APTA Bus Maintenance Webinar Series

birthdaytestAI and Robotics

Nov 17, 2013 (3 years and 10 months ago)

98 views

John Carney, General Manager, CMTM

Worcester Regional Transit Authority

APTA Bus Maintenance Webinar Series


“Remote Diagnostics”


Worcester Regional Transit Authority


The WRTA is responsible for the provision of public transit services to thirty
-
five (35) communities within the Worcester County region, and is funded
with federal, state and local monies, as well as fare box revenue. WRTA was
created pursuant to Massachusetts General Laws, Chapter 161B, in August
1974.



CMTM, a division

of First Group,

is WRTA’s current Contractor for fixed
-
route service and demand

response
paratransit service

management
Services.



The

WRTA is the second largest RTA
in

Massachusetts serving the second
largest city in New England


Active Fleet


46 buses


Qty 6
-
1996 RTS


Qty 7
-

1998 RTS


Qty 2
-

2000 RTS


Qty 8
-

2008 Gillig


Qty 15
-

2010 Gillig (4 diesel/electric hybrid)


Qty 8
-

2012 Gillig (3 diesel/electric hybrid)



Future Fleet Additions/Replacements


6 Additions
-

Spring 2013
-

Proterra (fast charge electric)


Fleet Expands to 52 Buses


15 Replacements
-

Fall 2013
-

Gillig (10 diesel/electric hybrid)

WRTA Fleet Composition


$
3.9m ARRA Funded



TranSystems



Procurement and Implementation Consultant



Clever Devices


Prime Contractor



Improve Operational Efficiency, Cost
-
Effectiveness, Security,
Marketing and
Customer Satisfaction through
System
-
wide
Technical Enhancements



Major Goals Included:


Increase the availability of transit information to its
customers


Improve dispatching, operational efficiency and cost
effectiveness


Increase driver and passenger safety and
security


Improve Maintenance Efficiency Using Smart Technologies


Intelligent Transportation System


One Vendor and Total System Integration


Giro HASTUS/Stratengen & Adept/Route Match Integration


CAD/AVL Fixed Route Integrated with Demand Response ADA VANS


Arrival Prediction System “Real Time Information”


Automated Vehicle Stop Announcements


Next Bus Wayside Arrival “Real Time”


Interactive Voice Recognition IVR


Web Based Bus Tracker System Voice/Text/QR Codes


One Point Operator Log On


Automated Passenger Counting APC


Traffic Signal Priority TSP


VoIP Voice over Internet Protocol Data and Voice Communications


AVM Automated Vehicle Monitoring System


Data archival, management and reporting system


The WRTA’s Solicitation Included

Maintenance

Features

“Improving Maintenance Efficiency Using


Smart Technologies”


IVN Intelligent Vehicle Network



AVM Automated Vehicle Monitoring



Location stamping of faults



Intelligent Work Order Integration



Integrate with Turley RTA
Maintenance System




Automated Work Orders



Paperless Shop



Vehicle Availability Reporting



Integrated Gas Boy Fuel and Fluids
Reporting



Bus in the Box


Complete ITS Solution

Integrated
&

Modular

CleverCAD™

Automatic Voice


Annunciation

Automatic Vehicle

Monitoring

Automatic Passenger

Counting

BusTime


IVN®


AVM is a decision support system that provides simple, accurate, and
timely vehicle performance information



AVM monitors and collects faults and operational performance data from
on
-
board systems



Automated wireless transfer of information to maintenance and
operational personnel

AVM
-

Automatic Vehicle Monitoring

AVM


Vehicle Health and Performance

WRTA/CMTM Lessons Learned


J1708/J1939 Compatible


SafetyVision

18 DVR’s $67,000


Gateways


I/O Controls $7,100


ThermoKing

$ 13,800


Twin Vision Smart Series $57,960


Software/Firmware Updates


Ron Turley RTA


Data Storage Memory $200,000


Cellular Rates vs. Conventional Radio


Hand Held Radio


New Bus Specification Consideration


Of Which 54 Faults have been deemed
Critical

by the CMTM Maintenance Team

Vehicle Health Monitoring


Number of Monitored Faults &
Performance Measures

Monitored Sub
-
Components

Gillig (J1939)

