Beena Vision Systems, Inc.

WheelView

Product Description
&
Specifications

July 2004

1235 Hightower Trail, Suite 140

Atlanta, GA 30350
Tel: (678) 597-3156
Fax: (678) 597-3158
info@beenavision.com Rev:2.01
www.beenavision.com
Table of Contents:

Company:................................................................................................................................................... 4
System Description .................................................................................................................................... 4
Enclosures ............................................................................................................................................. 5
Acquisition, Processing and Control Unit ............................................................................................. 6
Remote Monitoring and Diagnostics ..................................................................................................... 6
Local Remote Control............................................................................................................................ 6
Image Acquisition and Processing......................................................................................................... 7
Measured Parameters............................................................................................................................ 7
Operation: .................................................................................................................................................. 8
Remote Train Presence Sensors ............................................................................................................ 8
Triggering Sensors................................................................................................................................. 8
AEI......................................................................................................................................................... 8
Image Acquisition and Processing......................................................................................................... 8
Calibration............................................................................................................................................. 9
Tests at different installation conditions.............................................................................................. 10
Database.............................................................................................................................................. 10
Installation requirement ........................................................................................................................... 11
Performance: ............................................................................................................................................ 12
Resolution ............................................................................................................................................ 12
Accuracy as reported by actual tests ................................................................................................... 12
Sample Accuracy Results:.................................................................................................................... 13
Software ................................................................................................................................................... 14
Monitoring/Control/Management Software......................................................................................... 14
Installation/Calibration Software ........................................................................................................ 15
Digital Image Acquisition/Processing Software .................................................................................. 15
Database software ............................................................................................................................... 15
Specification: ........................................................................................................................................... 16
Contact Information ................................................................................................................................. 17

WheelView Product Description 2.01 Beena Vision Systems, Inc. Page 2 of 17

 Visit us at

www.beenavision.com

WheelView Product Description 2.01 Beena Vision Systems, Inc. Page 3 of 17

Company:

Beena Vision Systems, Inc. has dedicated its

efforts into the applications of Machine Vision
Technology in transportation industry, and more
specifically, in train monitoring and railroad
industry. The first product of this company is a
non-contact wheel profile measurement system.
Accuracy and reliability of the system is proven
by extensive system tests in several installations
in the last four years.

The company is well equipped to design and develop high

technology wayside monitoring equipment for railroad and
transportation applications. Company is currently involved
with the development of several other products based on
machine vision technology for railroad applications.
Two view of WheelView
laboratory at Beena Vision’s
Atlanta office.
System Description

Beena WheelView is one of BeenaView series of systems designed for wayside train
monitoring applications. The system is used to perform accurate wheel wear monitoring where
100% of wheels are inspected regularly. Therefore, the system can be used to monitor wheel wear
rate and patterns, prevent costly accidents
caused by condemnable wheels, and
optimize wheel maintenance scheduling.

Beena WheelView uses multi-camera &

stereo machine vision technology to
accurately and reliably measure the wheel
profile and all its relevant parameters. The
system is easily installed under the rail at a
proper location. The system installation
does not require significant rail/track
modification and easily fits between to ties
as shown in the figure.
A view of an installed system between two ties.

WheelView Product Description 2.01 Beena Vision Systems, Inc. Page 4 of 17

 A side view of an installed system. The integrated AEI system readers are
also shown.

Enclosures
Enclosures of WheelView are one of the important components of te system. They are all fully
sealed and temperature controlled enclosures that are installed under the rail and hold imaging
equipment. The system uses effective Peltier effect heating/cooling systems. That is why the
system can survive in very harsh, very cold, and very hot environments. The double-layer,

A front and back view of all steel enclosures of BeenaView.

Electronics of each enclosure is also shown on the right.

insulated enclosures are all constructed using fully industrial grade

material and all connectors are military grade.

The system consists of four enclosures installed under the rail, two
enclosures for each trackside. That is, the imaging components in two
enclosures (one in each side of the rail) are used to measure profiles of all
wheels passing through that rail. All enclosures are connected to a central
data acquisition and processing unit. Also, every enclosure has its own
control/data acquisition unit that is connected through a control/data bus to the central control
unit.

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Acquisition, Processing and Control Unit
Control and processing units are all installed in a standard 19-
inch cabinet. The cabinet also houses all surge protection units,
power supply units, computer display monitor, manual control
unit, local RF remote control receiver, keyboard/mouse drawer,
and other equipment.

