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Track Box- Accelerated Testing Facility for Railways

The track is a complex set of elements whose behavior changes significantly over time. This is especially relevant in the case of ballasted tracks, which require more maintenance than slab tracks...

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Track Box- Accelerated Testing Facility for Railways

The track is a complex set of elements whose behavior changes significantly over time. This is especially relevant in the case of ballasted tracks, which require more maintenance than slab tracks.

We are offering a complete testing facility for railways tracks - Accelerated Load Testing facility -

TRACK BOX- A facility whose objective is to test, at 1:1 scale, complete railway track sections of conventional and high-speed lines for passenger, freight and mixed traffics, at speeds of up to 400km/hr. Its principal’s advantage is the possibility of performing fatigue tests in a fast way, as in one working week, the effect of passing-by trains during the year in a real section can be modeled- thus this not only simulates the field conditions but also accelerates the process of testing.

Knowing the long-term behavior of the track under different conditions, materials used, traffic levels, etc. helps to optimize the operating costs of the lines and of course to prevent possible incidents and accidents.

The Track Box – is a structural support system to test the complete track section together with the different layers that form the embankment for track on ballast or the components for track on concrete slab, all at full scale.

This system makes it possible to simulate the performance of the track against the forces experienced during operation.The purpose of this bench is to simulate the real fatigue conditions (in 1:1 scale) to which the railway infrastructure is subjected in an accelerated way, being able to simulate, for example, 20 years of track use in a few weeks. The system has the possibility to simulate different types of track sections and different uses:

Conventional
High-speed lines
Subway
Freight
Mixed use

The track box has the following applications: -

Test on the ballast track and slab track.
Test with passenger, freight and mixed train.
Static, quasi-static and dynamic test.
Tests of fatigue in superstructure elements.
Vibration propagation test.
Sleeper lateral resistance test.
Geomechanically test on ballast and sub ballast.

Test systems for the railway industry – PUFIB

The PUFIB multipurpose testing bench can perform biaxial static and dynamic tests (tensile, compression, bending and torque) on complete track set. The system comprises of Test Frame, Hydraulic System and Actuators, Control Electronics, Force...

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Test systems for the railway industry – PUFIB

Test Standards

The PUFIB machine allows testing in accordance with the main international standards, including: EN 13146-1 (Determination of longitudinal rail restraint), EN 13146-2 (Determination of torsional resistance), EN 13146-4 (Effect of repeated loading), AREMA chapter 5, as well as other standards belonging to entities such as GOST, UIC, AS, etc.

Test Frame

High stiffness testing frame with a versatile design including a T-Slot base that allows to perform different type of test.
Main test frame (available for 150 and 300 kN) for axial loading, consisting of 2 columns and a movable crosshead with lateral hydraulic jacks that allow to vary the height of the crosshead.
Lateral reaction wall allowing the application of transverse loads by means of the secondary actuator of the system.

Hydraulic System and Actuators

It incorporates the new EcoHydraulic system, which provides major improvements over traditional hydraulic control systems in terms of efficiency (up to 20% higher), adaptive flow and pressure control depending on the instantaneous test load, giving it a longer life, less maintenance and lower oil consumption.
Closed-loop control of force and travel by a highresponse servo valve.
Thanks to its integration with the testing software, it is possible to automatically perform safe shutdown operations, check the operating time of the hydraulic plant for scheduled maintenance and digitalize all the alarms of the hydraulic system.
Vertical actuator. Double-acting and double-rod hidrostatic actuator. A contactless sealing bushing allows very low friction and minimum stick slip. It can withstand non-axial loads that may occur during the test.
Secondary transverse actuator. Double acting single rod hydraulic actuator for static and pseudo-static loads with a typical capacity of 50 kN (others available).

