UEEIV – SIH

Die Erneuerung von Eisenbahnweichen

mit langlebigen und wartungsarmen
Komponenten

Oktober 2009

VAE GmbH
www.voestalpine.com/vae
  32 companies
The VAE Group  19 countries
 4100 employees
North America:
8 locations
Europa: 19 locations

Mexico:
1 location

Asia: 5 locations

South America:
1 location

South Africa:
3 locations Australia: 1 location

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PRODUKTPALETTE:
Weichen und Gleisanlagen
- Standardweichen
- Weichen für Metro und Straßenbahn
- Weichen für Hochgeschwindigkeit
- Weichen für Schwerlast
- Gleisanlagen und Komponenten (Dilatationen, Isolierstöße…)
Weichen Stellvorrichtungen
- Verschlüsse (SPHEROLOCK)
- Hydraulische Stellvorrichtungen (HYDROSTAR…)
- Elektrohydraulische Antriebe (CONTEC)
Weichen-Überwachungen
- Elektronische Überwachungen
- Elektromechanische Überwachungen
Fahrzeug Überwachungen u.a.
- Heißläuferortung …
- Fahrleitungsüberwachung…(Fa. SST)
Spezifische Beratungen und Untersuchungen

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Weiche auf
Holzschwellen

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 Weiche auf Holzschwellen
mit Pandrol Fastclips
 
 
 

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Weichen auf
Betonschwellen

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Maximum Initial Quality
quality Higher Initial
Quality
HIGH extends
initial quality MAINTENANCE
PRE- INTERVALS
ASSEMBLED

LOW
initial quality

time
maintenance maintenance maintenance End of lifetime

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Preassembled turnout
loading of the switch section

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VAE GmbH
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VAE - BWG TECHNOLOGY: DIVIDED CONCRETE SLEEPERS FOR
TRANSPORTATION OF PREMOUNTED PANELS

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Delivery of pre-mounted Turnouts on concrete sleepers to site

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Vormontierte Weiche
Komplettlösung – Steckerfertig Plug & Play

 Voll funktionsfähig
vormontiert
 “Just in time” an
die Einbaustelle
 Kurze
Einbauzeiten
 Kurze
Streckenssperre
 Spart Zeit und
Geld

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WEICHE AUF BETONSCHWELLEN

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TURNOUTS ON SLAB TRACK

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 BWG
Direct Rail Fastening with Pandrol Fastclip
  and through - bolts
 
  or tension clip Skl 14
with sleeper screws

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 BWG
High elastic Fastening
Type FPURp 620-000

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 High-elastic base plate system
„Brandenburg“

Steel base plate

on top of elastic pad

elastomer
springs

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Switch device on wooden bearers
 

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Zungenvorrichtung auf Betonschwellen

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 Damages on tongues
  Lack of grinding is leading to material breakage.
 
  NO WELDING ON FLEXIBLE AREAS OF TONGUES !

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BROKEN SWITCH BLADE TOP
NO WELDING ON FLEXIBLE AREAS OF TONGUES !

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 Branding 60E1A1 (ZU1-60) R260 (S900A)

DO 07 60E1A1

Name of Steel grade Year of Rail section

manufacturer rolling

VAE GmbH
www.voestalpine.com/vae
Head hardened tongue rail from steel grade
R350HT according to EN 13674-2

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 Steel grades acc. EN 13674-series
and new developments
Hardness Brinell
Tensile strength
Alongation in %
(….) = According to UIC860
GRADE HB N/mm² %
R260 (900A) 260-300 880 10
R320Cr (1100) 320-360 1080 9
R350HT (-) 350-390 1175 9 Head hardened
R350LHT (-) 350-390 1175 9 Head hardened
R370LHT (-) 370 1280 9 Head hardened

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 Optimized Transition Geometry
FAKOP / KGO
Ohne FAKOP

Mit FAKOP

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FAKOP / KGO Turnout Design
A-x

15 mm 1435

A-x

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TOZ TRAGFÄHIGKEITSOPTIMIERTE ZUNGEN

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Schmierung von Verschlüssen und Gleitplatten:
 
 
Hoher Verbrauch von Schmiermitteln
Schotterbett wird verschmutzt
Gefahr für das Grundwasser
Gefährliche Arbeit am Gleis

Schmierungsfreie Weiche:

Kein Schmieren von Zungenvorrichtungen

Kein Schmieren von Verschlüssen

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LUBRICATION – FREE
 
 
ECOGLISS - INSERTS

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SAFEROLL of Austrian Railways

 to eliminate lubrication of
sliding chairs and for use in
switch devices and movable
crossings.
 Retrofitting is possible
 Disadvantage:
Position between sleepers

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BWG, Integrated switch roller, lubrication – free plate

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Roller device
PIROLL

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iFAST with PIROLL
Inner side rail fastening and switch roller

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 Weichentechnologie
neue Befestigungsmittel und Rollensystem
iFAST
innere elastische Backenschienenbefestigung

iFAST clip

PIROLL
Tandem roller

PIROLL
integriertes
Rollensystem

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 Weichentechnologie
Rollen für bewegliche Herzstücke

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Locking Mechanism
Clamp Point Lock vs Spherolock
Open locking device FULLY ENCAPSULATED SPHEROLOCK:
with LOW MAINTENANCE NEED
High maintenance need

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 FUNCTION PRINCIPLE OF SPHEROLOCK

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 SPHEROLOCK RETOFITTED
with traditional switch machine

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SPHEROLOCK®
 Installations between sleepers or in hollow sleeper

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 SPHEROLOCK® innovative locking device
 Technology

 Same functionality as a
conventional Clamp Lock
 Innovative locking by locking jaws
integrated in cylindrical houses
 Permanently lubrication
 Encapsulated design
 Reduced vibrations – dynamic de-
coupling between switch and lock
 Completely pre-assembled lock –
easy to install – no machining at
the installation site

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The Austrian Group:
Hydraulic Setting Devices and Electronic Monitoring
Systems as Standard at Austrian Federal Railways

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High Speed Rail Link Taiwan, Turnout
Monitoring System VAE Roadmaster 2000
 All turnouts are
equiped with VAE
Monitoring System
„Roadmaster 2000“
 Multiple number of
switch machines !!!

