InnoTrans

The power electronics used in this new type of traction transformer from this exhibitor make it smaller and lighter than other, conventional models, as well as improving the efficiency of the train. The new PETT (power electronic traction transformer) is based on an innovative multilevel inverter topology, which uses high performance IGBT (insulated gate bipolar transistor) semiconductors and mid-frequency transformers. These replace the conventional combination of transformer and rectifier. The mid-frequency transformer also reduces noise levels. As part of a long term partnership between Swiss Railways (SBB) and ABB a PETT pilot installation is currently being tested in a shunting locomotive . This is based at the main station in Geneva and is powered both by a 15 kV AC and 1.5 kV DC supply. The PETT currently being deployed has a rated output of 1.2 MW and can produce up to 1.8 MW over short periods.

At InnoTrans 2012, French manufacturer ACKSYS introduces its new and extremely robust wireless product: « WLn-ABOARD ». The technology of this innovative WiFi device has been specifically tailored for railway applications. It features all the proven technologies of the “WLg-ABOARD” and offers above all a dual radio IEEE 802.11n a/b/g (up to 2 x 300 Mbps). This dual RF design is the outstanding attribute of the entire solution, allowing the WLn-ABOARD to operate simultaneously two separate networks for carriage bridging and in-carriage communication and to provide a secure and highly available wireless connection. WLn-ABOARD enables operators to improve mobile communications in motion (thanks to its optimized roaming performances: handover = 0 ms) and to develop a wide range of new in-vehicle networking applications such as wireless Internet access, Voice over IP, passenger WiFi services, CCTV and smart vehicle diagnostic/maintenance.

For the first time the OmniPlanar TOP 230 AMR series of train radio antennas combine the technique of analogue antenna 2m band radio systems and digital communication systems, for example for Tetra / GSM / UMTS / GPS / WLAN. This allows shared use of different radio systems on a single antenna with an extremely slim design and an antenna height of just 140mm. According to the manufacturer this provides one of the flattest 2m band antennas on the public transport market. Based on the selective coupling of the respective frequency range through high quality connectors of the N-type series, the cost-intensive splitters normally required for broadband antennas used on railways can be dispensed with. This selective coupling improves the effectiveness of the individual bands compared with conventional multi-band broadband concepts with only a single connection. A super-flat 2m band antenna with a design height of only 60mm is being introduced at InnoTrans 2012.

In paragraph 4.2.8. “Reporting system of railway wagon movements” the EU regulation (TSI) “Telematics Applications for Freight Traffic” specifies that data such as ‘wagon departure’, ‘wagon arrival’, ‘hazardous goods’ and the UIC number must be stored and electronically accessible. NUMBERCheck, a new, intelligent optical system, automatically collects the relevant data when wagons are entering or leaving the shunting station or container terminal, factory or port area and makes this information available to the respective railway or industrial data network. In addition to each wagon number, images of the wagons that pass through are also stored. This recorded information provides details about the condition of each wagon, so that any possible damage can be clarified or claims can be submitted. Through interfaces with nearly all known railway companies the system also offers automatic billing for the owner of the infrastructure.

The bogie lifting system from Austrian company Autolift GmbH can be installed at ground level next to supported track. The telescopic construction provides an effective lift of 1,800 mm at installation depths of just 1,500 mm. Four telescopic underfloor jacks under the bearing cases raise the bogie so that the wheels can still turn freely. The use of mobile axle supports and a centrally positioned underfloor pair of jacks means that entire axles can also be removed and set down, and the remaining bogie frame and axle can also be jacked up. The lifting system provides easy access all around the bogie and underneath it too. Existing, supported track can be converted in a bogie workshop without requiring major constructional measures. Early in 2012 this exhibitor installed six of these bogie lifting systems in a metro depot in Oslo. Longitudinal crossbeams can be used to include additional applications for tram bogies, which have a shorter wheelbase.

