transportation en rail

8/13/2019 Transportation en Rail

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TRANSPORTATION

Mechanical gearboxesand gear wheels for masstransportation

Wikov 2012 - 01


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Content

Gearbox designing - process

Gear units for:

Trams

Metro

Monorail system

EMUs

DMUs

Locomotives

Trolleybuses & Electro-buses & Hybrid-buses

Gearbox testing

Bevel gear sets

Gearbox overhauls

Spare parts

Point machines

Licences and Know how

Certificates

Contacts


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Gearbox designing - Process

1) Customers submission

2) Draft calculation of gear toothingand bearings


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3) Draft preliminary design +

preliminary dimensional drawing

4) Consultation and precisingcustomers submission

5) Final calculation of gear toothingand bearings


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7) Calculation of gear box rigidity

and stiffness Finite ElementMethod

Areas of load action

Definition of bolted connection ofsplit face

Breakdown of force reactions

Von Mises stresses on shafts

Shafts deformation by load action

Contact pressure distribution overbolted connection in the split face

Tension on gear casing

Gear casingdeformation

Drive suspension calculation


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8) Draft and optimization of toothing

modifications

9) Final drive design (SolidEdge)

Profile corrections

Longitudinal corrections


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High floor trams gearbox type AWBD-H

Gearbox typeOne stage bevel (hypoid)

axle drives AWBD-H

Description

One-stage bevel gearboxtransmits torque fromengine to the axle.Gearbox connection withan engine is via cardanshaft. Axle is acomponent of gearbox.

Vehicle type RT8D5M, T6A5

Nominal power 40 - 85kW)

Max. speed of input shaft 1,946rpm

Max. torque moment oninput shaft

640Nm


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High floor trams gearbox type AWDD-N

Gearbox type

Two stage bevel-helical

axle drives withcyklopaloid gearingKlingelnberg AWDD-N

Description

Two-stage bevel-helicalgearbox transmits torquefrom engine to the axle.Gearbox connection withan engine is via cardanshaft. Axle is a

component of gearbox.

Vehicle type T6A2, KT4D

Nominal power 54kW



980Nm


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High floor trams gearbox type AWDD-N

Gearbox type

Two stage bevel-helical

axle drives withcyklopaloid gearingKlingelnberg AWDD-N

Description

Two-stage bevel-helicalgearbox transmits torquefrom engine to the axle.Gearbox connection withan engine is via cardanshaft. Axle is a


Vehicle type T8M-700IT

Nominal power 110kW



609Nm


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Partially low floor trams - gearbox type AWHD-Z

Gearbox type

Helical axle drives withsolid shaft for partiallylow-floor tramsAWHD-Z

Description

Two-stage helicalgearbox transmits torquefrom engine to the axle.Gearbox connection withan engine is via flexiblecoupling. Axle is acomponent of gearbox.

Vehicle typeKODA 03T, 13T, 14T,16T

Nominal power 90kW



1,100Nm

DestinationOstrava, Olomouc, Most,Plze, Brno, Praha,Wroclaw


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Gearbox type

Helical axle drives with

solid shaft for partiallylow-floor trams AWHD-Z

Description

Two-stage helicalgearbox transmits torquefrom engine to the axle.Gearbox connection withan engine is via flexiblecoupling. Axle is a


Vehicle typeKODA-Inekon 10T,Inekon TRIO 12

Nominal power 90kW


Max. torque moment on

input shaft

1,100Nm

DestinationPortland, Tacoma,Seattle, Washington


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Gearbox type


solid shaft for partiallylow-floor tramsAWHD-Z

Description



Vehicle type KODA 06T

Nominal power 115kW



1,100Nm

Destination Cagliari Sardegna


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Gearbox type


solid shaft for partiallylow-floor trams AWHD380Z

Description



Vehicle type Vario LF2Plus

Nominal power 90kW



519Nm


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Gearbox type


solid shaft for partiallylow-floor trams AWHD-Z

Description



Vehicle type RT6N


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Partially low floor trams complete drive with AWHC-Z gearbox for Cold Climate Conditions

Gearbox type


hollow shaft AWHC419Z

Description

Gearbox transmitstorque from engine to theaxle. Gearboxconnection with anengine is via flexiblecoupling. Axleconnection with a

gearbox is via flexiblecoupling mounted onholow shaft of gearbox.

