Alstom opens a bogie test and validation centre

It was designed in response to the opening up of the railway market and the reduction of train development times and its objective is threefold: to capitalize on the companys technical know-how, to speed up product reliability processes, and to ensure a more efficient startup. The centre went into operation in May 2009 with applications on the next generation of Ixège bogies that will equip some of Alstoms future tramways and tram-trains.

Four to six months of tests to simulate 30 years of commercial service
Alstom is a rail sector multi-specialist and innovation is core to all of its activities. Its new test centre allows it to develop its expertise with regard to bogies, essential components for train performance and safety. In particular, it will enable Alstom to integrate and manage all design phases of a new bogie, from development to fine-tuning and validation. Up to now, and throughout the rail sector as a whole, only the individual underframes and parts of bogies were validated on a test bench, with fatigue tests and tests of other components simulated by computer. This meant that Alstom first developed each of the components and then validated the fully-assembled bogie during endurance tests performed on the train. This process gave an on-going appreciation but did not allow a full anticipated validation of the bogie for 30 years of commercial service.

The use of the test bench for complete bogies revolutionizes this process by reducing the time needed to ensure product reliability. In addition, technical teams can test the bogies under conditions nearly identical to those of commercial service. For example, checks can be run on the performance of a bogie equipped with all its components during slow or rapid acceleration phases, whether in a straight line or in a curve. The impact of the underframes weight on the bogie as well as the mobile and unevenly distributed load of passengers is also measured. By repeating these tests according to standardized, regulated cycles , the physical change in the bogies over time can be determined. Thus, before being put in service, an Alstom bogie equipped with all its components will have undergone at least 10 million fatigue test cycles which, in just four to six months of tests, will simulate nearly 30 years of commercial service. For example, it has equipped the Ixège bogie for the Citadis tramways with more than 460 stress, temperature, torque measurement and displacement sensors. Feedback is immediate and adjustments are made continuously throughout the development phase of the bogie. With the improvements expected to be made on the new bogie test bench, it will eventually be possible to simulate a route with even greater precision by incorporating possible track defects.

By validating its bogies according to this process, long before they are put into commercial service, Alstom can identify the parts that will be most in demand and most vulnerable over the long term. It can therefore offer its customers proven products thank to the tests perform on prototypes prior to their market launch. The advantage is twofold: operators have a fleet which is reliable and fully operational from day one, and Alstom can reduce non-quality costs, benefit from the reliability of its products, and optimize their maintenance.

Unique integrated test equipment
The Neuhausen centre houses the latest bogie validation technology in a 400 m2 building. Through a unique combination of technical expertise and equipment, Alstoms aim is to create maximum synergies among its various programmes and capitalize on its know-how.

All of Alstoms future bogies will be tested at the Neuhausen centre, including those used on urban stock, high-speed and very high-speed trains. Permanent-magnet motor bogies specially designed for Alstoms latest generation of very high-speed trains will also undergo additional testing at the site in the coming months. To cover the entire range, Alstoms teams have two principal test benches, one for complete bogies and the other for underframes. These are used to force a running underframe on the three axes. The forces applied can reach 200 Newton kilogrammes (20 tonnes) on the lateral axis, 120 Newton kilogrammes (12 tonnes) on the longitudinal axis, and 1,000 Newton kilogrammes (100 tonnes) on the vertical axis. When static, the vertical forces can be as high as 1,200 Newton kilogrammes (120 tonnes). The other smaller test benches are used to test components, such as anti-roll bars, suspension systems, dampers and springs.

This centre, which required a total investment of 2.5 million, is fully integrated into Alstoms organization. Its experts work closely with Alstoms 120 engineers and technicians in charge of bogies. Each year, Alstom produces 3,000 bogies.

About Alstom Transport
With a focus on sustainable transport, Alstom Transport develops and offers the most complete range of systems, equipment and services on the rail market. Alstom Transport can manage an entire transport system, from rolling stock to signalling and infrastructure, and offers turnkey solutions. In 2008-2009, Alstom Transport's had turnover of 5.7 billion, and its orders had increased by 9% over the previous financial year. Alstom Transport has a presence in more than 60 countries and employs 27,000 people.

Press contact
Laurent Gerbet - Tel. + 33 (0)1 57 06 92 83
laurent.gerbet@transport.alstom.com

Website:www.transport.alstom.com