Early High-Speed Detection of Hot Runners Using Infrared Temperature Sensors

The Risk of Overheated Bearings

Overheated bearings on train axles, known as hot runners, pose a significant risk to rail transport. Particularly in freight trains, where onboard sensors are often omitted for cost reasons, external temperature control is crucial. Mechanical defects such as leaks or insufficient hydraulic oil can cause bearings to overheat. In the worst case, a locked axle can derail a train.

The challenge is to monitor trains while they are moving. External sensors must precisely detect overheated axles to trigger alarms in time. The high speeds of passing trains and challenging environmental conditions such as dust, rain, or extreme temperatures complicate the measurement process. Additionally, temperature monitoring is particularly critical at locations such as tunnel entrances or major railway junctions, where failures must be prevented.

Moreover, in countries with aging rail infrastructure, hot runner incidents are more frequent. This issue is particularly prevalent in vast railway networks such as those in India, China, or the United States, where manual inspections would be impractical due to the sheer length of the tracks. Automated solutions are therefore required to ensure continuous and reliable monitoring of trains, regardless of environmental conditions.

To avoid disruptions and protect critical infrastructure, high-precision contactless temperature measurement using infrared technology is necessary.

Increased Safety Through Continuous Fast Touchless Temperature Monitoring

The implementation of Optris infrared technology for monitoring overheated axles significantly reduces train failures and enhances railway safety. Thanks to the fast response time of the sensors, overheated bearings can be detected in real-time, allowing corrective actions to be taken before any damage occurs.

The use of Optris pyrometers ensures consistently high measurement accuracy. Contactless measurement enables low-maintenance operation, reducing operating costs. Particularly in freight transport, where no onboard sensors are available, the Optris solution enables precise external monitoring.

Moreover, the real-time data processing capabilities of Optris infrared sensors allow railway operators to establish alarm thresholds for different environmental conditions. For example, if a temperature spike is detected before a tunnel entry, an automatic safety check can be triggered, preventing potential disasters before they occur.

As a market leader in infrared technology, Optris offers a proven and field-tested solution for high-speed train temperature measurement. No other system provides a comparable response time to the CTlaser 4ML. With its compact design and high resistance to vibration and shock, it is ideal for demanding industrial applications. The ability to operate in harsh environments without requiring frequent maintenance makes the CTlaser 4ML an excellent long-term investment for railway safety systems.

Thus, Optris provides a reliable, cost-efficient, and innovative method for early detection of hot runners, making railway operations safer and more efficient.