The processing unit is scalable, where the number of processors (CPU’s) can be increased to meet
the processing speed requirements and train traffic load of the installation site.
The system is connected to a dial-up, LAN, or WAN line for remote
control, monitoring and data access purposes. The communication
channel bandwidth determines the amount and speed of data that can be
transferred to all central stations.
Every measurement station has its own local database where the local
data (wheels measured at that station) are stored. There is also an
alarming system to send messages to all relevant personnel in case a
condemnable wheel is located. Parameters to determine condemnable
wheels and alarming procedure are customized for each customer.

Remote Monitoring and Diagnostics

WheelView is equipped with several tools for monitoring, maintenance and diagnostics. For
example, all system inputs commands, outputs levels, relay functions, power supplies outputs,
enclosure shutter position, enclosure temperatures and humidity, ambient temperature and
humidity, AEI system function, axle counter outputs, train presence sensors and triggering system
functions are continuously monitored and all failures are reported to maintenance staff
immediately.
Such functionality in the system is designed to make its maintenance an easy and manageable
task where for the most part, local trained maintenance personnel can operate and maintain the
system.

Local Remote Control

The system is also equipped with a local remote control
unit so maintenance personnel can easily operate key
enclosure functions while standing by the trackside,
near enclosures. For example, enclosure shutters,
heaters and coolers, lasers, washers, etc can be
manually tuned on and off using this radio remote
control unit. The typical distance of the enclosures from
the bungalow is 100 ft. This unit can also be used
during calibration operation.

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Image Acquisition and Processing
All CCD cameras in all enclosures are connected to fast image grabbing units inside the central
data acquisition and processing unit. The optics used in the imaging system is specially designed
for this application. Every component of the system is selected and tested to optimize the quality
of the images taken for optimal processing results.
The temperature-controlled enclosures ensure that every laser unit is operating at its maximum
output power. Optical quality glasses are used in the viewing window of each enclosure,
appropriate optical filters are used to minimize the effect of undesired ambient light in the
imaging sensors, all camera and laser angles are optimize to limit the effect of sunlight and other
unwanted light on the CCD sensors, and finally, high quality CCD sensors and lenses are used to
create the sharpest possible images at high speed.
We also have developed sophisticated image possessing algorithms and reconstruction procedures
to process acquired images and produce the profile curve. This curve is subsequently used to
measure wheel parameters. Wheel diameter and tracking position are also calculated during this
process.

Measured Parameters
Measured parameters by WheelView for each wheel are
• Wheel Hollow
• Flange Height
• Flange Width
• Flange Slope
• Rim Thickness
• Wheel Diameter
• Optional parameters including: Tracking Position, Tracking Error

Sample Excel sheet report

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Operation:
System is installed under the rail in a stable and tangent track
position. System has a high tolerance for vertical (and horizontal)
displacements of the rail and wheels that may occur due to heavy
carloads and tracking repairs.

Remote Train Presence Sensors

After a train presence sensor (see figure) detects an incoming train,
sensitive system components such as lasers are powered on and the
enclosure shutters are opened. These far located (train presence)
sensors are usually installed about 100 yards away from the
installation point in both sides. Dragging equipment detectors can
be installed at appropriate location for system protection.

Triggering Sensors
Train wheel are used to trigger the imaging devices. After a
wheel arrives at the trigger sensors (see figure), every wheel of
the train is imaged using at least two cameras. The triggering
system is designed to be direction and speed insensitive. All
sensors are fully industrial types that are designed for railroad
applications.

AEI
After wheel images are grabbed, they are passed to the processing unit to determine wheel
parameters. The system is installed together with an Automatic Equipment Identification (AEI)
system. The AEI is an integral part of the system. Using AEI, every wheel in the fleet can be
identified and traced for as long as that wheel is at service.
Using AEI generated information; an ID code is generated for every wheel that has passed the
system. This code is usually a combination of the CarID number and the wheel position in the
car. From user’s point of view, every wheel can be traced
back in time for as long as its data is retained in the
database, that is user selectable.

Image Acquisition and Processing

For every wheel at least two images are taken, one from
tread side and the other from the flange side. The flange
side image is used to determine the flange position, and to
measure a complete end-to-end profile of the wheel,
including the back side of the flange. This section of the
profile is used to perform a correct rim thickness
measurement and also determine the tracking position. An actual flange side image.

