HYTRONICS

HYTRONICS
The Next Generation of Point
Machines and Setting Devices
Introduction of Hytronics Products For Turnouts
Using RAMS Analysis
Craig Bishop – Engineering Manager
HYTRONICS
30/11/2011
AGENDA
Introduction
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• Target
• RAMS Explained
• What is Hytronics?
Products
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Features
Spherolock®
Ecostar
Hydrolink®
IE2010 Detection System
Hydrostar®
Example – Spherolock®
Conclusions
HYTRONICS
30/11/2011
INTRODUCTION
Introduction
• Current generation point machines and setting devices have been
successful in providing acceptable levels of performance and
reliability to date
• Economic pressure for rail systems to perform (Freight / Passenger)
• Minimal track time available for maintenance or activities
• New technical solutions are required with the introduction and
understanding of RAMS criteria
• To achieve this what are the challenges that need to be overcome:
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HYTRONICS
Higher performance (reliability)
Lower costs (Affordability)
Increased safety factor (highest achievable Standard)
Compatibility
30/11/2011
INTRODUCTION
Target
• Develop a new generation of point machines (driving) and
setting devices (locking and detection) of critical products in
turnouts based on Total Cost Of Ownership
• Improve RAMS criteria
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Reliability
Accessibility
Maintainability
Safety
• Improved LCC
• Life Cycle Costs
HYTRONICS
30/11/2011
INTRODUCTION
What is RAMS?
R eliability
A vailability
M aintainability
S afety
HYTRONICS
30/11/2011
INTRODUCTION
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RAMS Explained
• RAMS is a well structured method to describe in a
quantitative and qualitative manner the Reliability, Availability,
Maintainability and Safety of a system, a sub-system or a
component of a system.
• Reliability, Availability, Maintainability and Safety are not just
the most important characteristics of all products, but form a
major part of a products performance and acceptance.
• The goal of RAMS Management is to minimise potential
risks for humans and the environment and to maximise the
reliability and safety of the products.
HYTRONICS
30/11/2011
INTRODUCTION
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Reasons behind RAMS
• Increasing customer demand
• (becomes more and more mandatory for supply contracts)
• Support for introduction of new products
• Identification of critical and unreliable items at an early stage
of development (reliability prediction)
• Shows the close connection between safety, reliability and life
cycle costs
HYTRONICS
30/11/2011
INTRODUCTION
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Definitions of RAMS
• Reliability:The ability of a component to perform a required
function
- under given conditions and
- over a given period of time
• Availability:The ability of an item to be in a state to perform a
required function
- at a given instant of time or over a given time interval
• Maintainability: The ability of an item to be retained in or
restored to a state in which it can perform a required function
- under given conditions of use
- when maintenance is performed under given conditions and using stated procedures and
resources
• Safety: Freedom from unacceptable risk of harm
HYTRONICS
30/11/2011
RAMS Procedure
Supplier
Customer
Customer Specification
Identifying the Requirements
concerning RAMS
Acceptance of the RAMS
Management Plan
Issue of RAMS
Management Plan
Input : field data,
experience feedback,
technical knowledge
Acceptance of the Safety
and Reliability Report
Output
Carrying out different
RAMS Analysis
Safety and Reliability
Report
Verification of the predicted RAMS figures
in operation (Failures, repairs, time, etc)
HYTRONICS
30/11/2011
INTRODUCTION
What is Hytronics
• Hytronics is the combination of Hydraulic and Electronic
elements for a mechanical solution for Turnouts
HYDRAULICS
ELECTRONICS
Innovative solutions
HYTRONICS
HYTRONICS
30/11/2011
PRODUCTS
General Features
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Low life cycle costs
Easy installation and adjustment
Availability for all turnout geometries
Encapsulated design with sealed components
Installation between rails
Ability for machine tamping without removing
Easy inspection for maintenance purposes
Compatibility & adaptability with existing equipment
Suitable for switch and swing nose crossings
HYTRONICS
30/11/2011
PRODUCTS
Spherolock ® (locking)
• Already used extensively in Australia
• Rail head locking device
• Switchblade held elastically to stockrail
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Internal locking system
Mounted to both stockrails for stability
Fully enclosed
Compatibility to suit most switch machines
Trailable
HYTRONICS
30/11/2011
PRODUCTS
Ecostar Switch Machine (Driving)
• Electro Hydraulic Switch Machine
• Monoblock hydraulic system with
integrated manual pump
