SYSTEM FOR WORKING ON A TRACK

Abstract

A system for working on a track with a track maintenance machine has a machine controller and a work unit controlled thereby, with sensors being arranged to monitor the work unit. In this context, the sensors are coupled to a data acquisition module for the separate recording of sensor data, with the data acquisition module being connected to a computing unit in which a first algorithm for calculating result data from the sensor data is set up. In this way, the system contains additional structural components for processing sensor signals. With the data acquisition module and the computing unit, different evaluations of the working mode can be performed independently of an existing monitoring function.

Claims

1-15. (canceled)

16. A system for working on a track, comprising: a track maintenance machine containing: a machine controller; a work unit controlled by said machine controller; sensors disposed to monitor said work unit; a data acquisition module, said sensors are coupled to said data acquisition module for a separate recording of sensor data; and a computer, said data acquisition module connected to said computer in which a first algorithm for calculating result data from the sensor data is set up.

17. The system according to claim 16, wherein said computer is set up to calculate at least one parameter from the sensor data recorded during a work sequence.

18. The system according to claim 16, wherein said data acquisition module is set up for multi-channel data recording and is coupled as a slave to said computer functioning a master.

19. The system according to claim 16, further comprising a monitor for monitoring said work unit, which records the sensor data at a lower sampling rate than said data acquisition module.

20. The system according to claim 16, further comprising: a database; and a communication means, said computer is coupled to said database via said communication means in order to receive program data for modifying the first algorithm or for setting up a second algorithm.

21. The system according to claim 19, wherein said communication means includes a virtual private network (VPN) router.

22. The system according to claim 16, further comprising a storage device, said computer is connected to said storage device to store the sensor data and/or the result data.

23. The system according to claim 16, further comprising a modem, said computer is coupled to a computer network via said modem for data transmission.

24. The system according to claim 16, wherein said work unit is a tamping unit and/or a stabilizing unit.

25. The system according to claim 23, wherein said sensors include a movement sensor for recording a vibration cycle.

26. The system according to claim 17, wherein said computer is coupled to said machine controller to automatically specify optimized working parameters.

27. A method for operating a system for working on a track, the system having a track maintenance machine with a machine controller, a work unit controlled by the machine controller, sensors disposed to monitor the work unit, a data acquisition module, and a computer, which comprises the steps of: generating sensor signals for monitoring the work unit by means of the sensors; supplying the sensor signals to the data acquisition module for separate sensor data recording; and calculating result data from the sensor data by means of a first algorithm set up in said computer.

28. The method according to claim 27, which further comprises calculating parameters of a work sequence as the result data and transmitted to the machine controller.

29. The method according to claim 27, which further comprises transmitting program data to the computer for modifying the first algorithm or for setting up a second algorithm.

30. The method according to claim 28, wherein in a first step, new program data are loaded into a storage of the computer and, in a second step, the new program data are activated after a restart of the computer.

31. The method according to claim 27, which further comprises transferring the result data from the computer to an external computer via a virtual private network tunnel or via an offline connection.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In the following, the invention is explained by way of example with reference to the accompanying figures. The following figures show in schematic illustrations:

[0021] FIG. 1 Track maintenance machine

[0022] FIG. 2 Block diagram of the system

[0023] FIG. 3 Processing of program data

[0024] FIG. 4 Processing of sensor and result data

DESCRIPTION OF THE EMBODIMENTS

[0025] The system comprises, for example, a tamping machine as a track maintenance machine 1 for working on a track 2. Such a track maintenance machine 1 has a tamping unit and a lifting and lining unit as work units 3. In addition, a stabilising unit can be arranged as a work unit 3. The work units 3 are controlled by means of a machine control 4. Furthermore, the track maintenance machine 1 comprises a measuring system 5 for recording an actual geometry of the track 2.

[0026] Sensors 6 are arranged to monitor the work unit 3, which is designed as a tamping unit. An exemplary sensor 6 is described in the Austrian patent application A 290/2018 of the same applicant. Sensors 6 mounted on the tamping unit or on the other work units 3 measure accelerations and/or forces acting on individual work unit components. Temperature measurements can also be useful in order to monitor the condition of a work unit 3.

[0027] The respective sensor 6 generates sensor signals S.sub.S, which are recorded by means of a data acquisition module 7 (DAQ) and further processed as sensor data S.sub.D. For this purpose, the data acquisition module 7 is connected to a computing unit 8. In this computing unit 8, a first algorithm P.sub.1 (program) is set up to calculate result data E.sub.D from the sensor data S.sub.D. This result data E.sub.D is used to evaluate the work sequences performed with the work units 3 or to evaluate the condition of the track 2 worked on. For this purpose, the result data E.sub.D include corresponding parameters.

