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

RISSB 2014 Turnout Workshop

Turnouts for low life cycle costs

Franz SODIA

MEng, MBA, MIEAust, CPEng

CEO voestalpine VAE Railway Systems


VAE Group: The Turnout People since 163 years

World Market and Technology Leader

4,500 people

42 locations


VAE: Turnouts, switch machines, monitoring

For all speeds, axle loads, gauges, profiles ...

speed

axle load


VAE Railway Systems in Mackay

State of the Art Design and Manufacturing


TCO (Total Cost of Ownership), LCC

Driven by the Initial Quality

Purchase costs

Operational costs


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


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


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


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


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)


GEOMETRY


What to take care for

Guiding and bearing: GEOMETRY



Y / Q ratio to be checked

R [ m ]

v [ km / h ]

μ [ - ]β [ grad ]

FG

FZ

Q

Y

β, μ



Maintenance reccomendations essential



Implementation of canted profile in turnouts

Grinding after installation

Canted plates

Asymmetrical rail

Milling in production



Asymmetrical clothoids

a, k

acceleration a and curvature k are

increasing linear along the way x

2

31

x

R1

R2

R3



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



Multibody dynamic simulation results

Distance along the track [ m ]

Latl

For c

eL

ftW

hA

xl e

1(N

e wt o

ns

x1000)

AREA Standard Turnout #20, 133RE rail

T/O 133RE-680-#20, tangential

Clothoid T/O 136RE10-4000’/2100’/4200’-#20 tangential, new proposal



Verification of simulation by field tests

55

60

65

70

75

80

85

90

95

100

105kN

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



Rail wheel contact and the sinusodiol run

b

b

r 2 r 1r



Sinusodioal run is interrupted in turnouts



KGO (Kinematic gauge optimisation) Stockrail gauge line under controlled variable gauge widening

Thicker tongue rail provides additional wear reserve



KGO (Kinematic gauge optimisation) KGO enables sinusodial run in turnouts by active kinematic steering



KGO (Kinematic gauge optimisation) Already standard at many Australian Railways


MATERIAL


Guiding and bearing: MATERIAL

Harder rails have positive effect at system wear

Hardness ratio rail / wheel

Wear

facto

r

0,5 1 2

0,5

1

2

Total System

Wheel

Rail



Latest stage of evolution: Bainitic rails



Full deep head hardened rails



Full deep head hardened rails



Cast Austenitic Manganese Steel Developed, patented and licensed by VAE

Explosive depth hardening state of the art



Cast Austenitic Manganese Steel Developed, patented and licensed by VAE

Explosive depth hardening state of the art


COMPONENTS


COMPONENTS: Switch device

Switch rail sections according to axle loads Including KGO and fully head hardened rails

AREA 136 TWUIC 60E1A1



iFast inner stock rail fastening



Compact roller systems Fully integrated in plate and retrofit


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

sp

ee

d [km

/h]

FABRICATED

COMPOUND

MONOBLOCK

MONOBLOCK

EXPLOSIVE

DEPTH

HARDENED

SWINGNOSE



(Swing) Spring Wing


CRADLE LONG WINGRAIL

MAXIMAL TRANSITION AREAS PER DIRECTION

WELDED CAST

32 2 23


SNX design principles


COMPONENTS: Crossings for > 40 t axle loads

SNX with long wing rails and AREA 136 TW


COMPONENTS: Switching, Locking, Monitoring

Pre-condition for pre-assembly and p&p install


High impact to initial quality

P&P installation only if switch machines included


Rodding and asymmetrical vibrating masses

Damaging ballast and avoiding tamping


Evolution step 1:

Encapsulate locking systems


Evolution step 1:

Encapsulate locking systems


Evolution step 2:

Transfer rodding in inbearers and enable tamping


Evolution step 3:

Transfer switch machine in one single inbearer


Evolution step 4:

Get rid of the inbearers


Evolution step 4:

Get rid of the inbearers


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


Remote condition monitoring

Fully integrated in switch machines


Example for latest state of the art evolution

> 40 t thick web KGO switch machine on sleeper


TCO CALCULATIONS


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


Investment decision methods

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



Similar investment horizon is essential

years



WACC of railway is essential driver


Evolution of Turnouts

Selection of intelligent design – by the client


Conclusion

Evolution or intelligent design? Intelligent design selected by the user.

„Innovation is

bringing inventions successful to the market“

Josef Alois Schumpeter,

1883 - 1950

http://www.google.at/url?sa=i&source=images&cd=&cad=rja&docid=cQeHITEUhONC0M&tbnid=Nvnf9aa3aj0khM:&ved=0CAgQjRwwAA&url=http://rogerpielkejr.blogspot.com/2012_05_01_archive.html&ei=2dmOUa-hNqqOiAfJ94DIDg&psig=AFQjCNEQ7lnmFqxJKbSlWojvy7QppDuKPw&ust=1368402778012258


Engineering

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