Yards

North American rail yards are a vital resource for operators, and come in a variety of sizes, types, and levels of technology used to operate them. Yard management methods can range from simple to complex including:

  • Manual switching operations are used, requiring the train driver to obtain an assigned route within the yard, exit the vehicle, manually throw the levers of the appropriate switches, and return to the vehicle to move along the route.
  • Power switches have been incorporated, but the buttons must be pushed manually to align the switches. Since they are electrically powered, less physical effort is required compared to throwing manual switches. Drivers obtain their route, exit the train, push the appropriate buttons to properly align switches, and return to the vehicle to drive train to the assigned location.
  • Yard is automated, but with train detection technology that has become inadequate, unreliable, or expensive and time consuming to maintain. System operation is negatively affected in conditions such as flooding, snow and ice, or when the deteriorated track/ballast conditions common to yards are present. 
  • Yards that have implemented state-of-the-art train detection technology that is highly reliable, robust, and can provide additional data for more efficient yard operations. These systems allow trains to enter, exit and maneuver freely through the yard without driver intervention. The ideal system provides the information needed to optimize resources and throughput, thereby increasing the operator’s overall revenue. This is in contrast to less efficient yard operations that can have a negative impact on operator profitability.

Challenges with switch point protection and yard automation

Complex track and switch layouts

Challenges

Yards typically have complex track and switch layouts that require modification of the rail for installation of the joints, bonds and wiring required for track circuit-based switch protection. Most wheel detectors installed in yards today as an alternative to track circuits do not require insulated joints and bonds, but still require drilling of the rail for installation. These processes are expensive and time consuming, and may be difficult or impossible in yards where tracks and/or switches are designed in tight formations.

Frauscher Benefits 

Easy Installation regardless of layout 

Frauscher wheel sensors do not require insulated joints or drilling of the rail that is required with other train and wheel detection systems. Each sensor is installed in five minutes using the Frauscher rail claw, with no additional special equipment required. Even in a large yard, installation of all wheel sensors can be completed in a short period of time. Yards with complex track or switch layouts or narrow spaces pose no difficulties, due to this quick and easy installation method and minimal space requirements. In addition to the significant savings on materials, time and manpower, the operator does not have to close the entire yard or sections of it for long periods of time, thereby maintaining productivity.

Installation – time and cost

Challenges

Track circuits are costly and time consuming to install. For each individual track circuit, the rail is drilled, and an insulated rail joint and wiring are installed. If track circuits are chosen to automate a busy yard, sections would have to be closed for long periods of time to complete the extensive work. This is costly for a number of reasons, including reduced yard productivity, cost of the required materials, and the man hours needed to complete this complex installation. Other wheel detection systems on the market also require drilling of the rail for installation, adding to cost and downtime.

Frauscher Benefits 

Easy Installation regardless of layout 

Frauscher wheel sensors do not require insulated joints or drilling of the rail that is required with other train and wheel detection systems. Each sensor is installed in five minutes using the Frauscher rail claw, with no additional special equipment required. Even in a large yard, installation of all wheel sensors can be completed in a short period of time. Yards with complex track or switch layouts or narrow spaces pose no difficulties, due to this quick and easy installation method and minimal space requirements. In addition to the significant savings on materials, time and manpower, the operator does not have to close the entire yard or sections of it for long periods of time, thereby maintaining productivity.

High maintenance and lifecycle costs

Challenges

The insulated joints and bonds used with track circuits require frequent inspection and maintenance, incur high lifecycle costs, and are expensive to replace. Track and ballast conditions in the yard must also be closely monitored to ensure proper operation. Other wheel detection systems require frequent maintenance and calibration in an attempt to reduce miscounts. These miscounts, which can occur frequently, require manual intervention to reset. AC/DC traction systems require a sophisticated type of track circuit that will likely add to maintenance requirements. These additional maintenance activities increase downtime and worker time on track.

Frauscher Benefits 

Remote and preventative maintenance

The optional Frauscher Diagnostic System FDS and Remote Monitoring Display RMD provide remote access to system operations and predictive maintenance information from all outdoor equipment locations in the yard. This capability allows the operator to troubleshoot the system from any location. Preventive and targeted maintenance can then be performed, often remotely, minimizing time spent on track for periodic resets and maintenance.

Switch point limitations – fouling

Challenges

Conventional switch protection systems are limited in their ability to reliably detect fouling at switches. For track circuits with insulated rail joints, accuracy is compromised if any rust, current leakage, etc. is present. The margin of error may be further increased where jointless circuits are in use.

Frauscher Benefits 

Accurate switch protection

By utilizing Frauscher wheel sensors for switch protection, fouling is reliably detected and collisions at the switch are prevented. Because the precise point of detection is simply the exact location of the wheel sensor, there are no issues related to joints or deteriorated conditions. The position of the wheel sensor does not change over time, so switch protection is consistently accurate.  

Adverse environmental conditions

Challenges

Yards equipped with conventional systems often find operations negatively affected by environmental conditions common to yard environments such as flooding, snow, and severe temperatures. Downtime can result in system delays for a transit yard, and direct loss of revenue in a freight yard.

Frauscher Benefits 

Performance unaffected by harsh environmental conditions, steel ties or low traffic

Frauscher wheel sensors are immune to the effects of harsh environmental influences, performing reliably and maintaining high uptime regardless of track and ballast condition. Water, snow, or ice that have accumulated in the yard, or extreme temperatures, will not adversely affect Frauscher systems. Axle counters are also immune to issues encountered by track circuits in yards that are equipped with steel ties. Finally, in yards that are less busy or not at full capacity, rusty rails that may result from infrequent passage of trains will not cause shunting issues, due to the inductive operating principle of our wheel sensors.

