Edition 30 September 2011

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1 R a i l V e h i c l e S y s t e m s Edition 30 September 2011 T h e c u s t o m e r m a g a z i n e o f K n o r r - B r e m s e R a i l V e h i c l e S y s t e m s Cover Story Knorr-Bremse in Asia Projects Montreal Metro opts for Knorr-Bremse brakes Products Energy-saving systems for trains Quality Joining forces to ensure quality

2 Edition 30 September 2011 Contents Editorial Domingo Mendieta, 3 Member of the Board of Directors of Knorr-Bremse Asia Pacific (Holding) Limited News in brief Latest information 4 Products On track for greater efficiency 6 Applying the pressure 22 Cover Story Knorr-Bremse in Asia - High-class mass market 8 Interview with Dr. Leung 10 Changing markets 12 Suzhou extension opens 14 Projects Planning advantage 16 Montreal Metro opts for Knorr-Bremse brakes 18 Quality Joining forces to ensure quality 19 Aftermarket/ Precise planning 20 services E-NEWS-0030-EN 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 for the latest update. The figurative mark K and the trademarks KNORR and KNORR-BREMSE are registered in the name of Knorr-Bremse AG. Copyright 2011 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. Imprint: Publisher: Knorr-Bremse Systeme für Schienenfahrzeuge GmbH September 2011 Information for Knorr-Bremse s worldwide customers and business partners Central Editorial Office: Knorr-Bremse Systeme für Schienenfahrzeuge GmbH Marketing Tanja Mohme Moosacher Straße München Germany Tel Fax Conception, text, and design by: Knorr-Bremse Systeme für Schienenfahrzeuge GmbH Text: Torsten Rienth Realization: KB Media GmbH Layout, graphics: Cathrin Huber Printed by: Weber-Offset GmbH 2

3 Editorial The main focus of this edition of our Informer is on Asia. There are few other regions of the world that are enjoying such dynamic rates of growth, with major cities planning their own metro systems, governments building high-speed rail lines between major economic centers, and transport companies investing in efficient heavy-duty locomotives and state-of-the-art freight wagons. All this is benefiting Knorr-Bremse Rail Vehicle Systems, and our revenues from the Asia-Pacific region have been growing steadily. This is due not just to the buoyant economic situation in the region but also to what we offer our customers: a local presence (as in all markets), outstanding systems competence, innovative products and excellent service. And by service we mean not just good relations with customers and business partners, but also our excellent aftermarket service, which is designed to keep our systems running efficiently and to prolong their operating life for as long as possible. The large-volume orders received from Asia in recent years are now beginning to trigger demand for servicing and spare parts in the region. In China in particular, Knorr-Bremse has responded by further expanding its aftermarket capacity and by opening an extension to its Suzhou facility in spring In addition to generally upgrading our service capabilities, we have also developed a service center, expanded the field service teams that work directly with customers at local level, and further upgraded the skills of our service engineers. Domingo Mendieta, Member of the Board of Directors of Knorr-Bremse Asia Pacific (Holding) Limited We hope you will enjoy the pictures of the Suzhou opening ceremony, and also the detailed account of the Asian aftermarket provided by our interview with Aftermarket Director Dr. Johnny Leung. We have also provided you with a brief summary of the changes currently occurring in the various markets in Asia. This edition also looks behind the scenes in other markets. For example our latest agreement with locomotive manufacturer Voith demonstrates how proper delivery planning can be of advantage to everyone concerned, even when unit volumes are relatively low. We also describe how Knorr-Bremse is using a new SAP-based capacity planning tool to ensure that it meets its warranty obligations from the very first day. And we present our wide range of hydraulic brake calipers. Furthermore we show how top quality can be achieved through intensive collaboration between customer and supplier, how Knorr-Bremse s subsidiary Microelettrica helps save energy, particularly on international mainline services, and how Knorr-Bremse recently won an important contract from Montreal Metro. Finally, we provide you with a short overview of upcoming trade fairs at which we will be showcasing our innovative products. We look forward to welcoming you there! I hope you enjoy reading this edition of the Informer! Best wishes Domingo Mendieta 3

