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'BZA,.~·U.L REPOR~ NO R!FERENCE USE ONLY 'BZA,.~·U.l REPOR~ NO. FRA/ORD-77/45.1 POTENTIAL MEANS OF COST REDUCTION IN GRADE CROSSING MOTORIST-WARNING CONTROL EQUIPMENT Volume I: Overview, Technology Survey and Relay Alternatives C. L. DuVivier W. Sheffeld L. M. Rogers H.J. Foster Storch Engineers 824 Boylston Street Chestnut Hill MA 02167 . -~- I . DECEMBER 1977 FINAL REPORT DOCUMENT IS AVAILABLE TO THE U .S. PUBLIC THROUGH THE NATIONAL TECHNICAL INFORMATION SERVICE, SPRINGFIELD, VIRGINIA 22161 Prepared for U,S, DEPARTMENT OF TRANSPORTATION FEDERAL RAILROAD ADMINISTRATION I Office of Research and Development Washington DC 20590 · NOTICE This document is disseminated under the sponsorship of the Department of Transportation in the interest of information exchange. The United States Govern­ ment assumes no liability for its contents or use thereof. NOTICE The United States Government does not endorse pro­ ducts or manufacturers. Trade or manufacturers' names appear herein solely because they are con­ sidered essential to the object of this report. Technical I<eport Documentation Page 1 2 F R-;;;-i-,-Po_'R---:D--:-~---:7_7,1 ~~·o_c'-~-::-n-' _~ r--:- __4_5_.I _'__G_oy_e,_"m_en_,_Ac_ce_ss_,o_n_NO_' --+:-3_, 2_(_°7=-'°'_0g.=--7 9lf6 L 5 POTE1NTttt'MEANS OF COST REDUCTION IN GRADE 1 , Repo,' DO'e I CROSS I NG MOTORI ST - WARNI NG CONTROL EQUI PMENT ~~-~~~~~~,:on.~0~.~n7cod. i Volume I: Overview, Technology Survey and ~ Relay Alternatives 8. Pedo,m,ng O,gon"o',on Repo" No, j 7, Aupnarls) 1 C.L. DuVivier, L.M. Rogers, W. Sheffeld, and DOT-TSC-FRA-76-21,I r-H'7--,:,T~_.Lj:;:..u..:,,,,,,,,,-::'tL-,,,,p,-,----r +-:-I-:-O '--;;'o.k Un,' No :T-RA-IS-I--- ,-- 9. Performing Orgonl.z.atlon Name and Address " , . , Storch Engineers* RR828/R8323 I 824 Boy 1s ton St r ee t 1-7:11,-,-(:::-o-n-,'-0c-,-o-,-=-G-,o-n,--:N--:o-----~l Chestnut Hill MA 02167 DOT-TSC-870 i 13 Typeof RepO"ondPe"od (oye,ed I ---:-e12=-,-S=-p-on-.-o-"n-g-A-g-e-nc-y-N-o-m-e-o-nd-Ad-d-,e-,-, --------------------. Fina 1 Rep 0 r t 'I U.S. Department of Transportation Federal Railroad Administration June 19~4-March 1976 Office of Research and Development 14. Sponsoring Agency Code Washington DC 20590 15. Supplementcry Noles U.S. Department of Transportation *Under Contract To: Transportation Systems Center Kendal Square Cambrid2e MA 02142 16. Abs1roct The results of a recent study of railroad-highway grade crossing warning system technology are presented. Emphasis in the investigation was placed on the determination of the potential for significant reduction in equipment, installation and maintenance costs through improvements sought within a framework of the basic (track circuit) system concepts now prevalent. This study comprises a comprehensive survey of current practices and hardware) an analysis of all major cost elements, and a consideration of potentially beneficial technical changes. The effort is concentrated on the equipment involved in train detection and the activation of warning devices. Special attention is given to European practices. The applicability of European signal relays and of mercury-wetted reed relays to the North American situatio is analysed. 