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VAE GmbH

www.voestalpine.com/vae

VAE GmbH

www.voestalpine.com/vae

DIL

.01

Rail Movement Joints

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DiamondsDILATATIONEN

Buffer Stops

SleepersCoach-Screws

Transition RailCheck Rail

Insulating Joint

Layouts, Turnouts andTurnout Components

Setting Devices

Electronic Systems

SPECIAL TRACKWORKCOMPONENTS

Intelligent Turnout Systems,Logistics

Ramp Crossing TurnoutTrailable Turnout

2


Dilatationen

SWITCH TO THE RIGHT TRACK

Rail movement joints are required

when tracks are layed across

engineering structures such as

bridges and viaducts. These struc-

tures are exposed to changes in

lengths due to ambient influences

like traffic load, temperature and

wind. These influences sometimes

lead to angular rotations of the

end spans in the abutment.

Rail movement joints are installed

to bridge such length variations

and - if required - to accommodate

angular rotations of the end spans.

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Buffer Stops



Insulating Joint


Setting Devices

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3


Optimised geometry and wheel/rail contact

Milling of the switch rail Manufactured with integrated CAD/CAM systems from special high-tensile materials, e.g. S900 A, HSH (Head Special Hardened), high-manganese cast steel.

Less wear

Lower forces

Reduced accelerations

Less maintenance

Low life cycle costs

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Optimization of rail movement joints by use of

Multibody-dynamic vehicle simulations as mass-spring-damper system and track with variable sections

Computer Aided Design CAD

Finite element analysis

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The contact area of wheel / rail corresponds almost completely with the design criteria of a switch device.

Wheel contact geometry (Del-ta-Kappa, constant curvature difference with different wheel positions)

Load-optimized switch and wheel transition

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Buffer Stops



Insulating Joint


Setting Devices

Electronic Systems




4


Different microstructure and hardness in the switch rail sectionl

Milling of the switch railProduction

The rail movement joints are

manufactured in accordance with

the technical terms of supply of

UIC and CEN, supplemented

by specific requirements of

the customer and the decade-

long experience of VAE.

The switches are prepared for

mounting of common types of

locks and switch machines.

For medium and high loads the

material grade R260 (S900) is

used for stock rails and switches.

Cast troughs are made from

high-manganese steel according

to UIC 866 and machined on the

running and the contact surfaces.

For highest loads, rails grade R350

HT (S900 HSH) (Head Special

Hardened) are used. They are

manufactured using a special

heat-treatment process. The fine

perlitic structure has particularly

high wear resistance, high tensile

strength and elongation which is

important in case of rolling contact.

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Buffer Stops



Insulating Joint


Setting Devices

Electronic Systems




hardened area

shape of the milled tongue rail

hardeness HBW

5


Forging manufactured

Forging designed

Inductive Heat Treatment

Switchblade forging

The asymmetrical switch profile is

forged at the end to the required

rail profile. The tools and devices

for this essential technology are

designed and manufactured by

VAE in order to ensure top-class

quality and a reliable manufac-

turing process. The welded joint

is never in the transition area.

Heat Treatment

The zone with decreasing hardness

values in the HAZ of the forging is

eliminated by VAE using an elec-

tronically controlled heat-treatment

process. This patented process of

VAE reduces the formation of soft

spots on the running surface of

the switch. After the forging, the

fishing table has the same dimen-

sions as the rolled rail. The area

of the head and foot is machined

to get the required dimensions.

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Buffer Stops



Insulating Joint


Setting Devices

Electronic Systems




6


Rail Movement Joints „Scarf Type“ The expansion rails for small and

medium range of movements are

made from halved flat-bottom

rails or full-head rails. Some

railways use this type of rail

movement joint for securing the

end of a continuously welded

track. For securing the gap in

the running edge (dependent on

design) a check rail is required

for medium expansion lengths.

