Locomotives REALIZING SYSTEM SYNERGIES

Transcription

1 Locomotives REALIZING SYSTEM SYNERGIES 1

2 THE PERFECT COMBINATION OF HIGH-QUALITY & SERVICES Windscreen Wiper Motion Controller HVAC System Brake Control & Wheel Slide Protection Vehicle Control Unit HMI Router Switch icom Ecometer Smartio They are used to pull regional expresses and high-speed trains or as workhorses for heavy freight haulage. Without the sheer versatility of locomotives, worldwide rail transportation would be unthinkable. Manufacturers develop individual solutions tailored to customers specific requirements often using modular concepts. Whatever segment is involved, Knorr-Bremse has proven technologies for all conceivable scenarios, ensuring the highest safety standards with innovative, cost-effective solutions and service concepts offering operators long-term value-added. Sanding System Brake Resistor Brake Caliper Air Dryer Compressor Auxiliary Power Supply Brake Discs KNORR-BREMSE Knorr-Bremse is the world s leading manufacturer of braking systems for rail vehicles. The product portfolio also includes entrance systems, HVAC systems, auxiliary power supply systems, control components and windscreen wiper systems, platform screen doors, friction material, driver assistance systems, and control technology. As a technology leader through its products the company has been making a decisive contribution to greater efficiency, cost effectiveness and safety in the international rail business. IFE IFE is the leading manufacturer worldwide of automatic entrance systems for rail vehicles. The guiding principle Success through Quality and Innovation has marked the company s development for more than 70 years. Today, external and internal doors, door control units and access devices are among the range of solutions offered. With the experience of an unparalleled 650,000 entrance systems delivered in the company s history IFE continues to shape the industry. MERAK Our mission is to be the most respected partner for rail climate control solutions, through shared values, engineering experience, and global presence. Close customer cooperation, continuous improvement, and innovation have made Knorr-Bremse a world leader for heating, ventilation, and air conditioning (HVAC) systems, with some 100,000 units in successful daily service. MICROELETTRICA SCIENTIFICA Microelettrica Scientifica, based in Italy, has been developing and producing power switches, transducers, resistors and fans dedicated to the most advanced applications of the rail vehicle industry and industrial applications for more than six decades. The company s high product quality results from continuous research, realized in close cooperation with its customers in order to precisely and punctually meet their needs. POWERTECH Knorr-Bremse PowerTech is a leading supplier of advanced auxiliary power supply solutions, ensuring effective power conversion in all types of rail vehicles. Combining more than 100 years of extensive experience with comprehensive engineering competence, we support customers with tailor-made compact, highly reliable and efficient power supply solutions life-long services around the globe included. SELECTRON State-of-the-art rail vehicles can only be realized with advanced control technology. For many years, Selectron Systems AG has been successfully developing such solutions for the automation, networking, and control of rail vehicles. As Selectron is able to utilize the worldwide Knorr-Bremse sales and service network it can provide its customers with even better support at international level. KIEPE ELECTRIC Full range of electrical systems, traction/power supply inverters, climatization and cooling systems (motor, battery, traction). Kiepe Electric GmbH is one of the global leaders in electrical systems and traction technology for local public transport vehicles, including LRVs, metro trains and buses. With more than 100 years of experience, the company not only offers pioneering electrical equipment for rail vehicles and buses but also a broad range of related maintenance services. Its comprehensive refurbishment offer for existing vehicles helps many vehicle operators cope with financial pressures. 2 3

3 BRAKE More than 110 years of experience have made Knorr-Bremse the world s leading manufacturer of rail vehicle braking systems. The company s skills are evident not just in the individual components it manufactures but also in their perfect interaction the key to a braking system that meets the highest standards of functionality, reliability and safety. Building on both proven and innovative technologies, Knorr-Bremse works closely with customers to develop project-specific solutions from a single source with a carefully designed combination of electronic, pneumatic, mechanical and hydraulic components. A single, direct interface ensures cost-effective and resource-efficient integration into the overall vehicle system. CUTTING-EDGE TECHNOLOGIES AIR SUPPLY AAR AIR DRYER LD1000 n 10-year main overhaul interval n Suitable for OE projects and upgrade of existing fleet n Low LCC n Suitable for robust environment, underfloor installation possible, rated IP69K BOGIE EQUIPMENT COM- PACT BRAKE CALIPER RZT n Improved protection against water and ice n Increased robustness n Higher spring brake performance n Exchangeable to RZS n Less installation space CCB-3 n Improved mission reliability n Life-cycle cost reduction n Standardization of interfaces for global markets n Improved diagnostics n Safety certification for global use n Improved configurability n Shorter lead times SOLUTIONS BENEFITS FOR THE CUSTOMER The more closely braking systems are networked with other rail vehicle sub-systems, the greater the benefit for the operator, as this reduces overall complexity by avoiding redundant infrastructure. For example the braking system s vehicle weight sensors can be used by the HVAC system to adjust output when passenger density drops. PRODUCTS FOR ALL STANDARDS Knorr-Bremse is the partner of choice for regional train applications with systems based on more than 110 years of development, production and practical field experience. It provides innovative, TSI-compliant solutions tailored to local requirements, all current global standards (UIC, AAR, GOST, Chinese Standard, ARA) and individual operating scenarios. And its worldwide production and service network meets even the strictest requirements for local content. 4 5