Control Electronics

The system incorporates the new MD5i control electronics for dynamic control of the main actuator with 24-bit resolution and 10 kHz closing loop frequency for fast and accurate control of testparameters. This means, among other advantages, that minimal variations in force or deformation can be observed during the test.
The system incorporates the new MD2i control electronics for static control of the secundary actuator with 24-bit resolution and 2.5 kHz closing loop frequency.

Force Transducer (Load Cell)

High stiffness force transducer for static and dynamic testing.

Stroke Transducer

Magnetostrictive linear position sensor, absolute, non-contact, digital output, with direct mounting inside the piston, resolution 0.5 μm.

Test Standards

Test systems for the railway industry – MFDIB series

The MFDIB series of testing machines enables fatigue and dynamic tests to be performed on rail joints, supports and concrete sleepers (ties). The system comprises of Test Frame, Hydraulic System and Actuators, Control Electronics, Force and...

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Test systems for the railway industry – MFDIB series

Test Standards

The MFDIB series allows testing in accordance with the main international standards, including:

RAIL JOINTS: EN 13230-2, EN 13230-3, EN 13230-4, EN 14587-1, EN 14587-2, EN 14730-2, AREMA capítulo 4, etc.
SUPPORTS AND SLEEPERS: EN 13230-2, EN 13230-3, EN 13230-4, AREMA chapter 30, AS 1085.14, etc.

Testing Frame

• High stiffness design including the standard bending device (3 points) and an integral protection system, with side doors for the introduction of the sample (rail). The doors are equipped with electric safety locks.

• As an option, additional test devices can be incorporated such as: extended lower plate for sleepers test, 4-point bending, compression, etc.

Hydraulic System and actuator

• It incorporates the new EcoHydraulic system, which provides major improvements over traditional hydraulic control systems in terms of efficiency (up to 20% higher), adaptive flow and pressure control depending on the instantaneous test load, giving it a longer life, less maintenance and lower oil consumption.

• Closed-loop control of force and travel by a highresponse servo valve.

• Thanks to its integration with the testing software, it is possible to automatically perform safe shutdown operations, check the operating time of the hydraulic plant for scheduled maintenance and digitalize all the alarms of the hydraulic system.

• Double-acting, double-rod hydraulic cylinder (with symmetrical chambers). The piston is coated with an anti-friction material and it is driven by the hydrodynamic cushion. A contactless sealing bushing allows very low friction and minimum stick slip.

• Low friction 2nd stage sealing and scraper are designed to allow high speed any high motion frequencies.

Control Electronics

• The system incorporates the new MD5i control electronics with 24-bit resolution and 10 kHz closing loop frequency for fast and accurate control of test parameters. This means, among other advantages, that minimal variations in force or deformation can be observed during the test.

Force Transducer (Load Cell)

• High stiffness force transducer for static and dynamic testing.

Stroke Transducer

• Magnetostrictive linear position sensor, absolute, noncontact, digital output, with direct mounting inside the piston, resolution 0.5 µm.

Test systems for the railway industry – MFPIB series

The MFPIB series of testing machines allow automatic static and quasi-static bending tests to be performed on welded rail joints in accordance with the main international standards. ). The system comprises of Test Frame, Hydraulic System and Actuators...

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Test systems for the railway industry – MFPIB series

The MFPIB series of testing machines allow automatic static and quasi-static bending tests to be performed on welded rail joints in accordance with the main international standards. ). The system comprises of Test Frame, Hydraulic System and Actuators, Control Electronics, Force and Stroke Transducers.

Test Standards

EN 13230-2, EN 13230-3, EN 13230-4, EN 14587-1, EN 14587-2, EN 14730-2, AREMA chapter 4, as well as other standards belonging to entities such as GOST, UIC, AS, etc.

The high stiffness test frame is manufactured by a welded and bolted structure. Class 0.5 according to EN-ISO 7500-1.

Available in capacities of 2000, 2500 and 3000kN.

Test Frame

• Compact design including the standard bending device (3 points) and an integral protection system, with side doors for the introduction of the sample (rail). The doors are equipped with electric safety locks.

