Bearings for Railway Transport 70 Years — Proven Solutions for You

Proven solutions for you

BEARINGS FOR RAILWAY TRANSPORT 70 YEARS — PROVEN SOLUTIONS FOR YOU

Kharkov Bearing Plant (HARP) is one of the largest CIS manufacturers of bearing products and the only Ukrainian manufacturer of bearings for railway transport.

Today HARP holds leading positions in the production of railway bearing units for the entire «1520 space» and bearings for some market segments in the CIS: agricultural machinery, electrical engineering, automotive industry, mining and metallurgical complex, and others.

The main development trends are: producing of new types of radial roller bearings with short cylindrical rollers and bearing units, strengthening of its position as a manufacturer of bearings for railway rolling stock, development of ball bearings of higher accuracy class, producing of hot-stamped and turned semi-finished products for automotive, railway and industrial bearings.

Great manufacturing and design experience allow HARP to develop new advanced bearing solutions for railways and reduce time on market.

Products for railway transport • Axle box bearings for freight cars and locomotives • Bearings for traction motors of locomotives • Tapered bearing units • Cylindrical bearings units CONTENT

Page 4 Application

Page 5 Energy efficient HARP bearing units with extended lifetime

Page 6 CRU Duplex (Cylindrical Roller Unit) for freight and passenger cars

Page 7 TBU (Tapered Bearing Unit) for freight and passenger cars

Page 8 Axle box cylindrical roller bearings for freight cars

Page 9 Axle box cylindrical roller bearings for freight and passenger cars

Page 10 Axle box cylindrical roller bearings for locomotives

Page 11 Axle box cylindrical roller bearings for electric traction motors

Page 12 Research and development

Page 13 Testing certification center

Page 14 Quality management

Page 15 Sales geography Application

Axle boxes of freight cars

Axle boxes of locomotives

Traction motors of locomotives

Generators and reduction gears of locomotives

Underground and tram cars

4 Application ENERGY EFFICIENT HARP BEARING UNITS WITH EXTENDED SERVICE LIFETIME

Specially developed innovative bearings: • Cartridge units for axleboxes of freight and passenger railway cars – CRU 130x250 and TBU • Cartridge units for axleboxes of locomotives – CRU 160x270 (Cylindrical Roller Unit) • Sealed units for traction electric motors of locomotives – CRB (Cylindrical Roller Bearings)

Main advantages in comparison with conventional cylindrical bearings (CRB): The principal integrated result of the optimized design and technology is maintenance intervals increase by more than 2.5 times (800 000 km and more).

BY MEANS OF: ACHIEVED: • optimal roller profiling • reduction of maximum contact stresses on the raceway • high requirements for roller surface quality (up to 10%) and on the roller end face contact areas (by • special heat treatment of rings 3…4 times) • more precise realization of optimal geometry • increased operation durability of units and microgeometry of rings • reduction of wear rate on the raceway and on the roller • use of special Klüberplex BEM 41-132 HARP end face contact areas (by 2...4 times) grease • lower bearing unit operating temperature (by 10-20°C) • reduced mechanical losses and, as a consequence, lower energy consumption for traction

The design of the CRU 130x250 with flange rings has eliminated one of the major drawbacks of axlebox unit — low reliability of the face mounting, caused by the presence of a spacer ring in the classical design. Dynamic axial force on the axlebox face is reduced by 4 times.

Unique Klüberplex HARP grease, developed together with Klüber Lubrication (Freudenberg Group), Germany, is the only grease that, along with record high resistance to wear and to contact fatigue surface damage, low starting and running torques, provides high performance under low-temperature conditions down to -60°C.

The results of the monitoring of the operation of cars equipped with CRU 130x230 bearings proved higher operation reliability of axlebox units — the average number of uncouplings due to failures of the axlebox units per year for one car was reduced by 4 times, compared to cars equipped with conventional cylindrical bearings. The result is reduction of the operating costs for the axlebox unit and costs for preventive maintenance and repair of the bearing units during the service life of a car.

