London Underground P&C Development. Presented by Darren Sharp, Principal Engineer, P&C, London Underground

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1 London Underground P&C Development Presented by Darren Sharp, Principal Engineer, P&C, London Underground

Point Systems on LU for New Works Current Points Specification BB54M modified flexure shallow depth switches Switch rollers with phosphor bronze Concrete bearers with direct fixation throughout

2 Point Systems on LU for New Works Current Points Specification BB54M modified flexure shallow depth switches Switch rollers with phosphor bronze Concrete bearers with direct fixation throughout except through slide and heel plates. Modular where required. Sonneville Blocks or Delcor Direct Fix in tube E-plus clips with 8.5mm rubber pad Cast Mono-bock crossings with Explosive Depth Hardening 4 ft Surelock (Siemens) direct drive point machine with 130mm toe opening and slotted soleplate. RCM as standard PRS12 Mechanical Supplementary Drive with tubular rod and drop bracket

Switch Design Principals used in LU Bull Head, Full Depth and Shallow depth designs now include increased flexing length to reduce

Applying foot relief across the range for all flat bottom shallow and full depth switch designs increases switch flexibility at heel.

Linished underside of switch rail with low friction and anti-corrisive coating Apply Snipe cut to existing designs that are known not

3 Switch Design Principals used in LU Bull Head, Full Depth and Shallow depth designs now include increased flexing length to reduce forces to throw the switches and help achieve a compliant flangeway. Longer switches are being extended by up to 3 beds. Applying foot relief across the range for all flat bottom shallow and full depth switch designs increases switch flexibility at heel. Use low friction slide surface and switch rollers (inc BH). Lubricate with Interflon. Linished underside of switch rail with low friction and anti-corrisive coating Apply Snipe cut to existing designs that are known not to achieve a 50mm flangeway with 105mm toe opening eg FB BV switches. Widen Toe Opening, 130mm for Surelock and 160mm for new points design. Increases flangeway and produces a more natural curve

4 Snipe Cut Included on the inside of the switch rail to increase the free wheel clearance. The snipe cut removes material from the non-running side of the switch blade to provide a parallel clearance path. This reduces the planing length and stock rail support of the switches. Support is improved by adding additional distance blocks at the end of planing. Applied to all FB AV,BV,AVs and BVs switches

5 Point Machine and Points Operating Equipment Design 3D model (Solidworks) enables elements to be analysed, space constraints realised, and provide snap shots for I & M manuals. 4ft Surelock provides direct drive to rail with 130mm toe opening.

6 F-Melba switch flexure also used to determine natural switch opening for Supp Drive settings. Shown here is the system installed at South Kensington 254pts with 110mm toe opening.

7 F-Melba switch flexure New Evsm with 130mm toe opening from 4ft Surelock. Reduces forces by 30% compared to Evsm with 110mm toe opening. Also assists in setting switch openings at mid drive.

8 P&C Product Development in LU Bullhead Cast Crossings Installed at Seven Sisters, Victoria Line in May Uses Pandrol TVA baseplates in casting with 166m deep casting and 5mm pad. Legs are inclined BH leading into existing BH crossing chairs. Wings are inclined following Bullhead geometry providing improved guidance and support through wheel transfer area. Designs available for 1 in 8, 9, 10, 12, 16 and 20 along with some bespoke saddles for use at White City.

9 Continuous flange on foot allows for varying bearer spacing to avoid moving bearers and also reduces likelihood of fatigue cracking at foot. New internal structural design used to provide this improvement.

10 1 in 12 Bullhead Cast Crossing installed at Highbury and Islington 5071pts on the Victoria Line

11 Ecotrax Composite Bearer Trials Ecotrax Composite Bearers trial at Stonebridge Park Depot. Dimples on sides and bottom for improved lateral stability

Used as full renewal or spot replacement within timber layouts.

12 Improved durability, pull out force, lateral restraint. Lighter than hardwood bearers. Used as full renewal or spot replacement within timber layouts. Trials for splicing by jointing and gluing to commence shortly. Also used for slipper run trials in place of hardwood.

14 Hand-over to Martyn Scoble for presentation on Optimising Point Systems.

15 Optimising Point Systems Presented by Martyn Scoble, Lead Point Systems Engineer, London Underground

16 The Mission Design points system which will deliver a Mean Time Between Failure of 10 Years That system will also be the longest turn out on London Underground, an SGvsm And, make it compliant to standard And, improve maintainability And, demonstrate its safe to use

17 The Assumption By reducing the amount of effort to move the switch rails and maintaining a constant level of effort, the system will be reliable

18 The Theory F-Melba switch flexure used to determine natural switch opening for Supp Drive settings.

19 The Theory Force behind headcut Force at headcut Force at mid drive Aggregate force on front stretcher bar Balance of load 3 Crank Supplementary Drive - 4 Crank Supplementary Drive 5.01kN 3.11kN 5.09kN 3.16kN 3.46kN 5.37kN 2.96kN

20 Concept Selection

21 Concept Selection

22 Design Improvements Articulated Stretcher Bar

23 Design Improvements Direct pick up for supplementary drive

24 Design Improvements Surelock Double Drive

25 Design Improvements Supplementary drive beyond the headcut Lots of rollers Lost motion moved to the centre of the track

26 The Results

27 Rollers London Underground SG Panel Tes2ng at Sandiacre Trace: Curren t v Time Red (Baseli ne) Green Blue Mage nta Cyan Mov e: Nor mal ID: Rollers Slide (at bearer Chairs posi2ons) Environment Condi2ons All Down Cleaned, Degrease d, and Wiped Dry Dry Front Up As above Dry 5 Up As above Dry 9 Up As above Dry 12, 16, As above 18, 20 Up Dry

28 Current Draw Operations Operations Zero Operations

29 Point machine force Increased retention force

30 Supplementary Drive force Increasing force at headcut

31 Conclusion The Results so far are positive The force to move the switches is surprisingly low Improvements in maintainability Next Steps Understand how we can prevent drift in the supplementary drive set up Gain product approval of the improvements

London Underground Point and switch system development. Anna Cornish, Principal Project Engineer, Integration and Development

1 London Underground Point and switch system development Anna Cornish, Principal Project Engineer, Integration and Development 2 London Underground point system development Finding the 21st century As