Railway applications - Axleboxes - Performance testing

This European Standard specifies the principles and methods for a rig performance test of the system of axlebox rolling bearing(s), housing, seal(s) and grease. Test parameters and minimum performance requirements for vehicles in operation on main lines are specified. Different test parameters and performance requirements may be selected for vehicles in operation on other networks (e.g. urban rail). This standard is historically developed for outboard applications but can be used for vehicles with other bearing arrangements (e.g.: inboard application or single wheels).
It gives some possible examples where a "sequenced performance test" addresses the broad range of different service conditions within a specific application or vehicle platform into account.
It describes in detail the water tightness test and basic principles and minimum requirements for a field test.
This European Standard only applies to axleboxes equipped with rolling bearings and greases according to EN 12080 and EN 12081.

Bahnanwendungen - Radsatzlager - Prüfung des Leistungsvermögens

Diese Europäische Norm legt die Grundlagen und Verfahren für die Prüfung des Leistungsvermögens auf dem Prüfstand der Baugruppe Radsatzlager, bestehend aus Wälzlager(n), Lagergehäuse, Dichtung(en) und Schmierfett, fest. Für Fahrzeuge im Betrieb auf Vollbahnen sind die Prüfbedingungen und Mindestleistungsanforderungen spezifiziert. Für Fahrzeuge im Betrieb auf anderen Schienennetzen dürfen davon abweichende Prüfbedingungen und Leistungsanforderungen gewählt werden (z. B. städtische Schienenbahnen). Diese Norm wurde ursprünglich für Außenlagerungen entwickelt, gilt jedoch auch für Fahrzeuge mit anderen Lageranordnungen (z. B. Innenlagerungen oder Einzelräder).
Sie enthält mögliche Beispiele, in denen eine „sequentielle Leistungsprüfung“ die breite Vielfalt von verschiedenen Betriebsbedingungen innerhalb einer spezifischen Anwendung oder einer Fahrzeugplattform berücksichtigt.
Sie beschreibt detailliert eine Wasserdichtheitsprüfung und die Grundlagen und Mindestanforderungen einer Betriebserprobung.
Diese Europäische Norm gilt nur für Radsatzlager, die mit Wälzlagern und Schmierfetten nach EN 12080 und EN 12081 ausgestattet sind.

Applications ferroviaires - Boïtes d'essieux - Essais de performance

Železniške naprave - Ohišja ležajev kolesnih dvojic - Preskušanje delovanja

General Information

Status
Published
Publication Date
20-Jul-2021
Technical Committee
Current Stage
6060 - National Implementation/Publication (Adopted Project)
Start Date
01-Jul-2021
Due Date
05-Sep-2021
Completion Date
21-Jul-2021

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SLOVENSKI STANDARD
SIST EN 12082:2017+A1:2021
01-september-2021
Železniške naprave - Ohišja ležajev kolesnih dvojic - Preskušanje delovanja
Railway applications - Axleboxes - Performance testing
Bahnanwendungen - Radsatzlager - Prüfung des Leistungsvermögens
Applications ferroviaires - Boïtes d'essieux - Essais de performance
Ta slovenski standard je istoveten z: EN 12082:2017+A1:2021
ICS:
45.040 Materiali in deli za železniško Materials and components
tehniko for railway engineering
SIST EN 12082:2017+A1:2021 en,fr,de

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST EN 12082:2017+A1:2021
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SIST EN 12082:2017+A1:2021
EN 12082:2017+A1
EUROPEAN STANDARD
NORME EUROPÉENNE
June 2021
EUROPÄISCHE NORM
ICS 45.040 Supersedes EN 12082:2017
English Version
Railway applications - Axleboxes - Performance testing

Applications ferroviaires - Boïtes d'essieux - Essais de Bahnanwendungen - Radsatzlager - Prüfung des

performance Leistungsvermögens

This European Standard was approved by CEN on 19 June 2017 and includes Amendment 1 approved by CEN on 2 May 2021.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this

European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references

concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN

member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by

translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management

Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,

Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,

Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and

United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels

© 2021 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 12082:2017+A1:2021 E

worldwide for CEN national Members.
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SIST EN 12082:2017+A1:2021
EN 12082:2017+A1:2021 (E)
Contents Page

