Railway Brake Systems Failure

Abstract

Railway braking systems are essential elements of the train infrastructure that provide the secure and effective operation of the railway network. However, these systems’ failures can have serious repercussions, including accidents, service interruptions, and sometimes even fatalities. With an emphasis on the causes, detection techniques, mitigation tactics, and recent technological developments in this area, this literature review attempts to study and evaluate the knowledge already available on railway brake system failure (Zang et al., 2019). This assessment’s results will help us better comprehend the difficulties caused by braking system failures and offer insightful recommendations for enhancing safety and dependability in railway operations.

Introduction

Zhou and Lei (2020) found that the safe and effective acceleration and stopping of trains is made possible by railway brake systems, which are essential parts of train operation. Serious repercussions, including accidents and derailments, as well as delays and disturbances in the transportation network, can result from the breakdown of these systems. Therefore, it is crucial to comprehend the reasons behind and effects of railway brake system failures to ensure railroad operations’ security and dependability.

Numerous studies have been done throughout the years to look into the failures of railway brake systems from different angles (Dindar et al., 2020). This study of the literature integrates and assesses the amount of information already available on this subject, offering a thorough overview of the causes, effects, and mitigation measures associated with failures of railway brake systems. This review explores common themes, knowledge gaps, and future directions for more studies by analyzing earlier studies’ findings.

Zang et al. (2019) studied numerous academic fields, including mechanical dynamics, engineering, human factors, materials science, and maintenance procedures. They concluded that they are involved in researching railway brake system failures. Researchers have attempted to investigate the intricate interplay between these parameters and their impact on braking system performance by using a multidisciplinary approach. It is feasible to create efficient tactics for reducing brake failures and improving the general safety of railway operations by recognizing these interdependencies.

Several causes of railway brake system failures include mechanical issues, material deterioration, operating mistakes, environmental issues, and insufficient maintenance procedures. Ekberg (2009) found that material deterioration can be brought on by wear, corrosion, or heat stress, while mechanical breakdowns may involve problems with brake shoes, pads, or discs. Brake system failures can also be attributed to operational mistakes, such as using inappropriate braking tactics or failing to recognize and act upon warning indicators. Additionally, braking systems may experience failure due to external reasons like severe weather or uneven track surfaces that place much strain on them.

Chen (2013) conducted a study which concluded that railway brake system failures can have far-reaching effects on various stakeholders. Brake failures can cause collisions, injuries, and fatalities for passengers and crew. Furthermore, cancellations and delays due to braking system failures can cause railway businesses to suffer significant financial losses since they have an adverse effect on scheduling, freight transportation, and overall operating effectiveness. In order to put into practice effective preventative measures and create successful backup plans, it is necessary to comprehend the effects of braking system failures.

Researchers and professionals, such as Ekberg (2009), have investigated several techniques to reduce the hazards related to breakdowns of railway brake systems. These include strengthening maintenance methods, applying advanced monitoring and diagnostic techniques, and streamlining operating processes. Brake system designs are also being improved. Additionally, materials science and technology improvements allow one to create cutting-edge braking systems with improved performance and dependability under various operating situations.

As a result, railway brake system failures pose severe threats to railroad operations’ dependability, efficiency, and safety. This literature review aims to thoroughly examine the body of information on this subject, illuminating the factors contributing to braking system failures and their effects and methods for mitigating them (Appoh et al., 2021). This review adds to a better understanding of the complex aspects impacting brake system performance by combining the findings from earlier studies. It also guides future research projects to enhance the dependability and safety of railway brake systems.

