innovative rail fastening systems - schwihag · 2 3 schwihag‘s innovative rail fastening...

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SCHWIHAG‘S INNOVATIVE RAIL FASTENING SYSTEMS

PRODUCTS 4

DEVELOPMENT 8

PRODUCTION 10

QUALITY ASSURANCE 12

TECHNICAL INNOVATIONS 13

SCHWIHAG RAIL FASTENING SYSTEMS

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The rail fastenings supplied by SCHWIHAG are based on systems which have been put to the test in practice for decades. SCHWIHAG has technically and economically optimised these systems.

SCHWIHAG provides consulting, development, design, production, delivery and service for rail fastenings and the following applications:

:: Standard railway lines:: High-speed lines :: Heavy freight transport :: Underground railways :: Commuter railways:: Tramways:: Industrial railways

and in the following types of track construction:

:: Ballast track with concrete sleepers:: Ballast track with wooden sleepers:: Ballast track with steel sleepers:: Slab track:: Bridge beams (beams on steel bridges):: Transition areas

with regard to:

:: Rail profile and cant:: Sleeper geometry:: Line layout

(e.g. tight radii, large gradients) SCHWIHAG rail fastening systems are:

:: Proven standard systems (standard KS-track or W-track)

:: New developments to customer requirements:: Adaptations with optimised components, e.g. new

tension clamps for existing sleepers for retrofitting or conversion

:: Special designs for difficult installation situations:: Systems with special surface protection for the

RFS components to customer requirements for critical environmental conditions

:: Systems with highly effective sound insulation (structure-borne sound/vibrations)

:: Systems for transition areas, e.g. at tunnel/bridge with large relative movements between the rail and support

MODERN TECHNOLOGY FOR THE TRACK

SCHWIHAG rail fastening systems offer many advantages for assembly and installation:

:: Can be completely preassembled in the sleeper factory:: Due to sorted delivery, completely automated

preassembly is also possible in the sleeper factory:: Quick, automated, mechanical final assembly on the

construction site possible with assembly speed of > 400 m/h track

Tension clamp Skl 14 in preassembly position

Tension clamp 14 tensioned

Other advantages:

:: Tension clamps are produced free of surface decar-burisation (see page 13 of the brochure) > maximum dynamic fatigue strength

:: High-quality long-term corrosion protection availa-ble (see page 14 of the brochure) > The dynamic properties are maintained for the complete life

:: High elasticity > Results in improved load distribution (deflection curve) along the rail, therefore, associated significant reduction in point loading on all track components such as the rail, rail fastening system, sleeper and ballast

:: Integral anti-tilt protection > prevents overloading of the tension clamp in extreme load situations

:: Integral electrical insulation > is achieved by using the insulating plastic fastening components: angle guide plate, rail pad and dowels

:: Modularity > enables universal usability for all railway applications from the tramway, underground railway, and heavy load through to high speed traffic

:: Precise batch marking > Lettering is made using laser technology and enables exact dating of the produc-tion date of each batch (see page 14 of the brochure)

:: Heavy-duty dowels > Special design of the dowel geometry in conjunction with optimised material selection enables high pull-out forces and safety against excessive torques (see page 14/15 of the brochure)


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RAIL FASTENINGS FOR CONCRETE SLEEPERS AND SLAB TRACK

RAIL FASTENINGS FOR WOODEN SLEEPERS

Tension clamp Skl 14 and Skl 12 as well as spring clip SSb2 for slide baseplate URg 57 on W switch bearer

RAIL FASTENINGS FOR SWITCHES

Tension clamp Skl 14 on concrete sleeper (W-fastening)

Tension clamp Skl 15 for System 300-1 for slab track

Tension clamp Skl 12 on elastically supported baseplate as single support point for slab track

Tension clamp Skl SL 1 for heavy-haul systems on concrete sleeper

Tension clamp Skl 12 on wooden sleeper (KS-fastening)

System BSP-FF-B1 with Skl SL1, concrete

System BSP-FF-B2 with Skl SL1, steel

RAIL FASTENINGS FOR TRANSITION AREAS

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Targeted research and product development play an important role in SCHWIHAG. The requirements for forward-looking track components are determined through continuous dialogue with the railway engi-neers of the railway companies.

The 3D CAD system Pro Engineer is used to develop new products and to adapt or optimise products that have already proven their worth. The necessary FEM analyses are then performed on the basis of this CAD data. Prototypes are examined in our own test labo-ratory to determine their general technical properties and their suitability for use in railway operations. Continuous load (endurance) tests can be performed according to the test conditions of international standards and/or the specifications of the railway companies.

