USA: The technology is developed by the American freight operator in partnership with the Georgia Tech Research Institute. Since last November, the wheel integrity system has been operating in Burns Harbor. This year, more systems are planned for installation at several sites.
The system incorporates six synchronised cameras capturing around 55 ultra-high-resolution images per wheel at speeds up to 110 km/h. Self-learning AI algorithms analyse these images, then the Norfolk Southern specialists receive the data to detect and eliminate the defects.
Norfolk Southern officials say that the wheel integrity system has already identified a critical casting flaw on a wheel set. The conducted investigation initiated an industry recall of the production of that supplier with the confirmation of seven such defects across North America.
Automated freight car wheel detection system fro Norfolk Southern. Source: Norfolk Southern
The new technology is based on the existing digital train inspection (DTI) portals, developed and deployed by the operator. But unlike portals, which examine entire trains, the wheel integrity system focuses only on wheel sets. Meanwhile, since January 2025, the stationary DTI portals have identified more than 50 wheels with issues on North America’s network.
