Norfolk Southern Testing New Wheel Integrity System
Written by David C. Lester, Editor-in-Chief
Crack on railroad car wheel (image courtesy of Norfolk Southern)
ATLANTA –– Norfolk Southern has developed a wheel integrity system that it's now testing in Indiana.
Wheel cracks will lead to derailments if not discovered quickly. Norfolk Southern is concerned about wheel cracks going undetected, including on cars coming on to their network that may not have been inspected recently.
In order to address the challenge, the railroad developed and deployed the first-ever wheel integrity system, which it designed and developed entirely in-house.
This new technology builds on the success of NS’s Digital Train Inspection (DTI) portals, which use AI-powered visual systems to scan trains at track speed and detect a range of defects. Since early 2025, these portals have identified over 40 wheel integrity issues.
The new wheel integrity system is purpose-built for wheels. It captures ultra-high-resolution images from critical angles, using specialized camera placement and lighting to differentiate between grease, dirt, water, and actual cracks. This equipment dramatically reduces false positives and enhances early defect detection.
More specifically, this system uses six synchronized cameras (three per side) to capture up to 14 high-resolution images per wheel, even as trains travel up to 70 m.p.h. The images are then analyzed by advanced Artificial Intelligence (AI) algorithms.
The first installation of this system is Burns Harbor, Ind., which is a strategic site near Chicago, one of NS’ busiest hubs. The location allows NS to inspect trains coming onto its network as soon as possible.
This new system came to fruition through a deep cross-functional partnership. Digital & Technology, Mechanical, Communication & Signals, and the Network Operations Center (NOC) have worked closely throughout development.
Once testing is successful and complete, Norfolk Southern plans to install the systems in other locations on the network in 2026.
