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EN 12082:2007+A1:2010: Railway
applications - Axleboxes - Performance
testing [Required by Directive 2008/57/EC]
 Декември 2010

БДС EN 12082:2007+A1

ICS: 45.040 Заменя:

БДС EN 12082:2008.

Железопътна техника. Букси. Експлоатационни изпитвания

Railway applications - Axleboxes - Performance testing

Европейският стандарт EN 12082:2007+A1:2010 има статут на български стандарт

от 2010-12-17.

Този стандарт е официалното издание на Българския институт за стандартизация на

английски език на европейския стандарт EN 12082:2007+A1:2010.

32 стр.
© 2010 Национален № за позоваване:БДС EN
. , , 12082:2007+A1:2010
, 1797 ,
. , .“ ” 3
 НАЦИОНАЛЕН ПРЕДГОВОР

Този стандарт е подготвен с участието на БИС/TK 70 "Железопътен транспорт".

Следват 30 страници на EN 12082:2007+A1:2010.

,
:

- : , . , . 3, 1
- On-line : www.bds-bg.org
- +359 2 873-55-97
- : info@bds-bg.org
EUROPEAN STANDARD EN 12082:2007+A1
NORME EUROPÉENNE
EUROPÄISCHE NORM October 2010

ICS 45.040 Supersedes EN 12082:2007

English Version

Railway applications - Axleboxes - Performance testing

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

performance 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 Ref. No. EN 12082:2007+A1:2010: E
worldwide for CEN national Members.
EN 12082:2007+A1:2010 (E)

Contents Page

Foreword ..............................................................................................................................................................3!
Introduction .........................................................................................................................................................4!
1! Scope ......................................................................................................................................................5!
2! Normative references ............................................................................................................................5!
3! Terms and definitions ...........................................................................................................................5!
4! Information and conditions to be agreed and documented ..............................................................6!
5! Watertightness test................................................................................................................................7!
6! Rig performance test .............................................................................................................................7!
6.1! General ....................................................................................................................................................7!
6.2! Execution ................................................................................................................................................7!
6.3! Carrying out the test ..............................................................................................................................9!
6.4! Acceptance criteria ................................................................................................................................9!
6.5! Rig test report ..................................................................................................................................... 10!
7! Field test .............................................................................................................................................. 11!
7.1! General ................................................................................................................................................. 11!
7.2! Carrying out the test ........................................................................................................................... 11!
7.3! Test parameters .................................................................................................................................. 11!
7.4! Acceptance criteria ............................................................................................................................. 11!
7.5! Field test report ................................................................................................................................... 12!
Annex A (normative) Rig performance test ................................................................................................... 13!
A.1! Schematic example of test rig ........................................................................................................... 13!
A.2! Temperature measurement................................................................................................................ 14!
A.3! Grease sampling zones ...................................................................................................................... 17!
A.4! Definition of loading ........................................................................................................................... 18!
A.5! Definition of test cycles ..................................................................................................................... 19!
A.6! Graphical presentation of test cycles ............................................................................................... 21!
A.7! Temperature criteria ........................................................................................................................... 22!
A.8! Mechanical and physico-chemical acceptance criteria .................................................................. 23!
A.9! Watertightness test............................................................................................................................. 23!
Annex 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!

2
 EN 12082:2007+A1:2010 (E)

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.

3
EN 12082:2007+A1:2010 (E)

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.
4
 EN 12082:2007+A1:2010 (E)

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 19-503 2 ), 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.

5
EN 12082:2007+A1:2010 (E)

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).

6
 EN 12082:2007+A1:2010 (E)

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 Fr n and the nominal axial load Fan is carried out by means of
the methods described in A.4. The constant radial load is designated Fr , and the varying actual axial load is
designated Fa . 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;

7
EN 12082:2007+A1:2010 (E)

Fr Fr n
d) device arranged to subject each axlebox to a constant radial force = ;

Fr
e) measuring device to monitor this radial force ;

Fa
f) device arranged to subject each axlebox to an alternating axial force ;

Fa
g) measuring device to monitor this alternating axial force ;

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 F0 (the axle load), in newtons;

b) wheel diameter at the limit of wear d min , in metres;

c) vehicle speed limit ν max , 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 designated ν n .

110 vmax
n= (1)
6 ! d min

8
 EN 12082:2007+A1:2010 (E)

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.

