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Track Leveling Sensor

Track leveling sensor have promoted the transformation of railway maintenance from "experience driven" to "data-driven" through technological upgrades. They have irreplaceable advantages in improving safety and reducing full lifecycle costs, and are one of the core technologies for intelligent railway operation and maintenance

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超平传感器

Product Overview

This ultra-flat sensor is a track flatness detection device specifically developed for the railway sector. It focuses on core scenarios such as railway line inspection and track acceptance, and can accurately capture key parameters such as track surface undulations and smoothness deviations. It addresses the shortcomings of traditional detection tools, such as insufficient precision and poor adaptability, helping railway maintenance units improve line safety management and operational efficiency.

Key Features

Submillimeter level accuracy:

It can detect subtle deviations such as track flatness, levelness, and gauge (such as 0.1mm level), far exceeding traditional manual detection.

Comprehensive coverage:

Continuously scanning the entire length of the track to avoid omissions in manual sampling, especially suitable for high demand scenarios such as high-speed railways.

High-Precision Micro-Difference Detection
In daily railway inspection scenarios, it can accurately identify minor undulations and deviations on the track surface. Compared with traditional detection tools, its detection accuracy is significantly improved, enabling maintenance personnel to detect subtle track defects in advance. This helps prevent minor deviations from gradually accumulating and causing issues such as train jolts, increased wheel-rail wear, and other potential hazards, thereby significantly enhancing the smoothness and safety of line operation.

Full-Range Environmental Adaptability
Designed for harsh railway environments such as high temperatures, high humidity, and dusty conditions, the sensor features excellent protective performance. Even under extreme operating conditions, it can stably output data, ensuring that inspection tasks are not restricted by weather or geographical constraints. It also possesses strong resistance to acid and alkali corrosion, enabling long-term stable operation in various complex corrosive environments and effectively preventing monitoring interruptions caused by environmental corrosion.

Fast Compatibility with Existing Railway Equipment
During scenarios such as inspection vehicle modifications or detection system upgrades, the sensor supports mainstream interfaces like RS485 and Ethernet, enabling seamless compatibility with commonly used railway inspection terminals and data platforms. Without requiring additional custom adaptation modules, installation and debugging can be completed in a short time, effectively shortening the overall deployment cycle.

High Vibration and Shock Resistance, High Wear Resistance
During railway inspections, the sensor frequently contacts the track and is susceptible to friction from sand and gravel. Its detection end is made of a special material composition, which results in a lower wear rate compared to ordinary stainless steel under a daily inspection intensity of 10 km, ensuring a long service life. Even when passing through rail switches and curved tracks where vibrations are intense, the sensor maintains uninterrupted data acquisition.

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Application Scope

Track leveling sensor have promoted the transformation of railway maintenance from "experience driven" to "data-driven" through technological upgrades.

They have irreplaceable advantages in improving safety and reducing full lifecycle costs, and are one of the core technologies for intelligent railway operation and maintenance.

Railway Daily Operation and Maintenance Inspections
Deployed on track inspection vehicles or handheld devices, the sensor detects 0.1mm-level smoothness deviations in the track. It assists maintenance personnel in proactively identifying smoothness anomalies caused by rail wear and loose fasteners, thereby reducing train vibration during operation and mitigating safety risks.

Application in New Railway Track Acceptance
Adapted for the acceptance phase after new railway track installation, it verifies whether the track top surface smoothness complies with railway construction standards. By replacing traditional manual straightedge inspections, it enhances the accuracy of acceptance data and improves operational efficiency.

High-Frequency Monitoring for Heavy-Haul Railways
Given the characteristics of heavy-haul railways, such as high axle loads and rapid track wear, the sensor enables high-frequency tracking of smoothness deviations caused by track surface wear and settlement. This supports the development of targeted maintenance plans, helping to extend track service life and reduce maintenance costs.

Dynamic Smoothness Monitoring for High-Speed Railways
Deployed on high-speed inspection EMUs, it synchronously detects the track top surface smoothness during train operation. Aligned with the millimeter-level deviation requirements of high-speed railways, it ensures both operational safety and passenger comfort.

FAQ

Can this sensor be directly connected to the existing railway operation and maintenance data platform?
Yes, it supports commonly used railway communication interfaces such as RS485 and Ethernet, enabling seamless integration with mainstream track operation and maintenance management platforms and inspection terminals. No additional development is required for interfacing procedures—once connected, it can transmit data in real time.

Under high-intensity railway inspections, does the sensor require frequent maintenance?
The maintenance frequency is very low. With its wear-resistant detection end, under a daily inspection intensity of 10 km, the sensor’s performance can be maintained by simply cleaning the detection surface once per quarter. Compared to ordinary sensors that require monthly maintenance, this significantly reduces the workload for upkeep.

Will low temperatures of -20℃ in winter affect detection accuracy?
No. The sensor has a built-in low-temperature compensation algorithm, and its operating temperature range covers -20℃ to 70℃. Even in cold winter environments along northern railway lines, detection accuracy remains stable at ±0.1mm, with no data deviation or device lag.

Which key parts of high-speed trains primarily use the ultra-flat sensors?
They are mainly used in critical areas such as bogies, tracks, catenaries, and traction systems. On bogies, they monitor vibration and temperature; on catenaries, they measure tension; and on tracks, they detect displacement, ensuring safe and reliable train operation.