THE CUSTOMER MAGAZINE OF KNORR-BREMSE RAIL VEHICLE SYSTEMSEDITION 38 | AUGUST 2014

Informer

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INFORMER | Edition 38 | August 2014

EDITORIAL

E-NEWS-0038-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 www.knorr-bremse.com 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 2014 © 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.

EDITORIAL Dr. Robert WassmerChairman of the Executive Board of Knorr-Bremse Systeme fürSchienenfahrzeuge GmbH 03

NEWS Latest news 04

COVER STORY Through the desert 06Smart pressure cleaning 09

Dr. Robert WassmerChairman of the Executive Board of

Knorr-Bremse Systeme fürSchienenfahrzeuge GmbH

INFORMATION FOR KNORR-BREMSE’S WORLDWIDE

CUSTOMERS AND BUSINESS PARTNERS

IMPRINT:Publisher:

Knorr-Bremse Systeme für Schienenfahrzeuge GmbH

Marketing: Katharina BachemMoosacher Straße 80

80809 MunichGermany

Tel. +49 89 3547-0Fax +49 89 3547-2767

www.knorr-bremse.com

Realization: KB Media GmbH, Heidrun MollLayout, graphics: Cathrin Huber

Text: Thorsten RienthPrinted by: Pera Druck GmbH

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CONTENTS

CUSTOMERS + PARTNERS For low-temperature conditions 10Green power 12Interview with M.Z. Medeubaev,President of “Locomotive” JSC:Huge growth potential inKazakhstan 14Whisper brakes 16Three questions for ... Peter Möller, DB Schenker Rail 17

INNOTRANS 2014International platform forrail vehicle technology 18

PRODUCTS + SERVICES The future of entrance systems –Generation 4 – smaller, lighter, stronger 22The new DNA of RailServices 24Innovation Leadership 27

There are only a few weeks to go before InnoTrans – the world’s biggest rail technology exhi-bition – opens in Berlin. As usual, the focus is on recent developments in the rail sector and in particular on the latest innovations. This year Knorr-Bremse is showcasing its products and services under the motto of "KNORR-BREMSE – CREATIVE SYSTEMS – GLOBALLY". As pioneers of leading-edge rail vehicle technology we are constantly driven by the desire to improve our products and services and maximize customer benefit.

The exhibits we are showcasing in Berlin offer impressive proof of this determination: our brake control system for Chinese high-speed trains plays a crucial role in bringing trains trav-eling at speeds of up to 380 km/h safely to a halt; the VV1000T oil-free compressor for the North American market significantly reduces life cycle costs compared with conventional oil-lubricated compressors; under the title of “Leading Innovations” we are presenting state-of-the-art brake components that will shortly be launched on the market; and we are also showcasing a new door system from our subsidiary IFE that uses modern technology to achieve significant weight savings. Knorr-Bremse also recently became involved in the high-performance on-board power supply segment, and we will be informing you about this at InnoTrans. Finally, our RailServices division has further extended its portfolio. All in all there will be a lot to see, and we look forward to your visit.

The various systems featured at InnoTrans all have one thing in common: they set new stan-dards of efficiency, safety and life cycle costs.

The main theme of this Informer is the Haramain High Speed Railway project in Saudi Arabia – the first high-speed train line in the world to run entirely through desert conditions. It is hardly surprising that Knorr-Bremse was chosen to supply the trains’ braking, door and HVAC systems. The sand filters of our subsidiary Merak attached to the HVAC units use compressed air filter cleaning for the first time in a mobile application and promise to considerably re-duce maintenance requirements.

Innotrans opens its doors on September 23. We look forward to seeing you and having in-teresting discussions at Booth 104 in Hall 1.2. We would also encourage you to visit Micro-elettrica in Hall 17, Booth 228 as well as our new subsidiaries from the high-performance on-board power supply segment at Booths 212 and 214. Their new Knorr-Bremse brand will be officially launched at InnoTrans on Tuesday September 23.

You will find an admission voucher for the exhibition in this copy of the Informer.

Yours sincerely

Dr. Robert Wassmer

© Talgo

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INFORMER | Edition 38 | August 2014 | News

» NEWS

CHINESE AWARD Knorr-Bremse enjoys a share of around 90 per cent of the Chinese market for high-speed train braking systems. At the end of June, the popularity of the company’s brak-ing technology amongst Chinese manufacturers was underlined when it received a “Special Contribution Award 2013” from manufacturers CNR Tangshan Rail Ve-hicle Co. Ltd. The annual prize, which is partly sponsored by the regional government of Taizhou, honors suppliers and partners who have displayed particularly high levels of commitment during the previous year.

BOMBARDIER SUSTAINABILITY AWARD Once a year, Bombardier Transportation honors suppliers who have distinguished themselves in terms of the sustainability of their products and supply processes and have also demon-strated outstanding social responsibility. In 2014 the Supplier Sustainability Award in the category “Companies with more than 500 employees” went to Knorr-Bremse. “As manufacturers of safety-critical systems, we have long since integrated sus-tainability and product responsibility into our corporate cul-ture – and they are crucial for our future viability,” commented Dr. Robert Wassmer, Chairman of the Executive Board of Knorr-Bremse Systeme für Schienenfahrzeuge GmbH, at the awards ceremony held in Berlin on June 30. According to Christoph Schwärzler, Director Corporate Social Responsibility Strategy at Bombardier Transportation, one of the reasons for making the award was that “we are impressed by the way Knorr-Bremse meets its social obligations and how it systematically inte-grates its responsibilities into day-to-day operations.”