4 BRAKE OIL-FREE COMPRESSOR 2.0 n Specially optimized design to minimize noise and vibrations n Cold starts without preheating, down to -50 C n No oil exchange, no disposal of used oil, no contaminated condensate to collect SCREW COMPRESSOR n Special design to cope with tough rail operational conditions n Low compressor noise level n Virtually pulsation-free delivery of compressed air PISTON COMPRESSOR n Self-supporting, flange-mounted motor compressor set n Rugged construction and long-life performance INTELLIGENT AIR DRYER n Diagnosis with continuous monitoring of air dryer condition n Optimized closed-loop regeneration minimizes purge air losses n Compact, lightweight modular design n Low noise emission Brake Control Air Supply BP-COMPACT n For UIC and GOST markets n Intelligent combination of pneumatic and electronic control n Tailored to various customer requirements n High availability through in-built back-up n Modular design for optimized maintenance CCB II n Modular design n For AAR market MOTION CONTROLLER KIT n Brake, traction and master controller n Robust modular design, proven application n Small, flexible installation space n Compatible with UIC standard DISTRIBUTOR VALVES n KE for UIC n KAB60 for GOST Bogie Equipment WHEEL-MOUNTED BRAKE DISC n Standardized interface and mounting on wheel n Resistant against thermal cracks due to movable friction disc n Robust design with high safety against external shocks and vibration COMPACT BRAKE CALIPER UNIT n Optimized design regarding weight, assembly and costs n Reduced maintenance and long overhaul period n One interface to bogie n Highly modular design TREAD BRAKE UNIT n Modular design n Flexible mounting n High output forces n Flexible design for high lateral movements CLEANING BLOCK UNIT n Wheel surface conditioning to improve friction n Flexible mounting in bogie n Robust and service-proven design Friction Technologies PADS OPTIPAD / ISOBAR / FLEXPAD n High friction stability at high temperatures and reduced hot spots at brake discs n High mechanical resistance n Optimized for high energy applications PADS PROPAD n Large product portfolio covering the specific demands of each application n Noise-optimized designs to avoid squealing n Standardized UIC designs and 15% increased lifetime KRS designs PROBLOCK UIC AND AAR n High- and low-friction products n Wide range of designs for both UIC and AAR applications n Low wear levels 6 7

5 BRAKE Auxiliaries SANDING n Suitable for manual or automatic sand filling n Continuous innovation n Lighter weight and smaller installation space n Drying, heating and loosening of the grit WIPER n Expertise with all vehicle types n Extensive investigations and tests to guarantee durable products n Long-term product support with spare parts delivery of 30 years DIAGNOSTICS/iCOM icom transfers the mobile device philosophy to the railway industry: n Condition monitoring (icom Monitor) n Driver advisory system (icom Assist) n Energy metering (icom Meter) n Developer tool (icom Developer Studio) n Energy management (icom Energy Saver) n Service tool (icom Service) WHEEL FLANGE LUBRICATION SYSTEM n Reduced wheel/rail wear n Increased vehicle availability n Reduced RCF development n High system reliability n Improved cleanliness n High efficiency n Low maintenance 8 9