Common Failure Modes of Railway Brake System Failures

Numerous typical forms and modes of railway brake system failures have been documented in the literature. The braking system’s many parts and subsystems are susceptible to these problems (Hartong et al., 2011). The following list includes some often noted kinds and modes of failures of railway braking systems:

1. Brake Pad Wear. Brake pad wear occurs on a variety of occasions throughout the world. One frequent sort of failure mentioned in the literature is brake pad wear. Longer stopping distances and decreased braking efficacy result from brake pads undergoing excessive wear. Numerous occurrences that resulted in slower braking reactions, higher collision risks, and longer braking distances have been linked to brake pad deterioration.
2. Brake Disc Overheating. Leite et al. (2022) conducted a study which concluded that instances of brake disc overheating often occur all over the world. Inefficient braking is caused by brake discs being exposed to too much heat and may deform, break, or fail. The brake discs can become extremely hot when strong braking is used for an extended period. This failure mode has been seen in certain situations. The results are reduced braking capability, more wear on other brake parts, and possibly failing brake systems.
3. Brake Cylinder Leak. Brake cylinder leaks have occurred on numerous occasions all around the world. Hydraulic or pneumatic brake fluid leakage from brake cylinders can cause brakes to lose all power or only have a partial effect. There have been reports done by Hartong et al. (2011) about brake cylinder leaks, which can impair stopping distances, increase accident risk, and degrade braking effectiveness.
4. Emergency brake failures. Emergency brake failures have been involved in several events globally. For instance, a passenger train operated by Amtrak derailed in Philadelphia, Pennsylvania, resulting in many casualties and injuries. Bhattacharya et al. (2019) confirm that the emergency braking system malfunctioned while the train approached a high-speed bend. Another object hit the locomotive due to the failure, ascribed to a track obstacle that rendered the brake hose inoperable and prevented the use of the brakes.
5. Air brake system failures. Air brake system failures occur regularly all around the world. For instance, in the Runaway Train occurrence, a crude oil-carrying uncrewed train in Lac-Mégantic, Quebec, crashed and detonated. Chen (2013) confirms that the train’s air brakes were not used correctly, which caused them to lose some stopping power. An insufficient number of handbrakes applied and a technical problem with the locomotive caused the air brakes to disengage, which led to the failure gradually. Another contributing cause was an inadequate number of handbrakes applied. There were several fatalities and considerable environmental harm as a result of this catastrophic brake failure.

These instances highlight the causes and effects of railway braking system failures in actual situations. Since these failures frequently include various elements, including mechanical, operational, maintenance, and environmental concerns, it is crucial to carry out thorough investigations to identify the underlying reasons (Leite et al., 2022). Researchers and business experts may draw lessons from these disasters and put them into practice to prevent such errors in the future.

Failure Causes and Mechanisms of Railway Brake System Failures

Railway brake systems failures can be ascribed to several things, including wear and tear, material degradation, design faults, manufacturing errors, inappropriate maintenance procedures, ambient conditions, and human factors. Here is a review of these elements that is based on the literature:

1. Improper Maintenance Practices

Apple et al. (2021) concluded that poor maintenance procedures could significantly impact the braking system’s effectiveness. Brake system failures can be caused by periodic inspections, insufficient lubrication, disregard for warning indicators, or neglect to replace old components. Routine neglected maintenance chores can accelerate wear and degradation and raise the probability of breakdowns.

2. Design Flaws and Manufacturing Defects:

Ming-yan, Wang, and Liu (2014) conducted a study which concluded that design errors or manufacturing problems may cause brake system failures. For example, improper component sizing or location might result in subpar braking performance or early failure. The dependability and safety of the brake system might also be jeopardized by manufacturing flaws, including inconsistent material quality, machining faults, or poor assembly.

3. Material Degradation:

Factors which include thermal stress, fatigue, and corrosion can all contribute to material deterioration. Ekberg (2009) mentions that brake parts weakened by corrosion may perform poorly and have less structural integrity. Repeated loading and unloading cycles can lead to fatigue failure, which eventually fractures and cracks the materials. The tremendous heat produced while braking can cause warping, distortion, and even failure in brake discs and drums. Therefore, thermal stress is significant in this situation.

4. Wear and Tear:

Brake system failures can result from wear and tear. As a result of the constant friction created by the brake, shoes, discs, braking, pads, and drums gradually deteriorate. According to Telawi (2014), longer stopping distances and higher accident risks might result from excessive wear, which reduces the efficacy of the braking system.