INNOVATIVE SUPPLY CHAIN SOLUTIONS

Every year, a jury made up of representatives of well-known spe-cialist institutes and audit companies honors the best supply chain in the manufacturing sector. This year, Knorr-Bremse was amongst the four companies shortlisted for the award, with the Rail Vehicle Systems division’s end-to-end supply chain solution designed to im-prove the exchange of information with suppliers and customers. Roland Becker, Head of Logistics and Supply Chain Management at Knorr-Bremse Systeme für Schienenfahrzeuge GmbH, received a cer-tificate at the EXCHAiNGE specialist conference in Frankfurt on June 24. The SCM Award is presented annually to the best supply chain in manufacturing industry by the Management Consulting division of PricewaterhouseCoopers in collaboration with the specialist journal “LOGISTIK HEUTE”, the House of Logistics & Mobility (HOLM) and the Fraunhofer-Institut für Materialfluss und Logistik.

KNORR-BREMSE WINS CNA AWARDOn July 10 Knorr-Bremse Rail Vehicle Systems received the “Intelligence for Transportation and Logistics” innovation award from the Nuremberg-based Center for Transportation & Logistics Neuer Adler (CNA) for its newly developed Brake Pipe Length Estimation (BPLE) system. BPLE provides the driver of a freight train with a fast and easy way to check brake availability along the entire train, benefiting both the safety and efficiency of freight train operations. The system uses a sensor to measure the volume of air being fed through the train’s braking system and then calculates the length of the entire main brake pipe on the basis of this. The driver can check this against the train length in his documentation and identify any critical discrepancies. In contrast to the traditional method of checking the brakes, this process takes just a few minutes. The system promises to en-

hance the flexibility and reliability of rail freight transportation. A pre-production version is currently being tested on the large-scale test rig at Knorr-Bremse, and operation in a test locomotive has al-ready proved successful. The start of se-ries production of BPLE is scheduled for the end of 2015.

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KNORR-BREMSE EXPANDS PORTFOLIOModern rail vehicles offer passengers top levels of com-fort combined with modern on-board infotainment systems. The electricity required to operate HVAC sys-tems, screens, passenger power points and catering equipment is supplied by high-performance on-board power supply systems – and these are set to become even more important in the future. With its acquisition of Transtechnik GmbH & Co. KG in Holzkirchen and Ber-lin-based PCS Power Converter Solutions GmbH, Knorr-Bremse, as a global systems specialist for rail vehicles, has added two leading power converter manufacturers to its portfolio. The new specialist field will be incorporated into the Group as a separate brand to join existing ones like IFE, Merak and Westinghouse. On Tuesday Septem-ber 23 in Hall 17, Booth 212+214, this new Knorr-Bremse brand will be officially presented at the InnoTrans Exhibi-tion. We look forward to welcoming you there.

▲ Christoph Schwärzler, Director CSR Strategy, Bombardier Transportation, Dr. Robert Wassmer, Chairman of the Executive Board, Knorr-Bremse Sys-teme für Schienenfahrzeuge, Stefan Bräuherr, Head of Corporate Responsi-bility, Knorr-Bremse AG and Charles O’Donnell, Chief Procurement Officer, Bombardier Transportation (l. to r.).

▲ Dr. Petra Seebauer, Editor of LOGISTIK HEUTE, Cornelia Creischer, Managing Director Commercial Logistics, Colgate-Palmolive, Roland Becker Head of Logistics and Supply Chain Management, Knorr-Bremse Rail Vehicle Systems Harald Geimer, PwC Management Consulting (l. to r.).

Norbert Schäfer, Chair of the Executive Board CNA e.V., State Secretary Franz Josef Pschierer, Bavarian Ministry of Economics and Media, Energy and Technology, Dr. Dieter Wilhelm, Executive Board Member, Knorr-Bremse AG responsible for the Rail Vehicle Systems division and Karl-Hermann Klausecker, cluster spokesman Rail Technol-ogy (l. to r.).

▲

▲ Xi Guohua, President, CNR, Zhang Junqing, Vice President, TRC, Joseph Han, Managing Director, KB Suzhou andTong Li, Chief Engineer, LCRI/ZH (l. to r.).

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INFORMER | Edition 38 | August 2014 | Cover Story

ACROSS THE DESERT

THE NEW HIGH-SPEED RAIL LINK CURRENTLY BEING BUILT BE-TWEEN THE HOLY CITIES of Mecca and Medina in Saudi Arabia is one of the world’s most challenging rail projects. Knorr-Bremse is demonstrating its engineering skills by supplying braking, door and HVAC systems for the trains.

The most recent pilgrimage to Mecca with the Kaaba – Islam’s holiest site – attracted some two million people and the figure is set to increase, with forecasts predicting that the number of pilgrims to Mecca and Medina could quadruple in the next ten years. That would leave the west of the country facing a massive volume of traffic and passengers. In response to this, Saudi Arabia has attached top priority to the new “Haramain High Speed Railway” project. The idea is that

from 2017 onwards pilgrims will be able to travel at high speed for 445 kilometers across the desert from Medina to Mecca and to Jeddah international airport. In the high season trains will depart at eight-minute intervals carrying a total of 160,000 pas-sengers per day. This is the first high-speed rail line ever to be built almost completely through desert terrain, and the extreme heat and the sand pose huge challenges in terms of the trains’ systems and the track construction.

© Talgo

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INFORMER | Edition 38 | August 2014 | Cover Story

communication ensures efficient exchange of information and experience, thereby enabling existing know-how to be put to the best use and synergies to be even bet-ter exploited throughout the project cycle. Interdisciplinary teams for field service and commissioning are just two examples of this concept.

KEEPING SAND OFF THE RAILSThe desert sand also means that a new

GLOBAL KNORR-BREMSE PROJECT MANAGEMENT ENSURES EFFECTIVE IMPLEMENTATION The braking system developed by Knorr-Bremse España includes an ESRA-based EP Compact brake control system including wheel slide protection, SL 20 screw-type compressors, steel brake discs and Isobar brake pads. Spanish subsidiary Merak is responsible for supplying the HVAC sys-tems – highly compact units including self- cleaning sand filters that are installed both

ALL SYSTEMS DESIGNED FOR TOUGH, SANDY CONDITIONSSpanish rail vehicle builder Talgo is to supply the operator – Saudi Railways Organization (SRO) – with 36 high-speed trains based on the Talgo 350. 35 of these will consist of two power cars and 13 passenger cars, while a special VIP version will have just ten passen-ger cars. The trains will travel at 300 km/h on track designed for speeds up to 320 km/h. Knorr-Bremse Group companies are supply-ing the braking, door and HVAC systems.