Significant reduction of labour consumption and costs when assembling wheelsets: the bearing is delivered pre-assembled, greased and adjusted for radial clearances and dimensions of a bore of inner rings, and does not require any additional operations prior to mounting on the axle. As a result, installation time is reduced, as are the production capacities, personnel and energy required.

Can be mounted or dismounted on existing equipment: application of duplex bearings means that the purchase and installation of special new equipment is not required.

AS A CONSEQUENCE: • • low life cycle cost for a railway car • improved traffic safety

5 CRU Duplex (Cylindrical Roller unit) for freight and passenger cars

Double radial roller bearing with short cylindrical rollers and shields.

CRU 130x250 is designed for installation in axleboxes of freight cars with axle load of 23.5 tonnes and pedestal opening of 320 mm, as well as in the axleboxes of passenger cars. Its design is completely interchangeable with existing units and can be installed to replace mass produced CRB bearings (36-42726E2M and 36-232726E2M).

СRU 130 x 250 Maintenance intervals, km 800 000 Dimensions (d x D x B), mm 130 x 250 x 160/161.2 Weight, kg 34.9 Load capacity, kN dynamic 1001 static 1548 Maximum rotational speed, RPM 1800 Allowable temperature range -60…+120°C

Axlebox unit with CRU 130X250

This is a sealed double bearing unit adjusted for radial clearances and dimensions of a bore of inner rings. Basic geometric parameters of the internal design are fully compatible with serially produced axlebox bearing units with long-term experience of reliable operation in the railways.

The microgeometry of the rollers and bearing rings is distinguished by the optimized profiles, stricter requirements (letter «Y») for surface machining and special heat treatment of the material. The bearing is lubricated with Klüberplex BEM 41-132 HARP, specially developed together with Klüber Lubrication (Freudenberg Group).

6 TBU (Tapered Bearing Unit) for freight and passenger cars

TBU 130 x 230 TBU 130 x 250 TBU 150 x 250 Maintenance intervals up to 800 000 km Dimensions (d x D x C), mm 130 x 230 x 150 130 x 250 x 160 150 x 250 x 160 Weight, kg 38.5 47.9 42.3 Load capacity, kN dynamic 990 990 1011 static 1720 1720 1930

Axlebox unit with CRU 130X250 Double-row tapered roller bearing unit

The TBU is designed for installation in the axleboxes / with adapters of freight cars with axle load of 23.5, 25 tonnes and higher, and pedestal opening of 260 mm, as well as in the axleboxes of passenger cars.

This is a double-row cartridge bearing with tapered rollers, adjusted for clearances and lubricated with Klüberplex BEM 41-141 HARP grease. The bearing has a built-in seal, preventing penetration of water, dust, dirt, etc. into the bearing. All surfaces of the bearing are protected by a layer of phosphate coating, preventing them from corrosion damage. The bearing is supplied ready for installation by pressing.

7 Axle box cylindrical roller bearings for freight CARS

GOST 3042726EM and 3232726EM 42724EM1 and 232724EM1 Designation DIN (WJ/WJP 130x240) (WJ/WJP 120x240) Dimensions (d x D x B/C), mm 130 х 240 х 80 120 х 240 х 80 Weight, kg 14.8 15.7 Dynamic, kN 540 540 Load, kN Static, kN 780 780 Radial clearance, mm min 0.130 max 0.180 min 0.130 max 0.180 Application Axle boxes of freight and passengers Axle boxes of freight and passengers cars cars

80-0.25 80-0.25

Single-row radial roller bearing with short cylindrical rollers WJ/WJP 130x240 and WJ/WJP 120x240. Bearings are designed for axle boxes of freight and passengers cars for track gauge of 1435 mm

3 (standard gauge). Bearings are manufactured in

-0.0 compliance with standards DIN EN 12080 and DIN EN 12082. 240 -0.025 130

WJ/WJP 130x240

8 Axle box cylindrical roller bearings FREIGHT AND PASSENGER CARS

Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5

TBU WJ/WJ NU NJ WJP (TBU 130x230 / (CRU 130x150) (32000) (42000) (232000) TBU 150x250)

Overall dimensions, Load, Bearing designation mm kN Maximum Weight, rotational Fig. Application International kg speed, No. GOST d D B/С(S) dynamic static designations RPM

