Product. Clear view in short- and long- distance transport Windscreen wiper and wash systems

Transcription

1 R a i l V e h i c l e S y s t e m s Edition 16 July 2007 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 Product Clear view in short- and long- distance transport Windscreen wiper and wash systems Sanding systems Research & Development Rotary current drives for hydro appliances in light rail transit

2 No. 16 July 2007 Contents E d i t o r i a l Dr. Gropengiesser 3 Innovationen Für Einstiegssysteme Research and Development Rotary current drives for hydro appliances in light rail transit 4 P r o d u c t s Windscreen wiper and wash systems 7 Sanding systems 12 Imprint: Publisher of this print: Knorr-Bremse Systeme für Schienenfahrzeuge GmbH Moosacher Straße München Germany Phone: Fax: For questions regarding the Informer please contact your local Knorr-Bremse representative or Ms Karin Dirscherl Phone [email protected] 2

3 Editorial Dear customers, Dear reader, Continuity and changes It goes without saying that continuity does not mean standing still but the development in connection with the ability to change its full strength. Even those who remain faithful to traditions can and must respond to changes with appropriate conditions. Knorr-Bremse faced this task and began already some years ago to advance the optimization and expansion of its products. In our Austrian factory in Mödling we built custom windshield wiper- and washing systems for all vehicle types. Dr. Frank Gropengiesser, Chairman of the Executive Board Knorr-Bremse Systeme für Schienenfahrzeuge GmbH. With foresight, Knorr Bremse located that facility in the same place as a further major business area for sanding systems. The most modern testing equipment is employed for the production and quality inspection to further optimize the systems. On the following pages you learn more about our extensive spectrum of products that distinguishes itself through high quality and economic viability. Concentration on core competence With the development of hydro appliances, Knorr-Bremse can look back on a long-time experience with rotary current motors. Our credo: to continuously adjust and develop approved products regarding performance, functionality and market request. Therefore more and more manufacturers decide in favour of the use of hydro appliances on street and city trams for the compact brake technologies of Knorr-Bremse. To embrace difficult challenges and actively convert into innovative solutions that is to design the future in this lies the secret of a company s business success that exists over 100 years. On the following pages you can learn practice-related examples in detail. Enjoy your reading! Your Dr. Frank Gropengiesser No. 15 März

4 No. 16 July 2007 Solutions, that move Rotary current drives for hydro appliances in light rail transit The low-floor construction in modern light rail transit has considerably improved the passenger comfort regarding the boarding and deboarding. Without the use of extremely compact brake technologies this would not have been possible. For the electro hydraulic supply and control units with rotary current drive, the so-called hydro appliances from Knorr-Bremse are now established. In the meantime, the installed height does not exceed 100 millimetres. 4

5 Many manufacturers of modern low-floor vehicles have decided to use hydraulic brakes. The technology enables a high concentration of strength, energy, and performance in a very small area. This creates generous design possibilities for the passenger area and widens the options for the exterior design. Compact energy supply Within the motor-pump-units of hydro appliances, the pump is clearly smaller and lighter than the one in its electric drive. Therefore, the size of the electrical drive is a crucial factor. Here, not only the sizes are important, but also the variability, with regard to the individual adjustment to the specific space envelope of the vehicle. Very often, this space is between the longitudinal beams of the low-floor vehicle, where the associated equipment will be placed in a horizontal position. Direct current or rotary current? In many low-floor vehicles the hydro appliance is energized by the vehicle battery. In this case, mechanically commutated, direct current, permanently energized motors are used. The brushes along with the collectors that are necessary for such solutions, are subject to a relatively high wear factor. Ultimately the brakes are used in daily light rail applications where short distances between stops is frequently the case. Accordingly the burden that the brushes and also the collectors are exposed to is extremely high. The intervals, in which these components have to be serviced are therefore relatively short. This reduces the actually high availability of this supply solution. Therefore more and more operators are thinking about a less complex and maintenance-friendlier form of the drive. Here, rotary current motors are technically and economically interesting alternatives. Also, rotary current drives are small and save maintenance effort Less maintenance effort thanks to rotary current drives Because the rotary current drives do not need either brushes or collectors, it works almost maintenance free. Even the bearings and gaskets that show the highest wear in rotary current drives exceed the durability of the brushes and collectors by a high factor. Extended palette for hydro appliances Knorr-Bremse has recognized the advantages of rotary current motors on this segment of the Light Rail Vehicles and has therefore correspondingly widened its product program with power and control units. The installed height is often not more than 100 millimetres. Presently the first units are being integrated into a vehicle platform.the installation is possible in a vertical as well as in a horizontal position. Small, powerful and flat 100 mm high with rotary current drive electro hydraulic power and control unit. 5

