Mechanized Maintenance of

Turnouts, (P&T)

Rainer Wenty
Plasser & Theurer

Warszawa, 01.07.2014, UEEIV SITK International Conference 1

 Agenda
• Turnout Maintenance – a Cost Benefit
• Tamping Machines
• Ballast Distribution and Stabilising
• Ballast Cleaning in Switches

Warszawa, 01.07.2014, UEEIV SITK International Conference 2

 Agenda
• Turnout Maintenance – a Cost Benefit
• Tamping Machines
• Ballast Distribution and Stabilising
• Ballast Cleaning in Switches

Warszawa, 01.07.2014, UEEIV SITK International Conference 3

 Systematic Mechanical Switch
Maintenance -
an Economical Option !
• Switches and crossings make up 1/5 of fixed assets.
Replacement value ÖBB: 1 billion US$.
• The replacement costs for switches are on average
per meter of calculated specific length up 3,8 times
higher than per meter of track.
• The annual costs of switches are - depending on the
type of switch, up to 4,8 times the costs for 1 meter
of track.
• Switches - an important capital asset.

Warszawa, 01.07.2014, UEEIV SITK International Conference 4

 Prolonged Track Life
due to Systematic, Timely Switch
Maintenance
• Faults that are not remedied in due time, lead to a
further amplification of the fault....
• .....and shorten track life.
• Regular maintenance work extends track life by an
estimated 20 - 30%.

Warszawa, 01.07.2014, UEEIV SITK International Conference 5

 The Quality of
Mechanical Switch Maintenance
• The standard of quality of machine work cannot be
achieved manually with power tampers.
• Machine work extends the intervals between
maintenance as compared to manual labor.

Warszawa, 01.07.2014, UEEIV SITK International Conference 6

 Cost of Lowering the overall costs by
increased use of machines
maintenace
1200

1000

800
units

Costs for manual

600
maintenance
400

200 Costs for machine

operations
0
less use of machines greater use of machines

Warszawa, 01.07.2014, UEEIV SITK International Conference 7

 Agenda
• Turnout Maintenance – a Cost Benefit
• Tamping Machines
• Ballast Distribution and Stabilising
• Ballast Cleaning in Switches

Warszawa, 01.07.2014, UEEIV SITK International Conference 8

 Basics Demands on Turnout
Maintenance Systems
• Turnouts are complex – they demand specially
designed work units
• The tools must access all parts of the turnout
• Overstress of turnout parts during maintenance has
to be avoided

Warszawa, 01.07.2014, UEEIV SITK International Conference 9

 Lifting and Slewing Unit
• Lifting hook for the complex areas
• Roller lifting clamps for fast maintenance

Warszawa, 01.07.2014, UEEIV SITK International Conference 10

 Lifting and Slewing Unit

Warszawa, 01.07.2014, UEEIV SITK International Conference 11

 Tamping Units
• One- or two sleeper tamping units
• Single or double tools
• Splithead or tilting tools

Warszawa, 01.07.2014, UEEIV SITK International Conference 12

 One sleeper unit

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 Split Head Unit

Warszawa, 01.07.2014, UEEIV SITK International Conference 14

 Split Head Unit

Warszawa, 01.07.2014, UEEIV SITK International Conference 15

 Two Sleeper Unit

Warszawa, 01.07.2014, UEEIV SITK International Conference 16

 Operators Position
• Variations in operators position – dependendin on
complexity of turnout and demands on working
speed
• One or two tamping operators
• Seperate turnout tamping cabin or one tamping
cabin for all

Warszawa, 01.07.2014, UEEIV SITK International Conference 17

 Operators Cabin „complex“

Warszawa, 01.07.2014, UEEIV SITK International Conference 18

 Operators Cabin „simple“

Warszawa, 01.07.2014, UEEIV SITK International Conference 19

 Mode of Work - Output
• From simple work mode
• One sleeper tamping
• Cyclic
• Split Head
• To high capacity tamping
• Two sleeper tamping
• Continuous
• Tilting tools

Warszawa, 01.07.2014, UEEIV SITK International Conference 20

 3 – Rail Lifting
4 – Rail Tamping
• No Overstress
• Full support of turnout

Warszawa, 01.07.2014, UEEIV SITK International Conference 21

Turnout Tamping Machines
SOME DEVELOPMENTS
 Some Developments
High Capacity Machines

