Rail Vehicle Systems
Edition 29 | April 2011
The customer magazine of Knorr-Bremse Rail Vehicle Systems
Cover story Knorr-Bremse in the Near and Middle East Innovation E3D and the "Intelligent" sliding step Product Innovative sand filtration system Quality Process model harmonized Edition 29 | April 2011
CONTENTS
Editorial Dr. Ralf Voß, 3 Member of the Executive Board, Knorr-Bremse Systeme für Schienenfahrzeuge GmbH
CSR Demonstrating responsibility 4
Innovation E3D and the "Intelligent" sliding step 7
News in brief Current affairs 8
Cover story Planning for tomorrow and beyond 10 Interview with Peter Karius 12 Desert metros 14
Product Innovative sand filtration system 16
Quality Process model harmonized 17
Project Brake and door systems 6 for Swiss Railways Safety certificate for EP Compact platform 18 Moscow Metro: Opening and closing 19 every 48 seconds
Location Expansion in Suzhou 20
Exhibition UITP 2011 in Dubai: Global solutions 22
E-NEWS-0029-EN Imprint: Information for the worldwide customers and business partners of Knorr-Bremse This publication may be subject to alteration without prior notice. A printed copy of this Publisher: Central Editorial Office: Conception, text and design by: document may not be the latest revision. Please Knorr-Bremse Systeme für Knorr-Bremse Systeme für Knorr-Bremse Systeme für contact your local Knorr-Bremse representative or check our website www.knorr-bremse.com Schienenfahrzeuge GmbH Schienenfahrzeuge GmbH Schienenfahrzeuge GmbH for the latest update. The figurative mark "K" April 2011 Marketing and the trademarks KNORR and KNORR-BREMSE Tanja Mohme Text: Torsten Rienth are registered in the name of Knorr-Bremse AG. Copyright 2011 © Knorr-Bremse AG. All Moosacher Strasse 80 rights reserved, including industrial property 80809 Munich Design: KB Media GmbH rights applications. Knorr-Bremse AG retains Germany any power of disposal, such as for copying and Tel. +49-89-3547-0 Layout, graphics: Cathrin Huber transferring. Fax.+49-89-3547-2767 www.knorr-bremse.com Printed by: Weber-Offset GmbH
2 2010 was a successful year for Knorr-Bremse, with further growth in the Rail Vehicle Systems division driven by a significant sales increase in Asia. This was not just triggered by the current economic upturn – it was also the fruit of our long-term corporate strategy of maintaining a local presence on a global basis. We offer customers throughout the world a combination of systems competence, innovative products and comprehensive aftermarket service .
We have deliberately chosen the Middle East as our focus, as many of the countries in the region have experienced unprecedented growth in rail transportation over the last ten years – whether in the form of high-speed trains in Turkey or metros on the Arabian Peninsula. While investment in public transport systems is currently subject to critical review in many parts of the world, in the Middle East Dr. Ralf Voß, planning is well underway and in many cases construction has already started. Another reason for the Member of the Executive Board, focus of this Informer is that Dubai is hosting the 59th World Congress of the International Association Knorr-Bremse Systeme für Schienenfahrzeuge of Public Transport (UITP) from April 10 to 14, and Knorr-Bremse will be represented at this event with GmbH an exhibition stand.
Many innovative Knorr-Bremse products are already well established in the region –for example the Westinghouse platform screen doors installed in Mecca Metro, which ensure platform safety on a metro system capable of transporting 72,000 passengers per hour in each direction. You can read more about this project on pages 14 and 15, and on page 16 you will find a description of the new HVAC system with sand filter that was specially developed by Knorr-Bremse‘s Spanish subsidiary, Merak for the climatic conditions in Saudi Arabia.
This edition of the Informer includes further interesting articles: we report on Knorr-Bremse's membership of the UN Global Compact and the responsibilities this brings; we describe the expansion of the Knorr-Bremse site in Suzhou, China; and we introduce the new E3D door system and intelligent sliding step from IFE. Other articles focus on safety certification of a modular electro-pneumatic braking system, important successes in North America, the TWINDEXX Swiss Express project and Moscow Metro, for which Knorr-Bremse is supplying several different systems. Further innovations will be presented at the UITP in Dubai.
We would be delighted if you could join us there at Stand C200 in Hall 8.
We look forward to seeing you!
