Worldwide on Track. Components and Systems for Rail Vehicles

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1 ZF Friedrichshafen AG Special Driveline Technology Rail Drive Systems Friedrichshafen Germany Phone Fax ZF Friedrichshafen AG Commercial Vehicle Technology Rail Vehicle Dampers Bogestrasse Eitorf Germany Phone Fax ZF Friedrichshafen AG Commercial Vehicle Technology CV Chassis Modules Dr.-Jürgen-Ulderup-Str Stemwede-Dielingen Germany Phone Fax Worldwide on Track rail@zf.com Scan QR code and go ahead! Components and Systems for Rail Vehicles Driveline and Chassis Technology EN

2 Innovations of Great Value "ZF is serving the mobility of human beings and goods with its products. Only innovations which make trains fast, safe, and comfortable motivate customers to travel in them. This is an obligation and a challenge at one and the same time." Lars Kräft Director Product Line Rail Drive Systems Friedrichshafen Thomas Memmesheimer, Head of Sales and Development Rail Vehicle Dampers Eitorf Ludger Hülsmann Head of Sales CV Chassis Modules Dielingen Worldwide on Track Worldwide, ZF Friedrichshafen AG is recognized as an excellent and reliable partner for innovative Driveline and Chassis Technology. Every year, the ZF Group invests approximately five percent of its sales in Research and Development. As a result, ZF is among the leading companies in terms of technology, quality, and service. Based on an over 60-year tradition in the rail business with manufacturers and operators of rail vehicles, ZF stands for flawless, reliable, and long-lasting driveline and chassis products in future-oriented rail travel applications. 2 3

3 The Driving Force Driveline Systems from ZF The things that manufacturers and operators of rail vehicles expect in the future have already been turned into practical reality in the form of ZF products: Increased driving comfort and safety with reduced fuel consumption and lower emissions. Highly integrated products and superlative systems expertise are the key to this. All driveline components are provided from a single source. The weight-optimized precision components are all perfectly matched within identical modules and can be combined to suit different performance classes. Driveline systems from ZF are more than the sum of their parts. ZF s extensive in-house expertise translates straight into added value for the customer. It is this knowledge that extends the service life of ZF products and makes them more economical. A process aided by the intra-company transfer of technical know-how. For example, some aspects of transmission technology from the commercial vehicle sector can be utilized for rail travel. This cuts down development time. 4 5

4 DMU ZF drive systems for diesel railcars profit from this transmission technology that ZF as a technological leader for modern driveline technology sets standards. Decade-long experience and quality guarantee perceptible customer values. has been proven 1,000,000 times in road transportation. Leading system houses and engine manufacturers trust ZF transmission systems that offer more ride comfort and safety with reduced fuel consumption. 1 1 ZF-EcoLife Rail One Model Range for All Applications ZF-EcoLife Rail is a modern, six-speed powershift transmission. Combined with a gearset reversing transmission, it is perfectly matched to DMUs with engine torques of up to 2,500 Nm. Thanks to the optimized torque converter, the vehicle accelerates in an ideal manner. The integrated retarder provides a higher braking torque when decelerating, thus also offering more safety whilst also ensuring reduced wear for the mechanical braking system at the same time. Maintenance costs are reduced and the environment is protected. The "Fail Safe Principle" ensures more safety on the rails; the ZF-EcoLife Rail runs reliably with the best availability, low fuel consumption, and constantly excellent shifting comfort, even when dealing with high temperatures. The improved cooling concept is matched to modern diesel engines belonging to the Stage 3b standard and permits oil sump temperatures of up to 120 C. The Rail Drive Control System (RDCS) is the central communication interface between the train control unit and the ZF system [transmission, retarder, gearset reversing transmission] and controls the shift reversal process ZF-AS Rail Shifting Automatically, Driving Economically The automatic ZF-AS Rail transmission convinces with its highly developed shift strategy. The 12 gears constantly keep the engine in an optimum, economical speed range and save fuel. Combined with the ZF gearset reversing transmission and the Rail Drive Control System (RDCS), ZF provides a system that is ideally harmonized. A housing manufactured from light metal combines all of the transmission components, including the dry clutch and electronic control unit in a compact and protected manner. This enables simple installation and reduces the axle loads whilst only weighing 360 kg. ZF offers three performance versions up to 3,100 Nm of input torque. Numerous ratio variants and a high level of transmission efficiency reduce fuel consumption and emission levels. 4 The Rail Drive Control System (RDCS) Intelligently Networked RDCS is the central communication interface between the train control unit and the ZF system and controls the entire shift reversal process automatically. It forms the control unit between all transmissions and axle reversing transmissions in the vehicle with the lowest possible cost of integration. The RDCS ensures a stable electrical integration of the ZF components in the train environment. The entire system is EMC certified and fulfills the valid fire protection directives. 4 3 ZF Gearset Reversing Transmission/Bevel Gear Drive The Modular Top Performer Gearset reversing transmissions (master) drive the wheelsets or control/ change their direction of travel; and like the bevel gear transmission (slave), they are setup as modules. The transmission ratio of these systems can be variably selected for the bogies, with one or two driven axles. Possible: Axle loads of up to 22 tons. Adapted axle drive module construction kits in the respective performance class are available for all automatic ZF transmissions. The Rail Drive Control System (RDCS) controls the entire shift reversal process in an automatic manner and reduces the cost of integration for the entire system. 6 7

