paul zammit - asset standards authority transport for nsw - signal testing, detection and...
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Signalling Turnouts
National Turnouts WorkshopMay 2014
Paul ZammitAsset Standards Authority
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• Track & Signals• Signalling Principles• Turnout Stability• Points Locking• Points Detection• Turnout Types
• Switch Rollers• Back Drives• Points Strategy• Achieving Maintainability• Signalling Controls• Emergency Operation
Contents
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Signals construction
Track construction
Track & Signals
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Turnouts are required to be:• Safe• Functional• Reliable• Maintainable
Turnouts are challenged
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Signalling Principles
• Large steel structures that require significant force to move• Exposed to rolling stock forces• Exposed to the elements• Points operate occasionally or frequently, but their availability (locking
and detection) is 24/7
• Effective track stability and geometry• Simpler effective signalling design • Proper installation (track and signalling)• Regular testing to ensure continued operation within specifications• Achieving maintainability objectives (track and signalling)
Solution
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• In accordance with the desired route request or overlap
Operate the switches
• Mechanically secure (lock) points in correct position• Fail the lock if points obstructed• Detect the position of the lock
Provide & prove locking
The aim of signalling turnouts
• Lock the point position with train approaching• Hold the points in the route until train has passed
Lock the route
Detect the switch position
• Prove the closed-switch and open-switch positions
Designed on fail safe principles-including mechanical components
Regularly maintained by competent personnel to ensure it performs its
designed safety and functional requirement
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Signalling Principles
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The steel in-bearer arrangement is engineered to provide a solid
square box
Avoids the points goingout of square
Anchored fixings keeps the signalling
square with the switch and stock rails
Turnout Stability
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• Closed-switch cannot open by 3.2 mm* or more, nor can the point lock enter if the closed-switchis open by 3.2 mm* or more
• For reliability, the point lock is adjusted to fully enter with a closed-switch opening of at least 1.6 mm**
Power operated points
Point lock test
Exception for Claw Lock points
* Extended to 4.8 mm** Extended to 3.2 mm
Points Locking
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• Open-switch openings (at the switch-tip) checked-typically 125 mm
• Rear flangeway clearances checked to 60 mm +/-5 mm
Points Locking
Switch-tip & Rear flangeway
Switch openings test
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Points Locking
• The point lock does not permit the open-switch to close by less than 100 mm
• The point lock is prevented from engaging if the open-switch opening is less than 100 mm Less Than 100mm
1. Point Lock Fails
2. Detector Contacts Broken (Open Circuit)
Catchpoints switch-tip
Switch openings test
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Flank Protection
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The amount of coveragethe operating bar provides
to the point lock
(measured at the moment detection is broken)
Points Locking
Maximum CoveragePoint Lock Coverage
Operating Bar
Point Lock
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Point lock coverage test
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Points LockingMinimum point lock coverage
• Measured at the moment detection is broken
Spherolock points
>=25 mm
Lock Coverage
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>=25 mm
Lock Coverage
Claw Lock points
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Points Detection
• Closed-switch / Open-switch• Mechanical detection• Electrical detection
• Combined with points mechanism• Stand alone• Dependant/independent on point lock
Closed-switch
Go at 3.2mm or lessNo-go at 4.8mm or moreExceptions available for trailing (only) points
Detecting the switch position
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Points DetectionDetecting other vital movements
• Point lock position• Bolt lock position• Point lock coverage (operating bar)• Electro pneumatic types
• Plunger lock position• Control valve spool position• Pos & neg motor air pressure• Back drive (in some cases)
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Points Detection
Plunger Lock Dog
Contacts Made Normal (NWKR) when Locking Plunger
Contacts Made Reverse (Cut-off Valve) when Clear of Plunger
Plunger Clearance
Electro pneumatic points- Detecting plunger lock position
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Points DetectionElectro pneumatic points- Detecting control valve spool position
Air Motor
Main Spool
Micro SwitchMicro Switch
Control Spool
Cut-off Valve
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Points DetectionElectro pneumatic points- Detecting pos/neg motor air pressure
Negative Air PressurePositive Air Pressure
Back Contact Made Front Contact Made
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Turnout Types
Electric combined mechanism
Claw Lock mechanism
Spherolock mechanism
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Turnout TypesConventional combined mechanism
M3aCombined
Mechanism
Internal Point Lock& Detection
Deflection Ramp
Points Rodding
Detector is dependentwith the point lock
Both switches areoperated simultaneously
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Turnout TypesClaw Lock mechanism
Switches operate independently
84MElectric
Mechanism
InternalDetection
ExternalPoint Lock
Steel In-Bearer(contains rodding)
Independent switch position & point lock detection
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Turnout TypesClaw Lock operation
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Turnout Types
Steel In-Bearer(contains rodding)
T Style Crank
Back Drive
Spherolock mechanism
External Lock
Switches operate independently
Independent switch position & point lock detection +
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Turnout TypesSpherolock operation
Spherolockinternal workings
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Schreck-Mieves (Teksol) switch rollerfor 60kg rail full height switches
RotorRail switch rollertype RIC294 toe end
CDP in-plate switch roller
CDP switch roller assembly
Schreck-Mieves EKOS (Teksol)switch roller for conventional switches
Switch Rollers
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Back Drives
Single rodding back drive Spring assist mechanism
Older types
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Back DrivesNewer type
Double rodding using T cranks
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• Spherolock or Claw Lock mechanisms• D84M electric machines or Electro pneumatic type• Trailable mechanisms in yards• Standardised layouts and switch drillings • T crank style double rod back drives
Preferences
• Improved stability …integrity & reliability• Facilitate tamping and mechanised track maintenance• Efficient due to reduced maintenance time• Safer due to minimal trackside infrastructure
Benefits
Points Strategy
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for Sydney metropolitan area
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Achieving Maintainability
• On-track access and duration• Point mechanisms located on the safest side of the track• Affect on adjacent tracks• Spare parts standardisation• Turnout components and drillings standardisation• Familiarisation
• Limit the number of different types• Provide specific performance requirements
• Signals / Track co-ordination• Simplicity of mechanisms
Considerations for achieving objectives
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Achieving MaintainabilityPhysical Position M3A Mechanism 84M Mechanism Electro Pneumatic
Mechanism
On-trackin danger zone
Points detectorLock detectorDrive detectorElectric motor
ClutchCut out crank
Points detector…………………..
Drive detectorElectric motor
ClutchCut out crank
Points detector…………………..…………………..
Air motor…………………..…………………..
Off-trackout of danger
zone
Fuse and SwitchCut out timer
ESML
Fuse and SwitchCut out timer
EOL
Control valvesShuttle valves
Pressure switchEOL
(integrated within unit)
Note: Circuitry on the interlocking side is considered similar for all applications
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Achieving MaintainabilitySupporting mechanised track maintenance
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Signalling ControlsEvolution
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Emergency Operation
ESML- Emergency Switch Machine Lock
EOL- Emergency Operation Lock
• Electric PointsTrackside cupboard containing an indexed crank handle or fortress key that fits into specific points
• Electro pneumatic (EP) PointsNewer style EP points provide push button release & operation of the points
Older style EP points do not have provision for emergency operation except by the maintainer
Points can be manually operated in the field under failure conditions
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Thank you