Document No. RDSO -SPN-RE-MVIS-2018 ( Rev. 1) (Draft) Date Issued : 08.06.

2020
Specification Title: Machine Vision Based Inspection System for Rolling Stock

RESEARCH DIRECTORATE
RESEARCH DESIGNS & STANDARDS ORGANIZATION
Manak Nagar, Lucknow – 226011

RDSO -SPN-RE-MVIS-2018 (Rev -1)

Machine Vision Based Inspection System

for
Rolling Stock

CONTENTS

1.0 Disclaimer

2.0 Copyright

3.0 Address for communication

4.0 Introduction

5.0 Technical requirements

6.0 Installation requirements

7.0 Functional requirements

8.0 Hardware requirements

9.0 Software requirements

10.0 Safety Requirements

11.0 Output requirement

12.0 Submission of documents

13.0 Type of tests

14.0 Training

15.0 Literature

16.0 Scope

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Document No. RDSO -SPN-RE-MVIS-2018 ( Rev. 1) (Draft) Date Issued : 08.06.2020
Specification Title: Machine Vision Based Inspection System for Rolling Stock

1.0 Disclaimer: -
This specification is based on the studies of various literatures/papers available
worldwide by RDSO. Although every care is taken in specifying details
adequately and unambiguously, RDSO shall not be liable for any kind of
damages / losses incurred by any and all due to errors or omissions in this
document.
This document may mention numerous commercial and proprietary trade names,
registered trademarks and the like (not necessarily marked as such), patents,
production and manufacturing procedures, registered designs, and designations.
RDSO wishes to point out very clearly that the present legal situation in respect
of these names or designations or trademarks must be carefully examined before
making any commercial use of the same. Names of industrially produced
apparatus and equipment may be included to a necessarily restricted extent only
and any exclusion of products not mentioned in this document does not imply
that any such exclusion has been based on quality criteria or any other qualifying
consideration.
2.0 Copyright: -
RDSO has the copyright of all its publications. No part of these publications may
be reproduced in any form without the prior permission of RDSO. Enquires
relating to the copyright should be addressed to Executive Director
(Administration), RDSO.
3.0 Address for communication: - For this specification, the address for
communications is: -
Director – Research (Mechanical),
Research Directorate,
Research Designs & Standards Organization,
Manak Nagar,
Lucknow,
Uttar Pradesh,
India,
Pin: 226 011
Fax: +91 (522) 2465746
Phone: +91 (522) 2465746, 2450179
E-mail: - [email protected]

4.0 Introduction: -
Current practice for preventive maintenance inspections of rolling stock over IR
is largely based on manual inspection which is either trackside or pit examination
of stock in stationary or slow moving condition. Visual inspections are performed
by trained manpower either in a pit or trackside location but remains dependent
on individual judgment. Besides, the stationary inspection deprives the
maintenance staff of significant information of dynamic behavior of the vehicle.

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Document No. RDSO -SPN-RE-MVIS-2018 ( Rev. 1) (Draft) Date Issued : 08.06.2020
Specification Title: Machine Vision Based Inspection System for Rolling Stock

Automated inspection by machine vision based systems has the potential to

overcome these limitations of human inspection. The systems can be placed
closer to the track or between the rails where it may be considered unsafe for a
human to be positioned when a train passes.
This specification covers requirements for design, development and supply of all-
weather Machine Vision Based Inspection System, herein after referred as
MVIS, of Rolling Stock based on trackside/ within track mounted Equipments.
The purpose of this specification is to spell out the functional and technical
requirements of a MVIS system.

Tenderer shall acquaint himself/his design team about various types of rolling
stocks operational on IR network and the types of defects required to be
detected by proposed MVIS system under this specification.

The specification is generic in nature with focus on functional requirements. The

system meeting the specified functional requirement will qualify this specification
however, since the specification is generic in nature and pertains to a technology
being introduced for the first time on Indian Railway the tendering
agency/procurement agency should define the eligibility criteria in terms of a
minimum number of system in service for specific period of time for the bidders
to qualify as capable supplier for the system.

5.0 Technical Requirements: -

5.0.1 The MVIS System for Inspection of running trains should be able to
monitor the following parameters/defects for all types of Rolling Stocks, at
train speed in the range of 5 to 100 Kmph.

