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Vortok International Switch Roller System

Vortok Rotorrail Maintenance Free Switch Roller Systems Rotorrail is manufactured under licence from Mazzi Technology Vortok Switch Roller System Rotorrail Proposal Contents 2 Introduction 3 Concept and Method of Operation 4 Main Features 5 Business Case 6 Worldwide Approvals 7 - 8 Installation Appendix 10 Material Specification 11 - 12 Trial Examples 13 15 Photo and CAD Gallery 16 Integrated Rollers

Vortok Switch Roller System Rotorrail Proposal Contents 2 Introduction 3 Concept and Method of Operation 4 Main Features 5 Business Case 6 Worldwide Approvals

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Transcription of Vortok International Switch Roller System

1 Vortok Rotorrail Maintenance Free Switch Roller Systems Rotorrail is manufactured under licence from Mazzi Technology Vortok Switch Roller System Rotorrail Proposal Contents 2 Introduction 3 Concept and Method of Operation 4 Main Features 5 Business Case 6 Worldwide Approvals 7 - 8 Installation Appendix 10 Material Specification 11 - 12 Trial Examples 13 15 Photo and CAD Gallery 16 Integrated Rollers Approvals and Test Report Section 18 Vortok ISO Accreditation 19 25 RFI Italy.

2 Latest Homologation and test report + Translation 26 Original Railtrack UK Certificate of Acceptance 27 31 Network Rail UK Replacement Certificate 32 37 EBA Germany Approval + Translation 38 Network Rail Integrated Roller Certificate of Acceptance 39 42 Latest Network Rail Certificate of Acceptance 43 Spoornet South Africa 1 Introduction Non functioning switches/turnouts are a long standing problem for network operators worldwide, often resulting in daily heavy applications of grease by track workers upon the worst offending mechanisms. The drive to reduce costs and eliminate the environmental impact of greasing has resulted in the design of Roller systems for switches. What makes the Vortok Rotorrail System particularly attractive is the ability to retro-fit the product to almost every existing Switch design, associated baseplate and fastening System without having to modify them.

3 The product was designed to meet several challenging design criteria, including: Eliminating the need for greasing of baseplates. Work as a retro-fit solution. Fit virtually all baseplate/fastening designs with no need to change or adapt in any way. Quick and simple installation process with no, or very little possession time required. Affordable solution with significant cost savings for the operator. Maintenance free. (Occasional visual inspection) Ability to cope with severe local environmental conditions where necessary. (Mines, steel works etc.) Remain clear of tamper areas. Rotorrail surpasses these original criteria whilst offering new levels of reliability, significant cost savings and environmental benefits. This document gives more detail of the Rotorrail product, includes details of the different variants already supplied by Vortok , installations worldwide and the approvals that exist.

4 Left: Rotorrail Unit supplied to Bay Area Rapid Transport (BART) USA. Below: Rotorrail installation Network Rail United Kingdom. 2 Concept and Method of Operation The principle of the Rotorrail is very simple, to reduce friction to such an extent that the Switch operates reliably without the need for heavy, or indeed any, greasing. The Rotorrail System uses rollers cantilevered over the side of the baseplate structure. The switching blade only takes the mass of the traffic when it is touching the running or stock rail. In this position, the foot of the Switch blade is touching, and transfers the wheel load to, the original chair surface. When one side of the Switch is closed the matching Switch blade is open and takes no wheel load. The Rotorrail unit is positioned so that the first Roller is just touching the foot of the Switch blade in the closed position and thus the unit is not taking any load.

5 Rotorrail unit shown in this ready mode with the Switch blade in the closed position. When the Switch is operated the closed blade moves away from the stock rail and immediately rides up onto the first Roller . The Roller is designed to lift the Switch blade, typically by 4mm, and as soon as the Switch blade is lifted most of the drag / friction associated with greased systems disappears. The actuation mechanism only has to act against the rolling resistance and any flexure of the Switch blade. Rotorrail unit shown in the actuated mode with the switchblade in the open position. The Switch blade is now free to travel to its fully open position. The opposite matching blade will of course now move from the open position, supported initially on the Rotor Rail, to the closed position, where it drops off the Roller onto the chair surface ready to take traffic load.

6 The Structure of the Rotorrail takes support from the baseplate and uses the existing fixings. By using the existing fixings and being designed around the existing baseplate structure the Rotorrail can be installed very quickly, each unit taking less than 5 minutes to install. 3 Main Features. The unique method of positioning the rollers cantilevered over the side of the baseplate structure, taking support from it, enables the System to be easily designed/adapted for virtually all baseplate designs. The above also allows a rail network to rapidly install on both new and importantly retro fit to existing turnouts without changes to baseplate or fastenings at all. Maintenance free with no greasing required. The specially hardened type sealed rollers are lubricated and sealed for life, therefore offering immediate labour savings by eliminating the need to grease.

7 No adjustments. The units require no vertical adjustment as they work on a fixed height lift and therefore cannot be incorrectly set by track workers. The System will fit onto, and use, the existing baseplate screws, no special fixings required at all. Vastly improved reliability of Switch performance and reduction in the wear and tear. Potential energy savings as motor power can be turned down and motor life extended. Simple installation. Whether fitting to new turnouts or existing systems in track the installation process takes no more than 10 minutes per unit requiring no possession of the line. Not prone in any way to damage from tamping machines. Ability to choose problem baseplates where it is obvious the rail is in heavy contact with the riser plate and prone to sticking. In the unlikely event of damage or failure the units can be replaced within minutes.

8 Queensland Rail Australia 4 Business Case The Vortok Rotorrails have an initial purchase cost and an associated installation cost, the latter being particularly small due to the quick installation time. Once installed, they are maintenance free, and therefore free from ongoing costs*. Rotorrails are designed to remove problems, and therefore costs, from the operators network: Grease Application Costs. This is often a daily occurrence requiring teams of track workers spending many hours a week greasing the baseplates. Grease Removal/Cleaning Costs. Grease attracts dirt, which in turn renders the grease that builds up on the baseplate useless by forming a hardened paste. This requires cleaning before being re-greased. Switch Failure Cost. What is the cost to the operator of traffic that has to be stopped until the Switch is loosened?

9 The above are immediate cost savings upon installation, however it is also worth bearing in mind that additional ongoing hidden savings will benefit the operator. Power Savings. The actuation motors can be turned down to save power as the switchblades will require less force to move them. Extended Motor Life. This reduction to the level power required by the motor to move the switchblade should extend its working life. Reduction to Wear and Tear. The wear and tear to the Switch is reduced dramatically as the switchblade now has a much smoother movement. Staggered Roller variant installed to Canadian Pacific Railway. A saving of up to 96% is not unusual after the fitting of Rotorrail units. Visual inspection is recommended during normal inspection/ Switch adjustment regimes. 5 Approvals.

10 Rotorrails were originally designed by Mazzi Technology in Italy. Vortok International now design and manufacture Rotorrail units under licence for the global market outside of Italy and Spain. The original homologation for Rotorrail came from FS in Italy in 1999 after extensive trials. Italy now has several thousand units in operation with a sub 1% failure rate. Vortok first began the design and development of Rotorrails to the in 2000. The trials in the UK were undertaken by Railtrack, now Network Rail, and full product acceptance after successful trials was granted in 2003. There are over 1,700 Rotorrails in operation in the UK and the performance has been so successful that an additional acceptance certificate has been awarded for different variants in 2006. Copies of the latest approval certificates etc are to be found in the appendix, including; RFI Italy, EBA Germany and Network Rail in the UK.


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