European foreword ....................................................................................................................................................... 4

Introduction .................................................................................................................................................................... 5

1 Scope .................................................................................................................................................................... 6

2 Normative references ................................................................................................................................ 6

3 Terms and definitions ................................................................................................................................... 6

4 Symbols and abbreviations ......................................................................................................................... 8

5 Test specification ......................................................................................................................................... 10

5.1 General requirements ................................................................................................................................ 10

5.2 Test specification content ......................................................................................................................... 10

5.2.1 General ............................................................................................................................................................. 10

5.2.2 Rig tests ............................................................................................................................................................ 10

5.2.3 Field test .......................................................................................................................................................... 11

6 Water tightness test .................................................................................................................................... 11

7 Rig performance test ................................................................................................................................... 12

7.1 General ............................................................................................................................................................. 12

7.2 Test execution ............................................................................................................................................... 12

7.2.1 Test rig ............................................................................................................................................................. 12

7.2.2 Test parameters............................................................................................................................................ 13

7.3 Carrying out the test .................................................................................................................................... 14

7.3.1 Pre-test ............................................................................................................................................................. 14

7.3.2 Performance test .......................................................................................................................................... 15

7.4 Acceptance criteria ...................................................................................................................................... 15

7.4.1 Results obtained during the test ............................................................................................................. 15

7.4.2 Results obtained after the test ................................................................................................................ 16

7.5 Performance test report ............................................................................................................................ 16

8 Field test .......................................................................................................................................................... 17

8.1 General ............................................................................................................................................................. 17

8.2 Carrying out the test .................................................................................................................................... 17

8.3 Test parameters............................................................................................................................................ 18

8.4 Acceptance criteria ...................................................................................................................................... 18

8.4.1 Results to be obtained at intermediate inspections during the test ......................................... 18

8.4.2 Results to be obtained after the test ..................................................................................................... 18

8.5 Field test report ............................................................................................................................................ 18

Annex A (normative) Rig performance test ..................................................................................................... 20

A.1 Schematic examples of test rigs .............................................................................................................. 20

A.2 Temperature measurements ................................................................................................................... 21

A.3 Grease sampling zones ............................................................................................................................... 23

A.4 Definition of forces ...................................................................................................................................... 24

A.5 Definition of test cycles .............................................................................................................................. 24

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SIST EN 12082:2017+A1:2021
EN 12082:2017+A1:2021 (E)

A.5.1 Speed Classes and cumulative distances for testing ........................................................................ 24

A.5.2 Conditions for sequenced tests ................................................................................................................ 25

A.5.3 Particular conditions for similar rolling bearing(s), grease or box housing .......................... 25

A.6 Graphical presentation of test cycles .................................................................................................... 26

A.7 Temperature criteria .................................................................................................................................. 27

A.8 Mechanical and physico-chemical acceptance criteria ................................................................... 28

A.8.1 Mechanical criteria ...................................................................................................................................... 28

A.8.2 Physico-chemical criteria .......................................................................................................................... 29

A.9 Reference to existing approval results ................................................................................................. 31

A.9.1 General ............................................................................................................................................................. 31

A.9.2 Preconditions for applicability of existing results ........................................................................... 31

Annex B (informative) Sequenced performance tests ................................................................................. 34

B.1 General ............................................................................................................................................................. 34

B.2 High Speed Train example ........................................................................................................................ 34

B.3 Passenger train example............................................................................................................................ 36

B.4 Freight train example.................................................................................................................................. 37

B.5 Peri-urban train example .......................................................................................................................... 39

Annex C (normative) Water tightness test ....................................................................................................... 41

C.1 General ............................................................................................................................................................. 41

C.2 Test conditions .............................................................................................................................................. 41

C.3 Test procedure .............................................................................................................................................. 42

C.4 Pass/fail criterion ......................................................................................................................................... 42

C.5 Test report ...................................................................................................................................................... 42

C.6 Sketches ........................................................................................................................................................... 43

C.6.1 Classic application ........................................................................................................................................ 43

C.6.2 Application with dynamic seals on both sides of the axlebox ...................................................... 44

Annex D (informative) Temperature evaluation examples ....................................................................... 45

