Optimizing friction management

Written by Mischa Wanek-Libman, editor
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Robolube “Linear” Wayside, Gauge Face Lubricator system.

Suppliers are investing in the development of new products that maximize uptime while reducing total cost of ownership.

 

Friction management has become an accepted practice to increase efficiencies and safety while lowering maintenance costs. The products and equipment used have evolved to require less material, reduce waste of that material and improve the practice for both top-of-rail and gauge-face applications.

L.B. Foster
L.B. Foster Co. says it continues to focus on optimizing payback and return on investment to its customers with the ultimate goal being to reduce the total cost of ownership (TCO) of friction management products throughout the global rail industry.

Jim Tanner, director field services, explained partnering with customers from designing the initial systems to assisting with ongoing maintenance and performance of equipment in the field all help meet specific needs of the company’s end use customers.

“Our objective is to maximize equipment uptime so that our customers are able to achieve the expected benefits of their specific friction management programs,” said Tanner.

According to Steve Fletcher, general manager, rail technologies, “Our business is vertically integrated across equipment, consumables, service and performance validation worldwide to provide a complete range of the various products and services that our customers need to implement a successful friction management program. And by design, this vertical integration places the pressure of performance directly on L.B. Foster. In addition, some customers have a variety of equipment and materials from various suppliers.  We bring the same dedication and commitment to helping all of our customers achieve the benefits of an effective friction management program.”

Fletcher added, “Innovative and robust product development to address customer needs remains a critical, ongoing process at L.B. Foster. For example, power consumption is a major concern with our customers operating friction management equipment in remote locations. In 2016, one of the areas we are focused on is power optimization. Also, we continue to invest in technology development of better performing, more economical consumable products.”

Fletcher said the company would continue to invest and develop mobile applications of friction management, as interest in the solution grows among L.B. Foster’s customers.

“For example, our AutoPilot™ advanced top-of-rail (TOR) spray application systems continue to gain market acceptance.  These systems can be more efficient in product application and are well suited to high traffic commodity routes, as well as in closed loop utility operations and with shortline railroads,” said Fletcher.

Brian Vidler, senior manager product solutions discussed the 15-year evolution of the company’s KELTRACK® family of TOR products to provide an intermediate coefficient of friction by deploying a dry film friction modifier.

“This characteristic delivers excellent performance while mitigating traction and braking issues that are experienced with alternative products. Also, individual friction modifiers are deployed through careful consideration of the amount of material applied over an effective carry down distance. Provided that the application strategy remains within the individual product performance parameters, effectiveness through this carry down zone is maintained.  When application rates or carry distances are stretched beyond their limits, inconsistent performance is experienced. This is one of the biggest discrepancies between actual and anticipated performance. Using the L.B. Foster approach we hold ourselves accountable for delivering the results our customers expect to achieve.”

Vidler recognized customer concerns surrounding potential material waste at the application site, which he says can come from a combination of the friction management material properties and the efficiency of the application equipment.

“Our equipment has evolved over time to be the most efficient equipment available, but we are not satisfied and continue to invest to improve in this area.”

Loram
Loram Maintenance of Way, Inc., introduced its GaugeShield product line to efficiently and effectively lubricate the gauge face of the rail.

“The GaugeShield design focuses on delivering performance and reliability, while simplifying routine maintenance and operation. The ergonomically-designed tank provides ample space for maintenance and inspection.

The removable grease tank insert allows for easy transfer of seasonal and different manufacturers’ greases and the cone shaped design funnels grease to the pump to decrease cavitation, ” said Jon Behrens, general manager – Friction Management at Loram.

GaugeShield’s dual output gear pump has fewer moving parts and the grease output is reliable and repeatable at all operating temperatures and can control two tracks with a single controller.  The patent pending dispensing bar, which uniformly dispenses grease across the top of the bar, has a removable insert for inexpensive replacement.

The GaugeShield can be remotely monitored with Loram’s monitoring and analytics package, which Behrens says provides the ability to quickly audit the uptime and accurately monitor and plan maintenance activities.
“Loram’s GaugeShield provides a new and improved method to help railroads reduce rail wear, curving forces, wheel flange noise and conditions that can cause derailments,” said Behrens.

