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Project

Lokotech implemented predictive analytics in service of locomotives

Customers: Locomotive technologies (Lokotech)

Moscow; Mechanical engineering and instrument making

Contractors: Clover Group
Product: Clover PMM (Predictive Maintenance & Monitoring) Forecast of technical condition of the equipment

Project date: 2016/03  - 2019/04

"The smart locomotive" — the system of intellectual repair of locomotives on a status.


The concept "Smart locomotive" is implemented since 2016. The project is implemented jointly Lokotech, "2050" and Clover Group. The module of search of anomalies of a system of predictive analytics Clover PMM which allows to analyze 260 parameters on locomotives 2TE116U and 3TE116U, on locomotives of TEP70U and TEP70BS – 308 parameters, on 2TE25KM - 270 of parameters is brought into trial operation. Specialists of groups of diagnostics of SLD work via the automated workplace "Smart Locomotive" web interface where in a schedule type operation parameters of the equipment of locomotives are displayed, information on automatically found anomalies in work of the locomotive is output. The Clover PMM system finds more than 60 types of violations in operation of the equipment and the modes of operation of locomotives.

One of the largest projects of Russia and the CIS on AI transformation (Artificial Intelligent) with transition to service on a status – the concept "Smart locomotive" which is implemented by Lokotech company – the market leader of the traction rolling stock of Russia. At the heart of the concept – application of mathematical models of predictive analytics, so-called, MX models (MathExperience) which combine mathematics and deep understanding of physical processes of the equipment of locomotives. Models allow to reveal beforehand prenegative conditions of equipment and to quickly take measures for prevention of failure of the locomotive on the line.

Creation of a system of service on a status using predictive analytics – the major stage for transformation of business processes of production companies. If earlier optimization came to an end at the level of local government and online data transmission where incidents continued to break out and they could not be warned automatically, then with the system of forecast service information circulates through mathematical models which predict behavior of the equipment and adopt experience of diagnosticians experts. Potential for business high: reduction of time for idle times, funds for unscheduled repairs, complete process optimization of service. Transition to service on a status changes all business processes of group and redefines work with customers.

2019: Results of implementation of Ctrl@maintenance in service maintenance of locomotives

The CEO of Ctrl2Go group, the chairman of the board of directors of Lokotech group Alexey Belinsky shared on June 6, 2019 experience of implementation in service maintenance of locomotives of Lokotech Group of the solution Ctrl@maintenance developed by Clover Group (enters into Ctrl2Go Group), on the basis of technologies of predictive analytics and artificial intelligence.

«
The assigned task turned out difficult. We achieved detection of anomalies in behavior of machines, made physical models of nodes of the locomotive for an explanation of the nature of their emergence. To receive true cost efficiency integration with schedule systems of resources of the enterprise which allowed to perform the order of spare parts and extra works even before run of the locomotive on repair was required — the CEO of Ctrl2GO group noted. — Thanks to the implementing solution Ctrl@maintenance it was succeeded to reduce unproductive idle times of locomotives to 22%. If in a complex to integrate other developments of group into processes, then a downtime of locomotives on repair work can be reduced in total four times.
»

For June, 2019 the project is implemented in Lokotech Group and provides "smart service" of nearly a third of all locomotive park of the Russian Railway (7.5 thousand locomotive sections) in 59 service depots.

2018

System implementation "Electronic passport of production"

The Lokotech group announced on December 19, 2018 project implementation "The electronic passport of production". A system is implemented within the program for digitalization and industrial automation and, as expected, will allow to optimize and increase its efficiency.

For December 19 a system is implemented on the Chelyabinsk ERZ. Earlier it was entered on the Ulan-Ude LVRZ and the Ussuriysk LRZ. The project is replicated on other enterprises of network.

«
Digitalization or digital transformation of business is a natural development of digital technologies. Lokotech dynamically implements digital-projects, and the electronic passport of production — one of them. In addition, we develop the concept of digital development — Digital Vision, until the end of the year we will define its main directions and we will start implementation — the managing director for development of digital Lokotech technologies Dmitry Sergienko told.
»

The basic principle of the electronic passport of production is that repair of the locomotive is controlled at each stage: in the program the status of execution of works is traced, their duration is estimated and also the typical notes arising on each of stages are fixed.

