Every two years in September InnoTrans provides a professional platform for innovative transport technology from all over the world. All the leading manufacturers in this industry will be presenting their latest vehicles, rolling stock, components and systems in the halls and on the rail track at the Berlin Exhibition Grounds. The Innovation Report provides an overview of the exciting array of product innovations at InnoTrans.
It is arranged alphabetically, according to exhibitors, and presents selected exhibits and offers. The images can be enlarged and downloaded at the click of a mouse.
The exhibitors presenting a world premiere at InnoTrans 2014, are marked with a world premiere button.
After ten years of practical experience in the use of 3D planning A+S is now introducing Version 4 of the KorFin software. It is available in English, Russian and German. KorFin enables rail, road and overhead power line routes to be incorporated directly in the planning of 3D models. The basis is provided by geodata such as site surveys, aerial pictures, environmental areas, vegetation and buildings. In interactive real time drafting the visual results are synchronised with data that is of particular relevance to the planning process, such as soil quantities, cross sections and costs. The 3D route planning is completed by integrating traditional design elements. When completed, together with integrated transformation and the relevant interfaces, the data provides wide-ranging access to geodata and existing routes. In this way KorFin permits real time processing for more extensive projects such as routes of up to 600 km in length, areas of up to 40,000 km², or the management of geodata for entire German federal states. The end result is 3D visualisation, finalised plans and the export of data for further use.
ENVILINE™ ESS (750V Hybrid) is a system for storing energy. It enables surplus braking energy to be stored. The accumulated energy is then transferred when needed to a DC traction unit, for example, when a vehicle is starting up. If required the ESS can be equipped with super-capacitors, so that energy can be briefly stored for applications requiring a high power density or the use of batteries, in order to achieve a higher energy density. ENVILINE™ ERS is a system that recovers the energy produced when a vehicle brakes. It consists of an inverter based on IGBT modules, which feed the vehicle’s surplus energy back to the AC network, thereby reducing total energy consumption. Other advantages of this system include an improvement in the quality of the AC grid energy supply and a power factor correction capability.
Some 600,000 people work in the railway industry, making it one of the main sources of employment in Germany, but it also faces the threat of a shortage of qualified specialists. Schienenjobs is the name of an employment portal dedicated to avoiding this situation. With its cross-company approach this platform covers the entire industry. Not only is it currently the largest job centre for the rail sector, but Schienenjobs is also a source of useful information and provides job applicants with useful advice about how to submit their applications. It covers subjects such as careers in the rail industry and sustainability in the rail transport sector. The range of information about jobs is being continually expanded for the benefit of newcomers to the industry and to inform young people about the many and varied career opportunities offered by the railway sector. Schienenjobs is supported by the Association of German Transport Companies, the German Railway Industry Association,, DB Mobility Networks Logistics, Bombardier Transportation, DEVK and BAHN-BKK.
ANDRITZ Maerz supplies fully automated tempering units for the heat treatment of the wheels used on high speed trains. All the processes are monitored individually for each wheel and are reproducible. In addition the registered data for different types of wheels and materials can be retrieved. Other special features of the heat treatment technology that has been developed by ANDRITZ Maerz include more even heating of the wheels to the required degree of tempering. This is achieved by means of single-layer charging with significantly reduced heating times compared with the heating of wheels when placed in a stack. The controlled cooling of the wheels in the tempering machines and subsequent tempering processes enable the high international specifications to be met for the tempering and structure of the wheels used on high speed trains.
The new IKON electronic closure system eCLIQ has been developed for the international market in response to customers’ specific requirements for a high degree of reliability under extreme environmental conditions, and a link to data management systems. It offers an extremely flexible method of managing the latest closure installations. It enables access authorisations to be updated immediately. The technical advantages of the flexible modular design include the reduced overall length of the cylinders and the centrical key channel. The plug-and-play solution is ready to use immediately following assembly. The advanced generation of chips with 128-bit AES encryption offers very high standards of security, accelerated communication and improved energy management. In addition to its compact design and striking styling, the eCLIQ also uses extremely robust and reliable components. Its manufacturer describes it as one of the most reliable and also one of the smallest electronic closure systems.
The French manufacturer ATI-INTERCO is exhibiting special connectors for use in harsh and extremely demanding environments at InnoTrans 2014. Made with high performance materials, these connectors have been designed for signal transmission and for use directly on the rail track. They provide for rapid connection and disconnection with maximum reliability. They also significantly reduce the time required for assembly/removal and for maintenance work, and eliminate any risk of wiring errors. Sealed to exclude moisture, these corrosion-resistant connectors guarantee secure attachment and clear signal transmission even when subjected to the kind of vibration experienced on rail track. Other features include effective resistance to high temperatures and ageing. The ATI-INTERCO company is the result of a merger in 2012 between ATI ELECTRONIQUE and INTERCONNEXIONS and has been a subsidiary of the Conesys Group since February 2013.
AUCOTEC AG is introducing its solution for rail vehicle wiring for the first time at InnoTrans 2014, from the electrical design to the making up of the wiring looms, to provide highly consistent data throughout the entire development cycle for the benefit of all concerned. The platform, which goes by the name of “Engineering Base” (EB), displays the data from the various disciplines in a uniform model, and also integrates the 3D development. EB enables users to carry out all aspects of functional planning, defining the wiring either graphically or only in alphanumeric form. The distances obtained from the 3D model determine the lengths of the cables and lines. If changes occur it is sufficient to simply synchronize the wiring looms with the cabling sections, and EB will immediately recalculate all the relevant line lengths. This eliminates the need to make manual corrections. Mechanical and electrical designing can take place parallel with one another. The EB manufacturing module integrates the data from both of these activities for the immediate creation of production documentation.