5. Environmental Conditions and Human Factors:

Zhou and Lei (2020) discussed that the performance of braking systems could be impacted by environmental factors such as severe temperatures, relative humidity, pollutants, and irregular track surfaces. The efficiency of braking might be hampered by adverse weather conditions such as heavy rain, snow, or heat. The braking procedure can be made much more difficult by contaminants on the track, such as oil, debris, or ice. On the other hand, brake system failures can be caused by human factors such as operator mistakes, insufficient training, and inappropriate braking tactics (Dindar et al., 2020). Increased wear, inefficiencies, and probable breakdowns can result from improper or inappropriate braking, overlooking warning indications, or having insufficient knowledge of the braking system.

These elements have been examined separately or in combination in studies published to determine how they affect railway brake system failures. Researchers want to create strategies for enhanced braking system design, operator training, maintenance practices, and monitoring methods by looking at these failures’ underlying mechanics and primary causes (Günay et al., 2020). Understanding these elements makes it possible to create durable braking systems that can resist the demands of operating environments and improve the security and effectiveness of railway operations.

Impacts and Consequences of Railway Brake System Failures

Railway brake system failures can significantly influence and have severe repercussions for many different parts of railroad operations. The literature offers information about the possible dangers, safety implications, operational disruptions, maintenance costs, and downtime related to these failures. Based on the research that is accessible, the following review of these impacts and consequences is provided:

1. Operational Disruptions

Dinmohammadi et al. (2016) state that brake system failures can severely disrupt railway operations. Trains that experience brake difficulties may require to be taken out of service for maintenance or inspection, which might cause cancellations, delays, and rescheduling of services. Operational hiccups can impact passenger travel plans, create congestion on the train network, and lead to financial losses for railroad firms.

2. Passenger Safety

PasseMalfunctions in railway brake systems directly threaten passenger safety per Dong (2010); trains may have longer stopping distances or fail to stop entirely in the instance of a brake failure, which raises the possibility of derailments, collisions, and accidents. Railway brake system failures can cause harm to passengers and crew members, as well as fatalities.

3. Maintenance Costs

Brake system failures cost railroad operators more money to maintain. As per Zoeteman (2001), braking systems and components must be repaired, replaced, and inspected to ensure safe operation. Replace pads, brake discs, or cylinders that are worn out can be expensive, particularly if failures happen frequently.

4. Downtime

Downtime can result from brake system malfunctions since trains must be taken out of service for maintenance and inspection (Tian et al., 2020). Downtime reduces trains’ availability and dependability, the railway system’s overall effectiveness, and delays in transportation services.

5. Potential risks

An, Lin, and Stirling (2006) found that railway operations may be exposed to risks and dangers when brake systems fail. Trains may need help regulating their speed, keeping safe distances, or reacting to emergencies when their brakes are not working. The infrastructure and train stock may sustain damage due to accidents, derailments, and other threats.

6. Reliability of trains

Brake system problems might harm the dependability of trains’ capacity to run safely and lose credibility if brake failures happen regularly among passengers and operators. Dinmohammadi and colleagues (2016) conducted a study which concluded that reliability problems could result in fewer passengers, a bad image among the general public, and lost business for the railroad.

7. Overall Railway System Performance

Brake system faults might negatively impact the performance of the whole railway system. The punctuality of other trains using the same network might be impacted by delays brought on by brake problems. Disruptions at the system level can affect logistics, intermodal connections, and the movement of commodities, which lowers efficiency and productivity.

These consequences and implications have been studied in the literature to highlight how crucial it is to handle brake system failures to protect passenger safety, preserve operational effectiveness, and reduce financial losses. Understanding how to brake problems affect the functioning of the entire railway system allows railway operators to prioritize preventative maintenance, implement efficient monitoring systems, and create emergency preparedness strategies.

Mitigation Strategies

Numerous best practices and mitigation measures are provided in the literature to avoid or reduce railway brake system failures. These tactics include various topics, such as condition monitoring techniques, maintenance methods, problem detection, component reliability increases, preventive maintenance, and system design improvements. Some of the often suggested mitigating tactics are outlined below:

1. Condition Monitoring

Sangiorgio, Mangini, and Precchiazzi (2020) confirm that techniques for condition monitoring are essential for spotting early indications of braking system deterioration. Identifying abnormalities or departures from typical operating conditions is made possible by monitoring techniques, including temperature monitoring, wear detection, vibration analysis, and non-destructive testing. The danger of failure is decreased by prompt maintenance actions made possible by continuous monitoring.

