Development of a condition monitoring of heat exchangers for corrosion progress and coolant condition

The transport sector, and thus also rail transport, needs to be completely decarbonised by 2050 at the latest. Considering the long service life of rail vehicles, this goal means enormous innovation and growth potential for the vehicle and supplier industry of railway technology in the coming years. This contribution presents the first results of a R&D project to reduce the total cost of ownership of passenger and freight railway vehicles. The reduced life cycle costs can be achieved over the operating lifetime, among other things, with condition monitoring approaches for critical components of cooling systems to enable diagnosis-based maintenance. Based on guided elastic waves, an integrated system is being developed to analyse the depth and position of corrosion damage to heat exchangers in rail vehicles. This method is to be supplemented by a refractive index sensor integrated in the coolant circuit which can be used to detect an incorrect coolant filling or corrosion residues in the coolant. First, an acoustic measuring technique was put into operation. Suitable piezoelectric transducers were selected and test measurements, including the introduction of artificial damages, along different paths on a representative heat exchanger were carried out and evaluated. Measurement signals can be received over different distances, and a monitoring of larger areas of the heat exchanger seems possible. In addition, plasmonically active sensor substrates with a gold nanostructure were produced and installed in a measuring flow cell to monitor the coolant condition. In laboratory tests, concentrations of water-coolant mixtures could be distinguished with the refractive index sensor. In the future, the refractive index sensing will be carried out by means of bypass flow measurement. Since the coolant is pumped in a circuit, the sensor system can be attached to one of the inlet/outlet lines.