The basic version of the analogue, SIL-certified rear view system RailEye consists of the RailMon monitor , two externally mounted RailCam cameras and the RailEyeSwitch router. When mounted on vehicles, power is only supplied to the RailEyeSwitch, which then powers the monitors and cameras. The use of video two-wire cable means that only a four-core cable is required for the video and voltage feed, thereby substantially reducing the amount of wiring in the vehicle. The reduced wiring and simplified installation work make the rear view system ideal both for new vehicles or for retrofitting. This innovative development has many applications, for example as a traditional rear view or door monitoring system, and also has a signal input for on-board signalling. The externally mounted cameras can provide single, split or quad images. In addition to the possibility for SIL certification, RailEye has also been granted EN50155 (railway approved), EN50121-3-2 (EMC) and EN45545 (fire safety standard) approvals.
The new compact, robust and inconspicuous AXIS P39-R network camera series has been specially designed for video surveillance in buses, trains, subway carriages and other vehicles. The cameras have water and dust-proof casings, and can stand up to adverse conditions such as vibrations, impacts, shocks and temperature fluctuations. This product series has an active tampering alarm which detects and signals tampering attempts such as spray-painting or blocking. The AXIS P39-R network cameras achieve optimum image quality in HDTV resolution and high processing performance as well as providing EdgeStore products for customers with sophisticated demands. The cameras are specially designed to respond rapidly to changes in lighting conditions, always producing superb image quality. Thanks to progressive scan techniques, the cameras can display moving objects without distortion. In “traffic light” mode, traffic light colours can be more easily distinguished in dark scenes.
Up to now, the fire behaviour of natural-rubber based materials has prevented them from being used in vibration-absorbing components requiring special fire protection properties. This disadvantage is now eliminated by material and processes developed by BATEGU. The exhibitor’s vibration components achieve maximum fire and passenger protection while maintaining optimal dynamic-mechanical properties. This, combined with the existing excellent ozone, ageing and weather resistance properties, high elasticity and an outstanding settling behaviour mean that BATEGU vibration components meet all the requirements for long-term, fault-free use in bogies. Thanks to their cold-condition flexibility extending down to -50 ° Celsius, the components can be used even in the most severe climatic conditions, and thanks to their resistance to steam and alkaline detergents, there are no restrictions with regard to normal railway vehicle cleaning operations. Certificates on conformity to EN 45545 can be provided.
The RailTuff™ BE43802 is a copper Cat 7 Ethernet data cable designed by Belden especially for the passenger railway market. It conforms to EN 45545-2 and EN 50155 (TX level) specifications and thanks to a transmission performance of 10 Gbps can be used to integrate multiple on-board applications. In addition, it helps copper cable installations to meet the requirements specified in EN 62580 and EN 61375. The new Ethernet data cable can be used at a wide range of ambient temperatures. Another highlight at this year’s show will be a live demonstration of a wireless link utilising Hirschmann™ OpenBAT Clear Space® Wireless products and the Parallel Redundancy Protocol (PRP) as described in IEC 62439-3. PRP dramatically improves the performance of a wireless network since it decreases the potential for data packet loss since no renegotiation and signal recovery times are involved. This protocol also improves transmission times by achieving lower latency and reducing jitter throughout the data transmission session.
BIW Isolierstoffe GmbH develops and manufactures technical textiles and products made from silicon, and has expanded its silicon portfolio in accordance with the changes to European fire safety standards in compliance with DIN EN 45545:Aug-2013 (CEN/ TS45545-2:2009). The result is a wide range of silicon materials, in both compact and foam form, and for all regular applications, for making hoses, cords, profiles, frames, straps, mouldings and flat seals. For most applications the hardnesses 50Sh-A, 60Sh-A and 70Sh-A achieve the tolerance level HL3, while the silicon foams achieve the tolerance level HL2. A wide range of individual tests covers the flue gas density and flue gas toxicity categories R1, R6, R7, R22 and R23. In individual cases the exhibitor can continue to meet national standards for specific products.
With its innovative XLIGHT and XTREME leathers BOXMARK aims to create trends for vehicle interiors of the future as well as making a valuable contribution to sustainability. Together with its lamination XLIGHT weighs only 600 g/m2, thereby helping to reduce the overall weight of the train. This reduces energy consumption, pollution and costs. XTREME is notable for its above-average durability, high wear resistance and outstanding stretching, tensile and tear-resistant properties. The award of numerous test certificates also confirms the remarkable resistance to mould, bacteria, disinfectants, sunlight, dirt, chlorine and sea water, oil, alcohol and water. XLIGHT and XTREME meet all international standards and are also available in combined form as a single leather product. These innovative leathers from this Austrian exhibitor can be used on all interior components.
With the aim of finding the best possible solution to meet the latest fire-prevention regulations, Cellofoam has developed a new sound and heat insulation product with water and oil repellent properties: Cello® F800 FR HO ALG. The versatile application options are characteristic for this innovative material. Whether used in ceilings, floors or side walls, in HVAC systems, ventilation ducts or as a special version for piping insulation – Cello® F800 FR HO ALG meets the requirements for HL-3 results of R1 as specified in the latest fire prevention regulations set out in EN 45545-2. Its corrosion-resistant aluminium surface fulfils the strictest hygiene requirements and effectively prevents fungus and mould formation, protects the material against penetration by liquids as well as providing excellent heat radiation reflection. Furthermore, it can be completely recycled, does not emit any formaldehyde and is REACH-compliant according to the state of the art (05/2014).
