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Railway Technical Handbook Volume 1 Back g Overview g Contents g Railway technical handbook Volume 1 Axleboxes, wheelset bearings, sensors, condition monitoring, subsystems and services Next g f Back f Overview f Contents Market value of the book 40 EUR ® SKF, AMPEP, @PTITUDE, AXLETRONIC, EASYRAIL, INSOCOAT, MRC, MULTILOG are registered trademarks of the SKF Group. All other trademarks are the property of their respective owner. © SKF Group 2011 The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior written permission is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of the use of the information contained herein. PUB 42/P7 10987/2 EN · July 2011 ISBN 978-91-978966-3-4 This publication supersedes publication 3561 E. Printed in Sweden on environmentally friendly paper. Certain image(s) used under license from Shutterstock.com 2 f Previous Next g f Back f Overview f Contents 1 Past and present 1 2 Bogie designs 2 3 Axlebox designs 3 4 Bearing designs 4 5 Bearing calculation 5 6 Bearing investigation 6 7 AXLETRONIC sensors 7 8 Bogie condition monitoring 8 9 Bogie subsystems 9 10 Services 10 11 Applications 11 Index References f Previous Next g 3 f Back f Overview f Contents 4 f Previous Next g f Back f Overview f Contents Railway technical handbook Volume 1 Axleboxes, wheelset bearings, sensors, condition monitoring, subsystems and services A handbook for the industrial designer and operator f Previous Next g 1 f Back f Overview f Contents 2 f Previous Next g f Back f Overview f Contents Foreword This railway technical handbook covers axleboxes, wheelset bearings, sensors, condition monitoring, subsystems and services. The handbook has been developed with various industry specialists in mind. For designers, this handbook provides the information needed to optimize a variety of features. For specialists of the railway operators, there are recommendations on how to maximize service life through appropriate mounting, maintenance and condition monitoring. The recommendations are based on experience gained by SKF during decades of close cooperation with the railway industry all over the world. This experience, along with customer input, strongly influences product development within SKF, leading to the introduction of new products and variants. General information about the selection and calculation of ball and roller bearings is provided in the SKF General Catalogue. This publication deals with questions arising from the use of special solutions for railway bogies. Data from the SKF General Catalogue is only repeated here when it has been thought necessary for the sake of clarity. Further information can be found at www.railways.skf.com Gottfried Kuře and team f Previous Next g 3 f Back f Overview Contents The SKF brand now stands for more Past and present than ever before, and means more 1 to you as a valued customer. Energy saving . 9 While SKF maintains its leadership as a Historical railway applications . 12 high-quality bearing manufacturer throughout the world, new dimensions Past and present bearing designs . 14 in technical advances, product support and services have evol ved SKF into a Lubricant saving . 16 truly solutions-oriented supplier, creating greater value for customers. Present rail focus . 16 These solutions enable customers to Global presence . 20 improve productivity, not only with breakthrough application-specific prod- Quality . 22 ucts, but also through leading-edge design simulation tools and consultancy services, plant asset efficiency mainte- Bogie designs nance program mes, and the industry’s 2 most advanced supply management Design principles . 25 techniques. Wheelset designs . 29 The SKF brand still stands for the very best in rolling bearings, but it now Springs . 32 stands for much more. Dampers . 35 SKF – the knowledge engineering company Bogie design examples . 36 Earth return . 40 3 Axlebox designs Capabilities . 43 Specifications . 45 Validation . 49 Designs . 54 Calculation . 62 Industrialization . 69 Testing . 70 4 f Previous Next g f Back f Overview 4 Bearing designs 8 Bogie condition monitoring Bearing capabilities . 73 LCC reduction . 153 Journal design . 75 Bogie monitoring . 155 Tapered roller bearing units . 77 SKF Multilog online system IMx-R . 160 Cylindrical roller bearings and units . 89 Applications . 163 Spherical roller bearings . 97 Bogie subsystems Bearing testing . 99 9 AMPEP . 165 5 Bearing calculation Articulation joints . 172 Calculation principles . 107 Wheel flange lubrication . 176 Basic rating life . 108 Services SKF rating life . 112 10 Service capabilities . 183 Advanced calculations . 116 Mounting . 184 6 Bearing investigation Dismounting . 190 Considerations . 123 Remanufacturing . 192 Trouble in operation . 125 Training . 195 Bearing damage . 126 Applications Damage and failure matrix . 135 11 High-speed vehicles . 198 7 AXLETRONIC sensors Diesel and electric locomotives . 202 Railway sensors . 137 Diesel and electrical units, passenger coaches . 204 Sensor capabilities . 