4 Edition 30 September 2011 News in brief Rail replaces air Rail operator Trenitalia recently placed an order for a number of new V300 ZEFIRO high-speed trains which - with top speeds of 360 km/h - represent serious competition for Italy s airlines. Knorr-Bremse Rail Vehicle Systems is involved in the project. Known in Italy as the ETR 1000, the V300 ZEFIRO is built by a consortium comprising Ansaldobreda and Bombardier. The order received by the two companies from state rail operator Trenitalia was for 50 eightcar trains to be built between 2012 and strict requirements. Trenitalia wanted the new trains to be capable of operating across national borders and to offer a combination of high seating density and enhanced comfort. In addition to supplying the HVAC system, Knorr-Bremse is also responsible for the doors. The modern car design, combined with the E3- DET door system, sets new standards in the high-speed sector. Despite their low weight, the doors offer impressive performance in terms of pressure resistance and functional flexibility, with opening widths of between 800 and 1,600 mm according to vehicle type. As well as offering high speeds, the ETR 1000 also had to meet further New office for Knorr-Bremse Japan The new office has everything a modern company needs in terms of space and technical facilities. You will find us at: 7F, Nittochi Nishi-Shinjuku Bldg , Nishi-Shinjuku Shinjuku-ku, Tokyo Japan Phone: Fax:

5 ANSWERS FOR TOMORROW S WORLD TRADE FAIRS IN 2011 Over the next few months Knorr-Bremse Rail Vehicle Systems will be attending a number of trade fairs and presenting its answers to tomorrow s challenges to a wide range of visitors. Suissetraffic, Bern, Switzerland, 6 9 September Suissetraffic, the international public transport exhibition and trade fair, will be taking place in Bern for the second time. It serves both as a meeting place and a communication platform for the entire public transport supplier sector. In Hall 3.0 at Stand D025, Oerlikon-Knorr Eisenbahntechnik AG and Knorr-Bremse GmbH Division IFE will be involved in a joint SWISSRAIL stand. III International Rail Salon, Sherbinka, Russia, 7 10 September The III International Rail Salon EXPO 1520 will focus on the latest developments in the fields of train equipment, technology, infrastructure, service and logistics. Knorr-Bremse Rail Vehicle Systems can be found in Pavilion 1 at Stand A24/1 in the far north of Europe, and visitors to Stand D03:18 will be able to find out what Knorr-Bremse Rail Vehicle Systems has to offer in this respect. Trako, Gdansk, Poland, October The Trako 2011 trade fair, which this year lasts for four full days, is Europe s second biggest rail vehicle exhibition after Innotrans. Amongst more than 400 companies, Knorr-Bremse Poland will be showcasing many products for the Polish market at Stand AusRAIL PLUS 2011, Brisbane, Australia, November This biggest annual specialist rail exhibition in the Asia-Pacific region offers decision-makers an excellent forum for discussing technological developments and investment opportunities. More than 300 exhibitors will be using the opportunity to showcase their latest developments. You will find Knorr-Bremse Rail Vehicle Systems at Stand 211. APTA, New Orleans, USA, 3 5 October 2011 Some 17,000 decision-makers from the rail sector will be meeting this year at EXPO 2011 in New Orleans. The exhibition is taking place at the same time as the annual meeting of the American Public Transportation Association (APTA), and large numbers of suppliers will be showcasing their latest innovations in the field of rail products. You will find Knorr-Bremse Rail Vehicle Systems in Hall 1 at Stand Nordic Rail, Jönköping, Sweden, 4 6 October 2011 The main focus of the Elmia Nordic Rail trade fair will be on rail solutions designed to meet the particular requirements of the Nordic countries. Demand for rapid, efficient rail transportation remains high 5

