IN2TRACK2

Cost-Efficient and Reliable High-Capacity Infrastructure

IP Coordinator: Felicity Osborn - NR

Overview
Objectives
Project Structure
Partners
Results and Publications
Project's News & Events
Contacts
Latest Project's News
- Video showing sequences of Factory Acceptance Testing of Next Generation Track Research
  22 March 2021
- Mechanistic-empirical permanent deformation models: Laboratory testing, modelling and ranking
  25 February 2021

Overview

Project title:

Research into enhanced track and switch and crossing system 2

Topic:

S2R-CFM-IP3-01-2018

Total Project Value:

€ 29 676 014,83

Duration:

from 01/11/2018 to 28/02/2022

S2R (Of H2020) co-funding:

€ 13 188 020,99

Coordinator:

Adam Glover
NETWORK RAIL INFRASTRUCTURE LIMITED

Complementary projects:

IN2TRACK, IMPACT-2

Previous Project:

IN2TRACK

Objectives

TD3.1 – Enhanced Switch & Crossing (S&C) System

Extending the simulation approaches for S&C dynamic behaviour and deterioration
Improving measurement systems including data transmission for S&C status surveillance to serve as a basis for predictive monitoring and enhanced maintenance procedures
Understand design principles, manufacturing technologies and installation processes required to deliver necessary enhancements
Testing and trialling of the demonstrator, performance data aggregation based on measurement plans including extensive analysis
Validation of extended simulation approaches and measurement systems

TD3.2 – Next Generation Switch & Crossing System

Next generation S&C sub-system integration work in collaboration with S-CODE;
Detailed design of next generation S&C components and sub-systems, considering advanced:
- Monitoring and control for self-diagnostics, self-adjustment and autonomous inspection;
- Mechatronic switch kinematics, incorporating system redundancy, to enable degraded operation and eliminate service affecting asset failures;
- Materials, design and manufacturing to optimise asset performance;
- S&C support conditions, designed from a whole system perspective;
- Small-scale prototypes and virtual demonstrations Technology Readiness Level (TRL) 5;
- Planning for full-scale prototyping and demonstration to achieve TRL6 within the SHIFT2RAIL Annual Work Plan 2020 (AWP20).

TD3.3 – Optimised Track System

Increasing the useful life of the track by optimising the component and track system;
Defining and improving the performance of the track system in terms of less traffic disturbance due to maintenance and faults of the assets;
Developing and deploying tools to determine track solutions that are technically, economically, environmentally and operationally beneficial including LCC and RAMS performance;
Deploying tools to provide means for pro-active management that sets out from a system approach and includes all necessary components from track bed to welding;
Improving environmental factors including reducing N&V;
Demonstrating enhanced track solutions.

TD3.4 – Next Generation Track System

To begin exploration of new track concepts to deliver a step-change in performance. Key activities will include:
- Innovative track system, sub-structure and track support solutions;
- Autonomous inspection and innovative methods for track maintenance and repair;
- Materials, design and manufacturing to optimise asset performance;
- Prototypes and demonstrators up to TRL5;
- Planning for full-scale prototyping and demonstration to achieve TRL6 within AWP20.

TD3.5 – Proactive Bridge and Tunnel Assessment, Repair and Upgrade

Developing new inspection methods to allow faster, more accurate inspection of tunnels and bridges including improved repeatability and reproducibility;
Developing new repairing, strengthening and upgrading methods which permit less traffic disturbance, fast installation with short track access time, allowing staging for traffic movement between track operations;
Proposing to align codes so uncertainties can be reduced and future new structures can be designed and constructed at reduced cost;
Developing noise and damping methods suitable for metallic bridges.

Project Structure

WP1 - Enhanced Switch and Crossing system demonstrator

The main objective of this WP is to support TD3.1 to improve the operational performance of existing S&C designs through the delivery of new and/or enhanced S&C sub-systems with enhanced RAMS, LCC, sensing and monitoring capabilities, self-adjustment, N&V performance, interoperability and modularity.

The research activities aim at results ranging from TRL5-6, while it is anticipated that successful demonstration in operational environment even touches TRL7.

WP2 - Next Generation Switches & Crossings

The overall objective of WP2 is to design and build a series of component and sub-system prototypes (up to TRL5) to evaluate a number of radically different concepts for future S&C systems.

WP3 - Optimised Track System

1The objective of WP3 is to significantly enhance the capabilities and performance of the track structure by building upon the work commenced within IN2RAIL and IN2TRACK and will contribute towards the overall concept of the DT. Precise track structure and its maintenance requirements will be established regarding: improved design to reach these objectives in a cost efficient manner; means to verify performance through virtual and physical tests; cost efficient maintenance; and monitoring to assess the current and future condition of the asset. These considerations are reflected in the proposed division of the WP into tasks. In addition, the track is strongly influenced by the operating vehicles and especially their running behaviour. To address this issue, a task is dedicated to wheel/rail interaction and related consequences.

