APTA Bus Maintenance Webinar Series “Remote Diagnostics”

John Carney, General Manager, CMTM

Worcester Regional Transit Authority

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

WRTA Fleet Composition



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)

Intelligent Transportation System

 $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

The WRTA’s Solicitation Included

              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

Maintenance Features

“Improving Maintenance Efficiency Using Smart Technologies”

 IVN Intelligent Vehicle Network  Automated Work Orders  AVM Automated Vehicle Monitoring  Location stamping of faults  Intelligent Work Order Integration  Integrate with Turley RTA Maintenance System  Paperless Shop  Vehicle Availability Reporting  Integrated Gas Boy Fuel and Fluids Reporting  Bus in the Box

BusTime™

Complete ITS Solution Integrated & Modular

IVN® CleverCAD™ Automatic Voice Annunciation Automatic Passenger Counting Automatic Vehicle Monitoring

AVM - Automatic Vehicle Monitoring

 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 – 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

Vehicle Health Monitoring

Number of Monitored Faults & Performance Measures Monitored Sub-Components

I/O Controls WABCO ABS Cummins Engine Detroit Diesel Safety Vision Cameras Allison Transmission Thermoking Vanner Battery Equalizer Hybrid Drive

Total Fault & Performance Measures Gillig (J1939)

150 1,601 5,242 75 105 184 1,388 37

8,782 RTS (J1708)

1,518 531 249 -

2,298

Of Which 54 Faults have been deemed

Critical

by the CMTM Maintenance Team

Vehicle Health Monitoring Year 1

The

Most Critical 54 Faults

as identified by the CMTM Maintenance Team ABS 51 Transmission 105 Hybrid Drive 8

Total Component Faults Monitored 3,090

Battery Equalizer 1,388 Climate Control 102 Engine 1,436

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 • ESW

DPF 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

New Vehicle Purchases

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 Detailed Acceptance Criteria Opportunity to Negotiate Longer Warranties by Sharing Data

Warranty

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

Maintenance

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

Legal

Secure Encrypted Event Files for Court Helps Identify Hard Brake Events Records Last Stop Events for Low MPH Accidents Precisely and Objectively Measures Events Deal in Facts Reduces Fictitious Injury Claims & Bogus Lawsuits Helps Settle Legitimate Claims for our Customers

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 Total Distance Vehicle Speed MPH Brake Applied (Yes/No) Peak Acceleration Date / Time Engine Speed (RPM) ABS Active (Yes/No) Peak Speed Event Duration Engine Load (%) 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 2 J1939 (SA Cummins CM2150 146 3 J1939 (SA Cummins CM2150 155 4 J1939 (SA Cummins CM2150 197 5 214 6 J1939 (SA Cummins CM2150 234 7 J1939 (SA Cummins CM2150 322 8 J1939 (SA Cummins CM2150 323 9 J1939 (SA Cummins CM2150 324 10 J1939 (SA Cummins CM2150 325 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.

Engine Coolant Temperature - Data Valid but Above Normal Operational Range Moderately Severe Level. Engine coolant temperature is above engine protection warning limit.

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.

Coolant Level - Data Valid but Below Normal Operational Range - Moderately Severe Level. Low engine coolant level detected.

Engine Oil Temp Engine Crankshaft Speed/Position - Data Valid but Above Normal Operational Range - Most Severe Level. Engine speed signal indicates engine speed above engine protection limit.

Injector Solenoid Driver Cylinder 1 Circuit - Current Below Normal, or Open Circuit. Current detected at injector Number 1 when the voltage is turned off.

Injector Solenoid Driver Cylinder 5 Circuit - Current Below Normal, or Open Circuit. Current detected at injector Number 5 when the voltage is turned off.

Injector Solenoid Driver Cylinder 3 Circuit - Current Below Normal, or Open Circuit. Current detected at injector Number 3 when the voltage is turned off.

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 12 J1939 (SA Cummins CM2150 332 13 J1939 (SA Cummins CM2150 418 14 J1939 (SA Cummins CM2150 435 15 J1939 (SA Cummins CM2150 471 16 J1939 (SA Cummins CM2150 555 17 J1939 (SA Cummins CM2150 596 18 J1939 (SA Cummins CM2150 597 19 J1939 (SA Cummins CM2150 687 20 J1939 (SA Cummins CM2150 1866 Injector Solenoid Driver Cylinder 2 Circuit - Current Below Normal, or Open Circuit. Current detected at injector Number 2 when the voltage is turned off.

Injector Solenoid Driver Cylinder 4 Circuit - Current Below Normal, or Open Circuit. Current detected at injector Number 4 when the voltage is turned off.

Water in Fuel Indicator - Data Valid but Above Normal Operational Range - Least Severe Level. Water has been detected in the fuel filter.

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

Engine Oil Level -Data Valid but Below Normal Operational Range - Least Severe Level. Low oil level has been detected by the oil level sensor.

Crankcase Pressure -Data Valid but Above Normal Operational Range - Moderately Severe Level. The crankcase breather filter requires maintenance.

Electrical Charging System Voltage -Data Valid but Above Normal Operational Range - Moderately Severe Level. High battery voltage detected by the battery voltage monitor feature.

Electrical Charging System Voltage -Data Valid but Below Normal Operational Range - Moderately Severe Level. Low battery voltage detected by the battery voltage monitor feature.

Turbocharger 1 Speed - Data Valid but Below Normal Operational Range Moderately Severe Level. Low turbocharger speed detected by the ECM.

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 22 J1939 (SA Cummins CM2150 1921 23 J1939 (SA Cummins CM2150 1942 24 J1939 (SA Cummins CM2150 2346 25 J1939 (SA Cummins CM2150 2357 26 J1939 (SA Cummins CM2150 2387 27 J1939 (SA Cummins CM2150 2448 28 J1939 (SA Cummins CM2150 2449 29 J1939 (SA Cummins CM2150 2554 30 J1939 (SA Cummins CM2150 2636 EGR Valve Controller - Out of Calibration. The EGR valve has failed the automatic calibration procedure at initial key-on.

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.

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

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.

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.

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.

Coolant Level - Data Valid but Below Normal Operational Range - Least Severe Level. Low engine coolant level detected.

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.

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

VGT Actuator Driver Circuit - Abnormal Update Rate. No communications on the J1939 datalink between the engine ECM and the smart VGT controller.

Presentation Notes

54 Critical Events that Worcester Mechanics Chose to Be Notified Of Catalyst Face Plugged - Root Cause Not Known. The front face of the aftertreatment diesel oxidation catalyst has been detected to be plugged with soot.

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.