6 HVAC HEATING, VENTILATION AND AIR-CONDITIONING In the rail sector, ergonomic working conditions are especially important for the drivers. Noise and vibration can be sources of distraction and a properly air-conditioned driver s cab is an essential part of an efficient, healthy, and safe working environment. Knorr-Bremse s HVAC systems ensure the right level of comfort, whether operating in mild, tropical, or even arctic conditions. Project-specific application of service-proven technologies means that systems can be flexibly configured for all vehicle types and operating environments, and always deliver the right performance with low weight, noise, and energy consumption. Available as roof-mounted or under-desk units, for newly-built vehicles or upgrades, Knorr-Bremse HVAC systems are in operation in all parts of the world with local teams ensuring seamless service, every day. COMPACT ROOF-MOUNTED HVAC UNIT n Designed for operation in some of the harshest conditions, in order to assure driver s comfort n Remote control panel located in the crew cabin for easy access n High reliability to support vehicle availability n Capable of operating at extreme ambient temperatures (above 60 C) CUTTING-EDGE TECHNOLOGIES COMPACT UNDER-DESK MOUNTED HVAC SYSTEM n Designed for operation in desert conditions, while maintaining the driver s comfort n The control panel and controller are installed outside of the HVAC unit for easy access n Dual refrigerant circuits for redundancy, capacity control, and energy optimization n Suitable for high-speed train operation n Capable of operating at extreme ambient temperatures of up to 55 C COMPACT ROOF-INTEGRATED HVAC CABIN UNIT n Two separate and independent refrigerant circuits (supply for driver s cabin and for the vestibule) n With active pressure protection and specific housing tightness n Integrated side channel blowers for fresh air support n High-quality stainless steel housing, suitable for aggressive environments n Maintenance access from inside the driver s cabin SOLUTIONS BENEFITS FOR THE CUSTOMER The more closely an HVAC system is networked with other rail vehicle sub-systems, the greater the benefit for the vehicle builder and operator, as this enables intelligent response to the other systems current operating status. For example the HVAC unit can be immediately shut down if a fire alarm is triggered, instead of continuing to blow air into the locomotive

7 POWER SUPPLY With growing comfort and safety requirements in modern rail vehicles, the power demand by various on-board consumers is constantly increasing. The on-board power supply system is thus assuming an increasingly important role. Knorr-Bremse PowerTech stands for more than 100 years of extensive hands-on expertise in power conversion, ensuring effective power supply and efficient energy distribution in all types of rail vehicles. With our comprehensive engineering competence and a proven track record of more than 30,000 converters in operation worldwide, we supply cutting-edge power converter solutions, distinguished by their compact design as well as high reliability and efficiency. Based on standardized modules, combined with a large range of optional product features, we closely work together with our customers to develop auxiliary power supply and distribution systems, tailored to their specific needs. Added to this, we ensure close proximity to our customers and maximum uptime of our systems through a broad portfolio of custom-fit service solutions and the integration into the global Knorr-Bremse service network. AUXILIARY POWER SUPPLY n Wide range of input voltages supporting global requirements n Scalable architecture for varying power demands n Optimized efficiency in silicon and silicon carbide n Supporting ail common communication interfaces n Suitable for all mounting positions n Parallel switching of AC as well as DC outlets possible STAND-ALONE BATTERY CHARGERS n Broad range of input voltages n Scalable based on modular design n Efficient and highly reliable n Supporting IP, CAN and MVB communication n Flexible mounting positions incl. 19 enclosure n Parallel switching of DC outlets possible INVERTERS FOR VARIABLE VOLTAGE, VARIABLE FREQUENCY LOADS n Demand-driven power supply for vvvf loads (HVAC, air supply unit) n Convection-cooled module n Stand-alone or integrated into load n Optimized power management on vehicle level n Full-scope diagnostic functions for improved LCC SOLUTIONS BENEFITS FOR THE CUSTOMER The more closely power supply systems are networked with other rail vehicle sub-systems, the greater the benefit for the vehicle operator. For example a smart air supply unit could adjust compressor performance when the train enters a station, thereby reducing noise emissions

