Advancing Rail Research and Innovation: The Work of the Gibela Engineering Research Chair at Stellenbosch University
Professor Annie Bekker, Chair of the Gibela Engineering Research Chair at Stellenbosch University, recently delivered an insightful presentation on the significant role of research and innovation in South Africa’s railway sector. Hosted by the University of Pretoria, the presentation formed part of its annual Railway Research and Training Review. The Gibela Rail Consortium, comprising Alstom and uBumbano Rail, is leading efforts to rejuvenate South Africa’s passenger rail network through the manufacture of 600 new trainsets. Beyond manufacturing, Gibela is also responsible for technical support and spare parts supply until 2035, ensuring the long-term sustainability of the rail system.
The Role of the Gibela Engineering Research Chair
The Gibela Engineering Research Chair serves as a bridge between academia and industry, focusing on research, training, and social impact. While universities may not always directly solve industry challenges, they cultivate rail-minded professionals equipped with the necessary expertise to support the sector. The research chair is committed to fostering a new generation of engineers through student-driven projects, spanning undergraduate, master’s, PhD, and postdoctoral levels, all of which contribute to building technical leadership. With the aim of having rail-minded individuals with the right skills to serve the industry. Read more here: https://gerc.sun.ac.za/
Pioneering Research in Railway Monitoring and Asset Management
A central objective of the research chair is to develop niche expertise in monitoring applications and asset management technologies, particularly for the Gibela X’Trapolis Mega train. Hopefully, the outcome of this can be moved to other aspects or providers in the rail sector. The research integrates sensors, data, engineering models, and analytics into digital services, ensuring that railway data is more accessible and usable. To this end, real-world measurement environments, such as depot-based testing and track monitoring, play a crucial role in collecting accurate data for analysis. Although much of the work to date has taken place in the depot.
Advancements in Digital and Cyber-Physical Systems
Digital transformation is a key focus area, with the integration of cyber-physical systems aimed at enhancing rail operations. The research leverages digital modelling, real-time data exchange, and operational analytics to drive efficiency. However, challenges such as data silos when a product may move from design into implementation and operation as well as restricted proprietary data access have led to a strategic focus on simpler, adaptable solutions tailored for the operational phase of railway systems.
Innovative Approaches to Wheel Maintenance and Rail Condition Monitoring
Wheel maintenance is a pressing issue in South African railways, with traditional contact-based profile measurements requiring significant time. The research team has trialled a camera-based wheel wear measurement system, achieving promising results in detecting flange height variations. Additionally, a laser-based wheel profile measurement system has been calibrated for deployment in “live rail” environments in the track laboratory. These innovations could lead to more frequent, automated inspections, improving maintenance efficiency.
Rail forces and track interactions are being analysed using strain gauge systems, with early findings identifying local track defects. The research explores how these defects produce distinct vibration signatures, enabling the detection of problematic wheels.
Each time a wheel with a specific defect strikes the rail, it generates a unique pattern—much like a musical symphony. Just as one can distinguish between a violin and a trumpet playing the same note, these vibration signatures can differentiate between various wheel defects.
To refine this approach, high-resolution and high-frequency measurements are being used to build a comprehensive database of defect signatures. By monitoring train wheels, researchers are effectively creating a library of these patterns. The goal is to leverage data-driven analysis and advanced signal processing techniques to identify faults, even if some degree of misdetection occurs.
A key achievement of this research is the ability to detect defects at very low speeds—down to 4 km/h—making it viable for use in a depot environment. This is achieved through a combination of laser sensors, which pinpoint wheel locations, and accelerometers measuring track vibrations.
Developing Digital Infrastructure for Rail Safety and Performance
The research chair is also contributing to the development of dynamic railcar models, integrating real-world measurements with digital tools. Collaboration with industry experts is essential to refining these models and improving their accuracy. Additionally, thermal imaging technologies are being trialled to detect track defects, offering a sophisticated means of monitoring rail conditions in real time.
Enhancing Infrastructure Monitoring and Train-to-Train Communication
Rail infrastructure monitoring is increasingly being integrated with rolling stock data to provide comprehensive insights into track conditions. The research team has developed a digital infrastructure that transmits real-time track defect information to remote dashboards. This capability holds great potential for mapping the passenger rail network and improving maintenance decision-making.
Moreover, train-to-train communication is an emerging area of research, with fleet management logs being analysed to assess driver performance and operational efficiency. The goal is to establish a framework for evaluating train operation quality based on available data.
Human-Centric and AI-Driven Solutions in Rail Operations
Innovative research is also being conducted on using human input as a sensor. By analysing passenger feedback and onboard train conditions, researchers aim to integrate subjective and objective data into a unified digital highway for railway analytics. Machine learning applications are being explored for predictive maintenance, focusing on pneumatic brake and door failure diagnostics.
The Future of Training and Skill Development
Recognising the importance of workforce development, the Gibela Engineering Research Chair is investing in training initiatives. A virtual reality (VR) welding simulator has been developed for the Gibela Training Centre, reducing material waste and improving training efficiency. Professional development programmes for Gibela personnel, short courses, and student workshops further contribute to skill enhancement in the sector.
Social Impact and Community Engagement
Beyond technical advancements, the research chair is actively engaged in social impact initiatives. A rail safety campaign, conducted in collaboration with the University of Pretoria and the Railway Safety Regulator, has reached 800 scholars across three provinces. The initiative has been recognised with an award from Stellenbosch University, underscoring its positive contribution to railway safety awareness.
The Gibela Engineering Research Chair is making significant strides in railway research, skill development, and technological innovation. With a strong focus on digital transformation, asset management, and infrastructure monitoring, the research is poised to enhance the efficiency and safety of South Africa’s rail sector. Through collaboration with industry and academia, the chair continues to drive meaningful progress in railway engineering and development.