Technical characteristics: Advantages

Short length

Economical solution for short movements

Depending on design, no welded joint

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Material grade Designation for stock rail and switchblade Hardness[HB] Tensile Strength

R260 (S900) x x 260 - 300 min. 880 N/mm²

R350HT (S900 HSH) x x 350 – 390 min. 1175 N/mm²

Technical characteristics:

Expansion length ± 50 to ± 200 mm Speeds for low and medium speeds Axle loads for low and medium axle loads / annual loads Requirements for low and medium stability

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Buffer Stops



Insulating Joint


Setting Devices

Electronic Systems




7


Schienenauszugsvorrichtung mit längsbeweglichen asymmetrischen Zungen Rail movement joints in this design

consist of completely clamped

stock rails and longitudinally

moving asymmetrical switches.

Their design principle corresponds

with that of a switch device there-

fore no check rails are required for

this design. The gauge widening

in the different positions is mini-

mal. This design can also be used

for curved tracks up to R = 350 m.

Technical characteristics: Advantages

Proven and economical solution for medium-length movements

Suitable for standard fastening systems

Overrunning in both directions at track speed possible

High wear allowance

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R260 (S900) x x 260 - 300 min. 880 N/mm²


Technical characteristics:

Expansion length ± 100 bis ± 300 mm Speeds for medium and high speeds Axle loads for medium axle loads / annual loads

Requirements for high stability

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ENGINEERING

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Buffer Stops



Insulating Joint


Setting Devices

Electronic Systems




8


Rail movement joints with longitudinally moveable stock rails

Design with sledgeVAE has developed special rail movement joints for large bridges with corresponding longitudinal and rotational movements of the end span. Compared to conventional products of this type, the VAE developed product has the following features:

The stock rails move longitudi-nally in two symmetrically arran-ged cast troughs with integrated switches

Wheel transition like that in a switch device of a turnout

No gauge widening

No check rails required

Use of sledges between abut-ment and the bridge for expansi-on lengths of

up to ± 600 mm 1 sledge

up to ± 900 mm 2 sledges

from ± 900 mm min. 3 sledges

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Levers below the sledges make sure that the lengths of the gaps is evenly spread. At the same time, small rotations of the end span are accommodated.

For large bridges the rail movement joint is attached to the supporting structure of the bridge with large rotations of the end span by means of a flexible spline girder. Arising angular deviations are elastically accommodated in vertical and horizontal directions and thus the sensible area of the length modifications in the rails is kept free of deformations.

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SWITCH TO THE RIGHT TRACK

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Buffer Stops



Insulating Joint


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9


Dual-track design

Advantages

State-of-the-art solution for large movements

High wear allowance

Extremely low maintenance

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Technical characteristics

Expansion length ± 1100 mm and higher Speeds up to top speeds > 300 kph Axle loads for high and highest axle loads / annual loads

Requirements for highest stability

VAE BASICS

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Buffer Stops



Insulating Joint


Setting Devices

Electronic Systems




Technical characteristics


R260 (S900) x x 260 - 300 min. 880 N/mm²


MN13 x as per UIC866

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Monitoring of Rail Movement JointsMonitoring of Rail Movement Joints

VAE offers an electronic monitoring system for rail movement joints on large bridges. This guarantees that the operating condition of rail movement joints is supervised non-stop. The operator is given information around the clock on the following subjects:

Rail movements

Longitudinal movements of the sledges

Twisting of the sledges

Rail temperature

Ambient temperature

As a consequence, maintenance work for the rail movement joints can be matched to the actual requirement. Costly inspections according to fixed maintenance schedules are no longer required.

Possible inadmissible operating con-ditions can be detected in advance and corrected in time.

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VAE BASICS

PRODUCTS

ENGINEERING

QUALITY


Buffer Stops



Insulating Joint


Setting Devices

Electronic Systems




VAE GmbHRotenturmstraße 5-9A-1010 WienT. +43/1/531 18-0F. +43/1/531 18-222www.voestalpine.com/vae

vae_dil_en

Documents

switch rail sectionlmilling

high loads

switch machines

switch device

highmanganese steel

special hightensile

high wear resistance

high tensile strength