Nencki Bogie Test Stand Evaluation Description

Nencki AG Tel.
+41 62 919 93 93
Railway and Vehicle Technology Fax +41 62 919 93 90
Gaswerkstrasse 27 www.nencki.ch
4901 Langenthal I Switzerland
Bogie Test Stand NBT
Technical Description for Evaluation purpose

Technical description Bogie Test Stand
1 Nencki Bogie Test Stand Evaluation
1.1 Why a Bogie Test Stand?
Increasing demand for bogie testing

Higher axle loads, reduction of noise, less wearing on the wheel/rail interface, reduction of life
cycle costs and specially the increasing conditions on bogies for high-speed trains are
demanding for an instruments which allow to test, to simulate the bogie's characteristics in the
workshop. Therefore rolling stock manufacturer and maintenance workshops are investing more
and more into bogie testing facilities.
What influences the derailing of a train?

There are two important factors which influence the
derailing index. On one side it is the lateral force (Y)
which is specially increasing in curves or in case of
strong side winds. On the other side it is the wheel load
(Q) which should be strong nough in order to resist the Y.
If for example one primary spring is too soft and the other
too hard this might cause different load on the wheels
and increasing derailing danger.
The purpose of a bogie test stand

The bogie test stand allows simulating the load of a vehicle or locomotive body in order to
control the wheel load and other important functions on a bogie after assembling or before
disassembling in the workshop
1.2 Short description of the functions of a bogie test stand
After positioning the bogie on the test stand, two hydraulic

cylinders apply a load (F) onto the application points
where normally the vehicle is fixed. The load is computer
controlled.
Now is determined how the simulated load is distributed to
each single wheel (Q).
Depending onto the available technology on the test
stand, it is possible to control the axle distance, axle
parallelism, suspension, unbalance run-out) and diameter
of wheels etc. fully automatic.
Nencki Bogie Test Stand Evaluation Description.doc Page 2 / 22

After the test all values are stored in the PC and can be printed as a protocol.
If several types of bogies and parameters must be tested, then it is necessary to use a machine
which can be easily adjusted for other bogie heights, gauges, from 2 to 3 axles etc.
The bogie test stand is the heart of the bogie maintenance

The bogie test stand allows a quick test of the conditions of a bogie before the maintenance
starts. The result is a base for the planning of the process. After maintaining, exchanging
components and assembling, the bogie and its functions can be examined entirely. This is the
only way to be sure that components have been assembled correctly.
It is much faster and economic to do modifications after realizing an error on the bogie stand
than disassembling the cabin of a vehicle after realizing the error after wheel weighing.
The test result which is the quality and function report is automatically stored and can be
recalled at any time in case of an incident.
1.3 Which type bogie test stand should be purchased?
Each application depends on the type of bogies which should be tested, on the regulations and
standards of the rolling stock and bogie manufacturer, the national and international rules of the
railway organisations and the railway company itself.
Nencki has developed a system which allows manufacturing a tailor-made customer and bogie
specific machine.
1.4 Important criteria for the evaluation of a bogie test stand
Criteria Our requirements

How many axles do our bogies have? 2 or/and 3
Which size do our bogie(s) have? See below
Which test and control features do we need?
(see chapter test functions)
Which test and control features could be required in the future
because of new regulation or new rolling stock?
What do we expect regarding after sales support and spare parts
supply?
Where the bogie test stand should be situated?
Which standards are relevant for the tests?

2 Range of Nencki bogie test stands

Nencki offers the below mentioned types of machines.
2.1 Nencki Bogie Press (NBP)

The press can apply with 2 load cylinders a force onto the bogie for assembly and disassembly
purpose. It is not possible to test the wheel load. This machine is not described in this
document.
2.2 Nencki Bogie Test Stand BASIC (NBT Basic)

The machine can test the wheel load and a some other functions. But it can not test any
parameter of the axle geometry. It is also not possible for any upgrading later on.
2.3 Nencki Bogie Test Stand COACH (NBT COACH)

The machine can test wheel loads, the axle geometry and many other functions. It is the optimal
solution for manufacturer and operators of EMU's, high-speed bogies, metro and tram bogies.
This type of machine is only suitable for 2 axles.
2.4 Nencki Bogie Test Stand LOCO (NBT LOCO)

This machine can test wheel load, axle geometry and many other functions on 2 and 3 axle
bogies of locomotives and EMU's etc.