[0028] Advantageously, the computing unit 8 and the data acquisition module 7 are interconnected in a master-slave architecture. The data acquisition module 7 comprises, for example, several DAQ units with 12 to 16 channels, with each channel being assigned a sensor signal S.sub.S. The data acquisition module 7 records the sensor signals S.sub.S at a high sampling rate in the range of several kilohertz in order to generate sensor data S.sub.D with high temporal resolution for subsequent processing.

[0029] For a pure monitoring function, however, sensor data S.sub.D with lower resolution are sufficient. Usually, few sensor data S.sub.D per time unit (e.g. sampling rate 1 Hz) are required to track the wear progression of a work unit component and to estimate possible servicing measures. Therefore, it is useful for the monitoring function to set up separate data processing with a dedicated data acquisition unit 9. A monitoring device 10 comprises other components, for example a microprocessor 11 and a modem 12 for transmitting monitoring data U.sub.D to a computing network (cloud) 13. Such a monitoring device 10 is described in AT 520 698 A1 of the same applicant.

[0030] It is useful to also use a modem 12 of the monitoring device 10 or a separate modem for a transmission of the result data E.sub.D generated with the computing unit 8. In this way, the result data E.sub.D and, if necessary, sensor data S.sub.D also transmitted are available centrally in the computer network 13. For example, the data S.sub.D, E.sub.D can be displayed and further processed (web access) by means of a secured online application (web app) on a computer 14 with a network connection.

[0031] The track maintenance machine 1 comprises, for example, a high-performance Linux server as a computing unit 8. This makes it possible to process the recorded signal data S.sub.D at a high sampling rate in real time. In any case, it is useful to adjust the sampling rate of the data acquisition module 7 to the processing capacity of the computing unit 8 to ensure real-time calculation of result data E.sub.D. Thus, various characteristic parameters of the work sequence can be determined directly on the track maintenance machine 1.

[0032] Furthermore, it is advantageous if the computing unit 8 is designed in such a way that CPU capacities are also available for processing advanced mathematical algorithms. These mathematical algorithms are models and calculation algorithms for the condition assessment of machine parts and for the adjustment of working parameters. All algorithms set up in the computing unit 8 are executed as tasks T.sub.1, T.sub.2, T.sub.n (processes). Specifically, a master application M runs on the computing unit 8, which starts and initiates individual tasks T.sub.1, T.sub.2, T.sub.n in a coordinated manner (FIG. 3).

[0033] In addition or alternatively to the transmission of sensor and result data S.sub.D, E.sub.D to the computer network 13, these data S.sub.D, E.sub.D are stored in a storage device 15, which is connected to the computing unit 8. For example, a dedicated processor (server) is implemented in the computing unit 8, which combines various system variables and stores the requested data S.sub.D, E.sub.D on a mass storage of the storage device 15. It is possible to transfer the stored data S.sub.D, E.sub.D via a data interface 16 to a computer 14, for example, during a revision of the track maintenance machine 1.

[0034] In the design version shown in FIG. 2, the system comprises communication means 17 for comparing program data with a database 18. For example, a VPN router, which is connected to the computing unit 8, is provided for this purpose. In this way, sensor and result data S.sub.D, E.sub.D can also be transmitted via a VPN tunnel 19.

[0035] Advantageously, the VPN tunnel 19 is also used for software updates of the computing unit 8 (FIG. 3). For this purpose, an initiated task T.sub.n checks whether a new algorithm is available in the database 18. For example, to that end, a comparison is made with the current versions of the running tasks T.sub.1, T.sub.2. If necessary, a modified algorithm P.sub.1 or a new algorithm P.sub.2 is loaded via the VPN tunnel 19, compiled, and attached to the task list T. By rebooting the computing unit 8, the new tasks are started and processed.

[0036] Such an update can also be used to analyse previously unnoticed sequences on the track maintenance machine 1. First, a new algorithm P.sub.2 adapted to the problem definition to be analysed is loaded into the computing unit 8 and compiled. For example, a corresponding task T.sub.2 writes the sensor data S.sub.D of some selected sensors 6 to the storage 15 if a specified event occurs. After a sufficient recording period, the collected data S.sub.D, E.sub.D are uploaded to the computer network 13 and analysed.

