How it works

From a CALIPRI export to fleet-wide analytics

WheelHub reads the CALIPRI open-standard XML (v3.0) and turns it into a live picture of your fleet — no new hardware, no integration project.

Works with your existing CALIPRI workflow

Your measurements, already in the right format

CALIPRI optical gauges record wheel profiles by laser light-section and export them as a documented, open-standard XML file. WheelHub speaks that format natively — nothing to install on the device. You map each vehicle type once, then upload its exports.

WheelHub is an independent product and is not affiliated with NEXTSENSE GmbH. We simply read the open export.

Four steps, set up once

Map each vehicle type once. After that, an export goes from the gauge to a fleet-wide view in minutes.

1 · Measure

Your team measures wheels with a CALIPRI optical profile gauge, exactly as they do today — against your existing measurement plans.

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2 · Export and upload

CALIPRI writes an open-standard XML (v3.0) export. You upload it to WheelHub.

Wheel Hub fleet dashboard for a demo operator: a headline naming how many sets have a wheel in the most severe tolerance band, wheel counts by band, a twelve-month health trend and a health bar per depot.

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3 · Map the vehicle, once

The export doesn’t say which reading came from which wheel. The first time a vehicle type arrives, WheelHub drafts a measurement plan from the file: carriages, bogies, axles and scan order. You check it and save it. Every later export of that vehicle is placed automatically.

Top-down schematic of a seven-car train from one inspection, every wheel drawn in its position and coloured green, amber or red by its tolerance band.

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4 · Review and analyse

You confirm each upload against its plan. Every dimension is then classified against the plan’s tolerance bands, wear is trended across inspections, and you see when each dimension is forecast to reach a limit its measurement plan sets.

Two trend charts for one wheel: flange angle falling and flange height rising since its last re-profiling, each continued by a dashed forecast with a widening range and a confidence rating.

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The wheels behind the data

Every dimension WheelHub trends traces back to real rolling stock — measured in the depot, re-profiled on the wheel lathe, and tracked through the bogie it rides under.

Rows of overhauled railway wheelsets lined up in the SBB maintenance works yard at Bellinzona — Overhauled wheelsets at the SBB works, Bellinzona

A Hegenscheidt underfloor wheel lathe with a wheelset mounted for re-profiling in a depot workshop — A Hegenscheidt underfloor wheel lathe re-profiling a wheelset

Close-up of a modern passenger-train bogie and its wheelsets beneath a railcar — A modern passenger bogie and its wheelsets

What WheelHub reads

The export is a flat list of measured points, in the order the gauge scanned them. It does not record which carriage, bogie or axle each reading came from. Your measurement plan does — so every reading lands on the right wheel in the hierarchy your team already thinks in, without guessing from point names.

DepotTrainWagonBogieAxleWheel

CALIPRI export — XML v3.0

<calipriexport name="HCMT_WHEEL_1" version="3.0"> // measurement plan = name
<session operator="…" depot="…" date="…">
<measurements>
<point name="90_W1"> // one wheel position
<dimension type="FlangeHeight" value="28.4">
<dimension type="FlangeWidth" value="32.1">
<profile …point cloud…>
<point name="90_W2"> // …and so on

What you get back

Once a vehicle is mapped, one upload gives a full read on every wheel.

Tolerance classification on every dimension, judged against your own measurement plan
Drafting-style wheel cross-sections with ISO dimensioning and profile overlays
Wear trending across inspections, and when each dimension is forecast to reach a limit its measurement plan sets
Per-wheel lifecycle — identity tracked through machining, switches, and replacement

Try it with your own export

A note on CALIPRI

CALIPRI is a trademark of NEXTSENSE GmbH. WheelHub is an independent product and is not affiliated with, endorsed by, or sponsored by NEXTSENSE GmbH or Hexagon AB. WheelHub reads the CALIPRI open-standard XML (v3.0) export to provide its analytics.