Limitations in scope of information

Challenges

Track circuits are unable to provide certain information that is important for the operator. One example is speed indication, which is needed to ensure proper braking. Inadequate speed control could result in damage to equipment or rolling stock or could cause a derailment. Track circuits are also unable to provide axle count for trains in the yard, information that is necessary to determine overall inventory and real-time capacity of each storage track.

Frauscher Benefits 

Advanced scope of information

The Frauscher Safe Ethernet FSE is a protocol that expands the system’s capabilities to provide information far beyond traditional vehicle detection. Additional real-time information that is available via the FAdCi and FSE includes the number of axles coming in, going out, and traveling within the yard, and more specific information such as the number of axles within a specific storage track section. This data is used by the yard management system to determine the remaining capacity of individual storage tracks. Also, a small track section designed with axle counters can detect cars before backing into the OS fouling zones. Speed indication information is also available to ensure precise braking, a function necessary to prevent damage to equipment, rolling stock, and a potential derailment.

Challenging track and ballast conditions

Challenges

Yards that are located in remote areas or have tracks that go unused for extended periods of time are subject to availability issues due to equipment failures. For these less active tracks, ballast and rail condition can cause shunting issues for track circuits, making them expensive or inappropriate for use in these yards. In yards where steel ties are installed, challenges for track circuits can also occur.

Frauscher Benefits 

Performance unaffected by harsh environmental conditions, steel ties or low traffic

Frauscher wheel sensors are immune to the effects of harsh environmental influences, performing reliably and maintaining high uptime regardless of track and ballast condition. Water, snow, or ice that have accumulated in the yard, as well as extreme temperatures, will not adversely affect Frauscher systems. Axle counters are immune to issues that are encountered by track circuits in yards equipped with steel ties. Finally, in yards that are less busy or not at full capacity, rusty rails that may result from infrequent passage of trains will not cause shunting issues due to the inductive operating principle of our wheel sensors.

Decreased throughput

Challenges

Frequent maintenance, or other equipment-based downtime, increases dwell time and decreases yard productivity. Decreased throughput in a transit yard can cause system delays, and the slowing or stoppage of freight yard traffic has a direct negative impact on profitability.  Short dwell times are therefore mandatory in yards, and necessary per Precision Scheduled Railroading (PSR) specifications.

Frauscher Benefits 

Reliable and stable performance

Downtime is reduced and consistent throughput is achieved due to the high reliability of Frauscher wheel sensors. When yard traffic is moving steadily and efficiently, freight operators are able to maintain and increase revenue, and meet the specifications of Precision Scheduled Railroading. Transits can move cars in and out of the yard quickly to accommodate daily use fluctuations.

Issues when implementing system upgrades

Challenges

Most train and wheel detection systems do not provide the option to gradually upgrade or “patch fix” an old or improperly functioning system with newer, more efficient technology. Since most systems are incompatible with one another, any new system installation would require the removal of the legacy system in order to install the new. This “all or nothing”, time-consuming replacement would cause major loss of productivity during the extended downtime in the yard. It would also prevent implementation of a gradual replacement schedule that would be beneficial where budgetary constraints might exist.

Frauscher Benefits 

Compatible with NAMUR sensors

The compatibility of Frauscher’s Wheel Sensor Converter WSC with NAMUR sensors is a benefit to operators. It eliminates the need to replace all of the NAMUR sensors in a yard when an equipment upgrade is desired,  providing the option to gradually replace them without affecting operations.

Can function as an overlay to existing track circuits

Frauscher’s axle counters can be used as an easy overlay to a yard’s existing signaling system, allowing patch fixes of hot spots. Patch fixing can continue and expand over time as access, budgets and other factors are considered. The systems can run in tandem for as long as the operator chooses, or until the yard is gradually cut over to the Frauscher system. This offers flexibility for the owner and operator of the yard, as upgrades can be completed in phases while the yard continues to operate at full capacity with no downtime. 

Solution

Efficient, cost effective and reliable yard automation and switch point protection solutions are possible using the Frauscher Advanced Counter FAdCi and Frauscher Wheel Sensor RSR110 or RSR180. Our waterproof (IP68 rated) wheel sensors are highly reliable in harsh environmental conditions such as flooding, snow, ice and extreme temperatures, and do not require modifications to track structure or switch layouts for installation. Frauscher axle counting systems can be interfaced to any existing crossing controller, using discreet IO or Ethernet. 

Frauscher axle counters have a maintenance cycle of once in two years, which is significantly less frequent than other systems. Advanced tools such as the Frauscher Diagnostic System FDS support remote diagnostics and data logging for further ease of maintenance. The remote diagnostic capability can reduce overall maintenance and life cycle costs, and also reduces time on track for personnel.

In automated yards, the FAdCi’s Counting Head Control CHC and Supervisor Track Sections STS advanced features can easily handle all rolling, switching, shunting, kicking, and shoving movements typical in a yard environment, without any issues.

These are just examples of the features and benefits that are included with every Frauscher axle counting system - superior performance and unique features essential for efficient operations.

Yard Applications

Non-Vital Switch Point Protection

Switch point protection can be achieved in a non-vital manner without fully automating the yard. One Frauscher Wheel Sensor RSR110 is installed around each entry or exit point of a switch, and train detection occurs via analog signal. Digital output would also be available by utilizing the Frauscher Wheel Sensor Converter WSC. The outputs of the RSR110 or WSC can be integrated with a suitable controller that performs the task of track vacancy detection, interfaces to the switch machine, and provides switch point protection.