SIST EN 12082:2008+A1:2011
(Main)Railway applications - Axleboxes - Performance testing
Railway applications - Axleboxes - Performance testing
This European Standard specifies the principles and methods for a rig performance test of the system of box housing, rolling bearings, sealing and grease. Test parameters and minimum performance requirements for vehicles in operation on main lines are specified in Clause 6 and Annex A (normative). Different test parameters and performance requirements may be selected for vehicles in operation on other networks.
Basic principles for a field test are also determined.
Bahnanwendungen - Radsatzlager - Prüfung des Leistungsvermögens
Diese Europäische Norm beschreibt Grundlagen und Verfahren für die Prüfung des Leistungsvermögens auf dem Prüfstand der Baugruppe bestehend aus Lagergehäuse, Wälzlager, Dichtung und Schmierfett. Für Fahrzeuge im Betrieb auf Hauptbahnen sind die Prüfbedingungen und Mindestleistungsanforderungen in Abschnitt 6 und Anhang A (normativ) spezifiziert. Für Fahrzeuge im Betrieb auf anderen Bahnnetzen dürfen davon abweichende Prüfbedingungen und Leistungsanforderungen gewählt werden.
Die Grundlagen einer Betriebserprobung werden ebenfalls festgelegt.
Applications ferroviaires - Boîtes d'essieux - Essais de performance
La présente Norme européenne décrit les principes et les méthodes d’un essai de performance sur banc, du système composé du corps de boîte d’essieu, des roulements, de l’étanchéité et de la graisse. Les paramètres d’essai et les exigences minimales de performance pour les véhicules en service sur les lignes principales sont spécifiés dans l’Article 6 et l’Annexe A (normative). D’autres paramètres d’essai et exigences de performance peuvent être choisis pour les véhicules en service sur d’autres réseaux.
Les principes de base d’un essai en service sont aussi déterminés.
Železniške naprave - Ohišja ležajev kolesnih dvojic - Preskus delovanja
Ta evropski standard določa načela in metode za preskuse delovanja opreme sistema ohišja, kotalnih ležajev, tesnila in maziva. Preskusni parametri in minimalne zahteve delovanja za vozila, ki delujejo na glavnih progah, so določeni v klavzuli 6 in dodatku A (normativni). Različni preskusni parametri in zahteve za delovanje se lahko izberejo za vozila, ki delujejo v drugih omrežjih.
Osnovna načela za preskušanje na terenu so prav tako določena.
General Information
Relations
Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Železniške naprave - Ohišja ležajev kolesnih dvojic - Preskus delovanjaBahnanwendungen - Radsatzlager - Prüfung des LeistungsvermögensApplications ferroviaires - Boîtes d'essieux - Essais de performanceRailway applications - Axleboxes - Performance testing45.040Materiali in deli za železniško tehnikoMaterials and components for railway engineeringICS:Ta slovenski standard je istoveten z:EN 12082:2007+A1:2010SIST EN 12082:2008+A1:2011en,fr,de01-maj-2011SIST EN 12082:2008+A1:2011SLOVENSKI
STANDARD
SIST EN 12082:2008+A1:2011
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 12082:2007+A1
October 2010 ICS 45.040 Supersedes EN 12082:2007English Version
Railway applications - Axleboxes - Performance testing
Applications ferroviaires - Boîtes d'essieux - Essais de performance
Bahnanwendungen - Radsatzlager - Prüfung des Leistungsvermögens This European Standard was approved by CEN on 8 November 2007 and includes Amendment 1 approved by CEN on 14 September 2010.