D.1 General ............................................................................................................................................................. 45

D.2 Nomenclature................................................................................................................................................. 45

D.3 Criterion A ....................................................................................................................................................... 45

D.4 Criterion B ....................................................................................................................................................... 46

D.5 Criterion C ....................................................................................................................................................... 46

D.6 Criterion D ....................................................................................................................................................... 47

D.7 Criterion E1 ..................................................................................................................................................... 47

D.8 Criterion E2 ..................................................................................................................................................... 47

Bibliography ................................................................................................................................................................. 49

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SIST EN 12082:2017+A1:2021
EN 12082:2017+A1:2021 (E)
European foreword

This document (EN 12082:2017+A1:2021) has been prepared by Technical Committee CEN/TC 256

“Railway Applications”, the secretariat of which is held by DIN.

This European Standard shall be given the status of a national standard, either by publication of an

identical text or by endorsement, at the latest by December 2021, and conflicting national standards

shall be withdrawn at the latest by December 2021.

Attention is drawn to the possibility that some of the elements of this document may be the subject of

patent rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent

rights.
This document supersedes !EN 12082:2017".
!The main changes with respect to the previous edition are listed below:
— A clarification on how to account for stops and variations in speed is added

— A clarification on how to evaluate the first four elementary trips as well as the pre-test is added

— A clarification on which type of axlebox to be tested in the field is added

— The location of the temperature sensor position in the target zone is better specified

— The temperature criteria are clarified and Annex D (informative) gives examples on evaluation

— Formula A.4 in A.9.2 “Preconditions for applicability of existing results” is corrected

— Annex ZA is removed since it is not relevant for this norm being a testing standard

NOTE Clause 6 of the previous version of the EN (EN 12082:2007+A1:2010) is referred to in both TSI's on

rolling stock and remains mandatory. Clause 7 of this version of the EN is an improvement of the Clause 6 of the

previous version and is therefore equivalent."
This document includes Amendment 1 approved by CEN on 11 April 2021.

The start and finish of text introduced or altered by amendment is indicated in the text by tags !".

!deleted text"

According to the CEN-CENELEC Internal Regulations, the national standards organisations of the

following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria,

Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia,

France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta,

Netherlands, Norway, Poland, Portugal, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland,

Turkey and the United Kingdom.
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SIST EN 12082:2017+A1:2021
EN 12082:2017+A1:2021 (E)
Introduction

To improve the reliability, availability, durability, the high speed capacity and maintenance of the

European rail transportation system, there is a need to ensure the required quality, safety and efficiency

of axleboxes that are covered by the set of standards: EN 12080, EN 12081 and EN 12082.

This European Standard has been drawn up with the purpose of standardizing the performance testing

of axleboxes for all types of rolling stock to ensure suitability for the required service, i.e. that the

assembly of box housing, bearing(s), seal(s) and grease is well suited for the service requirements.

This testing is made in two stages, a “rig test”, described in detail in this European Standard, and a “field

test”. The extent of testing to be applied depends on the novelty of bearing design, seal design, grease

formulation and/or box housing, as well as the application (see EN 12080 and EN 12081).

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SIST EN 12082:2017+A1:2021
EN 12082:2017+A1:2021 (E)
1 Scope

This European Standard specifies the principles and methods for a rig performance test of the system of

axlebox rolling bearing(s), housing, seal(s) and grease. Test parameters and minimum performance

requirements for vehicles in operation on main lines are specified. Different test parameters and

performance requirements may be selected for vehicles in operation on other networks (e.g. urban

rail). This standard is historically developed for outboard applications but can be used for vehicles with

other bearing arrangements (e.g.: inboard application or single wheels).

It gives some possible examples where a “sequenced performance test” addresses the broad range of

different service conditions within a specific application or vehicle platform into account.

It describes in detail the water tightness test and basic principles and minimum requirements for a field

test.

This European Standard only applies to axleboxes equipped with rolling bearings and greases according

to EN 12080 and EN 12081.
2 Normative references

The following documents, in whole or in part, are normatively referenced in this document and are

indispensable for its application. For dated references, only the edition cited applies. For undated

references, the latest edition of the referenced document (including any amendments) applies.

