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BIA-Brukerstyrt innovasjonsarena

Wear and friction reduction in wheel-rail interaction

Alternative title: Redusere Slitasje og Friksjon mellom hjul og jernbaneskinner

Awarded: NOK 13.5 mill.

Project Manager:

Project Number:

321499

Project Period:

2021 - 2025

Funding received from:

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Social awareness on the impact of transport on greenhouse gas (GHG) emissions and global warming is driving a shift from more polluting transport modes (such as flights and cars) to more energy-efficient rail transport. Additionally, political pressures, particularly due to new regulations aiming for zero carbon emission targets, are accelerating this transition. The expected increase in passengers and higher traffic frequencies necessitates robust, reliable, and environmentally friendly solutions that enable passenger growth without compromising safety or inflating maintenance, repair, and overhaul (MRO) costs. One of the most significant MRO expenses is associated with grinding and replacing wheels and rails, which can become non-compliant due to high wear rates and rolling contact fatigue (RCF). Optimizing lubricants and lubricant delivery systems can minimize wear, suppress RCF crack growth, reduce energy consumption, decrease noise pollution in residential areas, and improve air quality by reducing the release of metal debris. The WINTER project focuses on optimizing lubricants and lubricant supply systems in four Norwegian regions that span railways, lightweight trains, and metro systems—each with challenging wear, friction, and lubrication conditions. By tackling some of the most demanding areas in Norway, the project's results are expected to have broader applications across the country and beyond. In recent years, the WINTER project has implemented a novel approach to categorizing wear and friction-related losses. This approach uses thermal cameras and microphones to detect and analyze wear issues originating from wheel/rail contact. This innovative technique, combined with the development of a new environmentally friendly grease and the introduction of a new lubrication train, has resulted in a significant reduction in wear-related losses, particularly on the Flåm Railway. The successful application of these methods has led to substantial improvements, including extended wheel and rail life, decreased energy use, and lower noise levels. Due to the success on the Flåm line, this technique is now slated for implementation on other railway lines across Norway.

Social awareness on the effect of transport on the greenhouse gases emissions and global warming is producing a transition from more polluting transports (flights, cars/bus) to more energy-efficient rail transport. Indeed, the number of train passengers in Norway has increased by 50% since 2004 and by 3.4% in 2019 up to 80 million. These figures are also similar for metro and light rail. The increase in number of passengers, demands robust, reliable and environmentally friendly solutions that allow for passenger growth without compromising safety nor increasing maintenance, repair and overhaul (MRO). The WINTER project will therefore optimise lubricants and lubricant delivery systems for the Norwegian rail system. Improved friction management of the wheel-rail system will lead to a reduction of wheel and rail damage and thus decreased energy consumption, increased safety, reduced MRO costs, noise reduction in residential areas and improved air quality by diminishing metal debris and lubricant released to the environment. The products will be designed for the special conditions in different geographical regions that cover railways, lightweight trains, and metro that all have challenging wear, friction and lubrication conditions. This includes The Flåm Railway, Oslo Holmenkollen line and Trondheim´s Gråkallbanen tram line. By addressing some of the most challenging regions in Norway, the results obtained in the project are also expected to be applicable for other regions. The new products will be developed and tested in close cooperation with and between central companies in the Norwegian railway sector including Flåm Utvikling, Vy, Bane NOR, Sporveien, Boreal Bane, Norske tog, ELBA, Fuchs and R&D organisations (SINTEF & NTNU). The project is owned and managed by ELBA which is one of the main lubricant supply equipment in Norway and TransQ approved as supplier in the railway sector.

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Funding scheme:

BIA-Brukerstyrt innovasjonsarena