THE CUSTOMER MAGAZINE of KNORR-BREMSE RAIL VEHICLE SYSTEMS EDITION 38 | AUGUST 2014 INFORMER | Edition 38 | August 2014

Informer

THE CUSTOMER MAGAZINE OF KNORR-BREMSE RAIL VEHICLE SYSTEMS EDITION 38 | AUGUST 2014 INFORMER | Edition 38 | August 2014

Dr. Robert Wassmer CONTENTS Chairman of the Executive Board of Knorr-Bremse Systeme für Schienenfahrzeuge GmbH

EDITORIAL

There are only a few weeks to go before InnoTrans – the world’s biggest rail technology exhibition – opens in Berlin. As usual, the focus is on recent developments in the rail sector and in particular on the latest innovations. This year Knorr-Bremse is showcasing its products and services under the motto of "KNORR-BREMSE – CREATIVE SYSTEMS – GLOBALLY". As pioneers of leading-edge rail vehicle technology we are constantly driven by the desire to improve our products and services and maximize customer benefit.

The exhibits we are showcasing in Berlin offer impressive proof of this determination: our brake control system for Chinese high-speed trains plays a crucial role in bringing trains trav- eling at speeds of up to 380 km/h safely to a halt; the VV1000T oil-free compressor for the 2 North American market significantly reduces life cycle costs compared with conventional 3 oil-lubricated compressors; under the title of “Leading Innovations” we are presenting state- © Talgo of-the-art brake components that will shortly be launched on the market; and we are also showcasing a new door system from our subsidiary IFE that uses modern technology to achieve significant weight savings. Knorr-Bremse also recently became involved in the high- EDITORIAL CUSTOMERS + PARTNERS INFORMATION FOR performance on-board power supply segment, and we will be informing you about this at Dr. Robert Wassmer For low-temperature conditions 10 KNORR-BREMSE’S WORLDWIDE InnoTrans. Finally, our RailServices division has further extended its portfolio. All in all there Chairman of the Executive Board of Green power 12 CUSTOMERS AND BUSINESS will be a lot to see, and we look forward to your visit. Knorr-Bremse Systeme für Interview with M.Z. Medeubaev, PARTNERS Schienenfahrzeuge GmbH 03 President of “Locomotive” JSC: The various systems featured at InnoTrans all have one thing in common: they set new stan- Huge growth potential in IMPRINT: dards of efficiency, safety and life cycle costs. Publisher: Kazakhstan 14 Knorr-Bremse NEWS Whisper brakes 16 Systeme für Schienenfahrzeuge GmbH The main theme of this Informer is the Haramain High Speed Railway project in Saudi Arabia Latest news 04 Three questions for ... Marketing: Katharina Bachem – the first high-speed train line in the world to run entirely through desert conditions. It is Peter Möller, DB Schenker Rail 17 Moosacher Straße 80 hardly surprising that Knorr-Bremse was chosen to supply the trains’ braking, door and HVAC 80809 Munich Germany systems. The sand filters of our subsidiary Merak attached to the HVAC units use compressed COVER STORY Tel. +49 89 3547-0 air filter cleaning for the first time in a mobile application and promise to considerably re- Fax +49 89 3547-2767 Through the desert 06 INNOTRANS 2014 www.knorr-bremse.com duce maintenance requirements. Smart pressure cleaning 09 International platform for Realization: KB Media GmbH, Heidrun Moll rail vehicle technology 18 Layout, graphics: Cathrin Huber Innotrans opens its doors on September 23. We look forward to seeing you and having in- Text: Thorsten Rienth teresting discussions at Booth 104 in Hall 1.2. We would also encourage you to visit Micro- Printed by: Pera Druck GmbH elettrica in Hall 17, Booth 228 as well as our new subsidiaries from the high-performance PRODUCTS + SERVICES on-board power supply segment at Booths 212 and 214. Their new Knorr-Bremse brand will The future of entrance systems – be officially launched at InnoTrans on Tuesday September 23. Generation 4 – smaller, lighter, stronger 22 The new DNA of RailServices 24 You will find an admission voucher for the exhibition in this copy of the Informer. Innovation Leadership 27 Yours sincerely

E-NEWS-0038-EN This publication may be subject to alteration without prior notice. A printed copy of this document may not be the latest revision. Please contact your local Knorr-Bremse representative or check our website www.knorr-bremse.com for the latest update. The figurative mark “K” and the trademarks KNORR and KNORR-BREMSE are registered in the name of Knorr-Bremse AG. Copyright 2014 © Knorr-Bremse AG – all rights reserved, including industrial property rights applications. Knorr-Bremse AG retains all power of disposal, such as for copying and transferring. Dr. Robert Wassmer INFORMER | Edition 38 | August 2014 | News