ASTM D7303:2012, Standard Test Method for Determination of Metals in Lubricating Greases by

Inductively Coupled Plasma Atomic Emission Spectrometry

DIN 51460-1:2007, Testing of petroleum products - Method for sample preparation - Part 1: Microwave

incineration

DIN 51829:2013, Petroleum products - Determination of additive and wear elements in greases - Analysis

by wavelength dispersive X-ray fluorescence spectrometry
EN 12080:2017, Railway applications - Axleboxes - Rolling bearings
!EN 12081", Railway applications - Axleboxes - Lubricating greases
!EN 15663", Railway applications - Definition of vehicle reference masses

!EN ISO 11885", Water quality - Determination of selected elements by inductively coupled plasma

optical emission spectrometry (ICP-OES) (ISO 11885:2007)

ISO 15243:2017, Rolling bearings — Damage and failures — Terms, characteristics and causes

3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
axlebox

assembly consisting of the following major components: rolling bearing(s), grease, seal(s) and box

housing

Note 1 to entry: Further components such as axle end cap components, bearing sleeve, box cover(s), distance

rings, fasteners, labyrinth(s) may be also part of the assembly but their presence depends on the axlebox type

design.
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SIST EN 12082:2017+A1:2021
EN 12082:2017+A1:2021 (E)
3.2
box housing
structural component which contains rolling bearing(s), seal(s) and grease
3.3
ovality

change (permanent deformation) in the bore's shape of an axlebox housing becoming slightly oval

3.4
rolling bearing

bearing operating with rolling motion between the parts, supporting load and moving in relation to

each other
3.5
cartridge bearing

rolling bearing with two or more rows of rolling elements within a self-contained unit, greased and

equipped with integral seals
3.6
grease

semi-solid lubricant, which consists of a thickener and additives dispersed in lubricating oil

3.7
seal

component that protects the rolling bearing(s) against ingress of water and dust and retains grease in

the rolling bearing(s)
3.8
roller set
assembly of cage and rollers
3.9.1
inboard

!with reference to an axlebox with more than one bearing row" designates the bearing row closer

to the middle of the wheelset or the test rig
3.9.2
inboard

with reference to the vehicle or application, designates a configuration with rolling bearings that are

positioned on a wheelset axle between the wheels of a wheelset
3.10.1
outboard

with reference to an axlebox with more than one bearing row, designates the bearing row that is next to

the inboard bearing row to the outside direction
3.10.2
outboard

with reference to the vehicle or application, designates a configuration with rolling bearings that are

positioned on wheelset axle ends, outside of the space between the wheels of a wheelset

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SIST EN 12082:2017+A1:2021
EN 12082:2017+A1:2021 (E)
3.11
maximum operational test speed
max

maximum operational speed for normal service (in km/h) for which the vehicle shall be homologated

3.12
nominal rotational test speed
test

rotational speed (using the half worn wheel diameter) corresponding to V increased by 10 % (in

max
rpm)
3.13
target zone

defined area on the underside of an axlebox that is designed to have its temperature monitored by a hot

axlebox detector (HABD)
3.14
main line
railway network open to different types of rolling stock
3.15
urban rail

public transport systems permanently guided at least by one rail, intended for the operation of local,

urban and suburban passenger services with self-propelled vehicles and operated either segregated or

not from general road and pedestrian traffic
[SOURCE: CEN-CENELEC Guide 26]
3.16
network
infrastructure, on which any railway undertaking can operate rolling stock
4 Symbols and abbreviations

For the purposes of this document, the symbols and abbreviations given in Tables 1 and 2 apply.