[0037] FIG. 4 illustrates a further development of the system. The work unit 3 is monitored by means of various sensors 6. These sensors 6 and other sensors 6 arranged on the track maintenance machine 1 (inertial measuring unit, laser cutting sensor, hydraulic pressure gauge, etc.) provide sensor data S.sub.D to the computing unit 8 via the data acquisition module 7. By means of various algorithms P.sub.1, P.sub.2, P.sub.n, control-relevant parameters are calculated as result data E.sub.D. The respective parameters are fed back into the machine control 4, which subsequently results in an active intervention in the work process.

[0038] For this purpose, the machine control 4 (control system of the track maintenance machine 1) comprises a central control 20, by means of which several decentralised subsystems 21 are coordinated. These are, for example, a subsystem 21 for a speed adjustment of a vibration drive for generating vibrations, a subsystem 21 for a tamping tine opening width of a tamping unit, a subsystem 21 for an automatic penetration system for tamping tines, and a subsystem 21 for the work unit positioning.

[0039] Thus, physical parameters of the influenced work sequence are recorded and measured. The recorded parameters are fed as a data stream to the computing unit 8, with all tasks T.sub.1, T.sub.2, T.sub.n having full access to this sensor data S.sub.D. During the execution of the tasks T.sub.1, T.sub.2, T.sub.n, characteristic parameters of the work sequence are determined. These parameters are then fed back to the central control 20 in order to preset optimised working parameters for the subsystems 21. In this way, a higher-level closed-loop system with an observation-based controller is set up at the level of a distributed control system.

[0040] In an advantageous further development, the calculation of the optimised working parameters takes place directly in the computing unit 8. For this purpose, corresponding algorithms P.sub.1, P.sub.2, P.sub.n are set up in the computing unit 8. The newly calculated work parameters are specified for the central control 20. Thus, no parameter calculation takes place in the machine control 4 itself. Safety requirements applicable to the machine control 4 are not affected in this way.

[0041] The specification of new working parameters is explained in more detail using the example of multiple tamping by means of a tamping unit. In multiple tamping, vibrating tamping tines are lowered into a ballast bed at the same spot, and they squeeze several times to improve ballast compaction.

[0042] For parameter optimisation, sensor data S.sub.D is first recorded over a longer observation period. For example, pressures and strokes of squeezing cylinders of the tamping unit are recorded. Characteristic parameters are calculated for each recorded tamping cycle, which serve as basic data in the next step.

[0043] The basic data recorded with the present system are available offline to train a predictive model. Specifically, the recorded data and a respective target variable (number of tamping insertions per tamping cycle) serve as training data. The trained predictive model corresponds to a new algorithm P.sub.2 that enables a prediction of the target variable.

[0044] Through testing and validation, the new algorithm P.sub.2 can be further improved. The test data used differs from the previously used training data. The predictions of the target variables are adjusted to specified target values to evaluate the quality of the predictive model. If necessary, the algorithm P.sub.2 is subjected to a new training step to improve the predictive quality.

[0045] With the finished algorithm P.sub.2, the respective working parameter (target variable) is specified in real time directly on the track maintenance machine 1. As soon as the tamping tines penetrate the ballast bed, the sensors 6 provide meaningful sensor data S.sub.D for calculating parameters for the condition of the ballast bed. In any case, at the end of a first tamping insertion, sufficient sensor data S.sub.D are available to calculate reliable result data E.sub.D. In the present example, the result data E.sub.D of the machine control 4 specify in real time whether a further tamping insertion is necessary at the same spot in order to achieve the desired compaction.

[0046] A further advantage of the present system arises with multi-sleeper tamping units with several tamping units arranged one behind the other. These tamping units are lowered together into a ballast bed to simultaneously tamp several sleepers. Here, the sensor data S.sub.D recorded and processed in real time are used to control the individual tamping units differently. Specifically, the condition of the ballast bed that is determined when the tamping tines penetrate the ballast bed is used to specify different squeezing pressures. If necessary, different squeezing times are specified for the individual tamping units. In the case of simultaneous tamping of several sleepers, there is sometimes the problem that the ballast bed in its initial condition has a different ballast compaction under each sleeper.

[0047] For each tamping unit, a parameter calculated from the assigned sensor data S.sub.D already indicates the respective degree of compaction at the relevant spot of the ballast bed during a penetration process. By means of a corresponding algorithm P.sub.2, an adapted squeezing pressure and, if necessary, an adapted squeeze time are specified for the respective sub-control. In spots where the degree of compaction is already increased, less tamping energy is introduced into the ballast bed by reducing the squeezing pressure and the squeezing time. However, at penetration spots with a low degree of compaction, squeezing takes place with increased pressure and a longer duration. In this way, a homogeneous compaction of the ballast is achieved for the ballast bed section worked on with the multiple-sleeper tamping unit.