INNOVATIVE SUPPLY NEWS CHAIN SOLUTIONS Every year, a jury made up of representatives of well-known spe- » cialist institutes and audit companies honors the best supply chain in the manufacturing sector. This year, Knorr-Bremse was amongst KNORR-BREMSE EXPANDS the four companies shortlisted for the award, with the Rail Vehicle PORTFOLIO Systems division’s end-to-end supply chain solution designed to improve the exchange of information with suppliers and customers. Modern rail vehicles offer passengers top levels of com- Roland Becker, Head of Logistics and Supply Chain Management at fort combined with modern on-board infotainment Knorr-Bremse Systeme für Schienenfahrzeuge GmbH, received a cer- systems. The electricity required to operate HVAC sys- tificate at the EXCHAiNGE specialist conference in Frankfurt on June tems, screens, passenger power points and catering 24. The SCM Award is presented annually to the best supply chain in equipment is supplied by high-performance on-board manufacturing industry by the Management Consulting division of power supply systems – and these are set to become PricewaterhouseCoopers in collaboration with the specialist journal even more important in the future. With its acquisition “LOGISTIK HEUTE”, the House of Logistics & Mobility (HOLM) and the of Transtechnik GmbH & Co. KG in Holzkirchen and Ber- Fraunhofer-Institut für Materialfluss und Logistik. lin-based PCS Power Converter Solutions GmbH, Knorr- Bremse, as a global systems specialist for rail vehicles, has added two leading power converter manufacturers to its portfolio. The new specialist field will be incorporated into the Group as a separate brand to join existing ones like IFE, Merak and Westinghouse. On Tuesday Septem- ▲ Dr. Petra Seebauer, Editor of LOGISTIK HEUTE, Cornelia Creischer, Managing Director Commercial Logistics, Colgate-Palmolive, Roland ber 23 in Hall 17, Booth 212+214, this new Knorr-Bremse Becker Head of Logistics and Supply Chain Management, Knorr-Bremse Rail Vehicle Systems Harald Geimer, PwC Management Consulting 4 brand will be officially presented at the InnoTrans Exhibi- (l. to r.). 5 tion. We look forward to welcoming you there. KNORR-BREMSE WINS CNA AWARD CHINESE AWARD ▲ Christoph Schwärzler, Director CSR Strategy, Bombardier Transportation, Dr. Robert Wassmer, Chairman of the Executive Board, Knorr-Bremse Sys- On July 10 Knorr-Bremse Rail Vehicle Systems received the “Intelligence for Transportation and Logistics” innovation award Knorr-Bremse enjoys a share of around 90 per cent of the teme für Schienenfahrzeuge, Stefan Bräuherr, Head of Corporate Responsi- from the Nuremberg-based Center for Transportation & Logistics Neuer Adler (CNA) for its newly developed Brake Pipe Length Chinese market for high-speed train braking systems. At bility, Knorr-Bremse AG and Charles O’Donnell, Chief Procurement Officer, Estimation (BPLE) system. BPLE provides the driver of a freight train with a fast and easy way to check brake availability along Bombardier Transportation (l. to r.). the end of June, the popularity of the company’s brak- the entire train, benefiting both the safety and efficiency of freight train operations. The system uses a sensor to measure the ing technology amongst Chinese manufacturers was volume of air being fed through the train’s braking system and then calculates the length of the entire main brake pipe on the underlined when it received a “Special Contribution BOMBARDIER basis of this. The driver can check this against the train length in his documentation and identify any critical discrepancies. In Award 2013” from manufacturers CNR Tangshan Rail Ve- contrast to the traditional method of checking the brakes, this process takes just a few minutes. The system promises to en- hicle Co. Ltd. The annual prize, which is partly sponsored SUSTAINABILITY AWARD hance the flexibility and reliability of rail by the regional government of Taizhou, honors suppliers Once a year, Bombardier Transportation honors suppliers who freight transportation. A pre-production and partners who have displayed particularly high levels have distinguished themselves in terms of the sustainability version is currently being tested on the of commitment during the previous year. of their products and supply processes and have also demon- large-scale test rig at Knorr-Bremse, and strated outstanding social responsibility. In 2014 the Supplier operation in a test locomotive has al- Sustainability Award in the category “Companies with more ready proved successful. The start of se- than 500 employees” went to Knorr-Bremse. “As manufacturers ries production of BPLE is scheduled for of safety-critical systems, we have long since integrated sus- the end of 2015. tainability and product responsibility into our corporate cul- ture – and they are crucial for our future viability,” commented Dr. Robert Wassmer, Chairman of the Executive Board of Knorr- Bremse Systeme für Schienenfahrzeuge GmbH, at the awards ceremony held in Berlin on June 30. According to Christoph

▲ Norbert Schäfer, Chair of the Executive Schwärzler, Director Corporate Social Responsibility Strategy at Board CNA e.V., State Secretary Franz Josef Bombardier Transportation, one of the reasons for making the Pschierer, Bavarian Ministry of Economics award was that “we are impressed by the way Knorr-Bremse and Media, Energy and Technology, Dr. Dieter meets its social obligations and how it systematically inte- Wilhelm, Executive Board Member, Knorr- Bremse AG responsible for the Rail Vehicle ▲ Xi Guohua, President, CNR, Zhang Junqing, Vice President, grates its responsibilities into day-to-day operations.” Systems division and Karl-Hermann TRC, Joseph Han, Managing Director, KB Suzhou and Klausecker, cluster spokesman Rail Technol- Tong Li, Chief Engineer, LCRI/ZH (l. to r.). ogy (l. to r.). INFORMER | Edition 38 | August 2014 | Cover Story

6 ACROSS THE DESERT 7

THE NEW HIGH-SPEED RAIL LINK CURRENTLY BEING BUILT BE- TWEEN THE HOLY CITIES of Mecca and Medina in Saudi Arabia is one of the world’s most challenging rail projects. Knorr-Bremse is demonstrating its engineering skills by supplying braking, door and HVAC systems for the trains.

The most recent pilgrimage to Mecca with the Kaaba – Islam’s from 2017 onwards pilgrims will be able to travel at high speed holiest site – attracted some two million people and the figure for 445 kilometers across the desert from Medina to Mecca and is set to increase, with forecasts predicting that the number of to Jeddah international airport. In the high season trains will pilgrims to Mecca and Medina could quadruple in the next ten depart at eight-minute intervals carrying a total of 160,000 pas- years. That would leave the west of the country facing a massive sengers per day. This is the first high-speed rail line ever to be volume of traffic and passengers. built almost completely through desert terrain, and the extreme In response to this, Saudi Arabia has attached top priority to the heat and the sand pose huge challenges in terms of the trains’ new “Haramain High Speed Railway” project. The idea is that systems and the track construction.