The CYCLOJET HEAVY DUTY (HD) series from Singapore-based company Cyclosystem Pte Ltd is a range of fully automatic mechanical parts washers that use spray jet cleaning technology. It is suitable for cleaning large and intensively used spare parts for the railway industry. It is available in single or multiple stage form to permit flexible processing, allowing users to meet simple or very sophisticated cleaning requirements. The multiple stage version offers cleaning, rinsing and drying. The integrated spray jet cleaning technology enables almost all angles of the parts to be washed and the units are self-propelled by the forces of the jet itself – with the aid of the exhibitor’s special rotary water distributor system. The washing solutions are automatically diverted for separation in reserve tanks or can also be added into the main cleaning tank. The system is 100% water-based with automatic filtration and 100% recycling, making it sustainable and environmentally-friendly.

With its FAIST Rail System the plant constructor, based in Krumbach, has developed a highly effective and visually pleasing system of soundproofing for sections of rail track in compliance with RIL 804.5501. This system has been approved under TM 2011-278I.NVT4 by DB Netz AG for high speed sections of v = 300 km/h. It is based on a structure which differs significantly from other available soundproofing walls. Among the outstanding advantages of the new system are that the elements are made of aluminium and are self-supporting, i.e. do not require any additional framework. This design saves on resources, because the elements can be produced in lengths of between 2 and 5 m. Consequently larger distances between the uprights are possible, thus facilitating assembly of the system. The FAIST Rail System provides excellent sound insulation, achieving a sound absorbency value of 31 dB as defined by DIN EN ISO 717 and an absorption degree of 14 dB.

As a leading supplier of Wiper & Wash systems to the global rail market English exhibitor Hepworth Rail Internation is making use of InnoTrans 2012 for the official introduction of its latest innovation. The fully rail compliant and functional Rain Sensor meets most customers’ requirements for the increased number of new driverless trains and provides clear view facilities for passengers. This development also provides significant benefits and improved operational safety for drivers of all new and retrofitted vehicles. This new development has been fully tested and approved and is currently on trial in Korea. It has also been proposed for further projects both in Europe and Australasia. The new railway sensor is part of the exhibitor’s continued drive towards development and innovation that meets its customers’ requirements and points the way forward.

Building on Hypertac’s proven BOA circular connector, which is used throughout the European and worldwide rail market, Hypertac has designed a new mini platform for the ASFA system The new range of 13 way circular connectors is available with innovative anti-tampering screws to prevent any kind of external human intervention. It comes in six different colours, with the plugs being plated with different coloured anodic oxidations. The system changes its functionality depending on which male connector the operator plugs into the receptacle, with different colours being assigned to different functions. A 21 way version is available. Other configurations with additional numbers of contacts are also feasible. The exhibitor points out that these interconnect solutions have been well received by the railway signalling market mainly on account of their high reliability, a result of the proven technical features of the hyperboloid contact technology as well as the company’s ability to accurately meet specific customer requirements.

This Japanese company is providing details at InnoTrans 2012 about its current development activities. These include a support system for ensuring railway safety. In this connection a number of items have been developed, including a wheel inspection device, a supersonic rail flaw detector and a device to attract the driver’s attention to prevent excessive speed or failure to stop at a designated station. Developers are also working on a location indicator for railway trains and various labour-saving devices. As the exhibitor points out, the intention is to ensure that rail transport is both safe and comfortable. Its exhibits at InnoTrans consist of a wheel flat detector (Fig. 1), compact rail grinding equipment, a rail profile measuring system (Fig. 2), a rail grinding support system and a driver support system (GPS Train-Navi).

Silicon is a high performance material which has evolved from purely a niche product in the construction of rail vehicles and is now in regular use, to a large extent because of the contribution it makes to safety. This is because it does not cause smoke and soot when burnt, unlike different forms of rubber, (e.g. EPDM, NBR and SBR), which consist largely of carbon. The density of the flue gas produced by burning silicon is very low, and it is not toxic, indicating that it contains no halogen. The silicon made by this exhibitor also complies with the strictest industrial standards for the rail sector, such as NF F 16 101 (smoke category F0), CEN/TS 45545 (HL1), DIN 5510 (S4 SR2 ST2) and BS 6853, in some cases even when used to make foam material. The combinations produced by this Dortmund-based company have succeeded in overcoming the final disadvantage of these flame-inhibiting and safe materials: their limited resistance to mechanical stresses. The innovative FLEXCOMP® basic types made by this exhibitor now offer far more possibilities for designers to create covered and see-through components in traction units and rolling stock.

