Robin Stevens - Queensland Rail - Turnout design and components

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Robin Stevens 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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Robin Stevens - Queensland Rail - Turnout design and components

  1. 1. Robin Stevens Team Leader Track Design, Queensland Rail Turnout Design and Components
  2. 2. AGENDA • Turnout Terminology • Geometric Designs • Switch Types & Operation • Crossings Types • Check/Guardrail Types
  3. 3. Turnout Function
  4. 4. Turnout Points Assembly Crossing Assembly Guard Rails Sleeper
  5. 5. Switches Sliding Chair Plates Switch Stops Stockrails Points Components Heel Block Bearers Closure Rails
  6. 6. Hand Of Turnouts LEFT HAND TURNOUT RIGHT HAND TURNOUT Turnout curves to LEFT Turnout curves to RIGHT
  7. 7. Switch Hand Right hand switch Left hand switch
  8. 8. • Turnouts are manufactured in : 68kg, 60kg, 53kg, 50kg, 47kg, 41kg, 31kg & 22kg Rail • Queensland Rail standard Turnout range of angles includes: 60kg – 1 in 8.25, 9, 10, 12, 16 & 25 53kg – 1 in 8.25, 9, 10, 10.5 & 12 50kg – 1 in 8 & 12 47kg – 1 in 7, 7.5, 8, 9, 10, 11, 12, 13, & 14 41kg – 1 in 5 ,5.5, 6, 6.5, 7, 7.5, 8, 9, 10, 11, 12, 13 & 14 31kg – 1 in 5 ,5.5, 6, 6.5, 7, 7.5, 8, 9, 10, 11, 12, 13 & 14
  9. 9. • Grooved Rail Tram Turnouts :
  10. 10. GEOMETRIC DESIGNS
  11. 11. Geometric Designs Standard Tangential
  12. 12. Standard Tangential
  13. 13. Toe of Switch (T.S.) - the thin end of the switch Theoretical Point of Crossing (T.P.C.) - intersection of gauge lines at crossing Heel of Switch (H.S.) - the switch end having full rail section Radius (R) - radius of the centre line of main curve radius (r) - radius of the turnout curve measured to the rail Gauge (G) - gauge of track
  14. 14. Crossing Rate - rate of crossing, expressed as the side of a right angled triangle Crossing Angle (A) - angle of crossing in degrees Switch Angle (B) - angle between the switch gauge line and stock rail gauge line Heel Centres (d) - the distance between gauge lines at the heel of the switch Switch Length (S) - the length of the switch from heel to toe Lead (L) - distance from toe of switch to T.P.C
  15. 15. Formulae : Lead (L) = (G-d) cot {1/2 (A + B)} + S Radius (r) = G-d Cos B – Cos A
  16. 16. • Switch Length (S) = 5000 mm • Crossing Rate (N) = 1 in 10 • Heel Centres (d) = 160 mm • Thickness of Tip = 3 mm 1 IN 10 SIMPLE TURNOUT 3 • Gauge (G) = 1067 mm • Crossing angle (A) = tan-1 1/N = tan-1 1/10 = 5.710 deg
  17. 17. Crossing angle (A) = tan-1 1/N = tan-1 1/10 = 5.710 degrees Switch angle (B) = sin-1 d - thickness of switch tip S = sin-1 160-3 5000 = 1.79 degrees
  18. 18. Lead (L) = (G-d) Cot {1/2 (A + B)} + S = (1067-160) Cot {1/2 (5.710+ 1.799)} + 5000 = 907 Cot 1/2 (7.509) + 5000 = 18 820 mm or 18.820 m Radius (r) = G-d Cos B - Cos A = 907 0.9995068984 - 0.9950371902 = 202922 mm or 202.922 m
  19. 19. TANGENTIAL TURNOUT DESIGN L N RADIUS RADIUS WK G J G 90° B RADIAL LEAD X O W GAUGEA M B C
  20. 20. HIGH SPEED TURNOUTS
  21. 21. Contra Flexure Turnout Similar Flexure Turnout Main Turnout road Main Turnout road Main Turnout road FLEXED SPECIAL TURNOUTS
  22. 22. CURVED TURNOUT ISSUES • High lateral forces • Increased switch wear • Increased maintenance • Higher potential for wheel climb • Difficult to maintain geometry 10 STRAIGHT TURNOUT CURVED TURNOUT
  23. 23. Sleeper Layout – Fan Shaped The fanned arrangement of sleepers allows for non handed concrete sleeper sets
  24. 24. Sleeper Layout – Tangential
  25. 25. SWITCH TYPES
  26. 26. Standard Switch Narrow machined point of 3mm protrudes into gauge No machining on the stockrail The switch rail is machined and vertically set to override the foot of the stockrail
  27. 27. Manganese Tipped Switch High wear resistance Increased hardness which use interchangeable switch tip Applications of 47 to 68kg rail
  28. 28. Undercut Switch Point of switch is 3mm but is protected by undercut stockrail The stockrail has undercut machining on the gauge side of the head The stockrail foot is machined to allow the switch to close (not overriding)
  29. 29. Asymmetric Switches
