Wireless gearbox monitoring health system

Smart Oil Plug®

Temperature Detection

Vibration Analysis

Ferromagnetic debris

Smart Oil Plug® Wireless Gearbox Monitoring Predictive Gearbox Maintenance System

Wireless-enabled Smart Oil Plug®

Benefits of using Smart Oil Plug®

Wireless Gearbox Monitoring
Smart Oil Plug®

Increase Maintenance Efficiency

By adopting our solution, you can significantly enhance maintenance operations, streamlining processes and maximising resource utilisation for improved overall efficiency.

Wireless, Sensor-Based Solution

Our innovation leverages wireless gearbox monitoring technology and advanced sensors to offer a cutting-edge solution. It enables real-time monitoring and analysis of gearbox health, providing you with crucial insights into performance and potential issues.

Extend Maintenance Intervals

With our technology, you can extend maintenance intervals without compromising on operational safety. Continuous monitoring allows for predictive gearbox maintenance, reducing unnecessary downtime and costs associated with premature overhauls.

Near-Instantaneous Reports

When user-defined thresholds are exceeded, our system generates near-instantaneous reports. This feature ensures that you receive prompt notifications about critical conditions, empowering you to take swift actions to prevent further complications.

Smart Oil Plug® Predictive Gearbox Maintenance Technology detects the following incidents:

Wear of gearbox components such as gears and bearings can cause an increase in noise and vibration, and lead to premature failure of the drive-train.

Our SmartBug/SOP technology identifies early gearbox issues; the pictured example exceeded fleet average vibrations, prompting client inspection and repair.

Wear of gearbox components

Gear Pitting

Detect and address surface degradation and pitting on gear teeth.

Tooth Damage

Identify and rectify any impairment or wear on gear teeth.

Oil Loss

Monitor and respond to oil level reductions in the system.

Rotational Speeds

Keep track of rotational velocities for operational analysis.

Shaft issues can cause excessive vibrations, component loading and can lead to premature wear, catastrophic damage, and even derailments.

Our SmartBug/SOP technology is able to detect shaft issues. The pictured example shows amplitude modulation which was recorded by our technology, enabling the scheduling of proactive maintenance.

SmartBug/SOP technology

Duty Cycle

Monitor duty cycles to optimise maintenance scheduling.

Wheel pits are depressions or cavities on the wheel surface.

Stress Concentration: Wheel pits can act as stress concentrators, leading to a heightened risk of crack initiation and propagation.

Premature Wheel Wear: Pits can accelerate the wear of the wheel, reducing its lifespan and leading to increased maintenance and replacement costs.

Track Damage: Pits can lead to uneven wheel-rail contact, which might result in localised rail damage or wear over time.

Reduced Ride Comfort: Wheel pits can cause inconsistent wheel-rail interactions, leading to vibrations that affect passenger comfort.

Increased Inspection Need: Wheel pits necessitate more frequent inspections to ensure the wheel’s condition is safe for continued operation.

Solution: Our SmartBug/SOP technology detects early-stage wheel pits, alerting clients in time for preventative tyre turning instead of relying on mileage-based maintenance.

Wheel pits

Wheel flats are localised flat spots on train wheels caused by prolonged skidding, leading to increased vibration, noise, and track damage.

Our SmartBug/SOP technology automatically detects wheel flats, providing early alerts and trends; after detecting a 55mm flat, stakeholders were alerted, leading to the prompt turning of the wheel set.

Wheel flats

Damper Failures

Identify and manage failures in damping mechanisms.

Rolling Contact Fatigue (RCF) is frequently a prevailing damage mechanism for wheel pans.

Our SmartBug/SOP technology detects RCF and ride quality issues early, providing alerts and trends. The graph demonstrates its effectiveness in alerting clients to RCF, allowing timely wheel set turning and extending wheel pan lifespan.

Rolling Contact Fatigue

Engine Misfiring

Detect and address engine misfires for consistent performance.

Cardan Shaft Failures

Monitor and prevent failures in cardan shaft components.

Train Speed

Keep track of train speeds for operational and safety analysis.

Standard Detection

Wear of gearbox components such as gears and bearings can cause an increase in noise and vibration, and lead to premature failure of the drive-train.

Our SmartBug/SOP technology identifies early gearbox issues; the pictured example exceeded fleet average vibrations, prompting client inspection and repair.

Wear of gearbox components

Gear Pitting

Detect and address surface degradation and pitting on gear teeth.

Tooth Damage

Identify and rectify any impairment or wear on gear teeth.

Oil Loss

Monitor and respond to oil level reductions in the system.

Rotational Speeds

Keep track of rotational velocities for operational analysis.

Shaft issues can cause excessive vibrations, component loading and can lead to premature wear, catastrophic damage, and even derailments.

