Analysis of the operation of an automated system for measuring the geometric parameters of suspension spring coils

The article discusses an automated system for measuring geometric parameters of suspension spring coils. Spring suspension is an important element of the carriage undercarriage, it reduces the dynamic loads on the carriage elements, ensures smooth running, including on curved sections of the track, and reduces the intensity of wear build-up in all nodes and parts of the wagons. The regulatory documentation establishes requirements for the heights of springs located in one set, since a properly formed set ensures the safe operation of rolling stock. Currently, the geometric parameters of the suspension spring coils are monitored using manual standard tools. Carrying out these measurements requires considerable time. In order to reduce the measurement time and the influence of the human factor on the measurement results, and therefore reduce the error, it is necessary to develop specialized systems that will automatically determine the geometric dimensions and form kits for installation on the car.

The purpose of the study was to analyze the operation of an automated system for measuring the geometric parameters of suspension spring coils and selecting kits in accordance with the requirements of regulatory documentation. The principle of the installation is based on the automatic photographing of the spring on a contrasting luminous background from different angles and the analysis of the resulting images by specialized algorithms. Using the technology of technical vision, the geometric parameters of the object are determined in two modes of operation: continuous control of springs and the formation of sets. The results of the system's operation in wagon repair depots for one calendar year are analyzed. It is established that the control time of one spring does not exceed 5 seconds, and the formation of a set takes no more than 3 minutes without the need to replace the springs.

1. Sirina N. F., Kolodin A. E. Functional architecture of digital model of maintenance and repair of freight cars. Transport of the Urals. 2023;(76):14–19. (In Russ.). DOI 10.20291/1815-9400-2023-1-14-19.

2. Shinkaruk A. S., Bespalko S. V. Optimization of maintenance and repair system of passenger cars. Transport Engineering. 2024;(35):64–70. (In Russ.). DOI 10.30987/2782-5957-2024-11-64-70.

3. Smolyaninov A. V., Karmatsky V. F., Volkov D. V. Analysis of organizational and structural transformations of railway car repair enterprises. Innotrans. 2022;(46):37–43. (In Russ.). DOI 10.20291/2311-164X-2022-4-37-43. EDN WOUEZO.

4. Smolyaninov A. V., Karmatsky V. F., Volkov D. V. Reforming the wagon complex: results, problems, prospects. Innotrans. 2021;(42):57–61. (In Russ.).

5. Smolyaninov A. V., Karmatsky V. F., Solomennikov A. A. Analysis of the current state, problems and prospects of car repair production in the Ural Federal District. Innotrans. 2020;(38):37–43. (In Russ.).

6. Cherepov O. V., Lapshin V. F., Zvyagina M. A. Analysis of uncoupling cars for the transportation of mineral fertilizers with an axle load of 25 ton-force for current repairs. Transport of the Urals. 2024;(80):18–23. (In Russ.). DOI 10.20291/1815-9400-2024-1-18-23. EDN GYQVMD.

7. Rozhkova E. A. Assessment and forecasting of freight car technical state. Bulletin of Bryansk State Technical University. 2021;(102):40–47. (In Russ.). DOI 10.30987/1999-8775-2021-5-40-47. EDN KDWYTC.

8. Shmoilov A. N. Improving the maintenance of wagons with the use of automated thermal control systems buks. Izvestiya Tula State University. 2022;(2):617–620. DOI 10.24412/2071-6168-2022-2-617-621. EDN SBIVAJ.

9. Nagovitsyn V. S., Buinosov A. P., Dinislamov A. R. Selection and justification of the use of helical springs for railway rolling stock. Scientific and Technical Volga Region Bulletin. 2019;(2):38–41. (In Russ.). EDN YXGCAH.

10. Gomes Vítor M. G., Lesiuk Grzegorz, Correia José, Jesus Abíli. Fatigue Crack Propagation of 51CrV4 Steels for Leaf Spring Suspensions of Railway Freight Wagons. Materials. 2024;17:1831. DOI 10.3390/ma17081831.

11. Tursunov N., Absattarov S., Abdulazizovna M. D. Enhancing the mechanical and functional characteristics of structural spring steel through the advancement of heat treatment technologies. Vibroengineering Procedia. 2025;58:327–332. https://doi.org/10.21595/vp.2025.24992.

12. Absattarov S., Yunusov S., Tursunov N. Research of the stress-strain state and durability of freight wagon trolley springs by the method of finite element modeling in ANSYS. Vibroengineering Procedia. 2025;60:664–669. DOI 10.21595/vp.2025.25532.

13. Kuleshov A., Morozov D., Pykhalov A. Analysis of impact of static and dynamic loads on the structural elements of the rolling stock. Spravochnik. Inzhenernyi Zhurnal. 2024;4:43–50. DOI 10.14489/hb.2024.04.

14. Balalaev A. N., Zhebanov A. V. Identification of spring suspension springs with parameters unacceptable for operation on a virtual test bench. Transport of the Urals. 2025;(85):29–36. (In Russ.). DOI 10.20291/1815-9400-2025- 2-29-36. EDN FMUGKL.

15. Boronenko Iu. P., Merkushev S. V. Causes of fracture of 18-100 type bogie springs in operation. Transport of the Russian Federation. 2021;(95):41–43. (In Russ.). EDN BLUTGQ.