6 Edition 30 September 2011 Energy-saving systems for trains On track for greater efficiency Microelettrica Scientifica S.p.A., a member of the Knorr-Bremse Group based in the Italian town of Rozzano, develops and manufactures ecometers for measuring electricity consumption on trains, identifying potential savings and ensuring maximum operating efficiency. An electric locomotive pulling a train from Madrid to Stockholm has to cross a number of different countries, each with its own electricity supply. Starting off in the Spanish capital, it has to operate on a 3kV DC system, before crossing France, where the catenary system either operates at 1.5 kv or 25 kv, 50 Hz AC; then comes Belgium, which has the same system as Spain, Germany, with 15 kv, 16.7 Hz AC, Denmark which is like France, and, finally, Sweden, where the system operates with the same parameters as Germany. To make sure the train operates at maximum efficiency, the energy consumption on the various networks has to be precisely measured and the data passed from the train to the operator s control room. Various options for data transfer Weighing in at less than 30 kg and with a height of no more than 480 mm, the Ecometer can be swiftly installed by a technician and is designed to be maintenance-free. With a mere 0.2 percent deviation it is particularly accurate, and its modular design makes it very good value for money. Data transfer can take place according to the needs of the particular operator via optical fiber cable, existing loops or radio frequency. Elements of a complete energy- saving system For some time, systems such as Eurometer, Integrameter and City Metering have offered reliable consumption data capture and management. But the new ecometer from Microelettrica Scientifica now combines all these functions into a single system. The ecometer measures the current and voltage on both AC and DC networks and can therefore be used on all European systems to calculate the vehicle s consumption in relation to the current available from the catenary system. Combined with the Knorr-Bremse driver information system LEADER, Sydac simulators and appropriate consumption data management, it constitutes an important element in a comprehensive energy-saving system for trains. 6

7 ECOMETER - for measuring voltage and current in both AC and DC Ecometer DC - for measuring voltage and current in DC 7

8 Edition 30 September 2011 Knorr-Bremse in Asia Highclass mass market 8

9 There has been sustained growth in the Asia- Pacific region over recent years, but the market s potential is still far from exhausted. Corporate consultants Frost and Sullivan are predicting that the Asian mass transit segment alone will grow at an annual rate of between five and six percent to 2020 or beyond. The challenge is for manufacturers to come up with high volumes of state-of-the-art products to meet this demand. 9

10 Edition 30 September 2011 The Asia-Pacific region is on a roll - and constantly expanding! The Informer editors spoke to Dr. Johnny Leung, Aftermarket Director of Rail Asia Pacific, about future challenges for the aftermarket in Asia. Dr. Leung, Knorr-Bremse is currently recruiting a large number of new employees for the Asian aftermarket. What is the underlying strategy? Dr. Leung: In recent years we have been highly successful in this market - and that goes for braking, door and HVAC systems alike. Now operators are increasingly also expecting us to provide maintenance and overhaul backup to ensure the smooth running of these systems. You can best do this by recruiting highly qualified personnel - which is what we are currently doing. Incidentally that goes for all our sites in the region - they are all expanding their workforces in response to customer demand. And to further improve our levels of service we have strengthened our entire aftermarket operation. All our regional offices now have specially trained engineering, planning and process support specialists and 2009 saw a degree of consolidation taking place in the global rail market. What is the current situation in Asia? Dr. Leung: The name of the game is diversification. Once you go beyond individual regions, the markets begin to get very different. Australia, Singapore and Hong Kong are relatively welldeveloped, whereas this is not so much the case elsewhere. Basically, though, you can say that all these markets are developing well. The Asia-Pacific region is expanding - just look at China. As part of its current five-year plan, the Chinese government is set to build some 16,000 kilometers of high-speed line by By the end of this period, an additional 1,500 high-speed trains and some 13,000 heavy-duty locomotives will be in service That sounds like a tremendous opportunity for the aftermarket? Dr. Leung: Of course it is. Particularly in the transport sector, aftermarket service is essential. But it isn t easy to provide high quality. The safety aspect alone makes it very different from other industrial sectors. Knorr-Bremse is making huge efforts to improve its aftermarket service - even though it is already very good. As expected, the large volume of products supplied to Asia in recent years is now triggering demand for service. What challenges does Knorr-Bremse face in this respect? Dr. Leung: Our biggest challenge is to transform our organization from a predominantly spare part sales busi- 10

