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www.voestalpine.com/vae
voestalpine VAE GmbH
Modern Turnout Technology
for High Speed
DI Heinz Ossberger
Head of Corporate Engineering and R&D
voestalpine VAE GmbH
TER Workshop Vienna, 18th of October 2016
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voestalpine VAE GmbH
2 16.11.2016 HG Vortrag TER Wien
General High Speed Turnout Geometry High Speed Turnout Technology Switching Technology for High Speed Conclusion
Content
LCC
Performance, Quality
Costs
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voestalpine VAE GmbH
3 16.11.2016 HG Vortrag TER Wien
General High Speed Turnout Geometry High Speed Turnout Technology Switching Technology for High Speed Conclusion
Content
LCC
Performance, Quality
Costs
| |
voestalpine VAE GmbH
4 16.11.2016 HG Vortrag TER Wien
HIGH SPEED
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voestalpine VAE GmbH
VAE - High Speed Turnouts used in:
Germany, Austria, Switzerland, Finland, Netherland
Turkey, Spain, Taiwan, China, Korea
5 16.11.2016 HG Vortrag TER Wien
The VAE Group as a Main Supplier of High Speed
Turnout Technology Systems Worldwide
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voestalpine VAE GmbH
6 16.11.2016 HG Vortrag TER Wien
Identification of the optimal component on the base of LCC
Ownership Costs for
Maintenance,
Track closing,…
Capital Costs
LCC
Performance, Quality
Costs
Primary Goal of LCC Optimisation
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voestalpine VAE GmbH
7 16.11.2016 HG Vortrag TER Wien
Robust Drive, Locking and
Detection System
Minimizing of Forces Most Suitable Turnout
Component Design
• Turnout Geometry
• Elasticity
• Inclined Running Table
• TOZ Switch
• Swingnose
Crossing
• Roller Systems
• Hydrostar DLD System
Three Key Factors for a Successful
High Speed Turnout Technology
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voestalpine VAE GmbH
Force Oscillation in relation to the Spring Rate
Force
Length
Force Oscillation
Length Oscillation
Working Point
Force Oscillation
Working Point
Elastische
Fahrbahnlagerung
Kraft [kN]
Einsenkung
[mm]
8 16.11.2016 HG Vortrag TER Wien
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voestalpine VAE GmbH
9 16.11.2016 HG Vortrag TER Wien
High Speed Turnouts with Rheda Classic - Germany
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voestalpine VAE GmbH
Results of demonstrator installation: Significant reduction of contact forces by means of KGO and optimized
elasticity (soft pads) in S&C
VAE S&C has the lowest vertical force for the crossing (T/O E454)
0
50
100
150
200
250
E452 E453 E473 E454 Soft E454 Hard
Wh
eel f
orc
e [k
N]
S&Cs
Vertical force Track 3at the crossing
v=40
v=55
v=70
VOSSLOH VAE
16.11.2016 HG Vortrag TER Wien 10
INNOTRACK – Results SP3 Switches & Crossings
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voestalpine VAE GmbH
General High Speed Turnout Geometry High Speed Turnout Technology Switching Technology for High Speed Conclusion
LCC
Performance, Quality
Costs
16.11.2016 HG Vortrag TER Wien 11
Content
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voestalpine VAE GmbH
16.11.2016 HG Vortrag TER Wien 12
SYS File Railway Vehicles Model
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voestalpine VAE GmbH
Parabolic Geometry LH-Wheel
Parabolic Geometry RH-Wheel
VAE Clothoid Geometry LH-Wheel
VAE Clothoid Geometry RH-Wheel
At the wheel rail interface with a speed of 160 km/h
50 100 150 200 250 300
-30
-25
-20
-15
-10
-5
0
5
10
15
20
25
F1 L at l For. L f t W h A x le 1
D istance along the T rack (m eters)
(New
tons
x10
00)
F1 L at l For. Rgt W h A x le 1 F2 L at l For. L f t W h A x le 1 F2 L at l For. Rgt W h A x le 1
1. Turnout
2. Turnout
16.11.2016 HG Vortrag TER Wien 13
Lateral forces
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voestalpine VAE GmbH
Y31
Y32
Q31
Q32
Y41
Y42
Q41
Q42
Motrice ETR 500 Politensione 404 501-2
16.11.2016 HG Vortrag TER Wien 14
Measuring Locations on the Vehicle
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voestalpine VAE GmbH
15 16.11.2016 HG Vortrag TER Wien
-15
-10
-5
