Axle Sensor Fusion for Online Continual Wheel Fault Detection in Wayside Railway Monitoring
Organizations: GECAD, ISEP, Polytechnic of Porto, Rua Dr. António Bernardino de Almeida, Porto, 4249-015, Portugal
Abstract
Reliable and cost-effective maintenance is essential for railway safety, particularly at the wheel-rail interface, which is prone to wear and failure. Predictive maintenance frameworks increasingly leverage sensor-generated time-series data, yet traditional methods require manual feature engineering, and deep learning models often degrade in online settings with evolving operational patterns. This work presents a semantic-aware, label-efficient continual learning framework for railway fault diagnostics. Accelerometer signals are encoded via a Variational AutoEncoder into latent representations capturing the normal operational structure in a fully unsupervised manner. Importantly, semantic metadata, including axle counts, wheel indexes, and strain-based deformations, is extracted via AI-driven peak detection on fiber Bragg grating sensors (resistant to electromagnetic interference) and fused with the VAE embeddings, enhancing anomaly detection under unknown operational conditions. A lightweight gradient boosting supervised classifier stabilizes anomaly scoring with minimal labels, while a replay-based continual learning strategy enables adaptation to evolving domains without catastrophic forgetting. Experiments show the model detects minor imperfections due to flats and polygonization, while adapting to evolving operational conditions, such as changes in train type, speed, load, and track profiles, captured using a single accelerometer and strain gauge in wayside monitoring.
Figures & tables
| Code | Semantic | Signal | Description |
| S-WC | Wheel count | ✓ | Detects anomalies in wheel count using strain signals and embeddings. Flags missing wheels or signal degradation. |
| S-WI | Wheel indexes | ✓ | Adds temporal wheel indexes to detect spacing irregularities, misalignments, improper bogie assembly, or mechanical faults. |
| I-WI | Wheel indexes | ✗ | Uses only axle timing and counting to detect abnormal patterns, such as missing axles, or misalignments. |
| I-WD | Axle deformations | ✗ | Analyzes strain-based deformations, implicitly identifying uneven loading or undercarriage faults. |
| S-WD | Axle deformations | ✓ | Combines axle deformation signals with semantic axle context to capture subtle, early-stage anomalies. |
| Baseline | Flat | Polygonized | |
| Train load | 6 (full, half, empty, and 3 diff. unbalanced) | 1 (full) | 1 (full) |
| Irregularity profiles | 96 | 24 | 24 |
| Train speeds (km/h) | 40-220 | 60-200 | 60-200 |
| Defect locations | - | 3rd wagon, 1st/3rd left | 1st wagon, 1st right |
| Amplitude (mm) | - | 10-20, 25-50, 40-100 | .25-.35, 0.55-.75 |
| Depth (mm) | - | .02-.06, .09-.16, .23-.36 | 6-8, 12-14, 17-20, 29-30 |
| Model | Accuracy | Recall | Precision | F1 Score |
| Manual Features | 72% | 74% | 72% | 75% |
| VAE | 95% | 94% | 91% | 95% |
| + 1 Layer | + 4% | + 5% | + 8% | + 3% |
| + 2 Layers | + 0% | + 0% | + 0% | + 1% |
| TB | PD | DP | SD | |
| S-WC | .70 ± .01 | .71 ± .01 | .71 ± .01 | .76 ± .01 |
| S-WC* | .82 ± .01 | .82 ± .01 | .80 ± .01 | .83 ± .01 |
| S-WI | .61 ± .01 | .62 ± .01 | .59 ± .01 | .54 ± .01 |
| S-WI* | .72 ± .01 | .72 ± .01 | .70 ± .01 | .69 ± .01 |
| I-WI | .76 ± .02 | .78 ± .01 | .76 ± .02 | .84 ± .02 |
| I-WI* | .86 ± .01 | .86 ± .01 | .85 ± .02 | .89 ± .02 |
| Test statistic | p-value | |
| TB | 59.813 / 58.453 | 3.176e-12 / 6.129e-12 |
| PD | 59.253 / 57.333 | 4.163e-12 / 1.053e-11 |
| DP | 59.253 / 58.453 | 4.163e-12 / 6.129e-12 |
| SD | 53.920 / 51.706 | 5.470e-11 / 1.589e-10 |
| S-WI | I-WI | I-WD | S-WD | ||
| TB | S-WC | 1/1 | 1/1 | ,010/,010 | ,036/,029 |
| S-WI | ,036/,022 | ,010/,010 | ,010/,010 | ||
| I-WI | ,027/,054 | 1/1 | |||
| I-WD | 1/1 | ||||
| PD | S-WC | 1/1 | 1/1 | ,010/,010 | ,022/,014 |
| S-WI | ,029/,044 | ,010/,010 | ,010/,010 |
| Metric | Baseline | RS | P-RS | LB | P-LB | |||||
| 200 | 800 | 200 | 800 | 200 | 800 | 200 | 800 | 200 | 800 | |
| Forward Transfer | -0.0109 | -0.0102 | 0.0934 | 0.0377 | 0.1882 | 0.0947 | 0.1492 | 0.2427 | 0.3122 | 0.1414 |
| Backward Transfer | -0.0117 | -0.0038 | -0.0129 | -0.0219 | -0.1170 | -0.1136 | -0.0077 | -0.0018 | -0.1164 | -0.1240 |
| Intransigence Measure | 0.0104 | 0.0111 | 0.1086 | 0.0628 | 0.1990 | 0.1031 | 0.2192 | 0.3038 | 0.3637 | 0.1864 |
| Knowledge Gain Ratio | 3.1971 | 3.2005 | 2.8668 | 3.0277 | 2.5662 | 2.8927 | 2.4983 | 2.2169 | 2.0126 | 2.6144 |
Fault Diagnosis
Fault diagnosis identifies, localizes, and explains failures in engineered and computational systems using sensor data, logs, models, and domain knowledge.
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