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Modeling Switch Rail Wear Using Laser Profilometry for Predictive Maintenance
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1
Rzeszow University of Technology, Faculty of Civil and Environmental Engineering and Architecture, Al. Powstańców Warszawy 12, 35-959 Rzeszów, Poland
 
2
AGH University of Krakow, Department of Engineering Surveying and Civil Engineering, Al. Mickiewicza 30, 30-059 Kraków, Poland
 
 
Corresponding author
Jacek Paś   

Rzeszow University of Technology, Faculty of Civil and Environmental Engineering and Architecture, Al. Powstańców Warszawy 12, 35-959 Rzeszów, Poland
 
 
 
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ABSTRACT
The safe and uninterrupted operation of trains through railway turnouts depends significantly on the reliability and maintenance of track infrastructure, particularly in critical components such as switch and stock rails. This study presents the results of innovative field measurements conducted using a laser profilometer to assess vertical and lateral wear in operating turnouts subjected primarily to passenger traffic. The experiment was performed on a commonly used 60E1-500 turnout configuration under real traffic conditions, with rolling stock axle loads totaling 18 teragrams (Tg) and 27 Tg, respectively. The primary aim of the research is to develop a predictive framework for the degradation of turnout rails by correlating empirical wear measurements with specific operational parameters, such as axle load accumulation, switch geometry, and accessibility for tamping. By utilizing high-resolution cross-sectional rail profiles and examining wear distribution along the length of the curved switch rail, the study identifies areas most susceptible to premature degradation – particularly near locking devices where maintenance access is restricted. The novelty of this work lies in its integration of profilometric data into a predictive diagnostics context, which enhances the capability for proactive infrastructure maintenance and reduces dependence on manual inspections. The methodology and findings presented in this paper offer a scalable diagnostic model applicable to both conventional and high-speed rail systems, paving the way for data-driven asset management strategies across railway networks. The measured vertical wear reached up to 2.9 mm near the locking device area, while lateral wear exceeded 1.8 mm at critical cross-sections. These values confirm the location-dependent degradation and validate the measurement approach.
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