On Rotor Sensing (ORS) for Improved Rolling Stock Reliability, Efficiency and Performance.

The project between Digital Transit Limited (DTL) and the University of Huddersfield (UoH) aims to use On-Rotor Sensing (ORS) technology to improve safety, reliability, and efficiency in rail freight. ORS is a self-powered, wireless sensor that attaches directly to the axles of freight wagons, capturing crucial data on their condition, efficiency, and performance.

Unlike traditional monitoring, which relies on stationary sensors near the axle, ORS measures vibrations directly at the axle source, giving more accurate and detailed data. This data helps detect issues like worn bearings, wheel flats, brake failures, and hot axle boxes, which are common causes of freight train derailments and other costly incidents.

DTL and UoH have spent over ten years developing this ORS technology, which uses tiny, self-powered sensors that wirelessly send data via Bluetooth or Wi-Fi. Weighing just 250 grams, ORS units can be easily attached to each wagon axle cap, enabling continuous monitoring without the need for external power. This approach is much more efficient than conventional methods, which often depend on trackside sensors and need frequent maintenance.

The ORS system is already proving its value through testing, showing a clear improvement in detecting and diagnosing potential faults before they become serious. ORS technology makes it possible to monitor axle and bearing conditions in real-time, reducing derailment risks and improving wagon reliability.

This project aligns with the Freight Innovation Fund’s goals by helping to make rail freight operations safer, more efficient, and more environmentally friendly. ORS technology not only supports predictive maintenance and optimises freight journeys but also enables better use of available capacity, reducing waste and supporting sustainability goals.