Kind regards
Dr. Ralf Voß
3 Edition 29 | April 2011
Corporate Social Responsibility Demonstrating responsibility
Knorr-Bremse has signed up to the UN Global Compact, committing itself to supporting ten globally recognized basic principles in the fields of environment, labor standards, human rights and anti-corruption. The new Knorr-Bremse Group CSR strategy places corporate responsibility and sustainability at the very heart of corporate strategy.
environment, labor, human rights and anti-corruption and to mainstream these in its corporate activities. More than 6,000 companies all over the world are members of the UN Global Compact, and the German Global Compact Network includes more than 140 companies as well as public and civil society organizations such as the Federal Ministry for Labor and Social Affairs and Amnesty International.
The timing of Knorr-Bremse's membership of the Global Julia Thiele-Schürhoff, Head of the Central Corporate Social Compact was carefully chosen. Following the drawing up of Responsibility (CSR) Department the company's CSR strategy (see box), social responsibility is now an integral element in its overall corporate strategy. "We want to use our CSR strategy to strengthen business Five years after Knorr-Bremse Global Care was first set up development and corporate culture and ensure that our with the aim of helping people in need to help themselves, activities contribute towards sustainable development of the decision to join the UN Global Compact marks a further the economy and society," explains Julia Thiele-Schürhoff, important milestone in the company's realization of its Head of the Central Corporate Social Responsibility (CSR) corporate responsibilities. The Global Compact was set up in Department. Building on the strategy, an ambitious CSR 2000 by Kofi Annan, then UN Secretary-General, and program is to involve a number of further specific activities. participating companies commit to actively contributing Following the successful introduction of the first stage of towards making globalization a more equitable process in the ECCO2 climate strategy for improving energy efficiency, social, environmental and economic terms. other measures are to include a pilot project for carrying out CO2 audits at Knorr-Bremse sites, a review and analysis of By signing up to the Global Compact, Knorr-Bremse has suppliers' environmental and social standards, and integration undertaken to support the ten principles in the fields of of CSR aspects into Knorr Excellence processes.
4 For some time now, several major customers have expected Compact as an important, globally recognized benchmark. Knorr-Bremse to provide information about its compliance Together with the company's corporate values and the UITP with and management of environmental and social standards (International Association of Public Transport) Charter for or to sign up to an appropriate supplier's code. In so doing Sustainable Development, the ten principles enshrined in they make explicit reference to the ten principles of the Global the Global Compact provide a basis for all Knorr-Bremse's Compact. Knorr-Bremse, too, is currently developing a standard activities in the field. code of behavior for its own suppliers and is using the Global
The principles and fields of action for the CSR strategy
The CSR strategy contains five guidelines that lay down the company's main objectives. Activities are aimed at developing the business and strengthening corporate culture, protecting against risks, using global and local activities to contribute towards sustainable development and creating a positive public image for Knorr-Bremse. Sustainability is of particular importance for Knorr-Bremse as a family business, and this implies not only long-term business planning but also measures to secure a future based on economic, environmental and social balance – which should benefit customers as well.
KNORR-BREMSE INTENDS TO FOCUS ITS ACTIVITIES ON SIX AREAS:
Strategy and management Products and partners Environment and climate CSR Strategy: Employees and management a strategic approach to Commitment and society corporate responsibility Communication and cooperation The company's newly formulated CSR strategy systematically details how the company perceives its responsibilities in Every year, the CSR program will lay down specific objectives relation to the environment, the workforce and society as and measures for these areas. With its activities in the field a whole, and what its main areas of focus are going to be of "products and partners" Knorr-Bremse helps customers in the future. Starting with Knorr-Bremse's commitment to save energy and conserve resources and works with its busi- assume day-to-day responsibility for ensuring that people ness partners to implement higher environmental and social and goods reach their destination safely, the statement standards. For 2011, for example, the program includes a "Responsibility brings safety" sums up the aim of the CSR process of dialogue and benchmarking with key customers, strategy: Knorr-Bremse is determined to live up to the trust greater promotion of energy-efficient products and a pilot that is placed in the company on a daily basis and to operate as project for auditing CO2 emissions at the company's plants. a responsible and reliable partner in times of social change.
5 Edition 29 | April 2011
Project TWINDEXX Swiss Express Brake and door systems for Swiss Railways
Knorr-Bremse is to supply braking and door systems for 59 TWINDEXX trains ordered by Swiss Railways. In addition to vehicle body components – including the EP compact brake control system – the package includes complete bogie equipment, air supply modules with oil-free compressors and new E3D door systems.
it had given of a fully functioning prototype of the new door design at last year's InnoTrans trade fair. It also put huge effort into preparing the tender, producing all the technical documentation and several of the commercial documents to a degree of detail that is rare at that stage of the process.