8 POWER ELECTRICS Resistors enable safe, controlled braking to take place, contactors connect and disconnect circuits under load, and disconnectors change the configuration of the traction circuit when the catenary voltage changes. High-voltage metering transducers provide reliable data for the vehicle logic, drive control and many other measuring devices. Systems like these are often invisible to the outside world but are essential for the proper functioning of a modern vehicle. And however diverse their tasks, such control components have one thing in common: There can be no compromises in terms of safety. Microelettrica Scientifica s cutting-edge solutions have met this requirement for more than 50 years, and today the company is a global market leader in electrical and electromechanical control components for rail applications. LINE CONTACTORS n For AC and DC traction circuits n Up to 4 kv voltage rating n Available in 1-, 2-, 3-pole versions n Different power terminal positions PRE-CHARGING SYSTEM n AC/DC pre-charge contactor n Pre-charge resistor, with customizable resistance level, 1 to 100 ohm n Up to 4 kv voltage rating CUTTING-EDGE TECHNOLOGIES DC HIGH-SPEED CIRCUIT BREAKER n Vertical and horizontal mounting position n IP65 enclosures for underframe or on-the-roof installation n Extremely compact design n Up to 4 kv voltage rating n Thermal current up to 4.5 ka MULTI CHANGEOVER DISCONNECTOR n 1- to 4-pole versions, with different power terminal positions n Bistable, for very low power consumption n For multi-voltage platforms n Up to 4 kv voltage rating INTEGRATED COOLING TOWER n Integrates the braking resistor and the traction converter cooling radiator n Cooled by a centraxial fan n Braking resistor sections designed upon specification n Complete with internal piping and circulation pump LTX-HIGH-PERFORMANCE LINE CONTACTOR n Thermal current up to 1800 A n Rated voltage up to 4000 V n Very high breaking capacity in a small space n Electronic control and power saving system BRAKING RESISTOR n Naturally or ventilator-cooled n Custom-designed resistance value and cooling pattern n Custom-designed interfaces TRACTION MOTOR BLOWER n Centrifugal or centraxial design n Very high pressure n Highly customizable n High resistance to corrosion SOLUTIONS BENEFITS FOR THE CUSTOMER The more closely power supply systems are networked with other rail vehicle sub-systems, the greater the benefit for the vehicle operator. For example a smart air supply unit could adjust compressor performance when the train enters a station, thereby reducing noise emissions. MACHINE ROOM BLOWER n Centrifugal, centraxial or axial design n Very wide range of fans, with flexible design n High resistance to corrosion ENERGY METERING n System compliant with EN50463 standard for energy billing n On-board data transmission system, with Ethernet interfaces n Single transducer for measurement of voltage and current in AC/DC, for outdoor installation n Software for energy data analysis available n Suitable for new vehicles, or for overhaul projects 14 15

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10 CONNECTED ROUTER/SWITCH The new switches and routers provide flexible network architectures and meet the TCN standard IEC Configuration of individual devices within the network is carried out across the trains from one data access point. Application development, commissioning, and service are simplified. MAS 94X The new vehicle control unit family CPU 94x revolutionizes the control architecture of modern rolling stock. For the first time, it allows several autonomous user-programmable controllers (PLCs) to be bundled virtually in a single control unit. They have been developed to meet high safety (SIL0 to SIL4) and cybersecurity standards and thus provide optimum protection for people and equipment. Modern rail vehicles are highly complex systems incorporating braking, door and HVAC systems as well as traction, lighting and power supply components. They also carry a wide range of display units for vehicle diagnostics, passenger information and safety alerts. The train control management system (TCMS) links all these functions into a single, intelligent system that offers maximum precision, safety and reliability. This is where Selectron Systems AG comes in the market leader in rail vehicle control technology and automation. Selectron s comprehensive product portfolio includes freely programmable control units, central and distributed remote I/O systems and train setup components. At the heart of the systems is an EN compliant family of control systems. HMI The HMI portfolio includes display sizes from 8.4 up to The units are available as both SIL0 and SIL2 versions. The high processing power allows, among other things, multichannel video streaming over Ethernet; the display is particularly bright. The simple and intuitive graphical programming interface reduces development and commissioning times. MSG The design of the modular control unit is based on a power supply module and a central unit with the option of adding different sub-modules to create the optimum control unit for the task concerned. SOLUTIONS BENEFITS FOR THE CUSTOMER The more closely a rail vehicle s sub-systems are networked with each other, the greater the benefit for the vehicle builder and operator. For example cross-system diagnostics can make individual service tools superfluous. Cutting-edge control technology from Selectron Systems AG provides the perfect basis for this. KSD + KFM Powerful diagnostic tools and a worldwide service network ensure that life-cycle costs are kept to a minimum. This is the result of closely connected sub-systems, whose data is collected and evaluated by Kiepe System Diagnostics (KSD) and Kiepe Fleet Management (KFM). CUTTING-EDGE TECHNOLOGIES SMARTIO The smart remote I/O system ( Smartio ) simplifies the complexity of the wiring in the body of the vehicle, in the cabinet, and in the driver s desk allowing a lean design, savings on installation and service time, and is extremely space-saving and easy to install. It can be flexibly expanded for all applications and is, therefore, a just enough solution. The new CPU3xx Smartio controller family (SIL0/SIL2) has been added to the established Smartio I/O system. NBS Emergency brake switch (NBS), unlocked with socket spanner or returned to original position by means of a spring. Option of locked emergency hammer (DC 24 /.../ 110 V) MASTER CONTROLLER Hand-operated drive/brake master switch with analog/digital reference signal output, dead man s switch and operation mode switch. (DC 24 / / 110 V) 18 19