“STI 20” is a new patented system from the Italian company COLMAR for loading, transporting and unloading ballast and, unlike existing transport systems using specially designed railway cars, it results in considerable time savings and correspondingly lower maintenance and investment costs. This new system can be installed in standard railway cars. The ballast handling system is made up of two parts: the transport system and the devices for filling and emptying the containers. The transport system uses standard 20 foot containers with a capacity of 20 m³, which, even when fully laden, can also be transported by road. The loading and discharging system consists of a conveyor belt installed on a steel structure, which can also be connected to a normal railway freight car. The hydraulic and electric power required by this structure is supplied by a stand-alone diesel power unit which is remotely controlled. Up to five parts can be stacked one upon the other to enable this equipment to be transported.
The J-TECH JTCIR and JTVG range of connectors from CONESYS EUROPE, a division of Conesys Inc, has been designed to meet the needs of industrial customers in areas such as railway engineering, construction equipment and power generation. The reverse bayonet connectors offer easy and rapid 1/3 turn coupling with an audible click and additional visual yellow markings. The range of connectors has been designed for water-resistant use and meets the exacting requirements of the IP67 standard. The seals are made of flame-resistant neoprene, and rubber materials are also available as an alternative. They are interchangeable and can be joined to other VG95234 connections. The connectors are available in aluminium or stainless steel, with crimp and solder contacts and with gold or silver plating. Their resistance to shock and vibration conforms to the specifications of MIL-C-5015. All of the products in this range are designed to operate at temperatures of between -40 and +125 degrees Celsius.
Crescendi GmbH, based in South Tyrol, sells innovative urban and street furniture throughout the whole of Europe. The Augustaflex system is one of their main products. Signs and barrier posts get damaged every day due to careless parking, resulting in complicated and expensive repairs. Maintenance work is costly and hits municipal budgets hard. Now there is a solution to this: a flexible post base for signposts and barrier posts. The system can be quickly and easily integrated into existing or new road and traffic sign systems. If a car bumps into a post while parking, this gives way at the base and returns to its original upright position as soon as the force is removed. This effect is achieved by a powerful, optimised disc-spring which provides elasticity while still complying with regulations on the rigidity of road and traffic signs. This flexible post base reduces expensive repairs to damaged signs or eliminates them altogether.
As the exhibitor of the DAMM TetraFlex® system explains, this is the world’s most scalable and smartest digital TETRA radio infrastructure. It is available either with an outdoor or an indoor base station. The system is augmented by a comprehensive range of features and integrated software, such as network management, voice and data recording and a Dispatcher application. TetraFlex® provides for reliable, fast and uninterrupted TETRA voice and data communication in mission critical applications. The 100 per cent IP-based, distributed architecture ensures maximum flexibility in site and capacity expansions, even in live operation. The user-friendly, advanced API ensures the seamless integration of external applications such as Dispatcher. DAMM also incorporates the products TetraFlex® Android Client and TetraFlex® Windows Client – vendor independent soft terminals for non-critical voice and data communication via WLAN, WiMax, UMTS(3G) or LTE(4G) networks.
Deubad GmbH & Co. KG is a young company that specialises in supplying toilets and washrooms with safety handles for the disabled and the elderly. Until now it has mainly concentrated on care homes for the elderly, hospitals and senior citizens’ centres. More recently it has expanded to include toilets on trains. Based in Leonberg, this company is attending InnoTrans for the first time, where its exhibits include a range of retractable support handles. These are available either in stainless steel or aluminium, and are either epoxy powder coated or provided with a fine matt stainless steel finish. If sufficient quantities are ordered the powder coating is also available in a range of RAL colours to meet customers’ requirements. Deubad is already supplying a number of customers in Germany and abroad.
DEWETRON now also offers its instruments as “open systems”, with an expanded range of software solutions. For the first time driver libraries are available for such graphic development tools as “NI LabVIEW” and ”DASYLab”, which are particularly popular for test and measurement applications. Text-based programming languages such as C# are also supported. In another new development, not only Microsoft Windows (32 and 64 Bit) but also a Linux driver are now available. As a result it is now even easier to incorporate DEWETRON measuring instruments or core elements such as the tried and tested analogue, insulated signal amplifier DAQP/HSI, ORION A/D cards or the latest generation of TRION™ modules in existing test bench environments and to also seamlessly integrate the software. The display at InnoTrans will feature the DEWE2-A4, part of the new range of instruments. This is a compact measuring instrument with a very bright 13-inch display, which can also be powered by a battery if required.
The new door-opening button and the series 57 alarm signal have now been supplemented by an indicator light from EAO, providing passengers with coloured, illuminated symbols or text for warning or information purposes. In rail vehicles the applications range from a door or WC status indicator to an emergency and alarm system. Each unit is provided with 20 LEDs to produce the colours red, yellow, green, blue or white. Combinations of red/yellow, red/green or blue/white are possible with the two-colour version. The large information display, measuring 57 mm, offers plenty of space for text or symbols that can also be easily identified from a considerable distance, even in direct sunlight. The new indicator lights are based on the same design as existing Series 57 products, and therefore offer a high level of protection, rated at IP 69k, as well as tool-less final assembly and outstanding illumination, thereby providing enhanced passenger safety and improved handling for manufacturers and operators.
SERCAM® Shock combines maintenance-free GPS/ GSM long-term localisation with numerous functions for the remote monitoring of railway wagons. Developed from SERCAM® Rail, this system not only provides for the exact documentation of running and idling times, but now enables precise measurements to be made of impact and vibration too. The built-in acceleration sensor provides data about the duration, intensity and direction if impacts, such as may be caused by violent braking. This enables accurate evidence to be obtained in the event of damage to the wagon or its freight. The small outdoor hardware unit requires neither cables nor an antenna and can be quickly and efficient attached by means of a powerful magnet. This means that it can be easily retrofitted, is suitable for any type of wagon, and does not require any complicated structural modification. Positional and vibration data are relayed via the mobile radio network to an internet application in order to provide transparent management and reporting.