Swiss Railways insisted on the doors being Source: Bombardier Source: Bombardier designed to be as wide as possible in order to ensure a smooth flow of passengers. And with passenger comfort in mind they The order covers nine 4-section and fifty 8-section trains, also required the door seals to withstand the over-pressure with delivery of the first components scheduled for the end caused by traveling at high speeds and through tunnels. The of 2011, and the completed vehicles due for delivery development engineers came up with a special design of between 2013 and 2019. The first trains will go into service extra-wide, single-leaf, pressure-reinforced door. from December 2013 onwards. An option for more than 100 further trains has been agreed between Bombardier and The TWINDEXX double-decker multiple units operated by Swiss Railways and Knorr-Bremse is in the running to supply Swiss Express are some of the most modern rail vehicles the braking systems for these too. currently available. They include a large on-board restaurant and a spacious family car, as well as a business compartment If all the options are included, this constitutes the biggest offering space for business people to hold meetings or work single order ever received by Knorr-Bremse's subsidiary IFE. undisturbed. All seats are equipped with electrical sockets The fact that the company won the order for 1,664 passenger and Wi-Fi Internet connection. doorsets, 40 loading doors and 40 catering doors was due to a number of factors, one of which was the impressive display
6 New technologies from IFE E3D and the "Intelligent" sliding step
Presented for the first time at the 2010 InnoTrans trade fair in Berlin, the new E3D train access system from IFE is designed to offer higher standards of safety, reliability and comfort.
Passengers enjoy high levels of comfort thanks to a generous For a door to withstand high pressures, the seal has to run opening width and an efficient pressure seal when closed. without interruption around the entire door leaf – which is why access systems for high-speed trains exclusively use E3D is an electrically operated single-leaf pressure- single-leaf doors. reinforced door system designed for high-speed trains traveling at up to 300 km/h. It is essentially a combination E3D also has a highly sensitive obstacle detection system of the well-known E3 and DET systems with additional with two electrical safety switch strips in the main doorframe. features such as a compact installation envelope, a high degree of pre-assembly and easy maintenance. The doors and steps have been designed for the Swiss Railways TWINDEXX project. The E3D prototype showcased at InnoTrans 2010 featured a clear opening width of 1,400 mm and excellent pressure resistance, as well as high levels of reliability, with a passive sealing system that avoids the problem of inflatable seals.
INTELLIGENT SLIDING STEP
In addition to the new door system showcased at InnoTrans The mechanical properties 2010, IFE also presented a sliding step developed for of the E3D system double-decker trains. combined with the DET sealing system enable the Using a special mechanism the step adapts to the gap between door to withstand external train floor and platform. It is equipped with an ultrasound pressures of 6,000 pascals. sensor that measures the distance from the platform and The simple, robust closing calculates how far it needs to extend, stopping the step mechanism contributes to automatically between 3 and 4 centimeters from the platform the door's reliability. edge. This precise adaptation to the gap and height difference between step and platform offers greater safety for children and elderly people.
The sliding step is also equipped with a contact strip that prevents passengers from becoming caught in the step. The system is currently undergoing testing by Swiss Railways.
7 Edition 29 | April 2011
News in brief and current affairs
Series assembly of door systems
Door manufacturer IFE has further expanded its door assembly services. In addition to first assembly, it now also offers specific assembly aids and diagnostic instruments – or it can even carry out full series assembly for the customer. In 2009 the company signed a framework agreement with AnsaldoBreda covering assembly and assembly support for all the door systems it supplies. And in 2010, as part of the negotiations on equipping the FLEXITY 2 platform, IFE also concluded an initial agreement on door system assembly with Bombardier.
End-of-year figures for 2010 Vehicle manufacturers are increasingly relying on specialized systems suppliers to take over the task of door assembly. Using expert technicians In fiscal 2010 the Knorr-Bremse Group increased sales revenues by from the original equipment manufacturer is the only way to ensure almost EUR 1 billion, or 34%, to EUR 3.7 billion. The increase includes correct installation. When IFE assembles the door systems itself the positive currency translation effects in the amount of approximately EUR company is able to offer a guarantee that includes pre-defined standards 170 million. Assuming constant exchange rates, year-on-year operational of reliability. Such high standards can only be achieved through skilled growth stood at 28%. assembly by an expert.
Sales at the Rail Vehicle Systems division moved ahead from EUR 1.5 billion in the previous year to EUR 2.0 billion in 2010. The increase was primarily driven by a marked rise in sales of over 100% in Asia, where Knorr-Bremse has been progressively expanding its market presence since the late 1980s.
