Digital Depot is a pilot project that LocoTech Group of Companies together with Ctrl2GO Group have been implementing on the basis of the Bratskoe service locomotive depot (SLD) since 2018. At the moment, more than 30 different digital and technological solutions, combined into one intelligent system have been implemented in the SLD.
The main goal of innovations is to improve the maintenance efficiency and repair quality of the locomotives. Process automation minimizes the impact of human factors on the repair process quality, and modern digital and technological solutions reduce the time spent by the locomotives in the depot. Thus, the time spent on production operations will be reduced by 2 times, and labor productivity should grow by 30%.
The uniqueness of the Digital Depot project is in the unified integration of digital solutions. A key element of this complex system is a unified integration platform, where data is continuously transmitted from the locomotives and technological equipment of the depot. On the basis of this information, a forecast analysis of the technical condition of the locomotive fleet is built and resources are planned for more efficient organization of production processes, CEO of LocoTech Alexandr Mavrin said.
The project goal is to increase the coefficient of readiness for operation (CRO, the main indicator of the service company's efficiency) of the locomotive to 0.95, as well as to improve the quality of repair (which is reflected in the increase in service life and trouble-free operation). Achieving the required CRO is due to reducing the period of current repair (CR) CR-1 and maintenance (M) M-2. And improvement of repair quality due to objective control of technological operations with the use of modern digital means of measurement and identification.
In the framework of the Digital Depot project, NIITKD designed and put into operation a universal repair station. It allows to completely eliminate the need for locomotive maneuvers: multi-cycle works with a 3-section machine are carried out without rearranging sections in the workshops, thus the repair period is reduced to 16 hours or less. This is one of the important elements of the technological process transformation. In addition, the repair station is really smart, it is fitted with new equipment with the possibility of direct transmission of the captured data to the automated control system.
Other Digital Depot elements were also presented at the event.
For example, at the entrance to the depot, an intelligent frame with antennas for reading RFID tags of linear equipment and locomotives is installed. Tags are one of the data sources for the wheelset tracking system, which collects information about its measurements, presence and location within the polygon. Also on the frame there are cameras that recognize the locomotive number and the period of its entry into the depot.
At the depot entrance, a radio-controlled arrow is installed, which allows the driver to remotely switch the movement direction. It streamlines the process of shunting work.
Among the digital solutions, we can mention the system for measuring the tyre profile with laser profilometers. For tracking the state of the commutator device of the TM (traction motor), a digital specialized measuring system is used. The system for determining the brake pads wear, used in the Bratskoe depot, makes it possible to predict the date of their replacement.
The depot is equipped with a new "digital" control room, which receives information about all production processes in the depot and general statistics of planned indicators.
Digital solutions are integrated into a single planning system. The operation of this system is as follows: based on the data obtained, it predicts the probability of failure of a particular locomotive node, which allows to plan the necessary amount of works for each section before it goes into service. Then it automatically plans the volume of materials and the list of linear equipment needed for repair, and also brings to the employees already automatically drawn up work plan online, - Yuri Sumin, Digital Depot Project Manager, Ctrl2GO Group added. – The level of inventory in the warehouse is also digitized and, in the case of a shortage of any spare parts, the signal is also sent to the planning system for pre-ordering the necessary components. For quick receipt of inventory items, an automated vertical storage system is installed next to the repair stations, which allows for accounting and provision of repair kits for frequently used equipment for CR-1 operations.
Additive technologies, or 3D printing, allow us to solve the problem of supplying the most sought-after and small-scale products. With its help, it is possible to quickly produce individual parts directly in the depot.
All processes are monitored by the employees in real time, using special mobile devices with a set of interconnected mobile applications that are provided for each stage of maintenance and repair of locomotives. This allows you to minimize time and labor costs when collecting data about the the vehicle condition and increases the objectivity of the information received. It also reduces the time for distributing production tasks and making management decisions. The positive effects were also achieved by the reorganization of the depot staff. While maintaining the total number of employees, the organizational structure of the enterprise was rebuilt.
The result is a service organization in which the locomotive maintenance and repair in the depot takes place in the pit stop mode.