• As an option, additional testing devices can be incorporated such as: 4-point bending, compression, etc.

Hydraulic System and Actuator

• It incorporates the new EcoHydraulic system, which provides major improvements over traditional hydraulic control systems in terms of efficiency (up to 40% higher), adaptive flow and pressure control depending on the instantaneous test load, giving it a longer life, less maintenance and lower oil consumption.

• Closed-loop control of force and displacement by means of a high-pressure servo valve (Qn 20l/min)

• Double acting hydraulic cylinder (single rod) with internal seals and low friction guides to absorb the lateral forces that may occur during the test.

Control Electronics

• The system incorporates the new MD2i control electronics with 24-bit resolution and 2.5 kHz closing loop frequency for fast and accurate control of test parameters. This means, among other advantages, that minimal variations in force or deformation can be observed during the test.

Force Transducer (Load Cell)

• High rigidity strain gauge force transducer for static and quasistatic (low frequency) tests.

Stroke Transducer

• Digital stroke transducer with a resolution of 0.001 mm (1 micron) mounted on the outside of the actuator.

Test systems for the railway industry – PFIB series

The PFIB series of testing machines enables static tests to be performed supports and concrete sleepers (ties).The system comprises of Test Frame, Hydraulic System and Actuators, Control Electronics, Force and Stroke Transducers...

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Test systems for the railway industry – PFIB series

Test Standards

The PFIB series allows testing in accordance with the main international standards, including:
EN 13230-2, EN 13230-3, EN 13230-4, AREMA chapter 30, AS 1085.14, etc.

Testing Frame

• High stiffness design including the standard bending device (3 points).

• Hydraulic system and actuator as an option, additional test devices can be incorporated such as: tensile, compression, etc.

Hydraulic System and actuator

• Closed-loop control of force and travel by a highresponse servo valve.

• Low friction 2nd stage sealing and scraper are designed to allow high speed any high motion frequencies.

Control Electronics

Force Transducer (Load Cell)

• High stiffness force transducer for static testing.

Stroke Transducer

• Digital linear position sensor, digital output, resolution 1 µm

Multi-Axes Test Bench for Railway System

Our versatile arrays of components, accessories, and application software allow you to build your own cost-effective testing systems. We offers the tools and consults your needs to meet your test requirements for all kind of vehicle and rail components...

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Multi-Axes Test Bench for Railway System

Frame and Base Platen

Our comprehensive selections of high stiffness load frames perform a full spectrum of static & dynamic testing applications.

Actuators

We supply several series of high-performance actuators allowing you to achieve precise force and motion control during the testing.

Controllers

Designed to accommodate your growing test needs, we offer a wide range of controllers - from single channel units to large, multi-channel / multi-station solutions.

Hydraulic Power and Distribution

Flexible power units and distribution systems ensure high performance and smooth transitions.

Grips and Fixtures

Our hydraulic, manual, and pneumatic grips set the industry standard. Our fixtures provide precise data and customized designs.

Transducers

Load cells and displacement transducers ensure accurate, repeatable readout and reliable control.

High Speed Wheel & Rail Contact Simulation Testing System

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High Speed Wheel & Rail Contact Simulation Testing System

The high speed wheel & rail contact simulation system is to analyze and measure all the matters between wheel and rail contact surface during the high speed rotation.The system is organized by the main frame, wheel & rail disk specimen, wheel & rail driving motor, radial & thrust load actuator, contact angle & attack angle adjuster, EMG brake, environmental chamber, main control system, sensors, and etc.

There are various test can be done by this system such as rolling contact test (RCF test), adhesive strength test, wear test, etc. from subway to high speed train. In addition, the system has environmental simulation equipment of water, oil, wind, sand insertion with temperature control (-30℃~80℃).

