Contitech Railway Engineering XX © Gettyimages, 2014

ContiTech Railway Engineering XX © GettyImages, 2014

ContiTech Railway Engineering Expertise for the world’s railways

Air Spring Systems Whether it be on metros, trams, regional or high- speed trains, ContiTech Railway Engineering, as a development partner and OEM, can offer extensive expertise when it comes to innovative spring concepts for shock absorption and soundproofing.

Trains a global hit, and for good reason Innovative, safe and comfortable

Every day, millions and millions of To do this, we develop trendsetting All over the world, ContiTech people all over the world travel by rail. spring concepts for shock absorption Railway Engineering stands for From metros, to trams, to regional and and soundproofing in worldwide local – Recognised global market and high-speed trains. With increasing stan- and long-distance transport. Over the technological leadership dards in comfort and safety. Fully aware years, our primary and secondary spring – Creative innovation systems have made travelling by rail and of this responsibility, manufacturers – The highest standards in train an increasingly pleasant and quiet are building on the innovative spring functionality and safety concepts introduced by ContiTech experience. Not to mention faster, safer – A full product range for all areas Railway Engineering – the specialists in and more reliable. of application advanced spring technology. Each of our developments is put through – Customised, individual solutions For over 60 years, we at Air Spring its paces under authentic, real-life condi- – Qualified full service, from the Systems have been skilfully and tions in our certified testing laboratory initial request to series production passionately working on future-oriented – for maximum performance under – Highly accurate measurement solutions to improve public transport. extreme strain such as heat, cold or high and simulation processes Whether it be three stops by metro speed. – Guaranteed reliability and availa- to work, or to the other side of the bility of products and services country by high-speed train, we want As a full-service partner, we work closely – Global customer focus through every passenger to reach their destination with our partners to create customised, on-site presence in important as conveniently and reliably as possible. individual solutions – from material markets development, to product tests, sample – The world’s only independently production and series production, to certified test laboratory assembly and all necessary servicing and – Reliable spare parts business maintenance. . ContiTech Railway Engineering XX

Everything under one roof: Right from the start Full service on site

To make things as easy, comfortable SWING bogie example: For this train and safe as possible for our custom- module, we and our local partner Trans- ers, we provide full spring sets for Comfort supply the manufacturer PESA entire modules directly and “just with the full spring kit: primary springs, in time”, offering help and advice laminated elastomer springs, pivots, lem- right from the initial planning phase. niscate linkage, bumper stops, and rod Throughout the entire project, we en- connectors. sure on-site support, and guarantee customer goods are supplied close If requested, we also supply additional by. It doesn’t matter whether it’s for products such as shock absorbers and small series or large-scale projects – steel springs, thereby offering the most we don’t distinguish. effective form of full service.

When it comes to trams, PESA uses the full ContiTech spring kit for the SWING bogie. ContiTech Railway Engineering 05

Our services are of course governed by the recognised high ContiTech standards Our mission: in efficiency and quality. To ensure we can also produce small series in a cost- Top customer conscious manner, we look out for identical structures in comparable applications support requires wherever possible. full service And we have a responsibility to our customers, our own standards and, most importantly, the constant safety of the from the very passengers, to ensure every product is tested before delivery. first second

CAF CPTM Sao Paulo Spanish manufacturer CAF has also been relying on ContiTech’s consulting and product expertise for its CPTM trains in Brazil. Because with 2.7 million passengers a day, Sao Paulo’s suburban train network is one of the busiest in the world. © PESA Bydgoszcz S.A. ContiTech Railway Engineering XX

