New standards for weld geometry

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1 STANDARDS FOR WELD GEOMETRY WELD REGISTER SOFTWARE Coenraad Esveld Esveld Consulting Services 1

2 EXAMPLE of TRACK INNOVATION New standards for weld geometry 2

3 ORCE SED ENT E-BAS ASSES SSME OF WELD GEO OMET RY 3 F

4 EXISTING WELD GEOMETRY STANDARDS Grind off top p<03mm 0.3 For example Versine: 0 < p < 0.3 mm 4

5 WELD STANDARDS BASED ON FORCE F = Constant v Inclination dyn * * 2 Inclination: High-Speed < 1.0 mrad Conventional < 1.8 mrad 5

6 VELOCITY APPROACH The dynamic contact force as a function of the first time derivative: 2 dz Fdyn = C* v dx z M u(t) = z(t) K v Inclination 6

7 QUALITY INDICES (QI) dz Fmax dx max QI = = 1 F norm dz OK dx norm QI 1: Accepted QI > 1: Rejected 7

FORCE-BASED STANDARDS Conven ntional HSL HH

2 mrad 60 km/h 0.89 mm 2.8 mrad 80 km/h 0.

2 mrad 140 km/h 0.57 mm 1.8 mrad 200 km/h 0.

8 FORCE-BASED STANDARDS Conven ntional HSL HH Speed Versine Inclination 40 km/h 1.02 mm 3.2 mrad 60 km/h 0.89 mm 2.8 mrad 80 km/h 0.76 mm 2.4 mrad 100 km/h 0.70 mm 2.2 mrad 140 km/h 0.57 mm 1.8 mrad 200 km/h 0.41 mm 1.3 mrad 300 km/h 0.29 mm 1.0 mrad 100 km/h 0.45 mm 1.4 mrad ILPROF n in RAI ntation mplemen Im Old norm mm, -0 mm Norm: QI=1 8

9 RAILPROF MEASUREMENTS 9

10 NEW STANDARDS VERTICAL Advantages new standards: 1. Negative welds accepted; 2. At 140 km/h versines twice conventional value; 3. Speed dependent. d 10

11 NEW STANDARDS LATERAL Speed Versine 40 km/h 1.0 mm 80 km/h 0.7 mm 140 km/h 0.5 mm 200 km/h 0.5 mm 300 km/h 0.5 mm ROF n RAILPR tation in mplement Im QI=1 11

12 1 CHECKS AT PRORAIL % Frequency % Cumulative % 1.8 mrad (140 km/h) Limit at 80 km/h 100 welds per group CDF Moerdijk - Dordrecht (VSRT) Delft - Den Haag Lage Zwaluwe - Hollands Diep Weld Quality Index [-] (140 km/h) 12

13 1 OLD VERSUS NEW STANDARDS New Standards km/h Cum mulative Fre equency % Population 239 welds 58% 46% 3% Old Norm (0 0.3 mm) Independent of line speed 16 % passed Maximum Absolute. Inclination of Weld Geometry (25 mm base) [mrad] 13

14 DYNAMIC FORCE Low correlation force and versine High correlation force and QI 14

15 PRACTICAL IMPLEMENTATION Procedure: Sample weld geometry with digital straightedge Filter measured signal Determine 1 st derivative (inclination) Normalize with intervention value for line speed Calculate QI. QI < 1: OK, otherwise: grinding. 15

16 PRACTICAL IMPLEMENTATION Bluetooth 16

17 PDA SCREEN V = 140 km/h QI = 1.06 QI uniquely shows where should be ground 17

18 P SO OFTW WARE KTOP DESK All data and graphs can be shown on a PC; Results in pdf-format can directly be ed to customer. 18

19 REGISTRATIEFORMULIER THERMIETLASSEN WEEK NR.: Lasbedrijf BAM Rail BAM Rail Services Veemarktweg 4a 5223 AA 's Hertogenbosch Telefoon: Fax: naar: Naam uitvoerder: Spoor van: en km.: Tussen km.: Project nr.: Empl.: Serviceorder nr.: Spoor/wl. nr.: 1) Aankruisen wat van toepassing is 2) invullen wat van toepassing is Klimaat Uitvoering 1) /2) Locatie 2) Tijdstip 2) Profiel 1) Materiaal 1) Situatie 1) Voeg 1) Gemaakt volgens richtlijn ProRail J/N 2) Kilometrering / Wisselnummer Been L / R Bevestiging vast gezet (J/N) Rupslas Trek apparatuur gebruikt Verwarmingswagen gebruikt (Aan)Sluitlas Voegloos spoor Bruikbare sps. Trillingen bij lassen Las onderstopt Sp gelicht/geschift/gestopt Sps.Temperatuur [ C] 2) Droog 1) Nat 1) Overgang L=50 (SKV) Breed L=75 (SKV) Smal (SmwF-SOW5) oud tegen oud nieuw tegen oud nieuw tegen nieuw MHH (1100 N/mm2) 350 (l)ht Kopgehard MN (900N/mm2) (700 N/mm2) Ander profiel Ri 60 UIC 60 UIC 54 NP 46 S 49 Dag / Nacht Datum Opmerkingen: lasser A lasser B Lastechnicus Naam: Naam: Naam: Nr.: Nr.: Datum: Datum: Handtekening: Paraaf: Versie: 7 Datum: Doc. IS-F65.8

20 WELD REGISTER 20

21 WELD REGISTER 21

WELD REGISTER Weld info via Pocket PC; GPS

22 WELD REGISTER Weld info via Pocket PC; GPS coordinates, projection on Google Maps; Wireless data transmission via GPRS; Data stored in Access database; Selections per project, welder,..; Generation of commissioning document for payment of contractor. SERVER GSM/GPRS 22

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26 TRANSMISSION OF DATA 26

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28 WeldRegister Database 28

29 Commis ssioning docum ment pe er weld 29

30 GOOGLE MAPS Waardenburg Level Crossing Demo Project WeldRegister 30

31 TRANSMISSION OF DATA 31

32 EXPECTED COST SAVINGS Due to impact load reduction at welds: % of annual maintenance budget; ProRail budget in The Netherlands: ~ 250 mio for 4,500 single track; Savings: mio total, or 5 10,000 per km single track. Manual maintenance Renewal 70 % TOTAL MAINTENANCE AND RENEWAL COST ON NS 250 million per year for km track 20 % Price level l 2006 Mechanical Maintenance 10 % 32

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