Bogie Testing Rig System

This is a 1/5 scaled testing equipment system to analyze stability of bogie and wheel set. This system is composed of main frame, driven roller, hydraulic actuator, and controller. It is used to compare dynamic model prediction with scaled bogie simulator...

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Bogie Testing Rig System

Test Application

Wheel-rail contact force, wheel-rail compatibility, derailment coefficient test.


Track Box- Accelerated Testing Facility for Railways
Test systems for the railway industry – PUFIB
Test systems for the railway industry – MFDIB series
Test systems for the railway industry – MFPIB series
Test systems for the railway industry – PFIB series
Multi-Axes Test Bench for Railway System
High Speed Wheel & Rail Contact Simulation Testing System
Bogie Testing Rig System

Derailment Simulation Testing System

This testing system is to investigate the properties of rail Vehicle that influence the train behavior after one of the wheels sets has derailed. A mathematical model and natural experiment are carried out to investigate accelerations and displacements...

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Derailment Simulation Testing System

This testing system is to investigate the properties of rail Vehicle that influence the train behavior after one of the wheels sets has derailed.A mathematical model and natural experiment are carried out to investigate accelerations and displacements on the train body after the derailment.

High Speed Bogie Simulation Testing System

We provide the right solution though the state-of-the-art simulation techniques which are close to the actual situation in order to assess high-speed stability, curving performance, and other safety features...

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High Speed Bogie Simulation Testing System

Suspension Components Testing System:The suspension design is influenced to the stable of drive and enhances comfort. We provide all sorts of test solutions for the train suspension.

Test Application of Shock Absorber

Uniaxial life durability, Damping force characteristics, Extreme temperature, Friction, Gas pressure, High and low speed cycle, High speed impact

Test Application of springs (Air Spring, Coil Spring)

Uniaxial life cycle & performance Vertical life cycle & performance, Damping force characteristics, High and low speed cycle, High speed impact and Impact drop.

Brake Performance Test System

The Brake Performance Test System will be used for the performance of friction, wear and overheating of the brake disc, pad and shoes (components of brakes used in the railway vehicles) in accordance with relative international standards...

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Brake Performance Test System

Ultrasonic Rail Inspection Trolley

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Ultrasonic Rail Inspection Trolley

In practice, the ultrasonic testing procedure has proved to be the most suitable for detecting manufacturing and material fatigue defects occurring in rails and turnouts. The completed small manual inspection trolley is extremely suitable to detect internal rail and welding defects due to its light weight, inspection options and special ease of operation. The frame and the water tank of the newly developed small trolley are made of aluminum therefore the trolley is light. The water tank is built together with the frame, positioned at the bottom resulting in an even lower

centre of gravity for the trolley thus providing more stability. The height of the handgrip of the small trolley is adjustable for the sake of comfortable operation. The suspension of the head holding boats can be adjusted from the frame. The amplification values of the ultrasonic testing heads can be adjusted and saved separately. For the sake of comfortable operation the connection fluid to the head holding boats can be adjusted separately.

Testing mechanics:

- Each inspection head unit is mounted into a supporting frame thereby guiding them in the rail centre line and the sliding contact with the rail surface is also ensured
- The coupling liquid is conducted underneath the heads from the water tank
- The inspection heads are located in a plastic housing therefore the possibility of damages is very low and their lifetime and wear resistance is very favorable
- The rolling wheels are adjustable and equipped with a wheel flange that guides the device on the rail
- The rotary encoder is driven from the rear wheel axle

Eddy Current Measuring Device

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Eddy Current Measuring Device

The device is first of all capable to reveal the cracks on the rail head's surface or near the surface (Head Check). Because of the operating principle it can locate defects up to 5 mm damage depth.The position of the 4 probe heads can be adjusted separately on the running surface, on the leading edge and leading surface. 2 special magnets provide the leading and positioning of the probe heads. The processing and evaluation of the measuring results is mostly automatic, on the other hand it requires a lot of caution and competence to adjust the parameter. The output files are in .pdf format and contain not only the damage depth but the number of the cracks as well (per meter).

