Research infrastructure

Full-Scale Wheel-Rail Lab

Tampere University

Faculty of Engineering and Natural Sciences

Automation Technology and Mechanical Engineering

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The wheel-rail rig is used to study wheel-rail interaction (contact location, force, patch, etc), wear, rolling contact fatigue, lubrication, adhesion and friction modifiers.

Play the video on YouTube (opens in a new tab).

The rig was built by Pekka Salmenperä from TerraRail Group (now working at VR Fleetcare) 10 years ago, designed to analyze the rail wear. However, the rig was not completed and has since been stored in the warehouse. In June 2024, the head of TerraRail, Prof. Heikki Luomala, gave it to Prof. Xinxin Yu to support railway research.

It includes a frame, a full-sized wheel, and a carriage designed to hold the rail, with 3.5 meters in length, 2.5 meters in width, and 2.3 meters in height, a weight of 7,000 kilograms.
Vertical wheel loading up to 50 t. -> for heavy freight
Longitudinal rail translation with the loading up to 3.5 t. -> accelerate & decelerate the wheel
Lateral rail translation with loading up to 10 t. -> change wheel-rail lateral contact location and exert the wheel flange contact force to generate the wear and rolling contact fatigue
Change of wheel angle of attach (yaw rotation) -> simulate the curve
Wheel rotation control-> combine with 2 to control wheel creepages
The working cycle is designed with maximum 20 000 wheel pass per 24h. -> Simulate different traffic densities.
The wheel-rail frictional contact forces (vertical, longitudinal and lateral) will be measured using hydraulic force sensors (load cell) in the cylinder and calibrate with the strain gauge mounted on the rail.

Figure: Rig in June 2024, photo is owned by Xinxin Yu.

Figure: Rig in August 2026, photo is owned by Xinxin Yu.

Study of wheel-rail contact profile geometry, lateral locations and track irregularity using computer vision techniques

DIGIWHEEL is funded by TAU Imaging Research Platform.

Conventionally, the condition monitoring of the railway equipment is processed while the train stops, which easily leads to train delays and only reduces the likelihood of accidents. The most precise way is to monitor the current (ideally real-time) condition on a moving train to ensure a highly detailed forecast.

DIGIWHEEL aims 1) to develop an automatic inspection system for the condition monitoring of railway wheels and rails and its interaction location using computer vision and 2) to validate it under laboratory condition.

The resulting DIGIWHEEL computer simulation outputs will provide essential parameters for the maintenance of tracks and vehicles (wheel-to-rail profile geometry and track geometry), and the estimation of the wheel-to-rail interaction locations will contribute to decision-making algorithms and safety prediction for autonomous trains.

Contributed researchers: German Torres Vanegas.

Contact person: Xinxin Yu.

Renovation of full-scale wheel-rail rig

The infrastructure funding is funded by TAU Investment call.

The current unfinished machine includes a frame, a full-sized wheel, and a carriage designed to hold the rail. The machine measures 3.5 meters in length, 2.5 meters in width, and 2.3 meters in height, with a weight of 7,000 kilograms. This setup moves the test rail forward and backward under a standard locomotive or freight wheel to simulate real-world track conditions. The rig can simulate various track conditions, including track irregularities and wears. It provides a repeatable environment for studying wheel-rail contact and allows for precise control of parameters and variables.

Contributed researchers: Matti Linjama, Jyrki Tammisto, Teemu Launis, Erik Snellman, Janne Airaksinen.

Contact person: Xinxin Yu.