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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

Innovations in high (speed) performance maintenance

WP4 Ulla Juntti

Luleå University of TechnologyOctober 4th Paris

www.automain.eu

A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

High performance maintenance

High performance maintenance is a combination of all innovative, technical, logistic and managerial actions during the life cycle of any engineering asset to assure high dependability with minimum cost.

www.automain.eu

A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

Objectives

To provide more capacity for freight trains by: Speeding up large scale maintenance (e.g. grinding and

tamping) by elimination, reduction /isolation of performance killers, and elimination of cost and risk drivers.

Reduce maintenance time for switches and crossings by introducing a modular approaches, including the future technological requirements and current IMs’ practices.

Develop methods for introducing optimal maintenance methods and principles.

www.automain.eu

A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

tasks

1. Identification & documentation of performance killers and drivers which will facilitate development of guidelines to deal with performance killers;

2. High performance grinding3. High performance tamping4. Modular switches and crossings5. Optimised maintenance systems/principles and its

application

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

1. Performance killersGrinding (5)

Bad rout planning and short worksites Production targets not aligned to possession duration Lack of maintenance strategy and clear objectives Lack of cost effective maintenance limits (Thresholds) for

grinding Not adequate reporting of conducted maintenance, lack of

maintenance history Planning of possession time is not coordinated Lack of information (check list) about personnel skills,

education check list Lack of measurement equipment for monitoring RCF, wear,

plastic flow The instructions on how to grind is made manually, which put

a high demand on the personnel, mistakes are often made due to e.g. stress.

Low capacity on grindings vehicles No reports /lacking quality of conducted maintenance Data is stored in paper format in different files, not always

available when needed Reliability of grinding vehicles are not so good, the

supportability of spare parts is not good enough. Lack of modules/software for evaluation of each grinding

cycle No or lacking storage locations for grinding vehicles Only way to reach the grinding site is by track, not possible to

lift outside track when train passes. Bad quality on condition measures, not presented as easy

decision support Lack of enhanced planning software for optimised grinding on

a route by route basis

Tamping (3) Low utilisation of possession time, Time spent on

travelling to and traversing the work site (an issue likely to get worse given the tendency to remove switches an sidings), and other aspects related to the abilities of the equipment used.

Distance between the machine stabling point and the worksite

More knowledge of degradation, it is unclear how far track should be allowed to deteriorate and what rate should trig a special maintenance activity

There is insufficient understanding of the optimum point at which to plan intervention

Lack of standardisation regarding key tamping parameters such as the optimum speed of tamping, the pressure to be applied to the tamping tines, and the depth at which they are inserted. It was suggested that there is a need for better guidance on the optimum approach.

Better analysing of existing track recording data to trend deterioration rates

Limited flexibility and highly variable capability between machine types

Slow moving in between scheduled service trains the other work activities going on at the same work site

are interfering

Switches and crossings (2) ?

Lean analysis and Value Streamed mapping

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

2.High Performance grinding

To remove RCF, corrugation, wear and plastic deformation to increase LCC and life length

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

7

2. Rail Defects examples

Head checks Reduction of life

span Danger of rail

fracture

Danger of shelling

Squats - Reduction of life-span

- Danger of rail fracture

Corrugation- Noise

- Damage to the track

- Reduction of rail life-span

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

High Performance grinding

To remove RCF, corrugation, wear and plastic deformation to increase LCC and life length

Ongoing; Analysing Performance killers and cost drivers (Result from VSM)

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

2 .Grinding results

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

2. High Performance grinding

To remove RCF, corrugation, wear and plastic deformation to increase LCC and life length

Ongoing; Analysing Performance killers and cost drivers (Result from VSM)

Innovation = HSG High speed grinding, concept by Vossloh

Innovation by- High Speed Grinding -

Non-Intrusive Rail Maintenance

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

12

Rail Defects

HSG acts before surface defects develop

HSG removes the worn surface layer of the rail and prevents Rolling Contact Fatigue

Regular grinding with small material removal extends the rail life cycle

Technical University of Berlin has calculated a 50% reduction in life cycle costs

Def

ect d

epth

New rail Accumulated traffic (MGT)

Rail wear limit

No grinding

Rail life span without maintenance

Conventional preventive grinding

Corrective grinding

Rail life span with conventional grinding

HSG preventive grinding

Rail life span with preventative grinding

Preventativ Maintenance

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

13

Rail Defects

Countermeasures – Prevent Problem

German Way Rest of the World

Anti- Headcheck Profile(Stress relief)