Compared with the high-speed trains de-signed for operating at extremely low tem-peratures in Russia, the Mecca-Medina proj-ect is at the other end of the scale. “The high temperatures and desert conditions make this a unique challenge,” explains project manager Matthias Busch, Knorr-Bremse Es-paña. The systems are designed for tough, sandy desert conditions and include specif-ic developments such as Merak’s integrated self-cleaning sand filtration system – anoth-er example of how Knorr-Bremse uses its technical development and systems com-petence to produce customized solutions. “Of course it goes without saying that in such circumstances every last detail has to be meticulously checked and re-checked,” says Busch.

on the roof and inside the cars. Knorr-Bremse’s Austrian subsidiary IFE is develop-ing and manufacturing the Type DET-h1 pressure-tight sliding plug doors, which have been developed and extensively tested to ensure their reliability under the extreme climatic conditions found in the region. The internal doors between the cars are designed and supplied by IFE Tebel. But it is not just the technical specifica-tions that represent a challenge – inter- disciplinary collaboration is required to realize the project. “As well as Knorr-Bremse supplying a range of systems, various different Group sites all over the world are involved,” explains project manager Busch. For this purpose a project-specific, global project management team has been con-stituted, comprising the project managers of the individual systems. The coordinators are the interfaces to the customer and to all internal participating companies. Regular

approach has to be taken to track design. Sandstorms increase erosion of the track and technical infrastructure, the smallest particles of sand in the ballast bed can af-fect its stability, and drifting dunes can even completely bury stretches of track. The companies constructing the line have developed various strategies for dealing with these challenges. On the particularly sandy stretch between Mecca and Jeddah the line runs along an embankment that is up to 20 meters in height and constitutes a massive sand barrier. And over a stretch of more than 80 kilometers the engineers are planning to build a concrete wall at least one-and-a-half meters high alongside the track. Unusual circumstances call for un-usual solutions – and desert sand poses a challenge to construction engineers and operators alike.

SMART HIGH-PRESSURE CLEANING The sand filter systems installed in the trains for the Haramain High Speed Railway proj-ect are self-cleaning, thanks to Knorr-Bremse making clever use of an existing resource –compressed air. In Saudi Arabia, where temperatures can exceed 40° Celsius in the shade, high-perfor-mance HVAC systems are essential for trains. However, the problem of preventing sand penetration significantly shortens the sys-tems’ maintenance cycles. Fresh air has to be

filtered in order to efficiently keep out even the smallest of particles – but the filters have to be regularly cleaned. The more dirt they collect, the more often this has to happen. For cleaning the filters Knorr-Bremse makes use of a process that is already found in in-dustrial plants in desert areas – using com-pressed air. In the case of the Haramain High Speed Railway project, the development engineers have adapted this technique for a mobile application involving passenger coaches for the first time, drawing the com-pressed air from the pneumatic braking sys-

tem, where it is available in large quantities. “The challenge was to adapt the process to the design of the HVAC systems and to find a solution for the extremely limited installa-tion space available,” explains Felipe Perez, who heads the team at Knorr-Bremse Es-paña responsible for developing the system.

© Talgo

Knorr-Bremse España in Getafe, near Madrid.

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INFORMER | Edition 38 | August 2014 | Customers + Partners

DESIGNED FOR FREEZING CONDITIONS

THE KNORR-BREMSE GROUP’S SUCCESS IN CHINA IS DUE TO A CONSIDERABLE EXTENT TO ITS BRAKE MODULES for high-speed trains. The company has now extended the geographical reach of this technology by developing a low-temperature capability down to –40°C.

“We are talking specifically about the routes from Harbin to Dalian and Urumqi to Lanzhou,” explains Armin Gasch, responsi-ble for sales of braking systems for Chinese high-speed trains at Knorr-Bremse Rail Ve-hicle Systems. With its plans to extend the high-speed network from 10,000 to around 30,000 kilometers, China is now building

railroads in regions with the lowest winter temperatures in the entire country. “Various modifications have to be made to the vehi-cles if operators are to be able run a reliable train service all year round.” One such modification involves en- hancing the low-temperature capabilities of the brake modules. These are a mixture

of ultra-modern design and proven tech-nologies that meet the extremely high safety standards and operational require-ments of the heavily-used Chinese high-speed services. The modules contain the electronic control system for the brakes and also ensure compatibility with exist-ing, traditional pneumatic brake control.

▼ Access to the brake module for maintenance purposes is rapid and uncomplicated.

Speed-dependent brake force control en-sures compliance with specified braking distances while at the same time reducing wear and minimizing life cycle costs. In ad-

dition, modern wheel-slide protection sys-tems avoid damage such as wheel flats. The modules and their components also have to be specially protected against the harsh operating environment – for exam-ple sandstorms on the Urumqi to Lanzhou route – as well as low temperatures.

RAPID, EASY MAINTENANCE ACCESS DESPITE ENHANCED PROTECTIONThe brake modules not only use cold- resistant materials – they also have rein-forced housings that meet protection class IP54 requirements and prevent water, fine

sand or driving snow from penetrating the interior. At the same time they offer rapid and easy access for maintenance purposes. More than 7,000 brake modules for instal-lation in trains belonging to the CRH380B and CRH5 families have either already been delivered or are on the order books. The modules have identical connection interfaces and only differ in terms of the plug-in boards used, plus a few pneumatic elements. For example there are differenc-es according to whether they are to be in-stalled in a driven or a non-driven car. They can also be tailored to customers’ require-ments.