A. Side view defects

i. Broken / Missing Axle Box covers
ii. Major damages in Wheel Disc
iii. Open/hanging Doors of Wagons
iv. Laterally displaced Springs/ Shock Absorbers, as applicable
v. Measurement of wheel diameter
vi. Standard Wheel Profile defects (hollow tyre, deep flange, thin flange)
vii. Brake pads/ brake block Worn or missing
viii. Broken or missing Brake beams and pull rods
ix. Broken or missing suspension springs.
x. Missing/ Damaged Springs
xi. Missing Brake Block or key
xii. Missing/ damaged hand brake wheels

B. Underframe defects:
i. Visually detectable structural integrity defects like cracks etc. of
underframe, as visible from ground below the underframe between the
tracks.
ii. Yoke pin support plate bolts missing or broken for CBC stock
iii. Damaged Centre sill or other under frame members as visible to the
human inspector’s naked eye.

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Document No. RDSO -SPN-RE-MVIS-2018 ( Rev. 1) (Draft) Date Issued : 08.06.2020
Specification Title: Machine Vision Based Inspection System for Rolling Stock

iv. Missing CBC knuckle pins

v. Missing CBC operating handles
vi. Damaged/broken Empty Load devices
vii. Missing Brake gear items
viii. Broken or Bent Brake beams
ix. Missing/damaged brake pipe hose/feed pipe hose
x. Hanging parts

C. Top view defects:

i. Deformed/Bulged side walls, uneven loading of consignment etc.
ii. Open/hanging doors of wagons

5.0.2 It should confirm to following national/international standards:

A. Degree of protection for electronics- IP66
B. Degree of protection for optics- IP 65
C. Wheel contacts- IP67
D. OEM recommended Calibration methodology of the
system/subsystem/sub-assembly shall be submitted along-with the offer.
E. It should function in either direction of movement of train.
F. Time between passing of the train and communication to the central control
server should not exceed 10 minutes.
G. The system should be capable of automatic detection of approaching train,
automatic switching-on of relevant sensors, automatic monitor the defects
while the train is in motion, automatic transmission of data, alarms and
reports and automatic switching off of relevant sensors to conserve
electrical power.
H. The system should be able to work in ambient temperature range of -10˚ to
70˚C and relative humidity up to 100%.
I. System should have character recognition feature to extract details painted
on side walls of rolling stock for use in automatic report generation. The
drawings pertaining to location of stencil of vehicle particulars on side walls
shall be provided to successful bidder.
J. Supply, installation and commissioning of Suitable illumination for round-
the-clock working of equipment shall be provided.

K. Operational capability requirements –

i. Operating speed – 5 to 100 Kmph.
ii. Train length- upto 1000 axles
iii. Typical track profile- As per IRPWM 2004 amended from time to time:
Latest correction Slip(ACS-144)
L. Reliability parameters applicable for various defects :
S.no. Parameters/Defects Tolerances
1 Broken in two pieces or missing Axle box covers  False positive
2 Hanging parts alarms should
3 Major Damages in Wheel Discs not be more

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Document No. RDSO -SPN-RE-MVIS-2018 ( Rev. 1) (Draft) Date Issued : 08.06.2020
Specification Title: Machine Vision Based Inspection System for Rolling Stock

4 Open/hanging Doors of Wagons than 10%.

5 Laterally displaced Springs/ Shock Absorbers  False negative
6 Brake Pad missing alarms should
7 Broken or missing Brake beams and pull rods not be more
than 5%
8 Broken or missing suspension springs, in the visible range
 Reporting
should match
9 Structural integrity of underframe, as seen from bottom the seeded test
area between the track condition
10 Yoke pin support plate bolts missing or broken for CBC
stock
11 Damage in Wagons

M. Regulation and norms applicable-

i. EMVA 1288
ii. EN 55011:98 + A 1:99 + A2:02: class B
iii. EMV550121-4:00(immunity test)
iv. 73/23/CE, 93/68/CE
v. EC Directive 2006/860/CE
vi. EN55022:98 class A
vii. EN55024:98
viii. EN61000-6-4:01
ix. EN61000-4-2:2009
x. EN61000-4-3:2006 +A1:2008+A2:2010
xi. EN61000-4-4:2004 +A1:2010
xii. EN 301489-1
xiii. EN 55011-2-3:2017
xiv. EN 55022:2010
xv. EN 55024 :2010+A1:2015
xvi. EN 55032
xvii. IEC 61000-6-4:2018
xviii. IEC 61643-12,61312, 61214 & VDE 0100-534
xix. EN 50125-1:2014