9
EN 12082:2007+A1:2010 (E)

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

T z 20 = T zm − (Ta − 20) (2)

where

T z 20 is a temperature measured at a position z and then re-calculated to a temperature corresponding

to an ambient temperature of 20 °C;
T zm is a temperature measured at a position z (measured positions are loading zones and hot box
detector zone);
Ta is the ambient temperature measured in the same time as T zm and 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;

10
 EN 12082:2007+A1:2010 (E)

— 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.

11
EN 12082:2007+A1:2010 (E)

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.

12
 EN 12082:2007+A1:2010 (E)

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

13
EN 12082:2007+A1:2010 (E)

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

14
 EN 12082:2007+A1:2010 (E)

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

15
EN 12082:2007+A1:2010 (E)

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

16
 EN 12082:2007+A1:2010 (E)

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

17
EN 12082:2007+A1:2010 (E)

A.3.2 One-bearing axleboxes

Key
A bearing locking cap side zone
B bearing thrust collar side zone
C bearing inside zone

Figure A.6 — Grease sampling zones

A.4 Definition of loading

If not otherwise documented in accordance with Clause 4, the loads and forces shall be calculated by means
of Equations (A.1) to (A.3).

a) Reference vertical load:

1
F0 = mmax g (A.1)
j

b) Constant nominal radial force Fr n applied throughout the test:

1,2
Fr n = (F0 − m0 g ) = 0,6 (F0 − m0 g )
2 (A.2)

c) Periodic alternating axial force, as illustrated in A.6, applied at least half the time and during 5 s and only
when the test speed is greater than 20 % of the nominal test speed. The nominal axial force is:

18
 EN 12082:2007+A1:2010 (E)

1,2 & F # & F #

Fan = × 0,5 × 0,85 $10 4 + 0 ! = 0,255 $10 4 + 0 !
2 % 3 " % 3 "
(A.3)

where

F0 is the reference vertical load applied per wheelset on the track, in Newtons;

j is the number of wheelsets per vehicle;

mmax is the maximum mass of the vehicle in running order, in kilograms;

2
g is the acceleration due to gravity (9,81 m/s );

1,2 applies to 20 % safety margin over the reference vertical load;

1
applies to calculation of forces for one journal;
2

m0 is the mass of one wheelset, in kilograms;

0,5 is a factor to introduce an average lateral force throughout the operation;

0,85 is a coefficient that gives the maximum load before track displaces sideways (formula of
Prud'homme).

d) The tolerances of the forces applied on the test rig are:

1 for the Fr n value – +3/-3 % of the nominal radial force;

2 for the Fan value – +6/-6 % of the nominal axial force.

A.5 Definition of test cycles

A.5.1 Vehicles with a maximum travelling speed up to and including 200 km/h

Each test cycle shall last for 8 h; it shall include two elementary test trips and two stops:

— 3 h 50 min of rotation in one direction, including 3 h 40 min at nominal test speed;

— 10 min stop, with ventilation stopped;

— 3 h 50 min of rotation in the other direction, including 3 h 40 min at nominal test speed;

— 10 min stop, with ventilation stopped.

The test shall include a number of cycles such that the cumulative distance is at least 600 000 km.

A.5.2 Vehicles with a maximum travelling speed over 200 km/h

Each test cycle shall last for 4 h; it shall include two elementary test trips and two stops:

— 1 h 50 min of rotation in one direction, including 1 h 30 min at nominal test speed;

19
EN 12082:2007+A1:2010 (E)

— 10 min stop, with ventilation stopped;

— 1 h 50 min of rotation in the other direction, including 1 h 30 min at nominal test speed;

— 10 min stop, with ventilation stopped.

The test shall include a number of cycles such that the cumulative distance is at least 800 000 km.

A.5.3 Particular conditions for similar rolling bearing, grease or box housing

In case a simplified procedure is justified, for example if only one component has been changed, or there are
minor changes, then the test can be limited in distance.

The only purpose of this test is to verify, that when the bearing has reached a stable condition, the
temperatures do not change such that the criteria in 6.4 cannot be fulfilled.

Unless otherwise agreed, the cumulative distance to be considered is at least 100 000 km.

