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Digitisation makes wheelset wear calculable

Condition monitoring and forecasting with zedas®asset

The uneven wear behaviour of wheelsets is a challenge for fleet managers and workshop managers. Due to detected defects, vehicles have to be taken out of service at short notice. Also, workshop resources normally are not available ad hoc. Furthermore, long delivery times of wheelsets even worsen these problems. Intelligent digital solutions and experienced data analysts make wheelset wear calculable. In this article, you will learn how to make wheelset maintenance more efficient and predictable and how to increase the availability and safety of your rolling stock.

The end of the technically possible service life of wheelsets is usually only recognised at a very late stage. Often it is only noticed shortly before its end. Wheelsets of rail vehicles have to withstand huge loads and are subject to high safety standards. Depending on weather conditions, forces acting during operation (e.g. braking, gradients and curves), rail profile and reprofiling frequency wheelsets wear unevenly. It is quite difficult to determine ideal preventive measurement intervals.

This may result in unplanned non-availability of vehicles (due to safety defects on wheelsets detected at short notice) but also in unavailable spare parts or workshop resources. As a consequence, this might lead to unsatisfied customers, economic damages and penalties for non-compliance with transport contracts. In case of emergency, wheelsets, workshop capacities or vehicles are sometimes purchased at short notice at high costs from other market participants.

Digitalisation offers new opportunities to better use to full capacity the service life of wheelsets and thus to increase the availability of vehicles. Digital assistants such as zedas®asset combine data-based analyses, condition and limit value monitoring and asset management in a single platform. Regularly acquired measurement data offer the possibility of automatic forecasts on the wear of wheelsets. The comparison of forecasted and actual data specifies the forecast continuously and independently. The ideal time for measurement, reprofiling or wheelset exchange can be determined well in advance. Thus, wheelsets are fully technically used, unplanned times spent in the workshop are avoided.Screenshot Radsatzverschleiß mit Prognose big

The digital assistant keeps track of all deadlines. It automatically notifies responsible persons of impending limit violations, monitors stock levels and submits ordering suggestions. During these “actions”, the smart assistant also takes into account delivery times, which are often quite long.

If reprofiling and wheelset exchange can be planned well in advance, it will be possible to allocate all necessary resources at an early stage. Wheelset and material are delivered, a place in the workshop is reserved and the vehicle is ready for operation until the last day before the workshop appointment. Orders can be bundled and thus realised in a more cost-effective way. Unnecessarily high stock levels kept are avoided. An additional advantage is that complete ECM-compliant documentation is created for the complete measurement data and maintenance process. This digital life cycle file is available exactly for a certain wheel set and is also transferred, if the wheelset is used in a different vehicle.


Intelligent, digital assistants for analysis, condition monitoring and asset management increase the availability and safety of your rolling stock. Maintenance of wheelsets is more efficient and can be planned much better. The ideal time for the exchange of wheelsets or reprofiling of rail vehicles can be determined precisely.

The original article was written and published on LinkedIn by Chris Richter, Senior Sales Manager at ZEDAS.