0.30ecs

1ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
esveld.
comwww.
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comwww.
rail.
tudelft.
nlwww.
rail.
tudelft.
nlFORCE-BASEDASSESSMENTOFWELDGEOMETRYFORCE-BASEDASSESSMENTOFWELDGEOMETRYCoenraadEsveldCoenraadEsveldDelftUniversityofTechnologyEsveldConsultingServicesDelftUniversityofTechnologyEsveldConsultingServices2ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
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comwww.
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rail.
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nlwww.
rail.
tudelft.
nlDAMAGEDUETOPOORWELDGEOMETRYDAMAGEDUETOPOORWELDGEOMETRY3ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
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comwww.
rail.
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nlwww.
rail.
tudelft.
nlEXISTINGWELDGEOMETRYSTANDARDSEXISTINGWELDGEOMETRYSTANDARDSForexampleVersine:0ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
esveld.
comwww.
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comwww.
rail.
tudelft.
nlwww.
rail.
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nlThedynamiccontactforceasafunctionofthefirsttimederivative:Thedynamiccontactforceasafunctionofthefirsttimederivative:VELOCITYAPPROACHVELOCITYAPPROACHzvu(t)=z(t)MK2dyndzFCv*dx=2dyndzFCv*dx=5ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
esveld.
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rail.
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nlwww.
rail.
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nlzQI≤1:AcceptedzQI>1:RejectedzQI≤1:AcceptedzQI>1:RejectedQUALITYINDICES(QI)QUALITYINDICES(QI)maxmaxnormnormdzFdxQI1OKdzFdx==≤maxmaxnormnormdzFdxQI1OKdzFdx==≤6ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
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nlwww.
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nlFORCE-BASEDSTANDARDSFORCE-BASEDSTANDARDS1.
4mrad50kN100km/h0.
7mrad140kN300km/hInclinationFDynVelocity0.
9mrad65kN200km/h1.
8mrad35kN140km/h2.
4mrad15kN80km/h3.
2mrad5kN40km/hQI=1QI=1ConventionalConventionalHSLHSLHHHHImplementedinRAILPROFImplementedinRAILPROFTotalforceinprinciple225kNTotalforceinprinciple225kN7ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
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nlwww.
rail.
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nlNEWVERSUSOLDNORMNEWVERSUSOLDNORM1.
00.
30OldNorm0.
70.
21300km/hInclination[mrad]Versine[mm]Velocity0.
90.
27200km/h1.
80.
54140km/h2.
40.
7280km/h3.
20.
9640km/h0dz2zdx20.
31.
0mrad2πλπ==≈0dz2zdx20.
31.
0mrad2πλπ==≈02xzzsinπλ=02xzzsinπλ=2mλ=2mλ=02z02z0z0.
3mm=0z0.
3mm=For80km/hthenewnormis2.
4timesmorefavorablethantheoldnorm,providedshortwaveshavebeengroundoff.
For80km/hthenewnormis2.
4timesmorefavorablethantheoldnorm,providedshortwaveshavebeengroundoff.
8ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
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nlwww.
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nlLATERALGEOMETRYSTANDARDSLATERALGEOMETRYSTANDARDS0.
5mm300km/hVersineVelocity0.
5mm200km/h0.
5mm140km/h0.
7mm80km/h1.
0mm40km/hQI=1QI=1ImplementedinRAILPROFImplementedinRAILPROF9ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
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nlASSESSMENTOLDANDNEWONPRORAILASSESSMENTOLDANDNEWONPRORAILRP002432RP002432RP002945RP002945RP002949RP002949RP003125RP003125Oldnorm:Rejected,New:OKOldnorm:Rejected,New:OKOldnorm:OK,New:RejectedOldnorm:Rejected,New:Rejected10ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
esveld.
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tudelft.
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nlSELECTIONONPRORAILSELECTIONONPRORAIL00.
20.
40.
60.
81CumulativeFrequencyCDFMoerdijk-Dordrecht(VSRT)Delft-DenHaagLageZwaluwe-HollandsDiep0123456789WeldQualityIndex[-](140km/h)81%60%31%1.
8mrad(140km/h)1.
8mrad(140km/h)Limitat80km/hLimitat80km/h100weldspergroup100weldspergroup11ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
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nlOLDVERSUSNEWSTANDARDSOLDVERSUSNEWSTANDARDS00.
20.
40.
60.
81CumulativeFrequency012345678910111213MaximumAbsoluteInclinationofWeldGeometry(25mmbase)[mrad].
46%NewStandards3001408040km/hOldNorm(0–0.
3mm)isindependentoflinespeed16%passedOldNorm(0–0.
3mm)isindependentoflinespeed16%passed3%58%73%Population239welds00.
20.
40.
60.
