RAILWAY

Seven places on a railway where a measurement is worth more than an inspection.

Wheels, rail, under-gear, clearance, overhead line and depot components — measured in millimetres rather than judged by eye, on moving vehicles and in the shed. Built on 3D laser profiling and imaging that we specify, install and prove against your own wear limits.

DEPOT 1 2 WAYSIDE INSPECTION POINT 3 4 5 ON-VEHICLE & OVERHEAD LINE 6 7

Depot, wayside and on-vehicle measurement points. The same measurement engine and record structure sits behind all of them.

Where the measurements are taken

Each of these is an application in its own right. Most operators start with one, prove it, and add the next against the same records and the same limits.

The applications in more detail

What each system measures and what comes out of it. Sensor selection, accuracy figures and installation detail follow the trial on your asset — we do not quote a number we have not measured ourselves.

A

Wheel profile and diameter at line speed

Full wheel geometry on every axle of a passing train, without taking it out of service.

What is measured

  • Flange height, flange thickness and qR
  • Tread hollow and rim thickness
  • Wheel diameter and left/right variation per axle
  • Back-to-back where the layout allows

What comes out

  • Pass, warn or condemn against your own limits
  • Stamped with time, speed, direction, axle position and vehicle identity
  • Wheelset trending for remaining-life estimation
B

Wheel profile in the depot — handheld

The same measurement engine and the same wear limits, taken to the wheel in the shed.

What is measured

  • The identical parameter set as the wayside system
  • Measured against the identical wear limits
  • Wheelset and vehicle identity captured at the wheel

Why it wins

  • Repeatability that does not depend on operator technique
  • Immediate pass or condemn before the operator walks away
  • Serves as the verification reference for the wayside installation
C

Rail head profile and track geometry

Continuous rail condition captured from a moving vehicle, every profile carrying a chainage position.

What is measured

  • Rail head size, cant, face angle and vertical head wear
  • Gauge and gauge-face wear
  • Corrugation and surface irregularity
  • Rail surface defect indications

What comes out

  • Wear plotted against the design profile along the section
  • Exception reports sized for the permanent-way team
  • On-board processing and storage, so remote sections are covered
D

Under-gear and side inspection of a passing train

Full-consist imaging with trained defect models, plus 3D where the fault is a shape rather than a shade.

What is detected

  • Missing, broken or displaced under-gear components
  • Brake block and brake shoe wear beyond limit
  • Loose or hanging fittings, open covers, damaged springs
  • Vehicle identity by number recognition

What comes out

  • Confidence-scored alerts with the source image attached
  • Exception-only transfer — the full image set stays at site
  • Findings located to vehicle and axle position
E

Dragging equipment, clearance and loading gauge

One installation covering dragging equipment, underframe clearance and loading gauge as a measured envelope.

What is measured

  • Underframe clearance along the whole consist
  • Hanging, dragging or displaced parts
  • Vehicle height and width against the permitted envelope
  • Shifted or over-height loads

Why 3D beats a beam

  • Reports how far below the limit an object sits, not just that a line was crossed
  • Locates the vehicle and axle within the consist
  • Rejects steam, spray and debris that trip optical beams
  • Keeps the profile record for post-event review
F

Pantograph and overhead line geometry

Contact wire geometry and pantograph condition, measured as the vehicle passes — no contact and no possession.

What is measured

  • Contact wire height and stagger against the permitted envelope
  • Carbon strip wear depth and residual thickness
  • Uneven wear, chipping and cracking of the strip
  • Pan head tilt and horn condition

What comes out

  • Early warning of the wear pattern that precedes a dewirement
  • Exception records for both the overhead line team and the depot
  • Results tied to chainage or to vehicle identity
G

Bogie, brake and component inspection in the depot

Dimensional and defect inspection of parts once they are off the vehicle.

What is measured

  • Brake block and shoe thickness at the wear point
  • Bogie frame, coupler and casting dimensions
  • Spring free height and squareness
  • Surface defect area, depth and flatness

What comes out

  • Dimensional report per part against the drawing tolerance
  • Reuse, rework or scrap decision at the station
  • Records retained for traceability and trend analysis

One architecture behind every application

Every system on this page reuses the same layers. The sensing head, the fixture and the tolerance set change from one application to the next. The synchronisation, the verdict engine, the operator interface and the record structure do not.

Sensing
  • 3D laser line profiling
  • Line-scan and area imaging
  • Illumination and optics
Trigger and sync
  • Wheel sensors
  • Encoders and travel indexing
  • One time base, one index
Edge processing
  • Measurement tools
  • Defect inference
  • Tolerance and verdict
  • Local record buffer
Analytics
  • Vehicle and axle identity
  • Wear trending
  • Threshold management
  • Remaining-life estimation
Operations
  • Control-room alerts
  • Depot work orders
  • Dashboards and reports
  • Your own systems

Running across every layer: calibration and traceability, sensor health and self-test, time synchronisation and data integrity, remote diagnostics, access control and retention. That is what makes a second and third system cheaper than the first.

The part that kills railway projects

A sensor that measures beautifully on a bench and fails in month three at a wayside site is not a product. These are designed for on day one, not discovered during commissioning.

Ingress and weatherSealed enclosures, air purge or wiper on optical windows, heaters against condensation, drainage in pit installations.
Ballast, dust and sprayStandoff chosen to keep optics out of the strike zone, shrouding, and a window-contamination check that alarms before the data degrades.
Vibration and shockIsolated mounts, datum recovery after each pass, mechanical design validated against the passing-train load case.
Electromagnetic environmentShielding, isolation and cable routing for traction return currents and overhead-line fields.
Ambient light, night and glareLaser wavelength and optical filtering chosen so the measurement is unaffected by direct sun or by darkness.
Power, comms and remote supportBackup power, link budget for remote sites, remote diagnostics and log retrieval so a site visit is the exception.

How you can buy it

The same measurement capability, at whichever level of responsibility suits your programme.

As a systemOne bill of materials, one commissioning plan, one point of responsibility for the measurement holding its numbers in service.
As a sub-systemThe proven, calibrated measurement module only, for installation inside your own equipment or another builder's machine.
As componentsSensing and optics with local stock, local commissioning support and local warranty handling.

Give us one wheel, one rail section or one passing consist.

We bring the sensor to your depot or your track and capture real data on your asset — no slideware and no simulated results. Accuracy figures, sensor selection, installation detail and programme timescales are issued against your application, under a mutual confidentiality agreement.

Start a railway enquiry Call +91 93268 52006