11 Knorr-Bremse Service Center in Suzhou ness to a service-oriented one. This means above all offering one-stop solutions to customers. But we also have to do a lot of marketing of the service. Many Asian operators are becoming more aware that fleet safety standards and reliability can only be guaranteed if the necessary overhaul work is carried out regularly by properly trained personnel. After rapid growth in product sales in recent years, we now have to meet spiraling demand for aftermarket service. It s an exciting challenge - and there is no end in sight. Is that also the reason why Knorr-Bremse is expanding its service center in Suzhou? Dr. Leung: Yes, it s one of the reasons. Helped by colleagues from Europe, our local teams have built up a modern, efficient system for overhauling EP2002 brake control systems. But there is more to the expansion of Suzhou than just that. China is such a huge market that we have decided to build up an entire aftermarket department, consisting of four areas that work together as part of an overall whole. The sales team covers the main rail segments - high-speed trains, heavy-duty locomotives and metros - backed up by excellent databases and systems that enable them to precisely predict maintenance cycles far into the future. Then we have our field service teams, who help customers take care of the KB equipment installed in their rolling stock. The field service technicians keep the sales team updated on the current servicing situation. And the service center carries out the actual repairs and overhauls. Finally, the entire aftermarket department is supported by the supply chain management team, which provides logistical support. Asia, of course, does not just consist of China. How do the other countries in the region differ from the Middle Kingdom? Dr. Leung: Purely in aftermarket terms there are no great differences - apart from the sheer scale involved in China. The country is so huge that it calls for special treatment. We have to be able to provide high levels of service throughout the land - which is why we have distributed 100 members of the service teams around the entire country. Trains operating with our systems have valuable state-of-the-art technology on board, and our customers feel more confident if they can count on our support in their day-to-day operations. And of course we are glad to offer it! 11

12 Edition 30 September 2011 Rail developments in Asia Changing markets The Asian-Pacific markets for rail vehicles are as varied as the countries of that region. But they all have one thing in common: growth - driven above all by rapidly rising passenger and freight volumes. Here is an overview of the individual markets: China Virtually every city of over a million inhabitants in the Middle Kingdom is either building or planning its own metro system. With growing prosperity there is also increasing demand for efficient, safe rail freight transportation, and this is reflected in the figures for new registrations of freight cars and heavy locomotives. In the high-speed sector, an - albeit minor - change of strategy is taking place. Instead of operating at 350 km/h, as originally announced, China s high-speed trains on the four East West and North South axes are to travel at 300 km/h. So far, though, this speed reduction has had no impact on the expansion of the country s extensive high-speed network. India A major reason for rapid growth in the Indian rail market is the massive increase in private consumption. A large proportion of supra-regional freight is carried by rail, as it often takes too long by road, and air transportation would be too expensive. The Indian government is therefore currently modernizing its fleet, and Knorr-Bremse is helping to upgrade thousands of freight cars from conventional braking technology to modern bogie brakes that are lighter, more efficient and more reliable. As in China, many major cities in India are also investing in mass transit projects in a bid to avert the imminent collapse of their road traffic systems. 12

13 Japan Japan has a highly sophisticated rail network, with many private operators - particularly in the passenger segment - some of which have a history going back 100 years or more. Recent speed increases have turned the famous Shinkansen high-speed train into a serious competitor for the airlines on domestic routes. The high-speed sector currently operates some 4,200 passenger cars, and the equally popular mass transit sector has approximately 44,000 electric multiple units. Japan remains a difficult nut to crack for foreign vehicle builders and suppliers: the five major vehicle manufacturers in the country dominate more than 85% of the market. Hong Kong and SouthEast Asia Except in major conurbations, rail markets in Southeast Asia cannot yet compete with China or India in terms of growth rates. As in many other countries in the region, the number of rail vehicles is on the increase, but the main growth drivers are metros and suburban transportation systems. Major cities such as Singapore are either expanding their systems or upgrading older lines and stations. One feature of the market is operators increasing focus on safety-critical products. Korea The Korean rail market is relatively small and - as in Japan - largely dominated by domestic manufacturers and suppliers. There are, however, exceptions: Alstom, for example, supplied the high-speed train system for the KTX line between Seoul and Busan. In a bid to benefit more from global demand, Korean manufacturers and operators are now also looking to export more of their technologies and expertise. Australia Australia is one of the world leading transporters of ore and minerals, and this is reflected in the country s rail system. Many railroads are designated lines to transport materials directly from mines to seaports. Continual investment in infrastructure and rollingstock is ongoing to maintain productivity and growth expansion. The country also has an extensive interregional rail freight network, primarily for intermodal services. All capital cities have extensive and modern urban metro systems - primarily EMU s, with Melbourne supplementing its passenger services with a large network of LRVs. Intercity passenger transportation services are also available but in a limited capacity. 13