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 EN 12082:2007+A1:2010 (E)

A.6 Graphical presentation of test cycles

Key
1 speed variation
2 pre-test
3 performance test
4 detail of one test cycle
5 radial force
6 axial force variation (force at pre-test as agreed in 6.3.2)
7 detail of time history of axial force (enlarged time scale)

Figure A.7 — Graphical presentation of test cycles

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EN 12082:2007+A1:2010 (E)

Table A.1 — Cycle length for A.6 diagrams

Vehicle Time
Speed t1 t2 t3 t4 t5
a
t6 t7 t8 t9
b

v > 200 km/h 2×t2 (2×t3) + t4 + t5 10 min 90 min 10 min t7 + t9 5s 0,2 s 0–5s

v ≤ 200 km/h 2×t2 (2×t3) + t4 + t5 5 min 220 min 10 min t7 + t9 5s 0,2 s 0–5s
c
Tolerances ± 1 min ± 1 min ± 1 min ± 0,1 s ± 0,1 s ± 0,1 s

The graphical presentation in A.6 primarily describes the timing, however the rate of change and transition points
need not be linear.
a The stop period t5 may be prolonged if required (e.g. in case of laboratory incidents and operating practices), however, this is
not considered part of the cycle times.
b The value for t9 shall be selected by the customer, related to the application.
c Tolerance for test rig speed is ± 3 %.

A.7 Temperature criteria

Table A.2 — Temperature criteria

Criterion Characteristics Requirements

1 Maximum temperature of the bearing in the load " 100 °C

zone during the first 20 elementary trips, for an
ambient temperature of 20 °C.
2 Maximum temperature of the bearing in the load " 90 °C
zone during each elementary trip, for an ambient
temperature of 20 °C, excluding the first 20 For max 1 % of elementary trips, the maximum
elementary trips. temperature may be between 90 °C and 100 °C.

3 Maximum temperature in the HBD scanning zone " 80 °C

during the first 20 elementary trips, for an ambient
temperature of 20 °C.
4 Maximum temperature in the HBD scanning zone " 70 °C
during each elementary trip, for an ambient
temperature of 20 °C, excluding the first 20 For max 1 % of elementary trips, the maximum
elementary trips. temperature may be between 70 °C and 80 °C.

v " 200 km/h v > 200 km/h

5 Maximum temperature difference between the " 15 °C " 20 °C
two axleboxes, measured simultaneously in the
load zones in the course of each elementary trip, For max 2 % of elementary For max 2 % of elementary
when the maximum temperature of the hotter box trips, the max difference may trips, the max difference
in the load zone is # 50 °C, excluding the first 20 be between 15 °C and 25 °C. may be between 20 °C and
elementary trips. 25 °C.

6 Maximum temperature difference between the " 15 °C " 20 °C

two axleboxes, measured simultaneously in the
HBD scanning zone in the course of each For max 2 % of elementary For max 2 % of elementary
elementary trip, when the maximum temperature trips, the max difference may trips, the max difference
of the hotter box in the load zone is # 50 °C. be between 15 °C and 25 °C. may be between 20 °C and
25 °C.
7 For each box, maximum temperature difference " 10 °C " 20 °C
measured in the load zone between two
successive elementary trips, excluding the first 20 For max 2 % of elementary For max 2 % of elementary
elementary trips. trips, the max difference may trips, the max difference
be between 10 °C and 15 °C. may be between 20 °C and
25 °C.

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 EN 12082:2007+A1:2010 (E)

A.8 Mechanical and physico-chemical acceptance criteria

A.8.1 General

On completion of the test, the acceptance of the criteria in A.8.2 and A.8.3 shall be fulfilled.

A.8.2 Mechanical criteria

The following criteria shall be fulfilled:

— rollers and the bearing rings shall show no defects, such as spalling, smearing, heating;

— cages shall show no defects, such as breakage, cracks, deformation or abnormal wear;

— grease shall show no defective behaviour in terms of leakage, discoloration, smell, appearance etc.

A.8.3 Physico-chemical criteria

— The iron content in the grease shall be less than 0,5 % in the zones C or D in Figure A.5 and the zone C
in Figure A.6 and shall be less than 1 % in the zones A and B in Figure A.5 and Figure A.6.

— If the cages are made of a copper alloy, the copper content in the grease shall be less than 0,1 % in the
zones C or D in Figure A.5 and the zone C in Figure A.6 and less than 0,2 % in the zones A and B in
Figure A.5 and Figure A.6.

Grease samples will further be checked according to methods described in EN 12081.