Major service contract for Merak
Early this year, Knorr-Bremse subsidiary Merak North America signed its biggest ever service/repair HVAC contract with Metro North Rail Road.
The contract covers the overhaul of 850 HVAC units for the suburban operator's M7 series vehicles. Delivery of the units began in June 2009 and is scheduled to end in March 2014. For the five-year service/repair contract the scope of work includes incoming and outgoing functional tests, individual component inspection, cleaning, replacement of identified components, and refrigerant replacement. Once Merak has finished the last of the five year service/repair tasks on the 850 HVAC units, the first units delivered in 2009 will be due for their ten year overhaul program.
Thanks to Merak North America's performance and levels of customer satisfaction on this Metro North Rail Road service/repair contract, the company has received several inquiries from other transit authorities about carrying out their service/overhaul programs.
8 Patience and perseverance pays off
A new chapter has begun in the successful partnership between Knorr-Bremse and the Northeast Illinois Regional Commuter Railroad Corporation (METRA) with an order for 160 car sets of braking equipment.
It was back on July 11, 2003 that Knorr-Bremse, through its subsidiary Knorr Brake Corporation, was awarded a contract to supply 26 car sets of brake equipment for the Northeast Illinois Regional Commuter Railroad Corporation Electric Multiple Units program.
On December 23, 2010 Knorr Brake Corporation received an order for a further 160 car sets of brake equipment for METRA's new Electric Multiple Units procurement program. As with the original order, the scope of supply includes a VV120T oil-free air supply unit, emergency pipe control unit, truck control unit, ESRA electrical current unit, PEC7 Tread Brake Units (Block Brakes) and Master Controller. Delivery of the prototype cars is scheduled for August 2011, with series production Source: Wikipedia © amtrak_russ starting in November 2011 and ending in May 2015.
Significant contract from Washington D.C.
In 1998, Knorr-Bremse was awarded a contract to supply 110 car sets of braking system equipment for the Washington Metropolitan Area Transit Authority (WMATA) 5K series. In December 2010, the company received another major order from WMATA.
Just two years after the 1998 order, WMATA placed an option order for an additional 82 car sets of braking equipment. And in 2002 and 2004, equipment for further cars was ordered from Knorr-Bremse's subsidiary Knorr Brake Corporation. The orders also included HVAC systems from Merak and door systems from IFE. In March 2010, WMATA awarded Knorr Brake Corporation a contract for replacing 182 of the existing compressors with VV120-T oil-free air supply units.
The most recent success for Knorr-Bremse was in December 2010, when Knorr Brake Corporation and Merak North America were awarded a contract to supply the WMATA 7K series with 364 car sets of braking systems and HVAC equipment. Option orders exist for an additional WZK calipers. The Merak HVAC system will consist of two stainless steel 384 car sets. Delivery of pilot cars is scheduled in 2012, with series unitized roof-mounted assemblies. production starting in 2013 and ending in 2017. The award of the 7K series brake and HVAC systems contract was a The braking system is consistent with Knorr-Bremse's normal scope of direct result of Knorr-Bremse proven systems reliability, availability supply, which includes the VV120-T oil-free air supply unit, emergency and company's approach to customer service. pipe control unit, truck control unit, ESRA electronic control unit, and
9 Edition 29 | April 2011
Knorr-Bremse in the Near and Middle East Planning for tomorrow and beyond
10 Planning for tomorrow and beyond
Over the past ten years the Near and Middle East has been a global pacemaker in the development of rail transportation systems. From Istanbul to Mecca, new streetcar and metro systems, freight and high-speed lines are being planned and built in an effort to meet growing demand for transportation of passengers and goods. The focus is also on developing an attractive infrastructure for the post-oil era.
11 Edition 29 | April 2011
"People in the Middle East think in generations rather than years."
The Informer editors spoke to Peter Karius, Executive Manager International Sales at Knorr-Bremse Systeme für Schienenfahrzeuge GmbH.
