Mechanical Tests

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Italcertifer S.p.A. Laboratories offer a wide range of mechanical tests in the railway sector thanks to many years of experience in the field.

Italcertifer Labs directly follow up the test activities for the entire duration of the process: from designing the measurement chain, to setting up the sensors, up to the issue of the technical report passing through the performance of the test, as well as the analysis and processing of the acquired data.

All of these phases are characterized by the best competence and professionalism of the staff and the use of cutting-edge techniques and instrumentation, all in accordance with national or international reference standards.

The mechanical tests performed by the Italcertifer Laboratories are carried out both in static/quasi-static mode, also through the use of test benches in assets or in use, and in dynamic mode (that is, through in service tests on the track line).

During their passage at the prescribed speeds, Railway vehicles may generate unwanted air displacements and pressure blows that negatively impact both on the outside (i.e., workers or passengers on platforms, infrastructures, other crossing vehicles) and inside the vehicle itself (i.e., passengers and crew members/on-board staff).

Aerodynamic tests on these vehicles are necessary to verify their compliance with the standards required by the European Technical Specifications for Interoperability (TSI), according to the procedures described in the regulatory package relating to EN-14067.

Thanks to its know-how and instrumentation, the Italcertifer Laboratory is able to set up complete verified measurement chains, and – according to the reference standard – it can carry out tests aimed at measuring:

Air displacement on passengers on platforms and workers operating on the line (Slipstream effects);
Head Pressure Pulse;
Maximum variation of the pressure in the tunnels;
Custom tests on the ground and on board the train (internal/external), concerning pressure and wind speed.

The Laboratories of Italcertifer S.p.A. have a diagnostic train coach on which there is a track geometry acquisition system. The core of the system is the TGMS (Track Geometry Measurement System) module, which in turn consists of a laser module, a camera, and an inertial platform. There is also a GPS localization system that allows the synchronization of the measurements with the position of the line.

The geometric parameters acquired and processed by the system every 0.25 m are: longitudinal level, cant, alignment, track twist, radius of curvature, rail profile, track gauge, rail wear, real equivalent taper and steering index.

The system complies with both EN13848 and RFI standards for measuring the geometric quality of the track; it has also been verified according to the EN13848-2 Standard.

The main uses concern:

analysis of the track geometry (according to EN14363) and profiles for the purpose of driving dynamics tests
the calculation of the equivalent conicity as described in the EN 15302 Standard;
track diagnostics according to RFI operating standards.

Italcertifer S.p.A. Laboratories have test benches to carry out the following tests at their premises: track twist, weighing, souplesse, and flat curve; these tests are necessary to achieve the requirements to be able to carry out any running behaviour dynamic test

With a view to customer loyalty, Italcertifer Labs currently also have a mobile multifunctional test bench.

This bench has been created to combine regulatory and logistical needs, and to allow the customer to be able to carry out the following tests in the location he deems most appropriate:

Weighing (CEI EN 50215, EN 14363, EN15654);
Track Twist (§6.1.5.2 e §6.1.5.3 EN 14363[BL1] [MM2] );
Souplesse/roll coefficient/sway (UIC 505)

This can reduce costs and time due to planning a possible transfer of rolling stock to be tested in our laboratories.

Equipped with the latest technologies, the mobile multifunctional bench uses customized and non-commercial components, made to internal specifications, dictated by our know-how.

Designed and built to perform static tests on railway vehicles, today it represents the best solution to be able to carry out the on-site tests listed above.

Running behaviour of an on-line vehicle is one of the most important areas of railway traffic, not least for the fundamental impact it has on safety.

The verification of this behaviour is carried out through running dynamic behaviour tests dedicated to checking that the vehicle is in line with current Italian and European standards, prescribed by national standards and Technical Specifications for Interoperability (TSI). The methods for carrying out these tests are detailed in the reference standard EN-14363.

Italcertifer Laboratories are able to offer the complete package of design, management, execution and data analysis on driving dynamics tests according to EN-14363, starting from static tests up to on-line tests. All these things are provided thanks to the experience and know-how of its technical and management staff now consolidated over the years on EMU/DMU, locomotives, train coaches, bogies/wagons, work vehicles, and internal instrumentation sized to cover measuring chains of hundreds of channels, including telemetry.

In particular, the Lab is able to perform:

Static tests (Safety against derailment during circulation on twisted track)
Instrumented plane curve (§6.1.5.2 EN14363)
Track twisted curve (§6.1.5.1 EN14363)
Test bench track twist (§6.1.5.2 EN14363)
Souplesse (UIC 505 - EN15302)
Weighing (EN50215 - EN15654-2)

Tests on the line:

Driving dynamics - §7 EN14363 with simplified method and normal method with instrumented rooms
Calculation of the equivalent conicity following the measurement of the real profiles of wheels and track
Running comfort according to EN12299
Custom measures.

Italcertifer S.p.A. Laboratories have the skills and all the instrumentation necessary to perform noise tests emitted by vehicles, systems and sub-systems in the railway sector in accordance with the European reference standards.

Laboratory technicians and engineers perform:

Measures for the assessment of the acoustic pressure level and verification of compliance with the noise limits emitted outside the railway vehicle and defined by the TSI 1304/2014 and ISO 3095 regulations. In accordance with the standard regulations, tests are carried out with the vehicle in the following conditions: parking, starting, and transit at maximum speed. According to the type of test performed, the measurement equipment is positioned at well-defined measurement points.
Measures for the assessment of the acoustic pressure level and frequency and verification of compliance with the limits of the noise emitted inside the driver's cab of the railway vehicle defined by the TSI 1304/2014 and EN 15892 regulations. In accordance with the standard regulations, tests are carried out with the vehicle in transit at maximum speed and in parking condition while the acoustic warning horns are in operation (evaluation of amplitude and frequency). The measurement instrumentation is positioned near the driver's ear and at well-defined measurement points, based on the type of test performed.
Measures for the assessment of the acoustic pressure level and frequency and verification of compliance with the limits of the acoustic warning devices (horns) outside the railway vehicle, defined by the TSI 1302/2014 and EN 15153-2 regulations. In accordance with the regulations, tests are carried out with the vehicle parked while the acoustic warning horns are in operation. The measuring instrumentation is positioned in measuring points well defined by the regulations.

The measurement instrumentation used is in class 1 – calibrators and phonometers (sound level meters) and complies with the provisions of the international reference standard.

Italcertifer Laboratories also carry out both accelerometric measurements on components and vibration measurements in accordance with the provisions of the Italian Law Legislative Decree 81/2008 and the ISO 2631-1 and ISO 5349 Standards.

By means of accelerometric measurements it is possible both to carry out support activities for the design of components, for example the validation of numerical models such as those with finite elements (FEM), and to carry out investigation activities aimed at identifying the causes of possible problems.

The vibration measurements carried out in the field of safety in the workplace contemplate those in the whole body, which occur in cases where vibrations are transmitted to the human body through several points, such as, for example, cabins of railway vehicles (working vehicles and non-working vehicles as well), forklifts, mobile platforms, etc., where the operator can assume different positions (sitting and standing positions).

On the other hand, hand-arm measurements involve the transmission between the human body and the generic machine through handles, steering wheels and joysticks or the interaction with manual tools (screwdrivers, drills, grinders, etc.) and have the effect of generating damage to the muscular system as well as the skeletal apparatus.

All the measurement instrumentation used is subject to periodic calibration and is kept under control by the Italcertifer Laboratory through an adequate metrological confirmation process.