Our SmartBug/SOP technology is able to detect shaft issues. The pictured example shows amplitude modulation which was recorded by our technology, enabling the scheduling of proactive maintenance.

SmartBug/SOP technology

Duty Cycle

Monitor duty cycles to optimise maintenance scheduling.

Rail-Specific Detection

Wheel pits are depressions or cavities on the wheel surface.

Stress Concentration: Wheel pits can act as stress concentrators, leading to a heightened risk of crack initiation and propagation.

Premature Wheel Wear: Pits can accelerate the wear of the wheel, reducing its lifespan and leading to increased maintenance and replacement costs.

Track Damage: Pits can lead to uneven wheel-rail contact, which might result in localised rail damage or wear over time.

Reduced Ride Comfort: Wheel pits can cause inconsistent wheel-rail interactions, leading to vibrations that affect passenger comfort.

Increased Inspection Need: Wheel pits necessitate more frequent inspections to ensure the wheel’s condition is safe for continued operation.

Solution: Our SmartBug/SOP technology detects early-stage wheel pits, alerting clients in time for preventative tyre turning instead of relying on mileage-based maintenance.

Wheel pits

Wheel flats are localised flat spots on train wheels caused by prolonged skidding, leading to increased vibration, noise, and track damage.

Our SmartBug/SOP technology automatically detects wheel flats, providing early alerts and trends; after detecting a 55mm flat, stakeholders were alerted, leading to the prompt turning of the wheel set.

Wheel flats

Damper Failures

Identify and manage failures in damping mechanisms.

Rolling Contact Fatigue (RCF) is frequently a prevailing damage mechanism for wheel pans.

Our SmartBug/SOP technology detects RCF and ride quality issues early, providing alerts and trends. The graph demonstrates its effectiveness in alerting clients to RCF, allowing timely wheel set turning and extending wheel pan lifespan.

Rolling Contact Fatigue (RCF)

Engine Misfiring

Detect and address engine misfires for consistent performance.

Cardan Shaft Failures

Monitor and prevent failures in cardan shaft components.

Train Speed

Keep track of train speeds for operational and safety analysis.

Smart Oil Plug® Wireless Gearbox Monitoring Product Features

How our award-winning product helps clients to detect critical events early.  Predictive gearbox maintenance in a small, reliable system.

Smart oil plug®

Wireless Battery-powered Transmission

Smart Oil Plug®
Wireless Transmission Icon
TRANSMISSION

Wireless Data Transfer from the Smart Oil Plug® to the Gateway 

 
RSRU

Wireless gateway for data reception and transmission to the GDN®

Wireless Gearbox Monitoring Transmitter Receiver
Smart Oil Plug® Data Transmission Icon
CELLULAR CONNECTIVITY

Seamless data transmission via Wifi and 4G

GLOBAL DATA NETWORK

Upload to our GDN® for reporting and A.I. Analysis

GDN® Data Analysis Portal

Key Features of Smart Oil Plug®

Wireless Data Transmission

Our system employs cutting-edge wireless data transmission technology, enabling seamless and efficient transfer of critical data without the need for cumbersome wiring or physical connections.

Typical 3-Year Battery Life

With a remarkable battery life of approximately 3 years, our technology ensures prolonged functionality and reliable monitoring, reducing the need for frequent battery replacements and maintenance interruptions.

Collected Analytics Data Transfer

The analytical data collected by the Smart Oil Plug® (SOP) is securely and periodically transferred to a local gateway, facilitating centralised data management and allowing for comprehensive analysis and decision-making.

Automated Data Analysis and Reporting

The transferred data is automatically processed and analysed, generating insightful technical reports. This eliminates manual data processing efforts and provides actionable information for efficient predictive gearbox maintenance decision-making.

User-Adjustable Thresholds and Alerts

Our system offers user-configurable threshold settings, allowing customisation based on specific operational needs. When these thresholds are exceeded, automatic alerts are generated via SMS or email, promptly notifying relevant personnel to take appropriate actions.

ZF Transforms Global Rail Wireless Gearbox Maintenance with Smart Oil Plug®

ZF, a global technology leader, is transforming rail gearbox maintenance with our groundbreaking product, the Smart Oil Plug®. This wireless, sensor-based solution, developed in collaboration with Transmission Dynamics, empowers real-time monitoring and analysis of gearbox health and behaviour in railway vehicles. Integrated into ZF’s connect@rail platform, it offers comprehensive insights into the performance and health of railway vehicles and infrastructure, promising to enhance maintenance and reduce downtime significantly.

Following a strategic contract between ZF and Transmission Dynamics, Smart Oil Plug® will be seamlessly integrated into ZF’s connect@rail condition monitoring platform. This partnership leverages advanced sensor technology and cloud-based data analysis tools, ultimately enhancing efficiency, reliability, and safety in rail transportation.