The countries of the Near and Middle These are all very different countries – It seems as though all the growth is East are no longer just famous for their but they all agree about the need for concentrated on the Arabian Peninsula. skyscrapers and artificial islands. Why railroads? What about Turkey? Is it planning is it that these regions are investing so Peter Karius: Yes – that's true. But anything similar? much in rail transportation? their approaches differ. Smaller states Peter Karius: Turkey tends to be very Peter Karius: There are various factors like Qatar, Kuwait or cities like Dubai much underestimated with regards to involved. In Istanbul, it is driven by are planning to use a wide range of dif- rail. It has a population of 70 million – rapid population growth. In cities like ferent transportation systems. Saudi more than all the countries of the Ara- Abu Dhabi, it is the result of careful Arabia is working on a north-south bian Peninsula put together! Not only urban planning. In Mecca, the focus freight connection to transport phosphate, the major conurbations but also towns is more on pilgrim tourism. Of course which is mined in the north of the country. with less than a million inhabitants have the Soccer World Cup in Qatar will also The locomotives have already been started to develop their own streetcar bring a tremendous boost to the rail ordered – and Knorr-Bremse is supplying networks. And then there is the high- sector. Sometimes it's also a question the brake control systems. And then speed network that will link a number of prestige – but that's the same the there is Mecca. The Saudi Arabians of major cities in the east of the country world over. have to find ways of coping with the with Ankara, the capital, and Istanbul. extraordinary challenges of pilgrim Some of that line is already in operation. Why has the status of rail transportation tourism. So they're not only completing It's a huge project. In recent years in risen in recent years? Mecca Metro but also giving priority to Istanbul alone, vehicles have been Peter Karius: It can largely be explained the creation of a high-speed line linking ordered for four metro lines – more in historical terms. Certain railroad Mecca, Jeddah and Medina. than in Dubai. lines – for example between Istanbul and Baghdad – already exist, but it is That's a lot of building in one go. When it comes to planning, to what no secret that they have been getting Peter Karius: There are also two further extent does the decline of fossil fuels rather long in the tooth. Between 1970 major visions for the region. The first is play a role? and 2000 relatively little happened in a long-distance network connecting all Peter Karius: It plays a very prominent terms of buying new vehicles the countries of the Gulf. A link role. Of course many of these countries reconditioning, repairing or replacing between the individual states of the are trying to open up new sources of existing ones and extending lines. Now United Arab Emirates is already being income. The building of a railroad line people are catching up – and that planned and the first calls for tender to the phosphate deposits I mentioned includes metros, trams and freight have gone out. The idea is to extend in the north of Saudi Arabia is an example. networks as well as high-speed lines. the line from Kuwait along the Arabian And Dubai is hoping to exploit its Peninsula to Yemen at a later stage. position as a trade and exhibition center But these are long-term plans. The and an aviation hub – which, of course, other vision involves a line connecting requires a modern local public transport Saudi Arabia directly with Europe. system.
12 "People in the Middle East think in generations rather than years."
Peter Karius graduated with a degree in industrial engineering from Munich University of Applied Sciences in 1991. Since then he has held various positions in Sales and Systems at Knorr-Bremse. He has been Executive Manager International Sales with responsibility, amongst other things, for the countries of the Near and Middle East since early 2007.
What strikes one about most of these plans is that they are very much long-term. Peter Karius: Yes – the United Arab Emirates in particular are Knorr-Bremse offers solutions for all thinking in the long-term. They have developed visions for their system types. cities and are planning the infrastructure to go with them from the outset. In many ways that is a better approach than expanding transportation systems on a piecemeal basis after the event. Abu Dhabi, for example, has a "Masterplan 2030" that involves massive expansion of the city and its rail systems. In both the Near and Mid- dle East people think in generations rather than years.
Where there are opportunities there are also risks. What are the risks in this case? Peter Karius: Growth in this region cannot be taken for granted, that much is clear. We've already seen, during the economic crisis, how projects can disappear from the list. But generally speaking I think the outlook for the region is very good. On the other hand, political stability plays an important role. And, as always, it is difficult to look thirty years into the future. We've seen in Egypt, Tunisia and elsewhere how unexpected change can suddenly take place. But one trend can be predicted: more and more orders are going to come in from Asia – which is by no means bad news for us. We have a very strong foothold in the key markets in China, Japan and South Korea and various different technical standards are no obstacle – Knorr-Bremse offers solutions for all system types.
13 Edition 29 | April 2011
Brake and door systems in the Orient Desert Metros
Dubai was the first city in the Arabian Peninsula to start building a metro system, followed shortly afterwards by Mecca. Trains in both cities are equipped with state-of-the-art products from the Knorr-Bremse Group.