81CumulativeFrequency012345678910111213MaximumAbsoluteInclinationofWeldGeometry(25mmbase)[mrad].
46%NewStandards3001408040km/hOldNorm(0–0.
3mm)isindependentoflinespeed16%passedOldNorm(0–0.
3mm)isindependentoflinespeed16%passed3%58%73%Population239weldsQInormat140km/his3timesmorefavorablethanoldnorm00.
20.
40.
60.
81CumulativeFrequency012345678910111213MaximumAbsoluteInclinationofWeldGeometry(25mmbase)[mrad].
46%NewStandards3001408040km/hOldNorm(0–0.
3mm)isindependentoflinespeed16%passedOldNorm(0–0.
3mm)isindependentoflinespeed16%passed3%58%73%Population239welds00.
20.
40.
60.
81CumulativeFrequency012345678910111213MaximumAbsoluteInclinationofWeldGeometry(25mmbase)[mrad].
46%NewStandards3001408040km/hOldNorm(0–0.
3mm)isindependentoflinespeed16%passedOldNorm(0–0.
3mm)isindependentoflinespeed16%passed3%58%73%Population239weldsQInormat140km/his3timesmorefavorablethanoldnorm12ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
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nly=18,62x+20,93R2=0,0905010000,250,50,7511,25versine[mm]max.
dyn.
contactforce[kN]y=4,33xR2=0,9105010005101520max.
discretisedgradient(5mmbasis)[mrad]max.
dyn.
contactforce[kN]LowcorrelationforceandversineLowcorrelationforceandversineHighcorrelationforceandQIHighcorrelationforceandQICALCULATEDDYNAMICFORCESCALCULATEDDYNAMICFORCES13ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
esveld.
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nlDynamicforcelinearwithQIDynamicforcelinearwithQIDynamicforcelinearwithtrainspeedDynamicforcelinearwithtrainspeed0204060801001201401600246810max.
weldslope[mrad]Fdyn[kN]v=300km/hv=140km/hv=80km/hv=40km/hy=0,28xR2=0,98020406080100050100150200250300trainspeed[km/h]Fdyn[kN]slope:5mradCALCULATEDDYNAMICFORCESCALCULATEDDYNAMICFORCES14ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
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nlAXLEBOXACCELERATIONSAXLEBOXACCELERATIONSDynamicamplificationlessthan2.
2Dynamicamplificationlessthan2.
2y=0,23x+1,11R2=0,5911,21,41,61,822,200,511,522,53QI(140km/h)DAF(750Hz)15ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
esveld.
comwww.
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comwww.
rail.
tudelft.
nlwww.
rail.
tudelft.
nlProcedure:zSampleweldgeometrywithdigitalstraightedgezFiltermeasuredsignalzDetermine1stderivative(inclination)zNormalizewithinterventionvalueforlinespeedzCalculateQI.
zQIECSECSWeldGeometryStandardsWeldGeometryStandardswww.
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nlwww.
rail.
tudelft.
nlPRACTICALIMPLEMENTATIONPRACTICALIMPLEMENTATION17ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
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nlPDASCREENPDASCREENV=140km/hQI=1.
06V=140km/hQI=1.
06QIuniquelyshowswheretogrindQIuniquelyshowswheretogrind18ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
esveld.
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comwww.
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nlwww.
rail.
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nlDESKTOPSOFTWAREDESKTOPSOFTWAREAlldataandgraphscanbeshownonaPC;Resultsinpdf-formatcandirectlybeemailedtocustomer.
AlldataandgraphscanbeshownonaPC;Resultsinpdf-formatcandirectlybeemailedtocustomer.
19ECSECSWeldGeometryStandardsWeldGeometryStandardswww.
esveld.
comwww.
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comwww.
rail.
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nlwww.
rail.
tudelft.
nlCONCLUSIONSCONCLUSIONS1.
Theorybasedonfirstderivativeworksfineinpractice;2.
Steelstraightedgeisabsolutelyinadequate;3.
InsteadelectronicstraightedgeswithQI(RAILPROF);4.
HighcorrelationofforceandQI,lowcorrelationwithversine;5.
WithRAILPROFQImeasurement:Youseewhatyoudo;Higherquality;Lessrejectionsprovidedshortwavesaregroundproperly(alsonegativeweldsallowed);Extensionoflifecycle.
1.
Theorybasedonfirstderivativeworksfineinpractice;2.
Steelstraightedgeisabsolutelyinadequate;3.
InsteadelectronicstraightedgeswithQI(RAILPROF);4.
HighcorrelationofforceandQI,lowcorrelationwithversine;5.
WithRAILPROFQImeasurement:Youseewhatyoudo;Higherquality;Lessrejectionsprovidedshortwavesaregroundproperly(alsonegativeweldsallowed);Extensionoflifecycle.