Universal Tamping Robot 4.0
S7 PLS 16 4.0
The Revolution for Highest Tamping Quality
With significantly lower lifecycle costs compared to conventional tamping technology.
Cyclic single-threshold tamping machine for track and switches
EXCEPTIONAL INNOVATIONS
FOR A NEW CULTURE OF Tamping
At the heart of the machine is the latest generation of S7 tamping units, featuring the patented fully hydraulic tamping drive. This drive vibrates only when penetrating the track ballast and during tamping. In S7 automatic tamping mode, the tamping drive continues to tamp until optimal ballast compaction is achieved.
Optimal compaction is determined by measurement. Once optimal compaction is achieved, the vibration of the corresponding auxiliary cylinder is shut off to prevent the compacted material from loosening again. The individual auxiliary cylinders are controlled independently of one another. Once the last auxiliary cylinder has optimally compacted the threshold, the units are raised with the vibration turned off.
ENORMOUS WEAR REDUCTION
The tamping drives vibrate only when penetrating the ballast and during the tamping process; the rest of the time they remain stationary.
Furthermore, there is no need for a large number of rotating and wear-prone drive components. This results in significant savings on overhaul and maintenance costs. Additional low-wear technologies, such as disc brakes, along with simple maintenance and accessibility, guarantee low lifecycle costs for the entire tamping machine.
Significant NOISE AND DUST REDUCTION
- Noise reduction of more than -7 dB per ramming cycle and more than 50% fewer fine dust emissions
- Fewer wear parts – no rotating components or rolling bearings in the S7 ramming drive
- Significant reduction in lifecycle costs and easy maintenance compared to conventional ramming technology
S7 AUTOMATIC PLUG
FOR OPTIMAL COMPACTION
The S7 automatic tamping mode detects the condition of the ballast and automatically achieves optimal compaction by adjusting the tamping duration for each tamping cylinder and sleeper. This increases the durability of the track geometry compared to conventional tamping technology.
- Automated and computer-assisted control makes the tamping workstation easy to operate
- Pressure sensors in the tamping cylinder record the achievable compaction of the ballast bed during the tamping process
- Non-contact displacement sensors in the tamping cylinder measure the tamping stroke
- A ballast bed report with data analysis is generated directly on the tamping machine and uploaded to the S7 infrastructure management web platform INFRAME
ADDITIONAL LIFT INTEGRATED INTO THE MAIN LIFT
By integrating the auxiliary lift into the main lift, the switch is always automatically lifted at the same long sleeper. Additional components such as laser transmitters on the main lift and laser receivers on the auxiliary lift are no longer required. This prevents switch torsion, which negatively affects work quality and places mechanical stress on the switch.
OPTICAL MEASURING SYSTEM
Conventional measurement and control systems for track-laying machines are typically composed of steel cables, tensioning devices, sensors for measuring height and direction, and physical pendulums. Disadvantages of this system include the need for clearance space for the cables on the machine; external influences on the cables cause track alignment errors; oscillating or damped cables cause inaccuracies; insufficient cable tension or snagging of the cables disrupts operation; and steel cables can snap and exhibit drift. Physical pendulums are sensitive to vibrations and respond incorrectly to accelerations.
The optical measurement system from system7 avoids the disadvantages of mechanical steel cables such as sagging, snagging, swinging, breaking, conflicts with obstacles in the machine, system damping, temperature drifts, zero-point shifts, dependencies on vibrations, etc.
The optical measurement system consists of a digital optical camera system mounted on the central measuring carriage, which is located between the tamping units and the lifting and straightening device. The system consists of two digital, very high-speed (40 measurements/second) high-precision industrial cameras, which are arranged along a common optical axis. POWER-LED patterns are installed on the two outer measuring carriages. The POWER-LEDs are equipped with lenses for light concentration. The luminance is therefore very high.
The high luminance of the light pattern offers the following advantages:
- The camera's aperture is set to a narrow opening. This allows the system to operate independently of stray light and daylight
- The system operates regardless of weather conditions such as fog, rain, or snow
- Contaminants such as dust on the protective glass are automatically monitored by the system itself
The camera system detects the LED patterns using image recognition techniques and identifies them with high accuracy and reliability. The system is fault-tolerant. The system continuously monitors itself.
