Franz Sodia - Voestalpine VAE Railway Systems - Turnouts for low life cycle costs

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Franz Sodia 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: http://www.informa.com.au/railturnoutsworkshop14

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Franz Sodia - Voestalpine VAE Railway Systems - Turnouts for low life cycle costs

  1. 1. RISSB 2014 Turnout Workshop Turnouts for low life cycle costs Franz SODIA MEng, MBA, MIEAust, CPEng CEO voestalpine VAE Railway Systems
  2. 2. RISSB 2014 Turnout Workshop VAE Group: The Turnout People since 163 years World Market and Technology Leader 4,500 people 42 locations
  3. 3. RISSB 2014 Turnout Workshop VAE: Turnouts, switch machines, monitoring For all speeds, axle loads, gauges, profiles ... speed axle load
  4. 4. RISSB 2014 Turnout Workshop VAE Railway Systems in Mackay State of the Art Design and Manufacturing
  5. 5. RISSB 2014 Turnout Workshop TCO (Total Cost of Ownership), LCC Driven by the Initial Quality Purchase costs Operational costs
  6. 6. RISSB 2014 Turnout Workshop Example structure of TCO from ÖBB After change of maintenance strategy depreciation downtime maintenance driver: lifetime depending on initial quality driver: reliability depending on initial quality driver: initial quality source: ÖBB
  7. 7. RISSB 2014 Turnout Workshop Initial quality level Never can be achieved again by maintenance time quality mainte- nance mainte- nance mainte- nance end of lifetime LOW initial quality source: ÖBB
  8. 8. RISSB 2014 Turnout Workshop High initial quality: Research results Early first maintenance recommended time quality maintenance HIGH initial quality maintenance maintenance end of lifetime LOW initial quality MAINTENANCE INTERVALS Higher Initial Quality extends source: ÖBB
  9. 9. RISSB 2014 Turnout Workshop High initial quality: Research results time quality HIGH initial quality LOW initial quality source: ÖBB LIFETIME Higher Initial Quality extends MAINTENANCE INTERVALS Higher Initial Quality extends Implemented in maintenance strategy of ÖBB
  10. 10. RISSB 2014 Turnout Workshop How to achieve high initial quality System approach: solutions for specific functions Track specific function: guiding, bearing  GEOMETRY (reduce forces, accelerations, increase speed)  MATERIAL (reduce wear) Turnout specific functions: switching, locking, detecting, monitoring  COMPONENTS (designed for respective application)
  11. 11. RISSB 2014 Turnout Workshop GEOMETRY
  12. 12. RISSB 2014 Turnout Workshop What to take care for Guiding and bearing: GEOMETRY
  13. 13. RISSB 2014 Turnout Workshop Guiding and bearing: GEOMETRY Y / Q ratio to be checked R [ m ] v [ km / h ] μ [ - ]β [ grad ] FG FZ Q Y β, μ
  14. 14. RISSB 2014 Turnout Workshop Guiding and bearing: GEOMETRY Maintenance reccomendations essential
  15. 15. RISSB 2014 Turnout Workshop Guiding and bearing: GEOMETRY Implementation of canted profile in turnouts  Grinding after installation  Canted plates  Asymmetrical rail  Milling in production
  16. 16. RISSB 2014 Turnout Workshop Guiding and bearing: GEOMETRY Asymmetrical clothoids a, k acceleration a and curvature k are increasing linear along the way x 2 31 x R1 R2 R3
  17. 17. RISSB 2014 Turnout Workshop Guiding and bearing: GEOMETRY Calculation of forces and accelerations  Dynamic multi body simulation  Vehicle as spring – mass - damper model  Variable setctions of switch blade and radii through turnout Kinematic Response Dynamic Response L a
  18. 18. RISSB 2014 Turnout Workshop Guiding and bearing: GEOMETRY Multibody dynamic simulation results Distance along the track [ m ] LatlForceLftWhAxle1(Newtonsx1000) AREA Standard Turnout #20, 133RE rail T/O 133RE-680-#20, tangential Clothoid T/O 136RE10-4000’/2100’/4200’-#20 tangential, new proposal
  19. 19. RISSB 2014 Turnout Workshop Guiding and bearing: GEOMETRY Verification of simulation by field tests 55 60 65 70 75 80 85 90 95 100 105 kN 7.25 7.30 7.35 7.40 7.45 7.50 7.55 7.60 7.65 km Vertical Forces at 178kph on axle 3 1. Turnout 2. Turnout 1. Crossing 2. Crossing Simulation - Measurement
  20. 20. RISSB 2014 Turnout Workshop Guiding and bearing: GEOMETRY Rail wheel contact and the sinusodiol run b b r 2 r 1 r
  21. 21. RISSB 2014 Turnout Workshop Guiding and bearing: GEOMETRY Sinusodioal run is interrupted in turnouts
  22. 22. RISSB 2014 Turnout Workshop Guiding and bearing: GEOMETRY KGO (Kinematic gauge optimisation)  Stockrail gauge line under controlled variable gauge widening  Thicker tongue rail provides additional wear reserve
  23. 23. RISSB 2014 Turnout Workshop Guiding and bearing: GEOMETRY KGO (Kinematic gauge optimisation)  KGO enables sinusodial run in turnouts by active kinematic steering
