Cover Story Knorr-Bremse in Asia Project Platform screen gates

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1 R a i l V e h i c l e S y s t e m s Edition 26 May 2010 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 Project Platform screen gates Research & Development Knorr-Bremse product range Product Accessing the Chinese market Brake testing equipment

2 No. 26 May 2010 Contents E d i t o r i a l Domingo Mendieta COO Rail Asia Pacific 3 P r o j e c t Platform screen gates 4 Overnight retrofit Q u a l i t y DIN 6701 at Knorr-Bremse 6 An everlasting bond... S i t e s Rail Vehicle Services to be strengthened 8 Targeted acquisition Aftermarket Rail Services Training 9 Well trained R e s e a r c h & Knorr-Bremse product range 10 D e v e l o p m e n t Solutions for the entire train C o v e r S t o r y Knorr-Bremse in Asia 14 P r o d u c t Accessing the Chinese market 20 Clear view ahead with electro-pneumatic systems Brake testing equipment 22 Rapid, safe checking E-NEWS-0026-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 2010 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 May 2010 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: KB Media GmbH Printed by: Pera Druck GmbH 2

3 Editorial The economic crisis has had a massive impact on the market, and Knorr-Bremse has reacted accordingly, adjusting its capacities to the new market conditions. But that is only part of the picture: The company s basic strategy remains the same as before to offer innovative products with top safety and quality standards. Let us take a closer look at how we are pursuing this strategy on the Asian market where growth remains possible, even in times of crisis. From Knorr-Bremse s point of view it is not just our state-of-the art technologies that make a difference above all, it is the fact that we offer our customers completely localized products. To name two examples: The new braking system for the Japanese Shinkansen has been specially developed to meet the extreme demands of emergency braking when an earthquake occurs. Even the ventilation ribs on the brake disc have been specially modified to meet current Japanese noise emission regulations. The brakes we will be supplying for the Chinese CRH3 train meet all the specific requirements of China s new high-speed rail systems. Domingo Mendieta, Chief Operating Officer Rail Asia Pacific But this market is playing a prominent role in Knorr-Bremse s strategy a highly successful one that has brought contracts worth more than EUR 1 billion in the last 12 months. In addition to the CRH3 contracts, Knorr-Bremse is also supplying 1,120 passenger cars for Bombardier Sifang Transportation Ltd. CRH1 with braking and door systems. And the company has also become involved in the CRH2 platform developed by CSR Sifang Locomotives & Rolling Stock Co. Ltd. Knorr-Bremse is to supply bogie equipment for some 1,920 cars. This edition of the Informer contains a host of interesting details about the wide range of Knorr-Bremse on-board products, the retrofitting of Singapore s metro system with almost 2,000 Westinghouse platform safety gates and the latest developments in windscreen wipe/wash systems. It also provides information about the targeted acquisition of a leading, Australia-based specialist in driving simulators, how Knorr-Bremse has developed specialized systems and maintenance training for a wide range of vehicles, and why clueing is pushing the boundaries of train design. I hope you enjoy reading it. Domingo Mendieta 3

4 No. 26 May 2010 Platform screen gates Overnight retrofit Due to the success of the platform screen doors in the underground stations of the Singapore Metro, the Singapore Land Transport Authority decided to retrofit all of the above-ground platforms. Westinghouse Platform Screen Doors is tasked with designing and supplying the platform screen gates for use on the 36 existing above-ground platforms on the northsouth and east-west lines. 4