INSPIRED BY AVIATION ABSOLUTE POSITIONING SYSTEM
An inertial navigation system has been installed for the machine’s alignment measurement and control system. The camber is not measured using physical pendulums, but rather by the inertial measurement system. The installed inertial measurement system is insensitive to shocks, accelerations, and vibrations. The measurement of superelevation ishighly precise and accurate and independent of the vibrations caused by tamping. Measurement with the inertial measurement unit is highly accurate and is also suitable for higher measurement speeds.
If the track condition is unknown, a rapid measurement run is performed, and the system7 track geometry optimization program is used to determine a perfect target track geometry including correction data.
The system can also be used as an electronic track measurement car. It records the elevation of the left and right rails, the twist, the track alignment, and the superelevation. The output reports from the APPRec (approval recorder) are available in country-specific formats.
Control via CEO++: Track geometry computer and acceptance recorder in one
- Computer for automated machine control
- Live view of the acceptance report on the work screen
- Easy creation of track geometry data using an editor
- Alternatively, import existing geometry data
- Patented program for track geometry optimization
- Cameras can be optionally integrated into the work screen
Ballast BED Report
The ballast bed report, which is generated on the system7 tamping machines immediately after the work is completed, is based on measurement data from tamping unit sensors, parameters from the APPRec track geometry recording device, and the CEO++ control computer. This data is automatically analyzed using machine learning and summarized and output in the ballast report.
In addition to a graphical representation of the ballast bed properties and the compaction achieved, long-wave elevation errors before and after tamping are also plotted. A written summary assesses the ballast bed quality and indicates any potential defects in the track.
Open the gallery by clicking on the picture.
TWO-PERSON CREW
Thanks to the seamless integration of all system7 technologies, only a two-person crew is required today—a clear advantage over conventional machines and a significant factor in reducing operating costs.
The S7 tamping machine simplifies the operator’s tasks with an automatic tamping mode. Two touchscreens and two joysticks allow the operator to control the machine intuitively and easily. In automatic tamping mode, the machine calculates the optimal compaction itself based on the measured progression of compaction force and compaction stroke, and then fully automatically completes the compaction process.
While working, the machine measures the subgrade hardness and independently selects the optimal tamping parameters such as sinking speed, start and braking ramps, penetration frequency and amplitude, as well as tamping pressure. To ensure the operator always has the tamping area in view while working, the information necessary for tamping quality is displayed at foot level.
The necessary operating information is displayed within the tamping operator’s field of view. This is the ergonomically optimal position. For each tamping operation, the display indicates direction, height, and cross-height, as well as the proper functioning of the units and the measurement and control system.
SWITCHES ENGINEER
The switch engineer is composed of several assistance systems.
The illustrations show some of the assistance systems used.
Lifting Equipment Assistant
The lifting tool assistant automatically selects and controls the lifting roller or lifting hook, as well as their position. A laser scanner measures the area around the lifting position in front of the lifting and straightening device and calculates the possible attachment points based on this data. The lifting roller is used whenever possible. Based on this data, the exact threshold positions are determined, which are used to control the fully automatic approach.
Assistance System: Switch-Learning Mode
The switch learning mode assistance system allows the operator to record and save the movements and settings of the lifting and aligning unit and the tamping units. When working on the same or a similar switch at a later time, these movements and settings are retrieved and automatically applied.
The tamping operator is then primarily responsible for monitoring functions.
Open the gallery by clicking on the picture.
BALLAST BED ANALYSIS WITH SYSTEM7 INFRASTRUCTURE MANAGEMENT WEB PLATFORM "INFRAME"
Each tamping cylinder records the progression of ballast compaction as well as the distance traveled during tamping. This data is used to determine the hardness of the ballast bed. This information, along with GPS coordinates and a photo of the area around the sleeper, is transmitted to “INFRAME”, where the tamping operation is displayed on a map. INFRAME uses machine learning methods to analyze the data and generate recommendations for the railway. In addition, a ballast bed report is generated directly on the tamping machine and is also transmitted to the INFRAME web platform.
Remote Maintenance and Service
All system7 products are designed for remote support, remote maintenance, and remote diagnostics. Spare parts can be easily located and ordered via the 3D online spare parts catalog.
