Adam Scoles - Vossloh Cogifer Australia - Module 3: Turnout manufacturing The essential elements of dual gauge turnouts


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Adam Scoles delivered the presentation at 2014 RISSB National Rail Turnouts Workshop.

The RISSB National Rail Turnouts Workshop gives all those involved an in-depth forum for discussion and the sharing of expertise. A key element of this workshop is participation and knowledge sharing from audience as well as the workshop leaders. It is a chance for you to bring your experience and to take away new approaches for best practice.

For more information about the event, please visit:

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Adam Scoles - Vossloh Cogifer Australia - Module 3: Turnout manufacturing The essential elements of dual gauge turnouts

  1. 1. Dual Gauge Turnouts Presenter: Adam Scoles Company: Vossloh Cogifer Australia Date: May 2014 Location: Brisbane
  2. 2.  Dual Gauge Turnouts are an integral element of linking state to state through the various Dual Gauge rail networks within mainland Australia.  Vossloh Cogifer Australia is a designer and manufacturer of Turnouts and rail components in Australia and throughout Asia, VCA has been involved in Dual Gauge Turnout design and manufacture since the inception of dual gauge lines in Australia. Introduction
  3. 3.  Broad Gauge / Standard Gauge Dual Gauge Turnouts.  Standard Gauge / Narrow Gauge Dual Gauge Turnouts.  Geometries and Configurations  Design Considerations.  Manufacturing Considerations.  Switch options and movement.  Crossing Design.  Guarding.  Fastening. Introduction
  4. 4. Summary 1435mm 1067mm 762mm 610mm 1600mm 1435mm 1067mm 1000mm 1600mm 1435mm 762mm 1600mm 1435mm 762mm 1435mm 1600mm 1067mm 762mm 610mm 1600mm 1435mm 1067mm
  5. 5. Common Rail – is the rail opposite the dual rails, the common rail is always in use regardless of the trains bogey arrangement. Dual Gauge Rails – The two parallel rails that run opposite the common rail. Dual Gauge Turnout – Dual rails continue through on the straight or mainline track as well continuing through on the turnout or diverge leg of the turnout arrangement. Mixed Gauge Turnout – Turnout on dual gauge line where the dual gauge does not continue through both legs of the turnout, either one or both of the turnout legs are single gauge. Some parts of the industry will refer to these also as Dual Gauge Turnouts. Gauge Separation Turnouts – Turnout on a Dual Gauge Line, which splits the lines into two singular gauge lines. Terminology
  6. 6. Dual (Mixed) Gauge Geometric Configurations. LH Turnouts RH Turnouts There are multiple Standard Dual and Mixed Gauge turnout configurations. For true dual gauge turnouts there are technically only the two types, 1 & 8. Dual Gauge Turnouts
  7. 7. Dual Gauge Turnouts • Australian rail networks, which have dual rail lines and dual gauge turnouts, have different identifications for the same typical geometries. Dual (Mixed) Gauge Turnout Identification.
  8. 8. Typical Broad/Standard Dual Gauge Turnout. Common Rail Typical Standard/Narrow Dual Gauge Turnout. Dual Rails Distinctions between Narrow/Standard & Standard/Broad Dual Gauge Turnouts
  9. 9. Generally the Standard/Narrow Dual Gauge turnouts present fewer problems with both design and manufacture than the Standard/Broad Dual Gauge designs. More standard componentry can be used for Standard/Narrow Dual Gauge Turnouts. Standard/Narrow Dual Gauge Turnouts enable the use of standard fastenings in most areas. The Standard/Narrow Double V Crossing is basically two standard crossings. Switch movement for Narrow/Standard Dual Gauge Turnouts is essentially the same for conventional turnouts. Switch movement for Standard/Broad Dual Gauge is considerably limited. Guarding for Standard/Broad Dual Gauge Turnouts provides problems, again due to the limited gap between the gauges. Rail profile chosen has a bearing on fastening decisions. Standard/Narrow Dual Gauge Turnout Broad/Standard Dual Gauge Turnout. Distinctions between Narrow/Standard & Standard/Broad Dual Gauge Turnouts
  10. 10.  Many of the components which make up Dual Gauge turnouts are found in conventional turnout designs. The areas which are unique to Dual Gauge turnouts are:  Inner and Outer Switch and Stock Rail assemblies.  Double V Crossing Assembly.  K Crossings.  Special Guarding.  Plating and Bearer requirements. Standard Dual Gauge Turnout Componentry Standard Dual Gauge Components
  11. 11. Dual Gauge Turnouts – Switch Assemblies Dual Gauge Switch plates Standard Switch plates Standard Heel Block Assembly Dual Gauge Heel Block Assembly Standard/Narrow Dual Gauge Switch assembly.Broad/Standard Dual Gauge Switch assembly. Special Inner Stock Rail Special Guard Special Outer Switch Rail Special H Plate
  12. 12. Dual Gauge Turnouts V Crossings Wing/Heel Rail Double V Crossing for a Standard/Narrow dual gauge is essentially two standard V crossings. with a relatively minor modification to join the two individual crossings. The Fabricated Double V Crossing for a Broad/Standard dual gauge turnout requires design considerations which include provision for broad and standard flangeway clearances as well as adequate guarding within the one assembly. Solid Cast Manganese Steel Double V Crossings may be considered a more suitable design alternative to the fabricated type Broad/Standard crossing.
