Design of a robot for inspection and diagnostic operations of rail track facilities

Abstract

Purpose

The need to examine the integrity of infrastructure in the rail industry in order to improve its reliability and reduce the chances of breakdown due to defects has brought about development of an inspection and diagnostic robot.

Design/methodology/approach

In this study, an inspection robot was designed for detecting crack, corrosion, missing clips and wear on rail track facilities. The robot is designed to use infrared and ultrasonic sensors for obstacles avoidance and crack detection, two 3D-profilometer for wear detection as well as cameras with high resolution to capture real time images and colour sensors for corrosion detection. The robot is also designed with cameras placed in front of it with colour sensors at each side to assist in the detection of corrosion in the rail track. The image processing capability of the robot will permit the analysis of the type and depth of the crack and corrosion captured in the track. The computer aided design and modeling of the robot was carried out using the Solidworks software version 2018 while the simulation of the proposed system was carried out in the MATLAB 2020b environment.

Findings

The results obtained present three frameworks for wear, corrosion and missing clips as well as crack detection. In addition, the design data for the development of the integrated robotic system is also presented in the work. The confusion matrix resulting from the simulation of the proposed system indicates significant sensitivity and accuracy of the system to the presence and detection of fault respectively. Hence, the work provides a design framework for detecting and analysing the presence of defects on the rail track.

Practical implications

The development and the implementation of the designed robot will bring about a more proactive way to monitor rail track conditions and detect rail track defects so that effort can be geared towards its restoration before it becomes a major problem thus increasing the rail network capacity and availability.

Originality/value

The novelty of this work is based on the fact that the system is designed to work autonomously to avoid obstacles and check for cracks, missing clips, wear and corrosion in the rail tracks with a system of integrated and coordinated components.

Citation

Daniyan, I., Mpofu, K. and Nwankwo, S. (2023), "Design of a robot for inspection and diagnostic operations of rail track facilities", International Journal of Quality & Reliability Management, Vol. 40 No. 3, pp. 653-673. https://doi.org/10.1108/IJQRM-03-2020-0083