Table A.3 — Approval test

Characteristic Unit Requirement Test method

Consistency 0,1 mm # 200 ISO 2137
" 380 (1/4 cone)

Dropping point °C > 160 ISO 2176

Water content % for information ISO 3733

-1
Change of oxidation stability cm " 10 NF F 19-503

A.9 Watertightness test

A.9.1 General

This test is made in a static mode, with apparatus designed to simulate the spraying of water at the rear of an
(zone between the rear cover and the wheel).

A.9.2 Test conditions

The testing apparatus (see Figure A.8) sprays water between the back of a sealed end and the wheel
(simulated by a representative device) mounted on a dummy journal.

The apparatus is equipped with a pump and a flow regulator and water is sprayed by means of an arc-shaped
sprinkler.

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EN 12082:2007+A1:2010 (E)

The axlebox assembly consists of a dummy journal, sealing arrangement, bearings, the front and rear covers.
The simulated wheel is fixed at the end of the dummy journal.

The vertical distance between the uppermost position of the sealing cover and the arc formed sprinkler is set
at about 50 mm.

The curvature-plane of the sprinkler is perpendicular to the axis of the dummy journal and is line with the
space between the inner sealing cover and the device simulating the end face of the wheel.

The sprinkler sprays water towards the axlebox around about one third of the periphery.

A dummy translucent cover may be used on the front of the axlebox to enable observation of water ingress.

Some holes (closed off by plugs during the test) may be provided at the bottom of the axlebox. These allow for
easy draining and recovery of a great part of the water that may have penetrated the seal. These holes shall
be located at the front and the rear end of the housing and at the space between the bearings for two-bearing
housings.

The water is tinted to make it easier to check any water penetration.

The sprayed water flow is supplied at the rate of about 3 l/min.

A.9.3 Test procedure

The water flow is applied for at least one hour.

During the test, observation through the translucent cover (if used) allows a first appreciation of the quality of
the axlebox sealing (appearance or not of the tinted water).

After the test, the external parts of the axle box, dummy journal, simulated wheel etc. are first dried with rags.

The water is then recovered, if any, by removing the plugs (if used).

The dismounting operations are carried out over a drip-tray in order to drain and recover the water from the
axlebox.

A.9.4 Pass/fail criterion

After the test, no ingress of water into the axlebox shall be observed.

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 EN 12082:2007+A1:2010 (E)

Key
1 observation window
2 removable plugs
3 dummy journal
4 simulated wheel
5 arc shaped
Figure A.8 — Watertightness test – principle sketches

25
EN 12082:2007+A1:2010 (E)

Annex 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)

This European Standard has been prepared under a mandate given to CEN/CENELEC/ETSI by the European
Commission and the European Free Trade Association to provide a means of conforming to Essential
Requirements of the Directive 2008/57/EC3.

Once this standard is cited in the Official Journal of the European Union under that Directive and has been
implemented as a national standard in at least one Member State, compliance with the clauses of this
standard given in Table ZA.1 for HS Rolling Stock, Table ZA.2 for CR Freight Wagons and Table ZA.3 for CR
Locomotives and Passenger Rolling Stock, confers, within the limits of the scope of this standard, a
presumption of conformity with the corresponding Essential Requirements of that Directive and associated
EFTA regulations.

Table ZA.1  Correspondence between this European Standard, the HS TSI RST published in OJEU
th
dated March 26 2008 and Directive 2008/57/EC
Clause/ sub- Chapter/§/annexes of the TSI Corresponding text, Comments
clauses of this articles/§/annexes of the
European Standard Directive 2008/57/EC

The whole standard 4.Characterisation of the Annex III, Essential Clause 6 of EN

except for Clause 4 subsystem
is applicable.
4.2 Functional and technical
specification of the subsystem.
4.2.3 Track interaction and
gauging.
§4.2.3.3.2.3 Rolling stock
parameters which influence
ground based train monitoring
systems. Axle bearing health
monitoring. Hot axle box
detection for Class 2 trains
requirements 12082:1998 is quoted
in sub-clause
1 General requirements 4.2.3.3.2.3.2 of the
TSI (in the text it is
1.1 Safety written “Annex 6”, but
Clauses 1.1.1, 1.1.3 there is no annex 6
1.5 Technical compatibility and the sense of the
TSI text is “clause 6”).
2 Requirements specific to Thus this clause of
each subsystem EN 12082:1998 is
mandatory. Clause 6
2.3 Control-command and of EN 12082:2007 is
signalling the equivalent clause.
2.3.2 Technical
compatibility