At InnoTrans 2014 in Berlin the Italian company Eletech is presenting the PADIS automated diagnostic system for the pantographs used by electric and underground trains. This system assists with forward planning by automatically checking the pantograph for defects and wear. It does this by evaluating the most important characteristic parameters, which include, for example, the direction, wear on the contact strips, defects and the upward contact pressure. The PADIS 3D algorithm has been developed for this purpose and, using a three-dimensional model of the pantograph, it can issue warnings about defects within 60 seconds. With its high resolution the three-dimensional scanning system can detect cracks and other anomalies that would not be identifiable with a planar image. Various numerical parameters are compared with a reference model in order to carry out the evaluation.
The era-transceiver® permits reliable Ethernet transmission via optical line-of-sight connections designed especially for railway applications. The great advantage of this system is its electrical isolation between both terminals of the transmission link. This kind of transmission creates a secure connection that remains unaffected by mechanical vibration and electromagnetic interference impulses, thus ensuring high availability. As a result, the era-transceiver® is suitable for transmission of multimedia information with large data volumes and process-related bus signals such as are required for PA, PIS, CCTV, COMMS, PLD and TCMS systems. The different models of the era-transceiver® family are available with a variety of physical and optical interfaces and operate at transmission rates of 100 Mbit/s and 1 Gbit/s. Currently, era-contact is developing the next device generation which will achieve 10 Gbit/s to meet future demands for even higher transmission rates.
F.S.P. GmbH from Emmerich is exhibiting its new packaging solution for the first time at InnoTrans 2014: SNACK-NAPKIN, which can be individually printed. This is a special kind of serviette which can also be used as packaging for the food item, and also to wipe one’s face with afterwards. It enables the operators of snack bars to offer food such as pretzels, sandwiches and filled rolls in a more individualised format. SNACK-NAPKINS are made from a high quality Airlaid material, which is produced in dry form from cellulose and a binding agent using a special compressed air process. The material is available in the densities of 50, 60 or 70 g/m². The size of the SNACK-NAPKINS can be adapted to meet individual requirements, examples being 400 x 400 mm or 300 x 400 mm. They can be printed using the Flexo process, in up to four colours.
The ThermiCam from FLIR Systems is a heat sensor camera with a built-in detector to identify and count cyclists and vehicles using crossings equipped with signals. The heat sensitive images are used to identify vehicles and cyclists approaching and in proximity to halt lines, and in this way providing for the dynamic operation of the traffic signals. The ThermiCam is installed in the same housing as the well known TrafiCam and TrafiCam X-Video-Stream sensors, which are in use around the world. The main difference lies in the heart of the camera: The ThermiCam uses a heat sensitive camera instead of a standard camera operating in the visible light range. The intelligent ThermiCam sensor registers data and transmits it via a direct connection or an IP to the signal control unit, thereby providing for a more dynamic activation of the red or green phases. One of its main advantages is that, unlike standard CCTV video cameras, the ThermiCam can identify oncoming bicycles and cars from a considerable distance, even in the middle of the night.
RailConnect 360 software from GE Transportation can provide automated performance diagnostics as a means of analyzing transport performance and avoiding malfunctions and breakdowns. It supplies rail network operators with data to assist them in improving the reliability and availability of their installations and networks. This software also helps to improve processes and reduce life cycle costs. Big data and extended analysis functions based on this data also contribute to enhanced performance because inefficiencies in the system can result in increased running costs for railways, which can quickly mount up. With the right data and analyses it is also possible to cut fuel costs and reduce downtimes to a minimum. The use of real time planning algorithms can optimise routing decisions, leading to greater efficiency and offering customers substantial savings too.
The GILLAM-FEi-IDC20K from the Liege-based Belgian company is a portable device for testing switchgear. With its compact design it can also be used in confined spaces and in switchgear that is difficult to access. The GILLAM-FEi-IDC20K enables users to test all kinds of circuit breakers and safety switches. It is ideal for use with high currents with specific waveforms and for short circuit testing of switchgear and protective relays in the range 600 V to 3 kV DC, as used for railway power supply systems. It produces a primary current injection of up to 20,000 A (2,500 A per module) with a low voltage of 7.5 V. The programmable transient waveforms make it suitable for overcurrent testing and for testing complex, time-dependent fault conditions such as distant short circuits.
Grupos Diferenciales specialises in the production of bevel gears of maximum quality and precision. The company will be showing its new product range at InnoTrans 2014. This includes gear wheels with diameters up to 1,250 mm and produced using hard-finishing processes. The gears can be made using HPG and grinding processes, both of these being hard-metal machining processes that provide tremendous advantages, including in particular higher precision and strength of the gear teeth. The Spanish manufacturer also produces a wide range of straight bevel gears and differential transmissions. Some of the company’s highlights from this sector are also being shown at InnoTrans and include ground gears for locomotives, trams and high-speed trains.
A new type of safety system for automatic doors on public transport vehicles has been developed by Gummi-Welz GmbH & Co. KG of Neu-Ulm. It incorporates a fully automated light grid that cannot be seen from outside the vehicle, together with an electrical contact strip which is built into the finger protection profile of the door system. The light grid is a SITRANS alpha® S1-Rail from SITRON, which has been successfully used for many years, having already been installed over 35,000 times. The system is an approved safety device for use in rail vehicles and can even identify the smallest objects. It compensates automatically for any re-adjustments or for dirt or stains, is not affected by other sources of light, and automatically regulates its sensitivity level. It thus conforms to the requirements laid down in VDV 111/ prEN14752 for contactless anti-trap protection and for identifying when small objects are trapped. It complies in every respect with the specifications laid down by the Federal Railways Office.