RTS (J1708)

I/O Controls

150

-

WABCO ABS

1,601

1,518

Cummins Engine

5,242

-

Detroit Diesel

-

531

Safety Vision Cameras

75

249

Allison Transmission

105

-

Thermoking

184

-

Vanner Battery Equalizer

1,388

-

Hybrid Drive

37

-

Total Fault & Performance Measures

8,782

2,298

The
Most Critical 54 Faults

as identified by the CMTM Maintenance Team

Vehicle Health Monitoring Year 1

Total
Component
Faults
Monitored
3,090

ABS 51

Battery
Equalizer
1,388

Climate
Control 102

Engine 1,436

Hybrid Drive
8

Transmission
105

AVM is like having a diagnostic

laptop

connected to every
bus around the clock

Clever Devices Supported Systems

Engine


Cummins


Detroit
Diesel


John Deere


Caterpillar


Navistar

Transmission/
Propulsion


ZF


BAE


Allison


Voith

ABS


Wabco


Bendix

Multiplex


IO Controls


Vansco


Volvo


Actia


Allen Bradley


Siemens

Brake Wear
Monitoring


Geoguidance

Brake Insight


MGM Brakes
E
-
Stroke

Cooling Fans


EMP

Articulated
Joint


Hubner

Door System


Vapor


Volvo

Air
Conditioning


ThermoKing


Carrier

DPF


ESW

Supplemental
Heaters


ProHeat


Webasto


Spheros

Tire
Monitoring


SmarTire

TPMS

Battery
Equalizer


Vanner

Camera


Safety Vision


March
Networks


GE Mobile
View
Quattro


Apollo


Dedicated
Micros

The benefits of AVM
are
felt throughout
WRTA’s
entire organization

New Vehicle Purchases

Warranty

Maintenance

Legal

Empower our
Bus Inspectors at
Factory Acceptance Testing

Identify Issues Before Bus Delivery (New Gillig and
Proterra

Buses)

Make Data
-
Based Purchasing
Decisions
and Purchase
the Highest “Value”
Bus

Minimize Risk During Bus Acceptance

Implement More
D
etailed Acceptance Criteria

Opportunity to Negotiate Longer
W
arranties by Sharing Data

New Vehicle Purchases

Increase Warranty Recovery Claims

Automatically Identify Fleet Defects

Automate Warranty Service Requests

Reduce Parts and Labor Reimbursements

Reduce Overtime Due to Warranty Work

Measure and Manage with actual data

Make Informed Warranty Claim decisions

Warranty

Helps Reduce Bus Breakdowns in Service increasing MDBF/MTBF

Gives mechanics a single source of diagnostic information


reducing task time

Helps Eliminate Preventable Failures

Integration into our MMIS


Helps Automate the Work Flow Process

Reduce Overtime/Lower Parts Inventory

Lower Cost Per Mile

Maintenance

Secure Encrypted Event Files for Court

Helps Identify Hard Brake Events

Records Last
Stop Events
for
L
ow MPH Accidents

Precisely and Objectively Measures Events

Deal in Facts

Reduces Fictitious Injury Claims & Bogus Lawsuits

Helps Settle Legitimate Claims for our Customers

Legal

Forensic Investigations

19 Data Points Reported on Every Last Stop Event (Bus reaches 0 MPH)

Start Lifetime Odometer

Trigger Lifetime Odometer

End Lifetime Odometer

Average Acceleration

Peak Acceleration

Peak Speed

Total Distance

Date / Time

Event Duration

Vehicle Speed MPH

Engine Speed (RPM)

Engine Load (%)

Brake Applied (Yes/No)

ABS Active (Yes/No)

Throttle Position (%)

Distance

Time Zone

Daylight Savings Time

ACTM (Alternating Current Traction Motor) Torque Commanded (Hybrid Application)

