Rail Vehicle Systems H i g h – S p e e d Tra i n s Source: Siemens High-Speed Trains Air Supply | Brake Control | Bogie Equipment | Rail-Services | On-Board Source: Bombardier 2 Why do more and more high-speed train manufacturers and operators put their faith in Knorr-Bremse systems ? Rail Vehicle Systems Knorr-Bremse systems are impressive even at extremely high speeds At speeds of up to 400 km/h, enormous forces are generated. Trains that regularly travel long distances at high speeds require braking systems that can keep these forces under control – both safely and economically.
As well as lightweight, compact systems that can be used worldwide, there is a need for intelligent control systems. Knorr-Bremse is regarded as an international pioneer in this field. On the basis of tried-and-tested technologies, we develop innovative solutions offering top levels of safety, reliability, and economy. The systems we have developed are so efficient that they also score top marks in terms of environmental friendliness. Customers enjoy full support from a single source – from the initial planning stage and commissioning right down to aftermarket services.
Worldwide operator and customer audits regularly single out the consistent quality of our products and services for praise – and this is confirmed by our EN 50126 (RAMS and LCC) certification. 3 High-Speed Trains Systems Solutions For Every Market On-BOard S yS t e m S BOgie equipment a i r S u p p ly What is Knorr-Bremse’s complete “one-stop solution” for high-speed trains 4 ? Rail Vehicle Systems Air Supply Combined compressor and air treatment system Knorr-Bremse’s ready-to-install air supply equipment has been adapted in line with the trend towards increasingly compact, lightweight systems.
Our product portfolio includes low-vibration and low-noise screw compressors with an output of between 600 and 2,500 l/min. as well as air dryers and condensate collectors. A particularly economic solution is the first ever oil-free compressor, with life-cycle costs that are up to 50% lower than those of conventional compressors. B o gie Equipment Innovative design minimizes assembly and maintenance requirements Knorr-Bremse offers a wide range of compact, lightweight bogie equipment including low-maintenance compact brake calipers, low-wear brake discs, and innovative high-performance brake pads.
Sinter pads reduce the life-cycle costs of electromagnetic track brakes by up to 40%. The eddy current brake is completely free of wear components. Brake Control Ensuring the intelligent interaction of all brake functions With brake control systems, Knorr-Bremse ensures optimum functioning of all systems involved in the braking process and allow reliable stopping of the train in all operating conditions.
The highly flexible and configurable brake control system EP Compact, together with the modular electronic platform ESRA, manages the pressure control, anti-skid, wheel-slide monitoring and diagnostics, as well as further highly complex brake control functions. BraKe cO n t r O l O n-B oard Systems Doors, air-conditioning units, and more It is not just Knorr-Bremse braking systems that ensure greater safety and comfort in rail vehicles. Our on-board product portfolio covers a wide range of innovative products and solutions including vehicle and platform doors and air-conditioning units.
We also produce state-of-the-art electronic diagnostic systems and windscreen wiper and wash systems. R ail-S er vices A partner for all requirements throughout the entire product life-cycle Knorr-Bremse offers a wide range of rail-services ranging from individual consultancy and collaborative product development to homologation, commissioning, training, maintenance, repair, upgrading, and overhaul of all components – as well as a reliable supply of OEM parts. Whether you opt for individual services or the full package, everything is provided locally, either on-site or in one of our global service centers.
Testing Test benches for all products – worldwide Knorr-Bremse supplies test benches for all products and systems, customized and tailored to the customer’s requirements, to supplement longterm overhaul services with tools and products for daily maintenance. Several hundreds of test benches and test installations are in operational service with our customers worldwide – for example, as train brake tests, test benches for brake control products, compressors, air dryers, tread brakes, brake calipers, and more.
A perfect balance of high-quality systems and services Knorr-Bremse’s expertise in the field has gone into every single component and system. Top-quality components operate smoothly together to guarantee optimum functionality, high reliability, and maximum safety. Complex electronic control systems such as blending and brake management reduce wear to a minimum by ensuring balanced operation of all systems. The system can be configured either to use the vehicle bus system or a separate bus exclusive to the braking system. For each project, customers are closely consulted at the design stage.
