craig bishop, vae railway systems - turnout manufacture in australia

Download Craig Bishop, VAE Railway Systems - Turnout Manufacture in Australia

Post on 21-Aug-2014




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Craig Bishop, Engineer Manager, VAE Railway Systems delivered the presentation at the RISSB’s 2013 Rail Turnouts Workshop. The RISSB’s National Rail Turnouts Workshop 2013 gives all those involved an in-depth forum to consolidate and share the latest technical information for rail turnouts. Drawing on industry expertise, the workshop features technical and practical presentations that address key turnout functions in an every-day operational context. For more information about the event, please visit:


  • by Craig Bishop Engineering Manager VAE Railway Systems Pty. Ltd. Turnout Manufacture in Australia
  • To provide an insight into the key issues in the manufacture and supply of turnouts: The contractual issues that must be addressed Before During After The design and development functions to meet specifications The manufacturing and inspection processes Final Processing, Quality, Dispatch
  • I. Background II. Requirements Technical / Design / Materials / R & D III. Manufacture of Turnouts & Components Processs (Drill / Bend / Machine / Weld) Tooling Assembly (Switches / Crossing / Components) IV. Special Manufacturing Processs Flashbutt welding / Explosive Hardening V. Testing and Quality Assurance VI. Conclusions
  • Manufacturing In Australia There are only a few specialised suppliers that can manufacture & supply turnout assemblies in Australia. The industry is very specialised, with employees usually trained in house or from people with railway backgrounds. Traditionally turnouts were supplied only to the Rail Systems to their designs. Experience in Turnout knowledge is decreasing with allot of new designers, consultants & contractors. Allot of contracts are by tender with contractual conditions and a technical specification. Many of the supply contracts are also performance based and will require new designs with defined benefits.
  • Manufacturing & Supply in Australia (The supply of turnouts is varied and complicated with many requirements that affect manufacture) Customer specific Package Supply Partial or complete assemblies Variance in contract specifications Quantity of Turnouts Gauge required or dual gauge Specialised materials involved Rail size, many options Expansion Switch
  • Initial Requirements: Actions needed prior to manufacture. Technical clarification Design requirements Materials Research and development Timeframe / Delivery
  • In the Beginning: Is there special turnouts required (Not Standard) Are there existing designs available Complete supply, partial supply or just components What are the long leadtime components/ specialised components Are there type approvals required and are drawings required for customer approvals and manufacture What installation & maintenance information required **Generally due to the number of variations it is necessary to complete a separate work order or materials list for each turnout to cover all the specific purchased and manufactured parts**
  • How does the manufacturer ensure that the product will be configured correctly for the customers needs? Use an Identification Sheet Review specifications Ask questions up front Clarify anything that is uncertain Identification sign off sheet
  • Major items that cause delays: What is to be supplied (Scope) Handing of turnouts Rail type Inbearers/ concrete / Timber / Steel Positions of GIJs (if required) Type of operation of the turnout Switch Machine Specs & location Special designs (long leadtime) Complex Dual Gauge Turnouts Rail Rolling Mill Leoben, Austria
  • Additional functions that now form part of the manufacturing process: Trying to standardise designs between customers Fitting new designs to specific areas (civil interface) Approval drawings Weight and length calculations (lifting information) Assembly and Maintenance documentation
  • Crossovers Scissors Crossovers Flexed Turnouts Simiflexure Contraflexure Dual Gauge Turnouts Diamonds Mixed Gauge Diamonds Lap Beams Diamonds Double Slips Single Slips Expansion Switches Specialised Trackwork QR - Roma Street Flexed Scissors Crossover
  • Examples
  • Design Requirements for manufacture Layout drawings Manufacturing or details drawings Individual drawings for CNC programs Drawings for specialised components Modeling of components Checking of all drawings (Quality Assurance for design) Drawings and documentation submitted for approval Technical purchase information and details for suppliers **Some special designs may contain up to 25 drawings to complete for manufacturing** Jointless Boltless Managanese Cast Crossing (Monoblock) - 3D Model for casting
  • Typical Turnout Layout
  • Supporting design functions required Ensure interfaces of disciplines (Civil / Mechanical / Electrical) Concrete bearer coordinates and drawings for Suppliers The design and supply of operating rodding Special components (example. Castings) Bill of materials for manufacture Quality control / checksheets Loading and Dispatch documentation Interface between operating equipment & Swing Nose Crossing - Modelled to check interfaces
  • New Turnouts / Switch & Crossing Designs Require: Geometries to meet speed and axle loads wheel profiles to check overrunning conditions & transfer areas Machining angles, machining processs and special tooling CNC modelling for machining components Drilling positions and bolting arrangements Guarding of crossings and flange ways widths Crossing materials and hardness requirements Bearer type: timber / concrete / steel / polymer Plating, fastening and materials to suit nominated loads
  • Conventional full depth switch Tangential switch with asymmetrical rail Pivot heel switches Fixed heel switches Secant switch (non tangential) KGO tangential switch (new technology) Typical Turnout Switch Designs Tangential Switch SectionConventional Switch Section
  • Switch Assembly
  • Video of CNC program prior to actual manufacture CNC MACHINING
  • 5 15 18 10 24 50 30 35 150 40 100 22,510 200 180 160 140 120 100 Moveable high performance Swing Nose crossings Weldable into-track cast Manganese crossings With cast inserts Weldable into-track cast manganese crossings, prehardened Compound crossings with manganese-point and head Hardened wing and vee rails Fabricated crossings, bolted or with welded main and counter point annual load [MGT] axle load [t] speed[km/h] Crossing Types & Application
  • Manganese Nose Head Hardened Wing Rails SG iron Or Steel Blocks Head Hardened Heel Rails Flash Butt Welded To Manganese Nose Huck Bolts Elements of Compound Crossing
  • Standard Carbon Or Head Hardened Rail Manganese Insert Machined Top And Bottom Graduated Explosive Discharge Hardened Flash Butt Welded Heel Rails To Manganese Insert Submerged Arc Welded Heels SG Iron Blocks Huck Bolts Elements of Welded Heel Rail Bound Crossing
  • Base And Top Face Fully Machined Flash Butt Weld With VAE Austenitic Interface Process Graduated Explosive Depth Hardened Transition Faces All 4 legs welded onto casting The crossing assembly has no bolt holes Elements of Monoblock (JBM) Crossing
  • Swing nose crossing designs are supplier specific Very complex to design Each manufacturer has developed a SNX to suit their own, and customer requirements A swing nose crossing is dependent upon the loads, type of operating system and the sleeper geometry Are used for specific requirements, heavy haul, noise reduction Require special rollers Require signalling interface Swing Nose Crossing Design (Moveable Point Frog)
  • Typical SNX Sections
  • Typical Swing Nose Crossing
  • Special Component Design Material finishes: Attention to detail Ensuring all sharp edges are removed Stress elimination Development of new parts Stress considerations Finite element analysis Risk assessment
  • Materials used are very dependent upon the specification and the references to other Standards. Manufacturers and suppliers must manufacture to the standards, specifications and certify their products. Items such as: Manganese castings with heat details and metallurgical tests. Glued insulated joints with alignment and electrical testing. Switch machines by serial numbers. Operating rodding sets by compliance numbers. Material Specifications and Availability
  • Currently R & D forms an important part of the manufacturing process Most new proposals are submitted by manufacturers to improve performance or reduce costs (life cycle costing) Where new products and proposals are offered the manufacturer becomes respons