UTC 2022 Funding - Cycle 2 Research Projects

Project No.: CY3-OSU-07
Title: Multi-Sensory System for Railway Track Defect Detection
Performing Institution: Oklahoma State University
Principal Investigator: Joshua Li, Oklahoma State University
Start and Anticipated Completion Dates: 01/01/2026 to 01/15/2027
Abstract: Railway transportation is essential for moving passengers and freight across the U.S., but accidents continue to pose serious safety and economic risks. In 2022 alone, there were about 950 rail-related fatalities and 6,400 injuries nationwide. While human error and reckless behavior are major contributors, defective track infrastructure is a significant and preventable cause of accidents. Railway tracks are complex systems consisting of steel rails, crossties, fasteners, and ballast, all subject to heavy loads, temperature fluctuations, and environmental impacts. These stresses lead to issues such as broken rails, cracked or spalled crossties, loose or missing fasteners, geometry defects, and cross-level variations. Extreme weather conditions can further cause rail buckling or fracture. Failures in these components can trigger derailments, collisions, hazardous material spills, and major service disruptions. Although manual inspections and specialized vehicles are used, many defects go undetected between inspection cycles. Traditional manual inspections, although reliable for identifying visible rail defects, are labor-intensive and limited in scalability. To improve efficiency, various nondestructive testing (NDT) technologies, such as infrared imaging, acoustic emission, ultrasonic, and electromagnetic techniques, have been used primarily for internal defects. As surface defects become more prevalent, various methods have also been developed for detecting surface-level flaws, which can be broadly categorized into three approaches: static monitoring where sensors at fixed locations provide localized coverage; inspection trolleys which integrate sensors generally in the laboratory setting; and onboard sensing systems which enable real-time detection ahead of moving trains but suffer from high cost with varying imaging quality under different weather and lighting conditions. The primary objective of this project is to develop a comprehensive but low-cost multi-sensory system for railway track defect detection. The system will integrate binocular stereovision cameras, GNSS/GPS, and IMU sensors. The scope of this project includes development of a multi-sensory system including controller and field data acquisition, development of real-time data fusion and detection algorithms, and recommendations for system deployment on railway tracks. 
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