September 9, 2009 was a special date, they are safely and comfortably during company was responsible for even for a city like Dubai that is used the rush hour. Other cities are developing the entire braking to superlatives. It was then that the also coming to realize the advantages equipment for the vehicles, with crucial first metro system in the Middle East – of a properly equipped metro system components being specially designed at 75 km the longest fully-automated – Abu Dhabi is currently prioritizing to operate in the extreme local climate. railroad system in the world – was the planning of its own metro system. To prepare their products for desert officially opened. On the day of the conditions, Knorr-Bremse and its opening ceremony the eyes of the Spanish subsidiary Frenos even entire world were focused on this Safety in the simulated sandstorms to test the prestigious technological project on desert sands EP2002 brake control system and the Arabian Peninsula. The story is similar in Mecca, where oil-free compressor. The response the first of five planned metro lines from the operators in Mecca has been The 2,000,000-odd inhabitants of the opened in time for last year's Hajj extremely positive. city have been quick to take advantage – the pilgrimage that brings some of the new metro line – trains are three million Muslims to the holy city well filled and the positive impact every year. The crowds are so great Biggest single on the city's often congested streets that there is often a dangerous crush order in the com- can clearly be felt. Before the end of in the city's various thoroughfares. pany's history the year a second line is due to open, Mecca's investment in a metro system All the stations in Mecca are also with the trains also being equipped proved invaluable during the first Hajj equipped with door systems from by Knorr-Bremse. as it considerably reduced the hours Knorr-Bremse subsidiary Westing- pilgrims had to spend traveling house Platform Screen Doors. The first Another factor in the metro's success between the various religious sites. deliveries were made in time for the was the platform doors supplied by Hajj in November 2010 and represented Westinghouse Platform Screen Doors As in Dubai, the operators of Mecca a record for the company: never before (WPSD), which enable passengers to Metro have relied on the technical had so many platform screen doors embark and disembark rapidly, competence of Knorr-Bremse. The been installed in such a short time.
14 Pictured on opposite page, bottom left: Westinghouse platform edge doors in Makkah enhance safety levels
Pictured on opposite page, bottom right: One of the futuristic elevated stations on Dubai Metro
Pictured top left: The platform architecture treatments of Makkah Metro pays homage to Saudi traditions
Pictured bottom left: Dubai Metro platforms are color and treatment Within 18 months of receiving the order, 1,140 doors were ready themed; air, earth, fire, or water. This is an example of an "air" themed for operation at Arafat, Muzdalifah, Mina and Jamaraat stations. platform In a mere four months the company had installed door systems equivalent to a platform length of 5.6 km. Pictured bottom right: Part of an elevated stretch of Dubai Metro pictured against some of the city's incredible skyscrapers With completion of the first section, about 50% of the final capacity of Mecca Metro is now available. Once the second section opens, the system will be capable of transporting some 72,000 passengers per hour in each direction. Work on this section began immediately after the last Hajj, and by the time it is completed, Westinghouse Platform Screen Doors will have installed a total of 1,865 doors in Mecca.
15 Edition 29 | April 2011
Heating, ventilation and air conditioning Innovative sand filtration system
Knorr-Bremse subsidiary Merak designs and manufactures HVAC systems for all extreme
climatic conditions, including desert terrain where temperatures can reach above 55ºC. In
these extremely dry conditions, airborne sand and other particles are a serious issue and
it was necessary to adapt HVAC systems in order to ensure air quality and high efficiency.
Air quality has always been a priority for Merak. UV-C lamps Cyclonic filters: Air is directed through cyclonic filters to and CO2 level detectors have already been installed in several separate sand and only let clean air pass into the unit. A HVAC systems with more than successful results. These turbo ventilator then removes the sand from the solutions underline Merak's concern and interest in this cyclonic separator. This "auto sand emptying" is a way issue. of reducing maintenance costs. Filter bags: The air then passes through specifically Now, as part of its air-quality improvement initiatives, Mer- sized filter bags, where the remaining particles are ak has developed a sand filtration system for incorporation totally removed. into HVAC systems that separates sand and other particles from fresh air. This innovative system represents a further The result is that only clean air, free of sand, runs through advance in high-end HVAC technology. the HVAC unit, hugely improving air quality inside the train.
This innovative sand filtration system is a result of continuous THE SAND FILTRATION SYSTEM IS research and development work by Merak. Despite its success, BASED ON THE FOLLOWING STAGES: Merak will continue investing efforts in order to remain a Fresh-air grilles: Prevent large particles or water from pioneer in the field, offering the best adapted solutions for entering the system. Depending on the wind direction its customers' needs. and direction of travel, air is taken in from one side or the other of the train. In the case of a sandstorm, We would be delighted if you could find time to visit us at grilles from both sides can even be closed, protecting our booth at the UITP exhibition in Dubai, where this new the system. equipment, including the sand filtration system, UV-C lamp, and CO2 level detector, will be presented in detail.
16 Rail Excellence Process model harmonized
At the turn of the year the Rail Vehicle Systems division took over the Knorr-Bremse AG process model, thereby establishing a uniform worldwide standard for the entire Group.