17. Key Wo,d. lB. Distribution Statement Railroad-Highway Grade Crossings Grade Crossing Warning Systems DOCUMENT IS AVAILABLE TO THE U.S. PUBLIC THROUGH THE NATIONAL TECHNICAL Grade Crossing Signal Control INFORMATION SERVICE. SPRINGFIELD, Systems VIRGINIA 22161 • 19. Security Classtf. (of this report) 20, Secu,ily (1...iI. (of this pogel 21. No .•f Poge. 22. P,ice Unclas s ifie d Unclassified Form DOT F 1700.7 (8-72) Rep ,odueti on of comp Ieted poge author; zed • PREFACE The work described in this report was part of an ove~all program at the Transportation Systems Center to provide a technical basis for the improvement of railroad-highway grade crossing safety. The program is sponsored by the Federal Railroad Administration, Office of Research and Development. Volume I of this report includes an overview, and two separate studies carried out under contract, one relating to the overall technology and cost of grade crossing control subsystems, and the other exploring the use. of relays other than the conventional rail­ road signal type. A detailed analysis of reliability aspects and assessment of the potential applicability of solid-state devices is contained in Volume II. The executive summary in Volume I covers both volumes. The work reported upon herein has benefitted greatly from the cooperation of many people in the railroad and railroad supply industry, as well as those in the commercial relay supply industry. In addition, the cooperation of European National Railway adminis­ trations and several prominent European manufacturers made a much better understanding of European practice possible. The project is under the overall direction of Dr. John Hopkins, while management of the Transportation Systems Center grade crossing protection program is the responsibility of Mr. Robert Coulombere. ;;; Preceding page blank METRIC CONVERSION FACTORS App,oliml" Conv.,lionl 10 Mouic Mouu,.. --: ~ App,ollml.O Convo'lioni from Motric ...o..u'o. --: ::: -:: S,.hl Will •• W•• In•• 1I.I.i,l, ~, To Fid S"'ol S,.hl Will. Y... I ... 1I.It,JIy ~, T. fi.i1 S,_hl --: ;; LENGTH o N LENGTH - mil IUTlOUU 5 0.04 Inches --: !: centlll'll'lUUS 0.' Inches ].] lee. h Inch•• 2.5 cenl.me'orS --: melers yards yd h leel 30 cenl.mel8rs ~ I.' ~IIQlTlDlll"n miles yd y""" 0.9 ... 0.6 mil•• 1.6 1... lomelerS _00 -:: ~ --: AREA AREA ~ - en?- sqllare cenllme._s 0.16 square Inches .n' on' sqU•• Inche. •.5 square l:enllmeler, em' ~ 00' squ e melers , .2 aquare .,.,d:l .,r h' sq~,e OJ). square meier, 00' 'ee' --: loin' "I r. kllwnelers 0.4 sq....re miles 00" yd' AqY.l.nI .,ards 0.8 s.qUjll. ~'OfS 00' 1 ~ ... heel"'es (10,000 m ) 2.5 _c;re" ~. 00" toque'. mil•• 2.• squarll kllomelen ...' acr•• 0.' hectare. h. < -= ~ MASS (woight) MASS f..oig~1I ~ -= grams 0.036 ounce" 28 9r ams 0' -= • k,IO!JI"ams 2.2 pound. Ib Ib pounds o.•s kilograms •-'I -. tonnes J.1 ....nn lona 11000 k91 shOll tons 0.'1 lonnes l 12000 Ibl ~ VOLUME VOLUME II .. ,.. leas.poull 5 mlllllliers ml ml mlllilll8fS O.Ol lIuld ouncea T.... labl.spoons 15 m,1l II 110'-"­ ml I lien 2.1 pili'. .. q1 II 01' livid ounc•• 30 mllllhiers 001 Inltl's 1.06 g,sll~. cup, 0.2' 11I8r5 h1Of" 0.28 .. p,nlS 0.41 Illen m' cubiC mele':II ]& -'"cubiC 1..1 ..'h' Qlllar1S 0.'15 hlers 00' cubiC nelers 1.] cubic yard. yd' .'..' g811011S ].8 I'lers h' cubiC loel 0.03 I::ublc meters 00' yd' cubiC yards 0.16 cubiC mIners 00' TEMPERATURE (o ..ctl (neet) TEMPERATURE °c CelsIUS 9/&1_ hhren_11 "f 18fI'ClI8t'ature _321 ' .........IUN 0, F.tu..nI\eII S/9lah. Cel!,lus °c t.