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 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 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, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre:
Avenue Marnix 17,
B-1000 Brussels © 2010 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 12082:2007+A1:2010: ESIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 2 Contents Page Foreword .3Introduction .41Scope .52Normative references .53Terms and definitions .54Information and conditions to be agreed and documented .65Watertightness test.76Rig performance test .76.1General .76.2Execution .76.3Carrying out the test .96.4Acceptance criteria .96.5Rig test report . 107Field test . 117.1General . 117.2Carrying out the test . 117.3Test parameters . 117.4Acceptance criteria . 117.5Field test report . 12Annex A (normative)
Rig performance test . 13A.1Schematic example of test rig . 13A.2Temperature measurement . 14A.3Grease sampling zones . 17A.4Definition of loading . 18A.5Definition of test cycles . 19A.6Graphical presentation of test cycles . 21A.7Temperature criteria . 22A.8Mechanical and physico-chemical acceptance criteria . 23A.9Watertightness test. 23Annex ZA (informative)
!!!!Relationship between this European Standard and the Essential Requirements of EU Directive 2008/57/EC of the European Parliament and of the Council of 17 June 2008 on the interoperability of the rail system within the Community (Recast)"""" . 26 !!!!deleted text"""" Bibliography . 30 SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 3 Foreword This document (EN 12082:2007+A1:2010) 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 April 2011, and conflicting national standards shall be withdrawn at the latest by April 2011. 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 includes Amendment 1, approved by CEN on 2010-09-14. This document supersedes !EN 12082:2007". The start and finish of text introduced or altered by amendment is indicated in the text by tags ! ". !This document has been prepared under a mandate given to CEN/CENELEC/ETSI by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive 2008/57/EC. For relationship with EU Directive 2008/57/EC, see informative Annex ZA, which is an integral part of this document." According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: 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, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom. SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 4 Introduction 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, sealing and grease is well suited for the service requirements. This testing is made up of two stages, a "rig performance test", described in detail in this European Standard, and a "field test”. When rig performance testing is specified, it needs to be carried out in accordance with this European Standard. The extent of testing to be applied depends on the novelty of bearing design, seal design, grease formulation or box housing, as well as the application (see EN 12080 and EN 12081). The rig performance test will check the satisfactory function of the assembly during a simulated journey. It is to be applied only if the axlebox is composed of elements delivered by suppliers that operate a quality management system1). The field test comprises monitoring on vehicles in service of a sufficiently large sample of axleboxes during a high mileage.
1) The systems used should offer equivalence with EN ISO 9001. SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 5 1 Scope This European Standard specifies the principles and methods for a rig performance test of the system of box housing, rolling bearings, sealing and grease. Test parameters and minimum performance requirements for vehicles in operation on main lines are specified in Clause 6 and Annex A (normative). Different test parameters and performance requirements may be selected for vehicles in operation on other networks. Basic principles for a field test are also determined. 2 Normative references The following referenced documents are indispensable for the application of this European Standard. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 12080, Railway applications — Axleboxes — Rolling bearings EN 12081, Railway applications — Axleboxes — Lubricating greases ISO 2137, Petroleum products — Lubricating grease and petrolatum — Determination of cone penetration ISO 2176, Petroleum products — Lubricating grease — Determination of dropping point ISO 3733, Petroleum products and bituminous materials — Determination of water — Distillation method NF F 19-5032), Matériel roulant ferroviaire — Méthode d'essais des graisses pour boîtes d'essieux à roulements — Essai dynamique de la stabilité a l'oxydation des graisses 3 Terms and definitions For the purposes of this European Standard, the following terms and definitions apply. 3.1 customer railway undertaking, manufacturer or buyer of railway rolling stock or subassemblies, or their representative 3.2 railway undertaking organisation or its representative, whatever status it has, which is responsible for the registration of rolling stock 3.3 supplier supplier of rolling bearings, sealing, grease or box housings for axleboxes, manufactured under his responsibility 3.4 axlebox assembly of box housing, rolling bearings, sealing and grease
