INNOVATIVE RAIL FASTENING SYSTEMS :::::::::::::::::::::::::: - Schwihag

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SCHWIHAG‘S
INNOVATIVE RAIL
FASTENING
SYSTEMS
SCHWIHAG RAIL FASTENING SYSTEMS
PRODUCTS 4
DEVELOPMENT 8
PRODUCTION 10
QUALITY ASSURANCE 12
TECHNICAL INNOVATIONS 13
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MODERN
TECHNOLOGY
FOR THE TRACK
The rail fastenings supplied by SCHWIHAG are
based on systems which have been put to the test
in practice for decades. SCHWIHAG has technically
and economically optimised these systems.
SCHWIHAG provides consulting, development,
design, production, delivery and service for rail
fastenings and the following applications:
:: Standard railway lines
:: High-speed lines
:: Heavy freight transport
:: Underground railways
:: Commuter railways
:: Tramways
:: Industrial railways
and in the following types of track construction:
:: Ballast track with concrete sleepers
:: Ballast track with wooden sleepers
:: Ballast track with steel sleepers
:: Slab track
:: Bridge beams (beams on steel bridges)
:: Transition areas
with regard to:
:: Rail profile and cant
:: Sleeper geometry
:: Line layout
(e.g. tight radii, large gradients)
SCHWIHAG rail fastening systems are:
:: Proven standard systems
(standard KS-track or W-track)
:: New developments to customer requirements
:: Adaptations with optimised components, e.g. new
tension clamps for existing sleepers for retrofitting
or conversion
:: Special designs for difficult installation situations
:: Systems with special surface protection for the
RFS components to customer requirements for
critical environmental conditions
:: Systems with highly effective sound insulation
(structure-borne sound/vibrations)
:: Systems for transition areas, e.g. at tunnel/bridge
with large relative movements between the rail
and support
SCHWIHAG rail fastening systems offer many
advantages for assembly and installation:
:: Can be completely preassembled in the
sleeper factory
:: Due to sorted delivery, completely automated
preassembly is also possible in the sleeper factory
:: Quick, automated, mechanical final assembly on the
construction site possible with assembly speed
of > 400 m/h track
Tension clamp Skl 14 in preassembly position
Tension clamp 14 tensioned
Other advantages:
:: Tension clamps are produced free of surface decarburisation
(see page 13 of the brochure) > maximum
dynamic fatigue strength
:: High-quality long-term corrosion protection available
(see page 14 of the brochure) > The dynamic
properties are maintained for the complete life
:: High elasticity > Results in improved load distribution
(deflection curve) along the rail, therefore, associated
significant reduction in point loading on all track
components such as the rail, rail fastening system,
sleeper and ballast
:: Integral anti-tilt protection > prevents overloading of
the tension clamp in extreme load situations
:: Integral electrical insulation > is achieved by using
the insulating plastic fastening components: angle
guide plate, rail pad and dowels
:: Modularity > enables universal usability for all railway
applications from the tramway, underground railway,
and heavy load through to high speed traffic
:: Precise batch marking > Lettering is made using laser
technology and enables exact dating of the production
date of each batch (see page 14 of the brochure)
:: Heavy-duty dowels > Special design of the dowel
geometry in conjunction with optimised material
selection enables high pull-out forces and safety
against excessive torques (see page 14/15 of the
brochure)
SCHWIHAG RAIL FASTENING SYSTEMS
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RAIL FASTENINGS FOR CONCRETE SLEEPERS
AND SLAB TRACK
Tension clamp Skl 14 on concrete sleeper (W-fastening)
Tension clamp Skl 15 for System 300-1 for slab track
Tension clamp Skl 12 on elastically supported baseplate
as single support point for slab track
Tension clamp Skl SL 1 for heavy-haul systems on concrete sleeper
RAIL FASTENINGS FOR
WOODEN SLEEPERS
Tension clamp Skl 12 on wooden sleeper (KS-fastening)
RAIL FASTENINGS FOR
TRANSITION AREAS
System BSP-FF-B1 with Skl SL1, concrete
System BSP-FF-B2 with Skl SL1, steel
RAIL FASTENINGS FOR SWITCHES
Tension clamp Skl 14 and Skl 12
as well as spring clip SSb2 for
slide baseplate URg 57 on
W switch bearer
SCHWIHAG RAIL FASTENING SYSTEMS
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SCHWIHAG
DEVELOPS, TESTS
AND PRODUCES RAIL
FASTENING SYSTEMS
Targeted research and product development play an
important role in SCHWIHAG. The requirements for
forward-looking track components are determined
through continuous dialogue with the railway engineers
of the railway companies.
The 3D CAD system Pro Engineer is used to develop
new products and to adapt or optimise products that
have already proven their worth. The necessary FEM
analyses are then performed on the basis of this CAD
data. Prototypes are examined in our own test laboratory
to determine their general technical properties
and their suitability for use in railway operations.