WP4 - Next Generation Track

The overall objective of WP4 is to improve the track system substantially, targeting a time horizon of some 40 years beyond current state-of-the art, in order to provide a step change in performance. Prototypes and virtual demonstrators (up to TRL5) will be provided.

WP5 - Assessment and Improvement of Tunnels and Bridges

1The WP aims at providing new tools for monitoring and to extend the life of structures. In addition the WP will work on finding motivated requirements for bridges to be built for high speed traffic.

WP6 - Project Management

1The objectives of this WP are:

To ensure effective coordination of the project;
To ensure efficient management of common consortium activities;
To ensure effective overall administrative and financial management of the project;
To ensure the running of a quality assurance process;
To manage the risks and propose mitigation strategies and contingency measures if needed.

WP7 - Technical Co-Ordination and Technology Demonstrators Integration

This WP enables seamless and effective technical co-ordination and system integration by providing the WP leaders with a platform for project integration. This wider objective is structured as follows:

To ensure the successful technical progress of the project, delivered to time, cost & quality;
Resolution of technical issues;
Successful system integration;
Successful adoption of innovation by the rail industry;
Management of risks, with mitigation strategies in place and contingency measures ready to be activated;
Management of the consistency between project results and the strategic objectives of the partners at the level of Steering committee and alignment to SHIFT2RAIL overall objectives.

WP8 - Dissemination, Communication and Exploitation

1To ensure that the project results & outputs are disseminated widely and effectively exploited by their target groups. The specific objectives are:

Establish dissemination platform to facilitate wide-spread information transfer within SHIFT2RAIL JU;
Set up communication channels with other SHIFT2RAIL members and open calls and implement a “knowledge transfer” across SHIFT2RAIL projects to ensure a stable link/communication;
Work within the framework provided within the SHIFT2RAIL JU’s Communications Strategy;
Ensure that the project outputs reach targeted decision makers and stakeholders;
Ensure that appropriate dissemination strategies are applied;
Work collaboratively with industry partners, including the European Union Agency for Railways to facilitate the implementation of IN2TRACK2 results in applicable codes and standards.

Partners

Coordinator

Beneficiaries

Results and Publications

At the moment there are no publications available.

Project's News & Events

Video showing sequences of Factory Acceptance Testing of Next Generation Track Research

22 March 2021

See the link

•Cast block heaters

•Measurement of longitudinal profile of weld repair (Stand-alone unit)

•Operation of brakes of DDR unit:

•Positioning machine over identified defect

•Clamping of DDR Unit to rails: Location and design of clamps

•Rail Profile measurement: Existing rail profiles on either side of area to be repaired will be measured. Measurement technique will be explained.

•Excavation/Milling out of defect: Demonstration will be for excavated dimensions of 100mm (L) X 10mm (D) x Full head width.

•Profile measurement: Measurement of excavated profile to confirm width of welding bead oscillation.

•Weld restoration: Restoration will be undertaken using three layers + a sacrificial layer.

•Preheating: Rails are preheated to 60-800C using the cast heating blocks that are placed manually over location of the defect – automation of heater placement will be considered as part of follow-up project.

•Measurement of temperature: Automated spot measurement of temperature within excavated cavity and adjacent parent rail.

•Automated cutting of welding wire

•Automated peening after each layer of weld deposition

•Automated forced air cleaning of deposited and peened layer

•Automated repetition of weld deposition and supporting tasks to deposit two further layers and a sacrificial layer.

•Automated measurement of welded profile height to establish reprofiling requirements

•Reprofiling of repaired area: Automated computer controlled milling (rough & finish profiling)

•Profile verification – automated 3D profile measurement to show blending of repaired area with adjacent rail

•Measurement of linear profile to demonstrate compliance with specification – this is a follow-up operation as the DDR unit would need to be moved to permit measurement over the required 1m span.

See Link

Mechanistic-empirical permanent deformation models: Laboratory testing, modelling and ranking

25 February 2021

Mechanistic-empirical permanent deformation models: Laboratory testing, modelling and ranking, by
Ana Ramos, Antonio Gomes Correia, Buddhima Indraratna, Trung Ngo, Rui Calcada, Pedro Alves Costa

Ballast and slab railway track structures are constructed from different materials, thus requiring different maintenance strategies. Therefore, this paper compares the settlement performance of both structures using laboratory experiments, and calibrates numerical models based upon the results. Firstly, a comparison of the short and long-term behaviour of ballasted and slab tracks under cyclic loading is performed at full-scale. Both tracks have the same track foundation but a different track superstructure, and are subject to 3 million cycles of loading. The results are used to develop and calibrate the short-term response of a 3D finite element model of both track structures. They are also used to calibrate an empirical permanent deformation model for the track foundation, where the number of load cycles and stresses are the main inputs. A strong agreement is found between the numerical and experimental results. This justifies the track modelling approach in predicting the long-term behaviour of track structures where the subgrade is influential. See Link

Contacts

Adam Glover

Project Coordinator

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