Enhanced algorithm for predictive maintenance to detect turbocharger overspeed in diesel engine rail vehicles

The reliability and safety of locomotives is crucial for efficient train operation. Repeated turbocharger failures in Israel Railways locomotive fleet have raised serious safety concerns. An investigation into the failures revealed that the uncontrolled acceleration and overspeed transients of the turbocharger shaft occurred before the failure. Early detection of potential turbocharger failures by predicting overspeed conditions is critical to the safety and reliability of locomotives. In this study, an enhanced novel algorithm for estimating the Instantaneous Angular Speed (IAS) of the turbocharger and diesel engines is presented to overcome the challenges of transient operating conditions of diesel engines. Using adaptive dephasing, the algorithm effectively isolates critical asynchronous vibration components that are crucial for the early detection of turbocharger failures. This algorithm is suitable for non-stationary speeds and is applicable to any range of rotational speed and rate of change. The algorithm requires the input of the basic parameters of the system, while all other parameters that control the process are determined automatically. The algorithm was developed specifically for the special operating conditions of diesel engines and improves predictive maintenance and operational reliability. The method is robust as it correlates between several characteristic frequencies of the rotating parts of the system. The algorithm was verified and validated with simulated and experimental data.