ALL SYSTEMS DESIGNED GLOBAL KNORR-BREMSE communication ensures efficient exchange SMART HIGH-PRESSURE filtered in order to efficiently keep out even tem, where it is available in large quantities. FOR TOUGH, SANDY PROJECT MANAGEMENT of information and experience, thereby CLEANING the smallest of particles – but the filters have “The challenge was to adapt the process to CONDITIONS ENSURES EFFECTIVE enabling existing know-how to be put to The sand filter systems installed in the trains to be regularly cleaned. The more dirt they the design of the HVAC systems and to find Spanish rail vehicle builder Talgo is to supply IMPLEMENTATION the best use and synergies to be even bet- for the Haramain High Speed Railway proj- collect, the more often this has to happen. a solution for the extremely limited installa- the operator – Saudi Railways Organization The braking system developed by Knorr- ter exploited throughout the project cycle. ect are self-cleaning, thanks to Knorr-Bremse For cleaning the filters Knorr-Bremse makes tion space available,” explains Felipe Perez, (SRO) – with 36 high-speed trains based on Bremse España includes an ESRA-based EP Interdisciplinary teams for field service and making clever use of an existing resource – use of a process that is already found in in- who heads the team at Knorr-Bremse Es- the Talgo 350. 35 of these will consist of two Compact brake control system including commissioning are just two examples of compressed air. dustrial plants in desert areas – using com- paña responsible for developing the system. power cars and 13 passenger cars, while a wheel slide protection, SL 20 screw-type this concept. In Saudi Arabia, where temperatures can pressed air. In the case of the Haramain High special VIP version will have just ten passen- compressors, steel brake discs and Isobar exceed 40° Celsius in the shade, high-perfor- Speed Railway project, the development ger cars. The trains will travel at 300 km/h on brake pads. Spanish subsidiary Merak is mance HVAC systems are essential for trains. engineers have adapted this technique for track designed for speeds up to 320 km/h. responsible for supplying the HVAC sys- KEEPING SAND OFF However, the problem of preventing sand a mobile application involving passenger Knorr-Bremse Group companies are supply- tems – highly compact units including self- THE RAILS penetration significantly shortens the sys- coaches for the first time, drawing the com- ing the braking, door and HVAC systems. cleaning sand filters that are installed both The desert sand also means that a new tems’ maintenance cycles. Fresh air has to be pressed air from the pneumatic braking sys-

8 9

Knorr-Bremse España in Getafe, near Madrid. Compared with the high-speed trains de- on the roof and inside the cars. Knorr- approach has to be taken to track design. signed for operating at extremely low tem- Bremse’s Austrian subsidiary IFE is develop- Sandstorms increase erosion of the track peratures in Russia, the Mecca-Medina proj- ing and manufacturing the Type DET-h1 and technical infrastructure, the smallest ect is at the other end of the scale. “The high pressure-tight sliding plug doors, which particles of sand in the ballast bed can af- temperatures and desert conditions make have been developed and extensively fect its stability, and drifting dunes can even this a unique challenge,” explains project tested to ensure their reliability under the completely bury stretches of track. manager Matthias Busch, Knorr-Bremse Es- extreme climatic conditions found in the The companies constructing the line have paña. The systems are designed for tough, region. The internal doors between the cars developed various strategies for dealing sandy desert conditions and include specif- are designed and supplied by IFE Tebel. with these challenges. On the particularly ic developments such as Merak’s integrated But it is not just the technical specifica- sandy stretch between Mecca and Jeddah self-cleaning sand filtration system – anoth- tions that represent a challenge – inter- the line runs along an embankment that is er example of how Knorr-Bremse uses its disciplinary collaboration is required to up to 20 meters in height and constitutes a technical development and systems com- realize the project. “As well as Knorr-Bremse massive sand barrier. And over a stretch of petence to produce customized solutions. supplying a range of systems, various more than 80 kilometers the engineers are “Of course it goes without saying that in different Group sites all over the world are planning to build a concrete wall at least such circumstances every last detail has to involved,” explains project manager Busch. one-and-a-half meters high alongside the be meticulously checked and re-checked,” For this purpose a project-specific, global track. Unusual circumstances call for un- says Busch. project management team has been con- usual solutions – and desert sand poses a stituted, comprising the project managers challenge to construction engineers and of the individual systems. The coordinators operators alike. are the interfaces to the customer and to all internal participating companies. Regular INFORMER | Edition 38 | August 2014 | Customers + Partners

sand or driving snow from penetrating the interior. At the same time they offer rapid and easy access for maintenance purposes. More than 7,000 brake modules for installation in trains belonging to the CRH380B and CRH5 families have either already been delivered or are on the order books. The modules have identical connection interfaces and only differ in terms of the plug-in boards used, plus a few pneumatic elements. For example there are differenc- es according to whether they are to be installed in a driven or a non-driven car. They can also be tailored to customers’ requirements.

CLEAR INTERFACES FACILI- TATE INTEGRATION INTO ASSEMBLY LINES The braking modules are delivered ready for installation, which makes for clarity re- garding responsibilities – to the benefit of 10 vehicle builders and Knorr-Bremse alike. 11 The box design and clear interfaces facili- tate integration into the manufacturers’ assembly lines. Developments like this low-temperature version of the brake module account to no small extent for Knorr-Bremse’s success in the Chinese high-speed market. The company’s market share in this sector currently China is extending its high-speed network into the coldest regions of the country. lies at around 90 per cent, and last year alone, it received orders for braking systems and bogie equipment for more than 400 high-speed trains. DESIGNED FOR FREEZING CONDITIONS But there is a further important reason for ▼ Access to the brake module for maintenance the Group’s success in China: to ensure purposes is rapid and uncomplicated. smooth running of the entire vehicle fleet, THE KNORR-BREMSE GROUP’S SUCCESS IN CHINA IS DUE TO dition, modern wheel-slide protection sys- 400 field service and local service center tems avoid damage such as wheel flats. colleagues are on constant 24/7 stand-by; A CONSIDERABLE EXTENT TO ITS BRAKE MODULES for high-speed The modules and their components also and a similar number of engineers ensures trains. The company has now extended the geographical reach of this technology by developing a have to be specially protected against the that products are adapted to local require- low-temperature capability down to –40°C. harsh operating environment – for exam- ments. ple sandstorms on the Urumqi to Lanzhou route – as well as low temperatures.

