Special pneumatics offer for the railroad industry
Pneumatics play a very important role in the rail industry, providing improvements in the efficiency and safety of rolling stock production processes and rail infrastructure maintenance. Therefore, pneumatics manufacturers like us, CPP “PREMA” S.A., strive to meet the needs of the rail industry. We offer dedicated solutions that meet the expectations of even the most demanding customers. In this article, we will present a special offer of pneumatics for the rail industry, aimed at ensuring maximum efficiency and safety at every stage of production and maintenance of rail infrastructure. We will discuss in detail examples from our offer for the railroad industry, as well as guides for choosing the right and best pneumatic solution. From this article, you will learn about the railroad applications of pneumatic equipment, as well as what criteria you should consider when choosing the right solution for the railroad industry.
CPP “PREMA” S.A. is the largest Polish manufacturer of power and control pneumatics used to mechanize and automate production processes in many industries. More than four decades of experience, allow us to create and develop special products, adapted to work in the harshest conditions found in rail transportation.
From our wide range of products, we especially recommend supporting components such as control panels, pneumatic actuators, compressed air preparation filters and a series of plate diverter valves – successfully applied to the pneumatic system of a FALNS series freight car.
We treat the problems of our customers as a priority. Thanks to good communication and flexibility, unique projects are created, which are appreciated in Poland and abroad. Our qualifications are supported by certificate of the Institute of Rail Vehicles “Tabor” and the CNTK qualification certificate accepted by the German Railway Authority Eisenbahn-Bundesamt.
Applications of pneumatics in the railroad industry
Pneumatics is an extremely important field of technology in the rail industry, as it allows for the control and regulation of the operation of many on-board as well as under-deck devices. Here are some examples of applications of pneumatics in the rail industry:
- Railroad traffic control – pneumatics allows to direct the operation of signals, semaphores and other signaling devices on railroad tracks. Today’s pneumatic systems make it possible to quickly and precisely regulate the movement of trains at railroad stations.
- Compact braking systems – pneumatic brake control systems are indispensable in modern railroad vehicle braking systems. They provide effective and rapid braking for trains in the event of an emergency, which is extremely important for railroad safety.
- Signaling systems – pneumatics is used to operate signaling systems that enable control of train traffic on railroad tracks. Thanks to pneumatics, it is possible to quickly and precisely control the operation of such important equipment for maintaining safety.
- Maintenance of railroad infrastructure – Pneumatics are also used in the process of maintaining and upgrading railroad infrastructure. Pneumatic tools can be used to repair damaged infrastructure components, such as tracks and railroad switches. Pneumatic valves are also useful for automation in inspection processes.
All of these applications of pneumatics in the rail industry allow for increased safety of rail traffic and efficiency of production processes and maintenance of rail infrastructure.
Choosing the right pneumatic solution
Choosing the right pneumatic solution in the rail industry can be a complicated process, and only a customized approach and special preparation for each design project can solve the problems raised by rail operators.
Here are some steps you should take to properly fit a pneumatic solution:
- The first step is to determine exactly what requirements the chosen pneumatic solution should meet. Various aspects such as performance, operation speed, precision, durability, safety and cost should be taken into account.
- It is worthwhile to carefully analyze the market and learn about the various pneumatic solutions available. You should compare them and choose the one that best suits your needs and requirements.
- It is important to work with a manufacturer that has experience in the field of pneumatics in the railroad industry. Such a manufacturer will be knowledgeable about various pneumatic solutions and will help with the design.
- Before making a final choice, it is a good idea to test various solutions and conduct tests under real conditions. This way, you can verify that the tested design meets all requirements and works properly.
In conclusion, choosing the right pneumatic solution in the rail industry is crucial to ensuring safety and efficiency in rail traffic. It is worth applying the above steps to make the right choice and achieve optimal results.
The railroad industry involves unusual solutions and very often needs special applications and products
CPP “PREMA” S.A., for many years, has been providing support in the supply of pneumatics and power hydraulics components both in the construction of new vehicles, as well as assisting in the maintenance of existing railroad machinery.
Our offer, combined with our construction and technological expertise and modern machinery fleet, are the key to ensuring the highest quality in even the most complex projects. In all of the above-mentioned sectors of the railroad industry, you can find pneumatic and hydraulic components manufactured by us, such as:
- Dedicated compressed air filters and filtering units
- Dedicated pneumatic actuators
- Dedicated manual diverter valves
- Check valves
- Hydraulic cylinders
- DTE CPP PREMA series solenoid valves
Implementation with Double-Acting Pneumatic Actuator D250×520 with Pneumatic Cushioning and Yoke in accordance with ISO 6431, VDMA 24562
Usage
Double-acting pneumatic actuators with pneumatic cushioning and yoke are used in pneumatic systems as actuators, adapted to railroad operating conditions.
Structure
The essential parts of a pneumatic actuator are:
- A front cover with G1 connection hole and pneumatic cushioning
- A back cover with G1 connection hole and pneumatic cushioning
- A Piston rod
- A piston
- A bushing
- A yoke
- A piston rod nut, studs with special nuts
In addition, the actuator includes:
- A piston rod guide sleeve
- A piston rod compact gasket (gasket-box)
- A piston seals
- A piston guide ring
- Air cushioning chokes
- Shock absorption throttling valve needles and “O” type sealing rings
The actuator requires no maintenance during operation. The internal parts of the actuator are lubricated with grease before assembly and do not need re-lubrication.
