CASE STUDY

Metro Trains Melbourne (MTM) operates the EV-120, a non-self-powered track and overhead inspection vehicle, nicknamed “Evie,” which relies on towing for transport between locations. The vehicle’s onboard odometer and GPS, critical for tracking mileage and ensuring timely maintenance, were not powered during transit, resulting in inaccurate odometer readings. MTM engaged IMTRAM to develop a solution to keep the existing odometer and GPS systems powered without relying on an axle-mounted approach, as specified in the project brief.

IMTRAM designed a compact, custom-built enclosure housing an uninterruptible power supply (UPS), a rechargeable lithium battery, charger, switch, relay and redundancy module. This system ensured continuous power to the odometer and GPS by toggling between two power sources: a 240V general power outlet (GPO) when available and the EV-120’s 24V cabinet supply when the GPO was unavailable. The redundancy module prioritized the 240V supply to charge the battery, switching to the 24V supply when necessary to power only the odometer, preserving the vehicle’s main power supply by halting battery charging. When neither power supplies were available, the system would switch to the internal lithium battery, ensuring the GPS and odometer were always tracking the movement of the vehicle.

Using AutoDesk Fusion, IMTRAM designed a compact enclosure to house all of the components.

After receiving the components, IMTRAM conducted bench testing to validate the system. Minor adjustments were made, including the addition of a resistor and a battery cut-off switch to optimize performance. The fully assembled enclosure underwent final testing, simulating both 240V and 24V power scenarios to confirm the redundancy module’s prioritization logic. The results were highly successful, ensuring reliable power delivery to the odometer and GPS. The enclosure was seamlessly installed on the EV-120, with no modifications required to the vehicle’s existing systems.

The solution delivered precise odometer readings, enabling MTM to accurately track the EV-120’s mileage and adhere to maintenance schedules. “Evie” now supports MTM’s vital network operations with enhanced reliability. This project, though small in scope, showcases IMTRAM’s expertise in electrical engineering, 3D design, fabrication, and installation, as well as our ability to deliver tailored solutions to meet specific client requirements.

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