CLEAR INTERFACES FACILI-TATE INTEGRATION INTO ASSEMBLY LINES The braking modules are delivered ready for installation, which makes for clarity re-garding responsibilities – to the benefit of vehicle builders and Knorr-Bremse alike. The box design and clear interfaces facili-tate integration into the manufacturers’ as-sembly lines.Developments like this low-temperature version of the brake module account to no small extent for Knorr-Bremse’s success in the Chinese high-speed market. The com-pany’s market share in this sector currently lies at around 90 per cent, and last year alone, it received orders for braking sys-tems and bogie equipment for more than 400 high-speed trains. But there is a further important reason for the Group’s success in China: to ensure smooth running of the entire vehicle fleet, 400 field service and local service center colleagues are on constant 24/7 stand-by; and a similar number of engineers ensures that products are adapted to local require-ments.

China is extending its high-speed network into the coldest regions of the country.

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INFORMER | Edition 38 | August 2014 | Customers + Partners

GREEN POWER

THE OIL-FREE VV1000-T DEVELOPED BY KNORR-BREMSE IS THE FIRST HIGH-PERFORMANCE COMPRESSOR for heavy-duty freight trains to operate without any oil lubrication. Volume production of this specially developed compressor was launched at New York Air Brake (NYAB) in May 2014. The first OE application began in July.

COMPARABLE OIL- LUBRICATED COMPRESSORS CONSUME AROUND 60 LITERS OF OIL PER YEARThe oil-free VV1000-T is currently being in-stalled in new heavy-duty freight locomo-tives for two North American Railroads, and represents a breakthrough in other respects as well. “The VV1000-T sets new standards, particularly in terms of reliability, life cycle costs and environmental compatibility,” says Eric Wright, Chief Engineer at NYAB.The savings promised by the new compres-sor go beyond the cost of the 60 liters of oil

per year consumed by conventional ones. Every oil-free VV1000-T compressor has an ongoing positive impact on the environ-ment, as there is no longer any need to dis-pose of the used oil and oil-contaminated filters. “Another advantage is the fact that there is no longer any risk of oil getting into the pneumatic braking system or the air dryer,” explains Wright. “That has a very positive long-term impact on the life and performance of the overall system.”

THE VV1000-T REQUIRES LESS FREQUENT MAINTENANCE “Oil also has the disadvantage that it gums up compressors during the course of their operation,” explains Wright. As this does not happen with the VV1000-T, maintenance intervals are longer. “Realistically, most con-ventional compressors have to be over-hauled every four or five years. In the case of the VV1000-T we recommend intervals of eight years.” There is another important aspect: the low-er the ambient temperature, the thicker and

more viscous oil becomes. Conventional oil-lubricated compressors usually have to be heated prior to start-up, but the VV1000-T does not require this – it can be started from cold at temperatures down to –50° Celsius.

COMPRESSOR PORTFOLIO EXTENDED The orders received from North American operators have enabled Knorr-Bremse Rail Vehicle Systems to enter a new market seg-ment: it is the first time the company has developed a high-performance oil-free compressor for heavy-haul freight loco-motives. The excellent performance of the VV1000-T in field trials and aftermarket in-stallations has prompted the railroads to specifically request the VV1000-T compres-sor be fitted on new locomotives. After more than four years of field testing, it went into volume production at the NYAB facility in Watertown, New York early this year.

LD1000 AIR DRYER IN SERIES DEVELOPMENT Along with the VV1000 T, the correspond-ing LD1000 air dryer is also currently be-ing developed to series maturity. NYAB and Knorr-Bremse can thus offer an opti-mized air supply system to accompany the VV1000 T that will set new standards on the AAR markets. Reliability, efficiency and ease of mainte-nance were at the focus in the technical design of the LD1000. This air dryer offers integrated three-stage pre-filtration, for ex-ample, and attains an overhaul interval of ten years. The start of series delivery is for planned for 2016.

▲ The assembly line for the VV1000-T compressor at NYAB in Watertown, NY. ▲ Assembly of a bearing cartridge. ▲ Inspection of a bearing.

▲ Completed VV1000-T compressors ready for shipment.

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INFORMER | Edition 38 | August 2014 | Customers + Partners

HUGE GROWTH POTENTIAL IN KAZAKHSTAN

THE INFORMER EDITORIAL TEAM SPOKE TO M. Z. MEDEUBAEV, President of “Locomotive” JSC, about the rail market in Kazakhstan. One of the biggest owners of traction vehicles in Kazakhstan, “Locomotive” JSC is a subsidiary of the state company JSC Nationalnaya kompaniya Kazakhstan temir zholy (JSC “NK “KTZH”). The company’s aim is to ensure reliable, safe and effective operation of locomotives for both passenger and freight transportation. Its customers include JSC “NC “KTZ”(84%), passenger carriers (15.5%) and private operators (0.5%).

Series VL-80 locomotives require mainte-nance every 48 hours.

Informer: Why did you opt for the KZ8A?M. Z. Medeubaev: In line with the tech-nical requirements of Kazakh Railways, tenders were invited from virtually all the best-known electric locomotive builders worldwide – for example Bombardier, Sie-mens, Alstom, Tzhutzhousker Elektrolokher-stellwerk and Transmashholding. Complex factors such as localization, development costs, and the cost of imported locomotives versus local ones were also taken into ac-count. The French company Alstom came up with the most convincing bid, so the de-cision went in favor of the KZ8A.

Informer: Knorr-Bremse was commis-sioned to develop the KZ8A’s braking sys-tem. What requirements do you have in this respect? M. Z. Medeubaev: We want the KZ8A to be a competitive electric locomotive for 1,520

mm track. Specialist engineers at Kazakh Railways looked at offers from manufac-turers of locomotive braking technology worldwide and decided in favor of your company. Knorr-Bremse braking systems are also being used for Alstom’s new KZ4AT passenger train electric locomotive and for the General Electric TEP33A diesel locomo-tive. For the ZK8A braking system Kazakh-stan Railway Company is looking for guar-anteed safety and high quality standards.

