Wireless gearbox monitoring system
Smart Oil Plug®
Temperature Detection
Vibration Analysis
Ferromagnetic debris
Benefits of using 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 utilises wireless gearbox monitoring technology and advanced sensors to provide a cutting-edge solution. It enables real-time monitoring and analysis of gearbox health, offering 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.
Key Detection Capabilities
The Smart Oil Plug® sensor detects and monitors the following critical parameters, all contained in a package designed to suit the existing filler/drain plug on the final drive.
Temperature
Tracks temperature variations to identify potential overheating issues. Can be applied in temperatures ranging from –40 to +85°C.
Vibration
Analyses vibration patterns to detect anomalies and potential mechanical failures.
Ferromagnetic Debris
Identifies the presence of ferromagnetic particles indicating wear and tear.
Oil Starvation
Detects oil loss or insufficient lubrication to prevent severe gearbox damage.
Continuous monitoring allows for predictive gearbox maintenance, reducing unnecessary downtime and costs associated with premature overhauls.
Smart Oil Plug® Wireless Gearbox Monitoring 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 Smart Oil Plug technology identifies early gearbox issues; the pictured example exceeded fleet average vibrations, prompting client inspection and repair.
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 Smart Oil Plug 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.
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 Smart Oil Plug technology detects early-stage wheel pits, alerting clients in time for preventative tyre turning instead of relying on mileage-based maintenance.
Wheel flats are localised flat spots on train wheels caused by prolonged skidding, leading to increased vibration, noise, and track damage.
Our Smart Oil Plug 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.
Damper Failures
Identify and manage failures in damping mechanisms.
Rolling Contact Fatigue (RCF) is frequently a prevailing damage mechanism for wheel pans.
Our Smart Oil Plug 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.
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.
Infrastructure
Our technology is capable of recording impacts corresponding to track defects and pinpointing the location, allowing for infrastructure monitoring that measures exactly what a live train experiences.
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 Smart Oil Plug technology identifies early gearbox issues; the pictured example exceeded fleet average vibrations, prompting client inspection and repair.
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 Smart Oil Plug 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.
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 Smart Oil Plug technology detects early-stage wheel pits, alerting clients in time for preventative tyre turning instead of relying on mileage-based maintenance.
Wheel flats are localised flat spots on train wheels caused by prolonged skidding, leading to increased vibration, noise, and track damage.
Our Smart Oil Plug 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.
Infrastructure
Our technology is capable of recording impacts corresponding to track defects and pinpointing the location, allowing for infrastructure monitoring that measures exactly what a live train experiences.
Damper Failures
Identify and manage failures in damping mechanisms.
Rolling Contact Fatigue (RCF) is frequently a prevailing damage mechanism for wheel pans.
Our Smart Oil Plug 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.
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 is set to be a game changer for global train operators in the coming years. Market data shows that the rail sector is expected to grow significantly over the next few years. This, combined with an increasing emphasis on greener, more efficient solutions where downtime is a serious and costly concern, means the rail aftermarket stakeholders will reap significant benefits from this product offer
Smart Oil Plug® Predictive Gearbox Maintenance 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
TRANSMISSION
Wireless Data Transfer from the Smart Oil Plug® to the Gateway
CELLULAR CONNECTIVITY
Seamless data transmission via Wifi and 4G
Key Features of Smart Oil Plug®
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.
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® is securely and periodically transferred to a local gateway, facilitating centralised data management and allowing for comprehensive analysis and 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 harnesses 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.
3. Real-time Outputs
Real-time Alerts
Get immediate SMS and email notifications to respond promptly to critical situations.
Gearbox Health Analysis
Explore in-depth predictive gearbox maintenance health insights from advanced data analysis.
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
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.”
Being able to monitor an increase of particles in the oil has been very beneficial in detecting units with concern, and allowing us to take appropriate action to prevent any potential unit failures. Reducing repair costs.
Access to the portal for monitoring live data has been easy to navigate and all the variables can be seen for each individual final drive."
(In partnership with ZF employing Smart Oil Plug® technology)
Ease of Wireless Gearbox Monitoring sytem 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®).
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