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Numerical and Experimental Characterization of a Railroad Switch Machine

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Numerical and Experimental Characterization of a Railroad Switch Machine machines Article Numerical and Experimental Characterization of a Railroad Switch Machine Dario Croccolo, Massimiliano De Agostinis, Stefano Fini * ID , Giorgio Olmi and Francesco Robusto ID Department of Industrial Engineering, University of Bologna, Viale del Risorgimento 2, 40136 Bologna, Italy; [email protected] (D.C.); [email protected] (M.D.A.); [email protected] (G.O.); [email protected] (F.R.) * Correspondence: stefano.fi[email protected]; Tel.: +39-051-2093455 Received: 15 January 2018; Accepted: 12 February 2018; Published: 17 February 2018 Abstract: This contribution deals with the numerical and experimental characterization of the structural behavior of a railroad switch machine. Railroad switch machines must meet a number of safety-related conditions such as, for instance, exhibiting the appropriate resistance against any undesired movements of the points due to the extreme forces exerted by a passing train. This occurrence can produce very high stress on the components, which has to be predicted by designers. In order to assist them in the development of new machines and in defining what the critical components are, FEA models have been built and stresses have been calculated on the internal components of the switch machine. The results have been validated by means of an ad-hoc designed experimental apparatus, now installed at the facilities of the Department of Industrial Engineering of the University of Bologna. This apparatus is particularly novel and original, as no Standards are available that provide recommendations for its design, and no previous studies have dealt with the development of similar rigs. Moreover, it has wide potential applications for lab tests aimed at assessing the safety of railroad switch machines and the fulfilment of the specifications by many railway companies. Keywords: railroad switch; railway junction; FEA; experimental; points 1. Introduction A railroad switch machine (RSM), turnout or set of points is a mechanical installation enabling railway trains to be guided from one track to another, such as at a railway junction or where a spur or siding branches off. One of the key safety requirements of railroad switches is related to achieving a suitable resistance against any undesired movements of the points, due, for instance, to the extreme forces exerted by a passing train in the case of the needle leaned to the rail (force F in Figure1). Many railway companies assume a force F = 100 kN as standard. This work deals with the development of FEA models aimed at accomplishing the structural design of the RSM under the aforementioned operating load. In order to validate such models, an experimental test bench has been designed and manufactured. This comprises two ad-hoc designed fixtures that allow the accommodation of the test piece on a standard INSTRON 8500 500 kN standing press and the application of forces up to a maximum of F = 300 kN. Issues of novelty arise from the lack of studies both in the scientific and in the technical literature dealing with the development of similar fixture devices. The developed testing rig can be used not only for FEA validation purposes, but also for experimental tests aimed at warranting the safety of the RSM and the accomplishment of design requirements by most railway companies. The originality of the performed non-trivial design task arises also from the lack of specific Standards providing recommendations or reference schemes for the execution of lab tests aimed at assessing the structural response of RSM under high loads. Machines 2018, 6, 6; doi:10.3390/machines6010006 www.mdpi.com/journal/machines Machines 2018, 6, 6 2 of 9 Machines 2018, 6, x FOR PEER REVIEW 2 of 9 Machines 2018, 6, x FOR PEER REVIEW 2 of 9 FigureFigure 1. 1.Geometry Geometry of of a a railroad railroad switch switch.. Figure 1. Geometry of a railroad switch. 2. Materials and Methods 2. Materials and Methods 2. Materials and Methods The Alstom RSM object of the present investigation is shown in Figure 2, along with some balloonsThe AlstomThe highlightingAlstom RSM RSM object the object k ofey the structuralof presentthe present components investigation investigation of the is shown machine.is shown in Figure in Figure2, along 2, along with with some some balloons highlightingballoons highlighting the key structural the key componentsstructural components of the machine. of the machine. Figure 2. 