5 EMU Designed according to customer requirements, they provide decisive support to On the basis of proven drive concepts, ZF develops individual solutions for electrical rail vehicles in city and tram transportation through to the high-speed sector. the implementation of innovative, environmentally-friendly, and efficient mobility. ZF drive components are easy-to-maintain, safe, and reliable. Input and output clutches can be supplied for all transmissions. 6/7 Transmissions for Subways (7) and Tram Vehicles (6) Proven Thousands of Times in Everyday Life Reaching the destination quickly, punctually, and comfortably; this requires a drive system with excellent efficiency, utmost operating smoothness, and noise-optimized design. ZF transmissions fulfill these expectations and convince thanks to a special gearing design and latest labyrinth technology even when dealing with extreme weather conditions down to -40 C. On the basis of FEM calculations (finite element method), these transmissions are designed in a weight-optimized manner and, depending upon the customer requirement, are supplied with an aluminum or nodular graphite cast iron housing. The assembly and easy-to-service design ensures low life cycle costs (LCC). 9 Wheelset Reliable Components for a Safe Journey Today, a journey in a high-speed train is similar to traveling in a plane. This means that quality, safety, and reliability are even more important. As a component supplier, ZF offers ground bevel gearsets manufactured from high-strength ZF 1A case-hardening steel that were specially developed for high loads/stresses in the high-speed sector. Thus, the wear pattern-optimized gearing ensures premium power transmission capacities /2 Bevel Gears and Spur Gear Drives Compact and Unique ZF develops customer-specific bevel gears, hypoid bevel gears (1), and spur gear drives (2). Depending upon the customer requirements, these drives are either single or two-staged, fully or partially cushioned, and are ideally adapted to confined spaces. Ground spiral bevel gears and helical cut spur gears with high total contact ratio ensure quiet operation. Tailor-made ZF transmissions increase passenger comfort and the efficiency of light rail vehicles. 3/4/5 Low-Floor Solutions Reaching the Destination Without Barriers The 100% low-floor technology in trams offers passengers a stepless entrance and passage without level differences. This calls for immensely compact transmission concepts as well as an unconventional, vehicle-specific design (3, 4). ZF transmissions are weight and noiseoptimized and also function reliably even after many years. In addition to the 100% low-floor solutions, ZF also offers transmission concepts for 75% low-floor vehicles (5) and high-floor solutions for conventional bogies. 8 ZF-Highspeed One Transmission for All Speeds Modern drive systems should be safe, reliable, environmentally friendly, comfortable, quiet, and economical. Above travel speeds of 250 km/h ( mph), the load and performance are very high. As a technological leader, ZF also sets the benchmark here, offering a perfectly fine-tuned transmission for use in highspeed trains with speeds up to 600 km/h ( mph). This single stage drive offers one housing for all ratios. The new, improved labyrinth technology as well as the gear technology with higher load capacity and noise optimized design is rounding the profile of this high performance transmission. 10 Hybrid Technology Economical and Environment-Friendly Hybrid technology combines the advantages of electric motors and diesel engines in a single unit. It combines low fuel consumption, fast acceleration, low noise levels, and exemplary emission values in a superlative drive system. In the parallel hybrid system, gasoline engine and electric motor drive the wheels separately or in combination. The main components are the electric motor and combustion engine, a battery, inverter, and a transmission. An intelligent control unit ensures that the advantages of both propulsion concepts are utilized to the full. The hybrid also stands out when it comes to economy, in that it offers greater comfort while braking, as well as better acceleration. Its capabilities are convincing in both operating modes. You can choose to set off fast, or slowly in "Eco" mode. 8 9

