TECHNOLOGY 02Rail Reprofiling
Technical Solutions
Mastering All Types of Rail Reprofiling vehicles
Sharing Our Advanced
Technology and Extensive Experience with
Railway Companies
Everywhere
Technology and Extensive Experience with
Railway Companies
Everywhere
Irregularities that develop on the rail running surface due to wheel-induced vibration and wear cause noise and vibration problems during train operation and shorten the rail’s service life. Rail reprofiling is performed to mitigate these issues.
However, if rail reprofiling is not performed properly, the rail condition may deteriorate again within a few weeks after the work is completed, reverting to its prior state.
Our work ensures long-lasting effectiveness through meticulous planning based on thorough on-site surveys conducted prior to performing the work and managing the finish through continuous monitoring during the work itself.
Furthermore, RAILTEC operates multiple types of rail reprofiling vehicles and possesses extensive expertise.
However, if rail reprofiling is not performed properly, the rail condition may deteriorate again within a few weeks after the work is completed, reverting to its prior state.
Our work ensures long-lasting effectiveness through meticulous planning based on thorough on-site surveys conducted prior to performing the work and managing the finish through continuous monitoring during the work itself.
Furthermore, RAILTEC operates multiple types of rail reprofiling vehicles and possesses extensive expertise.
We also provide our high-quality rail grinding technology, along with our extensive experience and knowledge, to other railway operators.
• Work Contracting
• Consulting
Please feel free to consult us if you are having any problems regarding your company’s rail reprofiling.
TECHNOLOGY 02-01Our Own Rail Reprofiling vehicles
Rail Reprofiling
There are two methods of rail reprofiling: grinding and milling, each of which has its own advantages and disadvantages.
We own and are thoroughly familiar with the machinery used for both methods, allowing us to select the best approach for the specific conditions of each work site.
We own and are thoroughly familiar with the machinery used for both methods, allowing us to select the best approach for the specific conditions of each work site.
Grinding
Uses multiple grinding wheels to grind away irregularities along the rail’s longitudinal axis.
• Handles both flattened and laterally worn rails
• Allows for easy adjustment of angle and pressure, enabling precise grinding.
• Handles both flattened and laterally worn rails
• Allows for easy adjustment of angle and pressure, enabling precise grinding.
- SPENO (Made in Italy)
SPENO
The system consists of a power vehicle and multiple rail reprofiling vehicles. Depending on the application, vehicles equipped with 16 grinding wheels are used on conventional lines, while on Shinkansen lines, two sets of vehicles operate synchronously. Specifically, vehicles with 32 grinding wheels are used on the Hokuriku Shinkansen, and those with 48 grinding wheels are used on the Sanyo Shinkansen.
- 6-Head Rail Reprofiling vehicle (Made in Japan)
Yoshiike Scientific Instruments Co., Ltd.
This transportable rail reprofiling vehicle consists of two cars—a grinding-type reprofiling unit and a power unit—which can be loaded onto two 10-metric-ton trucks for overland transport. It can switch between 1,067 mm and 1,435 mm track gauges, making it compatible with both narrow-gauge and standard-gauge tracks.
Milling
The rails are machined using a cutting edge called a tip, similar to shaving with a plane
• Generates virtually no grinding sparks or dust.
• A finished profile is generally achieved in a single pass, extending the rail's service life.
• Work can be halted at any stage during the process.
• Generates virtually no grinding sparks or dust.
• A finished profile is generally achieved in a single pass, extending the rail's service life.
• Work can be halted at any stage during the process.
- LINSINGER (Made in Austria)
Linsinger Maschinenbau GmbH
Consisting of a power unit and a work unit, the system’s compact size and small-diameter wheels allow it to operate on sections with sharp curves. Moreover, wheels can be easily replaced, enabling changes to the finished cross-sectional profile.
- ROMILL (Made in Germany)
ROBEL Bahnbaumaschinen GmbH
Consisting of a milling unit and a grinding/power unit, the system’s 512 cutting tips per wheel (a total of 1,024 for both sides) can be replaced on the vehicle with robotic assistance, enabling the removal of up to 2 mm from the rail surface in a single pass.
TECHNOLOGY 02-02Our Work Techniques
Rail Reprofiling
The general procedure for rail grinding is On-Site Surveying → Work Method Planning → Rail Reprofiling.
We have developed cutting-edge, proprietary methods for every step of the process to ensure that the effects of reprofiling persist not only immediately after completion but at the time of the inspection three months later. To guarantee this quality, we have incorporated two additional steps into our process: Completed Work Verification and 3-Month Follow-Up Inspection.
We have developed cutting-edge, proprietary methods for every step of the process to ensure that the effects of reprofiling persist not only immediately after completion but at the time of the inspection three months later. To guarantee this quality, we have incorporated two additional steps into our process: Completed Work Verification and 3-Month Follow-Up Inspection.
1 On-Site Surveying
Conventional Approach
• Performs a preliminary survey of obstacles, etc.