Whether it be tropical heat or polar cold, ContiTech can find the best solution for the biggest

of challenges. © Siemens, 2014 ContiTech Railway Engineering 07

Ice cold performance: Extreme climatic conditions Redefining standards

Vladivostok, -40°C: Rugged up warmly, many passengers wait on the platform Our conviction: for the next Intercity train, which ar- rives punctually at the station a few Trendsetting minutes later. Even in extreme climate zones, the transport infrastructure solutions are the must operate as reliably as it does everywhere else. result of strong Intense cold and drastic temperature fluc- tuations particularly pose huge technical partnerships challenges for air spring systems, as was AnsaldoBreda the case in the major project to upgrade Not just sought after in the cold the Russian rail network. The develop- vastness of Russia – AnsaldoBreda ment stages until 2030 include network has also fitted the new CDPTR Together with our partner, Siemens, we plans for routes from St Petersburg to the double-storey carriage with have found an innovative yet pragmatic Black Sea, and from the Caspian Sea to ContiTech solutions for regional solution for this, involving more than Vladivostok in Siberia. At speeds of up to services in sunny Tuscany. merely designing new air spring systems 350 km/h. for extreme conditions. In order to simulate the unusual requirements, we also developed a unique test bench with a cooling chamber reaching temperatures of –50°C.

As it turned out, our new development was a real milestone in terms of robust- ness. We leave nothing to chance. That’s the only way to successfully cope with even the more formidable of challenges. ContiTech Railway Engineering 08

Effective co-ordination: Project development in record time Optimum use of synergies

The task: Simultaneously develop sec- For example, we simultaneously pro- ondary spring systems for two com- vided our French customers, Alstom pletely new regional train systems. The and Bombardier, with specific new agenda: nine different product types, secondary spring developments for five of which are special, customised the two new Regio2N and Regiolis developments. The time frame: two regional rail systems. years from the first design draft to the live test. The planned total volume: A mini record: We had set a period of two 1,860 sets. The problem: None! years for development time before series production, but were able to deliver the Our advantage: We pool our expertise first products for live tests in the train Alstom LINT and capacities consistently, even beyond prototypes after just 18 months – includ- Not just sought after in France: the process chain. These synergies mean ing design phase, sample production, Alstom LINT trains also operate we are always able to meet even unusual extensive tests in our laboratory, and the as regional trains under the name requirements. successful approval process. of Coradia on Germany’s railways, fitted with ContiTech technology. This was made possible thanks to the smooth co-ordination by our engineers and production staff at six different loca- Our benchmark: tions, and the close collaboration with our Maximum customers directly on site. efficiency can only be achieved if all competencies are pooled intelligently ContiTech Railway Engineering XX

ContiTech technology passed all critical tests, even after a record-

Pushing performance boundaries: Compact speed limit Uncompromising lightweight construction © GHKANG, 2014

Inside, business people discuss the To guarantee maximum protection upcoming meeting over tea and snacks, against derailment, the secondary spring while outside, the landscape whizzes by system developed by us has a par- at almost half the speed of sound. 400 ticularly low vertical rigidity with small km/h at its peak and 350 km/h stan- amplitudes and high frequencies. The dard speeds pose extreme challenges specifications provided by our customer, for every single component on South Hyundai Rotem, stipulated a system Korea’s “High-speed Electric Multiple weighing less than 100 kilograms in total, Unit – 400 km/h Experiment”, or HEMU with a space-saving structure due to the 400x for short. compact bogie of the HEMU 400x. ContiTech Railway Engineering XX

Pushing performance boundaries: Compact speed limit Uncompromising lightweight

Faster, smaller, lighter, safer: construction ContiTech secondary springs keep setting benchmarks.