6 No. 16 July 2007 Intelligent solution electro hydraulic power and control unit for the operation of a combined brake and springing appliance in a horizontal construction 175 mm high with rotary current-drive. With the development of the new units, Knorr-Bremse benefited from its long experience with rotary current motors for hydro appliances. In particular hydraulic systems that combine a brake and hydro-pneumatic spring function have been integrated by Knorr-Bremse with rotary current motors for some time. Even with short-term rotary current failure, full functionality The robust construction of the low wearing rotary current motors have positive effects on the upkeep and the operational safety of the entire power and control unit. So the availability of the energy supply is secured from a certain magnitude of the hydraulics installation onwards by a hydro storage. In case the electric pump drive should not be in working order, the pressure pool in storage still enables the brake operation. Normally, the energy reserve within the pressure pool is still enough for several brake or release procedures. Therefore, short-term interruptions of the energy supply by using rotary current motors do not lead to any disturbance of the brake function. Emergency current from the battery network For the use of the smallest hydro appliances, the protection of the brake performance has to take place in a different way. These are not equipped with a hydro storage, but allow the brake functionality with the rotary current motor through a pure pumping operation. The solution is due to the binding to the battery network of the vehicle. This happens through the so-called electro hydraulic decentralized solution-helping unit. Therefore, in every case, the basic functionality of the brake is secured. The advantages of rotary current-driven power units More space in the vehicle thanks to compact construction Flexible adaptation of the specific mounting space envelope Long maintenance intervals through discontinuation of low wearing parts like brushes and collectors Secure brake functionality by energy failure thanks to hydro storage or binding to the battery network 6

7 A new perspective Clear view in short- and longdistance transport Windscreen wiper and wash systems for rail vehicles have been adaptations of solutions, that were for a long time specifically made for private cars and commercial vehicles. For some time more and more varied customer requests have forced Knorr-Bremse to separate the development for systems in the rail vehicle industry and the commercial vehicle area. Today, in this segment, the business offers a wide spectrum of high-quality solutions for every application. 7

8 No. 16 July 2007 DOSTO Motor Car Germany. EMU-BR423 Germany. The expansion and optimization for the offers for windscreen wiper and wash systems for rail vehicles are driven by the Austrian location in Mödling. Here originate the tailor-made solutions for every vehicle type. Due to the very high degree of standardization and thanks to the application of approved components the solutions mark themselves with a high economic viability and this over the entire live cycle. A particular importance lies herewith on a secured, long-term spare part supply that considers the long lifespan of rail vehicles. Windscreen wipers for high demands Many requirements for windscreen wiper and wash systems depend on the respective application: high-speed trains for example, have to be differently equipped than city trams. Vehicles that are exposed to extreme low temperatures are differently equipped than trains in mild climate zones. Other criterions are important for all applications. Therefore the windscreen wiper and wash systems of Knorr-Bremse are in every case reliable and always available, with a long lasting lifespan and strictly corresponding to fire protection regulations. On the following pages, we give you an overview of the performance palette of Knorr-Bremse in the area of the windscreen wiper and wash systems. To have for every journey quality in form and function Pneumatical Basic System (PBS) In new vehicles, pneumatically run windscreen wipers are hardly used anymore. That Knorr-Bremse still has these systems in the product range is an indication of the reliability and continuality of supply with respect to long-term supply promises for original parts. The torque of the pneumatic systems are 80 Nm. They do not require any binding to the power supply and are simply manageable.

9 AVE - S103 Spain. ICE3 and ICT-ET Germany. Electrical Basic System (EBS) These windscreen wiper and wash systems exists from components and appliances that are taken over from the automotive industry and then modified for rail vehicle requirements. The acquisition costs are low. All wiping movements and wiping angles are moved by levers and joint rods. The delivery of pre-assembled complete systems allows the expenditure for assembly of the complete system to be held at a low level. Electrical basic systems have, in comparison to pneumatic Systems, among other things, the following new functions available: Parking function Two wiper speeds Intervall wiping Dry wipe with two or three double-strokes after the washing procedure WI slow / WI fast / wash / INT / special functions product figure SWWS Product Portfolio Electrical High End System (EHS) Pneumatical High End System (PHS) Electrical Advanced System (EAS) Electrical Basic System (EBS) Pneumatical Basic System (PBS) TRAM EMU/DMU MT EMU/DMU LD HST vehicle requirements 70 km/h 160 km/h 360 km/h [ v max km/h]