0
5
10
15
20
25kN
7.25 7.30 7.35 7.40 7.45 7.50 7.55 7.60 7.65
km
-15
-10
-5
0
5
10
15
20
25N
7.25 7.30 7.35 7.40 7.45 7.50 7.55 7.60 7.65
km
1. Switch
1. Crossing
2. Crossing
2. Switch
Lateral forces: speed 178km/h, axle 3, deviating track
Simulation- Measurements
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voestalpine VAE GmbH
UIC60-7500/3000/15000-tg 0,026
16.11.2016 HG Vortrag TER Wien 16
Highspeed Crossover Gallese/Italy
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voestalpine VAE GmbH
Maximum lateral forces are
reduced by 25%
Maximum accelerations are
reduced by 36%
16.11.2016 HG Vortrag TER Wien 17
Results in Comparison with the Parabolic Geometry
Turnout tg 0,022
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voestalpine VAE GmbH
General High Speed Turnout Geometry High Speed Turnout Technology Switching Technology for High Speed Conclusion
LCC
Performance, Quality
Costs
16.11.2016 HG Vortrag TER Wien 18
Content
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voestalpine VAE GmbH
16.11.2016 HG Vortrag TER Wien 19
Switch Device
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voestalpine VAE GmbH
Stockrail Standard
16.11.2016 HG Vortrag TER Wien 20
TOZ- Comparison to Standart Design
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voestalpine VAE GmbH
Advantages: • Optimal combination between
switchblade thickness and stockrail
thickness
• Almost no gauge widening
• Additional thickness of the switchblade
in the most critical area
• Standard set of sleeper and plates are
suitable
• Prolonging the service life of the
product due to more material.
According Swiss/SBB findings twice
the lifespan.
16.11.2016 HG Vortrag TER Wien 21
TOZ- Load Rating Optimized Switch Rails
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voestalpine VAE GmbH
A TOZ Switch gives you double the Lifespan
compared to a Standard Switch!
16.11.2016 HG Vortrag TER Wien 22
TOZ- Load Rating Optimized Switch Rails
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voestalpine VAE GmbH
iFAST clip
PIROLL
plate integrated roller system
PIROLL
Tandem roller
16.11.2016 HG Vortrag TER Wien 23
iFAST
Elastic Inner Stock Rail Fastening with Pi Rolles
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voestalpine VAE GmbH
Advantages: • Easy assembling and
disassembling procedure
• Spring can be preassembled
• Flat spring rate
• Piroll fully integrated in the
plate
• Plastic rollers cannot damage
the switch blade when wrongly
installed
16.11.2016 HG Vortrag TER Wien 24
iFAST with PIROLL
Inner side rail fastening and switch roller
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voestalpine VAE GmbH
SNX with Cast Manganese Cradle: Sole plate consisting of:
- 1pc Cast Manganese Cradle
- 3pc Cast Steel Cradle
Point and Splice Rails – Profile 60E1
Closure Rails – Profile 60E1
Length: 25,940m
Geometry: 1:32,05
SNX Characteristics with Cast Manganese Cradle:
Sole plate consisting of:
- 1pc Cast Manganese Cradle
- 3pc Cast Steel Cradle
Point and Splice Rails – Profile 60E1A1
Closure Rails – Profile 60E1
Length: 20,390m
Geometry: 1:38,46
16.11.2016 HG Vortrag TER Wien 25
Swing Nose Crossings for High Speed Turnouts
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voestalpine VAE GmbH
SNX with Long Wingrails: Long Wing Rails made out of profiles 60E1 and
60E1A1
Point and Splice Rails – Profile 60E1
Length: 23,013m
Geometry: 1:38
SNX with Long Wingrails: Long Wing Rails made out of profile 60E1
Forged Vee Block
Closure Rails – Profile 60E1
Length: 23,016m
Geometry: 1:38
16.11.2016 HG Vortrag TER Wien 26
Swing Nose Crossings for High Speed Turnouts
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voestalpine VAE GmbH
General High Speed Turnout Geometry High Speed Turnout Technology Switching Technology for High Speed Conclusion
LCC
Performance, Quality
Costs
16.11.2016 HG Vortrag TER Wien 27
Content
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voestalpine VAE GmbH
28 16.11.2016
Pre – assembly
One stop shop including transportation, installation, commissioning
Easy Interface to the interlocking
Space requirements
Easy manual operation