139 Metro cars, light rail vehicles and tramways . 206 Applications . 151 Freight cars . 208 Index References f Previous Next g 5 f Back f Overview f Contents SKF – the knowledge engineering company From the company that invented the self- The SKF Group is globally certified to ISO align ing ball bearing more than 100 years 14001, the international standard for envi r- ago, SKF has evol ved into a knowledge o n mental management, as well as OHSAS engin eering company that is able to draw on 18001, the health and safety manage ment five technology platforms to create unique standard. Individual divisions have been solutions for its custom ers. These platforms ap proved for quality certification in ac cord- include bearings, bearing units and seals, of ance with ISO 9001 and other customer course, but extend to other areas including: specific requirements. lubricants and lubrication sys tems, critical With over 120 manufacturing sites world- © Airbus – photo: exm company, H. Goussé for long bearing life in many appli cations; wide and sales companies in 70 countries, mecha tronics that combine mech anical and SKF is a truly international corporation. In Evolving by-wire technology electron ics knowledge into systems for more addition, our distributors and dealers in SKF has a unique expertise in the fast-growing by- wire technology, from fly-by-wire, to drive-by- effective linear motion and sensorized solu- some 15 000 locations around the world, wire, to work-by-wire. SKF pioneered practical fly- tions; and a full range of ser vices, from de- an e-business marketplace and a global by-wire technology and is a close working partner sign and logistics support to con dition moni- distri bution system put SKF close to cus- with all aerospace industry leaders. As an example, virtually all aircraft of the Airbus design use SKF toring and reliability systems. tomers for the supply of both products and by-wire systems for cockpit flight control. Though the scope has broadened, SKF services. In essence, SKF solutions are avail- continues to maintain the world’s leadership able wherever and whenever customers in the design, manufacture and marketing of need them. Over all, the SKF brand and the rolling bearings, as well as complementary corporation are stronger than ever. As the products such as radial seals. SKF also holds knowledge engin eering company, we stand an increasingly important position in the ready to serve you with world-class product market for linear motion products, high- competencies, intellectual resources, and precision aerospace bearings, machine tool the vision to help you succeed. spindles and plant maintenance services. SKF is also a leader in automotive by-wire tech- nology, and has partnered with automotive engin- eers to develop two concept cars, which employ SKF mecha tronics for steering and braking. Fur- ther by-wire develop ment has led SKF to produce an all-electric forklift truck, which uses mecha- tronics rather than hydraulics for all controls. Bearings Lubrication Seals and units systems Mechatronics Services 6 f Previous Next g f Back f Overview f Contents Harnessing wind power The growing industry of wind-generated electric power provides a source of clean, green electricity. SKF is working closely with global industry leaders to develop efficient and trouble-free turbines, providing a wide range of large, highly specialized bearings and condition monitoring systems to extend equip- ment life of wind farms located in even the most remote and inhospitable environments. Working in extreme environments In frigid winters, especially in northern countries, extreme sub-zero tempera- tures can cause bearings in railway axleboxes to seize due to lubrication star- vation. SKF created a new family of synthetic lubricants formulated to retain their lubrication viscosity even at these extreme temperatures. SKF knowledge enables manufacturers and end user customers to overcome the performance issues resulting from extreme temperatures, whether hot or cold. For example, SKF products are at work in diverse environments such as baking ovens and instant freezing in food processing plants. Developing a cleaner cleaner The electric motor and its bearings are the heart of many household appli- ances. SKF works closely with appliance manufacturers to improve their prod- ucts’ performance, cut costs, reduce weight, and reduce energy consumption. A recent example of this cooperation is a new generation of vacuum cleaners with substantially more suction. SKF knowledge in the area of small bearing technology is also applied to manufacturers of power tools and office equipment. Maintaining a 350 km/h R&D lab In addition to SKF’s renowned research and development facilities in Europe and the United States, Formula One car racing provides a unique environment for SKF to push the limits of bearing technology. For over 60 years, SKF prod- ucts, engineering and knowledge have helped make Scuderia Ferrari a formid- able force in F1 racing.
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