“We are talking specifically about the railroads in regions with the lowest winter of ultra-modern design and proven tech- routes from Harbin to Dalian and Urumqi to temperatures in the entire country. “Various nologies that meet the extremely high RAPID, EASY MAINTENANCE Lanzhou,” explains Armin Gasch, responsi- modifications have to be made to the vehi- safety standards and operational require- ACCESS DESPITE ENHANCED ble for sales of braking systems for Chinese cles if operators are to be able run a reliable ments of the heavily-used Chinese high- PROTECTION high-speed trains at Knorr-Bremse Rail Ve- train service all year round.” speed services. The modules contain the Speed-dependent brake force control en- The brake modules not only use cold- hicle Systems. With its plans to extend the One such modification involves en- electronic control system for the brakes sures compliance with specified braking resistant materials – they also have rein- high-speed network from 10,000 to around hancing the low-temperature capabilities and also ensure compatibility with exist- distances while at the same time reducing forced housings that meet protection class 30,000 kilometers, China is now building of the brake modules. These are a mixture ing, traditional pneumatic brake control. wear and minimizing life cycle costs. In ad- IP54 requirements and prevent water, fine INFORMER | Edition 38 | August 2014 | Customers + Partners

more viscous oil becomes. Conventional oil- LD1000 AIR DRYER IN GREEN POWER lubricated compressors usually have to be SERIES DEVELOPMENT heated prior to start-up, but the VV1000-T Along with the VV1000 T, the correspond- does not require this – it can be started from ing LD1000 air dryer is also currently be- THE OIL-FREE VV1000-T DEVELOPED BY KNORR-BREMSE IS THE cold at temperatures down to –50° Celsius. ing developed to series maturity. NYAB FIRST HIGH-PERFORMANCE COMPRESSOR for heavy-duty freight trains to operate and Knorr-Bremse can thus offer an opti- mized air supply system to accompany the without any oil lubrication. Volume production of this specially developed compressor was launched at New York COMPRESSOR PORTFOLIO VV1000 T that will set new standards on the Air Brake (NYAB) in May 2014. The first OE application began in July. EXTENDED AAR markets. The orders received from North American Reliability, efficiency and ease of mainte- operators have enabled Knorr-Bremse Rail nance were at the focus in the technical Vehicle Systems to enter a new market seg- design of the LD1000. This air dryer offers COMPARABLE OIL- per year consumed by conventional ones. THE VV1000-T REQUIRES ment: it is the first time the company has integrated three-stage pre-filtration, for ex- LUBRICATED COMPRESSORS Every oil-free VV1000-T compressor has an LESS FREQUENT developed a high-performance oil-free ample, and attains an overhaul interval of CONSUME AROUND 60 ongoing positive impact on the environ- MAINTENANCE compressor for heavy-haul freight loco- ten years. The start of series delivery is for ▲ Completed VV1000-T compressors ready for LITERS OF OIL PER YEAR ment, as there is no longer any need to dis- “Oil also has the disadvantage that it gums motives. The excellent performance of the planned for 2016. shipment. The oil-free VV1000-T is currently being in- pose of the used oil and oil-contaminated up compressors during the course of their VV1000-T in field trials and aftermarket installed in new heavy-duty freight locomo- filters. “Another advantage is the fact that operation,” explains Wright. As this does not stallations has prompted the railroads to tives for two North American Railroads, and there is no longer any risk of oil getting happen with the VV1000-T, maintenance specifically request the VV1000-T compres- represents a breakthrough in other respects into the pneumatic braking system or the intervals are longer. “Realistically, most con- sor be fitted on new locomotives. After as well. “The VV1000-T sets new standards, air dryer,” explains Wright. “That has a very ventional compressors have to be over- more than four years of field testing, it went particularly in terms of reliability, life cycle positive long-term impact on the life and hauled every four or five years. In the case into volume production at the NYAB facility costs and environmental compatibility,” says performance of the overall system.” of the VV1000-T we recommend intervals of in Watertown, New York early this year. 12 Eric Wright, Chief Engineer at NYAB. eight years.” 13 The savings promised by the new compres- There is another important aspect: the low- sor go beyond the cost of the 60 liters of oil er the ambient temperature, the thicker and

▲ The assembly line for the VV1000-T compressor at NYAB in Watertown, NY. ▲ Assembly of a bearing cartridge. ▲ Inspection of a bearing. INFORMER | Edition 38 | August 2014 | Customers + Partners

Series VL-80 locomotives require mainte- mm track. Specialist engineers at Kazakh Informer: The first KZ8A locomotives are nance every 48 hours. Railways looked at offers from manufac- already in operation. What has been your turers of locomotive braking technology experience so far? Informer: Why did you opt for the KZ8A? worldwide and decided in favor of your M. Z. Medeubaev: The first 12 KZ8A electric M. Z. Medeubaev: In line with the tech- company. Knorr-Bremse braking systems locomotives began the field-testing phase nical requirements of Kazakh Railways, are also being used for Alstom’s new KZ4AT at the end of 2013, and a further three have tenders were invited from virtually all the passenger train electric locomotive and for been available to “Locomotive” JSC since best-known electric locomotive builders the General Electric TEP33A diesel locomo- the first quarter of 2014. So far they have all HUGE GROWTH worldwide – for example Bombardier, Sie- tive. For the ZK8A braking system Kazakh- proved extremely reliable in operation. As mens, Alstom, Tzhutzhousker Elektrolokher- stan Railway Company is looking for guar- this is a new series, staff has to be trained, POTENTIAL stellwerk and Transmashholding. Complex anteed safety and high quality standards. new standards established for train weights, factors such as localization, development a maintenance plan drawn up and technical ▲ M. Z. Medeubaev, President of “Locomotive” JSC. IN KAZAKHSTAN costs, and the cost of imported locomotives Informer: To what extent was Knorr- modifications undertaken on the basis of versus local ones were also taken into ac- Bremse’s experience with applications for the field test results. The positive reaction of count. The French company Alstom came low-temperature operations crucial? train personnel confirms that our decision THE INFORMER EDITORIAL TEAM SPOKE TO M. Z. MEDEUBAEV, up with the most convincing bid, so the de- M. Z. Medeubaev: I think it is still too early to go for the KZ8A was the right one. cision went in favor of the KZ8A. to draw any conclusions. So far the electric President of “Locomotive” JSC, about the rail market in Kazakhstan. One of the biggest owners of traction locomotive has only operated for one win- vehicles in Kazakhstan, “Locomotive” JSC is a subsidiary of the state company JSC Nationalnaya kompaniya Informer: Knorr-Bremse was commis- ter at low temperatures – and this year the Kazakhstan temir zholy (JSC “NK “KTZH”). The company’s aim is to ensure reliable, safe and effective operation sioned to develop the KZ8A’s braking sys- winter was relatively warm. But I am con- of locomotives for both passenger and freight transportation. Its customers include JSC “NC “KTZ”(84%), tem. What requirements do you have in vinced that the Knorr-Bremse specialists passenger carriers (15.5%) and private operators (0.5%). this respect? have developed a good braking system for M. Z. Medeubaev: We want the KZ8A to be the KZ8A that will cope with any challenges a competitive electric locomotive for 1,520 it may face. ▼ Knorr-Bremse has been commissioned to 14 develop the braking system for the KZ8A 15 electric locomotive.