2.5 Test and control functions of the Nencki Bogie Test Stands
Test feature Value

COACH
Basic
Loco
Load applied, synchronous or independent kN or mm

Wheel load on each wheel distributed kN
Wheel load compared between wheel, axles, average %
Height of points on the bogie frame from T.O.R mm
Height of secondary suspension from T.O.R. mm
Wheel diameter manually measured mm
Stiffness of each primary suspension kN/mm
(wheel load and suspension stroke under diff.loads)
Calculation of shim plates for primary suspension mm
Calculation of shim plates for secondary suspension mm
Secondary air suspension leakage test bar /pa
Air brake system leakage test bar / pa
Axle impedance measuring Ohm
Wheel shoulder distance mm
--- Axle distance (left and right side) mm
--- Axle parallelism (calculated from left and right distance) mm
--- --- Axle angle Mrad
--- --- Axle distance diagonal mm
--- Application of side force kN or mm
--- Movement of wheels in Y direction under vertical load or mm
under side force.
--- Wheel diameter automatic mm
--- Wheel run-out in X direction mm
--- Wheel run-out in Y direction mm
--- Wheel profile
--- Axle sensor function test
--- --- Changing of the wheel load under the condition that one kN
--- --- wheel will be
Measuring of lifted
tilting dQ/Q
angles Mrad
--- --- Testing wheel steering mechanism (radial bogie, Mrad, mm
navigator)

2.6 Checklist: Bogie dimensions and Load application points

(2 axle bogies)
Dimension Minimum Maximum

L Bogie over-all length
H Bogie over- all height
W Bogie over-all width
A Axle distance
G Gauge
WLP Lateral distance of loading points
HLP Height of loading point from T.O.R.
Bogie weight
Wheel diameter
Height of wheel flange

2.7 Checklist: Bogie dimensions and Load application points

(3 axle bogies)
Dimension Minimum Maximum

L Bogie over-all length
H Bogie over-all height
W Bogie over-all width
A1 Axle distance 1
A2 Axle distance 2
LF1 Loading points out of the centre, front
LF2 Loading points out of the centre, back
G Gauge
WLP Lateral distance of loading points
HLP Height of loading point from T.O.R
No. of loading points 2
Bogie weight
Wheel diameter
Height of wheel flange

3 Test functions
3.1 Wheel load measuring
The wheel load is the most important value on the bogie. The load of the vehicle should be
distributed equal to every single wheel. Unequal wheel load has very bad influence on the
derailing index, of running characteristic, wearing on the interface wheel/rail etc.
After application of the test load with the vertical load cylinders, the system records online how
the load is distributed to every single wheel.
3.1.1 Standards for loads and tolerances:

The designer/manufacturer of the bogie defines the range of the test loads. The values should
be written in the bogie's maintenance manual. Further standards are made by organizations
such as UIC, by the railway authority of a state or the operator of the railway/metro himself.
Standards are not given by the manufacturer of the bogie test stand.
The net weight of the bogie is recorded / calculated as well.
3.2 Compression stroke of the bogie under different loads

On the Nencki bogie test stands each vertical load cylinder is equipped with linear measuring
scale which allows the online recording of the compression stroke on the left and right side of
the bogie.

3.3 Calculation of shim plates for the primary suspension

Differences of the load between the wheels are often corrected by adding shim plates.
Nencki can provide the following modules:
3.3.1 Calculation of shim plates for primary suspension
In order to be able to calculate the height of the

shim plates for the primary suspension either
the stiffness of the primary springs (kN/mm) has
to be entered into the PC manually or better to
be calculated online during load application.
3.3.2 Testing of springs before installing the bogie

Please note: Disassembling of suspension on a bogie needs a lot of time. It is more productive
to test and combine the springs already before assembling the bogie. Nencki can also provide
advanced spring testing solutions.
3.4 Calculation of shim plates for the secondary suspension

Normally the height of shim plates for the secondary suspension depends on the values of the
height between T.O.R (Top of Rail) and top of secondary suspension.
The software module displays on which suspension which shim plate height should be added.
3.5 Measuring of height of points on top of the bogie frame

This traditional method is used mainly to measure the stroke of each suspension under different
loads. Therefore the operator positions leveling rulers over the wheel onto the frame and
measures the height or compares the height between the rulers with by an electronic digital
leveling instrument. After pushing a button the value is transferred to the PC.