N. The system design shall relate and comply with the above mentioned
standards. (In case of any contradiction, the strictest standard shall
apply). In addition to above, any other national/international standard
which is relevant to the technology for similar application in the railway
domain will also have to be complied with.
O. The system should be modular, with self-diagnostic features. The
system should be designed for compatibility with all important Railway
Standards, some of which have been mentioned in this document above.
P. The MVIS is expected to run in 24x7 mission critical modes (available
around the clock) without any human intervention. The system should be
programmed for self-checks periodically .This self-test must test all vital
elements. The result of self-tests shall be indicated on central server.
Q. The system should be equipped with robust, networked, alert-
management software with full suite of graphical analysis and diagnostic
tools. Full TCP/IP support should be inbuilt into the system to facilitate
smooth integration into all existing railway data networks.

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Document No. RDSO -SPN-RE-MVIS-2018 ( Rev. 1) (Draft) Date Issued : 08.06.2020
Specification Title: Machine Vision Based Inspection System for Rolling Stock

6.0 Installation requirements: -

i. The MVIS system shall not infringe the IRSOD and shall be installed in
consultation with authorised Railway Engineer. The tenderer must submit the
installation drawings of equipments for scrutiny and approval by the
purchaser. Installation clearance for specific sites shall be provided for
individual sites by the respective DRM-Mechanical based on the equipment
drawings and other documents submitted by the tenderer, as required by
DRM-Mechanical.
ii. The MVIS systems shall be installed such that they do not either require or
cause stoppage of train traffic when they are functioning/not functioning/under
breakdown/under maintenance.
iii. AC voltage range 110V to 230V, 50 +/-3Hz. shall be made available at
installation site by Railway. The maximum load on the power supply system
shall be indicated in the offer.

7.0 Functional requirements: -

i. The system should be able to detect and report all parameters/defects as
mentioned in Para 5.0.1.
ii. System shall log the date of train passing, time of train passing, speed of
train, number of axles passed, total number of vehicles in the rake.
iii. System shall be designed for a headway (time between two consecutive
trains pass) of 3 minutes.

8.0 Hardware requirements: -

i. In case the cameras are mounted on the rail or tie/sleeper or specially
designed sleeper by tenderer, the technical details and drawing(s) of such
sleeper shall be submitted along-with the offer.
ii. System will be equipped with UPS for graceful shutdown of equipment in case
of power failure. System should have feature of self-start/boot on resumption
of power supply.
iii. The MVIS system shall have provision for integration with RFID reader likely
to be installed by IR in future for automatic identification of vehicles. The
location of RFID tags on rolling stock shall be provided to successful bidder.
iv. System should have capability to integrate with 3rd party system for which
Interface control document (ICD) will be provided by Indian railways. Firm will
supply the ICD for the MVIS to the Indian railways.

9.0 Software requirements: -

i. The trackside equipment shall have the capability to record and locally store
raw captured data/images for last upto 500 trains and the processed reports
for upto 10000 trains.
ii. The supplier shall be responsible for providing required software for collecting
data, storage and presentation of reports sent by the trackside equipment.
iii. The system should have self-learning capability to improve its performance as
it acquires different types of defects passing over it during warranty period of
the system.
iv. The system should have inbuilt standard library of rolling stock defects being
used worldwide such as bogie defects, under-frame defects, wheel defect and
brake gear defects. However, standard component templates applicable to IR

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Document No. RDSO -SPN-RE-MVIS-2018 ( Rev. 1) (Draft) Date Issued : 08.06.2020
Specification Title: Machine Vision Based Inspection System for Rolling Stock

shall be provided to successful bidder. It is the responsibility of the bidder to