5 U p t i l l n o w o n l y t h e u n d e r g r o u n d m e t r o s t a t i o n s h a d b e e n f i t t e d w i t h t h i s p r o t e c t i o n s y s t e m b e t w e e n t h e t r a c k, t r a i n a n d p l a t f o r m, b u t t h e i r s u c c e s s p r o m p t e d t h e o p e r a t o r, S i n g a p o r e Te c h n o l o g i e s Elec tronics, to retrofit them to the 36 above - ground stations as well. Innovative platform screen doors in Singapore Installations of the new doors INSTALLATION Stages The Singapore platform screen gate retrofit project is divided into four distinct stages. Stage 1 is really a pilot stage which was successfully completed in December This phase included a total of 192 doorways installed at Pasir Ris, Yishun, and Jurong stations and these are now in service operation. Stages 2A, B, and C are already well underway and on schedule to be completed for the customer s deadline end of NEW Platform screen gate The platform screen gates being fitted to the Singapore Metro are of a type recently designed and developed by Westinghouse Platform Screen Doors. This new gate product has been jointly created by Westinghouse Platform Screen Doors in the UK and in China to address the needs of the global metro market, with the manufacturing of the gate system taking place at the recently opened new Westinghouse Platform Screen Doors production facility based in Guangzhou, China. PROTECTING AND GUIDING The Platform screen gates provide a half height (1.5 meter) barrier between track and train and as a result greatly improve passenger safety whilst making it easier for them to board as the stopping point of the train is always consistent; passengers are effectively guided into the train. The gates open automatically when the train stops at the platform and then close again when passengers have safely boarded and the train doors are closed. The use of platform screen gates (and full height platform screen doors) are also of great benefit to metro operators as headways can be maintained due to the consistent dwell time for the train made possible by their use. The platform screen gate can be fitted at the new-build stage or, in many cases, retrofitted as on the Singapore Metro. The world s first ever installation of full-height platform screen doors on a heavy metro system was carried out by Westinghouse Platform Screen Doors on Singapore Metro back in Since that time the doors have performed superbly, with millions of successful opening and closing cycles carried out. They continue today to enhance safety and the comfort levels on the platform for passengers (allowing the efficient and economical use of air conditioning on the platforms and forming a barrier against trackside dirt and noise), just as they were originally designed to do. 5

6 No. 26 May 2010 DIN 6701 at Knorr-Bremse An everlasting bond The use of adhesives in rail vehicles is a useful alternative to conventional joining technologies such as riveting or welding. Bonded components are lighter, make better use of the space available, are less prone to corrosion and are easier to repair. Knorr- Bremse is one of the first manufacturers to be certified to DIN standard 6701 for the use of adhesive bonding. Adhesive is applied to one half of a brake control panel baseplate prior to joining Rapidly developing technologies make standards necessary Rail technology is currently evolving at a rapid pace, with new insights and developments quickly being converted into practical solutions. In this context, the DIN 6701 quality standard was declared to be state-of-the-art by the Federal German Railway Authority two years ago. Since the start of 2010, companies using adhesives for building rail vehicles, trading in products bonded with adhesives, or offering services related to the construction, design, or repair of such products have to be officially authorized to do so. A system of authorization not only ensures that properly qualified personnel is involved but also that the best method of adhesion is used in each case thereby upholding the highest standards of safety. Provided these requirements have been met, a bonded component will last just as long as a welded one. Towards a global guideline The new German DIN 6701 quality standard has already established an excellent reputation and given that comparable quality standards do not exist anywhere else in the world is set to develop into a global guideline in the future. Knorr-Bremse can already ensure adherence to this standard if customers so require. Further sites to follow Since August of last year, Knorr-Bremse SfS GmbH has had six of its European sites audited according to DIN 6701 by the Fraunhofer Institute for Manufacturing and Advanced Materials, making it one of the first companies in the world to do so. The standard is to be phased in at further Knorr- Bremse sites in Europe and worldwide. 6

7 T h e m a i n a d v a n t a g e o f a d h e s i v e b o n d i n g i s t h e c o m b i n a t i o n o f m a t e r i a l s t h a t c a n b e j o i n e d. T h e r e i s l e s s n e e d t o t a k e p h y s i c a l p r o p e r t i e s a n d t e m p e r a t u r e i n t o a c c o u n t a s f a r a s t h e c o m p o n e n t s a r e c o n c e r n e d. I n t e l l i g e n t u s e o f b o n d i n g t e c h n i q u e s m e a n s t h e m o s t s u i t a b l e m a t e r i a l s c a n b e c o m b i n e d f o r p a r t i c u l a r o p e r a t i n g c o n d i t i o n s. T h i s n o t o n l y r e d u c e s c o s t s i t a l s o s p e e d s u p p r o d u c t i o n a n d u s e s l e s s e n e r g y. A n d g r e a t e r d e s i g n f l e x i b i l i t y u s u a l l y r e s u l t s i n e n h a n c e d p a s s e n g e r c o m f o r t a s w e l l. Auditors and Knorr-Bremse employees at the IFE plant in Brno Adhesive applied to control panel plates prior to joining Destruction of a bonded door sandwich construction 7