It goes without saying that Knorr-Bremse offers support during the homologation process as well as all the necessary on-site services across the entire product life-cycle. 5 High-Speed Trains C u t t i n g – E d g e Te c h n o l o g i e s Compressors Oil-free compressor Compact Brake Calipers Easy to install, maintenance-free, unusually lightweight The compact brake caliper unit has a completely redesigned mechanism for applying braking force that allows for considerable transverse axle movement and tilt without generating any internal stresses.
Requiring only a standard interface, it is easy to install, and sealed joints mean low maintenance. Its weight has also been reduced by up to an impressive 100 kg per bogie. Modular Brake Control EP Compact and ESRA – modular brake control With EP Compact, Knorr-Bremse has developed a flexible and powerful brake control system with central and distributed control coming from one family. Core functions can be expanded by adding a wide range of options offered by various modules of the EP Compact product family.
Especially for high-speed trains, Knorr-Bremse has developed innovative ESRA modules for new functions as defined in the TSI. Knorr-Bremse is the only brake supplier to offer an integrated solution for bogie monitoring and diagnostics comprising detection of non-rotating axles, derailment detection and additional diagnostic functions to improve service and maintenance. Knorr-Bremse was the first company in the rail vehicle industry to develop a compressor that operates without any oil. Lubrication is replaced by a special coating, and the unit is cooled by air taken in via the crankcase.
This innovative product is a winner in both environmental and economic terms. Expenses for oil changes, oil separation, and condensate disposal are avoided, and energy consumption, weight, and installation space are significantly reduced. Innovations that pay their way Reducing wear and tear and maintenance costs is a good way of saving money. More than any other manufacturer, Knorr-Bremse has succeeded in finely coordinating the complex interplay of different braking systems. Brake components that are prone to wear are only used when the wear-free electro-dynamic braking cannot cope on its own.
Even then, patented ISOBAR brake pads have proven longevity against conventional materials. Brake pads and discs require replacement less frequently, and their design enables them to be serviced rapidly. The brake calipers themselves are low maintenance. These examples demonstrate that if all the relevant factors are included in the calculation, the bottom line is savings for the customer. Customized service packages ensure that all Knorr-Bremse systems function smoothly for up to 30 years – anywhere in the world.
The secret is our combination of OEM expertise and a highly efficient service infrastructure. 6 Rail Vehicle Systems Brake Management Intelligent braking Stefan Aurich Team Leader, System Engineering High-Speed Trains “We produce utterly reliable systems for rail vehicles that are subject to heavy use. Our products offer everything: easy handling, low-cost, and uncompromising levels of safety. ” Economical braking is all about reducing the stress on wear components to a minimum. Knorr-Bremse ensures that friction brakes only come into operation when wear-free dynamic brakes are not enough.
A brake management system for the entire train calculates brake force distribution based on different data: available brake effort of the individual brake systems, vehicle weights and adhesion limits, and thermal limits of the friction brake are taken into account to blend the different systems and achieve a balanced braking. is it true that Knorr-Bremse’s high-speed solutions are also the best in the world in terms of economy ? 7 High-Speed Trains Satisfied Customers … 1 1 2 3 4 5 6 Wherever top quality is crucial for competitiveness Knorr-Bremse’s rail vehicle systems are not only cutting-edge technology – they are also market leaders.