  24. 24. RISSB 2014 Turnout Workshop Guiding and bearing: GEOMETRY KGO (Kinematic gauge optimisation)  Already standard at many Australian Railways
  25. 25. RISSB 2014 Turnout Workshop MATERIAL
  26. 26. RISSB 2014 Turnout Workshop Guiding and bearing: MATERIAL Harder rails have positive effect at system wear Hardness ratio rail / wheel Wearfactor 0,5 1 2 0,512 Total System Wheel Rail
  27. 27. RISSB 2014 Turnout Workshop Guiding and bearing: MATERIAL Latest stage of evolution: Bainitic rails
  28. 28. RISSB 2014 Turnout Workshop Guiding and bearing: MATERIAL Full deep head hardened rails
  29. 29. RISSB 2014 Turnout Workshop Guiding and bearing: MATERIAL Full deep head hardened rails
  30. 30. RISSB 2014 Turnout Workshop Guiding and bearing: MATERIAL Cast Austenitic Manganese Steel  Developed, patented and licensed by VAE  Explosive depth hardening state of the art
  31. 31. RISSB 2014 Turnout Workshop Guiding and bearing: MATERIAL Cast Austenitic Manganese Steel  Developed, patented and licensed by VAE  Explosive depth hardening state of the art
  32. 32. RISSB 2014 Turnout Workshop COMPONENTS
  33. 33. RISSB 2014 Turnout Workshop COMPONENTS: Switch device Switch rail sections according to axle loads  Including KGO and fully head hardened rails AREA 136 TWUIC 60E1A1
  34. 34. RISSB 2014 Turnout Workshop COMPONENTS: Switch device iFast inner stock rail fastening
  35. 35. RISSB 2014 Turnout Workshop COMPONENTS: Switch device Compact roller systems  Fully integrated in plate and retrofit
  36. 36. RISSB 2014 Turnout Workshop COMPONENTS: Crossings Designs according to axle loads and speed annual load [mgt]5 15 10 35 150 40 100 25 axle load [t] 200 140 100 speed[km/h] FABRICATED COMPOUND MONOBLOCK MONOBLOCK EXPLOSIVE DEPTH HARDENED SWINGNOSE
  37. 37. RISSB 2014 Turnout Workshop COMPONENTS: Crossings (Swing) Spring Wing
  38. 38. RISSB 2014 Turnout Workshop CRADLE LONG WINGRAIL MAXIMAL TRANSITION AREAS PER DIRECTION WELDED CAST 32 2 23 COMPONENTS: Crossings SNX design principles
  39. 39. RISSB 2014 Turnout Workshop COMPONENTS: Crossings for > 40 t axle loads SNX with long wing rails and AREA 136 TW
  40. 40. RISSB 2014 Turnout Workshop COMPONENTS: Switching, Locking, Monitoring Pre-condition for pre-assembly and p&p install
  41. 41. RISSB 2014 Turnout Workshop High impact to initial quality P&P installation only if switch machines included
  42. 42. RISSB 2014 Turnout Workshop Rodding and asymmetrical vibrating masses Damaging ballast and avoiding tamping
  43. 43. RISSB 2014 Turnout Workshop Evolution step 1: Encapsulate locking systems
  44. 44. RISSB 2014 Turnout Workshop Evolution step 1: Encapsulate locking systems
  45. 45. RISSB 2014 Turnout Workshop Evolution step 2: Transfer rodding in inbearers and enable tamping
  46. 46. RISSB 2014 Turnout Workshop Evolution step 3: Transfer switch machine in one single inbearer
  47. 47. RISSB 2014 Turnout Workshop Evolution step 4: Get rid of the inbearers
  48. 48. RISSB 2014 Turnout Workshop Evolution step 4: Get rid of the inbearers
  49. 49. RISSB 2014 Turnout Workshop Evolution step 5: Remote monitoring, condition based maintenance time data - failure level + failure level + tolerance - tolerance maintenance Condition based maintenance 0 time costs time costs Scheduled maintenance
  50. 50. RISSB 2014 Turnout Workshop Remote condition monitoring Fully integrated in switch machines
  51. 51. RISSB 2014 Turnout Workshop Example for latest state of the art evolution > 40 t thick web KGO switch machine on sleeper
  52. 52. RISSB 2014 Turnout Workshop TCO CALCULATIONS
  53. 53. RISSB 2014 Turnout Workshop Lowest TCO not always with latest technology Optimum has to be elaborated per application Operational Costs Purchasing Costs Total Costs Quality NPV [$] Optimal Solution Innovative Solution Standard Solution
  54. 54. RISSB 2014 Turnout Workshop Investment decision methods TCO calculation method
  55. 55. RISSB 2014 Turnout Workshop TCO calculation method Net present value difference of two solutions NPV of savings [$] time Difference of higher initial quality SAVING: Difference of savings during operation
  56. 56. RISSB 2014 Turnout Workshop TCO calculation method Similar investment horizon is essential years
  57. 57. RISSB 2014 Turnout Workshop TCO calculation method WACC of railway is essential driver
  58. 58. RISSB 2014 Turnout Workshop Evolution of Turnouts Selection of intelligent design – by the client
  59. 59. RISSB 2014 Turnout Workshop Conclusion Evolution or intelligent design?  Intelligent design selected by the user. „Innovation is bringing inventions successful to the market“ Josef Alois Schumpeter, 1883 - 1950
  60. 60. RISSB 2014 Turnout Workshop

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