10 No. 16 Juli

11 1.) Drive unit Electrical High End System 2.) Wiper drive Pneumatic High End System 3.) Washing pump + DC/DC converter 4.) Control element Electrical High End System 5.) Drive unit + wiper arm and wiper blade (EHS) + Adjustment Electrical High End System 6.) Wiper motor Electrical Basic System Electrical Advanced System (EAS) Windscreen wiper and wash systems were specifically developed by Knorr-Bremse for the rail vehicle industry. With regard to the technical realization of the wiper movement they are comparable to the EBS systems. However, they ensure particularly high performance concerning lifespan and reliability. The components and appliances correspond to the latest state of the art, with regard to the test, homologation for electromagnetic compability, shock, vibration, and environment among others. Long live span of at least 10 Million double-strokes Guarantee of spare part supply above 30 years Integration of the washing water lead through within the drive unit makes the additional penetration of the vehicle skin unnecessary. Secure and better driving convincing technique Electrical High End System (EHS) Windscreen wiper and wash systems as well as the EAS systems are especially constructed for the rail vehicle industry. All important for the high quality is the use of drives, turning angle transmitter, control systems, etc. from the IFE door drive system range. The components are long time proven through hard field operations in railway transportation. Wetting of the screen before the wiping in order to spare the front screen and wiper blade. Adaptive torque control drive (dry/wet screen) Synchronization of two wiper drives without mechanical connection Additional parking positions to the standardized parking position (i.e. far outside the wiping area/middle position/ washing street position) Flexible adjustment of the wiping angle, wiping speed and functions, such as the wiping and washing (wiping speed/interval pause times/wiping dry, etc.) High availability/reliability and life time with at least 12 Mio. double-stokes State of the art of the railway industry (i.e. EMV, fire protection requirements, shock and vibrations) Spare part supply guaranteed for over 30 years Washing water pipe is integrated in the drive Pneumatical High End System (PHS) The electro pneumatic systems were developed as hybrid systems especially made for high-speed vehicles with spheroid curved front screen. An electrical control receives the incoming signals from the control unit and wiper drive, transforms, and realizes the accesses functions over an electro pneumatic device unit. 200 Nm starting torque Pneumatic emergency mode Designed and aerodynamic optimized wiper area outside the field vision Realization of big wiping fields with the use of two wiper blades Knorr-Bremse has concentrated the development, construction, production, and quality testing of windscreen wiper and wash systems at the Austrian location Mödling. Short distances between all involved departments makes a fast reaction to customer requirements possible. This development process, starting from the first idea to the final delivery, considerably accelerates this process. In order to be able to guarantee the reliability of the systems in all business conditions, the facility is outfitted with the most modern testing equipment. To this counts, among other things, the installations for shock and vibration in order to analyse electromagnetically capabilities as well as the examination of the behaviour in continuous operation. 11

12 No. 16 July 2007 Sanding Systems Train trip with friction Valid when driving by train: the lower the coefficient of friction between the tracks and the wheel, the more slowly the vehicle must be moved in order to avoid accidents. It is not only in winter slippery: Moisture, dirt, or foliage disturbs the contact between wheel and track throughout every season. Against this Knorr- Bremse employs the same material for over 100 years: sand. Admittedly, with continually improved methods. Sand pipe heater in action. 12