All over the world, when manufacturers and operators make purchasing decisions, they take a wide range of factors relating to safety and economics into consideration. They find that the best results are offered by Knorr-Bremse’s unique combination of experience and innovation. Many customers opt for the full range of Knorr-Bremse systems and components for their high-speed trains. Examples for equipped high-speed trains worldwide: 1 BR 407 2 AVE S 103 3 AGV Pegase 4 CRH3 5 AVE S 102 6 KTX Korea 8 … Supplied With Excellent Products Air Supply
Oil-free compressor Oil-free air (environmentally friendly, no downstream contamination) Less complex system / fewer interfaces (no oil filter, no condensate collector) Almost maintenance-free, very low LCC Screw compressor Special design, related to tough railway operation conditions Low compressor noise level Virtually pulsation-free, delivery of compressed air Brake Control EP Compact Flexible brake control platform Central and distributed control Compact design Continuous pneumatic load correction Full set of auxiliary functions CENELEC- and TSI-compliant
Modular ESRA Intelligent combination of pneumatic and electronic control Intelligent blending and brake management Modular and suitable to the various customer requirements CENELEC- and TSI-compliant Bogie Equipment Wheel- and axle-mounted brake disc Standardized interface and fixation on wheel Resistant against thermal cracks due to movable friction disc Robust design with high safety against external shock and vibration Compact brake caliper Only one interface to bogie Highly modular design Optimized design regarding weight, assembly, and costs Reduced maintenance 9 Rail Vehicle Systems
Compact units Compact, light, reliable Protected: developed especially for installation beneath the frame All components to be maintained can be reached through a maintenance port Air dryer Dual-chamber regeneration dryer Lightweight aluminum design Integrated pre-filtration elements COMORAN – Condition Monitoring for Railway Applications Condition monitoring and diagnosis Derailment detection Reducing life-cycle costs Fulfillment of TSI requirements Modular motion controller kit Brake, traction, and master controller Compatible with UIC standard Small, flexible installation space Robust design, proven application
Isobar sinter brake pad Flexible sinter brake pad with highest brake performance Temperature resistant with constant friction behavior Long disc and pad life due to even temperature distribution on brake disc For overhaul, only replacement of friction elements necessary Eddy current brake No mechanical contact between brake and rail No wear and tear and low maintenance Noiseless braking Brake force does not depend on friction coefficient Constant brake force even at high-speed applications 10 Rail Vehicle Systems Where have Knorr-Bremse solutions already been tried and tested ? 11 High-Speed Trains T h e F u t u r e
What prospects for the future can Knorr-Bremse offer in the high-speed segment 12 ? Rail Vehicle Systems Secure Operation | Secure Investment | Secure Future The future belongs to technology leaders The extreme stress to which high-speed trains are subjected call for unusually high-performance, top-quality, and safe braking technologies. We offer to adapt every system to the specific operating conditions involved, thereby minimizing wear and tear and achieving top levels of economy and vehicle availability. As a manufacturer of braking systems with more than 100 years‘ experience, Knorr-Bremse has the necessary expertise to achieve this.
High levels of R & D investment ensure that our systems remain cutting-edge around the world. With railservices Knorr-Bremse offers a high-quality portfolio of maintenance and aftermarket services ranging from original spare parts and maintenance agreements right down to responsibility for complete systems during the entire life-cycle. Customers also benefit from a comprehensive network of service centers for all braking and on-board systems. 13 Rail Vehicle Systems Knorr-Bremse Systeme fur Schienenfahrzeuge GmbH Moosacher Stra? e 80 80809 Munich Germany Tel: +49 89 3547 0 Fax: +49 89 3547 2767 www. knorr-bremse. om Europe – Africa Austria – Modling Dr. techn. J. ZELISKO GmbH Tel: +43 2236 409 0 Knorr-Bremse GmbH Tel: +43 2236 409 0 Austria – Kematen/Ybbs Knorr-Bremse GmbH Division IFE Tel: +43 7448 9000 Czech Republic – Brno IFE-CR, a. s. Tel: +42 0532 159 111 IGE-CZ s. r. o. Tel: +42 0548 424 050 France – Reims Freinrail Systemes Ferroviaires S. A. Tel: +33 3 2679 7200 Germany – Berlin Knorr-Bremse Systeme fur Schienenfahrzeuge GmbH Zweigniederlassung Berlin Tel: +49 30 9392 0 Hungary – Budapest Knorr-Bremse Vasuti Jarmu Rendszerek Hungaria Kft. Tel: +36 1421 1100 Italy – Florence Knorr-Bremse Rail Systems Italia S. r. l.
Tel: +39 055 3020 1 Italy – Rozzano Microelettrica Scientifica SpA Tel: +39 02 575 731 Netherlands – Leeuwarden IFE Tebel Technologies B. V. Tel: +31 58 297 3333 Poland – Krakow Knorr-Bremse Systemy dla Kolejowych Srodkow Lokomocji PL Sp. z o. o. Tel: +48 12 260 96 10 Romania – Bucharest Knorr-Bremse SRL Tel: +40 37 400 5155 Russia – Moscow Knorr-Bremse Systeme fur Schienenfahrzeuge GmbH Tel: +7 495 739 01 13 South Africa – Spartan Knorr-Bremse (SA) (Pty) Ltd. Tel: +27 11 961 7800 South Africa – Johannesburg Microelettrica Scientifica (PTY) Ltd Tel: +27 11 794 3330 Spain – Madrid Merak Sistemas Integrados de Climatizacion, S.