Informer: Kazakhstan occupies a geo- ables the high-speed train to compete with graphical position between China and air or car travel. Russia. What importance does this have In recent years Kazakhstan Railway Compa- for the future development of the rail mar- ny has carried out a number of major proj- ket in Kazakhstan? ects on behalf of the state. One example is M. Z. Medeubaev: Kazakhstan’s rail market the construction of modern assembly facili- has huge growth potential because as a ties for diesel and electric locomotives and transit country between China, Russia and production plants for passenger and freight other Central Asian countries it benefits cars. I am convinced that the vehicles be- from the need for rail transportation link- ing manufactured for 1,520-gauge track are ing all the key regional markets. New routes competitive and have considerable export have already been built, such as the one potential. from Zhetigen to Usen, near the border with Turkmenistan, and the one to Horgos Informer: Kazakhstan Railway Company – the second rail link between Kazakhstan has ordered large numbers of the new and China. KZ8A series. What is their aim? In addition, the manufacture of goods des- M. Z. Medeubaev: Yes that is correct. “Lo- tined for the domestic market as well as comotive” JSC has signed an agreement © Alstom for export is supported by various govern- with the Kazakh electric locomotive assem- ▲ ment investment programs. An expanding bly plant EKZ Ltd. for the purchase of 200 The new KZ8A Series locomotive. economy impacts freight volumes, as can eight-axle Series KZ8A two-section locomo- be seen from the opening of the Zheskas- tives with an output of 8,800 kW. Delivery is gan–Beineu and Arkalyk–Shubarkul rail links scheduled for 2020. high-performance electric locomotives en- connecting central Kazakhstan with the Such a large procurement volume is a result able the weight of trains operating on elec- southwest of the country. firstly of the high degree of wear and tear trified routes to be increased, which in turn A further significant factor is the expansion of the Series VL-80 electric locomotives that increases transportation efficiency. One of the high-speed network by the state- form an important part of the “Locomotive” important argument in favor of the KZ8A is owned Kazakhstan Railway Company. This JSC fleet; and secondly it is simply a result its advantageous maintenance intervals of has increased passenger volumes and en- of the advanced age of the fleet. The new 20,000 km or 37 days. By comparison the © Alstom INFORMER | Edition 38 | August 2014 | Customers + Partners

THREE QUESTIONS FOR …

Peter Möller of DB Schenker Rail – the man responsible for coordinating purchase orders and materials availability for the project to fit the operator’s current fleet with low-noise LL brake blocks.

© Deutsche Bahn AG DB Schenker Rail aims to convert its entire fleet to LL brake blocks by 2020. Is this project running to schedule? Approval of the LL brake block in the summer of 2013 was an important milestone on the road towards quieter trains. DB Schenker Rail decided at an early stage to retrofit its fleet, and the process itself was launched at the start of this year with a view to converting 5,000 freight cars in 2014 and a similar number in 2015. In other words, by the end of next year – if you include new vehicles – a total of 20,000 will have been equipped with quieter brake blocks. And by 2020 we will have fitted “whisper” brake blocks to our entire fleet of some 60,000 freight cars. ▲ LL brake blocks have a significantly longer operating life than ▲ Manufacture of IB116* LL brake blocks at Icer Rail in Pamplona, Spain. ▲ Freight trains are becoming quieter. cast-iron ones. Knorr-Bremse is supplying the LL blocks directly to DB Schenker Rail's various workshops. How is this collaboration going? In July 2013 the LL brake blocks were approved for Europe, and contracts were 16 WHISPER BRAKES signed with the two suppliers in early 2014. From the very outset everyone worked 17 of all freight train operations take place us- together to meet all the challenges – major and minor – for example the creation of ing composite brake blocks. In other words, the necessary manufacturing capacity. Processes bedded in during the first half of NOW THAT LOW-NOISE ORGANIC LL BRAKE BLOCKS HAVE BEEN if noise levels are really to be reduced by 10 2014, and – in close consultation with DB Schenker Rail HQ – Knorr-Bremse was able dB(A), it will be necessary to refit virtually to cover the quantities of LL blocks required by DB Schenker Rail. The entire process APPROVED FOR USE THROUGHOUT EUROPE, operators are starting to retrofit the entire freight car fleet. of ordering and delivering now runs itself, but there is still a regular exchange of them to their fleets. Knorr-Bremse has been quick to identify this trend and is well positioned to meet demand. information between the two partners.

