Data-Driven Condition Monitoring of Fixed-Turnout Frogs Using Standard Track Recording Car Measurements

Turnouts are critical components of railway infrastructure, ensuring operational flexibility but also representing a significant share of track maintenance costs. The frog, as the most vulnerable part of a turnout, is subject to severe wear and degradation, requiring frequent inspection and maintenance. Traditional manual inspection methods are costly, labour-intensive, and susceptible to subjectivity. This study explores a data-driven approach to condition monitoring of fixed-turnout frogs using standard track recording car measurements. By leveraging over 20 years of longitudinal level and rail surface signal data from the Austrian track-recording measurement car, we assess the feasibility of using existing measurement data for predictive maintenance. Six complementary approaches are proposed to evaluate frog condition, including track geometry assessment, ballast condition analysis, rail surface irregularity detection, and axle box acceleration-based monitoring. Results indicate that data-driven monitoring enhances maintenance decision-making by identifying deterioration trends, reducing reliance on manual inspections, and enabling predictive interventions. The integration of standardised measurement data with advanced analytical models offers a cost-effective and scalable solution for turnout maintenance.