Straightness measuring device

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Straightness measuring device

The Straightness measuring device has been developed to check the geometry of running and directing surface of rails. It uses capacitive principle, so does not contain moving parts.Using the device the measurement of deformation can be performed in less than a second. The inspection of the running and directing surface can be executed separately with the relocation of the device. It calculates the deviation of the measured surface from the straight direction in a 1 m base by processing the signal of 200 sensors. It is capable of measuring also the straightness of insulated joints.

The hand-held computing unit (PDA or Smartphone) collects the measured data via Bluetooth RF connection, then processes, stores and displays them. The measuring software works with Android operation system. Besides the measured values and the threshold limits, the built-in thermometer data and the battery status are displayed as well.

- Measurable surface: steel, steel alloys, aluminum and other conductive materials
- Measuring range: +1 mm … -3 mm
- Resolution: 1 µm
- Accuracy: +1 mm ... -1 mm range 20 µm, +1 mm ... -3 mm range 3 %
- Measuring time: every sec
- Operating temperature: -20°C + 60°C

The Bore-Test Inspection (Hollow Rail Axle Inspection System)

This is an ultrasonic NDT hollow train axle inspection system. This is carried out by utilizing different angular and cero degrees ultrasonic probes to maximize the probability of detection. The complete axle is inspected from one side of the train in a very short time...

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The Bore-Test Inspection (Hollow Rail Axle Inspection System)

This is an ultrasonic NDT hollow train axle inspection system

This is carried out by utilizing different angular and cero degrees ultrasonic probes to maximize the probability of detection.
The complete axle is inspected from one side of the train in a very short time
The results of every inspection are recorded for further analysis and archiving including the calibration of the system.
Able to inspect different type of axles within a range.
Scanning head is automatically pushed into bore in increments from 1mm (normally 4mm or 5mm) and rotates 360° after each incremental movement

Neutral Temperature Measuring Device

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Neutral Temperature Measuring Device

Applied magneto-elastic testing method is based on the fact that rail magnetic characteristics are in connection with rail mechanical stress test. However this relation depends on material quality as well as on mechanical stress test, which are largely determined by permanent production stresses different case by case. The developed measuring method assumes constancy of material quality only within a specific rail section. Permanent production stress is eliminated by two measurements made under different stress conditions. Therefore a series of calibration tests must be carried out on the rail type to be examined.


Derailment Simulation Testing System
High Speed Bogie Simulation Testing System
Brake Performance Test System
Ultrasonic Rail Inspection Trolley
Eddy Current Measuring Device
Straightness measuring device
The Bore-Test Inspection (Hollow Rail Axle Inspection System)
Neutral Temperature Measuring Device

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National Reference Centre for Railways Test and Maintenance
Reference Laboratory for Railways Component Test
Advanced Auscultation Trains
Testing Track Box
Chassis Testing System
Bogie Testing System
Train Simulator
Shock Absorber Testing System
High Angle Torque Testing System
Multi-Axes Test Bench for Railway System
High Speed Wheel & Rail Contact Simulation Testing System
Bogie Structural Testing System
Derailment Simulation Testing System
High Speed Bogie Simulation Testing System


Suspension Components for Vehicle Dynamic Solutions
Railway Bogie Test System
Vibration Test System
Tunnel Shield Strength Test
Window Lift Motor Durability Testing System
Servo Hydraulic Dynamic Testing Machine
Fuel Injection Valve Testing System for Diesel Engine
Stern Tube Testing System for Ship Propulsion
Metal Fatigue Tester
Hydraulic Servo Actuators
Ultra Sonic Testing of Rail
Geometric Measurement of Tracks and Geometric Condition Survey
Measurement Examination and Qualification of Railway Rails
Qualification of new and used Superstructure Materials