It is recommended to replace the actuator repair set every 6 years during periodic repairs of the railcar according to its repair cycles. When replacing, the mating parts should be washed and oiled with grease. The recommended grease is ŁT4S or its equivalent.
If you find mechanical damage to the chrome working surface of the piston rod, immediately replace it along with the compact seal of the piston rod. If necessary, also replace the guide bushing in the front cover.
If you detect a leak, replace the piston and piston rod seals.
Photo: D250 x 520 actuator with yoke in working conditions
Implementation with pneumatic control for the opening system of the sides of FALNS type self-unloading wagons
Description of the control system
The system retains the existing actuators along with the mechanism for opening the flaps. Unlocking and locking the flaps in the open position ensures complete safety for the operator. The flap control system was changed, which is now made in modular form, and its configuration on the railcar is shown in the figure below.
The basic components of a control system are:
1 – Right control panel (mounted between the sides of the wagon)
2 – Left control panel (mounted between the sides of the wagon)
3 – Pneumatic control module mounted under the wagon containing control elements and performing logic functions
4 & 5 – Pneumatic wiring harnesses in a protective cover to prevent mechanical damage
6 – Pneumatic supply to the control box
8 & 9 – Executive elements – ISO D250 pneumatic actuators
All used pneumatic components can operate at ambient temperatures from -40 to +150°C.
The system is made in modular form consisting of closed components allowing its installation in FALNS-type self-dumping cars. The individual modules are built in appropriate boxes connected by pneumatic tubes protected from mechanical damage by a special cover and resistant to temperature. The system also includes air preparation elements, including a filter with an automatic condensate drain.
The configuration of the control panels mounted on the railcar is shown in the figure below.
The following items are located on the control panel:
1 – Pressure switch button
2 – Power on/flap closing button
3 – A flap opening button
4 – B flap opening button
5 – A+B flap joint opening button
6 – System pressure indicator
The pressure indicator (6) used in the system is designed to inform the operator whether there is a pressurized working medium in the pneumatic system.
The control system allows independent opening of the flaps of the two chambers of the carriage independently from one or the other side. The system uses a pneumatic pressure indicator to inform the operator of the existence of working medium pressure in the wagon’s installation. The indicator improves the safety of the operator both during unloading and driving. Driving a wagon with a pressurized pneumatic system is not allowed.
The photos below show how the control panels are mounted between the sides of the wagon.
The newly developed pneumatic control system is the result of CPP PREMA’s long experience in working with rolling stock plants. The installations produced by CPP PREMA have been in railcars since 1995 and have positive feedback from contractors.
The pneumatics components used are characterized by a high level of efficiency and durability in the very harsh operating conditions of railcars. All this experience allowed the creation of an avant-garde control system for opening the sides of a self-unloading railcar, combining the best solutions in the field of pneumatics with high operating qualities.
Advantages of pneumatics in the railroad industry
Pneumatics is an extremely important field of technology in the rail industry because it brings advantages such as:
- Safety – pneumatics is extremely important in the braking systems of railroad vehicles, which contributes to the safety of railroad traffic. Pneumatics can also be used to control the operation of signaling systems and semaphores on railroad tracks, helping to ensure the safe movement of trains.
- Precision – modern pneumatic solutions allow very precise control over the movement of railroad vehicles and signaling equipment. This makes it possible to accurately and efficiently regulate the operation of various railroad systems’ elements.
- Speed – pneumatics allows the rapid operation of various railroad equipment, which is essential in case of emergencies, such as the need to suddenly brake a train.
- Durability – pneumatics are characterized by high durability and resistance to external conditions, which is important for applications in harsh working conditions, such as on railroad tracks.
- Energy conservation – pneumatics enables reduced energy consumption in production processes and maintenance of railroad infrastructure, resulting in lower operating costs and better efficiency of operations.
All these advantages of pneumatics make it extremely important and increasingly used in the railroad industry in various production and maintenance processes.
Benefits of using pneumatics in the railroad industry
The use of pneumatics in the railroad industry brings many benefits. By using compressed air, it is possible to ensure smooth rail traffic, fast operation and precise control. In addition, pneumatics are robust and resistant to the conditions of the rail industry, which translates into higher reliability and longer life for pneumatic equipment.
In addition, pneumatics in the rail industry offer many solutions to help increase safety, including solutions to prevent overloads, surges and accidents. These benefits translate into increased efficiency and cost savings, which is especially important for the rail industry, since it includes many complex tasks to complete in a short period of time.
In summary, pneumatics are extremely important to the rail industry because they provide efficient and reliable performance that is crucial for the safety of passengers and employees, as well as for the efficiency of rail traffic. The use of pneumatic solutions allows for higher productivity, increased reliability and reduced construction, repair and maintenance costs of railroad infrastructure.
Elements of our production are found in, among others:
- Utility trains for repairing catenary networks belonging mainly to the “PNUIK”, “ZUE”, “TRANSKOL”, “SKANSKA” and “TRAKCJA POLSKA” companies:
- WM-15P00 – solenoid valves for remote control of a cassette and travel direction (both in the before and after upgrades versions),
- PS00.M – solenoid valves for remote control of a cassette and travel direction.
- Pociągach ratowniczych na bazie PS:
- PUN P9301 – cassette protection actuators,
- REM 80 – actuators and valves for the protection of the “trough selector”,
- UNIMAT, CSM – actuators and tamping unit protection valves,
- FALS – flap opening valves and actuators, pneumatic control panels and boxes.
It is worth remembering that if you have any questions or doubts about dedicated solutions, CPP “PREMA” S.A. staff are available to help you select the right system with solutions for the rail industry.