30-42724ЛМ WJ120x240x80-M 120 240 80 18.2 548 713 1800 4 Wheelset axle 30-232724ЛМ WJP120X240x81,2/80-M 120 240 81.2/80 18.2 548 713 1800 boxes of railway 5 42724EM1 WJ120x240x80 120 240 80 15.7 560 750 1800 cranes for wreck 4 trains 232724EM1 WJP120x240x80 120 240 80 15.7 560 750 1800 5 TBU 597826ХУКМУ 130 230 150 38.5 990 1720 1800 2 3042726EM WJ130x240x80 130 240 80 14.8 540 780 1800 4 3232726EM WJP130x240x80 130 240 80 14.8 540 780 1800 5 30-32726Л1М WJ 130x250x80-M/C4 130 250 80 18.5 554 722 1800 3 30-42726Е2М WJ130x250x81,2/80-C4 130 250 80 17.14 584 774 1800 4 Axle boxes of 30-232726E2M WJP130x250x81,2/80-M 130 250 81.2/80 17.14 584 774 1800 passenger and 5 30-42726Л4М WJ130x250x80M/C4 130 250 80 18.7 554 722 1800 freight cars, 4 electric trains 30-232726Л4М WJP130x250x81,2/80-M 130 250 81.2/80 18.9 554 722 1800 5 36-42726Е2М WJ130x250x80P/P6+C4 130 250 80 17.14 584 774 1800 4 WJP130x250x81,2/80P/ 36-232726Е2М 130 250 81.2/80 17.14 584 774 1800 5 P6+C4 H6- 130 250 160/161.2 34.9 1001 1548 1800 1 882726E2K1МУС44 30-42728ЕМ WJ140x260x80-C4 140 260 80 18.18 625 833 1800 4 WJP140x260x81,2/80 Axle boxes of 30-232728ЕМ 140 260 81.2/80 18.16 625 833 1800 5 -C4 special freight cars and electric 30-42728Л4М WJ140x260x80M/C4 140 260 80 19.9 625 833 1800 trains 4 30-232728Л4М WJP140x260x81,2M/C4 140 260 81.2/80 19.9 625 833 1800 5

Axle boxes of TBU 597830ХУКМУ 150 250 160 42.3 1011 1930 1800 2 freight cars

9 Axle box cylindrical roller bearings Locomotives

Fig. 1 Fig. 2 Fig. 3 Fig. 4

NU NJ NU+H NU+HJ (32000) (42000) (52000) (152000)

Overall dimensions, Load, Bearing designation mm kN Maximum Weight, rotational Fig. Application International kg speed, No. GOST d D B/С(S) dynamic static designations RPM

30-32630ЛМ NU2330-Е-М1 150 320 108 43.2 1090 980 1700 Diesel locomotive 1 30-42630ЛМ NJ2330-Е-М1 150 320 108 44.6 1090 980 1700 and tender axle 2 30-52630ЛМ NU2330M+HJ2330 150 320 123/108 46.2 1090 980 1700 boxes 3 30-32532ЕМ NU2232-E-TVP2 160 290 80 22.4 809 957 1800 1 Diesel locomotive 30-152532ЕМ NU2232P+PLC810-1 160 290 94/80 23.93 809 957 1800 and electric 4 30-32532Л1М NU2232-Е-М1 160 290 80 24.5 809 957 1800 locomotive 1 axleboxes 30-152532Л1М NU2232MAS+PLC810-1 160 290 94/80 26 809 957 1800 4 30-42532Л1М NU2232-Е-М1 160 290 80 25 809 957 1800 2 30-42536ЕМ NJ2236-Е-ТVР2 180 320 86 28.9 1010 1094 1600 30-52536ЕМ NU2236ТN+ NJ2236 180 320 98/86 30.3 1010 1094 1600 3 30-152536ЕМ NU22326P+PLC810-1 180 320 100/86 30.63 1010 1094 1700 4 30-42536ЛМ NJ2236-Е-М1 180 320 86 31.8 1010 1094 1600 2 Electric locomotive 30-52536ЛМ NU2236M+HJ2236 180 320 98/86 33.1 1010 1094 1600 axleboxes 3 30-152536ЛМ NU2236MAS+PLC810-1 180 320 100/86 33 1010 1094 1600 4 30-152536ЛМУ 30М1-152536ЛМУ 30М2-152536ЛМУ NU2236MASC4+PLC810 180 320 100/86 33.4 1010 1094 1700 4 30М3-152536ЛМУ 30М4-152536ЛМУ 30-32732ЛМ NU160x320x108M 160 320 108 41.7 1090 1211 1800 1 Diesel locomotive 30-52732ЛМ NU160x320x108M+HJ732 160 320 123/108 44.6 1090 1211 1800 axleboxes 3 30-42836ЛМУ 30М1-42836ЛМУ Electric locomotive 30М2-42836ЛМУ NJ2236MASC4 180 320 90/86 31.8 1010 1094 1700 2 axleboxes 30М3-42836ЛМУ 30М4-42836ЛМУ

