Norfolk Southern to expand use of wheel defect detection system

Norfolk Southern Railway plans to expand the use of its wheel defect detection system following the successful implementation of the technology at one train yard in November 2025.

The "wheel integrity system" uses six synchronized cameras to capture about 55 images of each wheel on passing trains moving up to 70 mph. Using AI algorithms developed by NS, the system analyzes the images to pinpoint defects that humans struggle to identify, NS officials said in a "Story Yard" post on the railroad's website.

NS implemented the system at its Burns Harbor yard in Portage, Indiana, on Nov. 24, 2025. The system has since identified a casting flaw on a vendor wheel set that, upon further investigation, resulted in an industry recall and the confirmation of seven defects, NS officials said.

The wheel integrity system was built on the success of the railroad's digital train inspection (DTI) portals, which have identified and removed from service over 50 wheels since January 2025. Since it is specific to wheels, the new system can capture higher resolution images from critical angles to identify cracks, NS officials said. The Class I developed the system in-house, with integration support from Georgia Tech Research Institute, they said.

"Wheel defects are among the most serious mechanical defects in the industry. The technology allows our railroaders to address maintenance needs promptly, enhancing safety, reducing service disruptions and protecting long-term asset performance," NS officials said in the article.

NS created a video about the technology, available to view here.