The Challenge
The rail transit authority in a major North American city relied on three twenty-year-old powered flatcars for essential maintenance functions, but they needed to be replaced due to long-term wear. Specifically, they needed a set of maintenance vehicles that could handle bridge inspection and repairs, cable-handling, and an overhead work platform.
The existing machines were custom built, so there was not an off-the-shelf solution to replace them and they would need extensive custom work to remain viable.
The key challenge was that each vehicle had to be capable of working in tunnels for extended periods, requiring a hybrid diesel/battery-powered system. Additionally, they needed a six-man cab, 40ft. of open deck, an overall length of no more than 50ft. in length, and a weight of less than 100 tons.
The Solution
Brandt was chosen for this project for our extensive experience working within the rail industry. Our track-record of success in building custom locomotives and power systems demonstrated to the customer that we had the specialized expertise that their project required. We also understood the needs of their business because of our close relationships in transit rail, built via the legendary R4 Power Unit. And, our unique ability to handle everything from scope development and design through to manufacturing, installation and final testing gave the customer confidence in a straightforward, turnkey process.
Once selected for the project, our expert team worked closely with the customer to develop an in-depth understanding of how their existing equipment was used, and what they would need from the replacements. The customer received regular updates throughout the process, providing feedback and making sure the solution would suit their application at every step.
Brandt’s engineers developed a set of three powered flatcars, including an under-bridge inspection unit, a scissor-lift work-deck unit, and a cable-handling unit. These machines could perform the required maintenance work with several improvements over the customer’s older equipment.
The hybrid electric-diesel power system was a key improvement. The older machines utilized a diesel-powered hydraulic system, which required more time and equipment to disperse emissions when working in tunnels. Brandt’s solution used batteries to power the hydraulic pump, which were supplemented by a small diesel generator. This system allowed them to work in tunnels for up to four hours without the need to addition equipment to handle the emissions. And, the batteries were compatible with the customer’s existing infrastructure, making integration seamless.
When working outside of tunnels, the new vehicles utilized a conventional diesel-powered system for increased power, allowing them to pull traincars for maximum utility. And, each vehicle was built with rail-standard air brakes and couplers to safely handle railcars.
Another improvement was a Brandt-developed self-levelling system for the scissor-lift work deck. This system ensured that the platform would lift straight up and down, regardless of the angle of the tracks and vehicle. That gave crews a safer, more stable platform they could count on in a wider range of applications.
The Result
The powered flatcars are perfectly suited to the customer’s requirements and they now count on this innovative equipment for critical maintenance tasks. The improvements Brandt made also boosted the customer’s productivity, allowing them to get more done while reducing track-time. Plus, these machines are backed by Brandt’s industry-leading support to keep them working harder for longer.
Throughout the project, Brandt’s transparent phased approach kept the customer well-informed, giving them confidence at every step that the solution would meet all of their requirements.
The final design, manufacturing, testing and installation was completed within the customer’s schedule, on-budget, and met or exceeded all of the requirements of the contract specification.