2-way rail grinding vehicle AT VM 8000-12E

Autech AG 5102 Rupperswil, Switzerland
Technical Specifications AT VM 8000-12E
Page 1
TECHNICAL SPECIFICATIONS
2-WAY RAIL GRINDING VEHICLE
TYPE AT VM 8000-12 Extended
with Rail Grinding Unit
TYPE IAT 2212
A hydrostatically-driven municipal vehicle with all-wheel drive and with four-wheel steering serves as the basic vehicle.
The two-way rail grinding vehicle is equipped with rail travelling gear that is also hydrostatically driven. The grinding
unit consists of 12 grinding shafts for the short-pitch corrugation grinding and reprofiling of grooved and Vignole rails.
A dust vacuuming system is installed. If desired, a water mist spraying system used as a dust barrier and a fire guard
against smouldering fires can be installed in the rail as well. The grinding shaft and rail travelling gear drives are
hydraulic, as are the angular adjustment and positioning of the 12 grinding shafts. The machine can be used on the
normal and metre gauges. For use in underground railways, the machine is equipped with a particle filter. The
compact outside dimensions permit use even in small clearance profiles.
Autech AG 5102 Rupperswil, Switzerland
Technical Specifications AT VM 8000-12E
Page 2
1. General information
Application:
This unit is used for to remove rust from new rails, to remove corrugations and small
waves, and to reprofile the rail head and the driving edge. With the AT VM 8000, both rails
can be processed at once.
Basic vehicle:
A hydrostatically driven all-wheel vehicle with spring suspension (make: Viktor Meili AG in
8862 Schübelbach, Switzerland), with three-seater tilting cabin and hydraulic connections
for additional devices.
Engine:
Detroit Diesel (Mercedes) Diesel Turbo 6-cylinder OM 926 LA, 322 HP at 2,200 rpm,
water-cooled, Euro IIIb, with catalytic converter (Euro 5)
Particle filter:
"Engelhard" exhaust gas cleaning system (optional)
Hydraulic oil:
Biodegradable
Drive:
Hydrostatic, with variable displacement pump and automatic drive; planetary gear axles;
engageable all-wheel drive
Road speeds
Rear-wheel drive:
All-wheel drive:
0 – 45 km/h
0 – 16 km/h
Rail speeds
Controlled from cab:
Radio-remote control:
0 – 20 km/h
0 - 5 km/h
Steering:
Hydraulic
Chassis:
Steel construction with spring suspension, sand-blasted, galvanised, caulked, and injected
Road brakes:
Foot brake, two-circuit with hydraulic disc brakes
Hydraulic spring hand brake
Hydrostatic service brake on drive axle
Rail brakes:
Hydrostatic wheel brake on all four rail wheels
Hydraulic spring parking brake on all four rail wheels
Tyres:
305/70 R x 19.5/quintuple
Fuel tank:
approx. 240 litres
Cabin:
COE (cabin-over-engine)
Three-seater tilting cabin
Air-suspended driver's seat
Passenger seat
Tinted, heated front windscreen
Heating
Defroster on side windows
Usual instruments
Intermittent windscreen wipers
Lighting according to regulation
Two sun screens
Radio/CD
Autech AG 5102 Rupperswil, Switzerland
Technical Specifications AT VM 8000-12E
Earth:
See the dimensional diagrams for CAT 3547
Length:
6,750 mm
Width:
2,100 mm (road)
Height:
2,950 mm (road)
Height:
3,100 mm (rail)
Weights:
Max. permissible overall weight:
Page 3
13,000 kg
2. Grinding principle
The rail grinding unit was conceived for the grinding of corrugations and small waves on the one hand, as well as for
the deburring and reprofiling of the rail driving edge and the outer edge of Vignole and grooved rails. The unit can
also be used to derust new rails or grind over joints, and so on.
2.1. Corrugation grinding
Corrugations are small waves that are formed on the head of the rail and that result in noise and wearing of the
rolling stock. With corrugation grinding, the rail head is processed with two rotating grinding wheels arranged in three
double-wave packages each (see figure below). The angle of each wave package can be adjusted individually. Three
different facets can thus be ground for each transversal. One to two transversals are made at the same grinding
angle, depending on the depth of the corrugation. Due to the adjustment of the vertical axes of the grinding wheels,
the rail head is reprofiled into multiple facets (Figure C, page 4). The angle differential and the number of individual
facets depend on the rail type or customer requirements (normally 5-6 facets). Grinding dust created during grinding
is extracted by a powerful vacuum cleaner with spark pre-separators. The sparks themselves are not extracted, but
rather prevented from exiting at the side via deflector plates.
Autech AG 5102 Rupperswil, Switzerland
Technical Specifications AT VM 8000-12E
Page 4
2.2. Deburring/reprofiling the driving edge
After a longer period of operation, the radius of the rail driving edge can change or seams can form. The following
method is used for the deburring and reprofiling of rail edges: through grinding with rotating grinding wheels, whereby
the grinding shafts can be inclined in an infinitely variable manner up to 72°. A fixed angle adjustment suffices for
deburring. When reprofiling, a 15° angle differential may be necessary, depending on the desired precision of the
radius of multiple facets (see Figure D).
3. Technical data and description of grinding unit IAT 2212

