Railroad switch

Summary

A railroad switch (AE), turnout, or [set of] points (CE) is a mechanical installation enabling railway trains to be guided from one track to another, such as at a railway junction or where a spur or siding branches off.

A right-hand railroad switch with point indicator pointing to right
Animated diagram of a right-hand railroad switch. Rail track A divides into two: track B (the straight track) and track C (the diverging track); note that the green line represents direction of travel only, the black lines represent fixed portions of track, and the red lines depict the moving components.
Large stations may have hundreds of normal and double switches (Frankfurt am Main main station, Germany).
Switch blades in motion (Hong Kong Mass Transit Railway light rail)
Abt switch used in 1895 built Dresden Funicular Railway (photo of 1985)

The most common type of switch consists of a pair of linked tapering rails, known as points (switch rails or point blades), lying between the diverging outer rails (the stock rails). These points can be moved laterally into one of two positions to direct a train coming from the point blades toward the straight path or the diverging path. A train moving from the narrow end toward the point blades (i.e. it will be directed to one of the two paths, depending on the position of the points) is said to be executing a facing-point movement.

For many types of switch, a train coming from either of the converging directions will pass through the switch regardless of the position of the points, as the vehicle's wheels will force the points to move. Passage through a switch in this direction is known as a trailing-point movement and switches that allow this type of movement are called trailable switches.[1]

A switch generally has a straight "through" track (such as the main-line) and a diverging route. The handedness of the installation is described by the side that the diverging track leaves. Right-hand switches have a diverging path to the right of the straight track, when coming from the point blades, and a left-handed switch has the diverging track leaving to the opposite side. In many cases, such as rail yards, many switches can be found in a short section of track, sometimes with switches going both to the right and left (although it is better to keep these separated as much as feasible). Sometimes a switch merely divides one track into two; at others, it serves as a connection between two or more parallel tracks, allowing a train to switch between them. In many cases, where a switch is supplied to leave a track, a second is supplied to allow the train to reenter the track some distance down the line; this allows the track to serve as a siding, allowing a train to get off the track to allow traffic to pass (this siding can either be a dedicated short length of track, or formed from a section of a second, continuous, parallel line), and also allows trains coming from either direction to switch between lines; otherwise, the only way for a train coming from the opposite direction to use a switch would be to stop, and reverse through the switch onto the other line, and then continue forwards (or stop, if it is being used as a siding).

A straight track is not always present; for example, both tracks may curve, one to the left and one to the right (such as for a wye switch), or both tracks may curve, with differing radii, while still in the same direction. Switches consume a relatively high proportion of a railway maintenance budget.[2]

History edit

 
Control stand of a defunct railroad switch on the way from Pyin Oo Lwin to Goteik viaduct (Myanmar)

Simple single-bladed switches were used on early wooden railways to move wagons between tracks. As iron-railed plateways became more common in the eighteenth century, cast iron components were made to build switches with check rails.[3] In 1797, John Curr described the system that he developed which used a single iron blade, hinged on a vertical pin that was tapered to lie against the plateway.[4] By 1808, Curr's basic design was in common use.[5]

The use of a sprung rail, giving a smooth transition, was patented by Charles Fox in 1838.[6]

Prior to the widespread availability of electricity, switches at heavily traveled junctions were operated from a signal box constructed near the tracks through an elaborate system of rods and levers. The levers were also used to control railway signals to control the movement of trains over the points. Eventually, mechanical systems known as interlockings were introduced to make sure that a signal could only be set to allow a train to proceed over points when it was safe to do so. Purely mechanical interlockings were eventually developed into integrated systems with electric control. On some low-traffic branch lines, in self-contained marshalling yards, or on heritage railways, switches may still have the earlier type of interlocking.

Operation edit

 
The operation of a railroad switch. In this animation, the red track is the one traveled during a facing-point movement. The switch mechanism, shown in black, may be operated remotely using an electric motor or hand-operated lever or from a nearby ground frame.

A railroad car's wheels are primarily guided along the tracks by coning of the wheels,[7] rather than relying on the flanges on the insides of the wheels. When the wheels reach the switch, the wheels are guided along the route determined by which of the two points is connected to the track facing the switch. In the illustration, if the left point is connected, the left wheel will be guided along the rail of that point, and the train will diverge to the right. If the right point is connected, the right wheel's flange will be guided along the rail of that point, and the train will continue along the straight track. Only one of the points may be connected to the facing track at any time; the two points are mechanically locked together to ensure that this is always the case.

A mechanism is provided to move the points from one position to the other (change the points). Historically, this would require a lever to be moved by a human operator, and some switches are still controlled this way. However, most are now operated by a remotely controlled actuator called a point machine; this may employ an electric motor or a pneumatic or hydraulic actuator. This both allows for remote control and monitoring and for the use of stiffer, strong switches that would be too difficult to move by hand, yet allow for higher speeds.

