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Cooperation: ZF in the ’advanced TrainLab‘

April 2020

The ZF sensors are located on the bogie of the test train.
Photo: ZF Friedrichshafen AG

ZF Friedrichshafen AG is cooperating with Deutsche Bahn AG in testing new technologies in the rail sector in the ‘advanced TrainLab’ – a test vehicle of Deutsche Bahn AG based on an ICE-TD train, which is currently being used for testing purposes on the tracks of the Federal Republic of Germany.

Connect@rail is an advanced system for condition monitoring, which allows comprehensive status recognition of components of the test train. Furthermore, connect@rail enables the rail infrastructure to be checked for potential dangerous points. In this way, safety and efficiency in rail traffic can be increased. In Germany alone, 18.4 million people commute to work every day – that is 59.4 percent of all employees. And the trend is rising. The car is still the first choice for employees. But traffic jams, the lack of parking space and increasing emissions require a rethink. If rail transport is to play a greater role in the mobility mix of the society, trains must be able to withstand peaks in capacity utilisation and higher frequencies, and operate more efficiently. It is also important to avoid downtimes. Deutsche Bahn is therefore researching the use of new, innovative technologies with the ‘advanced TrainLab’ – a rolling test laboratory based on a class 605 (ICETD) multiple unit train – in order to achieve these goals. ZF cooperates with DB AG and has installed its connect@rail system in the diesel-electric train set. For use in the ‘advanced TrainLab’, ZF is installing wireless acceleration sensors on the unsprung parts of the train’s bogie, which can also record the temperature behaviour, the vibrations and oscillations as well as the inclination of the train. The wheel-rail contact can also be monitored. In this way, connect@rail enables not only the monitoring of the vehicle, but also of the track condition.

Everything at a glance

The measurement and route data are transmitted to the ZF IoT Cloud and can be read out via computer or mobile device for evaluation and visualisation. The operator thus receives real-time analyses that help him to recognise the condition of the vehicle and the infrastructure and to plan maintenance cycles based on their condition. This ensures a smooth and cost-optimised operation of the entire fleet. Passengers benefit from more efficient rail transport and increased vehicle availability. The DB AG test train offers a unique opportunity to test the advanced condition monitoring system under real conditions, commented Dr. Klaus Geißdörfer, head of ZF’s Industrial Technology Division, on the cooperation. Under the motto Mobility-Life-Balance, ZF is working towards the goal of clean and safe mobility across all business units.

ZF Friedrichshafen Hall 20 | 580

Deutsche Bahn Hall B CityCube | 410