14 Edition 30 September 2011 New plant in China Suzhou extension opens Knorr-Bremse s Suzhou plant is the Group s most important site in China. Within the space of a mere twelve months Knorr-Bremse Suzhou succeeded in doubling its production output - one of the reasons why the plant has now been further extended. The opening ceremony took place in March of this year. Knorr-Bremse is benefiting to a large degree from the Chinese government s efforts to further expand the country s railway infrastructure over the next few years, which means that the company is stepping up its activities in the region. This positive outlook was reflected in the celebratory mood at the opening ceremony for Suzhou II+. Prior to the inauguration, the plant had been gift-wrapped, and guests were treated to a dragon dance, followed by a formal dinner. After the speeches and several awards, the event culminated in a brilliant firework display. 14

15 Official opening ceremony with entertainment program attended by high-ranking guests 15

16 Edition 30 September 2011 Electronic data interchange Planning advantage Kiel-based locomotive manufacturer Voith Turbo Lokomotivtechnik recently signed a supply contract with Knorr-Bremse Rail Vehicle Systems based on a system of electronic data interchange that for the first time integrates a customer s production cycle into Knorr-Bremse s own supply chain. This reduces the amount of capital tied up in buffer stock and creates greater flexibility for both companies. In the past, when a customer ordered components from Knorr-Bremse Rail Vehicle Systems, the traditional order processing system swung into action: the customer placed the order, for example by fax, Knorr-Bremse confirmed receipt and recorded the details into its own enterprise resource planning system. But because demand forecasting was carried out prior to receipt of the first order in order to prepare the supply chain, both parties had to factor in a time delay and maintain buffer stock - at considerable expense. Integrated planning can now help to cut this cost and reduce capital commitment. The example of the automotive industry This sort of approach has long been operating successfully in the automotive industry. The first step involves calculating and agreeing on the total volume of components to be supplied over the year and what quantities are to be delivered on which dates. Ancillary agreements define the time corridor within which customers can vary their order in response to their actual production rate and the extent to which they can do this. Despite the fact that order volumes are much lower than in the automotive industry, the rail vehicle sector can also benefit from such an approach. But it has to be based on 16

17 mutual trust - after all, it involves the customer giving the supplier access to reliable information about its production planning, and this information being integrated on a one-to-one basis into the supply chain. And to achieve this level of partnership, an electronic data interface is needed that enables the two companies SAP planning systems to communicate. Voith Turbo Lokomotivtechnik uses the interface to transfer information on its production cycle directly into Knorr- Bremse s production system, including any fluctuations within the agreed parameters. As soon as the information is received, Knorr-Bremse is able to adapt its production to the new delivery targets. Stable unit volumes facilitate delivery planning In the case of Voith, the delivery plan involves Knorr-Bremse supplying systems for 130 Gravita switcher locomotives ordered by Deutsche Bahn from the Kiel company. The new order processing system is particularly suitable in this case, as the volume involved is relatively high and demand is likely to remain stable over the entire three-year delivery period. The components are also standardized, so there are not likely to be any significant technical changes. The advantages are obvious: for both parties the need to hold buffer stocks is reduced. And because the data transfer takes place automatically via the EDI interface and orders are no longer processed by hand, the risk of errors in data transfer is reduced. EDI transfer also involves less manual input. The planning systems in both companies are permanently synchronized and instantly receive all information about deadlines, volume fluctuations, etc. Voith sets the benchmark for the energy, oil & gas, paper, raw materials and transport & automotive markets. Founded in 1867, the company is now one of the biggest family companies in Europe, with a workforce of nearly 40,000, sales revenues of EUR 5.2 billion and sites in 50 countries around the globe. Voith Turbo offers high-value components, systems and services in the fields of manufacturing, rail and road transportation and marine applications. Since 2005, Voith Turbo Lokomotivtechnik has developed and built the Maxima family of mainline locomotives and the Gravita family of switcher locomotives at its traditional base in the north German city of Kiel. Both companies have delivered positive reports on their experience with the EDI-based supply planning system since its introduction in February 2011: the system has bedded in and is running smoothly. ADVANTAGES OF THE ELECTRONIC DATA INTERFACE: No more paper required Buffer stocks reduced Less working capital tied up Reduced staff input Fewer processing errors l. to r.: Dr. Jonathan Paddison, Peter Jöns und Hinrich Krey (both Voith Turbo Lokomotivtechnik), Dr. Gert Assmann 17