Forensic Investigations

Composite Data Chart

Forensic Investigations

Vehicle Speed Chart

Forensic Investigations

Distance Traveled Chart

Forensic Investigations

Composite Data Chart

11:36:23.78 No Brake or

ABS
24 MPH

11:36:25.84 Brake & ABS

Applied
19.2 MPH

11:36:27.83 Brake & ABS


Applied
.8 MPH

Forensic Investigations

Left Hand Turn Incident at WRTA

12 MPH On Impact

8 MPH After
Applying Brake

8:53:20 14 mph

8:53:21 12 mph

8:53:22 8 mph

Questions

Presentation Notes

54 Critical Events that Worcester Mechanics Chose to Be Notified Of

1

J1939 (SA

Cummins

CM2150

143

Engine Oil Rifle Pressure
-

Data Valid but Below Normal Operational Range
-

Moderately Severe Level. Engine oil pressure signal indicates engine oil pressure
is below the engine protection warning limit.

2

J1939 (SA

Cummins

CM2150

146

Engine Coolant Temperature
-

Data Valid but Above Normal Operational Range
-

Moderately Severe Level. Engine coolant temperature is above engine
protection warning limit.

3

J1939 (SA

Cummins

CM2150

155

Intake Manifold 1 Temperature
-

Data Valid but Above Normal Operational
Range
-

Most Severe Level. Intake manifold air temperature signal indicates
intake manifold air temperature above engine protection critical limit.

4

J1939 (SA

Cummins

CM2150

197

Coolant Level
-

Data Valid but Below Normal Operational Range
-

Moderately
Severe Level. Low engine coolant level detected.

5







214

Engine Oil Temp

6

J1939 (SA

Cummins

CM2150

234

Engine Crankshaft Speed/Position
-

Data Valid but Above Normal Operational
Range
-

Most Severe Level. Engine speed signal indicates engine speed above
engine protection limit.

7

J1939 (SA

Cummins

CM2150

322

Injector Solenoid Driver Cylinder 1 Circuit
-

Current Below Normal, or Open
Circuit. Current detected at injector Number 1 when the voltage is turned off.

8

J1939 (SA

Cummins

CM2150

323

Injector Solenoid Driver Cylinder 5 Circuit
-

Current Below Normal, or Open
Circuit. Current detected at injector Number 5 when the voltage is turned off.

9

J1939 (SA

Cummins

CM2150

324

Injector Solenoid Driver Cylinder 3 Circuit
-

Current Below Normal, or Open
Circuit. Current detected at injector Number 3 when the voltage is turned off.

10

J1939 (SA

Cummins

CM2150

325

Injector Solenoid Driver Cylinder 6 Circuit
-

Current Below Normal, or Open
Circuit. Current detected at injector Number 6 when the voltage is turned off.

Presentation Notes

54 Critical Events that Worcester Mechanics Chose to Be Notified Of

11

J1939 (SA

Cummins

CM2150

331

Injector Solenoid Driver Cylinder 2 Circuit
-

Current Below Normal, or Open Circuit.
Current detected at injector Number 2 when the voltage is turned off.

12

J1939 (SA

Cummins

CM2150

332

Injector Solenoid Driver Cylinder 4 Circuit
-

Current Below Normal, or Open Circuit.
Current detected at injector Number 4 when the voltage is turned off.

13

J1939 (SA

Cummins

CM2150

418

Water in Fuel Indicator
-

Data Valid but Above Normal Operational Range
-

Least
Severe Level. Water has been detected in the fuel filter.

14

J1939 (SA

Cummins

CM2150

435

Engine Oil Rifle Pressure
-

Data Erratic, Intermittent, or Incorrect. The engine oil
pressure sensor is reading an erratic value at initial key
-
on.

15

J1939 (SA

Cummins

CM2150

471

Engine Oil Level
-
Data Valid but Below Normal Operational Range
-

Least Severe
Level. Low oil level has been detected by the oil level sensor.

16

J1939 (SA

Cummins

CM2150

555

Crankcase Pressure
-
Data Valid but Above Normal Operational Range
-

Moderately
Severe Level. The crankcase breather filter requires maintenance.

17

J1939 (SA

Cummins

CM2150

596

Electrical Charging System Voltage
-
Data Valid but Above Normal Operational
Range
-

Moderately Severe Level. High battery voltage detected by the battery
voltage monitor feature.