Resistant to snow, Ice, heat, sand
Others
HG Vortrag TER Wien
Customer requirements for HS Setting Systems
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voestalpine VAE GmbH
29 16.11.2016
Multiple single Point machines With/without End Position Detection
With local intelligent interlocking
every motor connected to remote interlocking
1 point machine for the switch, 1 for the frog Hydraulic connection
Mechanical rods
1 point machine for whole turnout – “COMBI”
Hydraulic connection
HG Vortrag TER Wien
Possible Solutions for HS Setting Systems
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voestalpine VAE GmbH
Multiple Single Drives
Connection to a “Local Interlocking Unit”
16.11.2016 HG Vortrag TER Wien 30
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voestalpine VAE GmbH
Multiple Single Drives
Connection to a Remote Interlocking
16.11.2016 HG Vortrag TER Wien 31
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voestalpine VAE GmbH
1 point machine for the switch
1 for the frog, hydraulic connection
16.11.2016 HG Vortrag TER Wien 32
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voestalpine VAE GmbH
33 16.11.2016 HG Vortrag TER Wien
Space Requirements for HS Setting Systems
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voestalpine VAE GmbH
34 16.11.2016 HG Vortrag TER Wien
Space Requirements for HS Setting Systems
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voestalpine VAE GmbH
Combines switch area and movable frog
System solution suitable for 2+1 and 3+2 locking positions
One active unit for switch area and movable frog
One active
unit
HYDROSTAR® ZV
Hydraulic coupling
switch / MPF
Only one electrical interface to
the interlocking cabin necessary!
HYDROSTAR® - Combi
16.11.2016 HG Vortrag TER Wien 35
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voestalpine VAE GmbH
36
16.11.2016 HG Vortrag TER Wien
High Performance Switching System Combined modulus designed setting, locking, detection system
For Switch devices and Moveable Point frogs
Requirements of innovative DLD D 3.2.5.
„…The ÖBB system has been successfully implemented on many switches. The
safety level is among the highest …
Therefore thus design can be taken as a reference for the Innotrack proposal as
described in the framed part…“
HYDROSTAR® - An Example
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voestalpine VAE GmbH
37
16.11.2016 HG Vortrag TER Wien
HYDROSTAR® - Overview
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voestalpine VAE GmbH
Applicable for turnouts with 10 setting levels in the
switch device and 4 in the movable frog section
Unique form fit locking principle
Locks the closed and the open tongue rail => the
system is not trailable
Applicable for slab track and ballast track
Visual end position indicators for manual operation
HYDROSTAR® - Functionality
16.11.2016 HG Vortrag TER Wien 38
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voestalpine VAE GmbH
Gauge ≥ 1430 mm
Switch opening: e.g. 70 / 78 / 88 / 98 / 118 mm
Swing nose opening: 29 to 120 mm continuously
adjustable
Not trailable
Setting time 4 to 12 seconds
Operational temperature range:
-40°C to +70°C
HYDROSTAR® - Technical Data
16.11.2016 HG Vortrag TER Wien 40
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voestalpine VAE GmbH
General High Speed Turnout Geometry High Speed Turnout Technology Switching Technology for High Speed Conclusion
LCC
Performance, Quality
Costs
16.11.2016 HG Vortrag TER Wien 41
Content
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voestalpine VAE GmbH
• Optimal Turnout
Geometry
• Most suitable
component design
• Preassembled Turnout
in the workshop with
tight tolerances
• Just in time supply
Highest Initial
Quality
• Smallest maintenance
requirements
• Longest Lifespan
• Life Cycle Cost
Optimisation
16.11.2016 HG Vortrag TER Wien 42
Plug and Play Turnout with JIT Supply
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voestalpine VAE GmbH
Thank you!
Heinz Ossberger
Head of Corporate Engineering and R&D
voestalpine VAE GmbH
16.11.2016 HG Vortrag TER Wien 43
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