In just eighteen months from customer Our philosophy: request to implementation in the test train, we developed, tested and delivered Innovations are not a completely new secondary spring system meeting both the stress and the ends in themselves, weight/size requirements. By concentrat- ing on aluminium as the basic material, but must instead e.g. on the lower pin and on the base and top plate, we were able to significantly un- dercut the stipulated weight limit and cre- fulfil a specific use ate a product weighing just 89 kilograms, while strictly upholding all requirements Hitachi CTRL for our customers for high-speed reliability and safety. ContiTech high-speed technology for Europe’s train services: The Hitachi fast train operates on the CTRL (Channel Tunnel Rail Link) between London and the Channel Tunnel at speeds of up to 225 km/h. ContiTech Railway Engineering XX12

Hard work: A tour de force between wheel and carriage Primary spring systems

As a link between axis and bogie frame, and high-speed passenger transporta- MEGI® springs by Phoenix guarantee ContiTech primary spring products tion, so that passengers can relax while good stability. Our customers also benefit reliably perform the complex task travelling. This technology is also gaining from a long product lifetime and a high of wheel-set mounting and bogie importance in freight haulage, because quality level. When it come to life cycle suspension. it ensures smooth running and reduces costs, ContiTech products are among the noise pollution by absorbing sound. best in the industry. In a true tour de force and under extreme strain, they minimise the effects result- Depending on application and specific The most common types of construction ing from contact between wheel and requirements, we develop the optimum at the primary spring level are: rails during the journey, competently technical solution in close collaboration absorbing vibrations and reducing impact with the customer, achieving an ideal bal- sound for smooth driving operations. This ance between vertical and transverse ri- particularly applies to local, long-distance gidity and a number of other parameters.

Primary Suspension

Conical springs Axle/Chevron springs Wheel set guide bushings Guide springs enable variation in lateral and enable a vast variation in rigidity as the standard rail solution for help guide the wheel set. They vertical rigidity, guarantee couplings, and good stability. wheel sets and power transmis- absorb lateral forces in steel excellent stability, and involve This space-saving solution is very sion in axle rockers, enable diffe- spring systems. low life cycle costs. popular. rent rigidities (axial/radial) depending on customer requirements. They come in various sizes. ContiTech Railway Engineering XX13

All about comfort: A smooth ride thanks to precise design Air spring systems for secondary springs

ContiTech has been developing and Another advantage of our spring technol- When it comes to air bellows, a distinc- producing air spring bellows and sys- ogy: With a constant, adjustable height, tion is made between half bellows, rolling tems for rail vehicles for over 60 years. the railcar body can also maintain an bellows, belted bellows and double con- ideal distance from the platform, meaning volution bellows. MEGI® springs are used As an elastic link between the bogie passengers can board and disembark the as additional springs. The half-hourglass and railcar body, they distance the railcar vehicle safely and comfortably. spring is particularly important here. body from platform irregularities by minimising the transmission of vibrations. We create these special features at a When following a curve in the track, technical level by perfectly combining they also enable lateral deflection in an air spring bellow meeting these the bogie. No other technical solutions requirements with a precisely aligned achieves such driving comfort, regard- MEGI® spring, which works as an addi- less of loading. tional spring.

Secondary Suspension

Half bellows Rolling bellows Belted bellows Double convolution bellows are the ideal solution for are used in confined constructed enable increased load-bearing are the technically simplest solu- bolster-less bogies. Thanks to spaces in tram bogies and low- capacity compared to conven- tion for air-suspended secondary the possibility of vast lateral floor bogies. tional bellows when used in springs. They are distinguished deformation, they are also perfect bolstered bogies. by a high degree of reliability, for high-speed trains, as well as and can perform large stroke modern bogies in local and metro movements. transportation. ContiTech Railway Engineering XX14

Perfectly co-ordinated: suspension and insulation Rubber moulded parts

Rubber moulded parts in wheels Rubber moulded parts in couplings Depending on the manufacturer’s de- Elastomer springs are used in central sign, single or multi-component rubber buffer couplings. They enable a fixed link moulded parts are used for the wheel between trains to be designed in both a tyre suspension. ContiTech develops and horizontally elastic and vertically rotat- produces rubber elements distinguished able manner. In doing so, the Phoenix by precisely co-ordinated suspension and rubber moulded parts absorb the forces insulation properties. On the one hand, generated at the centre of the coupling. our elements absorb the non-spring- mounted mass, and on the other, they Wheel set springs reduce wear and tear both on the wheels and on the platform. The crucial advantage for our partners? Longer-lasting wheel sets.