A device for measuring tram wheels has been successfully used for many years, and now a new model is available for train wheels. It is robust, simple to use and can be operated by one person.. The mechanical measuring instrument is attached to the wheel by magnets. This allows an unambiguous and rapid measurement of wear to be made in less than one minute. Readings can be obtained for qR (radius), Sh (flange height) and Sd (flange thickness), with an option of also measuring the flange width L including the seam S1. One of the advantages of the manufacturer’s concept is that the PSION WORKABOUT hand-held computer can be combined with all of this exhibitor’s measuring devices. This reduces purchase costs and simplifies the entry and archiving of all data. The measuring process is rapid and uncomplicated. Tolerances can be set, and if these are exceeded acoustic and optical signals are activated.
IBC Wälzlager GmbH already supplies an extensive and diverse range of linear roller bearings and telescopic guides for use in railway engineering, and this programme has now been expanded to meet its customers’ new requirements. The product range now includes new door opening systems, access steps, battery removal systems, cabinets housing electronic equipment and interior equipment. Roller units designed for specific applications are another new product. They can be used in door-opening systems and also for telescopic mountings for electronic units, which have to be latched in various positions for servicing purposes. This exhibitor also supplies sectionalised telescopic fittings for use in housings with restricted access, and these devices comply with all technical safety requirements. Among the outstanding features of the linear roller bearings and telescopic guides from IBC are their durability, simple operation and efficiency.
Ikusi is offering a Web tool for monitoring, quality control and supervision using data storage, analysis, display and utilisation technologies. This allows public transport operators to measure quality parameters and make decisions on the basis of the collected data and defined key figures to ensure compliance with quality targets or to determine the extent to which these have been fulfilled. By processing the data and conducting extensive analyses, the tool helps to achieve greater efficiency and more flexibility, comfort and safety for users and operators of public transport networks. All in all, the tool contributes to achieving tangible quality improvement and better values for key system-quality parameters. Ikusi has now added ticket barriers to its product range. These rugged, modular and adaptable units are equipped with remote control and supervision features and help to reduce fraudulent use of transportation services.
Inndes, a specialist Italian supplier of machinery and equipment for rolling stock maintenance, is presenting its latest bearing maintenance unit at InnoTrans 2014. TBU/ bearing replacement at specified intervals is prescribed by manufacturers to ensure the safety of rail vehicles. Reconditioned bearings are permitted, provided that the revision process has been certified. Inndes provides the technical expertise to comply with the requirements of TBU manufacturers. This exhibitor offers a versatile range of equipment to fit different TBU models and shapes. Inndes has also acquired a good reputation with its wheel puller press, a special universal machine for removing wheels from the axle. It is supplied complete with a high pressure SKF pump, which enables the machine to be raised on a platform and turned. Two types of platform are available, and the dimensions and structure are designed to provide the highest levels of safety and maximum productivity.
ISRINGHAUSEN is presenting the E version of its innovative NTS2 series of seats at InnoTrans 2014. This latest generation of seats, the E model, features not only new designs but also sets new standards in terms of ergonomics, safety and comfort. These seats are available in Comfort, Premium and NTS2 E versions. In addition to an improved range of functions they can support heavier weights and have multi-zone upholstery to provide the best possible support. The NTS2 E model is based on the Premium configuration and has electronically controlled seat adjustment with a built in memory function, and is also available with an optional card reader. The electrically operated seat functions actively assist the driver in his work processes by enabling the position of the seat to be easily and rapidly adjusted. The E versions are particularly suitable for use in advanced electric buses.
The light rail operating company Istanbul Ulasim, based in Istanbul, has developed a new approach for the procurement of rolling stock. Experience gained from operation and maintenance is incorporated directly in the product definition, and in the development and design of new rolling stock. Compared with conventional purchasing methods the procurement model that has been developed in this case offers a number of advantages such as reduced initial purchase and life cycle costs, improved quality and more comfortable vehicles, a uniform picture of the fleet and flexible delivery conditions. This has enabled a new generation of lightweight rolling stock to be designed, developed and ordered. They can be used as light rail trains or metros and, with their excellent reliability, safety, economy and modern design, they conform to European standards. These vehicles can be operated bi-directionally at speeds of up to 80 km/h and are equipped with a video surveillance system.
SimulationX is a multiphysical system simulation platform for the virtual product development of mechatronic systems. Based on the descriptive language Modelica and a network-oriented modelling approach, this software is used to support drafting, analysis and optimisation processes in the early stages of rail vehicle development. With preconfigured model libraries and easy-to-use interfaces, SimulationX provides for intuitive and flexible working in various development environments, embedded in existing tool chains. In the rail vehicle sector the emphasis is on driving dynamics, with propulsion, braking and suspension systems, as well as on programs for improving efficiency and reducing emissions. Current areas of development work where SimulationX makes a significant contribution are concentrated on hybrid propulsion units and regenerative solutions with improved management of auxiliary units such as motor cooling, air conditioning, the supply of compressed air and on-board power.
The new converged OAM platform from Kapsch CarrierCom makes applications available via a highly secure private cloud for the operation, administration and maintenance (OAM) of railway radio networks. The need for many of the physical servers can be eliminated through virtualisation. The duplicated design of all the infrastructural, system-relevant elements within the platform make it extremely robust and failure-resistant, ensuring that all the important functionalities are always available. In addition to improved cost efficiencies, in particular the fact that the entire network can be controlled and monitored through a central interface, is another major advantage. OAM tools from Kapsch CarrierCom have been designed specifically for railway operators and can be deployed in all the usual operational management activities. Tools from outside suppliers can also be integrated in the cloud service, thereby making this a worthwhile long-term investment.
