(1) Solution Overview

Urban rail transit track facilities are subject to long‑term repeated train loads and erosion from the natural environment, frequently triggering defects such as rail wear, missing or broken fasteners, foreign objects on track beds, and sleeper spalling. Conventional manual inspection occupies night maintenance windows, featuring low inspection efficiency, limited coverage, and inability to implement full‑process dynamic monitoring. The on‑board track comprehensive inspection system takes revenue‑service electric multiple units as carriers, integrates inspection equipment into the under‑train comprehensive inspection beam, and dynamically measures track geometric parameters (vertical alignment, track alignment, cross‑level, gauge, twist, curvature, etc.) and track inspection defects while trains operate normally. It addresses core pain points including low manual‑inspection efficiency, limited night maintenance‑window hours, and incomplete inspection coverage.

(2) Core Functions / Solution Composition

The system adopts a three‑tier architecture: "under‑train comprehensive inspection beam + on‑board intelligent fusion host + ground (cloud) platform". The under‑train comprehensive inspection beam is fitted with sensors including 2D laser measurement units (for rail profile inspection), 2D line‑scan modules, 3D high‑definition imaging modules, inertial measurement units, acceleration sensors and RFID beacon readers to collect track data. The on‑board intelligent fusion host undertakes front‑end data storage, analysis and computation. The ground platform visualizes defect data and statistical reports. System functions cover dynamic detection of track geometric parameters, automatic identification of track inspection defects, real‑time data processing and storage, train‑to‑ground data transmission, data visualization and report generation, as well as equipment self‑diagnosis and log management.

(3) Technical Highlights / Differentiated Advantages (Key Indicators)

High inspection accuracy: gauge accuracy ＜ ±0.8 mm, rail wear accuracy ±0.2 mm, vertical alignment accuracy ＜ ±1.0 mm;

Powerful identification capability: defect recognition rate ≥95%, false‑alarm rate ≤5%, missed‑detection rate ≤1%;

Precise positioning: triple‑fusion positioning combining vehicle speed sensors, RFID electronic tags and sleeper counting, with positioning accuracy ≤1 m;

High inspection efficiency: maximum inspection speed of 120 km/h, covering all categories of defects for rails, fastening components, track beds, sleepers, turnouts and track auxiliary equipment;

Comprehensive data management: supports compressed storage of raw data, lossless saving of defect images, trend analysis of historical data, and automatic generation and export of reports.

(4) Application Cases

(5) Customer Value

Replacing manual inspection, the system delivers real‑time, accurate and full‑section track condition data for track maintenance departments, upgrading conventional manual "blind inspection" to intelligent "precision inspection" and greatly relieving workload and labor costs for night‑window maintenance. Through automatic defect identification and precise positioning, it guides maintenance staff to arrive on‑site for rapid disposal, effectively mitigating train operation safety risks and ensuring safety under high‑density operation conditions.