For several years, Knorr-Bremse has possible – which again ensures ongoing structures to be combined with new, combined initiatives aimed at improvement of processes. innovative approaches. continuous improvement of business processes under the Knorr-Excellence In order to retain tried-and-tested The process stability this offers program. This program brings together processes the existing structures and applies to all parts of the company, all process-optimization initiatives on process organization within the from product planning logistics via a cross-divisional basis and also company were retained, with the 23 production right down to delivery of a creating a standard process model processes making up the Rail Excel- wide range of different components. for its management systems based lence management system being Ultimately customers, too, stand to on the Malcolm Baldrige, Deming or allocated to the nine elements of the benefit from these changes, as they EFQM quality awards. new process model. They have been can be certain that Knorr-Bremse renamed, but the documentation products continue to be manufactured structure and content of all processes to the highest standards. Continuous remain unchanged – enabling proven improvement This has created a common platform within the Group that also benefits Knorr-Bremse Rail Vehicle Systems in the long term. It facilitates access to business processes and improves communication within the company, as well as promoting a better understanding of process management and implementation. Such coordination also makes internal benchmarking
17 Edition 29 | April 2011
Safety Management Safety certificate for EP Compact platform
Following a comprehensive, cross-disciplinary safety case procedure, Knorr-Bremse has successfully achieved certification of the EP Compact brake control system.
For the first time ever a modular brake The safety function "Emergency the development, compiled the safety control system comprising electronic Braking" was assessed according to case and steered the certification and pneumatic components was the highest possible safety integrity process. inspected according to CENELEC safety level SIL4. An EN ISO/IEC 17020 standards EN 50126, EN 50128 and EN accredited institution (TÜV Süd) Generic, project-independent certification 50129. certified the brake system architecture, of EP Compact saves vehicle builders the hardware and software time and money. A product certificate The certificate, which is valid world- characteristics and the associated speeds up the vehicle approval process wide, confirms that basic braking pneumatic unit for the safety functions and demonstrates to the authorities functions have met the respective listed. In addition to this “functional that the vehicle is equipped with a safety targets: safety” the certificate also confirms safe, state-of-the-art braking system. conformity of processes and working System safety function methods to the V-model systems Emergency Braking SIL 4 engineering process established at System safety function Knorr-Bremse. Wheel Slide Protection SIL 3 System safety function The independent safety management Service Braking SIL 2 at Knorr-Bremse organized within the System safety function "Product Safety Group" accompanied Parking Brake SIL 2
18 Moscow Metro Opening and closing every 48 seconds
Purchasing new trains is part of the City of Moscow's ongoing upgrade of its metro system. The latest generation of Metrovagonmash Type 81-760/761 vehicles currently going into service has several Knorr-Bremse systems on board.
With more than nine million passengers every day, Moscow The first order for the Type 81-760/761 covers 53 vehicles Metro is one of the busiest networks in the world. The new that are due for delivery during the course of 2011. Almost trains from Metrovagonmash are equipped not only with 800 door sets have already been built at IFE's production Knorr-Bremse's VV120-T oil-free compressors, PC7 block facility in the Czech Republic since last November. Parallel to brake units and brake resistors from Microelettrica, but also the order for doors, Knorr-Bremse is also supplying Metro- with door systems from Knorr-Bremse's subsidiary IFE. The vagonmash with the oil-free compressors, block brake units Russian train manufacturer, in partnership with Moscow and brake resistors. Metro, opted for IFE doors to ensure that the new trains were provided with state-of-the-art technology. Moscow The orders received from Metrovagonmash have further Metro operates its trains at extremely short intervals of as strengthened the position of Knorr-Bremse in the Russian little as 48 seconds, so it is crucial for the doors to function metro market: Type 81-760/761 and Type 81-740 trains are reliably and efficiently. all equipped throughout with Knorr-Bremse VV120-T compressors and Microelettrica brake resistors.
19 Edition 29 | April 2011
Expansion of Suzhou II plant Expansion in Suzhou
Growing demand means Knorr-Bremse plant in Suzhou, Jiangsu province, is once again expanding – just a few years after it was first enlarged. Now the focus is not only on production but also on aftermarket capacity.