DB NETZ INTRODUCES Amongst European operators DB Schenker Rail makes the most extensive use of The German government has set itself an SMOOTHING THE WAY on creating the required production capac- NOISE-RELATED LL brake blocks. What has your experience been with them? ambitious target of reducing noise emis- Freight cars (which often operate at night) ity to meet operator demand. INFRASTRUCTURE CHARGE More than 2,700 DB Schenker Rail freight cars were fitted with LL blocks during the sions from railroad operations by fifty per are still frequently brought to a halt by noisy Most of the major operators have either al- first six months of 2014. The initial feedback from the field, above all in relation to the cent by the end of 2020 (reference year: cast iron brake blocks. Because LL brake ready started to refit their fleets or are plan- reduced level of operational noise, has been entirely positive. Our experts expect 2000). Much of the focus is on reducing blocks avoid this roughening effect, a pass- AUDIBLE IMPROVEMENT ning to do so in the near future, but small that we will have gathered sufficient operational data for a detailed assessment of track-related noise, but another impor- ing train equipped with such composite ONLY AFTER COMPLETE and medium-sized logistics companies the LL brake blocks within about a year’s tant aspect is the refitting of the country’s blocks on an average stretch of track gener- RETROFITTING have been slower to react. This means they time. freight car fleet with low-noise organic LL ates some 10 decibels (dB(A)) less noise – DB Schenker Rail is Europe’s biggest freight run the risk of suffering delays when they brake blocks. equivalent to a 50% reduction in subjective car operator, with a fleet of some 60,000 do decide to fit the brake blocks, as individ- The crucial issue here is the noise generated noise. Added to this, organic brake blocks – vehicles, all of which are being refitted with ual operators have already placed so many from contact between wheels and rails. If which can easily be retrofitted without any LL brake blocks. The company is sourcing firm orders that much of current production the surfaces of the wheel and rail are rough, need for adjustment of the brakes – make around half of these from Knorr-Bremse, capacity is already taken. vibrations are generated that the human for smoother braking and are also consid- and so far some 50,000 have been delivered. Economic incentives are also being provid- ear perceives as noise. The problem with erably lighter than conventional cast iron Every month 8,500 are shipped directly to ed for the use of LL brake blocks. German cast iron blocks is that they tend to roughen ones. around 20 workshops that are working track operator DB Netz, for example, intro- the wheel – which in turn roughens the rail. Quick to recognize the new trend towards on retrofitting them to DB Schenker Rail’s duced noise-differentiated that German reducing noise and improving braking freight cars. track operator DB Netz introduced noise- performance, Knorr-Bremse has combined But a significant reduction in noise from differentiated track access charging last its systems expertise with Spanish friction day-to-day freight operations will only be year. Fleet operators now have to pay more materials specialist Icer Brakes in a new joint achieved with a comprehensive retrofit pro- for noisy freight vehicles, and those who venture – Icer Rail. Now that the product gram. Experts estimate that there will only have already fitted LL brake blocks receive

has been approved for Europe, the focus is be an audible improvement if at least 80% a discount. Peter Möller, DB Schenker Rail ▲ INFORMER | Edition 38 | August 2014 | InnoTrans 2014

INTERNATIONAL PLATFORM FOR RAIL TECHNOLOGY

INNOTRANS (INTERNATIONAL TRADE FAIR FOR TRANS- 18 19 PORT TECHNOLOGY) – THE INTERNATIONAL PLATFORM for buyers and sellers of passenger and freight transport technology – takes place this year from September 23-26 in Berlin.

Leading manufacturers of vehicles and sys- DEMAND HITS A NEW HIGH MORE INNOVATIVE tems, suppliers, rail companies and industry Demand for exhibition space has increased APPROACH TO SHOW- and professional associations will feature in all segments – capacity in the outdoor CASING KNORR-BREMSE’S prominently in the upcoming event in Sep- and track areas was fully booked almost a INNOVATIONS tember. Over 2,700 exhibitors from the pas- year in advance. One new architectural de- Knorr-Bremse, a long-standing exhibitor senger and freight transportation sectors in velopment is the multi-functional CityCube at InnoTrans, can once again be found in more than 50 different countries will show- Berlin exhibition hall, which opened in May Hall 1.2, Booth 104. The motto this year is: case components, systems, and a wide of this year. This state-of-the-art building "KNORR-BREMSE – CREATIVE SYSTEMS – range of vehicles and rail technologies. offers InnoTrans two additional levels of ex- GLOBALLY" and the thematic design of the This year, the main focus of interest for visi- hibition space and brings the total number booth will reflect this core message. tors and the media will once again be on of exhibition halls to 40, rather than 38. The Product presentations will take place and new products and systems as well as further result is a greater range of products on dis- innovations will be showcased in the front developments of existing ones. Many inter- play, offering an even more comprehensive part of the ground floor in a stylized mock- national companies now synchronize their overview of the market. up of a train. Proven solutions in local mar- innovation cycles with the timing of Inno- This year also marks the premiere of the kets will be presented alongside innovative trans and regard the trade fair as an oppor- Future Mobility Park, where futuristic, cre- products, and visitors will be able to access tunity to premiere their latest products. This ative and visionary transport concepts will product information using interactive flat means that many exhibits will be on display be presented. And in the outdoor and track screens. It will also be possible to examine to the specialist public for the first time. This area there will be an additional display the products in greater detail and discuss year, a particular focus of innovation will be focusing for the first time on vehicles de- individual needs and possible solutions on sustainability and energy efficiency. signed for broad and narrow gauge tracks. with Knorr-Bremse experts. INFORMER | Edition 38 | August 2014 | Products + Services

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"KNORR-BREMSE – CREATIVE SYSTEMS – GLOBALLY"

THIS IS THE MOTTO UNDER WHICH KNORR-BREMSE WILL BE SHOWCASING AN EXTENSIVE PORTFOLIO OF INNOVATIVE SYSTEM SOLUTIONS FOR THE GLOBAL RAIL VEHICLE MARKET IN HALL 1.2, BOOTH 104 AT THE INNOTRANS EXHIBITION. In a few weeks’ time, the eyes of the rail vehicle sector will be on Berlin: on September 23, InnoTrans 2014 opens its doors to the public. As a pioneer in braking, door and HVAC technologies, Knorr-Bremse will be presenting sophisticated answers to present and future market challenges. A central focus will be on sustainable products with low life cycle costs that generate significant value-added for operators around the globe. INFORMER | Edition 38 | August 2014 | Products + Services

