Switcher tests completed

KZN Bieżanów and the Railway Institute have completed the testing process of the “Switcher”, an innovative system for transporting railroad turnouts. The tests were conducted in the railroad test bench in the Railway Institute, on test railroad sections in Żmigród near Olsztyn, and on the winding, mountain section of railway no. 98 Grybów – Ptaszkowa. Also, the train car’s descent from the Gotthard Pass. 

“The innovative and unique part of the system developed by KZN Bieżanów is the combination of the safe transport and unloading of the turnouts This solution should improve the initial quality of the turnouts incorporated into the PKP PLK’s railways and consequently extend their life cycle,” says Andrzej Massel, PhD Eng., Deputy Director for Research & Development in the Railway Institute.

As part of the tests conducted by the Railway Institute, a train car descent from the Gotthard Pass was simulated. This railway, with its highest point located at 1,151 m above mean sea level, features 26-28 ppt gradients along several dozen kilometres. Under such load, the braking system is exposed to prolonged heating. “The aim of that test, conducted on the test track in Żmigród, is to check the resistance of the braking system to thermal loads. The vehicle successfully completed the test,” adds Mr. Massel.

^{Various configurations of the Switcher system}

The “Switcher” completed the entire range of tests necessary to obtain the certificate of conformity to the requirements of TSIs (Technical Specifications for Interoperability), and certificates of acceptance of the railroad vehicle type. “At the moment, we are initiating the certification procedures in the Transport Technical Supervision, the Railway Institute and the Office for Rail Transport. We are hoping to complete the procedures this year,” says Ryszard Leszczyński, Chairman of the Board of KZN Bieżanów.

A complete set of tests was run by the Railway Institute in its Warsaw offices and on the test tracks in Żmigród near Olsztyn, and on the winding, mountain section of railway no. 98 Grybów – Ptaszkowa. The braking system underwent comprehensive tests – the correctness and intensity of braking was checked, the values of the static and dynamic working order of the brake gear; braking efficiency was tested in traffic tests. Furthermore, the train car underwent a series of dynamic tests in loaded and unloaded condition, as well as tests of noise, wheel load and curbs weight, performance on curvatures with minimum radius, and structural strength.

 “Switcher” is a rail vehicle developed by KZN, with 27.5 m length and integrated cranes and modules for mounting and bracing the turnouts during loading and unloading operations. The cranes are able to operate in small spaces, which enables unloading of the train car without the need to dismantle the electric traction. Digitally controlled cranes installed at both ends of the train car enable precise loading and unloading of the turnout both from a train car equipped with a crane, or a train car without the crane, used to transport the turnouts with larger radiuses. The flexibility of the solution makes it possible to transport all types of turnouts, including those with 1,200 m radius. The system will reduce the incorporation time of turnouts four times, at the same time eliminating the issue of insufficient quality control by the manufacturer and PKP PLK on the construction site.

The turnouts are crucial elements of the railway infrastructure. The condition of the turnouts directly affects the travel speed of the trains. Currently, ca. 44 thousand turnouts are in operation. Despite the fact that the annual replacement volume of turnouts is 2,550 devices (1,830 overdue replacements and 720 devices as part of the life cycle), in recent years only ca. 500 turnouts have replaced, which is by far too few to stop the infrastructure deterioration.