Informer: To what extent was Knorr-Bremse’s experience with applications for low-temperature operations crucial? M. Z. Medeubaev: I think it is still too early to draw any conclusions. So far the electric locomotive has only operated for one win-ter at low temperatures – and this year the winter was relatively warm. But I am con-vinced that the Knorr-Bremse specialists have developed a good braking system for the KZ8A that will cope with any challenges it may face.

Informer: The first KZ8A locomotives are already in operation. What has been your experience so far? M. Z. Medeubaev: The first 12 KZ8A electric locomotives began the field-testing phase at the end of 2013, and a further three have been available to “Locomotive” JSC since the first quarter of 2014. So far they have all proved extremely reliable in operation. As this is a new series, staff has to be trained, new standards established for train weights, a maintenance plan drawn up and technical modifications undertaken on the basis of the field test results. The positive reaction of train personnel confirms that our decision to go for the KZ8A was the right one.

Informer: Kazakhstan occupies a geo-graphical position between China and Russia. What importance does this have for the future development of the rail mar-ket in Kazakhstan?M. Z. Medeubaev: Kazakhstan’s rail market has huge growth potential because as a transit country between China, Russia and other Central Asian countries it benefits from the need for rail transportation link-ing all the key regional markets. New routes have already been built, such as the one from Zhetigen to Usen, near the border with Turkmenistan, and the one to Horgos – the second rail link between Kazakhstan and China.In addition, the manufacture of goods des-tined for the domestic market as well as for export is supported by various govern-ment investment programs. An expanding economy impacts freight volumes, as can be seen from the opening of the Zheskas-gan–Beineu and Arkalyk–Shubarkul rail links connecting central Kazakhstan with the southwest of the country. A further significant factor is the expansion of the high-speed network by the state-owned Kazakhstan Railway Company. This has increased passenger volumes and en-

ables the high-speed train to compete with air or car travel.In recent years Kazakhstan Railway Compa-ny has carried out a number of major proj-ects on behalf of the state. One example is the construction of modern assembly facili-ties for diesel and electric locomotives and production plants for passenger and freight cars. I am convinced that the vehicles be-ing manufactured for 1,520-gauge track are competitive and have considerable export potential.

Informer: Kazakhstan Railway Company has ordered large numbers of the new KZ8A series. What is their aim? M. Z. Medeubaev: Yes that is correct. “Lo-comotive” JSC has signed an agreement with the Kazakh electric locomotive assem-bly plant EKZ Ltd. for the purchase of 200 eight-axle Series KZ8A two-section locomo-tives with an output of 8,800 kW. Delivery is scheduled for 2020. Such a large procurement volume is a result firstly of the high degree of wear and tear of the Series VL-80 electric locomotives that form an important part of the “Locomotive” JSC fleet; and secondly it is simply a result of the advanced age of the fleet. The new

high-performance electric locomotives en-able the weight of trains operating on elec-trified routes to be increased, which in turn increases transportation efficiency. One important argument in favor of the KZ8A is its advantageous maintenance intervals of 20,000 km or 37 days. By comparison the

▲ M. Z. Medeubaev, President of “Locomotive” JSC.

▲ The new KZ8A Series locomotive.

▼ Knorr-Bremse has been commissioned to develop the braking system for the KZ8A electric locomotive.

© Alstom

© Alstom

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INFORMER | Edition 38 | August 2014 | Customers + Partners

WHISPER BRAKES

NOW THAT LOW-NOISE ORGANIC LL BRAKE BLOCKS HAVE BEEN APPROVED FOR USE THROUGHOUT EUROPE, operators are starting to retrofit them to their fleets. Knorr-Bremse has been quick to identify this trend and is well positioned to meet demand.

The German government has set itself an ambitious target of reducing noise emis-sions from railroad operations by fifty per cent by the end of 2020 (reference year: 2000). Much of the focus is on reducing track-related noise, but another impor-tant aspect is the refitting of the country’s freight car fleet with low-noise organic LL brake blocks. The crucial issue here is the noise generated from contact between wheels and rails. If the surfaces of the wheel and rail are rough, vibrations are generated that the human ear perceives as noise. The problem with cast iron blocks is that they tend to roughen the wheel – which in turn roughens the rail.

SMOOTHING THE WAY Freight cars (which often operate at night) are still frequently brought to a halt by noisy cast iron brake blocks. Because LL brake blocks avoid this roughening effect, a pass-ing train equipped with such composite blocks on an average stretch of track gener-ates some 10 decibels (dB(A)) less noise – equivalent to a 50% reduction in subjective noise. Added to this, organic brake blocks – which can easily be retrofitted without any need for adjustment of the brakes – make for smoother braking and are also consid-erably lighter than conventional cast iron ones. Quick to recognize the new trend towards reducing noise and improving braking performance, Knorr-Bremse has combined its systems expertise with Spanish friction materials specialist Icer Brakes in a new joint venture – Icer Rail. Now that the product has been approved for Europe, the focus is

on creating the required production capac-ity to meet operator demand.

AUDIBLE IMPROVEMENT ONLY AFTER COMPLETE RETROFITTING DB Schenker Rail is Europe’s biggest freight car operator, with a fleet of some 60,000 vehicles, all of which are being refitted with LL brake blocks. The company is sourcing around half of these from Knorr-Bremse, and so far some 50,000 have been delivered. Every month 8,500 are shipped directly to around 20 workshops that are working on retrofitting them to DB Schenker Rail’s freight cars. But a significant reduction in noise from day-to-day freight operations will only be achieved with a comprehensive retrofit pro-gram. Experts estimate that there will only be an audible improvement if at least 80%

▲ Manufacture of IB116* LL brake blocks at Icer Rail in Pamplona, Spain.

of all freight train operations take place us-ing composite brake blocks. In other words, if noise levels are really to be reduced by 10 dB(A), it will be necessary to refit virtually the entire freight car fleet.