2) NF — Association Française de Normalisation (AFNOR), 11 avenue Francis de Pressensé, 93571 La Plaine Saint-Denis Cedex, Tel.: +33 (0) 1 41 62 80 00, Fax: +33 (0) 1 49 17 90 00. SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 6 3.5 box housing structural component which contains rolling bearings, sealing and grease 3.6 rolling bearing bearing, operating with rolling motion between the parts, supporting load and moving in relation to each other 3.7 cartridge bearing rolling bearing with two or more rows of rolling elements within a single outer ring, greased and equipped with integral seals 3.8 grease semi-solid lubricant, which consists of a thickener and additives dispersed in a lubricating oil 3.9 sealing component that protects the rolling bearings against ingress of water and dust and retains grease in the rolling bearings 3.10 nominal test speed vehicle speed limit increased with 10 % 3.11 main line railway network open to different types of rolling stock 3.12 network infrastructure, on which any railway undertaking can operate rolling stock 4 Information and conditions to be agreed and documented The approval procedures for the rolling bearings are defined in EN 12080 and for the lubricating greases in EN 12081. The rig performance test is stipulated in both of these European Standards. For the rig performance test, the following is to be agreed between the customer and the supplier and shall be fully documented by the supplier: designation and characteristics of the rolling bearing according to EN 12080; designation and characteristics of the lubricating grease according to EN 12081; designation and characteristics of the sealing; designation and characteristics of the box housing; input data required for determining test parameters are further described in 6.2.2; extent of testing for rolling bearings for vehicles not in operation on main lines; extent of testing for rolling bearing, grease, sealing or box housing similar to service proven designs (see A.5); conditions intended for the field test (see Clause 7). SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 7 5 Watertightness test The customer shall specify whether a watertightness test shall be made. A suitable method (in static mode) is presented in A.9. A method for optional further dynamic testing is described in UIC 515-5. 6 Rig performance test 6.1 General The test consists of putting two axleboxes on a test rig and subjecting them to repeated loading cycles determined from the operating conditions of the vehicles to be equipped with these axleboxes. Two identical axleboxes including; rolling bearings, sealing, grease and box housing, assembled as for operating conditions shall be mounted on the test rig axle journals. After mounting, the clearance shall be as close as possible to the maximum of the tolerance for one axlebox and minimum for the other. During rig operation, the axleboxes are subjected to constant vertical loads and varying transversal loads which will produce radial and axial forces on the rolling bearings. Calculating the constant nominal radial force nrF and the nominal axial load anFis carried out by means of the methods described in A.4. The constant radial load is designatedrF, and the varying actual axial load is designatedaF. All these forces are applied on one journal with axlebox. Other test parameters including different radial and axial load cycles, speeds, bending forces on axle journal transmitted via the axlebox, analysis of temperature etc. can be applied as supplementary tests in agreement between customer and supplier. Before the real performance test, a pre-test shall be carried out. This does not constitute part of the official approval test for the bearings or grease being tested, but is intended to observe the thermal behaviour of the bearings while the grease is redistributed. The performance test consists of repeating identical cycles up to an agreed cumulative distance. The number of cycles and the test distance reflect the service conditions of the intended application. Throughout the test, the performance of the bearings will be monitored by measurement of temperatures, the values of which, both absolute and relative, shall remain within limits. Finally, on completion of the test, the bearings and the grease will be inspected and shall not show any changes beyond limits imposed. 6.2 Execution 6.2.1 Test rig The test rig shall apply testing conditions which are derived from the service operating conditions and ensure accurate monitoring of the axleboxes under test and at the same time minimize influence from the rig. Especially, it shall be avoided that disturbances on one axlebox are transferred to the other axlebox. An example of a test rig is schematically shown in A.1 and includes principally: a) axle or two synchronized axles, on which the axle boxes are mounted on the journals; b) rotation mechanism; c) device for measuring the rotational speed of the axle; SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 8 d) device arranged to subject each axlebox to a constant radial force rF = nrF; e) measuring device to monitor this radial force rF; f) device arranged to subject each axlebox to an alternating axial force aF; g) measuring device to monitor this alternating axial force aF; h) ventilation equipment to simulate the cooling in operation; i) sensors permitting temperature measurement: 1)
in general, two sensors in the loaded zone of both axleboxes, aligned centrally above the bearing rows with typical positions shown in Figure A.2 for an axlebox with two bearings and in Figure A.3 for an axlebox with one bearing; 2)
in the scanning zone of the hot box detectors (HBD), by a sensor in direct contact with the surface of the body as indicated in Figure A.4 (a non-contacting temperature sensor – measuring in the same zone – shall be used only in case there are no suitable surfaces to attach a sensor); 3)
of the ambient air stream which is directed at the axle boxes, measured at the outlet of the cooling fans. It shall be measured for both axle boxes (see Figure A.1). 6.2.2 Test parameters 6.2.2.1 General The test parameters will be defined on the basis of the operating conditions of the vehicles to be equipped with these axle boxes and documented in accordance with Clause 4. The following test parameters are required, agreed and documented before the test and presented in the test report: a) reference vertical load 0F (the axle load), in newtons; b) wheel diameter at the limit of wear mind, in metres; c) vehicle speed limit maxν, in kilometres per hour; d) pre-test procedure; e) test cycle and cumulative test distance, in kilometres; f) original grease quantity and, if required, re-lubrication interval and grease quantity. If deviations from the test parameters in A.4 and A.6 are agreed in order to simulate special operating conditions, this shall be indicated in the test report. 6.2.2.2 Rotational speed The maximum rotational speed, maintained most of the time during the test, is that of a wheelset on which the wheels are at their limit of wear and where the rotational speed is derived from the vehicle speed limit, increased with a safety margin of 10 %. The resulting rotational speed is the nominal test speed, n, in revolutions per minute. The nominal speed in kilometres per hour is designatednν. minmax6110dvn= (1) SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 9