  13. 13. K Crossings K Crossings for Broad/Standard Dual Gauge Turnouts show very little resemblance to a Standard/Narrow K crossing. Minimal distance between the dual rails. Only one point rail can be accommodated in the assembly The K Crossing is required in a Dual/Mixed Gauge turnout wherever the inner or outer dual rails cross over each other. K Crossing for a Standard/Narrow Dual Gauge turnout is not too dissimilar in appearance to the conventional K crossings in a Diamond. The major difference between the Standard/Narrow Dual Gauge K and the conventional K crossings in a Diamond is the noticeable absence of two housed rails. K Crossing Assembly for Standard /Narrow Dual Gauge K Crossing Assembly for Broad/Standard Dual Gauge
  14. 14. Switchable K Crossing Switchable K Crossings provide a direct wheel transfer from the moveable point rail to the running rails. The Switchable K design provides a much improved wheel transfer over the fixed type K Crossings. This design does not require point guarding. The Switchable K design does require switch-operating gear to move the points.
  15. 15. Dual Gauge Plating S/N Dual Guard Plate Where possible plating should remains the same for Dual Gauge turnouts as conventional turnouts. This is generally only possible for the common rail assemblies and the common rails. For the dual gauge assemblies and rails, extended length plates are required to accommodate the dual rails. The dual rail plates require adequate bracing and provision to ensure the dual rails and assemblies are secured to the platework. S/N Dual Guard Plate S/N Dual Switch Plate B/S Dual Plate 50kg B/S Dual Plate 53kg 19mm Gap 38mm Gap
  16. 16.  An essential element of any fixed nose crossing is to ensure the point noses are adequately protected and the correct wheel path is maintained  Conventional guarding of dual gauge crossings for Standard/Narrow turnouts is possible for most configurations.  Guarding for Broad/Standard Turnouts requires much more consideration with respect to fitting of guards into limited positions due to the smaller distance between the dual rails. Dual Gauge Guarding Point Rails Guarding For opposing K Crossing Noses.
  17. 17. Dual Gauge Bearers Design of Bearers is generally in accordance with conventional turnout bearers. The length of the dual gauge bearer is based on the greater of the two gauges. Structurally the bearer would be designed to accommodate the same forces as a conventional turnout. As Dual Gauge turnouts have longer plates to support the dual track and assemblies, consideration must be given to fixing points of plates to bearer to ensure the fixing points are located and centred correctly on the bearer.
  18. 18. Special Dual/Mixed Gauge Assemblies Common Rail Transfer: The Common Rail Transfer simply swaps the common rail from one side to the other whilst maintaining the dual gauge line. It is installed for a number purposes where transferring the common rail is required: Clearances with vehicles approaching platforms. Leading into existing yards where the common rail is on the opposite side. Leading into gauge separation turnouts where the common rail is required to be on the opposing side. Close a loop where again the common rail needs to swap to the opposing side of the line.
  19. 19. Special Dual/Mixed Gauge Assemblies Gauntlet Switch.  The purpose of the gauntlet switch is to transfer rolling stock from dual gauge track to gauntlet track.  The 3 rails on the dual track are converted into 4 rails for the gauntlet track.  Once through the gauntlet switch the gauges run independently of each other. There is no common rail. This provides both similar platform clearances for different gauges.  Safe and comfortable access to passengers.
  20. 20. Special Dual/Mixed Gauge Assemblies TR Type Gauge Separation Turnouts. There are a number of TR Turnout configurations in service in the Victorian Rail Network. The majority are gauge separation units. They have fixed point transfer zones. Speed through these turnouts is minimal. The transfer zones are often produced using solid manganese steel castings Common Rail Dual Rail Broad Gauge Standard Gauge BG Guard Figure 30. TR4 Fixed Point Transfer
  21. 21. Special Dual/Mixed Gauge Assemblies Typical TR Switch and Stock Assembly Replacement Broad Gauge Standard Gauge TR Replacement: Currently a number of the TR Turnouts are being replaced with a more conventional Switch/Stockrail assembly. Designed to be retrofitted to the existing TR Turnouts. Increased speed through the transfer area. No guarding is required. Requirement of addition of switch operating gear to move the replacement switchblade. Consideration must be given to signalling requirements.
  22. 22. Dual/Mixed Gauge Diamond: There are a number of possible configurations for diamonds. If we assume the dual gauge line is Broad/Standard the possible configurations are: Dual through Dual. Dual through Broad. Dual through Standard. Standard through Broad. The same configurations occur with Standard/Narrow Turnouts. Special Dual/Mixed Gauge Assemblies
  23. 23. Can we replace Dual Gauge Turnouts?
  24. 24. Conclusion  Dual gauge configurations are complex as compared to standard turnouts and configurations.  Design and manufacturing issues of the Broad/Standard Dual Gauge Turnouts are greatly compounded as compared with the Standard/Narrow type Dual Gauge Turnouts.  The complexities of Dual gauge turnouts and lines also extend to maintenance, operations and signalling areas.  Dual Gauge Turnouts and configurations will continue play a part in linking state to state through the various Dual Gauge rail networks within mainland Australia.  Considering the sometimes complex nature of Dual Gauge Turnouts and configurations, their introduction has been relatively successful in assuring effective guidance of rail traffic on Dual Gauge Lines.
  25. 25. Dual Gauge Turnouts Adam Scoles Vossloh Cogifer Australia Pty Ltd