THE REVOLUTION FOR HIGHEST TAMPING QUALITY OF PLAIN LINES AND SWITCHES
OUTSTANDING INNOVATIONS FOR A NEW TAMPING CULTURE
The heart of the machine is the latest generation S7 tamping bank with a patented full hydraulic tamping drive. The tamping drive vibrates only when penetrating the ballast and during tamping. In S7 automatic tamping mode, the tamping drive stops until the optimum ballast compaction has been achieved. Optimum compaction is determined by measurement.
When the optimum compaction is reached, the vibration of the corresponding tamping cylinder is switched off so as not to loosen the compaction state that has been reached. The individual tamping cylinders are controlled independently of each other. When the last tamping cylinder has optimally tamped the sleeper, the aggregates are raised with the vibration switched off.
HUGE REDUCTION ON WEAR
The tamping drives only vibrates during insertion and compaction of the ballast, the rest of the tamping cycle they are standing still. In addition, there is no need for a large number of rotating and wearing drive parts. This means high savings in overhaul and maintenance costs. Other low-wear technologies such as disc brakes guarantee low life cycle costs for the entire tamping machine.
INTEGRATION OF 3RD POINT LIFTING INTO MAIN LIFTING AND LINING UNIT
By integrating the additional lifting device into the main lifting unit, the switch is always automatically lifted at the same long sleeper. Additional devices such as laser transmitters on the main lifting device and laser receivers on the additional lifting device are not required. This avoids switch torsion, which has a negative impact on the quality of work and places mechanical stress on the switch.
S7 AUTOMATIC TAMPING FOR OPTIMUM COMPACTION
The hydraulic squeezing cylinders are equipped with integrated contactless position sensors and pressure transducers which individually stop squeezing in S7 automatic tamping mode as soon as the optimum compaction force is reached. Optimum compaction of the ballast extends the durability of the track layer and reduces the wear and tear on the ballast.
REMARKABLE NOISE AND DUST REDUCTION
The noise is reduced signiﬁcantly by more than -7dBA and respirable dust by more than -50% in comparison with conventional tamping banks which minimizes the burden of the operator and the environment.
BALLAST BED ANALYSIS WITH SYSTEM7 INFRASTRUCTURE MANAGEMENT WEB PLATFORM "INFRAME"
Each squeezing cylinder collects data of achieved ballast compaction and squeezing path. Thereof a quality ﬁgure for the ballast bed hardness is derived. Tamping data is uploaded to “INFRAME” were the tamping job is visible on a map with related GPS coordinates and an image of each sleeper surrounding.
BALLAST BED REPORT
The basis for the ballast bed report, which is created on the System7 tamping machines immediately after the work, is formed by measurement data from tamping unit sensors, parameters from the track geometry acceptance recorder APPRec and the control computer CEO++.
This data is automatically analysed using machine learning and summarised and output in the ballast bed report. In addition to the graphical representation of the ballast bed properties and the compaction achieved, long-wave longitudinal faults before and after tamping are also drawn. A written summary assesses the ballast bed quality and points out any single faults in the track
AUTOMATED INTUITIVE TAMPING OPERATION
The S7 universal tamping machine is facilitating the operator’s tasks through automation as far as possible in manual mode and even offers an automatic tamping mode. Two touch panels and two joysticks provide the operator a simple and intuitive work environment. In automatic tamping mode, the machine itself calculates the optimum compaction from the measured course of compaction force and compaction path and then completes the compaction process fully automatically.
The machine measures the ballast bed hardness during work and independently selects the optimum tamping parameters such as lowering speed, start and braking ramp, penetration frequency and amplitude as well as tamping pressure. To ensure that the operator has a constant view of the tamping area while working, the information necessary for the tamping quality is displayed in the foot area.
The necessary work information is displayed in the tamper’s field of vision. This is the ergonomically optimal position. For each tamping, the display signals the direction, height and cross level and the proper functioning of the aggregates and the measuring and control system.
The switch engineer is made up of several assistance systems. The illustration shows some of the assistance systems used.
Lifting tool assistant
The lifting tool assistant automatically selects and controls the lifting roller clamp or lifting hook, its position. A laser scanner measures the area around the lifting position in front of the lifting Lining unit and calculates the possible points of grip from this. In doing so, the lifting roller clamp is used preferentially. From this data, the exact sleeper positions are known with which the fully automatic tamping is controlled.
Switch learning mode assistance system
The switch learning mode assistance system allows the operator to record and store the movements and settings of the lifting-lining unit and the tamping units. When processing the same or a similar turnout at a later time, these movements and settings are recalled and automatically adjusted. The tamping operator is then mainly responsible for monitoring functions.
OPTICAL MEASURING SYSTEM
Conventional measuring and control systems for track-maintenance machines are usually constructed from steel chords, tensioning devices, measuring sensors for height and direction and physical pendulums. Disadvantages of this system are required clearances for the chords on the machine, external forces on the chords cause track position errors, vibrating or damped chords cause inaccuracies, lack of chord tension or hooking of the chords interferes with the function, steel chords can break and exhibit drift. Physical pendulums are sensitive to vibrations and react incorrectly to accelerations.
The optical measuring system from System7 avoids the disadvantages of mechanical steel chords such as sagging, hooking, vibrating, breaking off, conflicts with obstacles in the machine, damping of the system, temperature drifts, shifting of the zero points, dependencies on vibrations, etc.
THE SYSTEM7 PRECISION MACHINE MEASUREMENT SYSTEM
The System7 Precision Machine Measurement System consists of a digital optical camera system mounted on the centre measuring carriage, which is located between the tamping units and the lifting and straightening device.
The system consists of two digital very fast (40 measurements/second) high-precision electronic industrial cameras arranged in an optical axis.
POWER LED patterns are installed on the two outer measuring trolleys. The POWER-LEDS are equipped with lenses for light concentration. The luminosity is therefore very high.
The high luminosity of the light pattern has the following advantages:
- The aperture of the camera is closed wide. This makes the system independent of stray light and daylight.
- The function of the system is independent of weather conditions such as fog, rain or snow.
- Contamination such as dust on the protective glass is automatically monitored by the system itself.
The camera system detects the LED patterns by means of image recognition processes and recognizes them clearly and robustly. The system is fault-tolerant. The system continuously checks itself.
The measuring system is available in tropical and polar versions.
ABSOLUTE POSITIONING SYSTEM INSPIRED BY AVIATION
An inertial navigation system is set up for the machine’s approval record measurement and control system. The cant is not measured by physical pendulums, but by the inertial measurement system. The inertial measurement system is insensitive to shocks, accelerations and vibrations. The measurement of the cant is highly precise and accurate and independent of the vibrations caused by the tamping. The measurement with the inertial measuring unit is highly accurate and is also suitable for higher measuring speeds.
If the track geometry is unknown, a fast measuring run is carried out and a perfect nominal track geometry including correction data is determined with the System7 track geometry optimization program.
The system can also be used as an electronic track measuring trolley. It records the height of the left and right rail, the twist, the track direction and the cant. The output reports of the APPRec (approval recorder) are available country-specific.
S7 RAILWAY VEHICLE MONITORING "RAVEM"
Remote maintenance and web-based condition monitoring RAVEM via cellular network is a standard feature. Via WIFI the service manager can connect to the computer of the machine.
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