• Verifies the rail condition by visual inspection.
• Performs a preliminary survey of obstacles, etc.
• Verifies the rail condition by visual inspection.
＋RAILTEC’s Unique Approach
• Performs detailed measurement of cross-sectional rail profiles on-site site using measuring instruments.
• Performs detailed measurement of longitudinal rail irregularities using measuring instruments.
• Performs detailed measurement of cross-sectional rail profiles on-site site using measuring instruments.
• Performs detailed measurement of longitudinal rail irregularities using measuring instruments.
2 Work Method Planning
Conventional Approach
• Determines the number of passes (1 pass = 1 single-direction reprofiling operation).
• Selects the applicable grinding pattern sequence (grinding speed, grinding angle, grinding pressure).
• Determines the number of passes (1 pass = 1 single-direction reprofiling operation).
• Selects the applicable grinding pattern sequence (grinding speed, grinding angle, grinding pressure).
＋RAILTEC’s Unique Approach
• Sets work policies and objectives (such as the target finished cross-sectional profile).
• Sets the control pass for the rail cross-sectional profile during the work.
• Sets work policies and objectives (such as the target finished cross-sectional profile).
• Sets the control pass for the rail cross-sectional profile during the work.
3 Performing Rail Reprofiling
Conventional Approach
• Performs rail reprofiling in accordance with the work plan.
• Performs rail reprofiling in accordance with the work plan.
＋RAILTEC’s Unique Approach
• Performs the work while measuring the rail cross-section with the control pass.
• Modifies the grinding pattern sequence as necessary to achieve the target cross-section.
• Performs the work while measuring the rail cross-section with the control pass.
• Modifies the grinding pattern sequence as necessary to achieve the target cross-section.
4 Completed Work Verification
Conventional Approach
• Performs visual inspection of the rail condition.
• Performs visual inspection of the rail condition.
＋RAILTEC’s Unique Approach
• Verifies the achievement of work through measurement and analysis (rail cross-sectional profile, amount of metal removed, longitudinal rail irregularities, rail surface roughness).
• Verifies the achievement of work through measurement and analysis (rail cross-sectional profile, amount of metal removed, longitudinal rail irregularities, rail surface roughness).
5 3-Month Follow-Up Inspection
＋RAILTEC’s Unique Approach
• Verifies that the wheels on the FC and GC sides maintain non-contact operation, resulting in a narrow contact bandwidth based on the grinding marks.
• Verifies that the wheels on the FC and GC sides maintain non-contact operation, resulting in a narrow contact bandwidth based on the grinding marks.
TECHNOLOGY 02-03Work Contracting
Rail Reprofiling
We provide high-quality rail reprofiling services using our proprietary methods, including:
• On-site surveys and preparation of construction plans
• Work aimed at achieving planned completion specifications
• Completed work verification and 3-month follow-up monitoring
• On-site surveys and preparation of construction plans
• Work aimed at achieving planned completion specifications
• Completed work verification and 3-month follow-up monitoring
A Wide Selection of Machinery
Drawing on our extensive experience in operating a large fleet of rail reprofiling vehicles, we provide optimal track maintenance and repair services using our clients’ existing rail reprofiling vehicles. Because railway operators use these machines on a daily basis, they can clearly see the difference in the results and apply those insights to improve their future operations.
We can also perform work using our own six-head rail reprofiling vehicles.
We can also perform work using our own six-head rail reprofiling vehicles.
Please feel free to consult us if you are having any problems with the quality of rail reprofiling work.
TECHNOLOGY 02-04Consulting
Rail Reprofiling
Through the introduction and operation of rail reprofiling vehicles from numerous manufacturers, we have developed extensive expertise and operational know-how through the operation of rail maintenance machinery.
Building on this expertise and knowledge, we welcome inquiries from railway operators who are considering newly introducing rail reprofiling vehicles.
Building on this expertise and knowledge, we welcome inquiries from railway operators who are considering newly introducing rail reprofiling vehicles.
With Extensive Technical Expertise and Knowledge
Are you struggling to evaluate or conduct test runs on new machinery you plan to introduce because you lack technicians who have in-depth knowledge of that equipment?
Drawing on our extensive operational experience, we provide optimal rail maintenance solutions.
We also welcome inquiries regarding optimization of operations to accommodate new machinery.
If you are planning to purchase rail profiling vehicles manufactured overseas, we can provide assistance with everything from negotiations with overseas manufacturers in Europe to delivery process management, quality control, and final inspections.
Drawing on our extensive operational experience, we provide optimal rail maintenance solutions.
We also welcome inquiries regarding optimization of operations to accommodate new machinery.
If you are planning to purchase rail profiling vehicles manufactured overseas, we can provide assistance with everything from negotiations with overseas manufacturers in Europe to delivery process management, quality control, and final inspections.
If you have any questions or problems regarding the introduction of rail reprofiling vehicles, please feel free to consult us about anything.