POrtable WEigher for Railway VEhicles - POWERVE
The first and only fully portable system to weigh trains. We, at IVM, have engineered an innovative measuring instrument which measures the static weight force distribution loaded on track, by each rolling stock wheel. The system is so light and easy to use that can be quickly used by just two people. The easy installation and portability makes it perfect for use both along track and at workshops, you will be able to move the system to the track you prefer minimizing the movements of rail cars.
POWERVE uses a set of ramps to position the wheels into the measuring zone. This ad-hoc mechanical supports are leant on the rails and are used to rise a wheelset (or a bogie) by positioning each wheel on a pair of specifically crafted load cells. The load cells create a “cradle” in which each wheel is self-centered in a stable equilibrium condition. This particular design allows the rolling stock to stay still without the application of external constraint or forces. Therefore, the weight is not affected by tensions due to the braking forces.
WE WILL BE IN
POWERVE is a new high tech product for weighing trains. It uses cutting edge technologies in order to offer to the users a simplified approach to this kind of measurement. We specifically designed: the shape for the loading cells so as to minimize the errors deriving from the use in field, the shape for the ramps to safely place the wheels on the measuring zones and the hardware/software systems capable of working in perfect synergy to control and guide the measurement.
POWERVE measures the overall weight of a rolling stock by measuring one wheelset (bogie) at time.
The measurement procedure for each wheelset (or bogie) is really simple and guided by an intuitive Tablet application. The app will guide the operators in each step of the measurement. The measurement is carried out by using a shunting machine or a locomotive to pull the rolling stock so as to rise it on the ramps and let it sit in the measuring zone. Once on the load cells, the application automatically saves the measures and then asks to move the rolling stock down the ramps. To ensure a good result the measurement is repeated 4 times per wheelset (boogie). Once a wheelset (bogie) has been measured the system asks to move to the next in order to measure the whole rolling stock.
The simplified in field installation makes it ready to use in less than 10 minutes and only requires 2 people to install it. You just need to lean the ramps on the rails and place the load cells in their housings, then you are ready to go!
The system provides an accurate result for the weight of each wheel as well as the weight of the entire rolling stock. The measurement report provides useful information about the distribution of weights, those data can be used to balance the train weight distribution improving rolling stock safety.
REAL DISTRIBUTION ON TRACK
POWERVE weighs the train in the real working order conditions on the track. The measurement is carried out directly on track and this does not modify the train balance. Other systems rise the rolling stock and place it on a scale, in this way the primary and secondary suspensions are unloaded and then compressed again; this alters the load distribution.
The system is very light, it is less than 50 Kg (POW2X version) and is organized into 4 cases for an easy movement by 2 people.
MEASURE ON THE WHEEL TYRE
The way in which the system is interposed between the rail and the wheel ensures that the measuring point is the real point of contact between these two elements. The wheels’ points of contact are the same that the train has during his standard running on track. The fact that POWERVE touches the wheels only on the rolling circle ensures that the measure takes into account the actual wear of the wheels’ diameters (there could be a significant difference between new and worn wheel diameters that could alter the load distribution) – the sensitive elements are interposed between the wheel rolling circle diameter and the top of the rail taking the wear into account. In this way it weights the real load of each wheel and overcomes the limitations of other systems that measure on the wheel flange.
POWERVE design has been engineered so as to remove the necessity of external forces to stop the rolling stock on the measuring zone. The cradle shape of the ramps in conjunction with the shape of the load cells ensures that the wheel places itself in the measurement zone and stay still in a static equilibrium condition without the need of brake or tension forces. In this way only the real force loaded by the rolling stock on track is measured.
POWERVE, at the end of each measurement, automatically outputs the results in a digital PDF format ready to be shared by Email, Bluetooth and other means for data exchange. The automated data flow ensures that it is free of human transcription mistakes. The report also contains photos of the left and right side of the rolling stock which has been measured.
AUTO QUALITY CHECKS
The system automatically checks if all the measurements are statistically similar to each other, in case the measures are not consistent the Tablet application will ask to perform additional measurements.
All the electronic components of POWERVE are connected through wireless technology. This allows an easy installation and a compact design.
POWERVE is equipped with a built-in software to manage in real-time the system through a Tablet which wirelessly receives the measured data from the acquisition systems. It is designed to support the operator during the procedure, providing guidance on the necessary actions to perform during the whole measurement cycle.
