Development of the FXT Track System. presented by André Van Leuven Dynamic Engineering

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1 Development of the FXT Track System presented by André Van Leuven Dynamic Engineering

2 Existing Stiff LIM Track System Power rails Vehicle LIM Running Rail fastener LIM rail CSJ213 - APTA Dallas, June 3-6,

3 Fundamental design issues with ART trackwork High capital and installation cost for adapting LIM rail track. DF rail fasteners: specified with high vertical stiffness to ensure precise dynamic control of LIM gap (9 mm) versus low-track stiffness traditionally applied for rotary design for good track design. DF vertical stiffness: due to LIM performance requirements, ART specifies very stiff rail fastening systems (up to 24 kn/mm) or <1 mm vertical track deflection at max. loads versus 3 mm typical deflection for conventional transit track. Re-occurrence of rail corrugation: higher wayside vibrations and rail noise generally attributed to stiff trackwork resulting in additional routine track maintenance and rail wear. Maintenance effort to adjust LIM rail height CSJ213 - APTA Dallas, June 3-6,

4 Primary requirements of the new track system Improve Trackwork Cost: Fewer trackwork interface fasteners Installation tolerances Installation time Reduce concrete secondpour support structure Improve Vehicle Propulsion: Control LIM air gap variations Improve Environmental Impact: Vehicle interior & exterior airborne noise reduction (20 25 dba) Wayside trackwork groundborne vibration reduction (20 25 db) Electrical rail stray current control Improve Track Maintenance: Less rail grinding from rail corrugation Track and LIM rail adjustment more easily accessible CSJ213 - APTA Dallas, June 3-6,

5 FXT Rail Fastener System (3rd rail) Power rail Rail fastener LIM rail CSJ213 - APTA Dallas, June 3-6,

6 Technical Review Rail Fastener (10kN preload) CSJ213 - APTA Dallas, June 3-6,

7 Super resilient rail fastener Preload imposes a deflection (= compression) to the pad. Preload is such that the additional deflection will be less than 4 mm Preload is such that the springs are completely released under wheel passage Direct fixation resilient pad Total deflection without precompression δ>4mm δ<4mm Pre -Compression = = Preload Deflection felt by the rail CSJ213 - APTA Dallas, June 3-6,

8 Kingston FXT Installation and Testing CSJ213 - APTA Dallas, June 3-6,

9 Installation Process Install self-locking GRP inserts and 1-1/4 anchor fasteners Fewer guideway anchors improves isolation CSJ213 - APTA Dallas, June 3-6,

10 FXT Installation (1000 mm tie spacing ) CSJ213 - APTA Dallas, June 3-6,

11 Maintenance and Adjustments LIM rail shims (2 mm) and attachment location simplifies adjustment CSJ213 - APTA Dallas, June 3-6,

12 Power Rail Support and Isolation Option - improves isolation and eliminates final set-up CSJ213 - APTA Dallas, June 3-6,

13 Measurements to demonstrate a cost effective noise reduction Rail roughness measurements: on the stiff track (Kingston reference track) on the FXT track (new prototype) Track decay rate and rail impedance measurements: on the stiff track on the FXT track Wheel impedance measurements on the ART MKII Pass-by noise & vibration measurements: on the stiff track on the FXT track CSJ213 - APTA Dallas, June 3-6,

14 Measurements in Kingston - Rail is RE115 Fastener spacing [m] Fastener stiffness [kn/mm] Stiff track FXT track CSJ213 - APTA Dallas, June 3-6,

15 Roughness [db(re.1e-6m)] Rail Roughness Stiff track - Right rail Stiff track - Left rail FXT track - Right rail FXT track - Left rail ISO3095:2005 limit Third Octave Band Wavelength [cm] CSJ213 - APTA Dallas, June 3-6,

16 Track Decay CSJ213 - APTA Dallas, June 3-6,

17 Track Decay Rates - Vertical CSJ213 - APTA Dallas, June 3-6,

18 Track Decay rates - Horizontal CSJ213 - APTA Dallas, June 3-6,

19 ART mkii Wheel Impedance radial tread response axial tread response axial web response CSJ213 - APTA Dallas, June 3-6,

20 Third Octave Band RMS Level [db(a)(re.2e-5pa)] Noise Predictions with WR Software Stiff track 80 km/h Rail Wheel Total Third Octave Band Frequency [Hz] CSJ213 - APTA Dallas, June 3-6,