18 Edition 30 September 2011 American rail market Montreal Metro opts for Knorr-Bremse brakes A contract for 468 MPM-10 (Montréal Pneumatic Material 2010) metro cars was signed last fall between a manufacturing consortium and the operator of Montreal Metro. And at the end of May it was decided that Knorr- Bremse Rail Vehicle Systems would supply the air treatment systems and bogie equipment. The MPM-10 platform is being jointly developed by Bombardier and Alstom, with Knorr-Bremse due to deliver the air treatment systems to Bombardier, which is responsible for final vehicle assembly. The bogie equipment contract was signed with Alstom. Most of the metro cars are being manufactured in the Canadian province of Quebec, with final assembly at the Bombardier facility in La Pocatière. Alstom is producing its components in Sorel-Tracy. Since at least 40 percent of the Alstom bogie equipment has to be manufactured in Canada, Knorr- Bremse is partly collaborating with suitably qualified Canadian suppliers. The current plan is for the prototype of the new metro cars to be completed by June 2013, with series production being launched in February 2014 and running to September The Montreal Metro program is of strategic importance not just for the Knorr Brake Corporation in North America but also for Knorr-Bremse Europe. The development work already carried out on the Montreal systems means the company is well placed to tender for the next round of procurement for the Paris Metro. Both systems operate on rubber tires, so many of the products already developed for Montreal Metro can be adapted for Paris. 18

19 Methods from the automotive industry Joining forces to ensure quality Although production volumes in the rail vehicle industry are not nearly as high as in the automotive sector, quality assurance methods are increasingly being transferred from the latter to the former. This calls for close collaboration between customer and supplier. It is, of course, not possible to transfer QA methods directly from the automotive sector to the rail vehicle industry, which is more project-oriented and operated with relatively small unit volumes. Nevertheless, there has been an increasing trend towards adapting automotive methods for use in the rail sector. Conditions converging There is a good reason why this has been happening: shorter innovation cycles, reduced development and testing times and higher general quality requirements mean that overall conditions have started to converge in both sectors. Knorr- Bremse Rail Vehicle Systems has responded to this development by taking over a wide range of quality assurance methods from the automotive sector and adapting them for use in the rail vehicle industry. For example the company is the first in the rail vehicle sector to opt for across-the-board certification according to the IRIS standard - which was derived from the automotive industry. Knorr-Bremse ensures the quality of project development using DFMEA (Design Failure Mode Effects Analysis) and subjects its suppliers to a comprehensive process of training and approval. And in the field of production it uses process FMEAs and its own in-house Knorr Production System (KPS) based on the Toyota Production System. Close collaboration ensures quality The company s commitment to quality extends to the warranty period as well. If a warranty claim arises, Knorr-Bremse immediately launches a comprehensive error analysis procedure and takes full corrective measures aimed at minimizing risk using an approach based largely on methods used in the automotive sector. It also ensures that lessons are learned and preventive measures are taken to ensure that similar problems can be avoided in future projects. Ensuring that both parties benefit fully from this adaptation of quality methods calls for even closer collaboration than in the past. It involves drawing up improved specifications, optimizing testing, progressing standardization and working closely with the customer to localize the problem swiftly, reproduce it and come up with a permanent solution. 19