8 No. 26 May 2010 Rail Vehicle Services to be strengthened Targeted acquisition Knorr-Bremse has acquired the leading, Australia-based specialist in driving simulators for rail vehicles to expand its portfolio in a sector in which increased market opportunities are expected. The purchase of Sydac is part of a strategy of targeted acquisitions aimed at strengthening the company s market position in a number of areas. Knorr-Bremse permits a rapid integration and will continue to provide the resources to expand Sydac operations both locally and internationally. Sydac is well established in the driver training simulator market, which will complement the existing Knorr-Bremse products and expand the technological expertise. The purchase moreover offers synergies with existing activities and adds corporate value. Over recent years the company has built an impressive global business and has successfully won contracts based on its technical excellence, close attention to the customer s needs and competitive pricing. There are considerable synergies between Sydac and Knorr- Bremse and the purchase is an important step in the further globalization of the company s sales, with the majority of the employees continuing to be based in Sydac s headquarters in Adelaide. Plans are to see Sydac develop as the market leader in simulation. Sydac was established in 1988 and currently employs more than 130 people. The company has regional offices in three Australian states and an office in Derby, UK employing 19 staff. Rail driving training in a Reality theater ScotRail Class 334 simulator 8

9 Employees of Taipei Metro receive hands-on training Practical exercises and demonstrations form an important part of the training courses. Rail Services Training Well trained The only way to ensure maximum availability of rail vehicles is to have them serviced and maintained by properly qualified personnel. Because the situation in this segment had changed radically in recent years, Knorr-Bremse has developed specialized systems- and maintenance-training for a wide range of vehicles. The example of private freight cars illustrates the huge changes that have taken place in the maintenance scene. Since 2007, fleet operators have been wholly responsible for their vehicles and have had to make their own maintenance and repair arrangements. The conditions under which workshops operate have also changed. In the past, vehicles operated by the German railway company Deutsche Bahn AG were subject to DB s own regulations; now they have to comply with the new maintenance guidelines issued by the Association of Privately Owned Wagon Operators. At the same time, the need for training in systems, products, and maintenance has grown over the last ten years. This is partly because vehicle builders now usually sell new vehicles in conjunction with a training package, but also because rail market liberalization has resulted in a partial separation of fleet operations and vehicle maintenance. Another factor is the increasingly close links between pneumatic and electronic components as well as between braking equipment and other vehicle systems brake maintenance technicians have long since started to work with laptops as well as wrench. Modern braking systems may be designed to require a minimum of conventional maintenance, but at the same time there has been an increase in the number of incidents caused by sources outside the actual braking equipment itself. Resolving these issues calls for not only a thorough grounding in braking technology but also a good knowledge of the vehicle s various systems. The Knorr-Bremse customer training department offers courses in both these areas. In the case of systems- and maintenance-training for new vehicles, expert instructors provide a grounding in systems and products, combined with the necessary tools and equipment for ongoing preventive and corrective maintenance. In the aftermarket, systems, maintenance, and product training also for considerably older vehicles is provided, together with an introduction to test-bench use and commissioning for maintenance technicians. And by way of basic training, a range of introductory and advanced brake maintenance courses for multiple units, mainline passenger vehicles, and freight cars has also been designed, together with specialist courses on particular control systems. Further information about these courses and also individual training provisions is available from your regional Knorr-Bremse representative. 9

10 No. 26 May 2010 Knorr-Bremse product range Solutions for the entire train Safety, top quality, and maximum customer benefits are the hallmarks of Knorr-Bremse products. In addition to classic braking systems, the company also offers a portfolio of products for applications requiring a combination of optimum functionality and safety. Here is an overview: Control Components Air Conditioning Systems Driver Information Systems Windscreen Wipe/ Wash Systems Derailment Detectors Entrance and Detection Systems Platform Screen Door Systems Electronic Diagnostic Systems Signaling and Traffic Management Systems 10