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The tread side image is taken to measure the
remaining part of the profile and also to determine
the wheel diameter.
After both images are processed in sub-pixel
accuracy, the two parts of the profile are
reconstructed and matched to generate a complete
end-to-end profile of the wheel (shown below).
Furthermore, both cameras view the tread part of the

An actual tread side image.

End-to-end reconstructed profile, superimposed
on the profile measured with a Miniprof.
wheel. The redundant measurement of this
critical part of the profile is used to
improve the measurement accuracy of the
profile.
Typical images of the both cameras are
shown above. It is worth noting that both
shown images are taken at bright daytime.
This shows the minimal effect of daytime
ambient light on the quality of images.

Calibration
Calibration is another important part of the system installation. The
information generated from the calibration process is used to convert
the data from acquired images to the real-world coordinates, and
thus to the profile data. Calibration is performed using a calibration
object similar to the shown here. A yearly recalibration is
recommended. The system is equipped with several tools to detect if
the system needs recalibration. Recalibration is a rare requirement
for the system, unless an accident has repositioned enclosures.

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Tests at different installation conditions
The system has been installed and tested in many different climatic conditions. The system is
designed to withstand very hot and very cold weathers, vibration, etc. The following figures show
the system under operation under snowy conditions and at nighttime.

Database
The system includes a database of all
existing wheels in the fleet and their
corresponding measured data and
profiles. The data in the database can be
searched and viewed in a variety of
ways to show the wear rate of wheels,
with respect to time and other
parameters. Other statistical and time
analyses of data are also possible. This
data can help operators in their
maintenance scheduling and wear rate
measurement to prevent accidents that
may occur because of condemnable
wheels. (see software section)

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Installation requirement
One of the advantages of the system is its easy installation. The system is usually installed
between two ties with a concrete foundation underneath. That is one of the reasons that it can be
installed in a very short period of time and at a very low cost. The general requirements for
system installation are as follows:

1. System is installed in a relatively stable track position. System has a relatively high tolerance
for the vertical displacement of the wheel at the measurement point.
2. System has a 110VAC power requirement. The system has its own power supplies for all
system components.
3. System needs a relatively tangent and relatively flat segment of the rail for installation.
4. The distance between two ties for the system installation is about 32 inches.
5. A wayside bungalow with temperature control will be necessary. The temperature in the

A top view of an installed system

bungalow will be maintained in 40° F to 80° F range.

6. Some form of communication/networking line is required. This may be a wired phone line, a
wireless channel, or a LAN/WAN connection. This line is used for remote system
monitoring/maintenance and to transmit measured wheel data to the central computer and
database.
7. An AEI system interface is integrated into the system. AEI readers can be provided as an
integral part of the system
8. The installation site preparation will be performed with the specification provided by Beena
Vision Systems, Inc.

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Performance:
Resolution
Based on the imaging resolution and the sub-pixel processing of acquired images, the system
resolutions for measurement of different parameters are:

Parameter Resolution (mm)

Flange Height 0.05
Flange Thickness 0.05
Hollowing 0.05
Rim Thickness 0.1
Diameter 1

Accuracy (as reported by actual tests)

The system performance is evaluated through extensive tests. The tests were performed to
evaluate and optimize system measurement accuracy, repeatability, reliability, withstanding harsh
environments, maintenance requirements, AEI interface, installation procedure, surge protection,
long-term performance, etc.
The tests were performed in some permanent and some short-term installations. The following are
sample graphs to show the accuracy of the measured data.

System accuracy is measured as follows:

• All measurements falling within a ±1mm band of a manual measurement is considered
accurate for Flange Thickness and Flange Height.
• All Measurements falling with a ±0.5mm band of manual measurement is considered
accurate for Hollowing.
• All Measurements falling with a ±1.5mm band of manual measurement is considered
accurate for Rim Thickness.

Note: A manual measurement is performed at a single point around the circumference of the
wheel. A 0.2 mm around the wheel variance for flange parameters and a 0.5 mm variance for rim
thickness are considered in the accuracy measurement. Accuracy criteria and numbers are all
provided by TTCI.