In addition to the static and dynamic load tests, the following material tests can also be performed:

:: Hardness test:: Tensile/compressive strength test:: Grinding preparation and microstructural analyses

(optical microscopy):: Polymer tests (melting point, heat of fusion, glass

transition point):: Optical 3D measurement of components

SCHWIHAG AG‘s jig construction department enables the production of customer-specific adapters and test apparatus, which ensures optimum position adjust-ment and clamping of the components to be tested during the tests.

Biaxial, static and dynamic tests can be performed in the test laboratory. The max. vertical test force is 400 kN and the max. horizontal test force is 100 kN. The components can be tested, among other things, in a horizontal position (biaxial) or in an inclined test (mono-axial).

Based on this development concept, our customers‘ specific requirements can be implemented in new products or new product variants.

Following successful testing in the SCHWIHAG labo-ratory, the components and systems are subjected to further testing by an independent test institute as part of the approval procedure. Here SCHWIHAG works closely with renowned test and research facilities, e.g. the University of Technology of Munich or Dresden.

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SCHWIHAG AG in Tägerwilen (CH) with research and development facilities

Test laboratory with test equipment for continuous load (endurance) tests

Test machine for strength tests (tensile test) on material samples

SCHWIHAG GmbH, Radefeld near Leipzig

Test machine for recording spring characteristic curves

Selected variants or fail fastening tension clamps produced by SCHWIHAG

SCHWIHAG

DEVELOPS, TESTSAND PRODUCES RAIL FASTENING SYSTEMS

SCHWIHAG GMBH MANUFACTURES SCHWIHAG AG INHOUSE DEVELOPED PRODUCTS. SCHWIHAG GMBH HAS STATE OF THE ART PROCESSTECHNOLOGY FOR TENSIONCLAMP PRODUCTION.

Development and design laboratory of SCHWIHAG AG in Tägerwilen


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FROM THE WIRE TO THE FINISHED TENSION CLAMP: SCHWIHAG PRODUCES IN A FULLY AUTOMATED PRODUCTION PROCESS

QUENCHING AND HARDE-NING LINE

SORTED PACKAGING OF THE FINISHED PRODUCT

AUTOMATIC TRANSPORT INTO THE WAREHOUSE

INDOOR STORES - WAREHOUSE OUTDOOR STORESPRODUCTS ARE READY FOR DISPATCH

BENDING LINE SORTED TRANSPORT TO QUENCHING AND HARDENING

WIRE ROLL MADE OF SPRING STEEL

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We guarantee our customers that SCHWIHAG products are produced according to the following criteria:

:: Careful selection of suitable heavy-duty materials :: Selection of the optimum production method under

the aspects of product quality, flexibility and use of resources (manpower, material, energy consumption)

:: Continuous monitoring of the production processes and the product data through material and dimen-sional checks according to national, international standards or those specified by our customers.

SCHWIHAG has a quality management system certified to ISO 9001-2008 and for many years has been a Q1 supplier of Deutsche Bahn AG and a certified supplier of numerous other railway companies (including SNCF, Network Rail, RFI).

The SCHWIHAG production concept in conjunction with the SCHWIHAG logistics concept enables us to respond to customers‘ special wishes at short notice and to deliver standard products or special designs worldwide and on-schedule.

HIGH TECH IN THE TEST LAB

of this surface decarburisation the material is brittle and tends to form cracks, especially under dynamic loading. These cracks or incipient cracks produce a notch effect and propagate in the quenched and har-dened material and can cause a component to break. This process is also accelerated by increased formation of rust, which can occur especially in the area of the surface decarburisation.

The tension clamps produced using the SCHWIHAG method do not have any surface decarburisation zones and therefore achieve high dynamic fatigue strength.

SCHWIHAG tension clamps can be produced free of surface decarburisation thanks to a special heat treat-ment method in closed chambers.

Following the heat treatment of the spring steel the fine acicular, martensitic microstructure forms. If classical heat treatment methods are used with open processes, surface decarburisation forms all around the perimeter of a wire with circular cross-section: these are the starting points for cracking. In the area

NO SURFACE DECARBURISATION

Example of the microstructural change in metals caused by the heat treatment process: acicular martensitic microstructure

No surface decarburisation, free of incipient cracksMeasuring the tension clamp geometry by means of 3 dimensional digitising

All-round surface decarburisation with formation of incipient cracks

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schwihag bietet für spannklemmen aus Federstahl einen neuen hochwertigen langzeit-korrosionsschutz an. Mit diesem neuartigen korrosionsschutz kann die rostbildung nachweislich über die gesamte lebensdauer unter operativen Bedingungen deutlich reduziert werden. damit bleiben die dauerfestigkeits-eigenschaften der spannklemmen nahezu konstant über sehr lange einsatzzyklen.