6 LOCO+ Trains must measure up to trucks when it comes to freight transportation and must face up to passenger cars and planes when it comes to passenger transportation. In this competition, diesel and electric locomotives can only be successful if they convince with their driving power, load-carrying capacity, and endurance; moreover, they must operate in a highly economical and reliable manner at the same time. To this end, transmissions are needed that can ideally convert engine power on the one hand and operate in a powerful, robust, and durable manner on the other. In a nutshell: ZF transmissions! Certificates "Euroshuttle Transmission" for Electric Locomotive (CoCo) Achieving Success Thanks to Stamina Supreme load capacity and stamina are the characteristics of the fullycushioned, single-stage transmission complete with double-helical gearing and BBC universal joint coupling. The pinion is pressed onto the motor shaft and the output gear is supported on the hollow shaft housing via a tapered roller compact bearing. It is noise-optimized, easy-to-service, and ensures low life cycle costs by the proven utilization of i.e. a wear-free labyrinth seal. Certificates Trust is good control is better. Customers trust in us! And they have good reasons for this; moreover, we've got our excellent product quality documented and certified. Here, a brief excerpt from our certificate portfolio, including the IRIS certificate [International Railway Industry Standard]. We always out-performed set standards in audit and certification ratings; and we will do our utmost to maintain this high performance level. Once again good reasons for you, to continue relying on us! 4 1 ZF Axle Drives for Diesel Locomotives More Power, Less Wear Technological innovation and the mod- 3 ular design define the concept for the robust ZF axle drive. The basic transmission can be adapted in a customerspecific manner in a short period of time. Proven ZF quality warrants low wear, high interface flexibility, and consequently an easy-to-service, robust transmission with optimized life cycle costs (LCC), even when dealing with 4 4 ZF-Ergopower Quiet permanently high loads/stresses. Operation for Long Service Life ZF transmissions for track-laying vehicles set new standards on the market. Quiet operation and low peak loadings extend their service life and improve 3 "E-S 22 AT Axle-Hung Transmission" their reliability. They create greater comfort on board and inside the vehicle, for Electric Locomotive An Inexpensive Alternative and enable it to operate more economically. Their high helical gears minimize On the basis of the axle-hung transmission, ZF offers an inexpensive alternative noise levels. Vertically positioned, the for freight and passenger locomotives spur gear ratios bridge the height difference between input and output shafts. with a traveling speed of 160 km/h in proven ZF quality. Thanks to decades For this reason, the housing integrates of experience gained in the rail sector, the axle differential, dispensing with engineering a compact design for transmission components and excellent qual- the need for an additional transfer case. ZF-Ergopower transmissions are able ity labyrinth seals is part of the portfolio. to change direction of travel without an additional reversing stage

7 Innovations That Move People Suspension Components and Systems from ZF Modern chassis technology for rail vehicles should be quiet, comfortable, reliable, and environment-friendly. No easy undertaking when you consider the inherent technical challenges. Here is an example: In passenger transport, trains are now very much holding their own against airlines. However, once traveling at more than 250 kilometers an hour (>150 mph), wear and maintenance costs rise almost exponentially. As a technology leader, ZF is also setting new standards here, and offers perfectly matched damping components and systems for all types of rail vehicles. Globally networked processes with customers and suppliers form the basis for developing these high-tech products. Future-orientated product development and high-precision test procedures lead to ingeniously mature technical solutions built from high-quality and robust materials. Highly-skilled teams and the latest production technology guarantee maximum service life, the key to conserving resources. All products and production technologies are designed to have the lowest possible levels of environmental impact. Passengers and goods on the railways are also entitled to reach their destinations safely, quickly, reliably, and cost-effectively. ZF suspension components and systems lay the best possible groundwork for achieving this goal. Siemens-press photo 12 13