2. Diagnostics of Faults and Predictive Maintenance

Improved braking system dependability may result from integrating problem diagnosis systems and preventative maintenance strategies. In these methods, braking system performance characteristics are tracked and analyzed using sensors, data analysis techniques, and machine learning (Sangiorgio et al., 2020). Preventative maintenance can be planned by anticipating probable defects and estimating the remaining usable life of brake components.

3. Component Reliability Improvements

According to Appoh & Yunusa-Kaltungo (2022), brake system components may be more dependable and long-lasting. This strategy entails the study and development of new materials in order to improve the corrosion resistance of brake pads, shoes, discs, and drums, thermal stability and wear resistance. Reduced incidence of flaws and failures in braking system components can also be achieved by optimizing the design and manufacturing processes.

4. System Design Enhancements

Ishida (2013) conducted a study which concluded that reliability and performance could be increased by improving the overall braking system design. In order to do this, the brake component layout and configuration must be optimized. Additionally, installation and alignment must be done correctly, and cooling and thermal dissipation must be considered. Backup options can be offered if the primary braking system fails, thanks to system-level designs that include redundancy and fail-safe features.

5. Preventive and proactive maintenance

It is essential to undertake routine and organized maintenance to ensure components undergo routine inspections, cleaning, lubrication, and adjustment to guarantee their best operation and avoid braking system failures. Maintaining equipment enables prompt repairs or replacements by allowing for the early identification of possible problems before they develop into failures.

6. Human Factors and Training

Appropriate education and training for maintenance staff and train operators are required to maintain proper braking system operation and maintenance (Appoh & Yunusa-Kaltungo, 2022). The need to follow maintenance schedules, braking tactics, early warning indicators, emergency procedures, and emergency training should be stressed. Organizations can emphasize the importance of human factors and foster a safety culture to help stop brake system failures brought on by human mistakes.

7. Constant Development and Lessons Learned

The importance of a culture of ongoing development and failure-based learning cannot be overstated. Comprehensive examinations of braking system failures and dissemination of the industry’s lessons learned can aid in locating the core causes, creating preventative strategies, and putting best practices into action to reduce such failures in the future.

Railway operators may increase their brake systems’ dependability, safety, and efficiency using these mitigation methods and best practices (Ishida, 2013). Brake system failures and their effects on railway operations may drastically decrease by integrating new technology, ongoing monitoring, and preventative maintenance.

Knowledge Gaps

Several gaps and areas must be thoroughly addressed, even though the available literature offers insightful information about railway brake system failures (Tian et al., 2020). The need for more study and investigation is highlighted by these gaps. Some of the following areas demand further research:

1. The effect of new materials

Weight reduction, enhanced performance, and increased durability are possible advantages of using novel materials in braking system components, such as composite materials. More study is required to fully comprehend these materials’ long-term implications on braking system dependability, mainly their resilience to wear, fatigue, and external causes like corrosion.

2. Recent Developments in Condition Monitoring and Diagnostics

There is a need for more studies on improved monitoring and diagnostic approaches, even though condition-monitoring strategies have been discussed in the literature. For real-time monitoring, problem diagnosis, and preventative maintenance of braking systems this comprises designing and creating innovative sensors, machine learning approaches, and data analytics algorithms (Leite et al., 2022). Enhancing the precision, effectiveness, and dependability of condition monitoring systems can be the subject of research.

3. Considering human factors

Brake system dependability and safety are significantly impacted by human variables. The effect of workload, operator training, situational awareness, and decision-making on braking system failures needs to be better understood via further study. Investigating how corporate culture, training initiatives, and human error impact braking system dependability is part of this; therefore, developing tactics to reduce failures people cause is essential.

4. New Technologies for Brake Systems

Exploring new brake system technologies and their possible effects on dependability and safety is necessary as technology develops further. This area covers electronic control systems, regenerative braking systems, and electromagnetic brakes.