3.5.1 Digital leveling instrument:
Nencki provides the TOPCON DL digital leveling instrument. TOPCON is international

represented. On request we can provide also other types as Zeiss, Trimple etc. In the scope of
supply are a tripod and an interface to the PC of the bogie test stand.
3.6 Axle distance measuring, axle parallelism
Beside the wheel load, the axle parallelism is

one of the most important characteristics which
influences the running behavior of a bogie.
Bogies with non-parallel axles tend to drive
always a curve. As a consequence excess
wearing on the wheel / rail interface occurs as
well as vibration and noise which the
passengers will not appreciate.
Famous rolling stock manufacturers of high
speed trains recommend the measuring of the
axle parallelism during production as well as in
the maintenance of bogies.
During application of load onto the bogie, the wheel measuring carriages can move in
longitudinal direction (X) together with the wheels. Each movement is recorded online and
precise with the help of the integrated linear measuring scales within +/- 0.1 mm.
The bogie axle parallelism is calculated from the difference between the r.h. and l.h. axle
distance.

3.7 Measuring of wheel shoulder distance
Also called “wheel back to back” or “wheel

inner side” distance.
This distance shows whether the wheels have
moved on the axle. In such case the gauge has
changed. This function is specially needed in
bogie maintenance shops.
With the help of two laser sensors the distance
is measured fully automatic within +/- 0.2 mm
Nencki standard includes the measuring in one
position at the wheel rim.
In some countries it is required to measure the wheel shoulder distance on several points on the
wheel rim. In order to be able to fulfil this function fully automatic the wheels must be rotated on
the bogie test stand as described in chapter “rotation of wheels”.
3.8 Axle angle
If the angle of the axles is not correct, the

bogie tends to drive always in a curve. This
causes more wearing on the wheel/rail
interface, more vibrations and noise and
disturbs the driving of a sinus curve, the so
called wobbling.
3.9 Axle distance diagonal
In combination of wheel shoulder distance

(indirect gauge measuring) and the axle
distance the theoretical diagonal axle distance
can be calculated.

3.10 Leakage test of air suspension
This function allows testing the leak proofness

of the bolster under load and is an immense
help to adjust the height of top of suspension
over T.O.R. already on the bogie test stand.
After automatic pumping the required pressure
into the bolster, the load will be applied during
a free programmable time.
Any leakage would be recognized thanks to the
electronic pressure difference control. Time
and pressure are displayed online in a graphic.
If the pressure difference is out of the
programmed tolerance, an error will be displayed.
Additionally the height of top of the bolster compared with T.O.R is displayed as well. Thanks to
those values corrections as e.g. equalizing the height on the right and left side of the bogie can
be made easily.
Each bolster can be filled with air pressure and tested individually.
3.11 Testing of air leakage in the brake system

The above described air suspension leakage test unit can be e used as well for testing the
leakage of air in the brake system. If required the bogie test stand can be equipped with a third
(additional unit) for this test, which is more user-friendly.
3.12 Testing the function of the tilting mechanism
Some high-speed trains such as Pendolino

have this function which allows the tilting of the
vehicle on the bogie in order to achieve higher
speed in curves.

3.13 Wheel “Run-out” measuring
Also called “wheel concentricity, “wheel out of

balance”
Also this function is mainly used in
maintenance shops. During rotating the wheels
(only with very slow speed) the following
described values can be measured and
graphically recorded.
For these functions a “Y-Centering unit” is
required.
3.13.1 Concentricity of the wheels in Y-direction. (Wheel shoulder)

The concentricity is recorded with the help of each single wheel shoulder distance sensor.
It is shown in a curve and as an absolute value.
3.13.2 Concentricity of the wheels in Z-direction (diameter oval or not?)

The concentricity in vertical direction is recorded by means of rope governors. More about rope
governor see also in chapter “Electronic rope governors”
The result is shown in a curve and as an absolute value.
3.14 Wheel diameter measuring

One reason for unequal wheel loads can be different diameters on the wheel. Therefore it is
essential to know the exact wheel diameters. Nencki can provide the following alternatives for
wheel diameter measuring:
3.14.1 Manual input of wheel diameters on the PC.

The customer uses his own diameter measuring instrument. The diameters can be entered on
the PC manually.

3.14.2 Semi-automatic wheel diameter measuring.
The operator places the diameter measuring

instrument on each wheel. Basing on 3-points,
the diameter is calculated automatically and
recorded.
With an optional interface the diameters can be
transferred to the PC.
3.14.3 3. Fully-automatic wheel diameter measuring
While the bogie wheel is turning, a measuring

wheel with integrated encoder records fully
automatic the bogie wheel circumference.
The diameter is measured 70 mm (standard,
other on request) from the wheel rim.