Continuous load (endurance) tests can be performed
according to the test conditions of international
standards and/or the specifications of the railway
companies.
In addition to the static and dynamic load tests, the
following material tests can also be performed:
:: Hardness test
:: Tensile/compressive strength test
:: Grinding preparation and microstructural analyses
(optical microscopy)
:: Polymer tests (melting point, heat of fusion, glass
transition point)
:: Optical 3D measurement of components
SCHWIHAG AG‘s jig construction department enables
the production of customer-specific adapters and test
apparatus, which ensures optimum position adjustment
and clamping of the components to be tested
during the tests.
SCHWIHAG AG in Tägerwilen (CH) with research and
development facilities
Selected variants or fail fastening tension clamps produced by SCHWIHAG
Development and design laboratory of SCHWIHAG AG in Tägerwilen
SCHWIHAG GmbH, Radefeld near Leipzig
SCHWIHAG GMBH MANUFACTURES
SCHWIHAG AG INHOUSE DEVELOPED
PRODUCTS. SCHWIHAG GMBH HAS
STATE OF THE ART PROCESS
TECHNOLOGY FOR TENSION
CLAMP PRODUCTION.
Biaxial, static and dynamic tests can be performed
in the test laboratory. The max. vertical test force is
400 kN and the max. horizontal test force is 100 kN.
The components can be tested, among other things,
in a horizontal position (biaxial) or in an inclined test
(mono-axial).
Based on this development concept, our customers‘
specific requirements can be implemented in new
products or new product variants.
Following successful testing in the SCHWIHAG laboratory,
the components and systems are subjected to
further testing by an independent test institute as part
of the approval procedure. Here SCHWIHAG works
closely with renowned test and research facilities, e.g.
the University of Technology of Munich or Dresden.
Test machine for strength tests
(tensile test) on material samples
Test laboratory with test equipment for continuous load (endurance) tests
Test machine for recording spring characteristic curves
SCHWIHAG RAIL FASTENING SYSTEMS
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FROM THE WIRE TO THE
FINISHED TENSION CLAMP:
SCHWIHAG PRODUCES IN A FULLY
AUTOMATED PRODUCTION PROCESS
WIRE ROLL MADE OF
SPRING STEEL
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SORTED PACKAGING OF
THE FINISHED PRODUCT
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BENDING LINE 3 SORTED TRANSPORT TO
QUENCHING AND HARDENING
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AUTOMATIC TRANSPORT
INTO THE WAREHOUSE
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INDOOR STORES - WAREHOUSE 8 OUTDOOR STORES
PRODUCTS ARE READY FOR DISPATCH
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SCHWIHAG RAIL FASTENING SYSTEMS
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QUENCHING AND HARDE-
NING LINE
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HIGH TECH
IN THE TEST LAB
We guarantee our customers that SCHWIHAG products
are produced according to the following criteria:
:: Careful selection of suitable heavy-duty materials
:: Selection of the optimum production method under
the aspects of product quality, flexibility and use of
resources (manpower, material, energy consumption)
:: Continuous monitoring of the production processes
and the product data through material and dimensional
checks according to national, international
standards or those specified by our customers.
SCHWIHAG has a quality management system certified
to ISO 9001-2008 and for many years has been a Q1
supplier of Deutsche Bahn AG and a certified supplier
of numerous other railway companies (including SNCF,
Network Rail, RFI).
The SCHWIHAG production concept in conjunction
with the SCHWIHAG logistics concept enables us to
respond to customers‘ special wishes at short notice
and to deliver standard products or special designs
worldwide and on-schedule.
Measuring the tension clamp geometry by means
of 3 dimensional digitising
NO SURFACE
DECARBURISATION
SCHWIHAG tension clamps can be produced free of
surface decarburisation thanks to a special heat treatment
method in closed chambers.
Following the heat treatment of the spring steel the
fine acicular, martensitic microstructure forms. If
classical heat treatment methods are used with open
processes, surface decarburisation forms all around
the perimeter of a wire with circular cross-section:
these are the starting points for cracking. In the area
No surface decarburisation, free of incipient cracks
Example of the microstructural change in metals caused by the
heat treatment process: acicular martensitic microstructure
of this surface decarburisation the material is brittle
and tends to form cracks, especially under dynamic
loading. These cracks or incipient cracks produce a
notch effect and propagate in the quenched and hardened
material and can cause a component to break.
This process is also accelerated by increased formation
of rust, which can occur especially in the area of the
surface decarburisation.
The tension clamps produced using the SCHWIHAG
method do not have any surface decarburisation
zones and therefore achieve high dynamic fatigue
strength.