21 Third Octave Band RMS Level [db(a)(re.2e-5pa)] Noise Predictions with WR Software FXT track 80 km/h Rail Wheel Total Third Octave Band Frequency [Hz] CSJ213 - APTA Dallas, June 3-6,

22 Tel (dba) for Kingston for 80 km/h Stiffness FXT Rail Wheel Total MKII has important resonances at 800 Hz and 1600 Hz Wheel dominates total response below 315 Hz and above 2500 Hz CSJ213 - APTA Dallas, June 3-6,

23 Roughness [db(re.1e-6m)] Roughness during grinding Before grinding After grinding intermediate 1 intermediate 2 ISO3095:2005 limit Third Octave Band Wavelength [cm] CSJ213 - APTA Dallas, June 3-6,

24 Noise Simulations for ART MKII (Tel) Before (BG) and after (AG) grinding Roughness [db] Noise [db(a)] 40 km/h 80 km/h Stiff BG Stiff AG Grinding FXT AG Stiff AG Difference Small initial difference FXT has no roughness growth Initial difference is quickly eliminated CSJ213 - APTA Dallas, June 3-6,

25 Excessive corrugation: 5 weeks Voie 1 - courbe à gauche (9/6-10/12) exemple d UO UO St. Catherine 7SFDV Déplac Vert Déplac Vert Déplac Vert Déplac Vert Déplac Vert Déplac Vert Déplac Vert Déplac. Long. ( cm ) Dépl. Long. Min.: -0,05 cm DATE Dépl. Long. Max: 102,36 cm CSJ213 - APTA Dallas, June 3-6,

26 Noise Simulations for ART MKII (Tel) Excessive Corrugation Roughness [db] Noise [db(a)] 40 km/h 80 km/h 6 Sept Oct weeks Small initial difference FXT has no roughness growth Initial difference is eliminated in a few days CSJ213 - APTA Dallas, June 3-6,

27 Insertion loss [db(re.1e-9m/s)] Insertion Loss Stiff to FXT km/h 40km/h 60km/h 70km/h average Third Octave Band Frequency [Hz] CSJ213 - APTA Dallas, June 3-6,

28 [db(re.1e-9m/s)] Vibration levels for MKII at 40 km/h without FXT - OA:117.6dB(re.1e-9m/s) with FXT - OA:95.95dB(re.1e-9m/s) /3 Octave Band Center Frequency [Hz] CSJ213 - APTA Dallas, June 3-6,

29 [db(re.1e-9m/s)] Vibration levels for MKII at 80 km/h without FXT - OA:123dB(re.1e-9m/s) with FXT - OA:101.8dB(re.1e-9m/s) /3 Octave Band Center Frequency [Hz] CSJ213 - APTA Dallas, June 3-6,

30 20km/h 40km/h 60km/h 70km/h acceleration without brakes acceleration with brakes on Average vibration (1-1000Hz) [db(re.1e-9m/s)] Vibration measurements with TV FXT track (2009) Stiff track (2009) Case CSJ213 - APTA Dallas, June 3-6,

31 Technical Benefits FXT system combines running rail and LIM rail onto common platform FXT supports and maintains air gap relative to TOR Rail vertical deflection increases from <1 mm to 3-4 mm at max. load Reduced wheel impact forces and rail noise Elastomeric pads easily serviceable CSJ213 - APTA Dallas, June 3-6,

32 Technical Benefits Adapts / retrofits to existing ART DF track systems: Single anchor stud installed in-between existing rail fasteners Single anchor stud reduces number of embedded track fasteners: Single GRP insert per m rail minimizes stray current paths Reduces ground borne vehicle vibrations from trackwork: Provides 3-4 mm rail deflection versus <1 mm resulting in 25 db reduction in vibrations and reduced trackwork noise (similar to floating slab) CSJ213 - APTA Dallas, June 3-6,

33 Technical Benefits Reduces dynamic vehicle LIM air- gap variation: LIM rail floats with track deflection resulting in less adjustment Reduces effort for maintaining LIM rail TOR height: adjustment provision at top cap permits use of small hand tools Reduces track maintenance: Studies identify elimination of rail corrugation due to soft rail fasteners CSJ213 - APTA Dallas, June 3-6,

34 Conclusions Installed cost: up to 10% less DF vertical stiffness: specified as 4-6 kn/mm Super resilient rail fastening system: not prone to rail corrugation initiation Vibration mitigation similar to Floating slab track at fraction of cost (20 db reduction) Reduced Maintenance effort to adjust LIM rail height Easily adaptable: up-grade most existing slab track installations CSJ213 - APTA Dallas, June 3-6,

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