Remote Condition Monitoring: Keeping the rail industry on track for the future

4 Minute Read

Digital_Rail_Monitoring
Northern Rail Turbostar (1)

Remote condition monitoring (RCM) leverages sensor technology and data analysis to provide real-time insights into the health of critical assets. This proactive approach allows for early problem detection, optimized maintenance scheduling, and enhanced operational efficiency. By minimizing downtime and maximising asset lifespan, RCM contributes to significant cost savings and improved productivity.

The UK rail sector faces a complex operational landscape in 2024. Financial pressures, labor disputes, aging infrastructure, and evolving passenger expectations necessitate a strategic focus on efficiency, reliability, and customer satisfaction.  

Against this industry backdrop, RCM technology has emerged as a critical tool for achieving operational excellence and ensuring the long-term sustainability of rail services.

By leveraging advanced sensors and data analytics, RCM systems provide real-time insights into the health of rolling stock and infrastructure.

The Challenge

This case study explores how a number of UK train operating companies, including including ScotRail, Cross Country, East Midlands Railway and Chiltern Railways, needed a trusted industry partner that could design, install and support a real-time, remote engine monitoring solution to predict and prevent defects that would otherwise take trains out of service.  

Recognising the significant opportunities that RCM technologies present, particularly in ensuring the performance and longevity of the assets to enhance passenger experience, they each approached Unipart for a solution.

The Solution

Unipart’s RCM solution combines Instrumentel’s sensors, data analytics, machine learning and AI technology to provide operators and asset owners in sectors including rail, automotive, defence, manufacturing, utilities and aerospace, real-time and predictive insight into the health and performance of critical components.

By providing real time data insights into information such as the engine’s oil pressure, coolant level, vibration, temperature without the need for manual inspections, faults can be identified and eliminated before they occur to significantly lower costs, enhance safety, and optimise the availability of assets and equipment.

Generate a scene of a train yard with IoT sensors monitoring the condition of rail tracks and rolling stock, using a sleek industrial aesthetic. --ar 16:9

The Impact

Installing this solution in partnership with Unipart had the following impacts:

Mitigated disruptions: Predicted and prevented equipment failures, minimising downtime and service disruptions.   

Optimised maintenance: Transitioned from reactive to predictive condition-based maintenance strategies, reducing costs and extending asset lifespans.   

Enhanced passenger experience: Improved punctuality and service reliability, leading to increased passenger satisfaction.

Data-driven decision-making: Leveraged data insights to inform strategic asset management and operational improvements.  

Instrumentel delivered an effective solution which met challenging project constraints and timescales. The Instrumentel project and installation teams were extremely flexible, working in the environment of an operational depot.

“Productive and efficient working methods ensured the installation programme was delivered on time without impacting unit availability. The on-train monitoring recorder information, now being accessed remotely, is being utilised to investigate faults earlier, minimising maintenance downtimes.

Alasdair Thom, Senior Engineering Project Manager, ScotRail
The solution from Instrumentel allows CrossCountry and our partners to better understand the performance of the fleet and is highlighting problems before they become performance affecting. All of the teams are now working very closely and diligently following completion of fleet fitment of the initial RCM package.

Adrian Hugill, Head of Fleet and Engineering, CrossCountry
Our industry is changing, and we are waking up to the real world benefits a shift towards digital can afford us.

“This project is a prime example of how close collaboration between train operating companies, asset owners and supply chain innovators, like Instrumentel, is key to realising these benefits.

“We look forward to continuing to work with all involved to revolutionise the way in which we operate and maintain these important assets.

Chris Beales, Head of Digital Engineering Services, Porterbrook
Smart sensors for predictive maintenance

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