Total weight of the grinding unit: approx. 2,750 kg

Contact pressure while grinding: approx. 12,000 N
(6,000 N/rail); this force acts as an "uplift" on the carrier vehicle! (no additional weights required)

Curves with a radius greater than 20 m can be machined.

The daily preparation time of the grinding unit is max. 15-30 min. (emptying the vacuum cleaner, changing
grinding wheels, general cleaning work). While grinding, the 12 grinding wheels must be changed approx.
once an hour. Changing time: approx. 5 min.
Autech AG 5102 Rupperswil, Switzerland
Technical Specifications AT VM 8000-12E
Page 5

During grinding, the travelling speed amounts to about 2 - 5 kph. Three chamfers can be ground during each
transversal. During rail head grinding, the chamfer width amounts to about 3 - 12 mm; during edge grinding,
it amounts to about 2 - 8 mm. The chamfer width or grinding depth depends on the grinding pressure, which
can be infinitely adjusted by the operator.

The grinding depth on the rail head is approx. 0.2 mm per transversal. Up to 1 mm can be removed from the
driving edge per transversal (narrower chamfer).

For corrugations greater than 0.2 mm, multiple transversals with the same angle setting must be made.

In addition to the corrugation depth, the average grinding output depends very strongly on the quality of the
grinding wheels and hardness of the rails. A standard value of about 250 m of rail per hour can be expected
for pure rail head grinding at a corrugation depth of 0.2 mm.

In general, grinding is carried out dry. If grinding is to be carried out in the rain, special grinding wheels must
be used.

With the corresponding additional equipment (cf. Section 3.2/3.3), switch blades and frogs can be ground.
3.1 Operation

For the operation of the grinding procedure, two people are required. For safety reasons, however, we
recommend a third person be used for monitoring and driving.

The grinding unit is operated by one person each for each rail. This person can be found outside of the
vehicle (on the side or rear). The contact pressure is set during grinding using the potentiometer; the contact
pressure is then automatically kept constant using hydraulic proportional valves. The machine operators
monitor or regulate the various grinding angles.

Through an emergency stop button, the vehicle can be stopped immediately by any operator.

An approximately 10-day training is required for the operating personnel. To carry out the technical
maintenance and smaller repairs, we recommend an approximately five-day course.
Autech AG 5102 Rupperswil, Switzerland
Technical Specifications AT VM 8000-12E
Page 6
3.2. Additional disk wheel for grinding in the vicinity of the guide rail de switches (optional)
The inner edge of the rails (-45° to -90°) can be ground in the guide rail area of a switch using the additional disk
wheel mounted to the rear of the vehicle. The height and grinding angle can be adjusted and fixed into place as
required. The contact pressure is generated by hand.
All other parts of the switch can be processed using the grinding wheels of the normal grinding unit. In the process, all
12 wheels remain available.
3.3. PLC-supported grinding angle preselection (optional)
Up to 50 different angle presettings (grinding formulas) can be saved or called here. All six shaft pairs are
automatically moved to the preprogrammed angle positions. In addition to the most important fixed-programmed
recipes, individual angle settings and recipes can be saved in the "teach-in" method at any time.
3.4. Grinding process control system (optional)
The grinding process control system is a module, scalable tool for the automation of the grinding procedure. From a
single module, various measuring and control components can be combined into a customer-specific system. As a
whole, this comprises an intuitive keyboard, two screens (left/right rail), an axial control system, a scanner module
(cross-profile measurement), a profile memory for premeasurements and postmeasurements (Q-proof), and memory
card interface to the computer.
On the one hand, the "preprogrammed grinding" working method is supported. For this purpose, the user selects the
grinding program from 10 freely programmable fixed programs.
In the case of "targeted profiling," first both rail profiles are measured by laser and then compared with the digital set
profiles. To determine the grinding angle, an interactive error beam and the error spectrum are available to the user.
Finally, all six axles are reset at the press of a button.
Autech AG 5102 Rupperswil, Switzerland
Technical Specifications AT VM 8000-12E
Page 7
4. Rail travelling gear

Two hydraulically lowerable, rigid axles without spring suspension.