-nI*'1lNf' SUblraCllng temperalur. ·f 321 Of 32 98.6 212 -'~'" ~ " rOI' ,8~, ~ ,'~O, I"~O" .'':''~ Iii Ii' I iii -40 -20 0 20 40 60 80 100 ! 0e 11 °c TABLE OF CONTENTS Section 1. PART I. OVERVIEH . 1 2. PART II. TECHNOLOGY SURVEY .. '" . 7 2 . 1 Background... ............................. 7 2.2 Scope...... ............................... 8 2. 3 Approach.................................. 8 3. OVERVIEW OF G&~DE CROSSING WARNING SYST~!S AND PRACTIC:CS. ..................................... 10 4. COMPONENTS USED IN ACTIVE GRADE CROSSING WARNING SySTEMS........................................ 19 4.1 Introduction '" 19 4.2 Warning Devices 19 4.3 Arrangements of Warning Devices 24 4.4 Control Systems - Functional Description.. 27 4.4.1 Occupancy Detection................ 27 4.4.2 Speed Responsive Occupancy Detection. ......................... 29 4.4.3 Motion Detection 29 4.4.4 Manual Control 30 4.5 Control Systems, Train Detection Functional Operation............. 31 4.5.1 Train Detection by Occupancy 31 4.5.2 Motion Sensing............•.. w ••••• 33 5. CONSTRAINTS ON INNOVATION...................... 36 5.1 Introduction.............................. 36 5.2 Railroad Acceptance - Safety and Liability 36 5.3 The Market................................ 38 5.4 The Environment 39 5.5 Funding................................... 41 5.6 The Need for Compatibility and Adaptability.............................. 43 5.7 Work Rules 43 5.8 Practices and Procedures "...... 44 6. COSTS ASSOCIATED WITH PRESENT PRACTICES 45 6.1 Introduction..........................•... 45 6.2 Components for Cost Analysis ~ 45 6.3 Costs of Typical Installations 47 v TABLE OF CONTENTS (CaNT) Section 7 THE POTENTIAL FOR COST REDUCTION 53 7.1 Introduction. ................................ 53 7.2 Cost Reduction Potential in the Train Detection Subsystem 53 7.3 Cost Reduction Potential in the Control Subsystem. ................................. .. 54 7.4 Cost Reduction ~otential in the Vehicle Warning Subsystem 54 7.5 Cost Reduction Potential in the Interconnection Subsystem............•...•..• 54 7.6 Summary of Improvement Potential 55 8 ALTERNATIVE SUBSYSTEM CONCEPTS 57 8.1 Introduction...............................•. 57 8.2 Alternative Concept Generation and Selection. 57 8.3 Alternative Concepts . 59 8.4 Discussion- of Each Concept . 59 9 CHARACTERIZATION OF ALTERNATIVF,S 71 9.1 Introduction . 71 9.2 Alternative 1 - Universal Use of Shelf-Type Relays . 71 9.3 Alternative 2 - Universal Use of Plug-in Relays . 71 9.4 Alternative 3 - Development of Standard Modules . 71 9.5 Alternative 4 - Development of Plug-In Relay Rack Type Modules . 72 9.6 Alternative 5 - Use of Non-Vital But Highly Reliable Relays . 72 9.7 Alternative 6 - Development of a Solid State Substitute For Present Logic............•.... 72 9.8 Summary .•...... " . 73 10 CONCLUSIONS AND RECOMMENDATIONS (CONTROL SYSTF.~1_S). 75 10.1 Conclusions . 75 10.2 Recommendations ; . 75 11 TOPICS OUTSIDE THE SCOPE OF THIS STUDy . 77 11.1 Introduction.... 77 11.2 The Absence of a Fail Safe Vehicle Warning Display , 77 vi TABLE OF CONTENTS (CONT) Section 11.3 Credibility..............................
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