Introduction to EasyRail Wheel Flange Lubrication Systems

Slide 2

SKF Platforms

Slide 3

Railway Applications

2014-05-02 ©SKF Slide 3Willy Vogel AG, a brand of the SKF Group

Wheel Flange Lubrication – SKF EasyRail

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IntroductionWheel & Rail Lubrication Systems

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Slide 5

Why Wheel Flange Lubrication?

Flange Wear

Reduced Risk ofDerailment :

Rail wearArea of Wear

reduced friction coefficientin flange area requiresincreased shear forces toallow wheel climbing.

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How does Wheel Flange Lubrication work?

lubricating filmon wheel flange

lubricating filmon rail flange

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On-Board-Systems for Wheel Flange Lubrication

Function of OBS

• Lubrication module and lubricant based on the train

• Transfer & application of lubricant by compressed air

• Precise metering of lubricant by pump or spray nozzles

• Higher reliability than wayside lubricators

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What can WFL achieve for our customers?

• Less track and wheel wear

• Track resistance drops by up to 35%, without effect on braking

• Longer intervals between wheel reshaping or replacement

• Maintenance-optimized system configuration

• Increased availability/mileage of rolling stock + better LCC

• Prevent derailments by curbing tendency of wheel climbing

• Better and safer ride quality

• Compliance with environmental regulations

• Fuel/energy savings + use of biodegradable lubricants + less noise

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SKF EasyRail Lubrication – one Family, two Systems

Single-lineSystems

Dual-lineSystems

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How does it workEasyRail High Pressure

Dual Line Systems

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Slide 11

SKF EasyRail High Pressure Wheel Flange LubricationApplication

• Rail vehicles with a max of 20 mdistance between wheel sets to besprayed

• Max line length betweenpump and spray nozzle 10 m

• Lubricant system pressure upto 100 bar

Benefits

• operational under lowambient temperatureconditions

• selectable bi-directionaloperation

• separable nozzle feeding(right/left)

• exact spray-nozzle metering

New Spray nozzle design

SP8-5

Pump unitwith reservoir

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SKF EasyRail High Pressure Wheel Flange Lubrication

easy access toreservoir with pumpunit via outside flap

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Standard layout of SKF EasyRail High Pressure system

Piston pump

Reservoir

Filter

Spray nozzles

Control Unit

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Function of the Piston Pump for EasyRail High Pressure

Air command

Lubricant suction

Lubricant reliefvalve

Pneumatic reliefLubricant outlet

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How the SP8 nozzle works: Part I

• The metered quantity of lubricant is positioned beneaththe metering piston.

• The lubricant delivered by the pump pushes the control piston up to its stop.Control duct 1 leading to the metering piston is opened. The lubricant deliveredpushes the metering piston down. The metered quantity of lubricant beneaththe metered piston is pushed into the mixing chamber. The ejected lubricantcomes together with the compressed air in the mixing chamber and is sprayedout through the opening of the nozzle.

Control piston

Control duct 1

Control duct 2

Metering piston

Mixing chamber

Lubricant port

Air port

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How the SP8 nozzle works:Part II

• The pressure in the lubricant line is relieved after the pump stops. The control piston is moved into its initialposition by spring force. Control duct 2 from the bottom to top of the metering piston is enabled. The meteringpiston returns to its initial position, and the metered quantity of lubricant flows into the space beneath themetering piston.


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New SP8-5 nozzle design:

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Highspeed equipped with SKF EasyRail High Pressure


Alstom Pendolino - ETR 610

Alstom Cisalpino ETR 470 Alstom EMU CRH5

Alstom Pendolino Finland

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How does it workEasyRail Low Pressure

1 November, 2006 © SKF Group Slide 20

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SKF EasyRail Low Pressure Wheel Flange Lubrication

• Pressurized reservoir without separate grease pump

• Compact design and very low maintenance

• Separate nozzle feeding right/left

• Exact spray-nozzle metering

• Very high cycle frequency

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Inside view ofpressurized reservoir BF

4.5

Optical grease level

Air connection

Air reservoir

Grease reservoir

Lubricant outlet


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How the SP9 nozzle works• The pressurized lubricant is pushed into the piston’smetering slot.

• The controlled compressed air slides the piston up to its stop. As a result, themetering groove is now in front of the nozzle exit, and the air duct leading tothe metering groove is opened. The compressed air blows the lubricant out ofthe metering groove, and the lubricant/air mixture is sprayed out through thenozzle exit.

Air duct

Piston

Meteringgroove

Lubricant port

Air port


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How the SP9 nozzle works

• The compressed air applied to the nozzle is shut off. The piston assumes its initial position, and the meteringgroove is filled with lubricant again.


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Intercity equipped with SKF EasyRail Low Pressure


DB AG Tilting ICE Fleet

DSB Contessa Øresund-Express

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How does it workSKF EasyRail Compact

Single Line Systems

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SKF EasyRail Compact Wheel Flange Lubrication

Application

• Suitable for oil and fluid greasecontaining high percentage ofsolid additives (25%)

• Applicable on all vehicle types

• also suitable for retrofitting projects

Benefits

• Compact system

• Easy installation andmaintenance

• Low Life Cycle Cost

Flow divider

Spray nozzlesMP50 piston

pump

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Snapshot of WFL pump-reservoir module & positioning in bogie structure

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Standard layout of SKF EasyRail Compact system

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Revised unit design with 11 l reservoir & quickconnector for easy lubricant refilling

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Nozzlepositioning

Korail Metro TrainSeoul, South Korea

Lubrication Module,installed in bogie section

Control Unit110 V DC

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Pump with11 liter

reservoir


Diesel Shunter

Class T-239

Spray Nozzle

169-000-400

CS200

Control Unit

169-000-410

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Introduction to EasyRail Wheel Flange Lubrication Systems

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