According to representatives Lokotech, an essence consists that all cycle of works breaks into positions, for each of them the list of actions is defined. Upon transition of the locomotive from a stage to a stage there is an acceptance transfer: one crew notes that it performed those works which from it were expected according to the check sheet, and the host party — that work is performed qualitatively, there are no claims to it. All this is fixed in the electronic passport, i.e. control over the implementation of transactions becomes visual, explained in the company.

«
The plan of repair of locomotives is transferred to digit — the chief technologist of the Chelyabinsk ERZ Anton Napolskikh added. — Any employee of the plant or management company online can see repair of the locomotive.
»

At the same time it is important that system implementation is tied to the salary of employees and motivates production divisions on rhythm of work and quality improvement, emphasized in Lokotech. The coefficient of rhythm estimates timeliness of execution of works by crews, and quality coefficient — lack of notes or defects.

Beginning of implementation of Digital dispatching office

On September 20, 2018 it became known that Group "Lokotech" and Clover Group announced the beginning of implementation SmartMaintenance (Digital dispatching office) for transition to management of repairs of the traction rolling stock using technologies artificial intelligence.

«
We are going to start the solution in November, 2018 on East polygon, in particular, in service locomotive depot Vikhorevka. On project completion it will be already possible to speak about specific economic indicators. We expect to implement a system until the end of January, 2019.
Alexey Belinsky, chairman of the board of directors Lokotech
»

SmartMaintenance are the cornerstone the data on real and forecast technical condition of the equipment received from the Smart Locomotive system. Let's remind that it is started in Lokotech since 2016 and for September, 2018 operates on 6400 sections of locomotives in 40 service locomotive depots. The solution allows to analyze 23 types of the equipment of locomotives and finds more than 60 types of failures in operation of the equipment. Time for diagnostics of the locomotive in a system was reduced from 2 to 5 o'clock minutes.

SmartMaintenance automatically estimates and predicts technical condition of nodes and units of the locomotive, proposes the most optimal solution on time and volume of service. The solution transforms usual approaches to maintenance and repair (MRO), allowing to manage process in real time on a status.

During implementation changes in business processes of service company are planned: integration with already existing IT architecture, updating of job descriptions, personnel training. SmartMaintenance will be integrated with the ERP system for automatic formation of the plan of repair work for the park[1].

2017: Presentation of a system of intellectual analytics

The Smart Locomotive system is implemented since 2016. Its key functionality is as follows - on the locomotives equipped with the microprocessor systems of management (MSM) special sensors from which data come to the platform of the intellectual analysis are installed. The module of search of anomalies which allows to analyze 260 parameters on locomotives 2TE116U and 3TE116U 270 on 2TE25KM and more than three hundred on locomotives of TEP70U and TEP70BS, is brought into trial operation. Specialists of groups of diagnostics of SLD work via the automated workplace "Smart Locomotive" web interface where in a schedule type operation parameters of the equipment of locomotives are displayed, information on automatically found anomalies in work of the locomotive is output. A system reveals more than 60 types of violations in operation of the equipment and the modes of operation of locomotives. Until the end of 2017 it is going to adapt a System to work with data of 4200 more sections of locomotives.


Thanks to system implementation, specialists Lokotech can quickly keep track of technical condition of the locomotive park, without waiting for serious breakdowns and heavy repairs. And to save resources, money and time of both service company, and the main customer. The possibility of forecasting of faults will allow to increase efficiency of the park and infrastructure.

"The smart locomotive" is implemented on the platform of intelligent data analysis Clover IIoT, using technology of training of neural networks. When developing experience of General Electric and Siemens was analyzed.

As of September, 2017 Lokotech using the Smart Locomotive system diagnoses operation of the equipment about 1.3 thousand sections of locomotives that makes about 25% of the park of the traction rolling stock of Russian Railways equipped with microprocessor systems of management. A system is operated in 20 service locomotive depots. The Lokotech group until the end of 2017 is going to connect to an intelligent system of data analysis "The smart engine" of 6 thousand sections of locomotives.

At the end of August, 2017 group Lokotech and Clover Group within the international salon EXPO 1520 provided the tool of intellectual analytics — "The smart locomotive".

The CEO of Clover Group Denis Kasimov on the presentation \"Production digitalization as the instrument of increase in efficiency of service maintenance of the locomotive park\"
The CEO of Clover Group Denis Kasimov on the presentation "Production digitalization as the instrument of increase in efficiency of service maintenance of the locomotive park"

As of August 31, 2017, in "The smart locomotive" the module of search of anomalies thanks to which a system analyzes equipment operation parameters in real time and announces anomalies to group of diagnosticians in depot is started. Start of the module of the predictive analysis intended for forecasting of the moment of failure of nodes of the locomotive is planned for the beginning of October, 2017.