schwihag spannklemmen werden zukünfig chargen-genau markiert. die Beschriftung erfolgt mittels hoch-moderner lasertechnik und ermöglicht die exakte datierbarkeit des Produktionsdatums jeder charge.

langzeit- korroSionSSchutz

chargengenaue kennzeichnung

::::::::::::::::::: technISche InnovatIonen ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::

der dübel ist eine wesentliche komponente für schienenbefestigungssysteme auf Betonschwellen. damit kommt dem dübel als im Beton eingegossenes Bauteil hohe Bedeutung für die Funktionalität der schienenbefestigung zu. die Belastbarkeit von dübel-konstruktionen kann hauptsächlich anhand ihres kon-struktiven versagens festgemacht werden. dieses kann sowohl ein verlust der verbindung bzw. verzahnung des dübels mit dem schwellenkörper, z.B. herausreißen des dübels aus der schwelle bzw. Beschädigung des umgebenden Betons, als auch ein versagen der inneren dübelkonstruktion, z.B. auszug der schraube aus dem dübel, sein.

Ziel der entwicklung des neuen schwihag kunst-stoffschraubdübels sdü s3 war, die aus der schraube-dübel-kombination resultierenden Zugspannungen im Betonkörper zu reduzieren. dadurch soll in kritischen Belastungssituationen, die insbesondere bei der Mon-tage des gleises und der verspannung der schienen-befestigung auftreten, eine reserve gegen versagen

skl 14 ohne (links) und (rechts) mit neuem langzeit-korrosionsschutz

kennzeichnung von spannklemmen mittels lasertechnik

hochbelaStbarer dübel

schwihag kunststoffschraubdübel sdü-s3

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SCHWIHAG offers new, high-quality long-term corro-sion protection for tension clamps made from spring steel. With this new type of corrosion protection, rusting can be verifiably and significantly reduced over the entire life under operative conditions. In this way the fatigue strength properties of the tension clamps remain virtually constant over very long use cycles.

In future, each batch of SCHWIHAG tension clamps will be marked precisely. The labelling is carried out using highly modern laser technology and enables exact dating of the production date of each batch.

LONG-TERM CORROSION PROTECTION

PRECISE BATCH LABELLING

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The development objective was achieved in design terms by the geometrical formation of the dowel‘s external (male) thread and the allocation of the corresponding dowel internal (female) thread. In addition, different wall thicknesses were implemented in the design of the dowel‘s thread area. This material distribution causes any stress peaks occurring due to elastic and plastic deformation of the dowel material to be absorbed and therefore prevents damage to the surrounding concrete contour.

The newly developed plastic anchor dowel Sdü S3 can be used not only with the sleeper screw Ss 25 but also with the sleeper screw Ss 35. Damage to the internal thread of the dowel caused by incorrect positioning of the sleeper screw Ss 25 with pointed thread is preven-ted by special design of the internal thread runout.

Within the scope of qualification tests it was estab-lished that the new SCHWIHAG plastic anchor dowel Sdü S3 has a factor of safety of up to 4 for the pull-out force. The SCHWIHAG design also has a 3-fold factor of safety for the tightening torque, which is introduced into the dowel when tightening the sleeper screw. Apart from laboratory tests, this was also verified by practical tests on the track panel. When the sleeper screw was tightened and undone 10 times, no move-ment in the dowel crown was found and the bonding between the sleeper concrete and the dowel was completely intact.

The dowel is an essential component for rail fastening systems on concrete sleepers. The dowel, as a compo-nent cast in the concrete, is therefore very important for the function of the rail fastening. The loading capacity of dowel constructions can mainly be determined by its design failure. This can not only be loss of the connec-tion or keying of the dowel with the sleeper body, e.g. pulling out of the dowel from the sleeper or damage to the surrounding concrete, but also failure of the internal plug construction, e.g. pulling out of the screw or bolt from the plug.

The objective of the development of the new SCHWIHAG plastic anchor dowel Sdü S3 was to reduce the tensile stresses in the concrete body resulting from the screw-dowel combination. In critical loading situa-tions, which occur especially during laying of the track and the tightening of the rail fastening, this should en-sure a reserve against failure of the dowel construction and the bonding with the sleeper concrete.

Test sample after screwing in ten times using a power assembly tool in the screw in tests under practical conditions.

Skl 14 without (left) and with (right) new long-term corrosion protection

Labelling of tension clamps by means of laser technology

HEAVY-DUTY DOWELS

SCHWIHAG plastic anchor dowel Sdü S3

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SCHWIHAG AGTrack and Switch TechnologyLebernstrasse 3, CH-8274 TägerwilenTel +41(0)71 666 88 00 Fax +41(0)71 666 88 [email protected] www.schwihag.com

innovative rail fastening systems - schwihag · 2 3 schwihag‘s innovative rail fastening...

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