RBL, Inc.
RBL, Inc., launched the new Robolube “Linear” Wayside, Gauge Face Lubricator System at Railway Interchange 2015. The system, which duplicates the bead application of a hi-rail-style lubricator, uses less lubricant, which the company says will produce better results on high-density track.

“We have designed a stand-alone system that places the grease precisely on the Gauge Corner.  This design allows us to achieve the benefits of better lubrication results, better reduction of the coefficient of friction, less grease consumption and eliminates the high expense associated with wasted lubricant,” said Robert Pieper, president.

Pieper notes that all of the grease is consumed by the passing train and migrated down the track, depositing the lubricant where the train wheels dictate the need. He says by having no contact with the train allows the company’s application assembly to be placed in the track at the apex of the curve for bi-directional lubrication.

“The environmentally-friendly Robolube ‘Linear’ Lubricator does not require any catch or hazardous waste mats to be placed on the ties.  Waste and castoff of lubricant is virtually eliminated along with the problems associated with inadvertently creating environmental contamination of the lubricator site,” said Pieper.

In addition to the new system, RBL offers custom Robolube Model 200-40 Hyrail Lubricators, that offer the flexibility of two separate application systems in a single enclosure.

“One tank carries 200 lbs. of curve and flange grease and the other tank carries 40 lbs. of friction modifier. The lubricator can grease gauge face on the low or high rail, as well as apply friction modifier to the top of the low or high rail,” said Pieper.

SKF/Lincoln Lubrication Systems
SKF/Lincoln says it continues to simplify its products to reduce installation and total cost of ownership associated with its rail lubrication portfolio. Examples of this include the company’s new wheel sensor mount, which uses a stud-shim design to enable quicker mounting, a factor the company said is praised by lubricator maintenance personnel that deal with short track time windows. Additionally, the company says it built upon its

“brush-bar” applicator with the introduction of a new brushless gauge-face applicator and SKF/Lincoln’s solar panel options have been expanded to offer robust, simplified mounts for its lubricators.

The company says one of the most important developments for the SKF and Lincoln brands is the opening of the new SKF facility in St. Louis, Mo. The company says the facility features state-of-the-art manufacturing and distribution technologies that will optimize product quality and all phases of the supply chain.

Eric Nieman, SKF railway portfolio manager, says the company’s pumping and applicator equipment is designed to deliver friction modifiers and lubricants at the right time, at the right location and in the correct quantities.

“The consistent, dialed-in quantities of friction modifier applied at the correct location help to eliminate product waste and ensure that customers receive the most value from their chosen friction modifier,” said Nieman.

Whitmore Rail
Whitmore Rail’s top-of-rail friction modifier, TOR Armor®, launched in 2014 to provide optimum friction at the wheel-rail interface and, the company says, substantially reducing noise, wear and lateral forces. Today, Whitmore Rail says TOR Armor continues to lead the industry and proactively combats the many challenges faced.

Whitmore Rail explains TOR Armor is one of the only friction modifiers designed to precisely control friction at the desired level, it’s readily biodegradable and carry down and retentivity continues to be superior to other “positive friction” products in the market.

“To go along with our friction modifier, Whitmore Rail recently introduced a top-of-rail wiping bar, PolyTOR™, that can be used for heavy-haul freight and transit rail applications. Another key part of our comprehensive friction management product line includes our high-tech electric trackside lubricators called AccuTrack®. They deliver consistent output in all temperatures, come in a variety of tank sizes and can be configured for gauge face or top-of-rail applications,” said Bruce Wise, director of railroad sales at Whitmore.

“Most of our worldwide customer base continues to see the benefits of a solid rail friction management program and looks to Whitmore Rail for the next breakthrough. Because we make and offer the most comprehensive friction management line of products available, we project our business to grow significantly this year. Plus, our customers are always looking for new efficiencies and ways to lower maintenance costs and increase safety. We are ideally positioned to meet their specific needs because we offer the convenience of ‘one stop shopping’ to the railroads,” said Wise.

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