  30. 30. Thick Web Switches
  31. 31. 39, revesby, 30, Down -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 -100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 RailMate Template worn pass Vert Horiz Stockrail, Switch & Wheel interaction Section at toe of switch
  32. 32. 47, revesby, 2400, Down -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 -100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 RailMate Template worn pass Vert Horiz Stockrail, Switch & Wheel interaction Section at 10mm switch thickness
  33. 33. 51, revesby, 3900, Down -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 -100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 RailMate Template worn pass Vert Horiz Stockrail, Switch & Wheel interaction Section at 20mm switch thickness
  34. 34. 54, revesby, 4800, Down -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 -100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 RailMate Template new pass Vert Horiz Stockrail, Switch & Wheel interaction Section at 30mm switch thickness
  35. 35. PIVOT POINT, GAP IN RAIL SWITCH LENGTH LESS THAN 6m Pivot Heel Switches
  36. 36. CONTINUOUS RAIL, NOT GAP SWITCH LENGTH 7m TO 25m Fixed Heel Switches
  37. 37. Switch Rollers
  38. 38. WESTINGHOUSE M23A MACHINE WESTINGHOUSE T84M MACHINE SIEMENS S700 MACHINE Electric Operation
  39. 39. DETECTION HYDRAULIC CYLINDER Hydraulic Operation
  40. 40. Pneumatic Operation DETECTION PNEUMATIC CYLINDER
  41. 41. In-sleeper Operation
  42. 42. Mechanical Operation MECHANICAL LINKAGE CONNECTED TO LEVER FRAME
  43. 43. Trailable Operation
  44. 44. Manual Operation
  45. 45. CROSSING TYPES
  46. 46. Fixed crossing types: • Fabricated crossings. • Rail Bound Manganese crossings. • Compound crossings • Fully cast Monoblock crossings
  47. 47. Point rail Splice rail Wing rails rail Chocks Left hand crossing Fabricated Crossing FEATURES • Available in rail sizes form 20 to 68kg • Fabricated from rail steel & cast iron blocks • Maximum recommended axle load capacity 20 tonne • Maximum recommended mainline speed 80km • Light duty applications and yards
  48. 48. Welded Heel RBM Crossing RBM Crossing FEATURES • Recommended axle load capacity 30 tonne • Recommended mainline speed 120km • Suitable for suburban, freight and heavy haul lines
  49. 49. Manganese Crossing Nose Stainless Steel Insert Compound Crossings (MN Nose) Rail Steel Manganese Noses
  50. 50. Monoblock Crossing Base And Top Face Full Machined Flash Butt Weld to Standard Rail profiles Explosive Depth Hardened Transition Faces Cast Manganese Section Conventional Thermit Welding to Adjoining Track FEATURES Recommended axle load capacity 30 tonne. Recommended mainline speed 120km. Solid one piece manganese casting with no blocks or fasteners.
  51. 51. Nose Cross Sections 50 40 30 20 10 0 -110 -100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110
  52. 52. Crossing Nose & Wheel Transfer
  53. 53. Crossing Nose & Wheel Transfer 50 40 30 20 10 0
  54. 54. Switchable crossings types: • Swing Nose crossings. • Spring Wing crossings.
  55. 55. Swing Nose Crossings FEATURES • Recommended axle load capacity 40 tonne • Maximum mainline speed 160km • Suitable for suburban, freight and heavy haul lines • Continuous wheel contact with minimal impacts
  56. 56. Manganese Spring Wing Crossing • Designed for predominate mainline operation. • Provides continuous contact of wheel and rail. • Maximum mainline speed of 120m/h. • Maximum turnout speed of 25m/h.
  57. 57. GUARDRAIL TYPES
  58. 58. Check / Guard Rails •Purpose is to guard the wheels when traversing a fixed nose crossing •Needs to be correctly adjusted to prevent premature damage to the crossing nose
  59. 59. Effective Guard Rail Gauge CrossingGuard Rails
  60. 60. Standard Guard Rail • Manufactured from conventional rail section • Difficult to adjust due to fastening method to stockrail
  61. 61. Elevated Guard Rail • Manufactured from specialised rolled section (UIC33) • Independent from stockrail allowing for easy adjustment or replacement
  62. 62. Questions Turnout design can only improve !

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