MAXIMUM FLEXIBILITY THE FUTURE OF ENTRANCE SYSTEMS The new FLEX-DCU door control has a smart energy supply system for connected com- – GENERATION 4 – SMALLER, LIGHTER, ponents that reduces total power dissipa- STRONGER tion by almost a quarter by adjusting their operating modes (“ECO power principle”). The Flex-DCU is designed for a variable battery supply voltage of 24–110 V with a IFE – INNOVATIONS FOR ENTRANCE SYSTEMS – IS THE WORLD’S generous tolerance range and generates an LEADING SUPPLIER OF COMPLETE DOOR SYSTEMS for streetcars, metros, internal, stabilized operating voltage of 24 V, regional multiple units, mainline and high-speed trains. At the InnoTrans exhibition in Berlin the company is thus ensuring additional robustness against external influences. For operators the num- presenting state-of-the-art entrance systems that set new standards in every respect. ber of different electrical spare parts has been reduced, cutting delivery times and reducing inventory requirements. This new control enables conventionally commutated or brushless motors to be operated. A large range of monitoring func- tions at the inputs and outputs enables improved and adaptive diagnostics and condition-based maintenance.

22 SAFETY A PRIORITY 23 As product quality and system safety are priorities for IFE, the entire entrance system is equipped with various safety systems that already meet SIL2 standards. Additional systems such as electronic van- dalism protection against mechanical over- load and locking support for manual clo- sure operate even when the control unit is not connected. ▲ Drive system production line. Satisfied customers and operators – that is IFE’s goal. In response to customers’ re- quests and requirements, especially for regional operations, the entrance system has Any kind of delay can affect the economi- components in this new, slimmed-down any need for adjustment of basic settings rable products available in the market have also been validated for operation under ex- cal operation of rail vehicles – which is why system have been designed and tested to during initial installation and later servicing 3 to 4 times the amount of sound transmis- treme loads. manufacturers and operators require tech- maximize their operating life and set new or maintenance – saving time and avoiding sion and 50% higher heat loss. And yet the nically sophisticated systems that meet the standards in terms of installation, service possible sources of faults as a result of false overall weight of the system has also been latest standards and enable passengers to and maintenance. adjustment. reduced. board and alight as efficiently as possible. The 4th generation IFE entrance system has At InnoTrans a space-saving two-leaf ver- The punctuality, efficiency and reliabil- ▲ Door leaf production. More than 500,000 entrance systems in dai- an innovative drive and sliding step, rede- sion specially developed for regional trains ity of trains are determined by one crucial ly use are impressive proof that IFE meets signed door leaves with improved noise and will be presented. operation – the boarding and alighting of – and in many cases exceeds – market re- heat insulation and a new Flex-DCU control passengers. When the sliding step was be- quirements in terms of technology, safety, system. In combination this makes for an use of proven industrial components and ing redesigned, particular emphasis was durability and cost-efficiency. outstanding access system that is smaller adjustment-free design, with components SAFE AND COMFORTABLE therefore put on creating a reliable system and lighter, but also stronger – and above requiring minimal maintenance. Compared Growing demand for maximum passenger capable of operating under all environmen- all easier to maintain. The IFE E4 door drive with its predecessor model, the number of comfort means that noise and heat insula- tal conditions. The new but proven drive A SIMPLE CONCEPT WITH is equipped with a deformation–tolerant components has been reduced by more tion are becoming increasingly important concept prevents any risk of the sliding step MAXIMUM EFFECTIVENESS linear guide with a lighter, more compact than 40 per cent, and the weight cut by 20 for door design. Thanks to the use of new jamming. Integration of weight detection At InnoTrans IFE is presenting a new, com- design that adjusts to any movement of the per cent. This well-engineered system offers insulation materials and an improved pro- instead of the pressure mat reduces the pact entrance system design based on ma- vehicle during operation. Other advantages free opening widths of between 1,300 and file, the newly designed door leaf offers op- weight and installation height. ture, tried-and-tested technologies. All the are an improved locking mechanism, the 2,000 mm. The drive is designed to avoid timum noise and heat insulation. Compa- INFORMER | Edition 38 | August 2014 | Products + Services

speed trains. Performance, quality and local THE NEW DNA OF RAILSERVICES presence are the key elements in what is a unique service offer focused on reliable delivery, customer inventory optimization, IN RECENT YEARS, GLOBALIZATION AND LIBERALIZATION HAVE improved remanufacturing quality and re- TRIGGERED far-reaching changes in the rail industry and created entirely new challenges. The industry duced operating costs for the customer. All faces increased competition, pressure on prices and growing passenger demand for a modern, comfortable rail this is based on modern logistics concepts and consistent management of the entire experience. This has also had an impact on servicing, with its complex elements such as maintenance, overhaul delivery chain. A further important aim of and repair. Rail operators face crucial strategic decisions such as: to what extent should they outsource servicing the strategy is to make global competence to third-party providers? Should they purchase new vehicles or upgrade existing ones? Operators in Europe face available at local level – both in cultural these questions in particular, as their fleets grow progressively older. and system-specific terms. This requires key

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Technical progress is forcing operators an extensive range of services in this field. degree of flexibility and maximum custom- skills related to across-the-board service and vehicle builders towards even greater Rail vehicle systems from Knorr-Bremse are er benefit. A vision has been jointly devel- products within the organization being specialization for their own service staff advanced in technological terms, and a total oped to serve as a basis and guideline for redefined and made accessible. Following and they are having to invest increasing of 24 service centers all over the globe en- the new service strategy and provide the an analysis of market needs, the range of amounts in modern testing technologies. sure the comprehensive availability of mod- driving force behind the new organization. products has been extended. In the field of Servicing safety-critical sub-systems such ern servicing by highly trained specialists Customers increasingly expect high lev- logistics, services such as “kitting” or “box- as braking systems calls for a high degree of using state-of-the-art OEM-grade assembly els of availability and performance from ing”, reliable spare parts inventory, just-in- specialization and experience – something equipment and test rigs. rail systems, and this has been taken into time delivery and proactive obsolescence that Knorr-Bremse, as a brake manufacturer, These activities have been marketed by account in developing RailServices’ strat- management have been established.