One set of bandages for Vignole or corrugated rails according to customer desire

Wheel diameter of the flange wheels: min. 450 mm

All four rail wheels are driven individually via a planetary gearbox. The basic vehicle is lifted 100% when
being run on rails.

Hydrostatic drive like basic vehicle, can be switched between road and rail travel.

Max. velocity of rail travel: 20 kph

Hydrostatic service brake

Spring hand brake, also for emergency stop

Max. incline during grinding: 7%

Max. permissible incline/slope for transfer: 7%

Axle load: 6.5 to

Sand gritter

Onrailing and reverse travel with video monitoring
5. Dust extraction
The two-way rail grinding vehicle AT VM 8000 is equipped with a hydraulically driven suction fan with an air capacity
of about 3,350 m3/hour. The "Dalamatic" dust filter system has 12 filter bags with an area of 1m2 each.
The dust-laden air enters the device through the suction openings and is diverted using baffle plates. In the process,
flying sparks and coarse dust are already separated. After that, the fine dust is conducted through the actual bag
filter system. The extremely effective function of the bags contributes to high filtration performance. The dust collects
on the outer surfaces of the filter bags while the cleaned air flows through the filter medium. Nozzle tubes blow
compressed air blasts into the open sides of the bags at intervals. In this way, the air flow is briefly reversed to inflate
the bags and discharge the dust. The loosened dust falls into the drawer beneath the filter. The machine has heightadjustable spark and dust protection plates.
6. Water spraying device

Front and rear spray bar on the grinding unit, equipped with four Jato spray nozzles each, all stainless steel.

Hydraulic, maintenance-free piston pump, pressure range of 3 -180 bar

Spraying lance with 10m hose for high-pressure cleaning

500-litre water tank
Autech AG 5102 Rupperswil, Switzerland
7.
Wireless remote control (optional)

Two transmitters and two receivers per vehicle

Functions:
-

Technical Specifications AT VM 8000-12E
Page 8
Automatic adjustment of the grinding pressure for each shaft pair using the
potentiometer
Lifting of the grinding wheels
Emergency stop
Forward/reverse travel/Stop
Travelling speed infinitely adjustable using potentiometer
Horn
Both transmitters with integrated display of the grinding speed and grinding pressures of the individual shaft
pairs
8. Consumables and approximate service life
Filter bags
12 pcs. every 150 shifts
Grinding wheel (100x110xM20 left) 12 pcs. per hour
Diesel consumption approx. 30 l an hour
Unit price approx.
Unit price approx.
CHF
CHF
40.00
24.00
Autech AG 5102 Rupperswil, Switzerland
Technical Specifications AT VM 8000-12E
Page 9
9. Maintenance work
The most important maintenance according to the following maintenance table may be performed by authorised
personnel. Every 1,200 hours, we recommend a factory inspection by our personnel.
Task
Oil level control
Inspection of the V-belt
Inspection of the tyre pressure
Inspection of the distributor gear
Monitoring of the hydraulic hoses
Battery check
Check of the cooling hoses and cooling system
Check of the motor suspension
Check of the grinding unit suspension
Check of the headlights and lighting
Check of the wheel nuts
Cleaning or change of the air filter
Change of the motor oil, including motor oil filter
Change of the hydraulic oil filters
Change of the gear oil of the planetary gear
Change of the diesel filters
Check of the brakes
Oil change in the axles and gears
Oil change in the distributor gear
Change of the hydraulic oil
Check and inspection of the grinding unit
Function check of the grinding unit
Every 200
hours
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Every 600
hours
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Every 1,200
hours
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Autech AG 5102 Rupperswil, Switzerland
Technical Specifications AT VM 8000-12E
Page 10
Autech AG 5102 Rupperswil, Switzerland
Technical Specifications AT VM 8000-12E
Page 11
Autech AG 5102 Rupperswil, Switzerland
Technical Specifications AT VM 8000-12E
The design, technical data and dimensions may change without prior notice. Errors excepted.
Issued: Oktober 12
P:\PROSPEKT\Sz VM 8000\TBVM8000-12-Ext_E.DOC
Page 12