2.4 Rolling stock

2.4.2 Reliability and
availability
2.4.3 Technical
compatibility §3

3 This Directive 2008/57/EC adopted on 17th June 2008 is a recast of the previous Directives 96/48/EC ‘Interoperability of
the trans-European high-speed rail system’ and 2001/16/EC ‘Interoperability of the trans-European conventional rail
system’ and revisions thereof by 2004/50/EC ‘Corrigendum to Directive 2004/50/EC of the European Parliament and of the
Council of 29 April 2004 amending Council Directive 96/48/EC on the interoperability of the trans-European high-speed rail
system and Directive 2001/16/EC of the European Parliament and of the Council on the interoperability of the trans-
European conventional rail system’

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 EN 12082:2007+A1:2010 (E)

Table ZA.2  Correspondence between this European Standard, the CR TSI RST Freight Wagons
dated July 2006, published in the OJEU on 8 December 2006 and its intermediate revision published in
the OJEU on 14 February 2009 and Directive 2008/57/EC
Clause/ sub- Chapter/§/annexes of the TSI Corresponding text, Comments
clauses of this articles/§/annexes of the
European Standard Directive 2008/57/EC

The whole standard 4.Characterisation of the Annex III, Essential The axlebox is
is applicable. subsystem requirements considered as a
component of the
4.2 Functional and technical 1 General requirements Bogie and running
specifications of the subsystem gear Interoperability
4.2.3 Vehicle track interaction 1.1 Safety Constituent.
and gauging Clauses 1.1.1, 1.1.3
§4.2.3.4.1 Vehicle dynamic 1.5 Technical compatibility
behaviour, General
2 Requirements specific to
5 Interoperability constituents each subsystem
§5.3.2.1 List of constituents,
Vehicle track interaction and 2.3 Control-command and
gauging, Bogie and running signalling
gear 2.3.2 Technical
§5.4.2.1 Constituents compatibility
performances and
specifications, Vehicle track 2.4 Rolling stock
interaction and gauging, Bogie 2.4.2 Reliability and
and running gear availability
2.4.3 Technical
6 Assessment of conformity compatibility §3
and/or suitability for use of the
constituents and verification of
the subsystem
§6.1.3.2.1 Interoperability
constituents, Specification for
ICS, Bogie and running gear

Annex Y: Constituents Bogies

and Running Gear

27
EN 12082:2007+A1:2010 (E)

Table ZA.3  Correspondence between this European Standard, the CR LOC and PASS RST TSI (final
draft Rev 4.0 dated 24 November 2009) and Directive 2008/57/EC

Clause/ sub-clauses Chapter/§of the TSI Corresponding text, Comments

of this European articles/§/annexes of the
Standard Directive 2008/57/EC

The whole standard is 4.Characterisation of the Annex III, Essential

Ranges of
applicable. Rolling stock subsystem requirements
temperature defined
in this EN are an
4.2 Functional and technical 1 General requirements
open point of the TSI.
specifications of the
subsystem. 1.1 Safety
4.2.3 Track interaction and Clauses 1.1.1, 1.1.3
gauging. 1.5 Technical compatibility
§4.2.3.3.2 Rolling stock
parameters which influence 2 Requirements specific to
ground based systems. Axle each subsystem
bearing condition monitoring.
§4.2.3.5.2 Functional and 2.3 Control-command and
technical specifications of the signalling
subsystem. Track interaction 2.3.2 Technical
and gauging. Running gear, compatibility
Wheelsets
2.4 Rolling stock
2.4.2 Reliability and
availability
2.4.3 Technical
compatibility §3

WARNING — Other requirements and other EU Directives may be applicable to the product(s) falling within
the scope of this standard."

28
 EN 12082:2007+A1:2010 (E)

!deleted text"

29
 EN 12082:2007+A1:2010 (E)

Bibliography

[1] prEN 15437-1, Railway applications - Axlebox condition monitoring - Performance requirements - Part
1: Track side equipment

[2] prEN 15437-2, Railway applications -— Axlebox condition monitoring — Performance requirements —
Part 2: Onboard systems

[3] EN ISO 9001, Quality systems — Performance requirements (ISO 9001:2000)

[4] UIC 515-5, Powered and trailing stock — Bogies — Running gear — Tests for axleboxes

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