In a trailing-point movement (running through the switch in the wrong direction while they are set to turn off the track), the flanges on the wheels will force the points to the proper position. This is sometimes known as running through the switch. Some switches are designed to be forced to the proper position without damage. Examples include variable switches, spring switches, and weighted switches.

If a switch becomes worn or the operating rods become damaged, it is possible for the flange to split the switch, and go through the switch in the direction other than what was expected. This happens when the flange strikes a small gap between the fixed rail and the set switch point (whichever is touching the main line); this forces the switch open, and the train is diverted down the incorrect track. This can either happen to the locomotive, in which case the whole train can be directed onto the wrong track, with potentially dangerous results, or it can occur at any point through the train, when a random truck is directed down a different track from the rest of the train; if this happens on the front truck of a car, the usual result is derailment, as the trailing truck of the preceding car attempts to go one way, while the leading truck of the following car tries to go another. If it happens to the trailing truck of a car, the front truck will follow one track, while the trailing truck follows a parallel line; this causes the whole car to "crab", or move sideways down the track (derailment often results eventually, due to the lateral forces applied when the train tries to brake or accelerate). This can have disastrous results if there is any obstacle between the lines, as the car will be propelled into it sideways, such as happened in the 1928 Times Square derailment. In some cases, the whole train behind the car will follow the errant car onto the other track; in others, only one or a few trucks are diverted, while the rest follow the correct track. In cases where it is a simple siding, rather than a continuous parallel track, the diverted truck(s) can travel the whole length of the siding until it turns back to the main track, where it performs a trailing point movement, forces the switch open, and ends up back on the same track again, with only damage to the switches. This is far less likely in cases of diversion to a parallel track, since switches on both lines will often be interconnected, so to set the switch on the main line to straight-through will set the other switch to straight-through as well (otherwise there is a risk of turning off the track only to find the joining switch is set the wrong way, and running the train through it). Because derailments are expensive and very dangerous to life and limb, maintenance of switch points and other trackwork is essential, especially with faster trains.

If the points are rigidly connected to the switch control mechanism, the control mechanism's linkages may be bent, requiring repair before the switch is again usable. For this reason, switches are normally set to the proper position before performing a trailing-point movement.[8]

High-speed operation edit

Generally, switches are designed to be safely traversed at low speed. However, it is possible to modify the simpler types of switch to allow trains to pass at high speed. More complicated switch systems, such as double slips, are restricted to low-speed operation. On European high-speed lines, it is not uncommon to find switches where a speed of 200 km/h (124 mph) or more is allowed on the diverging branch. Switches were passed over at a speed of 560 km/h (348 mph) (straight) during the French world speed run of April 2007.[9]

The US Federal Railroad Administration has published the speed limits for higher-speed turnouts with No. 26.5 turnout that has speed limit of 60 miles per hour (97 km/h) and No. 32.7 with speed limit of 80 miles per hour (129 km/h).[10]

Operation in cold conditions edit

 
Gas heating keeps a switch free from snow and ice.
 
Similarly, an electric forced-air heater can keep a switch free from snow and ice.

Under cold weather conditions, snow and ice can prevent the proper movement of switch or frog point rails, essentially inhibiting the proper operation of railroad switches. Historically, railway companies have employees keep their railroad switches clear of snow and ice by sweeping the snow away using switch brooms (Basically wire brooms with a chisel attached onto the opposite end of the broom – quite similar to ice scrapers used today), or gas torches for melting ice and snow. Such operation are still used in some countries, especially for branch routes with only limited traffic (e.g. seasonal lines). Modern switches for heavily trafficked lines are typically equipped with switch heaters installed in the vicinity of their point rails so that the point rails will not be frozen onto the stock rail and can no longer move. These heaters may take the form of electric heating elements or gas burners mounted on the rail, a lineside burner blowing hot air through ducts, or other innovative methods (e.g. geothermal heat sink, etc.) to keep the point & stock rails above freezing temperatures. Where gas or electric heaters cannot be used due to logistic or economic constraints, anti-icing chemicals can sometimes be applied to create a barrier between the metal surfaces to prevent ice from forming between them (i.e. having frozen together by ice). Such approaches however, may not always be effective for extreme climates since these chemicals will be washed away over time, especially for heavily thrown switches that experience hundreds of throws daily.

