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Whilst some initial implementations of robotics for train inspection are starting to be trialled in the rail industry international, there is currently no established practice for the use of robotics for train maintenance. Even for maintenance in other industries the use of robotics is very early stages of maturity. This represented a significant opportunity for developing a facility to research this new area of application; however, it also created a significant challenge to design a robotic system for an application that did not currently exist!
The IRR had an outline of broad task types to investigate the possibility of automating but no detailed specific. Additionally, the available space for the Rolling Stock Maintenance Robotics Laboratory was relatively small, compared to real rolling stock maintenance facilities.
Through a successful tender process Olympus Technologies were chosen to partner with the Institute of Railway Research to develop, install and commission the Smart Rolling Stock Maintenance Research Facility.
The Rolling Stock Maintenance Robotics Laboratory within the research facility is set up like a small section of a rolling stock depot, with railway rails, an inspection pit underneath the rails, and space either side to access the side of the train including bogies, wheelset and underframe equipment. The flexible robot test cell was developed with two industrial robots on tracks that can move along either side a of a train positioned on the railway tracks, and a collaborative robot on a track in the inspection pit.
All three robot arms in the lab are controlled through a central PLC and can work together to carry out complex tasks. Additionally, a tool changer allows the industrial robots to automatically change their end effectors, and to swap end effectors between the two robot arms. The robot simulation and off line programming tool allows the IRR to carry out initial testing of tasks to be carried out in the laboratory and refine the design of bespoke end effectors before practical lab testing. The simulation tool also allows testing and development of much larger robotic system for real world implementation that would be too big to fully test and develop in the lab.
Alongside the Rolling Stock Maintenance Robotics Laboratory, a training suite was developed with a further collaborative robot - to provide further flexibility for testing a range of different application, early-stage concept development on scaled models of train components and training and development of staff and students.
The Rolling Stock Maintenance Robotics Lab is a core element of the SRSMRF, it is a mini ‘depot of the future’, for research into the use of robotics for train maintenance. Olympus Technologies were a key partner in helping to specify the range of robotic equipment for the lab, and also system design, safety management, equipment installation and commissioning.
The flexible test cell, collaborative robots and robot simulation tool have been invaluable in conducting research into this emerging area of application for robotics.
The IRR have so far developed five main case studies, all using largely different approaches and different functionalities of the range of equipment provided. Case studies so far include: