A turnout is one of the weakest links in the permanentway system and requires continuous attention andmaintenance for ensuring their proper geometry, serviceperformance and above all safety.

In certain high traffic density areas the points &crossings wear out within a very short period. Wearusually involves progressive loss of material due torelative motion between the two contacting surfaces(i. e. rail and wheels).

The cost of these components is comparatively much higherthan any other P. Way material. Therefore to enhance theservice life of these components reconditioning of worn-outarea by a combination of metal arc welding technique andconsumables have been introduced.

Translamatic Robotic Welder is a computer controlled arc-welder that utilizes a coated wire without gas.

Initially it is done in Northern Railway and then introduced inother Railways. After successful trial Railway Board vide letter -Track/21/2007/0401/7/CMS XING Dated 17.02.2010 andfurther by letter dated 17.10.2010 approved the reconditioningof worn out CMS Crossing by Translamatic Robotic Welding.

Eliminates operator exposure to weld fumes.

Records all welding events into memory for later download to PC.

Memory adapter, PC adapter, and software available as an option.

Automated control provides consistent welds.

Weld bead, patterns, and dimensions all electronically controlled.

Automatic call-up from memory.

Rugged lightweight construction.

Translamatic Robotic Welding

Before taking up In-Situ Reconditioning of CMS X-ing,removal of hardened metal , spelled edges, surface cracksand micro cracks are necessary. It is desirable to reach up toparent & sound layer.

The surface preparation is done by hydraulic grinders.The care shall be taken that no localized grinding shall bedone to avoid the excess heat generation.

Dye-penetration test after grinding is to be done in orderto ensure surface to be reclaimed free from cracks.

It is done by a ‘Translamatic Robotic welding’ machine. This is a very handy machine. It can be lifted by merely two persons. It works through software, data for which shall be feed in the data logger.

Data of area to be covered under welding is to be fed in a device called ‘Charlie’ Maper by Horizontal polygon and/or triangles on all three areas one by one.

Welding is done automatically without any manual interference, eliminating manual errors.

Welding each layers start & stop controlled by Charlie Maper.

Temperature should not be more than 100 degree at the start of each bead. No more than one run shall be deposited. The TRW is programmed in such a manner to follow skip welding sequence or to weld different portion of the X-ing by rotation.

The first round of Welding shall be done for wing rails (right and left) and nose of crossing.

After completion of first round of welding slag shall be removed by wire brush and light hammer.

Welding of the wing rail and nose of crossing for the remaining portion shall be completed gradually.

In order to obtain smooth finish profile and surface ofwelded CMS crossing grinding by DISC Grindingshall be done.

As per “Manual forreconditioning of MMSteel, point &Crossing,SEJ and CMSCrossing”.

The reconditioned crossing after finish grinding shall be subjected to visual inspection, dimensional measurement and freedom from presence of any surface defects during welding i.e. undercut, slag, porosity, cracks etc.

If it is found free from any defects during visual inspection then dye penetration test to be carried out to check any defects which are not found in visual inspection.

A speed restriction of 30kmph with OES+BLW is required during the work. Other necessary track protection arrangements have to be followed.

Operators/Applicators should be duly certified by the original technology providers of RDSO approved.

The work should be confirm to “Manual for Reconditioning of Medium Manganese (MM) Steel Points & Crossing Switch expansion joints (SEJ’s) and Cast Manganese Steel (CMS) Crossings-1996” published by RDSO, Lucknow.

Sl.N

o.

Description

of Items

Conventional

Reconditioning

Translamatic

Robotic

Reconditioning

1. Type of Welding Metal Arc Welding Core flux continuous feeding

2. Method of Welding Manual by Metal arc

welding

Automatic by Robotic in situ

welding method

3. Time Required for

Welding

More Less

4. Manpower

required

More (Up to 8 labours)

However additional 10

labours require for removal

and insertion of crossing

each time

Less ( Up to 6 labours )

5. Heat Input More Approximately 50 % less heat

input

than Metal arc welding is

required.

6. Metal Deposit over

Rail

Head after welding

Up to 3 mm up to 0.5 mm

7. Temperature

control

1. By water cooling 2.

Cooled air spray 3. Cooled

water spray

By giving less Heat input

8. Durability Depends on type of Welding

Electrodes used. 1. up to 15

GMT if H3 electrode used.

2. Up to 25 GMT if H3A

electrode is used.

3. up to 35 GMT if H3 B

electrode used. And

Maximum is 35 GMT

Minimum up to 80 GMT

9. Essentials Additional spare CMS Xing

is required

Not required as welding is

done in

situ

10. Disturbance to

adjoining track

Approach rail / gapless joint

disturbed during removal

and insertion of CMS Xing

No disturbance to adjacent

track

Thank You