Heating alone may not always be enough to keep switches functioning under snowy conditions. Wet snow conditions, which generate particularly sticky snow and whiteout conditions, may occur at temperatures just below freezing, causing chunks of ice to accumulate on trains. When trains traverse over some switches, the shock, vibration, possibly in combination with slight heating caused by braking or a city microclimate, may cause the chunks of ice to fall off, jamming the switches. The heaters need time to melt the ice, so if service frequency is extremely high, there may not be enough time for the ice to melt before the next train arrives, which will then result in service disruptions. Possible solutions include installing higher capacity heaters, reducing the frequency of trains, or applying anti-icing chemicals like ethylene glycol to the trains.[11]

Classification edit

 
A low-speed #6 right-hand switch between a main line and a rail yard

The divergence and length of a switch is determined by the angle of the frog (the point in the switch where two rails cross, see below) and the angle or curvature of the switch blades. The length and placement of the other components are determined from this using established formulas and standards. This divergence is measured as the number of units of length for a single unit of separation.

In North America this is generally referred to as a switch's "number". For example, on a "number 12" switch, the rails are one unit apart at a distance of twelve units from the center of the frog.

In the United Kingdom points and crossings using chaired bullhead rail would be referred to using a letter and number combination. The letter would define the length (and hence the radius) of the switch blades and the number would define the angle of the crossing (frog). Thus an A7 turnout would be very short and likely only to be found in tight places like dockyards whereas an E12 would be found as a fairly high speed turnout on a mainline.

On the London, Midland and Scottish Railway, switch curvatures were specified from A (sharpest) to F (shallowest), with the following corresponding radii:[12]

  • B – 613 feet (186.84 m) – simple crossover with a 1 in 8 crossing angle
  • C – 980 feet (298.70 m) – scissors or simple crossover with a 1 in 10 crossing angle
  • D – 1,379 feet (420.32 m) – double track junction switch with a 1 in 12 crossing angle

Safety edit

Switches are necessary for the operation of a railway, but they do pose a number of risks:

  • Reversing the points under a moving train will almost always derail the train.
  • Points might move due to the extreme forces exerted by a passing train. In an especially noteworthy and extreme case, a switch's setting was forcibly changed as a result of a disintegrated duo block wheel getting caught in a switch. This caused one of the world's worst rail disasters, the Eschede train disaster.
  • A train might stand so close to the frog of a switch that a passing train would collide with its side (the first train is then said to have been fouling the switch).
  • The necessary maintenance of the complex mechanical device might be neglected.
  • Tampering with a manually operable switch or operation errors in an interlocking may result in two trains being on the same track, potentially causing a collision.

Accidents edit

Switch-related accidents caused by one or more of these risks have occurred, including:

  • The 1980 Buttevant Rail Disaster at Buttevant, County Cork, in Ireland, when the DublinCork express was derailed at high speed after being inadvertently switched into a siding via ground frame operated points, resulting in 18 deaths.
  • Wrecks caused by switches being thrown open in front of the trains by saboteurs, as in the non-fatal derailments near Newport News, on 12 August 1992, and in Stewiacke, on 12 April 2001. To prevent these incidents, most unused switches are locked.
  • The Eschede train disaster in 1998 in Germany was one of the world's deadliest high-speed train accidents, resulting in 101 deaths. It occurred when a wheel rim of an ICE train failed at 200 kilometres per hour (120 mph), partially derailing the car. The wheel rim went through the floor of the carriage and was dragging on the ground. While passing through the station at Eschede it threw a switch, causing the rear wheels of the car to switch onto a track diverging from the track taken by the front wheels. The car was thereby thrown into and destroyed the piers supporting a 300-tonne roadway overpass.
  • The May 2002 Potters Bar rail crash at Potters Bar, Hertfordshire, in the United Kingdom, occurred when a switch sprang to a different position as a coach crossed it, a type of mishap called splitting the switch. The front wheels of a coach progressed along the straight track as intended, but the rear wheels slewed along the diverging track. This caused the whole coach to detach from the train and slew sideways across the platform ahead. The movement of the switch occurred beneath the final coach, so that the preceding coaches remained on the track. Poor maintenance of the points was found to be the primary cause of the crash.
  • The interim report into the Grayrigg derailment of 23 February 2007 blamed an incorrectly maintained set of points.[13]
    • On 31 July 1991, several cars derailed, killing seven passengers, due to a missing locking pin on the switch mechanism.[14]
    • Twenty-seven years later, on 4 August 2018, the Silver Star crashed into a parked freight train on a siding due to a misaligned switch, killing two crewmen.[15]

Components edit

Switchrails or points (point blades) edit

 
This detail of a switch shows the pair of tapered moveable rails known as the switch points (switch rails or point blades).
 
New style
 
Old style

The switch rails or points (point blades) are the movable rails which guide the wheels towards either the straight or the diverging track. They are tapered, except on stub switches in industrial sidings, which have square ends.