DB NETZ INTRODUCES NOISE-RELATED INFRASTRUCTURE CHARGE Most of the major operators have either al-ready started to refit their fleets or are plan-ning to do so in the near future, but small and medium-sized logistics companies have been slower to react. This means they run the risk of suffering delays when they do decide to fit the brake blocks, as individ-ual operators have already placed so many firm orders that much of current production capacity is already taken. Economic incentives are also being provid-ed for the use of LL brake blocks. German track operator DB Netz, for example, intro-duced noise-differentiated that German track operator DB Netz introduced noise-differentiated track access charging last year. Fleet operators now have to pay more for noisy freight vehicles, and those who have already fitted LL brake blocks receive a discount.

THREE QUESTIONS FOR … Peter Möller of DB Schenker Rail – the man responsible for coordinating purchase orders and materials availability for the project to fit the operator’s current fleet with low-noise LL brake blocks.

DB Schenker Rail aims to convert its entire fleet to LL brake blocks by 2020. Is this project running to schedule? Approval of the LL brake block in the summer of 2013 was an important milestone on the road towards quieter trains. DB Schenker Rail decided at an early stage to ret-rofit its fleet, and the process itself was launched at the start of this year with a view to converting 5,000 freight cars in 2014 and a similar number in 2015. In other words, by the end of next year – if you include new vehicles – a total of 20,000 will have been equipped with quieter brake blocks. And by 2020 we will have fitted “whisper” brake blocks to our entire fleet of some 60,000 freight cars.

Knorr-Bremse is supplying the LL blocks directly to DB Schenker Rail's various workshops. How is this collaboration going? In July 2013 the LL brake blocks were approved for Europe, and contracts were signed with the two suppliers in early 2014. From the very outset everyone worked together to meet all the challenges – major and minor – for example the creation of the necessary manufacturing capacity. Processes bedded in during the first half of 2014, and – in close consultation with DB Schenker Rail HQ – Knorr-Bremse was able to cover the quantities of LL blocks required by DB Schenker Rail. The entire process of ordering and delivering now runs itself, but there is still a regular exchange of information between the two partners.

Amongst European operators DB Schenker Rail makes the most extensive use of LL brake blocks. What has your experience been with them?More than 2,700 DB Schenker Rail freight cars were fitted with LL blocks during the first six months of 2014. The initial feedback from the field, above all in relation to the reduced level of operational noise, has been entirely positive. Our experts expect that we will have gathered sufficient operational data for a detailed assessment of the LL brake blocks within about a year’s time.

Peter Möller, DB Schenker Rail ▲

▲ LL brake blocks have a significantly longer operating life than cast-iron ones.

▲ Freight trains are becoming quieter.

© Deutsche Bahn AG

© Deutsche Bahn AG

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INTERNATIONAL PLATFORM FOR RAIL TECHNOLOGY

INNOTRANS (INTERNATIONAL TRADE FAIR FOR TRANS-PORT TECHNOLOGY) – THE INTERNATIONAL PLATFORM for buyers and sellers of passenger and freight transport technology – takes place this year from September 23-26 in Berlin.

Leading manufacturers of vehicles and sys-tems, suppliers, rail companies and industry and professional associations will feature prominently in the upcoming event in Sep-tember. Over 2,700 exhibitors from the pas-senger and freight transportation sectors in more than 50 different countries will show-case components, systems, and a wide range of vehicles and rail technologies. This year, the main focus of interest for visi-tors and the media will once again be on new products and systems as well as further developments of existing ones. Many inter-national companies now synchronize their innovation cycles with the timing of Inno-trans and regard the trade fair as an oppor-tunity to premiere their latest products. This means that many exhibits will be on display to the specialist public for the first time. This year, a particular focus of innovation will be on sustainability and energy efficiency.

DEMAND HITS A NEW HIGHDemand for exhibition space has increased in all segments – capacity in the outdoor and track areas was fully booked almost a year in advance. One new architectural de-velopment is the multi-functional CityCube Berlin exhibition hall, which opened in May of this year. This state-of-the-art building offers InnoTrans two additional levels of ex-hibition space and brings the total number of exhibition halls to 40, rather than 38. The result is a greater range of products on dis-play, offering an even more comprehensive overview of the market. This year also marks the premiere of the Future Mobility Park, where futuristic, cre-ative and visionary transport concepts will be presented. And in the outdoor and track area there will be an additional display focusing for the first time on vehicles de-signed for broad and narrow gauge tracks.

MORE INNOVATIVE APPROACH TO SHOW-CASING KNORR-BREMSE’S INNOVATIONSKnorr-Bremse, a long-standing exhibitor at InnoTrans, can once again be found in Hall 1.2, Booth 104. The motto this year is: "KNORR-BREMSE – CREATIVE SYSTEMS – GLOBALLY" and the thematic design of the booth will reflect this core message.Product presentations will take place and innovations will be showcased in the front part of the ground floor in a stylized mock-up of a train. Proven solutions in local mar-kets will be presented alongside innovative products, and visitors will be able to access product information using interactive flat screens. It will also be possible to examine the products in greater detail and discuss individual needs and possible solutions with Knorr-Bremse experts.

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"KNORR-BREMSE – CREATIVE SYSTEMS – GLOBALLY"

THIS IS THE MOTTO UNDER WHICH KNORR-BREMSE WILL BE SHOWCASING AN EXTENSIVE PORTFOLIO OF INNOVATIVE SYSTEM SOLUTIONS FOR THE GLOBAL RAIL VEHICLE MARKET IN HALL 1.2, BOOTH 104 AT THE INNOTRANS EXHIBITION. In a few weeks’ time, the eyes of the rail vehicle sector will be on Berlin: on September 23, InnoTrans 2014 opens its doors to the public. As a pioneer in braking, door and HVAC technologies, Knorr-Bremse will be presenting sophisticated answers to present and future market challenges. A central focus will be on sustainable products with low life cycle costs that generate significant value-added for operators around the globe.