At the beginning of 2011 this exhibitor was awarded a contract by Siemens to supply major components for fitting out the interiors of the RZD sleeper car. Metawell® aluminium sandwich panels will be used for the approx 20 m long by 2.50 m high longitudinal partitions and the ten compartment doors. The lightweight construction of these panels enables the extremely strict weight specifications to be complied with. Other major items features of the contract were the need to adhere to Russian and European fire safety regulations and the use of modern and ecologically sustainable materials. Another notable characteristic of the Metawell® panels is their suitability for the application of powder coatings. This produces a more even surface with greater resistance to scratching and to cleaning agents. The exhibitor installs all the components prior to delivery and is consequently able to supply a ready-to-install system. This significantly reduces assembly times at the Siemens plant in Vienna.

This exhibitor has designed its new, high performance Modular Power Connector (MPC) for supplying power to the electrical drive train of rail vehicles. Among its uses are to create contacts with transformers, traction motors, rectifiers and batteries as well as for carrying power between carriages. With ratings of 3.600 V and up to 700 A it is also suitable for many other industrial high current and high voltage uses. The robust plug-in connector with IP66/IP67 protection when plugged in is designed for demanding applications with over 500 insertion and withdrawal cycles. A variety of different insulators is available, all of them compatible, for various contact diameters and cable cross sections of 10 to 240 mm. Up to 15 modules can be combined. Optional coding prevents voltage reversal. Because the MPC has been developed for use in extreme conditions on the railways its features include vibration- and shock-proofing in accordance with EN 61373 and corrosion-resistance (240 h salt spray test) in accordance with EN 60068-2-11.

MöllerWerke, based in Bielefeld, develops and manufactures drive motor ventilator bellows under the band name möllerbalg®. It is presenting the latest model of bellows for the first time at InnoTrans 2012. Its advantages include a multilayer material made of silcon-Nomex fabric, an in-house development. The well-defined, permanent folds ensure the specific movement of the bellows. The external contour is fully enclosed and, unlike conventional ventilation bellows for drive motors, has no seams, a result of the use of vulcanised seals. Other advantages include the gas-tight seal and stability when subjected to excess internal pressure, due to the external rings embedded in the folds. The new bellows are also chemical- and wear-resistant, not affected by external impact, and very long-lasting.

EFT-NGTM is an innovative plug-and-use system for controlling strip-type heaters with a feedback loop. Its main characteristics are its process optimisation, easy maintenance and extreme flexibility. The hardware structure is another major advantage. This modular monitoring and control system enables up to ten different function modules to be connected up to one another in a variety of combinations in a supply monitoring unit. The use of EFT-NGTM makes the monitoring of self-limiting strip-type heaters very easy. The EFT-NGTM is a central monitoring and control unit with a common diagnostic output. With the improved diagnostic capabilities of the new system there is no longer any need for a complicated search for the source of the fault. The EFT-NGTM enables the temperature and other tolerance limits to be controlled and monitored with sensors. The new AFS, FS+ strip-type heaters and other qualities provide a robust, self-limiting heating system for points, third rails and other railway applications.

The project management software Projektron BCS enables users of a wide range of different projects to plan them efficiently, coordinate them easily and carry out a comprehensive evaluation. The Berlin-based software company is presenting its new edition to trade fair visitors for the first time at InnoTrans 2012: Projektron BCS.start. This tool is intended for project teams of up to 15 members. Equipped with the most important project management tools and with helpful support functions, this new entry-level solution is ideally suited for meeting the requirements of small and medium-sized companies. Projektron BCS, the main product, combines an extensive range of tools for projects and companies in one operator environment. With flexible currency selection and versions in up to seven different languages the Projektron BCS offers some outstanding features which can also be used for major international projects. The 400 customers throughout Europe include companies engaged in transport technology, one of them being Interfleet Technology GmbH in Wiesbaden.