All-round surface decarburisation with formation of incipient cracks
SCHWIHAG RAIL FASTENING SYSTEMS
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LONG-TERM
langzeit-
CORROSION korroSionSSchutz PROTECTION
schwihag SCHWIHAG bietet offers new, für spannklemmen high-quality long-term aus Federstahl corro-
einen sion protection neuen hochwertigen for tension clamps langzeit-korrosionsschutz
made from spring
an. steel. Mit With diesem this new neuartigen type of korrosionsschutz corrosion protection, kann
die rusting rostbildung can be verifiably nachweislich and significantly über die gesamte reduced over
lebensdauer the entire life unter under operativen operative conditions. Bedingungen In this deutlich way
reduziert the fatigue werden. strength damit properties bleiben of die the dauerfestigkeits-
tension clamps
eigenschaften remain virtually der constant spannklemmen over very nahezu long use konstant cycles.
über sehr lange einsatzzyklen.
PRECISE chargengenaue
BATCH
LABELLING
kennzeichnung
schwihag In future, each spannklemmen batch of SCHWIHAG werden tension zukünfig clamps chargen- will
genau be marked markiert. precisely. die Beschriftung The labelling erfolgt is carried mittels out using hochmoderner
highly modern lasertechnik laser technology und ermöglicht and enables die exakte exact
datierbarkeit dating of the production des Produktionsdatums date of each jeder batch. charge.
Skl skl 14 without ohne (links) (left) und and (rechts) with (right) mit neuem new long-term langzeit-korrosionsschutz
corrosion protection
Labelling kennzeichnung of tension von clamps spannklemmen by means mittels of laser lasertechnik
technology
schwihag SCHWIHAG kunststoffschraubdübel plastic anchor dowel Sdü sdü-s3 S3
hochbelaStbarer
dübel
HEAVY-DUTY DOWELS
der dübel ist eine wesentliche komponente für
schienenbefestigungssysteme The dowel is an essential component auf Betonschwellen.
for rail fastening
damit systems kommt on concrete dem dübel sleepers. als im The Beton dowel, eingegossenes
as a compo-
Bauteil nent cast hohe in the Bedeutung concrete, für is therefore die Funktionalität very important der for
schienenbefestigung the function of the rail zu. fastening. die Belastbarkeit The loading von capacity dübelkonstruktionen
of dowel constructions kann hauptsächlich can mainly be anhand determined ihres kon- by its
struktiven design failure. versagens This can festgemacht not only be werden. loss of the dieses connec- kann
sowohl tion or keying ein verlust of the der dowel verbindung with the bzw. sleeper verzahnung body, e.g.
des pulling dübels out of mit the dem dowel schwellenkörper, from the sleeper z.B. or herausreißen
damage to
des the surrounding dübels aus der concrete, schwelle but bzw. also Beschädigung failure of the internal des
umgebenden plug construction, Betons, e.g. als pulling auch out ein versagen of the screw der or inneren bolt
dübelkonstruktion, from the plug. z.B. auszug der schraube aus dem
dübel, sein.
The objective of the development of the new
Ziel SCHWIHAG der entwicklung plastic anchor des neuen dowel schwihag Sdü S3 was kunst- to reduce
stoffschraubdübels the tensile stresses in sdü the s3 concrete war, die body aus der resulting schraube- from
the dübel-kombination screw-dowel combination. resultierenden In critical Zugspannungen loading situa- im
tions, Betonkörper which occur zu reduzieren. especially dadurch during laying soll in of kritischen the track
and Belastungssituationen, the tightening of the die rail insbesondere fastening, this bei should der Monensuretage a des reserve gleises against und der failure verspannung of the dowel der construction
schienen-
and befestigung the bonding auftreten, with the eine sleeper reserve concrete. gegen versagen
The development objective was achieved in design
terms by the geometrical formation of the dowel‘s
external (male) thread and the allocation of the
corresponding dowel internal (female) thread. In
addition, different wall thicknesses were implemented
in the design of the dowel‘s thread area. This material
distribution causes any stress peaks occurring due to
elastic and plastic deformation of the dowel material
to be absorbed and therefore prevents damage to the
surrounding concrete contour.
The newly developed plastic anchor dowel Sdü S3 can
be used not only with the sleeper screw Ss 25 but also
with the sleeper screw Ss 35. Damage to the internal
thread of the dowel caused by incorrect positioning of
the sleeper screw Ss 25 with pointed thread is prevented
by special design of the internal thread runout.
Within the scope of qualification tests it was established
that the new SCHWIHAG plastic anchor dowel
Sdü S3 has a factor of safety of up to 4 for the pull-out
force. The SCHWIHAG design also has a 3-fold factor of
safety for the tightening torque, which is introduced
into the dowel when tightening the sleeper screw.
Apart from laboratory tests, this was also verified by
practical tests on the track panel. When the sleeper
screw was tightened and undone 10 times, no movement
in the dowel crown was found and the bonding
between the sleeper concrete and the dowel was
completely intact.
Test sample after screwing in ten times using
a power assembly tool in the screw in tests
under practical conditions.
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SCHWIHAG AG
Track and Switch Technology
Lebernstrasse 3, CH-8274 Tägerwilen
Tel +41(0)71 666 88 00 Fax +41(0)71 666 88 01
info@schwihag.com www.schwihag.com