Jmenovit penenvkon

125kW

Maximln otkyvstupnho hdele

4,032rpm

Maximln penenkroutic moment navstupnm.hdeli

775Nm


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Fully low floor trams gearbox type AWDC-N

Gearbox type

Bevel-helical gearbox for

standard axle bogie AWDC-N

Description

Gearbox transmitstorque from engine to thewheel. Gearboxconnection with anengine is via flexiblecoupling. Wheel/gearboxconnection is via flexible

coupling. Gearbox issuitable for traction bogiewith conventional axles

Nominal power 100 kW

Max. speed of input shaft 4,500 rpm


700 Nm


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Fully low floor trams gearbox type AWBC-Z

Gearbox type

Bevel final drive for

pivoting traction bogiewith indepedentlyrotating wheels - AWBC-Z

Description

Gearbox transmitstorque from engine to thewheel. Gearboxconnection with anengine is via flexible

coupling. Wheel/gearboxconnection is via flexiblecoupling. Gearbox issuitable for pivotingtraction bogie withoutmechanical linkage ofindependently rotatingwheels

Nominal power 45kW



400Nm


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Fully low floor trams epicyclic hub drive with flexible pin technology

Gearbox type

Epicyclic hub drive for

pivoting traction bogiewith indepedentlyrotating wheels

Nominal power 45kW



400Nm

The hub drive is equipped with HicksFlexible Pins

A well proven design concept thatensures load sharing betweenplanets and across tooth faces

Ideally suited for dealing withdynamic torsion loads and structuraldeflections induced by variable loads

The evolved Hicks pin usesadvanced design features to protectagainst overloadand enable helical

gears to be used


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Flexible pins & multi-satelite technology

Flexible Pin provides:

Equal loads between planet wheels

Uniform load across face width ofteeth sun/planet & planet / annuluscontacts

Uniform loads on planet wheel

bearings Uniform load under overload and

shock load conditions

Gear tooth loads are isolated fromgear case deflections imposed by

driven machine loadsMain features of f lex pin and multi-

satelite technology:

High reliability

Increased life time

Reduced weight & dimensions

Torque Advantage from Multiple Planets

Torque capacity 166%

3 planets 5 planets


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Metro gearbox type AWHC-Z

Gearbox typeHelical axle drives with

hollow shaft AWHC-Z

Description

Gearbox transmitstorque from engine to theaxle. Gearboxconnection with anengine is via flexiblecoupling. Axleconnection with agearbox is via flexible

coupling mounted onholow shaft of gearbox.


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Metro gearbox type AWHC-Z

Gearbox typeOne-stage helical

gearbox AWHC365ZNomiinal power 200kW


Nom. torque moment oninput shaft

958Nm


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Monorail

Gearbox typeGearbox for monorail

system

Description

Two-stage helicalgearbox transmits torquefrom engine to the axle.Gearbox connection withan engine is via cardanshaft. Gearboxconnection with drivewheel is via flexible

coupling.

Vehicle type Project Monorail Jakarta

Nominal power 100kW



643Nm


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EMUs gearbox type AWHD-Z

Gearbox typeHelical axle gearbox AWHD-Z

Description


Bogie type 6Ev, narrow-gaugeversion

Nominal power 85kW



562Nm

Destination Locarno


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EMUs gearbox type AWHD-Z

Gearbox typeHelical axle gearbox AWHD365Z

Description

One-stage helicalgearbox transmits torquefrom engine to the axle.Gearbox connection withan engine is via flexiblecoupling. Axle is acomponent of gearbox.

Nominal power 340kWRatio 3.86



3,528Nm


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EMUs gearbox type AWHC500Z

Gearbox typeHelical axle gearbox AWHC500Z

Description


coupling mounted onhollow shaft of gearbox.

Nominal power 180kW

Ratio 7.117



input shaft

1,522Nm


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EMUs gearbox type AWHC595Z 500kW, up to 160 km/h

Gearbox typeHelical axle gearbox AWHC595Z

Description


coupling mounted onholow shaft of gearbox.


Ratio 4.857

Max. speed of input shaft 5,257 rpm


input shaft

4,450 Nm


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EMUs gearbox type AWHC595Z 500kW, up to 160 km/h


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EMUs gearbox type AWHD-R

Gearbox typeHelical axle gearbox AWHD404R

Description


Nominal power 340kWRatio 4.79



2,865Nm


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EMUs axle wheels and pinions

EMU type 471 and 671 (575)

CityElefant (KODA)


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DMUs gearbox type AWDD-N / AWBD-N


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Shunting diesel-electric locomotives

One-stage helical gearbox for

shunting locomotive (CZ Loko)


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Shunting diesel locomotives gearbox type AWHD-Z

Gearbox type

Two-stage helicalgearbox AWHD-Z forshunting locomotive withhydrostatic drive

Description

Two-stage helicalgearbox transmits torquefrom hydraulic motor tothe drive axle of shutinglocomotive. Gearboxconnection with hydraulic

motor is via disc clutch.Axle is a component ofgearbox.