Table 1 — Symbols
Symbol Unit Description
average wheel diameter between new and fully worn
average
condition
m wheel diameter in new condition
max
m wheel diameter at limit of wear condition
min
maximum bore diameter under loaded condition of the
D m
max_n
new housing
minimum bore diameter under loaded condition of the
D m
min_n
new housing
maximum bore diameter under loaded condition of the
D m
max_r
reference housing
minimum bore diameter under loaded condition of the
D m
min_r
reference housing
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SIST EN 12082:2017+A1:2021
EN 12082:2017+A1:2021 (E)
Symbol Unit Description
F N force
N reference vertical force applied per wheelset on the track
a N axial test force
an N nominal axial test force
N radial test force
N nominal radial test force
2 2
g m/s acceleration due to gravity (9,81 m/s )
j - number of wheelsets per vehicle
wheelset mass and masses on the wheelset between
rolling circles, like brake disc, etc.
kg vehicle design mass according to EN 15663
max
n rpm rotational test speed corresponding to v
rpm !(see 3.12 nominal rotational test speed definition)"
test
estimated number of elementary trips needed to achieve
!N -
trips
the performance test (based on nominal speed)"
adjusted value of N to account for interruptions and
trips
!N -
trips_adj
variations in speed"
t s time of one test cycle (see A.6)
t s time of one elementary trip
ramp up or ramp down time from n = 0 → n = n or n =
test
t s
n → n = 0 during one elementary trip
test
t4 s time at rotational speed ntest during one elementary trip
t s stop time (n = 0)
time of one half load cycle of the alternating axial test
t s
force
time during which axial test force is applied (including
t s
ramp up and ramp down) within the period t
ramp up or ramp down time from F = 0 → F = F or
a a an
t s F = F → F = 0 during one half load cycle of the
8 a an a
alternating axial test force
t s axial test force recovery time
!ambient temperature (it is permitted to use a running
T °C average value for 30 min maximum to compensate for
rapid changes in the ambient temperature)"
!measured temperature at a position z and then re-
°C calculated to a temperature corresponding to an ambient
z20
temperature of 20 °C"
measured temperature at a position z (measured
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SIST EN 12082:2017+A1:2021
EN 12082:2017+A1:2021 (E)
Symbol Unit Description
positions are loading zones and target zones)
km/h speed of the vehicle
!(see 3.11 maximum operational test speed
km/h
max
definition)"
Table 2 — Abbreviations
Abbreviation Description
HABD hot axlebox detector
ICP inductively coupled plasma (spectrometry)
MEP mounted end play
XRF X-ray fluorescence (spectrometry)
5 Test specification
5.1 General requirements

The test specification shall consist of all the information describing test parameters and acceptance

criteria. It includes the inputs of the rig performance test, the optional water tightness test and the field

test.

The following information shall be fully documented in the test specification and shall be part of the

approval process. The requirements as specified in this European Standard shall be satisfied before a

claim of compliance with this European Standard can be made and verified.
5.2 Test specification content
5.2.1 General

The following requirements which are specified in the clauses referred to shall at least be fully

documented and included in the test specification.
5.2.2 Rig tests
a) Performance test:
— performance test report recipients list;
— quality management system accreditation and its scope;
— interface drawing showing mounting conditions of all components as in-service;
— boundary dimensions and interface tolerances of the rolling bearing(s);
— MEP requirements;
— conditions of production of the bearings (serial production, prototype);

— grease (according to EN 12081) designation, quantity and distribution, batch reference and

production date;
— specification of the test parameters according to 7.2.2;
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SIST EN 12082:2017+A1:2021
EN 12082:2017+A1:2021 (E)
— deviations to the test parameters in A.4 and A.6;

— approval procedure type with regard to Clause 14 and Annex E of EN 12080:2017 as well as A.9

of this standard;
— required test distance;
— deviations to the performance test report according to 7.5;
— possible extrapolation of the physico-chemical criteria according to A.8.2.
b) Water tightness test (optional):
— water tightness report recipients list;
— requirement of a water tightness test according to Annex C;
— quality management system accreditation and its scope;
— interface drawing showing mounting conditions of all components as in-service;
— conditions of production of the bearings (serial production, prototype);
— specification of the test parameters according to C.3.
5.2.3 Field test
— field test report recipients list;
— reference to the linked performance test report or proven design application;
— specification of the test parameters according to 8.3;
— required test distance;
— annual specified distance travelled of the intended service;
— minimum quantity of axleboxes to be monitored;

— duration (in terms of time or distance travelled) of each intermediate inspection interval;

— scope of monitoring and inspections activities;

— values for iron content and copper content if a grease analysis is specified and if not, for

information only.
6 Water tightness test

The test specification shall specify whether a water tightness test shall be made.

This test shall be performed as described in Annex C.
In case of a new seal, a water tightnes
...

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