MOVIA 248 pre-series train, designed and built by Bombardier Transportation Photo: Bombardier Transportation

Rolling Bearings in the Wheelsets,Gearboxes, and Current Collectors of theMOVIA Trains for London UndergroundExamples of Application Engineering

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In 1863, London Underground wasopened as the world’s first under-ground railway. When the first linesat even deeper levels opened in1890, the network became knownas “tube”. Today, London has oneof the biggest metro systems in theworld and carries nearly 1 billionpassengers a year with a fleet ofmore than 4 000 trains.

Bombardier Transportation receivedfrom Metronet Rail, the companyresponsible for maintaining andupgrading two thirds of the system,a large order for trains to replacepart of the fleet. A follow-up orderwas placed early in 2006, so thatnow a total of 1 778 metro carshave been ordered, including 47 eight-car Bombardier* MOVIA*248 trains for the Victoria Line.

The trains of the now fieldprovenMOVIA family are of a modulardesign to minimize maintenancework and maintenance costs.

Schaeffler Group Industrial hasalready equipped the two pre-series trains for the Victoria Linewith FAG axlebox bearings as wellas FAG rolling bearings for currentcollectors and gearboxes.

*Trademarks of Bombardier Inc. or subsidiary

Schaeffler KGProduct Line Railway BearingsGeorg-Schäfer-Str. 3097421 Schweinfurt (Germany)Phone +49 9721 91-0Fax +49 9721 91-3435E-Mail rail_transport@schaeffler.comInternet www.fag.com

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Technical data of MOVIA 248 trains

Train configuration 2 half-trains, each consistingof 4 cars

Max. speed 80 km/hMileage 135 000 km/yearExpected vehicle life 40 years

Axlebox bearings

All motor bogies and carrying bogies are equipped withaxlebox housings of type AMG100-T and rolling bearings of type TAROL100/175. Wheelset guidance isprovided by a metal/rubber spring. The axleboxhousings were subjected to extensive calculations(FEM) and load testing. The axlebox bearing haspassed a performance test based on EN 12082 requirements at Schaeffler’s own DAP-accredited testbay. Thus a modern TAROL bearing is used for the firsttime in London Underground trains whose performancesurpasses that of all earlier bearing versions.

Negative shoegear bearing assemblyfor current collectors

The special traction current supply system of LondonUnderground makes an additional negative shoegearbearing assembly in the middle of the motor bogiewheelsets necessary. For this application, SchaefflerGroup Industrial supplies an FAG assembly, consistingof tapered roller bearings that are paired in X-arrange-ment, in a housing of type AZZ165-K. A collector shoeis attached to the assembly which slides on the negative conductor rail.

Gearbox

The double-stage helical gear is built by the manufacturer Watteeuw. It is supported on one sidedirectly on the axle via the output shaft bearings; onthe other side it is connected to the bogie frame via anelastically supported torque arm. On the pinion shaft, two cylindrical roller bearings takeup the radial forces whereas a radially relieved fourpoint bearing accommodates the thrust loads. Thetapered roller bearing pairs on the intermediate shaftand output shaft are mounted in X-arrangement each.

Special designs

Pinion shaft: 2 ~ NU212-E (Cylindrical roller bearings)1 ~ QJ212 (Four point contact bearings)

Intermediateshaft: 2 ~ 33211 (Tapered roller bearings)Output shaft: 2 ~ T4DB170 (Tapered roller bearings)

The cylindrical roller bearings and four point bearingsare equipped with machined brass cages. The taperedroller bearings have pressed steel cages, some of themof reinforced design. To prevent creeping of the outerrings, all bearings have retaining grooves for lockingpins.