8 ZF offers a complete program of dampers. It ranges from vertical and horizontal dampers in primary and secondary applications to various yaw damper applications. This is the basis to implement innovative and efficient damping concepts in close cooperation with the customer. 1 1 Yaw Dampers compression directions are identical. Improved Safety at High Speeds The dampers possess block safety and 3 4 ZF yaw dampers increase the yaw movement resistance and minimize sine motion effects. The critical speed of the bogie is increased by this. Optimum technology from ZF combines three ingenious functional principles: The twin-tube and recirculating process, and the damper version with continuous piston rod. These deliver high dynamic stiffness. A space-saving design and a standardized modular structure make this unit economical to manufacture. By virtue of this special design, venting prior to the installation is not required. In addition, electrically switched valves can be installed. Yaw dampers are economical because they are easy-to-recondition. service lives well above the average. The damping forces in rebound and 2 Inter-Car Dampers with Integrated Rebound and Compression Spring - Use Also for Limited Installation Space Inter-car dampers are applied at the interfaces between the coaches in order to compensate for the relative movement of coach bodies. A special challenge was the development of a damping device with overlaid spring characteristics for rebound and compression, that can also be used in a very limited installation space. The spring characteristics of this damper can be defined within a rather wide range. 2 3 Horizontal Dampers Operate in Every Position ZF twin-tube dampers for horizontal installation are designed in a similar way to vertical dampers and offer the same advantages. A special feature is the design of the bottom valve. This special design ensures that, particularly when dampers are in a horizontal position, no air is able to enter their working chamber. This ensures that each damper can function reliably, even when installed in a horizontal position. 4 Vertical Dampers Cost-Effective and Efficient Vertically installed twin-tube dampers offer a range of advantages and are available in a choice of two sizes, to suit different load profiles. As you would expect from a ZF product, these units deliver exceptional lengths of service life. Piston and bottom valve settings can be adjusted, thereby achieving a high level of variance in terms of their characteristics curves. Their standardized and modular design is an essential requirement for cost-effective manufacture of these dampers. By virtue of this special design, the system is easy to recondition. As an option, an integrated lift stop is offered. This device holds the axle on the bogie and the bogie on the coach whenever these vehicles are being put onto the rails

9 5 Inter-Car Dampers for More Anti-Roll Stability in Trains Inter-car dampers are special variants of the ZF horizontal damper. These are used between two neighboring coach bodies. Their function is to inhibit lateral vibrations between the coach bodies, e.g. pitching, yaw and outof-phase rolling on long straights and wide curved tracks. 6 Crash System Minimize the Consequences of Collisions It is based on high-performance hydrodynamic impact absorbers, which can absorb forces depending on the strength of the collision. Light pushes are absorbed in the reversible function range. High energy levels, which can arise in collisions, are effectively converted into heat in the irreversible function range. The crash system is based on a modular assembly principle which can be adapted for different applications with respect to force levels and rail vehicle types. This flexibility enables the ZF crash system to be used in all types of rolling stock. 8 Torque Reaction Links Active Roll Stabilization (ARS) and Torque Roll Restrictors The torque reaction link is used as a flexible connection in anti-roll support applications. It transmits forces from bogie to carriage body. With our modular system, these links can be adapted to create perfect matches with customer requirements. Alternatively, vibration- absorbing rubber-metal mountings or zero-backlash sliding-contact bearings can be used to provide these flexible connections. The torque reaction links can be manufactured with longitudinal adjustment, or as fixed-length units. In addition, they can be used as transmission supports in the drive bogie. In this function, referred to as torque support, these units again provide a vibrationdamping mounting Electrically Switchable Yaw Dampers Reduce Costs Wheelsets and tracks wear when cornering as a result of the higher levels of wheel-to-rail forces. Electrically switchable yaw dampers, a recent ZF innovation, reduce these factors and also substantially cut down on maintenance costs. The principle: A bypass, controlled by a two-way valve, switches off the damping function when required. Vehicle acceptance tests are subject to maximum permitted wheel-to-rail forces. In some cases, these requirements can only be satisfied through the use of this technology. 9 Adjustable Wishbones Flexible Connection for Carriage Bodies Adjustable wishbones from the CV Suspension Module business unit of the ZF Group create flexible connections on carriage bodies beside the bellows. With variable length and adjustable spread angle, these units are ideally suited for flexible use in various connection systems. Versatile links transmit longitudinal and lateral forces. Among other things, they reduce noise levels and improve ride comfort. Their design is based on prevailing customer specifications