«
We will be able to predict faults and to control a status of the rolling stock. Thus, in the short term we will pass to repair "on a status" and considerably we will increase efficiency of the park. It will allow to save resources, money and time and the main customer, and service company — Ruslan Zhavoronkov, the project manager of digitalization of production "Lokotech" emphasized.
»

The principle of system operation "The smart locomotive" was shown "alive" on the interactive model where in the web interface on diagrams data on technical condition of the equipment of the locomotive are displayed and in the automatic mode anomalies are displaid.

Denis Kasimov, the CEO of Clover Group company told about technical features of the project. According to him, intelligent data analysis is a tool for obtaining valuable information which is necessary for production and service companies for effective management.

«
The companies need the tool which not just diagnoses operation of the equipment, and automatically reveals the hidden abnormal modes and defines what of nodes of the equipment will break, and with important detailing — when why at what operation modes, i.e. predicts breakdown — Denis Kasimov emphasized.
»

2016

Choice of the solution Ctrl@maintenance for predetermination of breakdowns of locomotives

In 2016 Lokotech Group announced competition on the solution which would allow to predict breakdowns of locomotives, a hardware failure between scheduled repairs. According to the results of the Russian company Clover Group which provided an operable prototype and proved that it using Big Data will be able to predict breakdowns of the equipment was selected.

Announcement of management model business

On September 22, 2016 Lokomotivnye technologii LLC company provided the innovation management model business – "The smart locomotive" which will allow to perform repair and service maintenance of locomotives on "actual state".

«
"We use advanced technologies to increase our competitiveness. Tools 4.0 - our future. With their help we are going to make a revolution in the course of repair of locomotives, to create the "smart" park of locomotives that will allow us to increase operational efficiency. But it is possible to gain the maximum industry effect only at the sonapravlenny movement towards use of new technologies at all levels of management of locomotive economy".

Yury Degtyarev, the First Deputy CEO "Locomotive technologies"
»

The purpose of transition to new management model business - increase in operational efficiency of business

Tasks:

  • Cutting of costs for not scheduled repairs
  • Quality improvement of repairs
  • Elimination of the facts of violations of the modes of operation of locomotives


A system will allow to conduct serious analytical researches, to debug and provide not only planned, but also repairs on "actual state" ("smart locomotive" technology). So, there will be an opportunity to perform online assessment of technical condition of nodes and units of the locomotive, to predict failure probability, to plan programs of repairs, to reveal violations of the modes of operation and to promote increase in effective management of the movement.

After implementation of intelligent systems specialists Lokotech will be able to predict and control technical condition of the locomotive on all lifecycle of operation. It will allow to lower considerably operating costs, the number of not scheduled repairs and to increase coefficient of technical readiness (the key production indicator) of the locomotive park of the country.

ACS Network diagram Lokotech

The automated process control system of maintenance and repair of locomotives in service locomotive [2]

Premises of system implementation Lokotech ASU Network diagram
Premises of system implementation Lokotech ASU Network diagram
ASU main units \"Network diagrams\" Lokotech
ASU main units "Network diagrams" Lokotech
Functionality of an ACS Network diagram Lokotech
Functionality of an ACS Network diagram Lokotech
Implementation of an ACS
Implementation of an ACS
Work of mechanics in an ACS Network diagram
Work of mechanics in an ACS Network diagram

The main result of work of PDO is formation of an objective picture about technical condition of a loco - motive at its setting on repair. The main output electronic document – the Notes tab the diagnostic card, being a task to masters of workshops on accomplishment of extra works for maintenance of the locomotive.

Sources of effect of implementation of an ACS Network diagram
Sources of effect of implementation of an ACS Network diagram
Calculation of a payback period of the Lokotech project
Calculation of a payback period of the Lokotech project
Complex monitoring of locomotives
Complex monitoring of locomotives

Notes

  1. of the Lokotech equipment will implement an intelligent system of management of repairs
  2. the depodanny presentations "The data warehouse of service locomotive depots as the future of digital production" Pshichenko Dmitry Viktorovich, the Chief Data Officer (Chief Data Officer, CDO) Lokotech