Innovating Rail Safety: K-State Engineers Develop Non-Contact Technology for Rail Stress Monitoring
Kansas State University engineers, led by Professor B. Terry Beck of the Alan Levin Department of Mechanical and Nuclear Engineering, are making significant strides in improving the safety of railway systems through a groundbreaking non-contact technology designed to monitor rail stress in continuously welded steel railroad rails.
With more than $300,000 in funding from the U.S. Department of Transportation’s Federal Railroad Administration, Beck and his team are working to address a critical issue in the railroad industry: rail stress. Excessive stress on rails, caused by temperature fluctuations or train loading, can lead to dangerous issues such as track buckling or rail breakage, which can result in derailments.
Addressing Rail Stress Challenges in the Railroad Industry
One of the most pressing challenges for the railway industry is the inability to accurately assess and monitor rail stress without physical contact, which can be time-consuming and potentially disruptive to rail operations. Track-related issues, like track buckling on hot days due to excessive compressive stresses or rail breakage caused by extreme cold temperatures and tensile stresses, are common and can significantly impact rail safety. Moreover, these stresses can worsen when subjected to the additional loading from train traffic.
Professor Beck explains, “Currently, no proven non-contact method exists for accurately assessing and monitoring the state of rail stress.” The research team is developing a non-contact technology to detect and continuously monitor rail stress, which could revolutionize how the railway industry ensures track safety and prevents derailments.
The Non-Contact Solution: Measuring Rail Neutral Temperature and Stress
The new approach will focus on monitoring the "rail neutral temperature", a critical factor in determining rail stress, as well as measuring the rail’s axial displacement (movement along the track’s axis) and temperature. Using **non-contact strain-measurement technology, the team aims to develop a system that continuously and accurately gauges the stress levels in the rail without requiring physical sensors or invasive tools.
According to Beck, the technology is based on field-hardened strain-measurement methods, which have already been proven effective in other fields. The project’s ultimate goal is to create a system that can be implemented across the railroad industry, ensuring a safer and more efficient way of monitoring rail health.
Collaboration and Field Testing: K-State Partners with BNSF Railway
This project is a collaboration between several key stakeholders, including Robert J. Peterman, professor of civil engineering at K-State, and John Bloomfield, engineering director at K-State’s Technology Development Institute. One of the project’s most important partnerships is with BNSF Railway, one of the largest freight railroad networks in the United States, which will provide valuable field testing opportunities.
The team will initially develop the technology in the laboratory using a special-purpose test frame at K-State’s facilities. After that, field testing will be conducted on continuously welded steel railroad rails with BNSF Railway to refine the technology and assess its real-world applications.
A New Paradigm for Rail Stress Monitoring
Professor Beck emphasizes that the new technology represents a completely new paradigm for the continuous, practical assessment of rail stress, which has long been considered the "holy grail" of the railroad industry. If successful, this method could be a game-changer in improving the safety and reliability of the nation’s rail network, reducing the risk of derailments and ensuring smoother, more efficient railway operations.
With the railway industry’s growing focus on safety and the prevention of catastrophic events, K-State’s innovative technology could offer a transformative solution for monitoring rail stress and enhancing overall rail infrastructure management.
This advancement in non-contact technology will not only improve railway safety but also pave the way for future innovations in how industries handle critical infrastructure monitoring. As the project progresses, the railroad industry may soon benefit from a safer, more sustainable approach to maintaining its tracks and preventing accidents.