10 ZF Products for Rail Vehicles at a Glance Short Routes and Fast Service. Worldwide. ZF-EcoLife Rail Gearset reversing transmission Torque support ZF provides you with a comprehensive and highly attractive range of products and services to ensure mobility anywhere, at any time. You can rely on our high-coverage service network for maximum quality covering the entire lifecycle. Seven days a week, round the clock, ZF has its own sales and service companies where staff is always available as local customer contacts and problem solvers. With over 700 authorized ZF After Sales Service Centers, the company can offer flexible and timely intensive support backed up by fast delivery of spare parts. Primary damper Yaw damper Secondary horizontal damper Our services at a glance: Use of ZF genuine spare parts Conversion and retrofitting of individual modules Major overhaul for complete drive systems Dynamic damping force measurements during train operation Maintenance-free rail vehicle dampers Easy reworking of rail vehicle dampers Investigations to optimize maintenance intervals On-site product training Provision of test equipment Industrial overhaul of ZF and non-zf transmissions Service concepts and service contracts Technical documentation Provision of workshop concepts and special tools Project management as service Worldwide ZF warranty Over 60 years of experience in rail transport Secondary vertical damper Primary damper Wheelset transmissions Modular kit system Individually combined modular components of all performance classes optimize the driveline. Ride comfort is increased and fuel consumption reduced. Safety The retarder protects the brake system without limiting safety. In the event of a loss of system pressure or failure of the power supply, the transmission automatically switches into neutral thanks to the "Fail Safe Principle". Profitability Low life cycle costs through integrated retarder: it preserves the service brake and reduces maintenance costs. Electromagnetically compatible Devices and systems of the vehicle, on the inside and the outside, work without problems meeting the requirements of the European EMC Directive. Systems integration Swift availability reduces downtimes; few interfaces increase reliability: ZF offers end-to-end responsibility. Simplified assembly A compact structure creates more freedom in design and facilitates assembly. No engine removal required

11 Research and Development to Secure Mobility Innovations are not a purpose in themselves for ZF; they must pay off, for manufacturers, operators and customers, but also for the environment and society. Each new development must prove itself among the conflicting priorities of these criteria. The ZF Group benefits from an international network of development centers: The main development locations are Friedrichshafen, Die lingen, Passau, Schweinfurt, Schwäbisch Gmünd, Northville near Detroit (USA), Pilsen (Czech Republic), and Shanghai (China). Worldwide, approximately 5,400 engineers work in Research and Development. Corporate R&D coordinates and supports the activities at the development center in Tokyo (Japan). Every year, ZF invests approximately five percent of its sales in Research and Development. With success, because innovative products from ZF set the standards for state-of-the-art technology again and again. Development work at ZF is organized according to decentralized and central functions. The divisions and business units focus on markets and product expertise, ensuring customer-centered, competitive technological product development. Corporate R&D works with a strong emphasis on basic research and theory and supports the functional development areas in the divisions. Economical Driving. Tailor-made Solution. An average of 30 years of operation in passenger and goods transport means one thing: The cost-effectiveness of a train depends to a large extent on the service life of its components. Faster journey and transport speeds, driving safety, and more demanding comfort requirements call for optimal components. Cheap can rapidly turn expensive. To maintain their competitiveness, ZF customers place their confidence in experience, quality, and tangible customer value. The key to this end: Intense customer-specific research and development work coupled with cuttingedge production technologies. The outcome: Enhanced service lives, higher mileages, and less wear on components and systems. This pays off for manufacturers and operators alike. The high skills level attained by its employees is also a core success factor for ZF. Employees play a key role for the company's success by identifying future requirements at an early stage and by devising appropriate solutions for its customers. They are the backbone of ZF's ability to innovate and to compete