Coupling springs

Wide product range: Many different solutions Connectors, buffers, rods

In addition to the aforementioned MEGI® primary springs, we also offer a number of other bogie products.

– Power transmission rods – Torque supports – Pivot pin connectors – Connectors/spherical bearings – Vertical and transverse buffers – Elastic bearings for vehicle couplings Rods Frame support bearings fitted with metallic rubber connec- are most commonly used in combi- tors are used in bogies for various nation with a coil spring. While the purposes. The design of these coil spring enables relatively large connectors depends exclusively vertical movements, the frame sup- on the relevant rod’s function. port bearing provides guiding in Conventional rods include lemnis- the x and y direction. The different cate links, torque supports, traction designs mean the rigidities in the X, links and pendulum support. Y and Z directions can be defined somewhat independently from one another. ContiTech Railway Engineering XX15

Maintaining contact: Bellows cylinders for pantographs Reliable sensor

When it comes to trains, travelling With our bellows cylinder, we have de- comfort is not just about comfortable veloped a future-oriented solution which seats; it’s also about pleasant tempera- guarantees optimum pantograph contact tures and sufficient lighting on evening pressure with the overhead wiring in all journeys. circumstances. The internal pressure of the only 20-centimetre-high bellows Whether it be for drive systems, control cylinder can be accurately and individu- systems, lighting or air conditioning, ally set to the requirements of the differ- modern rail vehicles operating locally and ent rail networks and systems, enabling long distance obtain their energy from perfect, consistent contact in all weather Triple convolution bellows electricity. Pantographs on the train roof conditions and at all speeds. made from fabric-reinforced elas- transmit the power into the vehicle inte- tomer materials ensure even pan- rior by maintaining permanent contact Our rubber material also boasts many tograph contract pressure in every with the overhead wiring. other advantages compared to conven- situation. A regulated compressed tional mechanical solutions: It is much air supply generates the necessary This contact should be consistent wher- lighter, longer lasting, lower maintenance, power inside the bellows cylinder, ever possible, even if the overhead wire UV-resistant, and with unrivalled weather- and is adjusted as required. height varies, e.g. through heat-related proofing. expansion, constriction in cold conditions, or as result of construction on bridges and in tunnels. ContiTech Railway Engineering XX

Original reliability: Service guaranteed Available worldwide

ContiTech has helped air springs break An exemplary catalogue of measures Guaranteed train availability through in global rail transportation. particularly ensures that our customers’ With our standardised solutions Millions of passengers and our custom- spare-part and maintenance require- and industrialised production pro- ers from all over the world place their ments can be planned for the long term. cesses, we can guarantee our cus- trust in our know-how and experience With competent consulting, early used tomers optimum train availability, in this field. It’s a level of reliability we parts tests, accurate laboratory measure- exclusively original replacement guarantee for a vehicle’s entire lifetime. ments and early assessment of needs, parts, and therefore minimised we ensure service and maintenance expense – even with re-engineering We only supply original spare parts work can be prepared systematically: requests. featuring identical properties as the first in a cost-optimised manner, more than product generation. Even for customer- twelve months in advance. specific solutions. Thanks to a global network of dealers, qualified technicians Another advantage: We can generally de- and experienced fitters all over the world, liver complete suspension kits for bogies, our products are available at short notice making the logistics processes easier for and can be reliably replaced. our customers, and guaranteeing the availability of all components. © ContiTech, 2014 ContiTech Railway Engineering 17