It is also equipped with control and visualization systems (both HW and SW) to control the measurement process, to display the results, to process data and to store them.
These features are aimed at limiting human errors and to guide the operator throughout the measurement process.
ACCURATE AND REPEATABLE
The system has been certified by an independent third party Notified Body to provide an in field accuracy of <1% for the total weight of the rolling stock and of <2% for the weight of each wheel. The system also offers a really high repeatability; thus it is precise instrument. The fact that POWERVE has been certified in field gives a real guarantee about its performance in real working condition.
CERTIFICATION AND REGULATIONS
POWERVE specification, design, metrological aspects and working procedure have been created following the most demanding European and Global regulations: France NF F 00-701 (Measurement of the static loads of wheels), Europe EN 50215:2011 (Section regarding the Weight Measurement for vehicles’ Acceptance Tests), Europe EN 14363:2016 (Section regarding the Static load per wheel for the Dynamic and Static behavior of the vehicle) and Japan JIS E 4011:1989 (Methods for the measurement of rolling stock’s mass).
Moreover, POWERVE is compliant with the EMC, CE directives for electromagnetic compatibility. The load cells themselves have been certified and tested by ACCREDIA laboratories, in compliance with UNI CEI EN 17025.
MEASURABLE ROLLING STOCKS
POWERVE allows to measure rolling stock composed of bogies with one, two or three axles.
By following our certified procedure POWERVE POW2X can weigh in two steps, first an axle (or bogie) and then the other, the following types of rolling stock: A-A (2 single axles) and B-B (2 bogies with 2 axles each).
In the same way, POWERVE POW3X allows to measure the following wheelsets arrangements: A-A, B-B and C-C (2 bogies with 3 axles each).
POWERVE can be used with wheels’ diameters from 750mm up to 1250mm (different wheel’s diameters are available upon request).
The minimum axle distance is 1800 mm. The minimum bogie center pivots distance is 3000 mm.
It is also possible to measure bogies interposed between two railcars.
MEASURING ONE WHEELSET AT THE TIME
The design of the load cells and their compact height ensures that the rolling stock is inclined of an insignificant amount. The fact the bogie center pivot distance is greater than the load cell’ height by orders of magnitude, ensures that the effects caused by measuring one wheelset at the time is negligible and does not affect the results.
The maximum weight that can be measured is 15 tons per each wheel (different weight ranges are available upon request). The system can resist a 200% of overweight per each wheel.
TYPE OF RAILS
The system can be used on every UNI50 and UNI60 rails (different rail profiles are available upon request). It can also be used with ground level rails; in this case it is required to remove a small portion of concrete around the rail in order to place the ramps correctly.
TRACK NOT PERFECTLY LEVELLED
The system can work properly on every straight and stabilized track that has been built to be in compliance with the maximum slope of 3‰ for rail yards.
POWERVE is available in two different kit versions complete of transporting cases:
POWERVE POW2X: This version offers 4 measuring points and is composed of 4 position ramps, 8 load cells, 4 acquisition boards, 1 Tablet PC (software included), 1 wireless router and 1 positioning ramp spacer.
POWERVE POW3X: This version offers 6 measuring points and is composed of 6 position ramps, 12 load cells, 6 acquisition boards, 1 Tablet PC (software included), 1 wireless router and 1 positioning ramp spacer.
The main versions of the POWERVE system are: POW2X (that measures 2 axles at the same time) and POW3X (that measures 3 axles at the same time).
The POW2X version allows to measure the following rolling stock wheelsets arrangement types:
- A-A (2 single axles) – in 1 measurement session;
- B-B (2 bogies made of 2 axles each) – in 2 measurement sessions;
- B-B-B (3 bogies made of 2 axles each) – in 3 measurement sessions;
The POW3X version allows to measure in addition to the POW2X version, also the following rolling stock type:
- C-C (2 bogies made of 3 axles each) – in 2 measurement sessions;
These main versions can also work together, allowing to measure more axles at the same time, as follow:
- POW4X, made of 2 POW2X (that measures 4 axles at the same time)
- POW6X, made of 3 POW2X or 2 POW3X (that measures 6 axles at the same time)
Other measurement configurations for different types of wheelsets arrangement can be customized upon request.