3d model of the Alstom RSM: (1) body; (2) lower plate; (3) pin; (4) hammer; (5) switching FigurerodFigure 2.; (3d6) 2cam. model 3d; model(7) ofdetection the of the Alstom rodAlstom; (8 RSM:) armRSM:. ( 1 )(1 body;) body (2; )(2 lower) lower plate; plate; ( 3(3)) pin; pin; ((44)) hammer;hammer; ( 5)) switching switching rod; (6) cam;rod;( (76)) detectioncam; (7) detection rod; (8) rod arm.; (8) arm. Due to confidentiality-related issues, the working principles of the machine cannot be described in detail.Due Theto confidentiality analysis was limited-related to issues, the verification the working of theprinciples mechanism of the against machine unwanted cannot be movements described ofinDue detail.the to points confidentiality-related The caused analysis by was a passing limited issues,train to the since verification the the working system of principlesthe is equipped mechanism of with the against machinetwo inte unwantedrlocking cannot movements devices. be described In in detail.fact,of Thethe once points analysis the caused full was stroke by limited a haspassing been to thetrain travelled, verification since the and system the of thepoints is mechanismequipped are in the with againstopen two (or inte unwanted closed)rlocking position, devices. movements the In of the pointsswitchingfact, once caused therod full by(5) aisstroke passingsecured has to train been the sincebodytravelled, (1) the by system and means the is ofpoints equipped a hammer are in with (4);the atopen two the interlockingsame(or closed) time, theposition, devices. detection the In fact, oncerodswitching the (7) full is stroke secured rod (5) has isto secured beenthe lower travelled, to platethe body (2) and by (1) themeans by pointsmeans of a areslider,of a inhammer thenot openrepresented (4); (orat the closed) samein the position, time,picture. the Thereforedetection the switching rod (5)therod is locking(7) secured is secured devices to theto comethe body lo intower (1) effectplate by means (2)preventing by means of a hammerany of amovement slider, (4); not at ofrepresented the the same rods, time,when in the thean picture. external detection Therefore force rod is (7) is securedappliedthe tolocking the along lower devices z-axis plate come to (2)the into bypoints, meanseffect and preventing of thereby a slider, to any notthe movement arms represented (8). of the in rods, the picture. when an Therefore external force the lockingis appliedAccording along z -toaxis the to requirements the points, and set thereby by railway to the companies, arms (8). the RSM should be validated under devices come into effect preventing any movement of the rods, when an external force is applied along the actionAccording of a force to the F =requirements 100 kN. The loadset by application railway companies, rate surely theaffect RSMs the should response be validatedof the structure. under z-axis to the points, and thereby to the arms (8). Thethe action testing of force a force of FF == 100100 kNkN. is The set loadby the application railway company rate surely in order affect tso the account response for dynamicof the structure. effects. InTheAccording order testing to forceattain to the of an requirementsF adequate= 100 kN isstiffness set set by bytheof railwaytherailway test fixture,company companies, it hasin order been the t RSModimensioned account should for dynamicfor be validateda maximum effects. under the actionloadIn order of of 3 00to a forcekNattain. The F an = overall 100adequate kN. dimensions Thestiffness load ofof application thethe test test piece fixture, rate are itsurely900 has × 300been affects × dimensioned210 themm response; therefore for a, of maximumthe the fixture structure. The testingwasload conceivedof 3 force00 kN of. inThe F two = overall 100 separate kN dimensions is parts, set by a the lowerof the railway andtest piecean company upper are 900grip, in× 300so order as × 210to toachieve mm account; therefore a certain for dynamic, the flexibility fixture effects. In orderduringwas toconceived attainmounting anin two adequateand separateunmounting stiffness parts, operations a oflower the and test on an the fixture, upper standing grip, it has press. so been as toIn dimensionedachieve order not a certain to transmit for flexibility a maximum any loadunwantedduring of 300 kN.mounting bending The overall and moment unmounting dimensions at the arms, operations of the test on fixture piece the standing arewas 900 shap ×press.ed300 as ×shownIn 210order mm;in not Figure therefore,to transmit 3. While the anythe fixture was conceivedlowerunwanted grip bendingis in atwo simple separatemoment C-shaped at parts, the interface arms, a lower the between test and fixturean the upper actuator was shap grip, threaded so asas andshown to the achieve in arms, Figure athe certain 3. upper While flexibilitygrip the duringhaslower mountingto gripretain is athe andsimple whole unmounting C- shapedRSM by interface operationsmeans betweenof four on M20the the actuator standing8.8 class thread bolts. press. and The In the orderbolted arms, notjoint the to upperis transmit doubly grip any overlapped:has to retain this the provision whole RSM allows by doublingmeans of the four frictional M20 8.8 surfaces class bolts. and hence The boltedthe transmissible joint is doubly load unwanted bending moment at the arms, the test fixture was shaped as shown in Figure3. While the foroverlapped: a given bolt this size provision and class al lows[1,2]. doublingExcept for the a few frictional details, surfaces the fixture and has hence to be the arc transmissible welded, therefore load lower grip is a simple C-shaped interface between the actuator thread and the arms, the upper grip has afor structural a given bolt steel size S275JR and class according [1,2].
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