6.2.2.3 Radial and axial forces The external forces are applied to each axlebox inducing forces on the rolling bearings, simulating as closely as possible the distribution of forces from the primary suspension. There shall be a constant radial force and an alternating axial force. Based on the load data specified in accordance with Clause 4, the values of radial and axial forces shall be calculated as defined in A.4 and the cycle of application of the axial load as defined in A.6. The axial force shall not be applied when the test speed is less than 20 % of the nominal test speed. 6.2.2.4 Air cooling An air cooling system shall provide an air speed of 8 m/s to 10 m/s measured close to the axleboxes, with this average value taken from several points across each axlebox in the area impinged by the air stream. This cooling is maintained constant when the test is running, however not during the stops. An air temperature of 20 °C is recommended. 6.3 Carrying out the test 6.3.1 General Unless otherwise agreed and documented in accordance with Clause 4, the test parameters, speeds and forces shall be those in 6.2.2, A.4, A.5 and A.6. 6.3.2 Pre-test Before running the performance test, a pre-test shall be run. The objective of this test is to observe the thermal behaviour of the bearings and to redistribute the grease. The pre-test is illustrated in A.6. It consists of four cycles, each made up of two elementary trips, one in each rotational direction. The speeds are 25 %, 50 %, 75 % and 100 % of the nominal test speed, respectively. The radial force shall be maintained during the test; the axial force is applied as agreed, e.g. 25 %, 50 %, 75 % and 100 % of the calculated nominal axial force. Each elementary trip is made up of a speed increase, a constant speed, a slowing down and a stop. The distance of each elementary trip is not predetermined; when the temperatures have stabilized – at least two hours within a 5 ° range – the trip is completed. 6.3.3 Performance testing The test consists in repeating identical cycles at the nominal test speed to a specified cumulative distance. A cycle consists of two elementary trips, one for each direction of rotation, separated by a short stop and composed of a starting period, a period of constant maximum speed and a slowing down period to stop. The stop period may be prolonged if required. The cumulative test distance (in kilometres), as well as the time at the nominal test speed during each cycle (in minutes), depends on the operating conditions in line traffic of the vehicles to be equipped with these axleboxes. The conditions defined in A.5 and A.6 are intended for main line vehicles, for other applications, the test parameters shall be in accordance with Clause 4. 6.4 Acceptance criteria 6.4.1 Results obtained during the test Throughout the test, no defect in lubrication shall occur as evidenced by unsatisfactory temperature. Likewise, there shall be no bearing defects (spalling, breakage etc.) or seal failures. SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 10 Throughout the test, temperatures shall be measured, during each elementary test trip, at different loading zones and hotbox detector zone. The measured temperatures shall be expressed relative to an ambient temperature of 20 °C by re-calculation with the aid of the following equation )20(am20−−=TTTzz
(2) where 20zT is a temperature measured at a position z and then re-calculated to a temperature corresponding
to an ambient temperature of 20 °C; mzT
is a temperature measured at a position z (measured positions are loading zones and hot box detector zone); aT
is the ambient temperature measured in the same time asmzTand at the same side of the
axlebox. This calculation is applied only for the assessment of the first four criteria in A.7, Table A.2. For each sensor position, the maximum temperature as well as the simultaneous differences between axleboxes shall be registered. Sufficient temperature data points shall be registered in order that the results may be interpreted according to the criteria of Table A.2. For the further evaluation according to the Criterion 5 in Table A.2, the maximum value of those simultaneous differences shall be used (i.e. the hottest load zone temperature of the hottest axlebox shall be compared with the coolest load zone temperature of the coolest axlebox). For consecutive elementary trips, the change of maximum temperatures for each load zone sensor position shall be noted and the maximum of those changes shall be used in the further evaluation according to the Criterion 7 in Table A.2. The limits to be observed and the tolerable number of violations are given in A.7, Table A.2. 6.4.2 Results obtained after the test On completion of the cumulative distance, the bearings shall be dismounted for examination; likewise grease samples from the zones indicated in A.3 shall be analysed. The mechanical criteria to be fulfilled by the bearings and the physico-chemical criteria to be fulfilled by the grease are defined in A.8. The grease quantity remaining in the bearing should for information be determined and compared with the grease quantity before the test. For cartridge bearings, the grease quantity is documented according to EN 12080. NOTE
For cartridge bearings, the loss of grease after the test should normally be less than 10 % of the original amount.