11 DERAILMENT DETECTOR Derailments are often caused by a single wheelset that comes off the rail but goes unnoticed by the driver because of the strong forward momentum of the train. When the next set of points is reached, the entire car can derail, dragging further ones with it. And when hazardous goods are carried, the results can be disastrous. A Knorr-Bremse derailment detector can help prevent such a scenario from developing. The system reacts within milliseconds to the lateral acceleration forces on the axle that are a typical sign of derailment and immediately alerts the driver. The detector system can operate either electronically or pneumatically and is suitable for a wide range of different vehicle types. WINDSCREEN WIPE/ WASH SYSTEMS Knorr-Bremse windscreen wipe/wash systems are available for the full range of rail vehicles streetcars, metros, locomotives, and high-speed trains. The product portfolio includes systems for segmental, parallel, or overlapping wipe areas as well as electronically synchronized wiper drive units. Electric, pneumatic or electropneumatic drive systems can be supplied according to customer requirements. ELECTRONIC DIAGNOSTIC SYSTEMS In addition to its derailment detectors, Knorr-Bremse also offers a range of further electronic diagnostic systems that make an important contribution to improving the safety and efficiency of entire vehicle fleets. These include wheel slip protection and roll monitoring, wheel lock protection, overheating sensors, and drive stability monitoring. 11

12 No. 26 May 2010 DOORS Quality and reliability combined with safety and economy are priorities for IFE Automatic Door Systems the specialist for internal and external doors and access systems within the Knorr-Bremse Group. A policy of ongoing innovation means that IFE can now offer complete automatic door systems for streetcars, light rail systems, metros, and urban trains as well as mainline and high-speed trains all over the world. DETECTION SYSTEMS The new DS5 goes further than traditional products, making it possible to detect flexible obstacles with dimensions down to 5x30 mm or rigid obstacles with a diameter down to 6 mm effectively increasing the system s sensitivity by a factor of ten. PLATFORM SCREEN DOOR SYSTEMS Half-height or full-height platform screen doors make an important contribution to safety by creating a protective barrier between embarking/disembarking passengers and the train and track. Each platform door system is synchronized with the train doors, effectively channeling passenger flows, enabling the train to run to schedule and enhancing overall operational efficiency. They also make low-cost platform climate control possible. Display screens can easily be incorporated into the system to show the timetable or announce the next train, and can also be used to generate advertising revenue. AIR CONDITIONING SYSTEMS Whatever the climate, Merak systems can be found providing air conditioning, ventilation, or heating in high-speed and urban trains, metros, and light rail systems, operating underground in major cities, across deserts, or in Siberian winter conditions. HVAC systems are available with or without heat pumps as compact or split systems for installation below the roof or under the floor. And protecting the environment is a priority when it comes to their manufacture, maintenance, and disposal. 12

13 CONTROL COMPONENTS Among the products manufactured by Knorr-Bremse subsidiary Microelettrica Scientifica are AC/DC contactors and isolators, resistors and electronic devices for railway applications. The company s portfolio includes four types of contactors and isolators operating at up to 4kV for loads up to 2,000A per pole. Contactors and isolators are supplied already assembled. Resistors ensure smooth, safe braking by dissipating the vehicle s kinetic energy electrically. Microelettrica Scientifica s high-voltage metering transducers are designed for voltages between 600V DC and 25,000V AC. The high-voltage signals are precisely converted into analogue outputs that can then be evaluated by the vehicle logic or drive control unit or by other measuring components. SIGNALING AND TRAFFIC MANAGEMENT SYSTEMS The traffic management product portfolio offered by Knorr-Bremse subsidiary Zelisko covers the entire range of optical displays based on state-of-the-art LED technology. Computer-controlled systems ensure the safety of level crossings, and light signals provide the locomotive driver with reliable information from the central control room. When it comes to railway signaling, Zelisko covers the entire product range, including optical roadside signals - half and full barrier systems, stand-alone-systems and main signal covered systems with an interlocking monitoring interface. For complex traffic management systems, Zelisko offers customers turnkey system solutions from the initial concept to project planning, installation and start-up. DRIVER INFORMATION SYSTEMS The LEADER system launched by Knorr-Bremse subsidiary New York Air Brake is a revolutionary driver information system that enhances the efficiency of train operations and considerably reduces energy consumption by recommending optimum handling for a particular route. By helping operators analyze train driver behavior, the special evaluation software not only improves train-handling performance but also increases overall operational efficiency. With its acquisition of Sydac, the Australian manufacturer of locomotive simulators, Knorr-Bremse has further extended its proactive approach to cost savings (see page 8). 13