acquaint himself with the components/assemblies of rolling stocks and various
defects available in Railway yards/workshops/depots/sheds etc, before
offering the system.
10.0 Safety Requirements: -
The equipment shall not fail on wrong side due to harmonic interference
generated by 3 phase thyristor, single phase thyristor, chopper controlled, tap
changer or other such technologies, locomotives and 25 KV Single Phase
OHE Supply.
11.0 Output requirement: -
i. The supplier shall launch, operate and maintain an internet-based website
during warranty and during comprehensive maintenance period for making
available the train reports.
ii. The website shall have the following features: -
a) Password based access so that only authorized personnel by DRM-
Mechanical can enter/edit/view/download data and reports
b) Differential privileges to different levels of users to access the resources
of the website
iii. The supplier shall supply a desktop computer at nominated place by DRM-
Mechanical of the configuration as specified in the clause on concomitant
accessories.
iv. The system output shall consist of data reports. Data acquired by the system
shall be sent to a web server and the following reports shall be available to the
users on demand.
v. Detailed report: - This report shall be in detail showing all parameters as
acquired by the remote wayside detector.
vi. The Software should produce a train consist list, comprising train arrival &
departure times, number of axles, axle spacing, axle speed, vehicle type,
number & image number for each vehicle.
vii. The system shall generate alarms based on the interpretation of the data. It
should give exception report. It should be possible to individually set preset
value for different type of alarms at each site from Central Control. It is the
responsibility of the bidder to acquaint himself with various types of defects
on Indian Railway’s rolling stocks listed in this specification. Allowable
limits/range (Pass/Fail criteria) for defects diagnostics, wherever applicable,
shall be communicated to successful bidder.
viii. Bidder shall submit the sample templates of dashboard report for each type of
defects mentioned in this specification, as generated by the proposed system
elsewhere worldwide alongwith offer. Reports/ messages shall convey the
following minimum data:
a) Date / time of train
b) Direction of movement
c) Vehicle position from start of train
d) Rolling Stock Number, (if legible/recognizable by the system), in
which the parameters were found out of range.
e) Short description / error code (should be easily understandable

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Document No. RDSO -SPN-RE-MVIS-2018 ( Rev. 1) (Draft) Date Issued : 08.06.2020
Specification Title: Machine Vision Based Inspection System for Rolling Stock

without need of referring to a table)

f) The image of defective portion in the rolling stock shall be uploaded
on web report.
ix. In case, IR decides to include new types of alarms in the system, then
supplier shall modify the software within a reasonable time at no extra cost to
Indian Railways during AMC/ Warranty.
x. Where required by special site conditions, OFC / Copper cable / RF-Link
connectivity shall be provided by the system provider for transfer of data.
xi. The backend server systems shall be maintained and operated by the system
provider. These servers shall be capable of storing and displaying (upon
demand) parameter reports for up to last 5 years.
xii. The access to these reports shall be provided by web based clients suitable
for use from desktops / laptops / netbooks and smart phones. Users of the
systems shall be provided logins / passwords for accessing the data.

12.0 Submission of documents:

(i) Test certificates: Test records, test certificates, performance curves, tables,
etc., of all inspections and tests, whether or not witnessed by IR personal ,
shall be supplied as soon as practicable after performance of each inspection
or tests. Two (02) sets of above mentioned documents shall be supplied
properly bound in books.
(ii) All test certificates shall be endorsed with sufficient information for
identification of the equipment and, material to which the certificates refer.

13.0 Type of Tests:

Inspection and testing of the equipment shall include all inspections, tests,
checks, procedures etc., whether mechanical, electrical or software related as
required to ensure that the equipment supplied meets the requirements of the
specification. Inspection and testing shall comprise, but not limited to :
a. Acceptance tests:
 Factory Acceptance Test (FAT): All sub- systems/assemblies shall
be demonstrated for satisfactory working of sub systems & assemblies.
Calibration of systems/sub-assemblies (wherever applicable) shall also be
demonstrated by firm. Successful capture of data/analysis by software by
input of a simulated data file (wherever possible) shall be demonstrated at
firm’s premises before supply of equipment. The detailed test plan for FAT
shall be finalized by successful bidder in consultation with RDSO.
b. Proving-out test requirement: -
The supplier and the DRM-Mechanical shall conduct the following proving out
tests after commissioning: -
i. Consistency test: - Detailed Test scheme for consistency test shall be
prepared by RDSO in consultation with successful bidder. This test is
intended to establish the following performance parameters:
(i) To examine and ensure the capability of equipment for faithful capture
of details like direction of motion, type of rolling stock(wagon/LHB
coach/ICF coach/Locomotive), date and time of passing, speed of train,
no. of axles, no of locomotives, no of vehicles other than locomotives

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Document No. RDSO -SPN-RE-MVIS-2018 ( Rev. 1) (Draft) Date Issued : 08.06.2020
Specification Title: Machine Vision Based Inspection System for Rolling Stock

under repeated running of test train/commercial train without any miss

(100%).
(ii) Few fault-seeded rolling stocks (faults selected from list in para 5.0.1)
shall be passed through the system. The system should be able to
demonstrate the reliability of fault detection as indicated in para
5.0.2(L).
ii. Calibration test: - As per OEM recommended procedure shall be
demonstrated at site after commissioning of equipment with all subsystem
operational.