E2-Profile0,3 mm removal per 50 MGT

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission14

HSG Grinding TechnologyConventional vs. High Speed Grinding

Conventional Grinding

HSG - High Speed Grinding

Speed 5 – 15 km/h 60 – 80 km/h

Material Removal~ 0,3 mm

(30 cm³/s, 320 g/s)~ 0,05 mm

(55 cm³/s, 400 g/s)

Operation Track possessionWithin regular Traffic(no track possession)

Removal of electr. Devices

Yes No

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

3. High Performance tamping

Switch and linetamper

Universal 0-30mm 30-60mm 60-80mm LiftP&T type Sleepers 1x 2x 3x InsertationsUnimat 08-475-4S 1x 500 300 150 m'/hUnimat 09-16-4S 1x 800 600 300 B.

Unimat 09-32-4S 2x 1100 800 400 B.

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

Tamping - ongoing

Trials were carried out at Deutsche Bahn to identify the impact of tamping parameters on tamping performance and quality.

Further analysis of tamping shifts regarding needed time for different process steps lead to a better basis for optimization and identification of “waste”.

First LCC analyses demonstrate the impact of tamping strategies on life cycle cost, quality and life time of track.

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

Modularisation of Switches and crossings

Subsystem to be modularised has been chosen, but 4.4 is behind schedule and still waiting for the VSM workshops and structured observation at NR and TrV.

Innovation – how to measure the degradation

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

S&C Monitoring Camera

Dan LarssonDamill AB

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

The Camera Kit

Prototype with weight of approx. 3 kg

WiFi router for wireless access

Web camera viewed via browser

Batteries for 6h operation

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

Installation

Installation time < 5min Isolated rod with bayonet

mount tip is attached to the camera kit

The overhead line has power still on

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

Camera in Position

Hook locked to catenary wire Stabilized by a fork around

dropper.

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

The Very First Images

Resolution 1600x1200 pixels

Contact wire in front

(Press NEXT PAGE again to animate switch changed)

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

Next Steps & More Ideas

Add a continuous power supply (not batteries) and get it safety approved for 16kV use.

Reduce weight. Add tilt motor to scan along track, 10-15 metres. Increase resolution (replace camera) to support

measurement from image. Test standard illumination from different angles. Test laser line illumination (3D-effect for sharp contours

and calculation of height of components).

www.automain.eu

A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

5. Optimised maintenance systems

Develop a generic optimization principle to complement the high performance maintenance in reducing track possession time leading to availability and capacity improvement at lowest possible LCC.

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

Models

1. Link and effect Model has been developed and failure data from a line in Sweden have been collected for verifying the model and to identifying the performance killers, so that improvement over track availability can be achieved. The preliminary results are encouraging.2. Capacity Model: The capacity model has been developed and data from another line has been collected and used for verification.

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

Link and effect model

Continuous monitoring through drivers and killers

Automatically updated compass with drivers and killers (D&K)

D&K• …• …

D&K• …• …

D&K• …• …

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

Capacity model

Maintenance actions considered includeInspectionGrindingTampingReplacement: Sleepers, IRJ, Fastener, other component

These four actions have the most track possession timeThese are core maintenance actions to control degradation (rail& track quality) & also availability

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

OPTIMISED MAINTENANCE SYSTEM

Track design capacity assurance The designed reliability and

availability for the existing tracks Availability Optimization

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

Track maintenance& cost Data

Degradationmodels for

rail track

Maintenance optimization and simulation models

Input parameters: Traffic density, Axel load Various forces, Train speed and Line description etc.

Input parameters: MTBF, MTTR, delay cost, hazard cost, cost of Loss of operation

replacement cost, labor cost etc.

Improved capacityat lowest LCC

Improved track availability at

lowest LCCObjectives

Framework for railway track maintenance optimization

Automated planning & scheduling

Grinding intervalTamping intervalInspection interval

Boundary limits to perform inspections, preventive

& corrective maintenance schedules

Economic→ Cost→ Profit

Technical→ Availability→ Reliability→ Lifetime

Safety/Risk→ Human→ Environmental→ Equipment

Traffic operation and condition

Data

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A Joint Research Project funded under the Seventh Framework Programme (FP7) of the European Commission

Deliverables/Milestones

D4.1 Improvements analysis; Improvements in high performance (speed) maintenance and modular infrastructure

D4.2 Optimised maintenance activities: Optimised maintenance activities, like grinding, tamping and other maintenance processes

MS6 Guidlines for High Performance maintenance