14 No. 26 May 2010 Knorr-Bremse in AsiaFast track to the future 14

15 China is busy building high-speed tracks, Japan is introducing a new generation of Shinkansen trains, and Singapore is modernizing its local rail network. The global economic crisis seems to have had little impact on the growth of rail transportation in Asia. And Knorr-Bremse is playing an active role in shaping the market, thanks to its carefully THOUGHT- OUT Asia strategy. 15

16 No. 26 May 2010 It sometimes seems as though the rail networks in Asia cannot expand quickly enough. In China, a highspeed route has just opened between Guangzhou in the south and the city of Wuhan on the Yangtze River, and further routes are currently at the planning or construction stage. In Japan, train operator JR East is introducing a new generation of E5 Shinkansen trains in a bid to compete with air travel. And the Tohoku high-speed line between Tokyo and Hachinohe will soon be extended as far as Aomori, on the west coast of the main island of Honshu. From India to Japan, major cities are planning new metro and light rail systems, expanding existing ones, or investing millions in modernizing them. And even in the most westerly part of Asia, things are on the move: Turkey is planning a metro line that will extend under the Bosphorus. Knorr-Bremse is to supply braking systems for the trains, which will be built by Hyundai Rotem a fitting symbol of cooperation that transcends continents. Step by step Knorr-Bremse established its first contacts with Asia back in the 1970s in China and, in the years that followed, the company adopted a consistent strategy of expansion. This culminated in the company expanding the product portfolio beyond its core business with braking systems to include automatic door systems and air conditioning equipment. Parallel to this, it established its various brands in the market. Close contacts pay off It is therefore no coincidence that the 2,720 new cars under development for the Chinese CRH3 high-speed train bear the unmistakable signature of the Knorr-Bremse Group. Braking systems from Munich will bring the trains safely to a halt, IFE door systems from Kematen in Austria will provide for smooth access at stations, and circuit breakers from Microelettrica Scientifica in ltaly will ensure safe electric circuits. Onethousand twohundred eighty of the cars will also be fitted with HVAC systems developed and manufactured by Merak at its plant in Madrid, Spain. This is not just a success story for the various group subsidiaries involved the systems to be supplied to the CRH3 are worth a total of EUR 500 million, making this the biggest single order in more than 100 years of Knorr-Bremse s history. Knorr-Bremse now has five joint ventures in China and the company s activities have begun to gather a momentum of their own. Thanks to its development and project management structures in China, Knorr-Bremse qualifies as a Chinese manufacturer, and this has cleared the way for the company s participation in numerous export projects in conjunction with Chinese rail vehicle builders. Together with CNR Changchun Railway Vehicle Company, for example, it won the tender for supplying braking systems and platform screen doors for the new metro in Mecca, Saudi Arabia. Together with the Dubai Metro, which opened last year, this major project in Saudi Arabia demonstrates the importance of the Middle East as a growth region. 16

17 2009 saw further positive developments in the rail vehicle segment in Asia. The main growth driver was China, where government economic stimulus programs ensured continued high demand for rail vehicles. The success of the company's strategy in China, with its own production facilities and close cooperation with Chinese partners, was confirmed when it received the largest order in its over 100-year history. source: Dr. Manfred Vohla Localization across the entire continent China remains Knorr-Bremse s most important market on the asian-pacific region. But customers in Japan (Tokyo), Korea (Seoul), and Australia (Sydney) also have competent Knorr-Bremse partners available locally. The philosophy underlying the company s operations in neighboring markets is the same as for its operations in China ensure a high level of localization for all types of requirement and deliver precisely the right product with the usual high Knorr- Bremse quality standards. The metro in Mecca is a case in point: Because some of the network runs overground, compressors had to be designed with a protection system to withstand sandstorms of up to 50 mph. Another example of a specific local development is the braking system for the latest generation of Japanese Shinkansen high-speed trains. In this case the Knorr-Bremse engineers developed a particularly lightweight version of the axle-mounted disc brake caliper. And the discs themselves, together with the flexible ISOBAR sintered pads, were especially developed for the extreme conditions in the north of Honshu. Even the cooling fins were specially adapted not so much to improve the cooling effect as to conform to the extremely strict Japanese noise emission requirements. 17