11 TRACTION FULL RANGE OF ELECTRICAL AND TRACTION TECHNOLOGIES. Kiepe Electric GmbH is one of the global leaders in electrical systems and traction technology for local public transport vehicles, including LRVs, metro trains and buses. With more than 100 years of experience, the company not only offers pioneering traction technologies for rail vehicles and buses but also a broad range of related maintenance services. Its comprehensive refurbishment offer for existing vehicles helps many vehicle operators cope with financial pressures. EXTENDED SERVICE LIFE AND MINIMUM MAINTENANCE. Products from Kiepe Electric are designed to be low-maintenance. Powerful diagnostic tools and a worldwide service network ensure that life-cycle costs are kept to a minimum. This is the result of closely interconnected sub-systems whose data is collected by Kiepe System Diagnostics (KSD) and Kiepe Fleet Management (KFM). These diagnostic and maintenance programs provide operators and service personnel with an overview of the operational and diagnostic data of installed components and reduce downtimes to a minimum. THE MECHANICAL AND ELECTRICAL COMPONENTS ARE IDENTICAL, WHICH REDUCES THE PART VARIETY AND ENSURES HIGH RELIABLILITY. TRACTION CONVERTER MODULES CUTTING-EDGE TECHNOLOGIES AUXILIARY CONVERTER MODULES TRACTION CONVERTER KIEPE n Compact power for heavy shunting and mainline locomotives n Traction converter with integrated input rectifier and braking controller n Supplies both motors of a bogie with up to 2 x 400 kw n Integrated converters supply auxiliaries and consumers redundantly and efficiently n Integrated start/stop function starts diesel engine using the starter battery; separate starter not necessary n Exciter supplied via the starter battery output n Compact, low-noise construction due to water-cooled design n Web-based diagnostics, including entire maintenance documentation as well as trouble-shooting and remedial action n Europe-wide homologation of locomotives considered LITECON The LiteCon control takes over the: n Converter control n Safety-relevant monitoring functions n Sub-system control n Diagnostic function Main properties: n All I/Os are isolated electrically n Ambient air temperature from -40 to +85 C n EN compliant Communication interfaces: n Ethernet, CAN (standard) n MVB, RS232 USB (optional) n Digital inputs and outputs n Analog sensor inputs 20 21

12 SERVICE A reliable service partner over the entire life cycle. All train operators are unique and their servicing requirements for braking and on-board systems are also highly specific. But they have one thing in common: They depend on their vehicles remaining operational at all times and in all places. The mission of our RailServices brand is to ensure that this happens for all Knorr-Bremse sub-systems and over the vehicle s entire life cycle. The extended RailServices portfolio includes comprehensive service and support for all our products and systems, including vehicle maintenance: Products and services creating genuine added value in line with ongoing changes in the rail sector RailServices is further developing its range of services: IMPROVED AVAILABILITY REDUCED LIFE-CYCLE COSTS PROFESSIONAL WORKFORCE INCREASED PERFORMANCE WORRY-FREE COMPREHENSIVE SERVICE JUST IN TIME SERVICE CENTERS ALWAYS CLOSE TO THE CUSTOMER Excellent service calls for rapid reaction times. With 30 service centers on all continents, our RailServices specialists are close at hand when local customers need them. The first European Rail Services sites already fulfill the requirements of European Regulation (EU) no. 445/2011 for freight wagons. MODERNIZATION CUSTOMER-SPECIFIC SOLUTIONS BREATHE NEW LIFE INTO EXISTING S RailServices provides innovative component upgrades and systems modernization for existing fleets. We offer attractive system solutions worldwide for rail vehicles of all ages. Modernization is delivered by RailServices specialists with expertise and above all, passion. It is our ongoing commitment to your operational needs and to continued product innovation that makes modernization projects a realistic and affordable option for our customers. icom DIGITAL PLATFORM 4.0 DIGITALIZATION ON BOARD Knorr-Bremse provides a digital, innovative platform for the railway industry 4.0. User-friendly applications on a single platform using one on-board computer unit and a back office. This is the flexible expandable Knorr-Bremse solution for the railroad 4.0. This retrofittable system extends rail vehicle diagnostics to cover not just specific systems but whole vehicles. By introducing tablets, smartphones and apps to the railroad sector, it offers unique access to data on the condition of the entire vehicle fleet. Sophisticated measurement and analysis processes combine with automatic diagnostics to enable icom to predict maintenance requirements in advance allowing operators to take measures pro-actively. This powerful and flexible system already supports additional applications such as driver advisory systems and energy metering as well as third-party products due to the open architecture

13 P-1204-EN Knorr-Bremse Systeme für Schienenfahrzeuge GmbH Moosacher Straße Munich Germany Tel: Fax: 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 2018 Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains all power of disposal, such as for copying and transferring.