The tipper for delivering and removing bulk materials to and from railway construction sites consists of a supporting frame whose dimensions and supports are exactly equivalent to those of a 20 foot container, and a movable skip positioned at right angles to the direction of travel and equipped with flaps. This skip is designed to tip the entire load clear of the rail track on which it is being transported. It can be carried on all standard forms of container transport such as railway cars, road haulage vehicles or ships. The tipping action of the skip is achieved using standard hydraulic cylinders. However, their energy is not provided in the usual way from a generator but from a hydraulic storage system, which is charged up by a small electric pump during the journey. The skips are controlled by means of a Profinet-based bus system, which enables the equipment to be operated not only manually but also in full or partially automated mode.
Creosote is used in the maintenance of wooden railway track sleepers (ties). In the course of the service life of such sleepers, a large amount of creosote oil leaches from the sleepers into the subsoil and from there into the ground water. This is the reason why the use of creosote oil has been prohibited in the Netherlands since 2005. In the meantime, the EU commission has also decided to ban the use of creosote oil throughout the EU as of 2018. The service life of wooden sleepers treated with creosote oil is roughly 25 to 30 years, whereas the service life of untreated wooden sleepers is around ten years. This means that the life-cycle costs of wood sleepers will rise considerably. The ban on creosote oil applications is the reason why Lankhorst has now developed an alternative using 100 % recycled plastics. The KLP® plastic sleepers have excellent properties and retain these throughout their entire service life of more than 40 years. KLP® plastic sleepers are maintenance-free, making them an excellent alternative to wooden sleepers.
With its continued development of the duroplasts BMC 0204 and SMC 0208, Lorenz has succeeded in creating materials that satisfy the latest fire safety requirements for components used in almost all areas of rail vehicle construction. In terms of their mechanical properties and their fire retardant qualities these duroplasts have been designed especially to meet new requirements in rail vehicle construction and were among the first products to satisfy fire safety tests in compliance with CEN TS 45545 Part 2, Categories R1/R5/R6/R10/R11/R22/R23/R24/R25 – HL3. On the railways SMC is used in particular for interior and exterior cladding, window frames, seats and hub caps. BMC is ideal for use in the production of small parts such as light switches and electrical plug-in connectors because it is suitable for compression, injection and transfer moulding processes. With a CTI value of 600 V, thermal conductivity of 1.35 W/mK and an oxygen index of 100 per cent it can also be used for electronic components.
Moxa’s new zoom IP camera, the VPort56-2MP, with 1,920 x 1,080 pixels, H.264 video compression, 10x optical and 16x analogue zoom, has been designed for the video monitoring of essential operational processes. The camera operates reliably in a temperature range of -40 to +75 degrees Celsius without the need for a fan. The designers’ remit was to improve the reliability of the system under extreme conditions while lowering the operator’s maintenance costs. It also offers extended EMC protection in accordance with EN61000-4-2/3/4/5/6 Level 3. Combined with the optional Moxa VP-PT1201 PT scanner, the VPort56-2MP can be converted into an IP positioning system with PTZ capability. An optional fibreglass ethernet interface can be used to facilitate installation and reduce costs, in particular for long distance installation. Other housings with IP66/ 68 protection and Class1 Division 2 certification are available if required.
The NOISE PHALANX® R300 aluminium noise reduction wall elements for installation on the nation’s railways have been approved by the Federal Railways Office for sections of track where speeds of up to 300 km/h are reached. The DB Netz AG user’s statement has been issued. These elements can be easily installed and require no maintenance. One of their special features is a newly developed bearing system capable of resisting dynamic load testing with five million load changes, without incurring any visible damage. The bearing enjoys utility model protection. MPA Dresden GmbH is the licensor of the noise reduction wall. NOISEPHALANX® R300, R200 and R160 elements provide advanced technological solutions for certified noise protection. The system comprises a single-sided, highly absorbent aluminium noise protection wall with elastomer profiles supporting the elements. The noise protection element has been developed in a joint venture involving project sponsors, engineers, consultants, experts and specialists.
The effort involved in painting complete (double-deck) trains can be reduced by a third or more using mt decore’s mobile fume and mist extraction system, which can be easily set up in just a few hours. This novel development by surface treatment experts specialising in special-effects painting and fibreglass repair and maintenance will be making its trade show debut at InnoTrans. This world-first was deployed for the first time at the DB Regio workshops in Cottbus. It is used to assist ad-hoc priming, complete paint jobs and graffiti-protection applications for wagons or complete trains of up to 4.80 m in height and can be used in railway wagon repair halls to avoid disturbing simultaneous maintenance work on other sidings. Due to the odours and emissions involved, this kind of work used to be carried out in separate halls, or the trains had to be sent to remote maintenance facilities instead. The system, which has two fume and mist extraction columns on the right-hand and left-hand sides of the painting section, can be moved to any location in Germany, and can be set up and adapted to local conditions in less than twelve hours.
Murrplastik Systemtechnik now includes an optional fire-resistant panel in its range of metal and plastic cable lead-through panels. This is installed behind the cable lead-through. In the event of a fire the cable lead-through openings are sealed and made fire-resistant for at least 30 minutes (E30) in accordance with DIN EN 1363-1. It operates according to the following principle: if a fire breaks out, i.e. at a temperature of 160 degrees Celsius, a material based on expanding graphite, which is incorporated in the fire-resistant panel, swells to forty times its original volume, expanding equally in all directions. As it foams this material forms a protective, insulating layer in the form of a fire-resistant, rigid foam that effectively seals all cable apertures. This prevents a fire from spreading from one side of a switchgear cabinet to the other: As a result neither fire nor smoke can penetrate the cable lead-throughs into adjoining spaces.