6.5 Rig test report Upon completion of the test, a report shall be established with at least this content: — designation and supplier of the products tested; — testing organisation, site, personnel responsible and description of the test rig (measuring equipment, sensors and their position, sampling periodicity etc.); — test parameters in accordance with Clause 4, 6.2.2, A.4 and A.5; — timing, distance and the finally observed stabilised temperature of the pre-test; SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 11 — results obtained during and after the test, enabling evaluation of the products to the criteria in 6.4, (A.7 and A.8); — declaration that the test was undertaken in accordance with EN 12082, including the information and
conditions agreed in Clause 4 regarding the rig performance test. This report shall be available to the customer and the supplier of the components tested. 7 Field test 7.1 General The axleboxes to be tested shall be composed of the system of box housing, rolling bearings, sealing and grease strictly identical to those which have satisfactorily passed the rig performance test. 7.2 Carrying out the test The axleboxes to be tested shall, as far as possible, be mounted on vehicles covering high annual mileage at the maximum operating speeds authorized for that category of vehicle, and with the highest possible axle loads. For main line vehicles with a speed limit up to 200 km/h, the test should last at least two years or 600 000 km; if the speed limit is over 200 km/h, at least 1 000 000 km. The number of axleboxes depends on the available rolling stock and is fixed by the customer. 7.3 Test parameters The customer shall specify the following in accordance with Clause 4: — test distance, in years or cumulative distance; — initial lubrication and grease designation (quantity and distribution are to be given by the supplier); — re-lubrication, interval and grease quantity, if any; — intermediate inspections, interval, sampling procedure and nature of the inspections; — number of axleboxes; — vehicle characteristics (axle load, maximum speed etc.). These conditions shall be determined to reflect the operating conditions and type of service for the application and prove the required reliability. 7.4 Acceptance criteria 7.4.1 Results to be obtained during the test During the test period and at the intermediate inspections, no defect in lubrication shall occur. Likewise, there shall be no bearing defects (spalling, breakage etc.) or seal failures. 7.4.2 Results to be obtained after the test At the end of the test period, the results to be obtained are defined in A.8. SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 12 7.5 Field test report Upon completion of the test, a report shall be established with at least this content: — designation and supplier of the products tested; — test parameters in accordance with 7.3; — testing organisation, personnel responsible; — description of the routes, track conditions and service duty; — reports from hot-box detection systems; — results obtained during and after the test, enabling evaluation of the products in relation to the criteria in
A.8; — declaration that the test was undertaken in accordance with EN 12082, including the information and conditions agreed according to Clause 4 as far as corresponding to the field test. This report shall be available to the customer and the supplier of the components tested. SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 13 Annex A (normative)
Rig performance test A.1 Schematic example of test rig
Key 1 temperature sensor 2 cooling fans 3 axial force, actuator and sensor 4 test axlebox 5 vertical force, actuator and sensor 6 support bearing 7 motor Figure A.1 — Schematic example of test rig SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 14 A.2 Temperature measurement A.2.1 Two-bearing axleboxes – measurement in loaded zone
Key 1 temperature sensor Figure A.2 — Typical position of temperature measurement in loaded zone SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 15 A.2.2 One-bearing axleboxes – measurement in loaded zone
Key 1 temperature sensor Figure A.3 — Typical position of temperature measurement in loaded zone SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 16 A.2.3 Hot box measuring
Key 1 temperature sensor NOTE
The location and dimensions of this zone for measurement is defined in prEN 15437. Figure A.4 — Temperature measurement in Hot Box Detector area SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 17 A.3 Grease sampling zones A.3.1 Two-bearing axleboxes
Key A bearing locking cap side zone B bearing thrust collar side zone C bearing inside zone D zone between
bearings Figure A.5 — Grease sampling zones SIST EN 12082:2008+A1:2011
EN 12082:2007+A1:2010 (E) 18 A.3.2 One-bearing axleboxes
Key A bearing lo
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