3.15 Testing of Navigator Function
Bogies with Navigator function also known as “Wheel steering bogies” and “Radial bogies”.
Thanks to the technology of changing the angle of the axles during running, trains achieve
higher speed in curve or metros are less noisy in curves.
3.16 Function test of the axle rotation sensor

This function is very interesting for maintenance shops. It shows whether the axle rotation
sensor is working properly. While turning the wheels (wheel rotation unit necessary) the
deflection comparison of the sensors value is made.
3.17 Axle rotating sensor

This allows the testing of the correct function of the mentioned sensor. Data output according to
the customer specific sensor. Values such as power supply, signal evaluation, nominal and the
actual transmitter values are possible.
In order to offer the correct solution, technical data of the axle rotating sensor should be
specified before.
This function can be realized only with rotating wheels.
3.18 Wheel unloading test, d Q/Q

This test provides information about the behavior of the suspension at the end of curves or on
uneven tracks.
While one wheel is lifted, the loads on the other wheels are measured. Interesting is the
smallest wheel load (the unloading). After lifting each wheel, all smallest wheel loads are
compared. A big difference would be an indicator that one of the primary suspensions is not
working correctly.
This test is based on the EN 14363 standard.

4 Mechanic
4.1 Components of the bogie test stand
1 = Load cylinder
2 = Horizontal beam
3 = Adapter
4 = Height adjustment
5 = Dropping rail
6 = Wheel measuring
carriage
7 = Hydraulic unit
Photo Swiss Railways Yverdon
8 = Digital levelling
instrument for
measuring of heights
9 = PC cabinet
10 = Electro cabinet
11 = Floor cover
Photo KTMB Malaysia

4.2 Definition of the geometry of the Nencki bogie test stand
Z = Height X = longitudinal in driving direction Y = transversal
4.3 Positioning of the bogie test stand in the work-shop
4.3.1 The “pit-version”
The rails in the workshop and the rails of the bogie test
stand have the same level. The parts with the base frame
and wheel measuring carriages stand in a pit under floor.
The bogies enter the test stand from on side and are
leaving at the other side. This guarantees an efficient
workflow and no additional handling is necessary.
Photo Pesa Poland

4.3.2 The “over-floor version”
This solution is recommended if the civil construction of the

building does not allow a pit or if the bogie test stand will
be positioned after a certain period on another place.
The bogie test stand can be equipped with (an) additional
support stand(s) on the in- and outlet side of the machine.
Bogie must be lifted/dropped with the help of the enduser's
crane onto/from the in-/outlet support stand.
Photo Dalian Locomotive China
4.4 The closed frame construction

Because to the closed frame design the Nencki bogie test
stand is a detached contained unit such as a machine tool.
This design has the advantage that the test force is
absorbed from the test stand itself - no force is applied to
the floor of the user's workshop. This has, in comparison
with a more economic solution which will be screwed with
anchors directly onto the floor, the following advantages:
• No special foundation necessary. Foundation must bear the load of the machine and the
bogie itself only
• The assembly of the machine is faster and easier
• The machine can be easily tested as a complete unit in the manufacturer's premises
• The precision of the machine is better
The base of the Nencki bogie test stand is a welded steel construction which can be separated
into two parts for transportation. It is equipped with 16 pcs. (2- axle machine) anti-vibration
leveling feet which allow the correct alignment of the machine during assembly.
Two rigid lateral twin columns support the horizontal beam with the load cylinders.

5 The test report

All test values are stored in the test result database and can be restored at any time.
If one of the test values that have been determined for a bogie lies outside the defined
tolerance, the fault will be displayed and saved in the report. If a value is incorrect, then the
bogie is assigned the status FAULTY in the report.
A report of totally eight pages report can be generated and printed. The end-user himself can
create new test reports. It can be selected which values should be shown in which column, line
and page.
It is also possible to show graphics in the report.

The data are stored in an Access database. This open structure allows simple integration into
higher-level systems.

6 Technical data (2-axle Bogie Test Stand NBT BASIC)
Bogie dimensions and test load
Maximum bogie dimensions LxWxH in mm Approx. 5000 x 3300 x 1200
Maximum bogie weight 12 to
Minimum axle distance To be specified
Gauge fix To be specified
Maximum test load, following versions available 2 x 250 kN

2 x 150 kN (standard)
Machine dimensions
Machine dimensions, without hydraulic and electrical cabinet L x W x H approx.