18 No. 26 May 2010 Consistent regionalization is the key to success! The editors of this Informer spoke to Stephen Ku, Director Business Development and Marketing Knorr-Bremse Asia Pacific, about Knorr- Bremse s plans in Asia. Knorr-Bremse has been focusing on Asia for decades. There must be good reason to do so, Mr. Ku. Stephen Ku: First of all: Knorr-Bremse is growing all over the world. But it is true that Asia plays an important role in the global economy in terms of growth. Secondly, Asia is one of the fastest-developing railway markets, and this is in line with the company s growth policy. Furthermore, Knorr- Bremse is a global leader in its relevant market segments, and Asia is eager to use Knorr-Bremse technology to enhance the safety and reliability of its railway systems. In what ways is the Asian market different from the company s core markets? Stephen Ku: The only difference I see is the culture in each Asian country. The market itself is not much different from the core markets. Asia largely follows UIC and AAR standards. How would you describe Knorr-Bremse s plans in Asia? Stephen Ku: The company is always customer-oriented as well as technology driven, and since the Asian market is growing so rapidly, Knorr-Bremse plans to establish an even stronger local presence in each country in the region. This will enable it to serve customer needs and maintain its leading role in Asia. Knorr-Bremse s local presence in Asia considerably increases customer benefits. How is this reflected in day-to-day business? Stephen Ku: Well, the obvious benefit is the fast response and better understanding of the customers needs. And the ongoing benefits what makes Knorr-Bremse products so extraordinary? Stephen Ku: It is regionalization that really makes them unique. Consistent regionalization or even localization is the key to success, both for ourselves and our customers. Our goal is to offer each customer the perfect product for its specific market needs. In addition to this, the product should represent greater value than our competitors products. We are definitely on the right track with all our efforts and we are getting better and better by the day. What are the implications of Knorr- Bremse s strong position for the company s cooperation with Asian partners? Stephen Ku: Partnership seems to be the best way of quickly establishing a strong foothold in the Asian market. So far, this approach has certainly brought satisfactory results in terms of our market share in the region. 18

19 The other Asian markets also developed positively. In India Knorr-Bremse posted further growth in the classical market for freight and passenger transportation vehicles. At the same time, the company also secured itself a leading position in the emerging market for metro systems. In Japan Knorr- Bremse was selected to supply bogie equipment for all of the power cars for the new generation of Shinkansen trains. 19

20 No. 26 May 2010 K n o r r - B r e m s e h a d a l r e a d y e q u i p p e d a h i g h - s p e e d t r a i n d e s t i n e d f o r C h i n a w i t h w i n d s c r e e n w i p e / w a s h s y s t e m s a s p a r t o f t h e C R H 3 p r o j e c t, b u t t h e l a t e s t c o n t r a c t f r o m t h i s r a p i d l y e x p a n d i n g e c o n o m i c g i a n t b r o k e n e w g r o u n d. F o r t h e f i r s t t i m e e v e r, a d o m e s t i c C h i n e s e v e h i c l e b u i l d e r o r d e r e d a s i m i l a r l y r o b u s t a n d r e l i a b l e w i p e / w a s h s y s t e m g i v i n g K n o r r - B r e m s e d i r e c t a c c e s s t o t h e C h i n e s e m a r k e t. T h e k e y t o K n o r r - B r e m s e s s u c c e s s i n s e c u r i n g t h e c o n t r a c t w a s n o t j u s t t h e c o m p a n y s t e c h n o l o g i c a l c o m p e t e n c e a n d e x p e r i e n c e b u t a l s o t h e e x c e l l e n t c o l l a b o r a t i o n b e t w e e n K n o r r - B r e m s e Austria and Knorr-Bremse S uzhou. 20

