3th International Conference in Warsaw "MODERN TRENDS OF FIRE PROTECTION IN ROLLING STOCK"

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Claire Shannon Rogers
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1 "MODERN TRENDS OF FIRE PROTECTION IN ROLLING STOCK" FIRE PROTECTION OF FLEXIBLE METAL/RUBBER COMPONENTS INCLUDING ELEMENTS IN BOGIES PRESENTATION BY DR. DANA GREFEN page 1

2 Content 1. Flexible metal/rubber components conforming to EN Application examples Requirements Previous rubber-standard version versus requirements of EN Material development 3. Results of material and component tests 4. Summary page 2

3 Metal/rubber components conforming to EN sealings and profiles window profiles bellows anti-vibration elements page 3

4 Requirements of flexible metal/rubber components conforming to EN requirements test method reference parameter unit maximum or minimum HL1 HL2 HL3 R9 M1: flexible metal/rubber components EX9: air bags for pneumatic suspension EX10: parts of the drive EX11: tyres T03.02 ISO : 25 kwm -2 MARHE kwm -2 maximum T10.03 EN ISO : 25 kwm -2 D s max. dimensionless T11.02 EN ISO : 25 kwm -2 CIT G dimensionsless maximum maximum - 1,8 1,5 page 4

5 Previous rubber-standard version versus requirements of EN Optical smoke density according to EN ISO STANDARD-component NR-Elastomer 25 kwm -2, 10 min Hazard-Level - HL2 Hazard-Level - HL3 Time sec page 5

6 Content 1. Flexible metal/rubber components conforming to EN Application examples Requirements Previous rubber-standard version versus requirements of EN Material development 3. Results of material and component tests 4. Summary page 6

7 Project BATEGU - Fire Safety comparison of components of a fire retardant mixture (without required dynamicmechanical properties) and a natural rubber compound for use as anti-vibration element based on rubber and fillers fire protection NR-compound rubber % fillers (carbon black and white) 40 % flame retardants (filler) 60 - % flame retardants (plasticizer) 5 - % fire protection properties + - anti-vibration properties - + CONFLICT!!! page 7

8 R&D targets fire protection in accordance with EN for flexible metal/rubber components, particularly for application in bogies, while maintaining the required functionality conversion of existing components to the current fire protection standard EN without any constructive changes of the previous components ensure emergency running properties abidance to international rules to protect human health and the environment (REACH, RoHS, Unife Railway Industry Substance List) page 8

9 BATEGU - Material development technical solution I BATEGU 9713: fire-protected material in a combination of material assembly of at least two elastomers in which one material ensures the mechanical properties (statically and dynamically) the second material provides the protective function in case of fire technical solution II BATEGU 9559: fire-protected material, which combines the static/dynamic properties and the fire protection in one material. page 9

10 Content 1. Flexible metal/rubber components conforming to EN Application examples Requirements Previous rubber-standard version versus requirements of EN Material development 3. Results of material and component tests 4. Summary page 10

11 Tests results EN tests Optical smoke density EN Hazard-Level - HL2 Time sec page 11

12 Test results of EN tests Requirement Test method Parameter Unit Max. or Min. HL1 HL2 HL3 Bategu 9713 Bategu 9559 R9 M1: flexible metal/rubber components EX9: Air bags for pneumatic suspension EX10: parts of the drive EX11: Tyres ISO EN ISO EN ISO MARHE kwm -2 Max HL 2/3 HL 2/3 D s max. dimensionless CIT G dimensionless Max HL 2/3 HL 2/3 Max. - 1,8 1,5 HL 2/3 HL 2/3 hardness +/ classification HL 2 HL 2 HL 2 HL 2 HL 2 HL 3 HL 3 HL 3 HL 3 HL 3! in the selection of suitable material for anti-vibration components continues to be: Spring deflection before shore hardness page 12

13 Laboratory test results BATEGU 9713 Dynamic testing test specimen: diameter x height: preload path in compressive direction: deformation amplitude in thrust direction: frequency: duration: cylindrical rubber-metal-buffer 34 mm x 25 mm 2 mm +/- 5 mm 6-10 Hz 10 mio cycles Test result: The test was ended positively after 10 million cycles. The material showed no damages (wear, cracks, etc.). page 13

14 Laboratory test results of BATEGU 9559 Service life - comparison page 14

15 Test result of BATEGU 9559 Service life - comparison Fatigue test NR 60 standard versus Bategu 9559 material 9559 NR NR 60 amplitude - thrust ± 4mm ± 4mm ± 6mm ± 6mm preload vertical 1mm 1mm 2mm 2mm cycles 1,80 Mio 1,75 Mio 1,10 Mio 0,95 Mio frequency 6 Hz 6 Hz 6 Hz 6 Hz damages no damage crack (5mm) no damage failure by depolymerization metal/rubber adhesion result X X page 15

16 Component test of BATEGU 9713 Static spring deflection F with load/ unload F with 18,3 mm load F with 36,6 mm load F with 55 mm load F with 36,6 mm unload F with 18,3 mm unload no dan dan dan dan dan max min BTG9713/NR NR-Standard art.no draw.no article : HIIA 1726 B : HS catalogue : Hollow Spring material : BTG material combination 60Sh / NR 60Sh Deflection in mm page 16