Findings

The literature on brake system failures in railways offers insightful information on the factors contributing to them and their causes, impacts, and mitigation tactics. These results emphasize the need to resolve braking system failures through an all-encompassing strategy incorporating maintenance procedures, condition monitoring, increased component dependability, improved system design, human factors considerations, and continual learning (Appoh & Yunusa-Kaltungo, 2022). Railway operators may improve their brake systems’ safety, dependability, and performance by implementing these mitigation techniques. These findings will eventually ensure passenger safety and the effectiveness of railroad operations.

The Problem of Railway Brake Systems in Canada

Several challenges can be encountered in railway brake systems in Canada, similar to those found in other railway networks worldwide. Some potential problems specific to Canada’s railway systems may include the following:

1. Harsh Winter Conditions: Canada experiences harsh winter weather in many regions, including heavy snowfall, low temperatures, and ice formation. These conditions can pose challenges for railway brake systems, leading to issues such as reduced friction, ice buildup on braking surfaces, or freezing of pneumatic components.
2. Environmental Factors: Canada’s diverse geography and climate can present unique challenges for railway brake systems (Dinmohammadi et al., 2016). Factors such as high humidity, coastal regions, or areas with significant temperature variations can affect the performance and durability of brake components.
3. Maintenance and Inspection: Adequate and regular inspections are essential for properly functioning railway brake systems. Ensuring consistent inspection schedules, appropriate cleaning, lubrication, and adjustment of brake components can help identify and address potential problems before they cause significant issues.
4. Heavy Freight Traffic: Canada has an extensive rail network, which carries substantial freight traffic, including bulk commodities like minerals, grains, and oil. The heavy loads and demanding operating conditions can place increased stress on the brake systems, requiring effective maintenance and monitoring to ensure safe and reliable operations.
5. Regulatory Compliance: Railway brake systems in Canada must meet specific regulatory standards and safety requirements set by Transport Canada (Chen, 2013). Compliance with these regulations is crucial to ensure the safe operation of trains and the prevention of accidents related to braking issues.

It is important to note that these are general potential challenges, and the specific problems faced by railway brake systems in Canada can vary based on factors such as the region, types of trains, operating conditions, and maintenance practices. Detailed information from railway authorities, industry reports, or news sources would provide more specific and up-to-date insights into the current problems facing railway brake systems in Canada.

Conclusion

In conclusion, the research on railway braking system failures provides insightful information on the causes, consequences, and mitigation tactics related to these failures. It draws attention to the complex nature of braking system failures, which can be caused by a variety of variables, including material deterioration, wear and tear, design faults, manufacturing problems, inappropriate maintenance procedures, environmental influences, and human factors (An, Lin, & Stirling, 2006). Brake system failures have severe consequences for safety, affecting passenger security and raising the possibility of collisions, accidents, and derailments. They also cause operational hiccups, higher maintenance costs, downtime, and other dangers to the infrastructure and rolling stock.

The literature offers a variety of best-recommended procedures and mitigation techniques to address these issues. They comprise proactive and preventive maintenance strategies, condition monitoring methods, fault diagnosis, component reliability upgrades, predictive maintenance, human factors considerations, and system design improvements. Railway operators may increase their braking systems’ dependability, safety, and efficiency (Hartong et al., 2011). Nevertheless, the literature still has specific gaps that call for more study. Some of these are investigating new braking system technologies, evaluating the effects of novel materials, enhancing condition monitoring and diagnostics, and considering human aspects when determining brake system dependability. A more robust brake system and improved safety measures will be developed due to continued study in these areas.

The literature on railway brake system failures is invaluable for learning about the origins, consequences, and mitigation techniques linked to these failures (Sangiorgio et al., 2020). It serves as a starting point for more investigation. It guides the creation of preventative measures, maintenance procedures, and technical developments meant to reduce the likelihood of braking system failures and guarantee the security and effectiveness of railway operations.

References

An, M., Lin, W., & Stirling, A. (2006). Fuzzy-reasoning-based approach to qualitative railway risk assessment. Proceedings of the Institution of Mechanical Engineers, Part F: Journal of Rail and rapid transit, 220(2), 153-167.

