How We Plan and Carry Out Freight Car Repairs

Our expert, Miroslav Orlovsky, explains how Rental Wagons specialists plan and execute freight car repairs, what the «Traffic Light Principle» is, how the predictive maintenance system operates, and how repair decisions are made based on careful data collection and analysis.

Miroslav Orlovsky Miroslav is working in the profession for over 20 years, advancing from a shift foreman at the Vilnius locomotive repair depot to the head of production at the repair base. His extensive experience enabled him to organize and lead analytical work in the technical department of UAB Eranium (Rental Wagons trademark). His current responsibilities include organizing and monitoring current and scheduled repairs of freight cars and communicating with repair bases and spare parts suppliers.

According to Miroslav, the process is based on the daily collection of information from all technical inspection points of wagons after repairs into a single database. The network of such points, owned by Rental Wagons, covers almost the entire territory of Eurasia. After analyzing the collected data, the company’s specialists plan and forecast the time frame in which a specific wagon will require repairs and optimize routes so that the wagon is at the specified location at the time repairs are needed. The location of each unit of rolling stock can be determined using the wagon location tracking system developed by Rental Wagons.

Predictive Maintenance and the Traffic Light Principle

Predictive analytics and the «Traffic Light Principle» are used to forecast freight car repair times. Let’s explore what this entails.

How the Traffic Light Principle is Used

The «Traffic Light Principle» is a method for monitoring the technical condition of the main components (such as castings) of a wagon, using color coding to indicate their condition. This method helps quickly assess the state of wagons and take necessary maintenance and repair actions.

Basic Color Codes:

1. Green — The car is in good condition and ready for operation. No immediate intervention is required.
2. Yellow — The car can be used, but the thickness of the wheel pair rim has reached 35-37 mm. This signals that attention is needed to the technical condition, but the car can still be used until work is carried out.
3. Red — The car can be used, but the thickness of the wheel pair rim has reached 25-28 mm. This signals that this wheel pair needs to be replaced soon.

This is how it looks on the screens of our specialists.

Methodology for Monitoring the Technical Condition of the Main Components

The use of the «Traffic Light Principle» for organizing wagon repairs allows:

1. Quick identification of wagons requiring different levels of maintenance.
2. Optimization of the planning and execution of repair work.
3. Increased safety of rolling stock operation.
4. Reduced wagon downtime and improved performance.

We have implemented and successfully applied this methodology for timely maintenance and increased reliability of transport operations.

Reasons for Wheelset Wear Out

«In freight cars, it’s mainly the wheel pairs that wear out», explains Miroslav.

They are subject to rapid wear for several reasons:

1. High Mechanical Loads: Wheel sets bear the weight of the entire car and the cargo being transported, enduring high dynamic loads, especially at high speeds and during braking.
2. Friction: Car wheels contact the rails, creating friction that causes wear of the contact surfaces. This is especially rapid in curved sections of the track where lateral friction increases.
3. Climatic Conditions: Temperature changes, humidity, and environmental influences affect the condition of wheel sets. Moisture can cause corrosion, and temperature fluctuations can cause thermal fatigue.
4. Rail Condition: Uneven or damaged tracks can increase wheel set wear. Defective rails, wavy wear, and improper rail connections all add to the load on freight car wheels.
5. Braking: Frequent and intensive braking causes thermal wear and mechanical damage to wheel surfaces, leading to overheating, deformation, and cracks.
6. Material Quality: The quality of steel and other materials used for wheel sets affects their durability. Lower quality materials wear out faster and require replacement.
7. Speed: Higher speeds increase wheel pair wear. High-speed trains need special wheel pairs with enhanced wear resistance.

All these factors combined mean that freight car wheel sets require regular maintenance and repair. Here’s what this information looks like in the Rental Wagons system.

Wheelset Repair Process

Wheelset repair is crucial for ensuring the safe and efficient operation of freight rail cars. The repair process consists of several stages carried out in specialized repair depots and workshops. Our expert Miroslav Orlovsky details how Rental Wagons handles wheelset repairs. Read more in our next article.

Comprehensive Freight Car Repair

To perform comprehensive repairs, highly qualified specialists, modern equipment, and technologies are required. Correctly performed repairs and regular maintenance significantly extend the service life of cars and directly affect the safety of your freight transportation.

Trust Us with Your Repairs!

At Rental Wagons, we prioritize the organization of technical maintenance and repair. We employ qualified specialists under the supervision of experienced experts. No matter where your rolling stock is located, you can always contact us for repairs, maintenance, or advice. We provide services in Asia, the CIS, and the Baltics to private wagon owners and organizations. Write to support@rentalwagons.com or call +370 65202371.