PJ Messtechnik, an accredited test center in accordance with ISO/ IEC 17025, was commissioned by Innofreight to carry out all the necessary steps for the approval of the innovative Y25 bogie. Innofreight develops freight wagons, containers and unloading systems and operates 22,000 containers and 3,500 wagons in 20 countries. The Y25 bogie completes the extensive portfolio of the Austrian freight wagon specialist.
The specifications for the new bogie were demanding: the bogie frame was to be manufactured fully automatically and designed to withstand the highly dynamic loads over 5 decades. Due to the expertise of the PJM team, the task was solvable. The structural analysis was carried out using the latest simulation and assessment methods. On the one hand, the standard loads were extended by the results of MBS simulations. On the other hand, the weld seam assessment was carried out using the effective notch stress concept to improve the prediction accuracy and thus enable lightweight construction.
PJ Messtechnik implemented the entire validation program in accordance with EN 13749 on the fully developed bogie frame:
- Structural analysis
- Static and fatigue laboratory tests at the Institute for Structural Durability and Railway Technology at Graz University of Technology
- Track tests under extreme conditions to validate the design loads
The result:
- The bogie frame is manufactured 100% by welding robots.
- The weight has been reduced by 25% compared to conventional designs, while at the same time increasing durability. As a result, the load capacity can be increased by 500 kg in future, which means lower costs and greater efficiency combined with greater robustness.
- Further advantages include less wear on the wheelsets and better braking performance.