14.0 Training: -
The tender should submit its training plan along with the offer. The training to be
imparted shall cover operation, troubleshooting, maintenance of all optical,
mechanical, electrical & electronic components and software applicable.
Tendering/procurement agency should define the training schedule.

15.0 Literature: -
The supplier shall provide following literature in two copies to DRM-Mechanical
along with the delivery of MVIS system.
i. Complete drawings
ii. Operating manual
iii. Maintenance manual
iv. Spare part catalogue
The tenderers shall provide a list of literature to be supplied with the machine in
his offer to the tender.

16.0 Scope: - The MVIS system shall be supplied on turnkey basis. The MVIS
system shall mean and include all equipment by the side of the track, cables –
electric, server computer, website, client computer, software of the track-side
equipment and software of the central server and any other element necessary
for optimal functioning of the system. The scope shall include
i. Supply: - Supply of
a) MVIS site equipment
b) Concomitant accessories
c) Spares
d) Maintenance tool kit
e) Literature
f) Material, as required for civil engineering work
g) Power cables, as suitable to the trackside equipment
h) Modem/communication equipment’s, as suitable to the trackside
equipment
ii. Installation at site: - Installation of the system would be done by and under
the supervision/direction of firm’s Engineers. It shall include the following: -
a) Civil engineering and other allied works (if required) such as construction
of hut of suitable size to house UPS, batteries, electronic and electrical
equipment, solar power system etc.; grouting supports for steel
enclosures/equipments, control box, battery box etc., necessary work
e.g. trench etc. for power cables for a maximum distance of three km. In
case the offered system requires track crossing or sleeper replacement,

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Document No. RDSO -SPN-RE-MVIS-2018 ( Rev. 1) (Draft) Date Issued : 08.06.2020
Specification Title: Machine Vision Based Inspection System for Rolling Stock

the offer shall be evaluated by Research Directorate of RDSO in

consultation with Track Directorate of RDSO and necessary approvals
shall be organized. Therefore the supplier shall provide the required
technical details in the offer.
b) Electrical engineering: laying of power cables for a maximum distance
of three km from the site to the main power distribution box where the
DRM-Mechanical has made the availability of electrical power of 230 V
50 Hz.
c) Provision of mobile connection and internet connection for transfer of
data and display of reports and audio-visual alarms from site of
installation to centralized location (as finalized by DRM-Mechanical of
concerned Division of Indian Railways). The recurring expenditure on
mobile connectivity for first one year from the date of commissioning
shall be borne by the supplier. Subsequent expenditure shall be borne
by Indian Railways for which the necessary arrangements have to be
done in advance by DRM-Mechanical.
iii. Web-server – The supplier shall launch and maintain an internet web –
server at any location with following features-
a) A comprehensive web-based software to access all system data and
images
b) A web based virtual train inspection portal to review all system images
and perform a virtual train inspection, when needed.
c) Multiple User password protected log-in
d) Differential access and usage rights to multiple level of users e.g. write-
only, read-only, administrator rights
e) Facility to export data in other data base formats e.g. MS-Excel and
XML.
f) The supplier shall offer at least two designs for web-user interface for
selection.
g) Sufficient capacity to handle data traffic with fast data transfer rate for
all authorized users (to be controlled by providing username and
password) who shall access though public internet access.
iv. Ownership and confidentiality of data and software: - All the data being
generated by the MVIS equipment, website, servers etc. with respect to
Indian Railway operations shall be the property of Indian Railways and shall
not be shared with 3rd party without explicit written consent of Indian
Railways.
i. The data shall be compiled, stored in a medium, transferred and made
available in a format as finally decided by Indian Railways in consultation
with final supplier preferably in MS-Excel at present but other formats
may be accepted later by Indian Railways if found suitable.
ii. The data shall not be divulged by the supplier to anyone other than
DRM-Mechanical and to those authorized by DRM-Mechanical.

v. Apart from the details mentioned in this documents, any other

accessory/component/system(s) essentially required for proper functionality
of the MVIS system, will fall under the scope of supply of the tenderer.

*****

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