A. Tel: +34 91 495 90 00 Sociedad Epola de Frenos Calefaccion y Senales, S. A. Tel: +34 91 145 9400 Sweden – Lund Knorr-Bremse Nordic Rail Services AB Tel: +46 46 3293 50 Switzerland – Niederhasli Oerlikon-Knorr Eisenbahntechnik AG Tel:+41 44 852 31 11 United Kingdom – Melksham Knorr-Bremse Rail Systems (UK) Ltd. Tel: +44 1225 898 700 United Kingdom – Derby Sydac Ldt Derwent Business Centre Tel: +44 1332 299 600 United Kingdom – Donchaster Techtrain Associates Ltd Tel: +44 1302 360043 Americ a Brazil – Sao Paulo Knorr-Bremse Sistemas para Veiculos Ferroviarios Ltda. Tel: +55 11 5681 1129 Canada – Kingston Knorr Brake Ltd.
Tel: +1 613 389 46 60 USA – Randolph Microelettrica USA LLC Tel: +1 973 598 0806 USA – Watertown New York Air Brake Corporation Tel: +1 315 786 52 00 USA – West Chicago Anchor Brake Shoe Company Tel: +1 630 293 1110 USA – Westminster IFE North America Tel: +1 410 875 1468 Knorr Brake Corporation Tel: +1 410 875 09 00 Merak North America LLC Tel: +1 410 875 09 00 A sia – Australia Australia – Granville NSW Knorr-Bremse Australia Pty. Ltd. Tel: +61 2 8863 6500 Australia – Adelaide Sydac Pty Ldt Tel: +61 8239 3600 China – Beijing Knorr-Bremse CARS LD Vehicle Brake Disc Manufacturing (Beijing) Co. Ltd. Tel: +86 10 5101 0999 Knorr-Bremse Nankou Air Supply Unit (Beijing) Co. Ltd. Tel: +86 10 5164 2640 Knorr-Bremse Systems for Rail Vehicles (Suzhou) Co. Ltd. Beijing Office Tel: +86 10 6802 9088 China – Guangzhou Westinghouse Platform Screen Doors (Guangzhou) Ltd. Tel: +86 20 8770 8700 China – Hong Kong Knorr-Bremse Asia Pacific (Holding) Limited Tel: +852 3657 9800 China – Qingdao IFE-Victall Railway Vehicle Door Systems (Qingdao) Co. , Ltd. Tel: +86 532 8793 8512 China – Shanghai Merak Railways Technologies (Shanghai) Co. , Ltd.
Tel: +86 21 5192 5800 China – Suzhou New District Knorr-Bremse Systems for Rail Vehicles (Suzhou) Co. Ltd. Tel: +86 512 6616 5666 This publication may be subject to alteration without prior notice. A printed copy of this document may not be the latest revision. Please contact your local Knorr-Bremse representative or check our website www. knorr-bremse. com for the latest update. The figurative mark “K” and the trademarks KNORR and KNORRBREMSE are registered in the name of Knorr-Bremse AG. Copyright 2007 © Knorr-Bremse AG – All rights reserved.
Including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring. China – Wuxi Merak Jinxin Air Conditioning Systems (Wuxi) Co. , Ltd. Tel: +86 510 8558 3133 India – Faridabad Knorr-Bremse India Private Ltd. Tel: +91 129 227 64 09 Japan – Tokyo Knorr-Bremse Rail Systems Japan Ltd. Tel: +81 3 53 91 10 13 Korea – Seoul Knorr-Bremse Rail Systems Korea Ltd. Tel: +82 2 22 80 55 55 Singapore – Singapore Knorr-Bremse Asia Pacific (Holding) Limited Tel: +65 6555 0105 P-1203-EN-03 09. 2010
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