Annual Report 2012 - Knorr-Bremse AG.

60 Report ProduCts // Rail vehicle systems
Rail Vehicle Systems
Thanks to the new
“whisper brake pad”,
the “Italo” Italian
high-speed train
operates extremely
silently.
Knorr-Bremse develops innovative “whisper brake pad”
The noise of train brakes can cause considerable annoyance to residents in the vicinity of railway lines,
but now Knorr-Bremse has developed a new high-performance brake pad that virtually eradicates
brake squeal and makes rail transportation more environmentally friendly – the high-tech Flexpad
Silent.
Brake squeal is caused mainly by a stick-slip effect that occurs at slow speeds as a result of the low
clamping force of the brake pads and low rotational speed of the brake disc. The brake pad repeatedly
adheres briefly to the disc, causing vibrations that trigger the unpleasant noise.
Knorr-Bremse tackled this problem on two fronts. To prevent the pads sticking to the disc, a compound
material was used that combines a high-friction sintered surface with a lubricated core. And a
mechanical sound damper was also developed with sound insulation between the pad and the
backing plate to absorb any vibration.
Having gained official approval, the “whisper brake pad” is now ready for use – and that includes the
high-speed sector. Since April of this year the Flexpad Silent has been in operation on Italy’s “Italo”
high-speed train – the “Ferrari on Rails” – on the line between Milan and Naples.
Knorr-Bremse launches highly complex brake control module
Brake control modules are essential to any braking system. Installed in the engine room of the locomotive,
they not only contain the control unit for the locomotive’s pneumatic brakes but also regulate the
brakes for the entire train via the main brake pipe. The equipment trestle integrates electrical and
electronic components, pneumatic control and air reservoirs and the brake equipment panel. During
the year in question, Knorr-Bremse developed a highly sophisticated brake control module of this kind
designed to operate at temperatures down to minus 50 degrees Celsius.
The module forms part of a braking system, the first examples of which were delivered to vehicle manufacturer
Alstom during 2012 for installation in 25 double freight locomotives ordered by rail operator
Kazakhstan Temir Zholy for use in Kazakhstan. Amongst other things the braking system includes the
specially designed KAB60 control valve and the BP Compact electronic HL control system modified to
meet the operating regulations of the GOST market.
In the run-up to its successful low-temperature testing of the braking system, Knorr-Bremse had invested
heavily in acquiring the necessary development expertise to manufacture GOST-standard
products for the Russian and CIS markets. Knorr-Bremse now also operates the only accredited testing
center outside Russia that is permitted to carry out certification of GOST components.
The order from Kazakhstan is doubly important for Knorr-Bremse. Firstly the customer has already taken
out an option on 175 more double locomotives; and secondly, delivery of complete locomotive
braking systems to Kazakhstan has enabled Knorr-Bremse to demonstrate its GOST competence –
which should stand the company in good stead when tendering for future projects in other CIS states.
Brake control system includes condition monitoring of bogie components
In the past, the main purpose of the brake control system was to operate the brakes and monitor their
functioning, as well as calculating vehicle speed and diagnosing wheelset rotation. Now, by doubling
up sensors and making intelligent use of existing interfaces, Knorr-Bremse has been able to extend its