4500 x 4500 x 5000 mm
Machine weight approx. 13 to
Hydraulic
Maximum pressure 240 bar
Tank 250 liter
Electric supply
Voltage 3 x 400 V, 1 x 230 V, 50 Hz, +/-

5%
Others on request
Fuse 63 A
Consumption Approx. 22 kW/h

Depending on the functions
Accuracy of the machine
Precision of load application +/- 100 N
Precision of wheel load measuring +/- 200 N

7 Technical data (2-axle Bogie Test Stand NBT COACH)
Minimum axle distance 1800 mm
Maximum axle distance 3000 mm
Gauges (fix or adjustable available) 850 - 1676 mm
Maximum test load, following versions available 2 x 250 kN (standard)

2 x 150 kN
2 x 300 kN
Machine dimensions

4500 x 4500 x 5000 mm
Hydraulic
Tank 250 liter
Electric supply
Voltage 3 x 400 V, 1 x 230 V, 50 Hz, +/-

5%
Others on request
Fuse 63 A

Precision of axle distance measuring +/- 0.2 mm
Precision of air leakage measuring 0.05 bar

8 Technical data (3-axle Bogie Test Stand NBT LOCO)
Minimum axle distance (axle 1 – axle 2) 2000 mm
Maximum axle distance (axle 1 – axle 3) 5000 mm
Gauges (fix or adjustable available) 850 – 1676 mm
Maximum test load, following versions available 2 x 300 kN

Higher on request
Machine dimensions

7500 x 4500 x 7500 mm
Hydraulic
Tank 250 liter
Electric supply
Voltage 3 x 400 V, 1 x 230 V, 50 Hz,

+/- 5%
Others on request
Fuse 63 A

Precision of axle distance measuring +/- 0.2 mm
Precision of air leakage measuring 0.05 bar

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Nencki AG Tel.

Bogie Test Stand NBT

Technical Description for Evaluation purpose

1 Nencki Bogie Test Stand Evaluation

1.1 Why a Bogie Test Stand?

Increasing demand for bogie testing

What influences the derailing of a train?

The purpose of a bogie test stand

1.2 Short description of the functions of a bogie test stand

After positioning the bogie on the test stand, two hydraulic

Nencki Bogie Test Stand Evaluation Description.doc Page 2 / 22

The bogie test stand is the heart of the bogie maintenance

1.3 Which type bogie test stand should be purchased?

1.4 Important criteria for the evaluation of a bogie test stand

Criteria Our requirements

Nencki Bogie Test Stand Evaluation Description.doc Page 3 / 22

2 Range of Nencki bogie test stands

2.1 Nencki Bogie Press (NBP)

2.2 Nencki Bogie Test Stand BASIC (NBT Basic)

2.3 Nencki Bogie Test Stand COACH (NBT COACH)

2.4 Nencki Bogie Test Stand LOCO (NBT LOCO)

Nencki Bogie Test Stand Evaluation Description.doc Page 4 / 22

Test feature Value

Load applied, synchronous or independent kN or mm

Nencki Bogie Test Stand Evaluation Description.doc Page 5 / 22

2.6 Checklist: Bogie dimensions and Load application points

Dimension Minimum Maximum

Nencki Bogie Test Stand Evaluation Description.doc Page 6 / 22

2.7 Checklist: Bogie dimensions and Load application points

Dimension Minimum Maximum

Nencki Bogie Test Stand Evaluation Description.doc Page 7 / 22

3.1 Wheel load measuring

3.1.1 Standards for loads and tolerances:

3.2 Compression stroke of the bogie under different loads

Nencki Bogie Test Stand Evaluation Description.doc Page 8 / 22

3.3 Calculation of shim plates for the primary suspension

3.3.1 Calculation of shim plates for primary suspension

In order to be able to calculate the height of the

3.3.2 Testing of springs before installing the bogie

3.4 Calculation of shim plates for the secondary suspension

3.5 Measuring of height of points on top of the bogie frame

Nencki Bogie Test Stand Evaluation Description.doc Page 9 / 22

3.5.1 Digital leveling instrument:

Nencki provides the TOPCON DL digital leveling instrument. TOPCON is international

3.6 Axle distance measuring, axle parallelism

Beside the wheel load, the axle parallelism is

Nencki Bogie Test Stand Evaluation Description.doc Page 10 / 22

3.7 Measuring of wheel shoulder distance

Also called “wheel back to back” or “wheel

3.8 Axle angle

If the angle of the axles is not correct, the

3.9 Axle distance diagonal

In combination of wheel shoulder distance

Nencki Bogie Test Stand Evaluation Description.doc Page 11 / 22

3.10 Leakage test of air suspension

This function allows testing the leak proofness

3.11 Testing of air leakage in the brake system

3.12 Testing the function of the tilting mechanism

Some high-speed trains such as Pendolino

Nencki Bogie Test Stand Evaluation Description.doc Page 12 / 22