Railway Surface Analyser and Visualiser for Precise Analysis, Detection, and Localisation of Rail Surface Roughness to Increase Track Inspection Productivity

Railway tracks offer a guided route for the safe and efficient movement of people, animals, and goods. However, interactions between wheels and rails, along with rail surface deformation, lead to the development of defects that cause roughness on the rail surface. This paper presents and discusses the design and development of an innovative Rail Surface Analyser and Visualiser (RSAV) aimed at increasing track inspection productivity by accurately analysing, detecting, and localising rail surface roughness (RSR). The RSAV combines linear variable differential transformer sensors, a high-resolution camera, and an encoder. RSR signals and videos were acquired from a siding track within a train depot and during non-revenue hours on a main line track in a mass rapid transit line in Singapore, then processed using signal and image processing techniques, and benchmarked against ISO 3095:2013 standards. Results consistently demonstrate that the RSAV can accurately detect and locate RSR variations, helping prioritise maintenance tasks to enhance railway reliability and safety.