• Modular Structure
• End position detectors that lock
into position (indicators)
• Fully Enclosed (IP67)
• Left & Right hand operation
• Trailable
• Configured to suit different interlocking systems
HYTRONICS
30/11/2011
PRODUCTS
Hydrolink® (Setting)
• Hydraulic force transmission
system for connecting multiple
setting devices (drive points)
• Only uses one switch machine
• Connect up to three setting levels
• Doesn’t impede tamping
• Compatible with various drives
and locking systems
• Minimised noise caused by vibration
HYTRONICS
30/11/2011
PRODUCTS
IE 2010 (Detection)
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Encapsulated end position detector
Fully sealed design
Easy to install as it comes pre-assembled
Monitors open and closed switchblades
Can detect gauge widening
Doesn’t affected tamping as its mounted on a sleeper
HYTRONICS
30/11/2011
PRODUCTS
Hydrostar® (Complete System)
Complete hydraulic switch operating system
One drive unit to synchronize all setting positions
Applicable for up to 12 setting positions
Mounted in inbearers allow it to be
tamped easily
• The system locks both open and closed
switchblades
• The systems is not trailable
• Includes monitoring system
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HYTRONICS
30/11/2011
PRODUCTS
Competence Centres and Additional Products
• HYTRONICS - VAH
• setting, locking and detection systems for standard, heavy haul and
high speed
• CONTEC
• Drives and control systems for turnouts for mass transit systems
• SST
• Diagnostic systems for rolling stock
• CDS Rail
• Fixed infrastructure asset monitoring
HYTRONICS
30/11/2011
EXAMPLE
FIRST INSTALLATION OF
SPHEROLOCK® USING RAMS
ANAYLSIS
HYTRONICS
30/11/2011
EXAMPLE - Spherolock®
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BACKGROUND
• Existing turnout with several failures per year
• Considerable amount of environmental contaminants
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Coal dust
Sand
Humid climate
Heavy Rainfall
Heavy vibration
• Constantly maintained
• Components fouling
• Constant call outs for
Failures
• Installed 2004
HYTRONICS
30/11/2011
EXAMPLE - Spherolock®
AIM:
• Increase Reliability by reducing number of
failures
• Increase Availability of the product to perform
under the current conditions
• Increase Maintainability with longer maintenance
intervals / cycles and easy adjustments
• Increase Safety by reducing time on track spent
identifying failures or repairing failures
HYTRONICS
30/11/2011
EXAMPLE - Spherolock®
JUSTIFICATION:
• Initial investment was higher than existing
• Easy to install and adjust
• Reduced installation times, lower installation costs, quicker
inspections times
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Easy to Access and Maintain
• Extended maintenance period means reduced maintenance
costs over the life of product
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Sealed locking system
• Eliminate contaminants from moving components to reduce
failures
HYTRONICS
30/11/2011
EXAMPLE - Spherolock®
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Example of parameters used for RAMS
Comparison of existing product with new product
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EXAMPLE - Spherolock®
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Capital investment
Logistical
Installation
Commissioning
Inspections
Maintenance
Failure repair
Mean failure rates per year
Mean breakdown
Train delay per minute
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EXAMPLE - Spherolock®
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Payback
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EXAMPLE - Spherolock®
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Life Cycle Cost Comparison
HYTRONICS
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EXAMPLE - Spherolock®
Turnout with Spherolock Locking Devices
HYTRONICS
30/11/2011
EXAMPLE - Spherolock®
Spherolocks® already in track around Australia
Spherolock installed in Pilbara WA
Spherolock installed QR Qld
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30/11/2011
Spherolock installed NSW
EXAMPLES
Other products used around the globe
• ECOSTAR
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Austria
Turkey
Brazil
Argentina
• HYDROLINK®
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Austria
Hungary
Turkey
Poland
Spain
HYTRONICS
30/11/2011
• IE2010
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Austria
Turkey
Brazil
South Korea
• HYDROSTAR®
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Austria
Germany
Turkey
Estonia
Poland
South Korea
• SPHEROLOCK®
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Australia
Austria
Hungary
Poland
South Africa
CONCLUSIONS
Improved RAMS means:
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LOWEST INVESTMENT
AND LIFE CYCLE COSTS
OF TURNOUT SYSTEMS
LOWEST
CONSTRUCTION COST
HIGHEST AVAILABILITY
EXTENTION of
INSPECTION AND
MAINTENANCE
INTERVALS
HYTRONICS
30/11/2011
THANK YOU
HYTRONICS
30/11/2011