NewTec, a provider of consultancy and development services for security related electronic systems, is presenting a world first, the TRDP test system NTOnTrack. TRDP, Train Realtime Data Protocol, is a uniform communication standard with far-reaching implications for future railway technology. NTOnTrack has been designed specifically for manufacturers, component suppliers and test facilities and can be adapted to meet the specific wishes of individual clients. Whether the requirement is for complete component/ certification tests, tests to accompany development work or long term testing, NTOnTrack offers the benefits of a high abstraction level, making the tester an “instant expert”. It allows for conformity tests in the form of automatic testing procedures, as well as automatically generated test reports. The system also provides for low level tests and “error injection” directly at bit level. This expertise and the testing process itself are being demonstrated using another world first: a model train controlled exclusively by means of TRDP.
Normally, faults in the surfaces of hot-rolled workpieces cannot be detected until they have cooled. In the meantime, many other workpieces may have been produced with the same fault. This problem can now be avoided using the innovative "DIRIS 3D HOT" inspection system. This system is based on laser light-section scan technology and permits contactless testing of surfaces that are still hot, such as rails immediately after leaving the rolling mill. This means that faults can be detected early in the production process and their causes can be eliminated, thus preventing large-scale production of rejects. This new method developed by the Austrian exhibitor has a great many advantages. For instance, it can detect and classify recesses only a few tenths of a millimetre deep. What is more, automation of surface inspection procedures also helps to improve occupational safety in handling steel products with temperatures of above 1000 ° Celsius, since the cameras, not the workers, have to withstand the heat.
Scorpion, a laser-based device from GRAW, provides detailed measurements of the wear on points, including tram points as well as flat bottomed and grooved rails. The readings are displayed using a 3D model of the object. This unit is particularly suitable for examining the wear on points elements and on track welds. The unit is placed on the element to be examined and the readings are obtained automatically. The control unit, with a keypad, LCD display and USB port for transferring the readings to a computer, is supplied with the necessary PC software to enable the data to be processed. In assessing the amount of wear, this system enables comparisons with corresponding 3D templates to be made, together with an evaluation of the 3D measurements, and the required reports are also produced at the same time.
The GRP (fibreglass) overhead line mast made by the Powerlines Group is the result of intelligent light-weight design work using nonconductive fibre-reinforced composite materials. Up to now, most masts for overhead lines have been made of steel or reinforced concrete, meaning that the overhead contact line had to be equipped with insulators. In contrast, the new fibreglass masts provide full insulation. By largely or even completely substituting the conductive materials, such as steel or reinforced concrete, it is now possible to build overhead lines without additional insulators. Eliminating expensive insulators allows economical and safe installation of the overhead lines. But the GRP material also has a number of other advantages: the material’s insulating properties provide considerably greater safety to crews working on installation projects and live lines. The light-weight material facilitates installation and largely eliminates the need for heavy construction machinery.
Wheels and rails have to be regularly checked and processed to ensure smooth running, reduce noise levels and maintain high safety standards. The Pramet range includes rail grinding tools, which are used by leading German companies and meet the strictest demands for accuracy and reliability. The new, improved models on display at InnoTrans have many distinct advantages. The cassette version contains a single basic tool for left- and right-hand scrubbing and smoothing. The version with a single cassette can perform three tasks: scrubbing, AHC and UIC profiling. One of the main features of the new grinders from Pramet is the excellent reliability of the disposable cutting insert.
SAB Bröckskes has developed several new data cables for use in rail vehicles: the “SABIX R 605 FRNC” version with coloured cores, the screened type “SABIX R 615 FRNC” and the pair-wise twisted type “SABIX R 645 FRNC TP”. With certification according to EN 45545 they offer vehicle manufacturers the maximum planning reliability and easy, flexible installation in locomotives and rolling stock. In addition to their outstanding flexibility these cables also meet the highest rail industry safety standards. With its new CAT 5e- and CAT 6 ethernet cables this 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 the effectiveness of resistance to conducting fire, smoke gas density and toxicity, SAB Bröckskes has now expanded its range to include ethernet cables for railway use that have been granted certification by an external agency.
In addition to complying with the statutory specifications laid down in DIN 32984, tactile guidance systems also make it easier for an increasing number of people to find their way around buildings and events. In a society with an ageing population there is an increasing need for such facilities. Tactile guidance systems provide just such assistance in helping people to find their way around. SFS Safety Flooring Systems is therefore using InnoTrans 2014 to introduce its two new products for interior use. The Safety-Floor TBI strips are used to guide people along a route. They are trapezoid and self-adhesive, measure 300 x 30 x 3 mm and can be used on a number of floor surfaces including PVC, stone and wood. The Safety-Floor TBI studs are designed to alert people to hazardous areas such as steps or ramps. They are also self-adhesive, approximately 3 mm in height, with a diameter of 30 mm, and can be used on materials such as PVC, stone and wood. The strips and studs are both made of wear-resistant polyurethane.
The REP right-angled connectors from Smiths Connectors provide a rapid, highly reliable and functional connection of all kinds of installations where a total seal is required. They are ideal for various technical applications in the railway sector, including system controls for sensors, warning signals, brakes, door security systems and lighting, in interior equipment for air conditioning and seating, and for passenger information systems such as displays, video equipment and loudspeakers. The REP series of connectors now includes straight contact pins as well as the existing angled pins, for installation on circuit boards. The REP series uses the reliable Hypertac hyperboloid contact technology, which ensures excellent resistance to shock and vibration. It is available in two, six and twelve pin versions. All the materials used comply with NFF 16-101, NFF 16-102, EN 45545-2 and UL94 V0. Only one size of contact is required to cover connections with cross sections of between 0.5 and 2.5 mm².