13 Sanding system SDN14. A lot helps a lot: following this motto, one could have eventually brought the sand on the tracks, when particulate matters were not an issue, and when using more or less energy was not important. The first sanding-generations were regardless of consumption and positioning of the sand. A mechanical tilting mechanism between sandbox and sand tube was opened by hand and the grit fell down and in the ideal case directly in front of the wheel. Soon however Knorr-Bremse developed solutions that were more precise: The fall sander and the sand stairways were replaced, at the end of the seventies with sand dispenser equipment SDN. Now the transports of the sand grains are not left to the gravity but send via compressed air into the gap between wheel and rail. Sand scattering is precision work Since then, Knorr-Bremse has put a lot of effort into the research and development of the eco-friendly optimization of the traction behaviour of wheels on the track. The new sanding system corresponds in the meantime to the highest requirements. Today, an ingenious traction management decides how much sand, at what speed and in which driving situation will be provided. In order that the sand trickles with every climate, it is loosened up and dried in a reserve box. The sand pipe end is heatable and remains always permeable even in icy temperatures. Safer, faster and more ecological under way If the driver has to take into account the effect of the sanding system when driving-off and braking, he has to be able to rely on its functionality at any time. Excluding the formation of sand lumps through easing and drying and always holding the sand pipe free is therefore of a crucial importance for a safe, fast and sensible ecological driving. This especially applies to streetcars in the urban local traffic, because braking and driving-off procedures are numerous. Respectively important is the saving of sand through the speed-specific turnout. By this means, the sand demand can be reduced by over 50 percent. Considerable cost savings through operative business can be achieved and the vehicle developers can reduce weight and mounting area in the bogie, car boxes, and sand reserve. Modular variety Not every application demands the full performance with which the Knorr-Bremse sanding system can be equipped today. Therefore, the customers themselves decide, on what to emphasise and which functions to give up. Therefore, on one hand there are systems available without heatable sand pipes and on the other hand, the vehicle-specific order can make it necessary to have longer sand pipes that have to be equipped with an 13

14 No. 16 July 2007 Demanding tests In order to guarantee the customer, from the first day, the full functionality of the sanding system, all technical possibilities of the different installation equipment for all types are tested in the Knorr-Bremse laboratory. By doing so, the engineers anticipate situations that could happen when assembling, adjusting, placing into operation or finally throughout the daily practice. Among other tests, the following are executed: sand distribution test: optimization of the system on the sand type that the operator uses shock test and vibration tests: to check the durability the system is exposed under extreme stress Climate tests: each component is individually checked for its temperature constancy in the climatic chamber. The behaviour of the system with wind is tested in the climate wind tunnel at the Arsenal Research in Vienna. additional after function or blowing out function. The control of the sanding system can be laid out electrically or pneumatically. To the further options counts the filling of the sand box with a pistol, a sand level indicator and equipment to monitor the sand level and sand conveyance. The models At present, Knorr-Bremse offers five basic types of sanding systems. Each one is available in different implementations and is adjustable in a flexible way to the specific needs of the customer. Three sanding systems are specifically made for the circumstances of streetcars without compressed air production. In every case the speed and situation dependence of the sanding is here standard: Two-direction sanding systems with compressor (Type SEJ): With this sanding type the drying of the sand store is effected in the lower area of the box. There is also a model without drying available. One-direction sanding systems with compressor (Type SDN15): Here the complete sand store is dried and the sand pipe is kept free through heating. The compressed air is generated with the help of a rotary vane-type compressor. This is either driven by a brush tainted direct current motor or by a maintenance-free electrically commutate synchronous motor with attached control. One-direction sanding systems with compressor (Type SDN31): As Type SDN15, but the generation of the compressed air is carried out through an intermediate pressure compressor. In addition the sand pipe can be equipped with an after or blowing-out function. Soon even more economical: sanding systems in modular construction For rail vehicles with centralized air compression there are two different sanding systems: Conventional sanding system (Type SD): This simple equipment is only suitable for applications where the use of sand is seldom necessary. It s done without all drying, blowing-out and heating functions. An adjustment of the sand distribution quantity to the speed is not possible. One-direction sanding system without compressor (Type SDN31): This equipment has the same functions as the same-named system for street cars. The air compression takes place through the pneumatic main container pipe of the vehicle. Sanding has a future The development and research work for more efficient and economical sanding systems is continuing. In computer simulations and field tests our engineers find new ways to render more precisely the sand quantity and the sand distribution. Soon all systems will be offered as a construction kit. The customer can then decide easily and more specifically for a complete solution that is exactly fitted to his requirements. 1.) TYPE: SEJ 2-Direction Sanding System with a compressor 2.) TYPE: SDN15 1-Direction Sanding System with a compressor 3.) Sandbox and Mounting parts 4.) Sanding System SD 5.) Sanding pipe heating on shock shaker 6.) Sanding System SDN14 14

15

16 R a i l V e h i c l e S y s t e m s K for Confidence By using genuine Knorr-Bremse quality parts you can be confident that your Knorr-Bremse rail systems retain their original integrity. With Knorr-Bremse guaranteed parts, you can also be confident that you are investing your budget wisely and ensuring that the original system design responsibility remains firmly with Knorr-Bremse. In the longer term, the cost of relying on non-genuine parts, with all the potential reliability, performance, and safety risks, will often be much higher! Confidence... with a K!