Vehicle type CMI (project)

Nominal power 91kW


Max. torque moment oninput shaft 1,523Nm


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Electric locomotives

Drive typeElectric locomotive drivewith helical one-stagegearbox

Description

Axle drive withtransverse traction motorconnected with gearboxvia input membranecoupling. Wheel-set/gearbox connectionis via jointed coupling

Vehicle type Electric locomotive

Nominal power 1,200kW


Nominal torque momenton input shaft

6,486Nm


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Electric locomotives

Axle wheels and pinions for electric

locomotives


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Diesel-electric locomotives spare parts


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Trolleybuses

One-stage helical gearbox with

output shaft option left or right

Vehicle type Trolleybus

Nominal power 240kW

Ratio 1.85

Nom. torque moment on

input shaft 1,307Nm


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Electro-buses epicyclic drive with flexible pin technology

One-stage epicyclic gearbox with

flexible pin technology designed byORBITAL2

Main features of flex pin and multi -

satelite technology:

High reliability

Increased life time

Reduced weight & dimensions

Vehicle type Electro-bus


Maximal motor power 241 kW

Ratio 4.00


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Testing Full load testwith continuous control of torque and motor speed

Continuous control of torque and

motor speed Simulating the torque characteristic of

rail vehicle driving cycle Testing the gearbox behaviour in

almost realistic conditions Recorded speed, torque or

temperature curve Possible cooling of gearboxes by airflowing through special fans, whichsimulates the air flow around thegearbox in the real environment ofthe vehicle

Test results are immediately appliedto the gearbox design, including, e.g.:gear modification adjustment,gearbox cooling or further noisereduction

The entire system is software-

protected against overloading


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Testing Full load testwith continuous control of torque and motor speed


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Testing Cold Climate Test

Test of complete drive (gearbox +

couplings + motor) for rail vehiclesoperating in CCC (Cold ClimateConditions)

Modular system of ClimateChamber

2 compressors 2 x 26kW + electricfans

Gradually cooling of gearbox up to- 45C (air temperature -50C)

Hard starting-up of the drive

Measuring temperatures inside ofgearbox; measuring pressures,output torque, speed and vibrations


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Testing Cold Climate Test- AWHD365Z gear unit


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Bevel gear sets with spiral gearing

Hypoid gearing Gleason - lapped

Hypoid gearing Klingelnberg HPGmethod

Non-hypoid cyclopalloid gearingKlingelnberg lapped or HPG


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Gearbox overhaul

We offer repairs and overhauling of

gearboxes for rail vehicles Tram axle gearboxes of type KD

and KODA

Others types of rail vehiclesgearboxes


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Spare parts

We offer deliveries of spare parts for

gear units such as: Gear wheels and pinions parallel

or bevel gear sets

Gearbox housings


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Point machines

Example of successful production

transfer from Great Britain to theCzech Republic:

Production of point machinesdesigned by Alstom company

Production since 2003

Produced more than 3500 pcs.


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Licences & Know How

KD (Siemens Kolejov vozidla)

The company Wikov MGI a.s. is theexclusive manufacturer and exclusiveseller of the below stated gearboxesand components of KD (SiemensKolejov vozidla) railway vehicles

production:Dieselelectric locomotives:

Gearboxes, gear wheels

Bevel pinions

Gearboxes for auxiliary drivesTram types (including all subtypes):

T3, K2, KT4, T4, KTNF8, T5C5,KT8D, KT8D5, T6A5, RT8D5M,T6C5, RT6N-1


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Licences & Know How

KODA

(KODA TRANSPORTATION a.s.)Wikov MGI a.s. is exclusiveauthorized licensed producer andsupplier of axle gearbox spare partsand big gear wheels for electric

locomotives - KODA and axlegearboxes for trams KODA-INEKON


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Licences & Know How

esk drhy, a.s. (Czech Railways)

Wikov MGI a.s. is certified astechnically qualified supplier by theD Certification Centre for:

Production of gearboxes for tractionrail vehicles

Production of auxiliary drives fortraction rail vehicles

Production of gear wheels andpinions for traction rail vehicles


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ISO 9001:2008

Bureau Veritas ISO 9001:2008 -

certification


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Contacts

Wikov MGI a.s.

Zbenk356, CZ-549 31 Hronov

www.wikov.com

Michal Stuchlk tel. +420 491 488 426 e-mail: [email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]

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