Certified quality: Competence in pushing limits Testing the future

Packed suburban trains taking people We conduct characteristic curve checks The multi-axial test bench can to work, train trips in record-breaking and destructive tests to precisely deter- precisely control how air spring Siberian temperatures, and business mine product properties. And, thanks systems behave under the harshest trips at half the speed of sound – when to sophisticated time-lapse tests under conditions. Which forces impact on extreme conditions push components extreme conditions, can make binding the system and how? How much to their limits, not a single detail develop- statements on product lifetime. deformation is there in the bellows? ment must ever be left to chance. Whether it be horizontal and verti- All results are directly incorporated into cal or along the longitudinal axis, all That’s why we have the world’s only test the product development. On the other stress scenarios are authentically laboratory for air spring systems in rail hand, we can also cater directly to our simulated. We similarly measure vehicles, which has been officially certi- customers’ requirements based on the temperatures generated by fied as independent. Twelve test process- extensive test data from an accredited frictional forces (picture), and es relevant to the rail industry have been laboratory. assess the tolerance for spring accredited under DIN EN ISO/IEC 17025. movements in the bogie. To ensure maximum safety for millions of In the test laboratory, we scientifically passengers. Now and in the future. simulate every conceivable situation well beyond what is actually required. We test things at their limits to redefine the boundaries of tomorrow – and thereby crucially help shape the future of rail transport through innovative solutions.

In addition to test benches for dynamic, static and even burst pressure tests, all stresses can be reconstructed and authentically tested using vehicle operation data. ContiTech Railway Engineering 18

ContiTech Railway Engineering Present worldwide

With our international production plants, partnerships and a worldwide sales network, we can guarantee rapid on-site presence – on virtually every continent. No service could be faster, more reliable or more customer-focused.

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● Production and portfolio companies ● ContiTech Service worldwide

Germany Russia ●1 Hannover ●12 Moscow 2 Hamburg ● Spain Belgium ●13 Cornellá 3 Antwerp ● Sweden China ●14 Motala 4 Shanghai ● Switzerland ●5 Changshu ●15 Dietikon France Turkey ●6 Gennevilliers ●16 Nilüfer-Bursa ●7 Le Chambon-Feugerolles UK India ●17 Rugby ●8 Sonipat Hungary Korea ●18 Nyíregyháza ●9 Cheonan USA Mexico ●19 Montvale ●10 San Luis Potosí ●20 Indianapolis Austria ●11 Wiener-Neudorf ContiTech Railway Engineering 19

< 300 The staff at ContiTech Railway Engineering develop and manu- facture high-tech products and systems at locations in China, Germany, Korea, France, India and Hungary. 19 locations in 16 countries

Awards 14 12 Shanghai, China: ContiTech Air 2 Spring System is one of the „50 17 6 3 1 15 11 18 most innovative companies at the 7 Rail & Metro China“ 20 19 13 16 Nyíregyháza, Hungary: Phoenix Air Spring Technology is named 4 9 10 5 „Industrial company of the year“ 8

Our locations are certified in accordance with: > IRIS (International Railway Industry Standard) > Q1 – Deutsche Bahn licence > Accreditation under ISO/IEC 17025 > All locations under ISO 9001 > Certification under ISO 14001 > Certification under ISO/TS 16949 Air Spring Systems ContiTech. Engineering Next Level

Market segment As a division of the Continental Group, ContiTech is a Railway Engineering recognised innovation and technology leader in natural rubber and plastics. As an industry partner with a firm Contact future ahead of us, we engineer solutions both with ContiTech Luftfedersysteme GmbH and for our customers around the world. Our bespoke Philipsbornstraße 1 solutions are specially tailored to meet the needs of the D-30165 Hannover market. With extensive expertise in materials and pro- Phone + 49 (0) 511 938-50042 cesses, we are able to develop cutting-edge technologies [email protected] while ensuring we make responsible use of resources. We Your local contact are quick to respond to important technological trends, www.contitech.de/contactlocator such as function integration, lightweight engineering and the reduction of complexity, and offer a range of relevant products and services. That way, when you need us, you’ll find we’re already there.

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