10 Axle box cylindrical roller bearings for electric traction motors Locomotives

Fig. 1 Fig. 2 Fig. 3 Fig. 4

NU NJ NJ+HJ NUP (32000) (42000) (62000) (92000)

Overall Bearing designation Load, kN Maximum dimensions, mm Weight, rotational Fig. Application kg speed, No. International GOST d D B/С(S) dynamic static RPM designations EDT-200B Н0-62417К1М NJ417М+HJ417 85 210 66/52 10.6 332 351 3600 traction motor for TE-2, TE-3, TEM- 3 1 diesel locomotives ED-118 ED-107А, ED-118 traction Н0-92417К2М NUР417-JP3 85 210 52 10.5 332 351 3600 motors for TE10, М62, TE-116, 4 TEМ-2 locomotives 80-32417М NU417-M1.С4 85 210 52 10.4 332 351 3600 Electric traction motors Traction motors for types Н0-32419М NU419-М1 95 240 55 13.5 419 443 3200 RT-113А, RT-51М, 1DT003 electric locomotives 1 Anchor bearing for triple traction 80-32322М NU322-Е-М1.С4 110 240 50 12.3 401 467 3000 converter TE-006 traction motors for ChME3 Н0-32424М NU424-M1 120 310 72 29.2 695 805 1900 -type diesel locomotives NB-406B, TL-3, TL-2K1, NB-412K Н0-42428М NJ428-М1 140 360 82 48.8 905 1046 1700 traction motors for electric locomotives 2 VL-8, VL-10, VL-15, VL-60, all indices Н0-32330ЕМ NU330-Е-М1 150 320 65 24.3 675 777 2300 ED-118А -type traction motors for all indices of locomotives of 2TE10, 1 Н0-32330МУ1 NU330-Е-М1 150 320 65 26.8 675 777 2300 2TE16 and 2M62 series Н0-42330ЕМ NJ330Т-Е-М1 150 320 65 24.67 675 777 2300 NB-418К6 type traction motors for VL-80 series electric locomotives, all 2 Н0-42330Л1М NJ330-Е-М1 150 320 65 26.96 675 777 2300 indices Traction motors for ChS4, ChS4Т 80-32134М1 NU1034-М1.С4 170 260 42 8.24 302 434 2200 electric locomotives Traction gear boxes for ER series electric locomotives, ER series traction 1 80-32140Л4 NU1040-М1.С4 200 310 51 15 430 626 1900 electric motors, traction gear box for E, 81-717, 81-714 type underground trains Traction gear box for ER series electric 80-92140Л3М NUP1040-M1.С4 200 310 51/39.5 15.8 430 626 1900 4 locomotives 80-32152ЛМ NU1052-Е-М1 260 400 65 29.16 627 1070 1800 Traction gear box for ER2R, ER2T, 1 ED2T, ED9 all indices, E12 series 80-92152ЛМ NUP1052-M1.C4 260 400 65/52.5 30.6 627 1070 1800 4 electric locomotives 30-42822Е2М WJ 110x215x75-M1 110 215 76 11,89 433 431 2600 Underground railway cars 30-232822Е1М WJP 110x215-P-M1 110 215 76 11,85 433 431 2600

