Sanding System

Sanding System

Sanding operation starts after the receiving blowcommand from the vehicle. There are two ways of sanding command; automatic command from the WSP system or manually pushing button command from the vehicle control panel. After receiving the sanding command, KKS-100 starts running with both compressor and solenoid.

At the routingunit, the pressured air exiting from the compressor come across with sand which flows from the sanding tank by the way of batching unit. The pressured air and sand mixture exits from the blasting unit pass the sanding hoses. Lastly, the mixture is being blownto rail and wheel intersection by the nozzle.

Sanding System Diagram Drawing
Sanding System Sand Tank

Sand Tank

One of the most important issues in sanding systems is the design and production of storage volumes with the correct geometry and sealing level. Sand tanks are uniquely designed for every project according to customers' requirements. Materials are chosen for their high wear resistance against sand-pressured air, such as aluminium alloy or stainless steel. All openings, such as sand filling caps, batching openings, sensor connections, indicator glasses, etc., are insulated against air and moisture. Thus, the sand is prevented from becoming lumpy due to moisture. The tank geometry is designed using various methods, considering system limitations;

  • There must be no geometries inside the tank that will cause the sand to remain stationary. For this reason, the most important point is that the tank has a defined slope.

  • This slope cannot be under 36 degrees.
  • Parametre Değer
    Material A15754/ A16082 / AISI 304
    Mounting Place Under Frame
    Mounting Type Screw
    Tank Volume Optional (14... 30 liters)
    Safety Class IP65
    Compatible Filling Types Top Filling Flap / Lateral Filling Flap / Both
    Güç 45W (S3)
    Earthing Type Screw Earthing
    Sanding System Batching and Routing System

    Batching and Routing System

    The batching and routing system consists of 3 subcomponents:
    1. Batching Unit,
    2. Solenoid,
    3. Routing Unit,
    The batching system, which is directly connected to the sand tank, allows the desired amount of sand to reach the routing unit while the sand is passing through the batching unit. The amount of sand to be blown can be adjusted from 400 to 1200 gr/min by means of the adjustable solenoid. Sand arrives in the routing system after being dispensed from the batching unit. The sand from the batching unit and the compressed air from the compressor are combined and transmitted to the nozzle through the distribution hoses.

    Parametre Değer
    Sand Flow 600-1000 g/30san ± 7% adjustable in range and tolerance
    Operating pressure 1bar
    Batching Method Batching with solenoid (Electro-mechanical adjustment)+[@Parameter] IP65
    Safety Class IP65
    Useable Max Speed 160km/h
    Operating voltage 24V DC (36, 72 and 110V DC options are also available)
    Power 45W
    Sand Quality and Size BN 918224
    Compressed Air Quality ISO 8573 Particle class: 7, Density <= 10mg / m, Humidity: 2
    Operating temperature EN 50155
    Socket Type EN 175301-803
    Sanding System Compressor


    Oil-free compressors offer significant advantages in terms of lifetime and mechanical properties. The required pressurized air is supplied by the oil-free compressor, which has been proven and utilized in numerous railway projects for sanding systems. Thanks to its innovative technology, it provides continuous service with minimal maintenance requirements. The specifications of the compact oil-free compressor are as follows:

    Parametre Değer
    Type of fluid Air
    Flow 80 1/min
    Max. Operating pressure 1500 mbar
    Operating pressure 1000 mbar
    Motor DC
    Nominal Voltage 24V DC
    Safety Class IP56
    Power 250W
    Weight 3,8kg
    STANDARDS EN 175301-803
    Compressed Air Quality ISO 8573 Particle class: 7, Density <= 10mg / m, Humidity: 2
    Sanding System Exterior Filling Flap

    Exterior Filling Flap

    Exterior filling flap, located on the vehicle's sidewall, provides the opportunity for quick and practical sand filling during maintenance. The sealing elements placed on the filling flap and in the sand passage pipe prevent any interaction between the environment and the stored sand. Air intake is prevented by a spring-pressed system at the sand filling pipe's mouth. By providing insulation, it eliminates the possibility of sand clumping.

    The flap features an open-and-remove system with a square-head, spring-loaded lock, which allows it to be closed without the need for a key after unlocking.

    An LED signal lamp, located on the filling flap, lights up when the sand level drops below 35%. The lamp can be easily seen and detected from the outside without the need to access the tank or the driver's panel.

    Parameter Value
    Material A16082
    Filling Method Refilling with pistol
    Mounting Type Screw
    Lock Type Spring Lock
    Lock Head 8mm square head
    Filling Inlet Protection Spring forced and Rubber
    Level Indicator Lamp Green/Red/White Led lamp
    Safety Class IP 66
    Sanding System Sanding Nozzle

    Sanding Nozzle

    Sanding via the nozzle increases the amount of sand passing between the wheel and the rail by 70% compared to sanding using only the hose. Nozzles produced with blowing outlet diameters of 19-25mm are the most effective sand transporting method between the wheel and the rail. One of the most important aspects of the system is applying the compressed air-sand mixture between the wheel and rail at the correct angle. The nozzle is positioned at a 15° angle to the intersection of the wheel and rail. Sand with an appropriate flow rate maintains the friction coefficient at the required level by remaining between the rail and the wheel. Special brackets, which are designed for each project, provide both positional stability and easy maintenance. Through the heating system added to the nozzle, uninterrupted service is provided in all climate and environmental conditions. The heater maintains the desired temperature in sections of the nozzle with the heat it emits through the sanding opening.

    Parameter Value
    Material A16082/AISI304
    Hose Type and Diameter Sanding Hose
    Hose Diameter 19mm
    Heater Type Cartridge resistance
    Heater Power 50-100watt
    Operating voltage 24V DC (36, 72 and 110V DC options are also available) IP67
    Safety Class IP67
    Hose Fire Protection EN 45545
    Electronic Hardware EN 50155
    Sanding System Adjustable Level Measurement Sensor

    Adjustable Level Measurement Sensor

    The sanding system has two different digital sand level indicators: one at the exterior filling flap and one in front of the driver. Both indicators receive sand level information from the capacitive level measurement sensor in the tank. The sensor warns if the sand level decreases below the critical level, which is specified according to customer choice. The sensor's changeable positioning option allows for the measurement of sand levels from various heights.

    Parameter Value
    Sensor Type Capacitive level sensor
    Operating Voltage Range/td> 10V... 30V DC (36, 72 and 110V DC options are also available)
    Standard IEC 60947-5-2
    Safety Class IP67
    Operating Temperature Range -25... 85°C
    Sensor Dimensions Ø 30 x 65.5 mm
    Sensor Housing Material A15754 / A16082
    Positioning 3 different positioning
    Sanding system photograph
    Sanding system photograph
    Sanding system photograph