a multi-body simulator into a device suitable for installation in a powered vehicle. From the test perspective, it was found that simulation is useful as a tool for enabling realistic hardware integration testing before a device is installed into the field.