11 RESEARCH AND DEVELOPMENT

In order to solve such a fundamental problem as the development of new generation of energy efficient bearing units with extended service lifetime, which have been initially developed for the specific operating conditions of the «1520 space», we have created:

• integrated mathematical models of units to be used for the optimal design to meet the specific operating conditions of the «1520 space» • mathematical simulation of the main technologies for mass production of components in order to optimize technological modes • special test benches for experimental research of units with physical simulation of the specific operating conditions of the «1520 space»

Mathematical simulation and optimization of the bearing units The main areas of mathematical simulation and optimal design: • optimal profiling (creating an optimal three-dimensional shape of contact surfaces — «crown of roller and raceways» as well as «roller ends and ring flanges») • optimization of microgeometry (compliance with the most important sizes at the micron level, technological solution for «surface integrity») • optimization of material structure variable in different areas of the part (achieved by special heat treatment technology for bearing components) • optimization of macrogeometric parameters of internal and external design of the bearing unit • development of special greases and high-performance cassette sealing systems • mathematical simulation and optimization of basic manufacturing technologies

Fundamental research and development have been carried out by the UPEC Joint Engineering Centre (JEC). The design was implemented by the Ukrainian Bearing Industry Design and Technology Bureau (UKTBPP, a part of the UPEC Group).

Special greases and high-performance cassette sealing systems have been developed in cooperation with well- known German companies — Klüber Lubrication and Simrit (Freudenberg Group).

The All-Russian Railway Research Institute (VNIIZHT) and the All-Russian Bearing Industry Scientific Research Institute (VNIIPP) also participated in the development.

12 TESTING CERTIFICATION CENTRE

Designing of a new generation of highly-resourceful and energy efficient bearings require a reliable experimental verification of all the results of mathematical simulation and final confirmation of the technical level of the product with certification tests. For this purpose, the UPEC Industrial Group has established the unique research and certification Test Centre for the bearing units. The Centre is equipped with three test benches with mechatronic assemblies (in cooperation with Beckhoff) and two benches with conventional hydraulic loading systems (in cooperation with Blumenbecker). The test benches are designed not only for determination of the gamma-percentile time to failure of axle box bearings, according to the certification methodsof the Certification system for federal railway transport (ST SSPhZhT) and European safety regulations EN 12082, but also for a wide range of tests. Among the important characteristics of these test benches there is a possibility to simulate specific static and dynamic loads and deviations inherent in various designs of bogies and adapters / axlebox units and the «1520 space» operating conditions.

Automated Bench Control and Monitoring Systems allow to easily change the testing programmes with on-line access to data during testing.

Testing of the service lifetime of new bearing products on the specialized test benches will reduce the time-to-market of new bearing products by 3-5 times. QUALITY MANAGEMENT

One of the priority tasks met by HARP is to ensure high quality of the products. Therefore all bearings pass a full complex of quality assurance tests to control over 50 different parameters.

The HARP Quality Management Department provides thorough monitoring of all processes related to the production, from receiving raw materials and to transferring finished products to the warehouse. In case of any divergences materials are rejected.

All products fully comply with the international standard ISO 492 and the CIS interstate standard GOST 520. The Quality Management System is certified by the DQS GmbH and meets the requirements of the international standard ISO 9001:2015.

HARP roller bearings for axle boxes of railway rolling stock are additionally certified in the EAC (Custom Union) and in the UkrSEPRO Certification System (Ukraine).

Standards DSTU GOST 520 (ISO 492) DSTU 8734:2017 EN 12080 EN 12082

Quality certificates ISO 9001:2015 IATF 16949:2016 TSI ISO 14001:2015

14 QUALITY MANAGEMENT SALES GEOGRAPHY

Ukraine Russia Kazakhstan Belarus Uzbekistan Georgia Azerbaijan Poland Lithuania Latvia Estonia Serbia Turkey 02.2020 HARP Bearing Plant

3, Industrialniy ave., 61055 Kharkov, Ukraine

Official distributor: PJSC «U.P.E.C.» Railway Department

Tel. +38 057 710 11 68 Fax +38 057 711 83 10 [email protected]