3D Scanning of Class 158 underframe and bogies for Angel Trains Ltd.

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Overview

DB ESG has supported Angel Trains with an investigation into an issue related to rolling contact fatigue on several Class 158 wheelsets operated by Transport for Wales Rail. These wheelsets have been experiencing premature tyre damage, necessitating tyre turning earlier than scheduled.

Angel Trains believed that DB ESG’s 3D scanning expertise could be a good tool in this investigation, providing valuable data. The process involved 3D scanning affected bogies and underframes both before and after tyre turning to assess whether the inherent variances in the bogie structures or bogie mounted equipment, combined with the tyre turning process, contributed to any geometric discrepancies. By comparing measurements before and after tyre turning any twist or misalignment caused by the process could be identified.

A key benefit of using 3D scanning technology is that the captured data can be accessed at any time, allowing for new measurements and analysis of different areas without the need to return to the site to conduct another survey.

Copyright: DB ESG

3D scan of bogie and wheelsets.

3D scan of bogie and wheelsets.

Copyright: DB ESG

3D scan of bogie and wheelsets.

3D scan of bogie and wheelsets.

Work to be undertaken by DB ESG

  • Initial trial of 3D scanning approach.
    • This method was tested on an East Midlands Railway’s Class 158 at Etches Park Depot.
  • 3D Scanning of Class 158 Bogie at Transport for Wales Rail’s Canton Depot.
    • Following a successful trial, the power bogies on another Class 158 unit underwent 3D scanning, both before and after tyre turning (pre and post packing).
    • Measurement comparisons were made between the each of the 3D scans.
    • DB ESG analysed the 3D scans by creating comparative overlays and taking the following measurements:
      • Axle and Damper Comparison Measurements
      • Individual Measurements
      • Primary Suspension Spring Comparison Measurements
      • 2D Wheel Profiles
      • Bogie Structure Deformation Comparison
      • The resulting data was summarised in a report, highlighting areas to investigate further.

This technology has proved to be extremely valuable, providing traceable and accurate bogie measurement data that is helping Angel Trains’ investigation

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