21 Accessing the Chinese market Clear view ahead with electropneumatic systems The demands made on windscreen wipe/wash systems are extreme particularly on high-speed trains. So it is not surprising that Chinese vehicle builders Bombardier Sifang Transportation Ltd. have put their faith in Knorr-Bremse quality and selected the Pneumatic High-end System manufactured by Knorr-Bremse Austria for their 80 CRH1 380 high-speed trains. Steel section tube reduces costs The system developed for Bombardier Sifang Transportation Ltd. is based on the same technological platform as the CRH3 with the difference that the system for the CRH1 380 has a new type of wiper arm made not of the usual carbon-fiber reinforced composite material but rather of steel section tubing. As well as offering the usual reliability of the Pneumatic High-end System wiper, the new wiper arm material brings a price advantage: Steel is cheaper than composite material, and the arm can also be bent to fit various parameters such as wiping angle and windscreen geometry, enabling Knorr-Bremse to offer a wide range of solutions for virtually all types of vehicle. This success story is all the more striking because the decision by Bombardier Sifang Transportation Ltd. to grant the contract to Knorr-Bremse represents a fundamental paradigm change for the vehicle manufacturer. In the past it used only electric wash/wipe systems for its projects, and the cost of an electro-pneumatic system like the Pneumatic High-end System also differs considerably from conventional electric wipe/wash systems on account of the technology involved, the functions, components, and performance data. Another deciding factor was Knorr- Bremse s more than 15-year track record of supplying the high-speed segment, combined with its experience with spheroidal curved windscreens a particular challenge for wipe/wash systems. This, combined with reliability and performance, was what tipped the balance in favor of the Knorr-Bremse system. In addition to the CRH1 380, the system with the new design of wiper arm is also to be installed in high-speed trains built by another Chinese manufacturer. By the end of the first quarter of 2010 the first field tests were due to be carried out on a prototype train. 21

22 HL P HL P No. 26 May 2010 Brake testing equipment Rapid, safe checking The use of static brake testing can considerably speed up marshaling processes, as it enables brake functionality to be checked on entire trainsets. Knorr-Bremse has incorporated tried-and-tested pneumatic systems into its brake testing equipment a highly successful strategy, as the company is now set to supply marshaling yards all over Germany. P (bar) 5,0 4,2 admissible leakage 0 pressure in brake pipe train is filled with air automatically leakage test automatic re-filling apply brakes release brakes brake test finished time uncouple the train from unit visual check all brakes applied visual check all brakes released permanent air supply connection to loco command "start" confirmation "airthight" or "to leak" command "apply brakes" command "release brakes" command "brake test finished" disconnect train from brake test unit A question of economy The main explanation for why such equipment is not more widely used is the structure of railway companies. Brake testing equipment is classified as part of the rail infrastructure, but in many cases it is employees of the freight fleet operators who are responsible for actual testing. This makes little economic sense, as operators often end up using a locomotive to supply compressed air to the braking system for testing. Such a locomotive can cost some EUR 3 million, and during brake testing which can last for up to an hour it is not earning any money. By contrast, static brake testing equipment can be purchased for about a tenth of the price, freeing up the locomotive for its proper purpose. Knorr-Bremse expertise in main components Knorr-Bremse brake testing equipment consists of two main elements the pneumatic system and the wireless electrical 22

23 A n e w l y f o r m e d t r a i n s e t i s o n l y p e r m i t t e d t o g o i n t o o p e r a t i o n o n c e a c o m p r e h e n s i v e b r a k e t e s t h a s d e m o n s t r a t e d t h a t t h e b r a k i n g s y s t e m i s f u l l y f u n c t i o n a l a n d s u f f i c i e n t f o r t h e p l a n n e d r o u t e a n d s p e e d a t a s k t h a t c a n b e c a r r i e d o u t b y s t a t i c b r a k e t e s t i n g e q u i p m e n t. control unit, which enables the technician responsible for the brake testing to transmit commands to the equipment without having to return to it each time. As the units are usually located in the open air, the demands made on the pneumatic system are such that no existing industrial components can be used which is where Knorr-Bremse s expertise as a brake specialist comes in. The pneumatic system consists entirely of components derived from the company s brake control technology. The situation is rather simpler when it comes to the control unit all that is required to ensure continuous functionality is an additional heating element. Robust GPRS units In the case of the wireless remote control system, Knorr- Bremse opted for robust GPRS units that operate over existing networks but are equipped with special additional software. The brake testing equipment itself contains a GPRS modem that transfers the technician s commands to the control unit. 23

24 R a i l V e h i c l e S y s t e m s Quality that convinces. All over the world, Knorr-Bremse products are used to move people and goods safely. In all types of rail vehicles, carrying passengers and freight and on platforms. That is why quality is so important for us. Our Quality First Initiative helps us create products that will function reliably throughout a long working life. Our goal of Zero Defects starts with the initial development stage and culminates in carefully designed manufacturing processes with regular quality control procedures. That way, everyone stays on the right track our customers and our customers customers.