Innovative technology for transporting and longitudinal unloading of turnouts in blocks
The aim of the project is to develop an innovative technology for transporting and longitudinal unloading of turnouts in blocks. As a result, a technology demo will be created, consisting of Switcher wagons and supplemented by a flat platform wagon and gantry cranes with a transport cart.
At present, in Europe there is no solution for installation of a prefabricated turnout (in blocks) on a one-track line. The critical point on multi-track lines is the recurring difficulty with obtaining track possession approvals, which often results in abandoning the prefabricated turnout construction method (in blocks).
The innovative technology will consist of:
- Transport technology using a new Switcher wagon equipped with a flat platform and using a set of gantry cranes and a transport cart;
- Unloading technology – unloading with a set of gantry cranes;
- Installation technology – transport of turnout blocks with a cart which can enter the turnout installation area on wheelsets and road-rail sets.
The developed technology will allow for unloading and installation of turnout blocks with radius of up to 1,200 meters on one-track lines and double-track lines without the possession of the adjacent track.
Installation of turnouts in blocks guarantees that the initial quality and parameters of the turnout provided by the manufacturer are maintained. It is commonly known, the initial quality translates directly into the durability of the turnout structure – the number and frequency of maintenance operations, the number of potential failures, reliability and service life of the entire structure.
New features and functionalities compared to alternative technologies will be as follows:
- The possibility to transport turnout blocks with a total weight of up to 49 tons on a one-track line from the wagon to the installation site, possibility to transport all turnout blocks with a radius of up to 500 meters at the same time. For turnouts with a radius over 500 m – transporting the entire turnout in two passes. Such system/technology functionality will eliminate shunting in order to position the unloaded block at the end of the set. Eliminating a time-consuming operation of about 30 minutes per turnout block.
- The use of gantry cranes which ensure that there are no deformations that occur when other installation and unloading methods are used. The most frequent deformations (about 25% of manually installed turnouts) will be eliminated, i.e.: change in the spacing of switch sleepers, failure to maintain the resulting parameters for the steel parts of the turnout, replacement of installation parts.
- The use of a wagon with a non-tiltable and flat transport platform for transporting frog blocks with long block elements – no need for shielding wagons, increased mobility and transport efficiency. For turnouts with a radius of 760 and larger – transporting frog blocks will not require shielding wagons. The cost of transport will decrease by approximately 5–10% (excluding two Res 412 wagons behind and changing the locomotive to a heavier one).
With new technology we will be able to instal turnouts with a radius of up to 1,200 meters on single-track lines, on double-track lines without actually possessing the adjacent track, and on station systems. As the same time, the unloading time will be reduced to about three hours.
The logistic system for transporting turnouts by KZN Bieżanów guarantees high initial quality of the installed turnout structures. The system protects turnout blocks against deformation and damage at the stage of loading at the production plant, transportation and unloading at the site of installation. The base of the system constitute the specially designed and constructed Switcher platform wagons – integrated with a safe and precise lifting system and modules for fixing and stabilizing during transport.
The new logistic and technological model for turnout installation will consist of a combination of the Switcher system (supplemented by an additional wagon – a flat platform) and a system of gantry cranes equipped with a specially designed transport cart. Such a combination will make it possible to quickly and precisely instal the turnout in the target location. The use of this technology on one-track lines is the only way to instal a turnout as a prefabricated system. In the case of station systems, the most important thing is the installation time and to limit the time of occupying neighboring tracks. With the new technology, this time will be significantly shortened. Another important aspect of this technology is the protection of railway control command and signaling equipment and catenary components.