18

J1939 (SA

Cummins

CM2150

597

Electrical Charging System Voltage
-
Data Valid but Below Normal Operational
Range
-

Moderately Severe Level. Low battery voltage detected by the battery
voltage monitor feature.

19

J1939 (SA

Cummins

CM2150

687

Turbocharger 1 Speed
-

Data Valid but Below Normal Operational Range
-

Moderately Severe Level. Low turbocharger speed detected by the ECM.

20

J1939 (SA

Cummins

CM2150

1866

Exhaust Gas Recirculation Valve Delta Pressure
-

Data Erratic, Intermittent, or
Incorrect. An error in the EGR delta pressure signal was detected at initial key
-
on or
the sensor failed the
autozero

test.

Presentation Notes

54 Critical Events that Worcester Mechanics Chose to Be Notified Of

21

J1939 (SA

Cummins

CM2150

1896

EGR Valve Controller
-

Out of Calibration. The EGR valve has failed the automatic
calibration procedure at initial key
-
on.

22

J1939 (SA

Cummins

CM2150

1921

Aftertreatment Particulate Filter Differential Pressure
-

Data Valid but Above
Normal Operational Range
-

Moderately Severe Level. The soot load of the
aftertreatment diesel particulate filter has exceeded the recommended limits.

23

J1939 (SA

Cummins

CM2150

1942

Crankcase Pressure
-
Data Erratic, Intermittent, or Incorrect. The ECM has
detected that the crankcase pressure signal is not changing with engine
operating conditions.

24

J1939 (SA

Cummins

CM2150

2346

Turbocharger Turbine Inlet Temperature (Calculated)
-

Data Valid but Above
Normal Operational Range
-

Least Severe Level. Turbocharger turbine inlet
temperature has exceeded the engine protection limit.

25

J1939 (SA

Cummins

CM2150

2357

EGR Valve Control Circuit
-

Mechanical System Not Responding Properly or Out
of Adjustment. The EGR motor has exceeded the duty cycle limit indicating a
stuck open EGR valve.

26

J1939 (SA

Cummins

CM2150

2387

VGT Actuator Driver Circuit (Motor)
-

Mechanical System Not Responding
Properly or Out of Adjustment. The smart VGT controller has detected incorrect
stop limits or the VGT is unable to move to the closed position.

27

J1939 (SA

Cummins

CM2150

2448

Coolant Level
-

Data Valid but Below Normal Operational Range
-

Least Severe
Level. Low engine coolant level detected.

28

J1939 (SA

Cummins

CM2150

2449

VGT Actuator Controller
-

Out of Calibration. The VGT has failed the automatic
calibration procedure at initial key
-
on. VGT will be in the open position.

29

J1939 (SA

Cummins

CM2150

2554

Exhaust Gas Pressure
-

Data Erratic, Intermittent, or Incorrect. The exhaust gas
pressure sensor is reading an erratic value at initial key
-
on.

30

J1939 (SA

Cummins

CM2150

2636

VGT Actuator Driver Circuit
-

Abnormal Update Rate. No communications on the
J1939
datalink

between the engine ECM and the smart VGT controller.

Presentation Notes

31

J1939 (SA

Cummins

CM2150

2637

Catalyst Face Plugged
-

Root Cause Not Known. The front face of the aftertreatment
diesel oxidation catalyst has been detected to be plugged with soot.

32

J1939 (SA

Cummins

CM2150

2754

Engine Particulate Trap Inlet Pressure
-

Data Valid but Above Normal Operational
Range
-

Moderately Severe Level. Excessive black smoke has been detected exiting
the engine and entering the aftertreatment diesel particulate filter.