is very much aware of. Knorr-Bremse under the RailServices brand egy and drawing up a program focused In addition, local maintenance support and Unfold new possibilities During the lifetime of a vehicle – which can for many years. Following a comprehensive on maintaining product value throughout training of local technicians is also available be up to 40 years – a wide variety of repair, review in 2012 they have now been adapt- the entire life cycle. The aim is to offer tai- to individual customers. Discussions have maintenance and upgrade work is required ed to meet the new challenges, and as a lor-made service packages to meet every also been held with various customers in to keep it in operation. In recent years Knorr- result RailServices can today provide a new, requirement – for freight cars, streetcars, a bid to achieve a better understanding of Bremse has positioned itself as a provider of extended range of services offering a high metros, urban light rail systems and high- their needs and wishes and to review fur- INFORMER | Edition 38 | August 2014 | Products + Services

INNOVATION LEADERSHIP

FOR KNORR-BREMSE, “INNOVATION LEADERSHIP” IS MUCH MORE THAN JUST A TRADE FAIR MOTTO. For the company’s employees. it is the basic principle and the self-concept under which Knorr-Bremse markets its products and systems.

This self-concept is based on the company’s offers excellent performance even under values: entrepreneurship, technological ex- conditions of extremely low traction with cellence, reliability, passion and responsibi- slippery rails, and was specified for the in- lity. dividual UIC, AAR and GOST markets. Knorr- “Innovation Leadership” is oriented toward Bremse also uses the vehicle speed data the needs of the customers and the trends acquired by its sensors for regulating its of the markets; it focuses above all on opti- new sanding system. Under low traction, it mization of economy, on reliability and on meters the delivery of sand in accordance the safety of rail vehicles. with vehicle speed and with even greater Essentially, the brakes of rail vehicles take precision between wheel and track; this en- ▲ effect at the point of contact between sures optimal traction with no disturbance ESRA Evolution control unit. wheel and rail. It is this small contact point to signal systems, and sand consumption is SERVICE PARTNER OF that determines whether the entire system reduced by up to 50 per cent. 26 is mediocre or excellent. ESRA Evolution – a further development bility of interfaces to TCMS. Products and 27 CHOICE Knorr-Bremse has been at home in these of the proven ESRA electronic control sys- subsystems can thus also be matched in a RailServices’ mission is to become “Service Partner of Choice” – which means an em- systems for more than 100 years and sees tem – offers maximum integration capa- simplified, more efficient application, and phasis on partnership and a determination to focus on customers’ individual needs. itself as the trendsetter in braking techno- servicing access is also facilitated. ther adjustments to the product portfolio. This new approach has also required an internal cultural change, and for this purpose logy. As the world market leader for brake Knorr-Bremse has set itself the task of provi- This is currently an ongoing and evolving employees with service in their DNA are being systematically promoted and trained. systems for rail vehicles, Knorr-Bremse of- ding new, certified systems solutions in pe- process. For Knorr-Bremse RailServices, providing service in future means the company’s ex- fers a full-line product range for highly in- riodic waves of innovation in order to offer At the same time the focus is on selecting perts will always be ready when rapid reaction times are called for; it means the ser- tegrated, intelligent systems for the com- genuine added value for vehicle manufac- the right employees – those who display a vice solutions and systems training provided will be tailored to individual customer prehensive control and regulation of the turers and operators. This is aptly reflected passion for their work and are always de- needs, and only original parts offering original performance will be used – with their dynamic braking forces acting on a train. in the trade fair motto "KNORR-BREMSE – termined to find the right solution for the availability ensured for decades. Brake control units for rail vehicles, such CREATIVE SYSTEMS – GLOBALLY". customer. Whether braking, HVAC, or door iCOM – a new service tool for intelligent condition monitoring of train components – as CCB, MB, EP2002 and EP Compact, are systems – or other Knorr-Bremse products is shortly due for release. If you want to find out more, come and visit us at InnoTrans. mechatronic systems solutions that con- – are concerned, customers now have a We look forward to seeing you there! stitute the backbone of safety engineering named contact person who will coordinate for tens of thousands of trains throughout everything at Knorr-Bremse. the world. Knorr-Bremse constantly works Modernization calls for a knowledge of on optimizing and improving the neuralgic systems that will improve a vehicle’s per- points of this backbone: formance or economy of operation: for The new RailServices initiative has success- The new MGS3 wheel slide protection sys- ▲ High performance anti-skid valve with example a new braking system can reduce fully prepared the ground for the future of tem with an extended regulation range integrated pressure sensor. the braking distance of a freight train and Knorr-Bremse’s service offer. Certain inter- make more frequent train scheduling pos- nal and external obstacles still need to be sible; or lighter equipment can enable the overcome in some areas, but the detailed volume of freight carried to be increased. analysis carried out has provided everyone Driver assistance systems or modern sand- concerned with a thorough understanding equipment are also available to make ing of the future direction for RailServices. the operation of rail vehicles easier, safer The first steps to implement the strategy in and more efficient. As well as supplying practice have already been taken, and will various components or systems the service be followed by further measures. All those on offer also includes their installation and involved in RailServices agree on this and maintenance as well as support for the nec- are willing to pursue the process to its con- essary approval processes. clusion. INNOTRANSVISIT US 2014AT 23 - 26 SEPTEMBER HALL 1.2 BOOTH 104 excellence ...

…IN TECHNOLOGY AND QUALITY. Delivering the highest levels of safety and availability for operators. This is the goal of Knorr-Bremse. | www.knorr-bremse.com |