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any need for adjustment of basic settings during initial installation and later servicing or maintenance – saving time and avoiding possible sources of faults as a result of false adjustment. At InnoTrans a space-saving two-leaf ver-sion specially developed for regional trains will be presented.

SAFE AND COMFORTABLE Growing demand for maximum passenger comfort means that noise and heat insula-tion are becoming increasingly important for door design. Thanks to the use of new insulation materials and an improved pro-file, the newly designed door leaf offers op-timum noise and heat insulation. Compa-

rable products available in the market have 3 to 4 times the amount of sound transmis-sion and 50% higher heat loss. And yet the overall weight of the system has also been reduced. The punctuality, efficiency and reliabil-ity of trains are determined by one crucial operation – the boarding and alighting of passengers. When the sliding step was be-ing redesigned, particular emphasis was therefore put on creating a reliable system capable of operating under all environmen-tal conditions. The new but proven drive concept prevents any risk of the sliding step jamming. Integration of weight detection instead of the pressure mat reduces the weight and installation height.

THE FUTURE OF ENTRANCE SYSTEMS – GENERATION 4 – SMALLER, LIGHTER, STRONGER

Any kind of delay can affect the economi-cal operation of rail vehicles – which is why manufacturers and operators require tech-nically sophisticated systems that meet the latest standards and enable passengers to board and alight as efficiently as possible. More than 500,000 entrance systems in dai-ly use are impressive proof that IFE meets – and in many cases exceeds – market re-quirements in terms of technology, safety, durability and cost-efficiency.

A SIMPLE CONCEPT WITH MAXIMUM EFFECTIVENESSAt InnoTrans IFE is presenting a new, com-pact entrance system design based on ma-ture, tried-and-tested technologies. All the

components in this new, slimmed-down system have been designed and tested to maximize their operating life and set new standards in terms of installation, service and maintenance. The 4th generation IFE entrance system has an innovative drive and sliding step, rede-signed door leaves with improved noise and heat insulation and a new Flex-DCU control system. In combination this makes for an outstanding access system that is smaller and lighter, but also stronger – and above all easier to maintain. The IFE E4 door drive is equipped with a deformation–tolerant linear guide with a lighter, more compact design that adjusts to any movement of the vehicle during operation. Other advantages are an improved locking mechanism, the

use of proven industrial components and adjustment-free design, with components requiring minimal maintenance. Compared with its predecessor model, the number of components has been reduced by more than 40 per cent, and the weight cut by 20 per cent. This well-engineered system offers free opening widths of between 1,300 and 2,000 mm. The drive is designed to avoid

IFE – INNOVATIONS FOR ENTRANCE SYSTEMS – IS THE WORLD’S LEADING SUPPLIER OF COMPLETE DOOR SYSTEMS for streetcars, metros, regional multiple units, mainline and high-speed trains. At the InnoTrans exhibition in Berlin the company is presenting state-of-the-art entrance systems that set new standards in every respect.

▲ Drive system production line.

MAXIMUM FLEXIBILITY The new FLEX-DCU door control has a smart energy supply system for connected com-ponents that reduces total power dissipa-tion by almost a quarter by adjusting their operating modes (“ECO power principle”).The Flex-DCU is designed for a variable battery supply voltage of 24–110 V with a generous tolerance range and generates an internal, stabilized operating voltage of 24 V, thus ensuring additional robustness against external influences. For operators the num-ber of different electrical spare parts has been reduced, cutting delivery times and reducing inventory requirements. This new control enables conventionally commutated or brushless motors to be operated. A large range of monitoring func-tions at the inputs and outputs enables improved and adaptive diagnostics and condition-based maintenance.

SAFETY A PRIORITYAs product quality and system safety are priorities for IFE, the entire entrance system is equipped with various safety systems that already meet SIL2 standards. Additional systems such as electronic van-dalism protection against mechanical over-load and locking support for manual clo-sure operate even when the control unit is not connected. Satisfied customers and operators – that is IFE’s goal. In response to customers’ re-quests and requirements, especially for re-gional operations, the entrance system has also been validated for operation under ex-treme loads.

▲ Door leaf production.

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THE NEW DNA OF RAILSERVICES

IN RECENT YEARS, GLOBALIZATION AND LIBERALIZATION HAVE TRIGGERED far-reaching changes in the rail industry and created entirely new challenges. The industry faces increased competition, pressure on prices and growing passenger demand for a modern, comfortable rail experience. This has also had an impact on servicing, with its complex elements such as maintenance, overhaul and repair. Rail operators face crucial strategic decisions such as: to what extent should they outsource servicing to third-party providers? Should they purchase new vehicles or upgrade existing ones? Operators in Europe face these questions in particular, as their fleets grow progressively older.

Technical progress is forcing operators and vehicle builders towards even greater specialization for their own service staff and they are having to invest increasing amounts in modern testing technologies. Servicing safety-critical sub-systems such as braking systems calls for a high degree of specialization and experience – something that Knorr-Bremse, as a brake manufacturer, is very much aware of.During the lifetime of a vehicle – which can be up to 40 years – a wide variety of repair, maintenance and upgrade work is required to keep it in operation. In recent years Knorr-Bremse has positioned itself as a provider of

an extensive range of services in this field. Rail vehicle systems from Knorr-Bremse are advanced in technological terms, and a total of 24 service centers all over the globe en-sure the comprehensive availability of mod-ern servicing by highly trained specialists using state-of-the-art OEM-grade assembly equipment and test rigs.These activities have been marketed by Knorr-Bremse under the RailServices brand for many years. Following a comprehensive review in 2012 they have now been adapt-ed to meet the new challenges, and as a result RailServices can today provide a new, extended range of services offering a high

degree of flexibility and maximum custom-er benefit. A vision has been jointly devel-oped to serve as a basis and guideline for the new service strategy and provide the driving force behind the new organization.Customers increasingly expect high lev-els of availability and performance from rail systems, and this has been taken into account in developing RailServices’ strat-egy and drawing up a program focused on maintaining product value throughout the entire life cycle. The aim is to offer tai-lor-made service packages to meet every requirement – for freight cars, streetcars, metros, urban light rail systems and high-