WheelView Product Description 2.01 Beena Vision Systems, Inc. Page 12 of 17

Sample Accuracy Results:
The figure in the right shows a
typical daytime measurement
accuracy of a single car. Generally,
flange and hollowing parameters are
measured with an accuracy of at least
%95 and rim thickness is usually are
measured with an accuracy of 90% or
higher. A typical well-installed
system provides an accuracy of about A typical accuracy graph provided by TTCI.
99%.

The system saves the results of

measurements in a database
along with its identification
information and its profile as an
x-y graph data. (left).
Consecutive measurements of
the same wheel are
superimposed to follow the
wear rate of that wheel.
An end-to-end measured profile superimposed on Miniprof
measured profile.

The figure in the right shows a scatter plot of a

group of measured parameter versus its actual
value. This shows a low measurement error
variance compared to the measurement range.
This graph is plotted for flange thickness from
results of several tests.

WheelView Product Description 2.01 Beena Vision Systems, Inc. Page 13 of 17

Software
Basic software components of VheelView are:

1- Monitoring/Control/Management Software (Process Management)

2- Digital Image Acquisition/Processing Software (DIAP)
3- Installation/Calibration Software (I/C)
4- Database/Data Search/Data Interface Software (DB)

Monitoring/Control/Management Software
Monitoring/Control/Management Software uses extensive input/output capabilities of the
system to monitor the system condition and control all components, including:
a. Enclosure temperature control & humidity monitoring
b. Enclosure shutter control
c. Turn all system components on/off when system starts and stops operating
(sensor triggered events)
d. Check functionalities of all components for local and remote maintenance
e. Manage the communication between all system components such as acquisition,
control, processing units, database, AEI, etc.
f. Report any malfunction locally and to all remote sites. All components of the
system have feed-back monitoring to determine possible problems of every
component.
g. Manage the communication between the local site and the central site using web
connection, leased line connection, dial up connection, etc. The system has a
client/server configuration.

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Installation/Calibration Software
Installation/Calibration Software has the task of providing the information needed during the
installation and system set up for AEI system, trigger system, and calibration.

Digital Image Acquisition/Processing Software

Digital Image Acquisition/Processing Software controls the image acquisition and performs
processing of acquired digital images. The imaging system can handle image acquisition at
high speeds. The software also manages the data processing task by dividing the task between
different CPU units.

Database Software
All the measured data including the profile data are stored in a database for further access.
Search for a specific wheel and/or car, a range of cars and wheels, interested parameters with
their desired ranges; drawing graphs, scatter plots; prediction of wear rate based on existing
data are among the tasks that can be performed by this software.

A sample of view of a Wheel Query in database.

WheelView Product Description 2.01 Beena Vision Systems, Inc. Page 15 of 17

Specification:

• Complete wheel profile measurement

• Speeds up to 65 mph (100 kmph)
• Enclosures: steel, double layer, insulated, with shutter and glare-free, stain and scratch
resistant paint
• Measured parameters:
Flange Height
Flange Width
Flange Slope
Tread Hollow
Rim Thickness
Wheel diameter
Full wheel profile (as a x-y graph)
Tracking Position (optional)
Tracking Error (optional)
• Integrated AEI interface
• RF remote control transceiver
• Capable of operating at harsh environments with sealed and air-conditioned enclosures:
Operating Temperature: -35°F-120°F
• Power requirement: 110VAC, 30A, Surge Protected
• Nominal Distance between bungalow and trackside: 100 ft
• Rated actual accuracy

Flange Thickness 1/32 inch (0.8 mm)

Flange Height 1/32 inch (0.8 mm)
Tread Hollow 0.02 inch (0.5 mm)
Rim Thickness 0.04 inch (1.0 mm)

• Remote monitoring/control capability

• Fast installation between two ties
• Automatic alarm reporting for condemnable or near condemnable wheels (local, ftp,
email, etc.)
• Sophisticated database for data save/search/retrieve operation
Can save millions of measured wheel records
Search based on all parameters such as Car ID, Wheel Position, Time,
measured parameter, etc.
Complete profile drawing, overlapping, trending capabilities
Automatic reporting (soft and hard)

WheelView Product Description 2.01 Beena Vision Systems, Inc. Page 16 of 17

Contact Information

For more information please contact:

Beena Vision Systems Inc.

1235 Hightower Trail, Suite 140
Atlanta, GA 30350
Phone: 678-597-3156
Fax: 678-597-3158
Email: info@beenavision.com
www.beenavision.com

WheelView Product Description 2.01 Beena Vision Systems, Inc. Page 17 of 17