Wheel defects, such as flat spots and cavities, are a frequent challenge in railway operations, leading to increased wear, operational inefficiencies, and repair expenses. Both wheel and bearing defects often develop progressively over time, making continuous monitoring essential for early detection and timely maintenance interventions.

Traditional inspection methods rely on visual checks before departure, but manual inspections are inconsistent and often miss early-stage defects. Viezo Powerail is an autonomous vibration and temperature IoT sensor that continuously monitors wheel health, providing real-time insights to prevent unnecessary interventions and optimize maintenance planning.

This case study examines Powerail’s impact based on real-world data from 2022-2024, focusing on validated detections and their impact on maintenance decisions.

Cost analysis – with vs. without Powerail

Scenario without Powerail
When a wheel defect remains undetected until severe deterioration, it results in increased costs:
– Unplanned wheel reprofiling – 1 000 – 1 500 EUR per wheelset
– Full wheelset replacement (if exceeding wear limits) – 4 000 EUR per axle
– Unplanned maintenance detours – minor delays or lower operational speed
– Operational downtime – 3-5 days, depending on workshop availability
Total potential costs per severe incident – 1 500 – 7 500 EUR

Scenario with Powerail
– By detecting wheel defects early, Powerail enables scheduled maintenance instead of unexpected interventions:
– Planned wheel reprofiling – 400 – 1 000 EUR per wheelset
– Labor costs for workshop maintenance – 100 – 200 EUR
– Operational downtime – minimal or 0 EUR (resolved within regular maintenance)
Total cost per incident with Powerail – 500 – 1 200 EUR

Estimated savings per incident with Powerail – 1 000 – 6 300 EUR

Operational benefits of Powerail

1. Proactive maintenance and scheduling
– Powerail reduces unplanned maintenance by enabling repair teams to address defects before they reach critical thresholds.
– Affected wagons can be rerouted in advance, minimizing unexpected disruptions.

2. Reduced downtime and workshop queues
– Unplanned failures result in 3-5 days of downtime on average, depending on workshop availability.
– Workshop queues can range from 1 week to 3 months, delaying necessary maintenance when not scheduled in advance.

3. Increased wagon availability and cost savings
– Powerail data helps prevent unnecessary reprofiling before IS1/IS2 inspections.
– Early interventions eliminate costly full wheel replacements.
– Operators experience up to a 30% reduction in workshop time, keeping wagons in service longer.

Real-world impact

Case 1. 8-month trial on a large wagon fleet. Powerail was installed on a fleet of freight wagons for 8 months to monitor wheel health. During this period:
– 6 validated wheel issues were detected and reported to maintenance teams.
– Maintenance was incorporated into scheduled interventions, preventing further deterioration.
– The operator maintained service reliability without unexpected downtime.

Case 2. 12-Month deployment in a mixed freight and passenger fleet. Over a 12-month period, Powerail continuously monitored a fleet operating across international routes.
– Multiple flat spots were detected early, allowing proactive maintenance scheduling.
– One severe case involved a flat spot of ±52mm, which — if unnoticed — could have required an urgent workshop visit.
– Early detection enabled rerouting to an internal maintenance facility, avoiding expensive third-party repairs.

Case 3. 12-month trial on freight operations. In 12-month deployment, Powerail continuously monitored a freight transport fleet.
– Progressively worsening wheel defects were identified in real time.
– Maintenance teams planned interventions efficiently, avoiding unplanned workshop visits.
– Fleet availability remained high, ensuring smooth operations and optimized maintenance planning.

The value of predictive monitoring with Powerail

Powerail’s real-time monitoring and predictive analytics have proven highly effective in identifying wheel issues before they escalate into costly failures. Since both wheel and bearing defects develop progressively, early detection is crucial for timely maintenance interventions.

By transitioning from reactive to proactive maintenance, railway operators can:
– Reduce maintenance costs;
– Optimize fleet utilization;
– Enhance operational efficiency.

Powerail is a cost-effective, scalable solution that ensures efficient and reliable railway operations for the future.