17 Component test of BATEGU 9713 Dynamic fatigue resistance test laboratory: test specimen: SZA-Prüfanstalt, Vienna Primary spring for ULF, Wiener Linien diameter x height: preload path in compressive direction: deformation amplitude in compressive direction: 250 mm x 220 mm 5 mm +/- 10 mm frequency: 1 Hz target: 1 million cycles, max. set after 1 mio cycles: 5 mm The test was ended positively after 1 million load cycles. The material showed no damage and a set of max. 3,5 mm. page 17

18 Component test of BATEGU 9713 Spring deflection after 1 mio load cycles specification / requirement free height 220 mm height under load 15,5 kn mm after 1 mio load cycles BATEGU 9713 comparison standard natural rubber 196,15 mm 196,61 mm article no VFR 7566 draw. No BTG article material Primary spring BTG 9713-/ NR Load in kn page 18

19 Component test of BATEGU 9559 Static spring deflection test specimen: material: F with load/ unload Hollow spring BATEGU 9559 to vers. NR-Standard F with 17,33 mm load F with 34,66 mm load F with 52 mm load F with 34,66 mm unload F with 17,33 mm unload dan dan dan dan dan Max Min NR-Standard BATEGU Deflection in mm page 19

20 Component test of BATEGU 9559 Static setting test specimen: Hollow spring HIIA 1866-D diameter x height: 86 mm x 96 mm (M3 +/- 1) testing procedure: 4 weeks under permanent load of 2000 N temperature: 23 C test results: setting in % start conditions setting after 4 weeks H0 f1 f2 setting after 4 weeks [mm] [mm] [mm] [%] NR Standard 95,5 35,49 35,93 1,23 BATEGU ,3 36,15 36,58 1,19 Result BATEGU 9559: no significant difference compared to NR page 20

Component test of BATEGU 9559 Multi-axial dynamic fatigue test testing laboratory: SZA-Prüfanstalt, Vienna test specimen: Primary spring NR Primary spring BATEGU 9559

21 Component test of BATEGU 9559 Multi-axial dynamic fatigue test testing laboratory: SZA-Prüfanstalt, Vienna test specimen: Primary spring NR Primary spring BATEGU 9559 vertical strength: max. 80 kn horizontal deformation amplitude: +/- 10 mm frequency: 1 Hz materials: fire protected elastomer BATEGU 9559 versus standard NR (series) page 21

22 Component test of BATEGU 9559 Static spring deflection before and after 1 mio load cycles NR BATEGU 9559 Deflection in mm Deflection in mm Primary spring with three set cycles and one measurement cycle to 120 kn Result BATEGU 9559 : lower set compared to NR page 22

23 Component test of BATEGU 9559 Dynamic stiffness BTG 9559 NR Result BATEGU 9559: lower stiffness loss compared to NR page 23

24 Component test of NR - BATEGU 9559 Dynamic stiffness (excerpt) BATEGU W NR Result BATEGU 9559: first visually visible damage at higher number of cycles compared to NR page 24

25 Component test of NR BATEGU 9559 Multi-axial dynamic fatigue test - Summary lower setting W less stiffness loss first visually visible damage at heigher number of loading cycles Cycles page 25

26 Summary Technology EN compliant elastomer materials developed especially for railway industry (BATEGU 9713 and 9559) are flame resistant, highly dynamic loaded, environement-fair, examined and confirmed maximum fire protection according to EN with optimal anti-vibration properties according to application and component type BATEGU-fire protection materials fulfill customers demands within the industry regarding the media and environmental resistance (ozone/uv, cleaning agents, salt, lubricant,...) temperature resistant: - 50 C up to +70 C paints/coatings (corrosion protection/colours) used by Bategu for components are EN compliant existing components can be manufactured to be fire resistant, dimensioned 1:1 emergency running properties maintenance-free fulfilment of highest safety and environmental standards: RoHS, REACH, Unife page 26

27 Summary strengthening of fire protection; no (legally covered) vehicle registration without EN to conform flexible metal/rubber components, particularly for application in bogies technically mature and tested EN compliant elastomer materials EN conforming BATEGU components are already available and operational all common anti-vibration components can be produced EN compliant (exception: air springs - is in progress) existing (not fire resistant) components can be produced 1:1 to fire-protected ones without any change of elastic properties (design modifications are not necessary) benefits for vehicle manufacturers/operators: NO constructive changes NO elaborate verification NO additional experts costs NO delays in the authorisation procedure almost constant LCC costs page 27

28 Thank you for your attention! BATEGU Gummitechnologie GmbH & Co KG Muthgasse 22, 1190 Vienna, Austria Tel: +43 (1) Fax: +43 (0) frank.schmitt@bategu.at Internet: page 28

29 References/Literature Literature: [1] EN : Railway applications Fire protection on railway vehicles Part 2: requirements for fire behavior of materials and components; German version EN : Pictures [2] BATEGU Gummitechnologie GmbH & Co KG Other notices: all the presented tests were made just with materials and components by BATGEU (NR = natural rubber, EPDM = ethylene-propylene-diene-rubber). page 29

EXCELLENT DESIGN AND EXCEPTIONALLY TOUGH AVENTICS BELLOWS CYLINDERS

EXCELLENT DESIGN AND EXCEPTIONALLY TOUGH AVENTICS BELLOWS CYLINDERS 2 Bellows cylinders Characteristics Bellows cylinders are an impressive solution They retain their shape but are still flexible, are