With its newly developed horizontal rail bending and straightening machine 1200 HE with a working force of 120 t, Stierli Bieger provides yet another universal press for general track works and the rail manufacturing industry. This powerful machine enables tongue, flat bottom rails and grooved rails to be worked effortlessly. The generously designed machine can accommodate any kind of tools, and even existing press moulding tools can be installed quickly and easily. This increases flexibility and reduces setup times, and the machine can be used for bending, forming, stamping and straightening. Another major advantage is that profiles can be loaded from above. The use of a crane to bring in the rails allows the workpiece to be handled during machining. Consequently horizontal rail bending and straightening machines can be used economically for large and small series and also for individual items. The controls can be adjusted individually to meet the production needs of each customer.
The use of low voltage starter batteries demands a short time current of several thousand amperes, and with lower temperatures more time and more power are needed. The starting process requires special batteries or high-caps, and the circuit for the starting process is operated in isolation from the on-board supply in order to prevent massive interference. SYKO supplies intelligent 1kW(BLG.H3 series) and 2kW battery chargers (BLG.H6 series) for starter batteries, which operate with the customary on-board battery voltages (24/ 36/ 72/ 110 V) used by the railways. This equipment has been designed to comply with railway standards with regard to EMC, environmental conditions, position insensitivity and technical fire safety specifications. The battery charge management system is processor-controlled and various excess temperature characteristics on different temperature sensors can be specified. An electrically isolated CAN-BUS with user interface is available as an option.
Syslogic specializes in embedded box computers for mobile use. With its Railway Computer Compact 71 the company has expanded its range of embedded computers for the rail industry. The Compact 71 has been certified in accordance with the railway standard EN50155 TX Category for this industrial sector. This unit is also provided with rugged M12 plugs that are designed to withstand even the most violent shaking and vibration. The M12 plugs are used to connect to two RS232 interfaces and one ethernet and one VGA interface. The Railway Computer is also equipped with two standard USB ports for rapid service updates. As an option these units can also be expanded by the inclusion of CAN and RS485 interfaces, also by means of M12 plugs. Like all industrial computers from Syslogic, the Railway Computer requires no moving parts. It has been designed for continuous operation (24/7) and its components have been approved for use in the extended temperature range of -40 to +85 degrees Celsius.
At InnoTrans 2014, terra international surveys Ltd. and PC Soft GmbH will be jointly presenting an integrated solution for railway infrastructure maintenance management. Regular monitoring of the condition of the tracks and roadway is important in deciding on the best maintenance strategy to use. Hence, a precise mobile condition survey of the track, roadway, subgrade and other infrastructure elements is carried out using several different sensors. terra international surveys Ltd. and PC Soft GmbH are offering mobile track measurements using a scalable multisensor platform. The measurements obtained in this way can be processed directly using the zedas®asset lifecycle management system application. The best maintenance measures are then deduced from the results of the track and roadway condition survey. This integrated maintenance management solution ensures high infrastructure availability at a relatively low cost.
The Berlin-based manufacturer of devices for testing construction equipment, TESTING Bluhm & Feuerherdt, in collaboration with IAB Weimar GmbH, has developed a simulator for a mobile cement mixer which can accurately replicate the actual requirements regarding a quantity of freshly mixed concrete when transported in an actual mobile mixer. During the development process care was taken to include important influencing parameters in relation to spreading and slump flow. The intention was to also include the temperature of the mix, mixing time, rotational speed of the mixing drum and performance parameters. The working properties of concrete being delivered to a site vary depending on the length of time it is being transported, the ambient temperature and the consistency of the material at the time it is placed in the drum. Changes to the spread of up to 90 mm have been recorded, which corresponds to a deviation of 1.5 in the consistency category. With the new mobile mixer simulator accurate predictions can be made in the laboratory, thereby enabling the cement works to more efficiently adjust the mix prior to delivery.
The German banking association “Deutsche Kreditwirtschaft” (DK) has granted approval for all components of the UX Solutions self-service vending machines. With this series of self-service products consisting of freely combinable modules, the exhibitor helps system integrators and vending-machine operators to meet the increasing demand for self-service solutions such as parking permit and ticket vending machines. All devices of the UX product series are certified in accordance with international security standards such as PCI. The various UX components can be combined to create flexible payment solutions for vending and self-service machines with large transaction volumes, while supporting all common payment methods. A first example of an application is the fitting-out of more than 200 latest-generation ticket vending machines for a leading public transport company in south Germany. These machines are being supplied by the renowned technology and service provider, Xerox.
The electronic components used in railway equipment are subjected to extreme external conditions. Rolling stock and signalling installations are designed to provide complete safety, many decades of reliable use and the maximum maintenance free operation. The WAGO-I/O-SYSTEM 750 XTR provides automation in those areas where other systems reach the limits of their capabilities: 750 XTR operates in both cold and hot conditions (-40 °C to +70 °C) and continues to work effectively even when subjected to extreme levels of vibration and shock. Compared with other solutions, 750 XTR requires no additional protective measures, and can cope with climatic and mechanical forces as well as with any possible overvoltages and EMC interference. The 12 mm wide bit modular bus terminals offer flexibility, with more space available on the supporting rails, reduced maintenance costs and increased productivity. With all these features 750 XTR is fully capable of meeting the technical requirements imposed by railways.
Complicated joints can often be avoided using bent metal profiles instead. In this way, optimum use can be made of even the tightest installation spaces. Moreover, welding and further processing costs can be avoided and handling effort can be minimised. This manufacturer produces special profiles and hollow profiles made of steel, stainless steel and nonferrous metals for a wide variety of sectors. The most distinctive characteristics of pre-bent parts made by Welser Profile are their extremely precise dimensions and their high-quality surfaces. At InnoTrans 2014, the company will be showing newly-developed and enhanced bent profiles for rolling-stock manufacturers. These products include side-panel profiles, door frames and roof frame bows, for example.