Appoh, F., & Yunusa-Kaltungo, A. (2022). A dynamic hybrid model for comprehensive risk assessment: a case study of train derailment due to coupler failure. IEEE Access, 10, pp.24587-24600.

Appoh, F., Yunusa-Kaltungo, A. & Sinha, J.K. (2021). Hybrid adaptive model to optimize components replacement strategy: A case study of railway brake blocks failure analysis. Engineering Failure Analysis, 127, 105539.

Bhattacharya, A. K., Fenerty, S., Awan, O. A., Ling, S., Jonnalagadda, P., Cohen, G., … & Ali, S. (2019). The 2015 Amtrak Philadelphia train derailment: an after-action review of the emergency radiology response at Temple University Health System. Journal of the American College of Radiology, 16(3), 370–379.

Chen, D. (2013, April). Analysis of Brake Failure and Runaway Accidents in Mountain Terrain in Canada. In ASME/IEEE Joint Rail Conference (Vol. 55300, p. V001T06A001). American Society of Mechanical Engineers.

Dindar, S., Kaewunruen, S., & An, M. (2020). Bayesian network-based human error reliability assessment of derailments. Reliability Engineering & System Safety, 197, 106825.

Dinmohammadi, F., Alkali, B., Shafiee, M., Bérenguer, C., & Labib, A. (2016). Risk evaluation of railway rolling stock failures using FMECA technique: a case study of the passenger door system. Urban Rail Transit, 2, 128-145.

Dong, H., Ning, B., Cai, B., & Hou, Z. (2010). Automatic train control system development and simulation for high-speed railways. IEEE Circuits and Systems Magazine, 10(2), 6-18.

Ekberg, A. (2009). Fatigue of railway wheels. In Wheel–rail interface handbook (pp. 211–244). Woodhead Publishing.

Günay, M., Korkmaz, M. E., & Özmen, R. (2020). An investigation on braking systems used in railway vehicles. Engineering Science and Technology, an International Journal, 23(2), 421-431.

Hartong, M., Goel, R., & Wijesekera, D. (2011). Positive train control (PTC) failure modes. Journal of King Saud University-Science, 23(3), 311-321.

Ishida, M. (2013). Rolling contact fatigue (RCF) defects of rails in Japanese railways and its mitigation strategies. Electronic Journal of Structural Engineering, 13(1), 67–74.

Leite, M., Costa, M. A., Alves, T., Infante, V., & Andrade, A. R. (2022). Reliability and availability assessment of railway locomotive bogies under correlated failures. Engineering Failure Analysis, 135, 106104.

Ming-yan, W., Wang, H., & Liu, Z. G. (2014). Reach on fault tree analysis of train derailment in urban rail transit. International Journal of Business and Social Science, 5(8).

Sangiorgio, V., Mangini, A. M., & Precchiazzi, I. (2020). A new index to evaluate the safety performance level of railway transportation systems. Safety Science, 131, 104921.

Telawi, S., Sima, Y., Machmur, B., Hayek, A., Börcsök, J., Pinders, U., & Schreiber, W. (2014, November). Network-based safety-related vibration and position analysis for railway vehicles. In 2014 International Conference on Connected Vehicles and Expo (ICCVE) (pp. 155-161). IEEE.

Tian, Z., Zhao, N., Hillmansen, S., Su, S., & Wen, C. (2020). Traction power substation load analysis with various train operating styles and substation fault modes. Energies, 13(11), 2788.

Zang, Y., Shangguan, W., Cai, B., Wang, H., & Pecht, M. G. (2019). Methods for fault diagnosis of high-speed railways: A review. Proceedings of the Institution of mechanical engineers, part O: Journal of Risk and Reliability, 233(5), 908-922.

Zhou, J. L., & Lei, Y. (2020). A slim integrated with empirical study and network analysis for human error assessment in the railway driving process. Reliability Engineering & System Safety, p. 204, 107148.

Zoeteman, A. (2001). Life cycle cost analysis for managing rail infrastructure: Concept of a decision support system for railway design and maintenance. European Journal of Transport and Infrastructure Research, 1(4).