Unimat 09-475/4S N-Dynamic

Unimat 09-4x4/4S Dynamic

Compact Machines

Plasser 08-16 SH

UST 79 S
Warszawa, 01.07.2014, UEEIV SITK International Conference 23
 Premium Programm for Turnouts
The All-In-One-Machine for Turnouts and Tracks
Unimat 09-475/4S N-Dynamic

Warszawa, 01.07.2014, UEEIV SITK International Conference 24

 Premiumprogramm für Weichen
• Supply of new ballast

Warszawa, 01.07.2014, UEEIV SITK International Conference 25

 • Film Unimat N-Dynamic
• 90041_Uni094754SNDyn_OT_DE_HD.wmv

Warszawa, 01.07.2014, UEEIV SITK International Conference 26

 The Split-Head-Technology

Warszawa, 01.07.2014, UEEIV SITK International Conference 27

 Machines for Road Transport

Warszawa, 01.07.2014, UEEIV SITK International Conference 28

 The Universal Machine for Urban
Systems
Self Loading Tamping Machine
Plassermatic 08-275/4 ZW

Warszawa, 01.07.2014, UEEIV SITK International Conference 29

 The Universal Machine for Urban
Systems

Warszawa, 01.07.2014, UEEIV SITK International Conference 30

 Agenda
• Turnout Maintenance – a Cost Benefit
• Tamping Machines
• Ballast Distribution and Stabilising
• Ballast Cleaning in Switches

Warszawa, 01.07.2014, UEEIV SITK International Conference 31

 Ballast Distribution and Stabilising
in Turnouts
• Ballast distribution
• Sweeping unit for ballast pick-up
• Shoulder ploughs
• Ballast hopper
• Stabilising
• Homogenous compaction in turnouts and
adjacent tracks
• Standard stabilising units
• Integrated or seperate machines

Warszawa, 01.07.2014, UEEIV SITK International Conference 32

 The Ballast Saving Machine
BDS - System for Ballast Management in Tracks and
Turnouts

Warszawa, 01.07.2014, UEEIV SITK International Conference 33

 Stabilising in Turnouts

Warszawa, 01.07.2014, UEEIV SITK International Conference 34

 Agenda
• Turnout Maintenance – a Cost Benefit
• Tamping Machines
• Ballast Distribution and Stabilising
• Ballast Cleaning in Switches

Warszawa, 01.07.2014, UEEIV SITK International Conference 35

 New Machines for Ballast Cleaning
in Turnouts

URM 700

ZRM 350

Warszawa, 01.07.2014, UEEIV SITK International Conference 36

 Nonstop in Turnouts
The Multitalent for Ballast Cleaning
URM 700

Warszawa, 01.07.2014, UEEIV SITK International Conference 37

 Cleaning Turnouts in Cyclic Mode
RM 80 UHR

Direction of work
Excavation area

Warszawa, 01.07.2014, UEEIV SITK International Conference 38

 Continuous Action Ballast Cleaning
in Turnouts

Warszawa, 01.07.2014, UEEIV SITK International Conference 39

 • Film URM 700
• 90048_URM700_DE-HDwmv

Warszawa, 01.07.2014, UEEIV SITK International Conference 40

 Ballast Cleaning with or without
Track - ZRM 350

Warszawa, 01.07.2014, UEEIV SITK International Conference 41

 • Film ZRM 350
• 90054_ZRM350_DE_HD.wmv

Warszawa, 01.07.2014, UEEIV SITK International Conference 42

Mechanized Maintenance of Turnouts
STATE OF THE ART TURNOUT
MAINTENANCE »»»
KEY TO SUCCESS
 Rainer Wenty
Plasser & Theurer
Export von Bahnbaumaschinen Gesellschaft m.b.H.

A-1010 Wien, Johannesgasse 3

Tel.: +43 (0) 1 515 72-0
Fax: +43 (0) 1 513 18 01
E-Mail: export@plassertheurer.com
www.plassertheurer.com
Illustrations and descriptions may contain optional equipment.
We reserve the right to make alterations in line with further technical developments.
Warszawa, 01.07.2014, UEEIV SITK International Conference 44