SAB Bröckskes manufacturer of halogen-free ethernet and gigabit-ethernet cables for use with railway technology has expanded its SABIX Rail product range to include the “SABIX R 660 CAT 5e” and “SABIX R 691 CAT 6”. With its new CAT 5e and CAT 6 ethernet cables the exhibitor has expanded its product portfolio for rail vehicle technology to include additional cables for use on the railways. “SABIX R 660 CAT 5e 2x2x22 AWG” and “SABIX R 691 CAT 6 4x2x26 AWG” satisfy the fire safety standard DIN 5510. Following tests to determine their resistance to conducting fire, smoke gas density and toxicity, the company has now expanded its range to include ethernet cables for railway use that have been granted certification by an external agency. Ethernet and/or gigabit ethernet networks in rail vehicles are just some of the applications for these new types. This applies in particular to the installation of passenger information systems, monitoring equipment and e-ticketing systems. Moreover, according to the manufacturer, the SABIX Rail range of cables meets the highest fire safety standards.

French company UNAC SAS developed its lightweight all-terrain vehicle, the X3, over ten years ago for the maintenance of overhead power lines on railways . The new all-terrain road-rail vehicle X6 is equipped with a high capacity working platform. It can reach heights of more than 10 m – 5 m from the top of the rail – which is well above the masts carrying the power lines. The X6 benefits from the features and functionality of the UNAC HYD-rev hydrostatic drive, giving it powerful and smooth access to the track. As with the X3, it takes less than five minutes to prepare for operations on rail track. While the vehicle is being driven onto the track, and while it is in use, the adjoining track remains free for normal railway operations. In developing this vehicle particular attention has been paid to its ergonomics and in making the controls simpler and easier. For example, fault diagnosis is assisted by a digital display, making the work of problem-solving so much easier.

Weidmüller Interface has extended its RockStar® HighPower range of plug-in connectors with the addition of the new "RockStar® HighPower-250-A" connector, which uses a crimp connection system, for 250 A and up to 4,000 volts. Like the “RockStar® HighPower” 550 A version they are of modular construction. The power contact, designed for loads of up to 250 A, is easy to install and takes up very little space, making it suitable for a number of different vibration-resistant versions. The two-part die-cast Size 8 aluminium housing, with attachment, base and mounting, has a large PE connector. The same applies to the frame into which it fits. The extremely impact- and corrosion-resistant casings have the protection level IP 68 or IP 69k and are easy to assemble. The manufacturer has redesigned the crimp contacts of the “RockStar® HighPower-250-A” to enable them to be removed through the M25 cable input aperture. Multiple, fine and precision copper wires of between 25 and 95 mm² can be easily connected using standard crimping tools.

The industrial ethernet rail switch has been designed for continuous use in railway systems, tunnels and signalling installations. Viper-212 conforms to the EN50155 standard and has stronger M12 plugs. The exceptional Gore-Tex membrane prevents the formation of condensation that occurs during the change from day to night. The managed layer 3 switch is provided with twelve 10/100 Mbit/s ethernet ports, each of which has a USB and an RS232 interface. With a reconfiguration time of less than 20 ms it is one of the fastest on the market, according to the manufacturer. With four priority queues the rail switch supports quality of service. The MTBF of 900,000 hrs guarantees long term, reliable deployment in the field. Without requiring manual reconfiguration the WeOS operating system can identify and compensate for any change in a vehicle’s position, turns or additions to the vehicle. This ensures that the flow of information to each car is maintained and data traffic remains stable throughout the journey.

The increasing trend in ticket printers and on-board computers used in public transport is for all-in-one solutions. This concept, in combination with the new smart mounting Panel from Austrian manufacturer Zelisko reduces to a minimum the amount of cabling required while at the same time maximising the scope of available functions. Despite the small dimensions of the panel the designers have been able to include the entire communication sub-assembly (UMTS/GPS) together with the emergency switch, electro-acoustic installation and vehicle data storage system. Even when the Zelisko FSD5plus on-board computer is not in operation or when it has been removed, an emergency call system can still be set up using the switch on the side, provided that a Zelisko mounting panel is available. As a result the operator’s vehicles become “travelling emergency call boxes”, thereby improving the safety of public transport. An alarm can also be activated by means of a foot switch in the event of a sudden assault on the personnel.