20 Growth in the Chinese rail market began to accelerate some being introduced in close collaboration with the company's ten years ago, and expansion continues apace. Many of high- other service centers and production units world-wide. speed routes have been planned and completed. With the backing of the Chinese government, a number of China's megacities have invested in new metro systems or expanded Consistent existing ones. At the same time, the state-owned railway quality standards company has started to invest in modern locomotives, metros The state-of-the-art equipment used for service operations and high-speed trains manufactured in Europe. By the end in China can stand comparison with Europe – and the same of 2010, for example, 3,500 locomotives and over 4.000 metros goes for the tools, key performance indicators and tried- equipped with Knorr-Bremse systems were in operation, and and-tested methods of the Knorr-Bremse Production System a further 1,000 locomotives and 1.200 metros are due for KPS. This means Knorr-Bremse can be sure of maintaining delivery in 2011. consistent quality standards all over the globe.
Comprehensive expansion Faced with such market growth, there was inevitably a need to expand operations in Suzhou, where Knorr-Bremse's manufacturing, sales, project management, design, procurement and accessory production are concentrated. Work therefore started in the summer of 2010 on expanding Suzhou II, the modern facility constructed by Knorr-Bremse as recently as 2007 in response to growing demand.
The first step involved the building of new staff facilities: a new canteen, changing rooms and shower facilities and expanding infrastructure. Then an additional production area measuring 6,500 m2 and a staff area of some 2,500 m2 were added. By the time the project is completed, the Suzhou plant will cover a total area of 22,500 m2 and employ a workforce of up to 1,000. In addition to the physical expansion, manufacturing processes have also been upgraded.
The new facilities at Suzhou II will provide more space for accessory production, assembly operations, recycling and storage of waste and dangerous substances. Knorr-Bremse has also used the opportunity to raise its environmental standards by adding extra heat insulation and installing a rainwater tank and solar module.
Local aftermarket service In addition to responding rapidly to increased demand for braking system components, Knorr-Bremse has also created additional aftermarket service capacity at Suzhou. As was to be expected, the large volume of systems supplied over the last ten years has begun to trigger demand for aftermarket services. Knorr-Bremse has invested in two areas, establishing a service center in Suzhou and at the same time expanding its field service teams. In both cases the company has endeavored not just to extend its service capacity but also to enhance its employees' maintenance skills. The changes are
21 Edition 29 | April 2011
UITP 2011 in Dubai Global solutions
Innovative capability, all-round service and outstanding systems competence: at the 59th World Congress of the International Association of Public Transport (UITP) to be held in Dubai from April 10 to 14, 2011, Knorr-Bremse will be showcasing its response to current and future market requirements.
In an increasingly mobile world an ever expanding role is Knorr-Bremse Systeme für Schienenfahrzeuge GmbH and being played by rail vehicles of all kinds. The UITP congress its subsidiaries will be among the exhibitors, showcasing and exhibition scheduled to take place in Dubai in April will groundbreaking products that make rail transportation bear the motto "Boosting public transport: Action!" safer, more efficient and more eco-friendly. Companies from all over the world will be presenting their latest public transport solutions. Displayed will be a platform edge door system from
22 Westinghouse Platform Screen Doors (WPSD) of the type cylinder and Teflon piston rings, the compressor does away installed on Makkah Metro. This system demonstrates how completely with the need for oil lubrication, offering much the operation of modern stations can be both safer and greater economy and efficiency combined with lower cleaner. Train doors are an important safety factor, and IFE environmental impact than conventional piston compressors. will be showcasing its new S3 door system, which offers equal degrees of safety, economy and reliability. The same It is no coincidence that this year's UITP Congress is taking goes for the new HVAC systems that will be presented by place in Dubai. In recent years the city has developed an Merak. Microelettrica will be showing exhibits from the unrivalled public transport system in a bid to cope with rapid field of power supply electronics and Knorr-Bremse itself population growth. By the year 2020 the city is set to have will be presenting the weight-saving EP Compact lite as well 318 kilometers of metro line and a 270-kilometer streetcar as the well-known EP2002. network.
Also on show will be a hydraulically operated brake caliper with hydraulic unit, the WZK compact pneumatic brake caliper for all types of vehicle with disc brakes, and the VV120-T oil-free compressor. With its specially coated piston and
23 R a i l v e h i c l e s y s t e ms
Quality that convinces.
Visit us at
UITP Dubai,
Hall 8 Stand C200
Through-out the world, Knorr-Bremse products are used to move people and goods safely. In all types of rail vehicles, carrying passengers and freight – and on platforms. That is why quality is so important for us. Our Quality First Initiative helps us create products that will function reliably throughout a long working life. Our goal of Zero Defect starts with the initial development stage and culminates in carefully designed manufacturing processes with regular quality control procedures. That way, everyone stays on the right track – our customers and our customers' customers. | www.knorr-bremse.com |