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09-16 Dynamic: the integrated Dynamic Track Stabiliser increases cost efficiency

The Japanese railway company JR-West is embracing a new machine concept: the 09-16 Dynamic tamping machine offers many features while retaining low axle loads. It’s the first time that a Dynamic Track Stabiliser has been integrated into a Japanese tamping machine.

No more restrictions for tamping work during summers

Until now, it was only possible to use tamping machines on conventional lines for eight months out of the year. During the four summer months, the risk for track buckling after tamping work was too high.

The DGS Dynamic Track Stabiliser ensures the required lateral track resistance (LTR) after a tamping machine has performed maintenance work. Using the integrated DGS, the newly designed 09-16 Dynamic produces the LTR, minimising the risk of track buckling. This reduces or even eliminates operational restrictions during summers while significantly increasing the machine’s cost efficiency and productivity.

JR-West’s very low axle loads of only 15 t posed a particular challenge during the design process, as the axle loads for comparable machines are 20 t or 22.5 t in Europe. Other limiting factors were the narrow gauge and the machine length: due to space restrictions in depots in Japan, the machine had to be designed with the shortest possible length.

However, all demands were met and the 09-16 Dynamic now combines a complete tamping machine with a DGS on a length of less than 35 m. In addition, it features a sleeper-end consolidator, a sweeping unit, fine sweeper brushes, rail fastening brushes, a track recording system, and an additional generator.

It is very important for us to eliminate working restrictions during summers. The integration of the DGS has revolutionised our maintenance plan. We can now design our operation schedule and the machine servicing plan more flexibly.

Yoshio Hasegawa JR-West

Reduced life cycle costs

In developing the 09-16 Dynamic, many customer requirements were addressed. Servicing was simplified, which is always an important factor when talking about life cycle costs.

Mr. Yasuda is one of Railtech’s most experienced technicians. As a consultant, he was involved in the project from the very beginning. The input of other machine operators informed practice-oriented solutions that address the requirements of daily servicing routines. After almost two years of preparatory work, more than 70 % of the machine operators’ wishes have been implemented in close collaboration with Plasser & Theurer.

The “wishlist” included the following three aspects.

1. New access to the tamping unit for servicing purposes

As the core component of the tamping machine, the tamping unit is also subject to the most stress. Frequent servicing should be carried out with utmost care. In the process, it is crucial to be able to check all servicing positions from different angles. Until now, it was only possible to check them from the front due to the rear locking position of the satellite.

The 09-16 Dynamic provides new and safe access routes for servicing. With the addition of a front locking position for the satellite, servicing is now possible from both the front and rear via secured access points.

Due to extensive and specific requirements, Japanese machines always present us with particular challenges. It is the first time that we have built a multifunctional tamping machine with an integrated stabiliser, a track recording system, and a sweeping unit. The 09-16 Dynamic is perfectly tailored to the Japanese network. We are grateful for all the positive feedback we have received after the machine was put into operation in Japan.

Josef Hofstätter, Plasser & Theurer

2. Integrated workshop

In the past, servicing often had to be performed outdoors. Poor working conditions often made it necessary to return to the depot. The 09-16 Dynamic has an integrated workshop in the front section of the machine. It offers plenty of space and holds all tools needed. As a result, servicing and smaller repairs, such as exchanging a cylinder, can be performed directly on the machine on-site.

3. Reducing dust in the working area

Eight special water nozzles were mounted in front of the tamping unit. Spraying water onto defined positions, they help to significantly reduce dust during tamping. The results are better working conditions and less cleaning work.

The intensive exchange between Plasser & Theurer and the users led to excellent results, particularly with regard to the ease of servicing. The 09-16 Dynamic has become like a family member to our operators

Kenta Yasuda Railtech, Consultant JR-West 09-16 Dynamic