33

J1939 (SA

Vanner

70 Series

EQFLT

Equalizer Fault

34

J1939 (SA

Vanner

70 Series

IMB

Voltage Imbalance Fault

35

J1939 (SA

Vanner

70 Series

OVF

Over Voltage Fault

36

J1939 (SA

Vanner

70 Series

UVF

Under Voltage Fault

37

J1708

Detroit

DDEC
-
IV

41

Too many SRS (missing TRS)

38

J1708

Detroit

DDEC
-
IV

42

Too few SRS (missing SRS)

39

J1708

Detroit

DDEC
-
IV

43

Coolant Level Low

40

J1708

Detroit

DDEC
-
IV

44

Coolant Temperature High

41

J1708

Detroit

DDEC
-
IV

44

Oil Temperature High

42

J1708

Detroit

DDEC
-
IV

45

Oil Pressure Low

43

J1708

Detroit

DDEC
-
IV

54

Vehicle Speed Sensor Fault

44

J1708

Detroit

DDEC
-
IV

55

J1939 Data Link Fault

45

J1708

Detroit

DDEC
-
IV

61

Injector 1 Response Time Long

46

J1708

Detroit

DDEC
-
IV

61

Injector 2 Response Time Long

47

J1708

Detroit

DDEC
-
IV

61

Injector 3 Response Time Long

48

J1708

Detroit

DDEC
-
IV

61

Injector 4 Response Time Long

49

J1708

Detroit

DDEC
-
IV

71

Injector 1 Response Time Short

50

J1708

Detroit

DDEC
-
IV

71

Injector 2 Response Time Short

51

J1708

Detroit

DDEC
-
IV

71

Injector 3 Response Time Short

52

J1708

Detroit

DDEC
-
IV

71

Injector 4 Response Time Short

53

J1708

Detroit

DDEC
-
IV

75

ECM Battery Voltage High

54

J1708

Detroit

DDEC
-
IV

84

Oil Level Low

31

J1939 (SA

Cummins

CM2150

2637

Catalyst Face Plugged
-

Root Cause Not Known. The front face of the aftertreatment
diesel oxidation catalyst has been detected to be plugged with soot.

32

J1939 (SA

Cummins

CM2150

2754

Engine Particulate Trap Inlet Pressure
-

Data Valid but Above Normal Operational
Range
-

Moderately Severe Level. Excessive black smoke has been detected exiting
the engine and entering the aftertreatment diesel particulate filter.

33

J1939 (SA

Vanner

70 Series

EQFLT

Equalizer Fault

34

J1939 (SA

Vanner

70 Series

IMB

Voltage Imbalance Fault

35

J1939 (SA

Vanner

70 Series

OVF

Over Voltage Fault

36

J1939 (SA

Vanner

70 Series

UVF

Under Voltage Fault

37

J1708

Detroit

DDEC
-
IV

41

Too many SRS (missing TRS)

38

J1708

Detroit

DDEC
-
IV

42

Too few SRS (missing SRS)

39

J1708

Detroit

DDEC
-
IV

43

Coolant Level Low

40

J1708

Detroit

DDEC
-
IV

44

Coolant Temperature High

41

J1708

Detroit

DDEC
-
IV

44

Oil Temperature High

42

J1708

Detroit

DDEC
-
IV

45

Oil Pressure Low

43

J1708

Detroit

DDEC
-
IV

54

Vehicle Speed Sensor Fault

44

J1708

Detroit

DDEC
-
IV

55

J1939 Data Link Fault

45

J1708

Detroit

DDEC
-
IV

61

Injector 1 Response Time Long

46

J1708

Detroit

DDEC
-
IV

61

Injector 2 Response Time Long

47

J1708

Detroit

DDEC
-
IV

61

Injector 3 Response Time Long

48

J1708

Detroit

DDEC
-
IV

61

Injector 4 Response Time Long

49

J1708

Detroit

DDEC
-
IV

71

Injector 1 Response Time Short

50

J1708

Detroit

DDEC
-
IV

71

Injector 2 Response Time Short

51

J1708

Detroit

DDEC
-
IV

71

Injector 3 Response Time Short

52

J1708

Detroit

DDEC
-
IV

71

Injector 4 Response Time Short

53

J1708

Detroit

DDEC
-
IV

75

ECM Battery Voltage High

54

J1708

Detroit

DDEC
-
IV

84

Oil Level Low

54 Critical Events that Worcester Mechanics Chose to Be Notified Of