Click on the image to view the full article.

How our Smart Oil Plug® system achieves results via Data Analysis

By combining numerous analytics techniques using both human-derived engineering analytics, combined with Artificial Intelligence, the Smart Oil Plug® system is able to give unparalleled diagnostics information.

1. Initial Data Organisation

Baseline Deviations

This enables rapid identification of irregularities, streamlining the troubleshooting process and minimising downtime.

Threshold Alerts

Employing an intricate alert system, we proactively identify deviations from established thresholds.

Spectral Analysis

This sophisticated technique uncovers nuanced patterns that can hold crucial information about system behaviour and anomalies.

Data Trending

This perspective offers invaluable insights into long-term behaviour patterns and potential trajectories.

Fleet Analysis

This comprehensive view empowers strategic decision-making by providing insights into fleet-wide performance, trends, and optimisation opportunities.

Usage Monitoring

This scrutiny allows us to identify wear and usage-related trends, facilitating predictive maintenance strategies.

2. Data Filtering

Human-Derived Engineering Analytics

Beyond the realm of automation, our process incorporates the expertise of human-derived engineering analytics. Our skilled professionals interpret the data in tandem with their industry know-how, adding a layer of contextual understanding that enhances the accuracy of our insights.

Multi-layer Perceptrons and Neural Networks

Utilising cutting-edge technology, we employ multi-layer perceptrons and neural networks. These advanced algorithms possess the capability to discern intricate patterns within the data, allowing us to uncover hidden correlations and anomalies that might go unnoticed through traditional methods.

  • Rolling Contact Fatigue Detection
  • Vibration Anomaly Detection
  • Wheel Flat Detection

3. Real-time Outputs

System Mobile SMS Alerts

Real-time Alerts

Get immediate SMS and email notifications to respond promptly to critical situations.

GDN® Data Analysis AI Portal

Gearbox Health Analysis

Explore in-depth predictive gearbox maintenance health insights from advanced data analysis.

Gearbox Testing Analysis Maintenance

Gearbox Condition

Quickly assess your gearbox's status at a glance through our user-friendly interface.

At the Coal Face: a real-life example of Smart Oil Plug® preventing incidents

Smart Oil Plug® Wheel Flats
"Looks like [SOP] picked up its wheels on the trip yesterday morning, taken out of traffic immediately.

Set was examined last night and booked to go one journey only to [the depot] today to get the tyre turned.

On examination these flats were reported as 55 mm long, which is obviously out of traffic.”
northern
Fleet Improvement Manager
Northern Railway

Ease of Wireless Gearbox Monitoring sytem installation

Smart Oil Plug® Wireless Gearbox Monitoring Installation

Replace existing oil drain or oil filler plug

Insert SIM card

Install gateway

requires 24 V power

Remote system check

by our team at Transmission Dynamics

Designed to suit

Variety of Sizes

Our product is available in a range of sizes, ensuring a perfect fit for your requirements.

Tailored Design for Space Constraints

We specialise in crafting designs that are customised to suit the available space, guaranteeing optimal utilisation.

Direct Replacement

Seamlessly replace your oil drain or oil filler plugs with our Smart Oil Plug® product, streamlining the upgrade process.

Uncompromising Quality Assurance: Ensuring Excellence at Every Step

An example of our testing rig, putting the Smart Oil Plug® through rigorous quality checks at Transmission Dynamics

Stainless steel transmitter

Aluminium gateway

Rail approved

Environmental Robustness

Rigorous Fatigue Testing

Endured comprehensive testing on a specialised rig for enduring reliability.

Extreme Temperature Resilience

Designed to excel in temperatures from -40°C to +85°C, ensuring reliable functionality.

Harsh Environment Performance

Engineered to thrive in demanding environments, providing consistent operation.

Certified for Toughness

Proven components for longevity and quality 

Part of the Transmission Dynamics Ecosystem

PANDAS-3R®

PANDAS-3R® offers patented ultra-miniature wireless accelerometer technology for real-time data on train shoe gear impacts, boosting maintenance efficiency, ensuring safety, and embracing the future of rail maintenance.

PANDAS-V®

This advanced system revolutionises rail industry practices by offering affordable and scalable remote condition monitoring solutions for electrified train pantographs and overhead lines.  By addressing maintenance challenges and enhancing efficiency, PANDAS-V transforms rail operations and sets new standards for monitoring and maintenance in the industry.

SmartBug®

SmartBug® is a compact wireless telemetry system, measuring strain, vibration, roll, and temperature with a long-lasting built-in battery, suitable for various applications such as rail, highways, offshore, and more, transmitting data via short-range radio (up to 50 m) to a local Gateway, then transmitted on for analysis through the Global Data Network (GDN®).

Want to know more about the Smart Oil Plug® experience?

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