In popular parlance in the UK and most other Commonwealth countries, the term points refers to the entire mechanism. In professional parlance, the term refers only to the movable rails and the entire mechanism is named turnout or points and crossings. Turnout and switch are terms used in North America in all contexts.

In some cases, the switch blades can be heat treated for improvement of their service life. There are different kinds of heat treatment processes such as edge hardening or complete hardening.

The cross-section of the switch blades also influences performance. New tangential blades perform better than old-style blades.

Crossing (frog or common crossing) edit

 
A one-piece cast crossing. The shiny line crosses the rusty line. This North American "self-guarding cast manganese" component without guard rails has raised flanges on the crossing, which may bear on the face of the wheel as it passes through.
 
The frog (left) and guard rail (right) of a switch

The crossing is the component that enables passage of wheels on either route through the turnout. It can be assembled out of several appropriately cut and bent pieces of rail or can be a single casting of manganese steel. On lines with heavy use, the casting may be treated with explosive shock hardening to increase service life.[16]

Guard rail (check rail) edit

A guard rail is a short piece of rail placed alongside the main (stock) rail opposite the crossing. These ensure that the wheels follow the appropriate flangeway through the frog and that the train does not derail.[citation needed]

Check rails are often used on very sharp curves, even where there are no switches.[17]

 
The switch motor (in this case an electric motor) and associated mechanism used to operate this switch can be seen to the right in the picture.

Switch motor edit

A switch motor or switch machine (point motor or point machine) is an electric, hydraulic or pneumatic mechanism that aligns the points with one of the possible routes. The motor is usually controlled remotely by the dispatcher (signaller in the UK). The switch motor also includes electrical contacts to detect that the switch has completely set and locked. If the switch fails to do this, the governing signal is kept at red (stop). There is also usually some kind of manual handle for operating the switch in emergencies, such as power failures, or for maintenance purposes.

A patent by W. B. Purvis dates from 1897.

 
An example of a mechanism used at a switch. The two points are linked together with a throw bar (also known as a stretcher bar). The throw bar extends to the lever on the near side of the track, which is used to throw the switch. This is an example of a low switch stand, used at locations where there is not sufficient clearance for a tall switch stand. This particular stand is designed to be trailed through by rolling stock, which will cause the points to become lined for the route that the wheels have passed through. It has a reflectorized target.
 
The manual switch of track drive manufactured by Walter Hoene, the port of Gdańsk before 1945, on the site of the former fuel depot

Switch stand (points lever) edit

A switch stand (points lever or ground throw) is a lever and accompanying linkages to align the points of a switch by hand. The lever and its accompanying hardware is usually mounted to a pair of long ties (sleepers) that extend from the switch at the points. They are often used in a place of a switch motor on less frequently used switches. In some places, the lever may be some distance from the points, as part of a lever frame or ground frame. To prevent the tampering of switches by outside means, these switches are locked when not in use.

Facing point lock edit

 
A set of points on the Strathspey Railway in Scotland. The facing point lock in the middle will need to be withdrawn using the blue lever (behind) on the left before the points themselves can be moved using the black lever (front). Once the points have been moved the lock will be pushed in again with the blue lever to lock the points in position.

A facing point lock (FPL), or point lock, is a device which, as the name implies, locks a set of points in position, as well as mechanically proving that they are in the correct position. The facing point part of the name refers to the fact that they prevent movement of the points during facing moves, where a train could potentially split the points (end up going down both tracks) if the points were to move underneath the train. During trailing moves, the wheels of a train will force the points into the correct position if they attempt to move, although this may cause considerable damage. This act is known as a "run through".

In the United Kingdom, FPLs were common from an early date, due to laws being passed which forced the provision of FPLs for any routes traveled by passenger trains – it was, and still is, illegal for a passenger train to make a facing move over points without them being locked, either by a point lock, or temporarily clamped in one position or another.[18]

Joints edit

Joints are used where the moving points meet the fixed rails of the switch. They allow the points to hinge easily between their positions. Originally the movable switch blades were connected to the fixed closure rails with loose joints, but since steel is somewhat flexible it is possible to obviate this looseness by thinning a short section of the rail's bottom itself. This can be called a heelless switch.

Straight and curved switches edit

Turnouts were originally built with straight switch blades, which ended at the pointed end with a sharp angle. These switches cause a bump when the train traverses in the turnout direction. The switch blades could be made with a curved point which meets the stockrail at a tangent, causing less of a bump, but the disadvantage is that the metal at the point is thin and necessarily weak. A solution to these conflicting requirements was found in the 1920s on the German Reichsbahn. The first step was to have different rail profile for the stock rails and switch rails, with the switch rails being about 25 mm (0.98 in) less high, and stockier in the middle.

Components gallery edit