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speed trains. Performance, quality and local presence are the key elements in what is a unique service offer focused on reliable delivery, customer inventory optimization, improved remanufacturing quality and re-duced operating costs for the customer. All this is based on modern logistics concepts and consistent management of the entire delivery chain. A further important aim of the strategy is to make global competence available at local level – both in cultural and system-specific terms. This requires key

skills related to across-the-board service products within the organization being redefined and made accessible. Following an analysis of market needs, the range of products has been extended. In the field of logistics, services such as “kitting” or “box-ing”, reliable spare parts inventory, just-in-time delivery and proactive obsolescence management have been established.In addition, local maintenance support and training of local technicians is also available to individual customers. Discussions have also been held with various customers in a bid to achieve a better understanding of their needs and wishes and to review fur-

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ther adjustments to the product portfolio. This is currently an ongoing and evolving process.At the same time the focus is on selecting the right employees – those who display a passion for their work and are always de-termined to find the right solution for the customer. Whether braking, HVAC, or door systems – or other Knorr-Bremse products – are concerned, customers now have a named contact person who will coordinate everything at Knorr-Bremse.Modernization calls for a knowledge of systems that will improve a vehicle’s per-formance or economy of operation: for example a new braking system can reduce the braking distance of a freight train and make more frequent train scheduling pos-sible; or lighter equipment can enable the volume of freight carried to be increased. Driver assistance systems or modern sand-ing equipment are also available to make the operation of rail vehicles easier, safer and more efficient. As well as supplying various components or systems the service on offer also includes their installation and maintenance as well as support for the nec-essary approval processes.

SERVICE PARTNER OF CHOICERailServices’ mission is to become “Service Partner of Choice” – which means an em-phasis on partnership and a determination to focus on customers’ individual needs. This new approach has also required an internal cultural change, and for this purpose employees with service in their DNA are being systematically promoted and trained. For Knorr-Bremse RailServices, providing service in future means the company’s ex-perts will always be ready when rapid reaction times are called for; it means the ser-vice solutions and systems training provided will be tailored to individual customer needs, and only original parts offering original performance will be used – with their availability ensured for decades. iCOM – a new service tool for intelligent condition monitoring of train components – is shortly due for release. If you want to find out more, come and visit us at InnoTrans. We look forward to seeing you there!

The new RailServices initiative has success-fully prepared the ground for the future of Knorr-Bremse’s service offer. Certain inter-nal and external obstacles still need to be overcome in some areas, but the detailed analysis carried out has provided everyone concerned with a thorough understand-ing of the future direction for RailServices. The first steps to implement the strategy in practice have already been taken, and will be followed by further measures. All those involved in RailServices agree on this and are willing to pursue the process to its con-clusion.

INNOVATION LEADERSHIP

This self-concept is based on the company’s values: entrepreneurship, technological ex-cellence, reliability, passion and responsibi-lity. “Innovation Leadership” is oriented toward the needs of the customers and the trends of the markets; it focuses above all on opti-mization of economy, on reliability and on the safety of rail vehicles.Essentially, the brakes of rail vehicles take effect at the point of contact between wheel and rail. It is this small contact point that determines whether the entire system is mediocre or excellent. Knorr-Bremse has been at home in these systems for more than 100 years and sees itself as the trendsetter in braking techno-logy. As the world market leader for brakesystems for rail vehicles, Knorr-Bremse of-fers a full-line product range for highly in-tegrated, intelligent systems for the com-prehensive control and regulation of the dynamic braking forces acting on a train. Brake control units for rail vehicles, such as CCB, MB, EP2002 and EP Compact, are mechatronic systems solutions that con-stitute the backbone of safety engineering for tens of thousands of trains throughout the world. Knorr-Bremse constantly works on optimizing and improving the neuralgic points of this backbone:The new MGS3 wheel slide protection sys-tem with an extended regulation range

FOR KNORR-BREMSE, “INNOVATION LEADERSHIP” IS MUCH MORE THAN JUST A TRADE FAIR MOTTO. For the company’s employees. it is the basic principle and the self-concept under which Knorr-Bremse markets its products and systems.

offers excellent performance even under conditions of extremely low traction with slippery rails, and was specified for the in-dividual UIC, AAR and GOST markets. Knorr-Bremse also uses the vehicle speed data acquired by its sensors for regulating its new sanding system. Under low traction, it meters the delivery of sand in accordance with vehicle speed and with even greater precision between wheel and track; this en-sures optimal traction with no disturbance to signal systems, and sand consumption is reduced by up to 50 per cent.ESRA Evolution – a further development of the proven ESRA electronic control sys-tem – offers maximum integration capa-

bility of interfaces to TCMS. Products and subsystems can thus also be matched in a simplified, more efficient application, and servicing access is also facilitated.Knorr-Bremse has set itself the task of provi-ding new, certified systems solutions in pe-riodic waves of innovation in order to offer genuine added value for vehicle manufac-turers and operators. This is aptly reflected in the trade fair motto "KNORR-BREMSE – CREATIVE SYSTEMS – GLOBALLY".

▲ High performance anti-skid valve with integrated pressure sensor.

▲ ESRA Evolution control unit.

…IN TECHNOLOGY AND QUALITY. Delivering the highest levels of safety and availability for operators. This is the goal of Knorr-Bremse. | www.knorr-bremse.com |

VISIT US ATINNOTRANS 2014

23 - 26 SEPTEMBERHALL 1.2BOOTH 104

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