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 Hydrostar Switch High Speed Turnout
 
Only 1 Switch machine necessary !
 
 

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SPHERLOCK INSTALLATION
ON CROSSING WITH MOVEABLE POINT

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 Crossing point - product range
Application on basis of optimal Lifecycle-costs
Moveable high performance point crossings
Weldable into-track cast manganese
crossings, prehardened
Weldable into-track cast manganese crossings
Compound crossings design VARIO 1800 crossing
point high strength steel W720, Wingrail Mn13
Compound crossings design VARIO 1800 crossing
point high strength steel W720 Wingrail HSH
Compound crossings with FVC-point and HSH wing rail
or in fineperlitic design
Fabricated crossings, bolted or with welded main and
counter point
200
180
speed[km /h]

160

140

120

100

axle load [t]

10 15 18 22,5 24 30 35 40 annual load [MGT]
5 10 50 100 150

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  TRANSITION
CROSSING INSERT & WORN WHEEL

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 Assembled Crossings
Application on basis of optimal Lifecycle-costs

200
180
160
speed [km/h]

140

120 PERLIT 1300

100 COMPACT 1400

axle load [t]

10 15 18 22,5 24 30 35 40 annual load [MGT]
5 10 50 100 150
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 product range Weldable into-track cast manganese crossings
Application on basis of optimal Lifecycle-costs

MONO MN 13

CENTRO MN 13

200
180
160 INSERT MN 13
speed [km/h]

Weldable into-
track
140 cast manganese
crossings
120
Weldable into-
100 track cast
manganese COMPOUND MN 13
crossings,
prehardened
axle load [t]
10 15 18 22,5 24 30 35 40 annual load [MGT]
5 10 50 100 150

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 WELDED CAST CROSSING IN TRACK
 
 
 

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 Milling of AMS (Mn13)
Crossings
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Manufacturing Equipment
Flash Butt Welding of cast crossings

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Explosive hardening
EDH

Hardness in Brinell
VAE GmbH 331 - 401 220 - 250
56 285 - 331 200 - 220
250 - 285
Cast Crossing „CENTRO Mn13“
with welded – on legs

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 STANDARDS AND NORMS FOR
THE DESIGN OF TURNOUTS
VAE has best knowledge of International Standards and is member of
Counciles of European Norms.
International Standards for turnout design and production are:
UIC – Standards
EN – Standards
TSI – Standard for Interoperability

VAE GmbH
www.voestalpine.com/vae
 STANDARDS OF UIC
CONCERNING TECHNICAL CHARACTERISTICS OF MATERIALS
 
FOR DESIGN AND PRODUCTION OF TURNOUTS
 
  (Selection)
Techn. Specification for the supply of rails UIC Code 860
Techn. Specification for standard profiles for point rails UIC Code 861-2
Techn. Specification for 60kg/m rail profiles UIC Code 861-3
Techn. Specific. for the supply of non-treated track supports UIC Code 863
Techn. Specification for the supply of sleeper screws UIC Code 864-1
Techn. Specification for the supply of steel track bolts UIC Code 864-2
Techn. Specification for the supply of spring steel washers UIC Code 864-3
Techn. Specification for the supply of fish-plates of rolled steel UIC Code 864-4
Techn. Specification for the supply of rail seat pads UIC Code 864-5
Techn. Specification for the supply of baseplates of rolled steel UIC Code 864-6
Techn. Specification for rolled profiles for baseplates for UIC rails UIC Code 864-7
Techn. Specification for rolled profiles for fish-plates for UIC rails UIC Code 864-8
Techn. Specification for the supply of cast manganese steel crossings UIC Code
866
Geometry of points and crossings permitting deviation speeds ≥100km/h UIC Code 711 R

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Wear-Ratios for different pearlitic Rail - Steels
improvement ratio of wear resistance

10
8,5
7
5 5
37
4 0L
HT
3 35 ,U
3 0H HC
32 T
0 Cr
2 26
1,7 0
22
0
1

200 220 260

260 320Cr 350HT 370LHT, UHC
Source: ERRI and European Railways
base grade for rails

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 Head-hardening of the rail, directly from the rolling heat

“HSH” Head Special Hardened

= R350HT, R370HT according to EN 13674-1

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 EUROPEAN STANDARDS OF CEN
CONCERNING DESIGN AND PRODUCTION OF TURNOUTS
(Selection)
  EN 13145 Wooden bearers for track and turnouts
 
 
EN 13230-4 Concrete sleepers for turnout and crossings
EN 13232-1 Turnouts and crossings: Definitions
EN 13232-2 Requirements for geometrical design
EN 13232-3 Requirements for wheel interaction
EN 13232-4 Actuation, locking, detection
EN 13232-5 Switch devices
EN 13232-6 Fixed common and obtuse crossings
EN 13232-7 Crossings with moveable parts
EN 13232-8 Rail expansion joints
EN 13232-9 Turnout assemblies
EN 13481-7 Fastening systems for switches and crossings
EN 13674-1 Vignole rails ≥46 kg/m
EN 13674-2 Switch and crossing rails
EN 13674-3 Check rails
EN 14811-1 Special rails (grooved rails)
prEN 15689 Cast manganese steel for crossings

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DANKE
FÜR DIE
AUFMERKSAMKEIT

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