20 Edition 30 September 2011 Rail-Services in Europe Precise planning A new SAP-based capacity planning tool enables Knorr-Bremse Rail Vehicle Systems to reliably meet its warranty obligations from day one. Using eurocap means the right tools and appropriately trained employees are available at the right time in the right place. 20

21 Precise planning of capacity for warranty periods is a complex task: When does the warranty begin? What system does it apply to? How many depots have to be manned? What exactly are the provisions of the contract (e.g. reaction times)? And what qualifications do employees need to be able to supply the service to the usual high Knorr-Bremse quality standards? Looking into the future Answering questions like these generates a mass of data that the responsible Field Service Manager needs to have constant access to. This is now possible, thanks to the SAPbased Field Service Software Tool eurocap, which is being used to record all European project data. At regular intervals, project leaders feed the current data and figures for their projects into the capacity planning database. The information helps the Field Service Manager to identify possible capacity bottlenecks in advance, enabling him to plan up to 18 months ahead and precisely predict when and where services will be required. This gives him time to order the special tools required for particular service tasks and ensure that all staff have the necessary training. Predicting staff shortages Operational deployment of the tool is based on the uniform worldwide quality standards laid down for Knorr-Bremse service. This is the only way that the Field Service Manager can, for example, transfer employees in advance to a depot where they are going to be required in the future. As well as being used in Europe, the eurocap tool is also ensuring the reliability of capacity planning in the Chinese market. The tools run independently of each other, with each Field Service Manager only having access to the countries for which he is responsible, but they are not separate: for example if a Chinese vehicle builder delivers to the Middle East, which is served from Europe, the data can can easily be exchanged. 21

22 22 Edition 30 September 2011

23 Hydraulic brake calipers Applying the pressure Knorr-Bremse produces a broad range of hydraulically actuated brake calipers for its braking systems. The compact modules have been developed for a wide variety of different vehicle platforms and chassis requirements. Hydraulic calipers respond rapidly and virtually without delay, enabling brake application, for example for short stopping distances, and brake release, for example to avoid wheel flats, to take place within the required time. Left: HC1P45+ spring-activated lever-type hydraulic brake caliper with remote mechanical release Right: direct-acting hydraulic frame-mounted caliper with elastic suspension Nowadays streetcars - especially low-floor vehicles - have an important role to play in the overall mobility mix. Hydraulic systems come into their own where a particularly high concentration of pressure and energy is called for and the available installation space is extremely limited. The use of hydraulics makes it possible to build a complex and compact chassis as an integral part of the vehicle. Modern pneumatic systems can also be compact and space-saving in design, but hydraulic systems currently represent the state of the art for low-floor vehicles. Concussion-proof Brake calipers have to operate in the harsh environment of the bogies, close to the road surface and the rails, where they are exposed to spray and splashing. They therefore have to be designed to function reliably for years under the most adverse weather and operating conditions. If required, most of the brake caliper types can also be attached in non-sprung locations. They can easily absorb the extremely strong acceleration forces resulting from wheel-rail contact. A combination of innovatory design and construction and many years of operational experience has enabled Knorr-Bremse to create products that are ideally suited to coping with such operating conditions. The primary objective in developing them is to offer long service life combined with minimum maintenance requirements. Despite the extreme forces the calipers have to absorb and transfer, they are designed to be lightweight. Vehicle builders and system suppliers can choose from a wide range of Knorr- Bremse brake actuators with features that can be flexibly varied and combined: actuation type - pressure or spring actuating force method of installation: fixed, floating or suspended type of emergency release (spring-actuated calipers) Knorr-Bremse has a team of experienced specialist engineers available to help with new developments, modifications or special requirements. 23

24 R A I L V E H I C L E S Y S T E M S COMORAN Condition Monitoring for Railway Applications The new system COMORAN - Condition Monitoring for Railway Applications - from Knorr-Bremse is an integral part of the brake system and identifies critical and safety-relevant conditions, such as damage to wheelset bearings, hot axle boxes, unstable running or derailment, according to TSI requirements. The system also provides comprehensive data that enables condition-based maintenance work to be carried out economically.

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