AST Transportation Engineering - AST Angewandte System-Technik ...

A.S.T. Transportation Engineering
Less operating expenses. More service quality.
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Systems. Conceptions. Solutions.
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Systems. Conceptions. Solutions.
Far more than just a system house:
A.S.T. Transportation Systems. Our objective? The best solution.
We started out with power management
systems for railways. That was more than
24
25 years ago. In those days, our systems
were just called "train preheaters".

Today, we are more than entitled to say that
transportation systems are our home turf. We
no longer have to prove that our conceptions,
systems and solutions are reliable and longlasting.
You will find our power management systems
in every major railway station in central Europe
and even further afield. Our aircraft weighing
systems are in use across the globe. Not only do
our power converters supply hundreds of
laptops in European passenger trains every
day; they also deliver the power for the precise
movements of film cameras, for instance, and
were involved in virtually all major European
film productions over the last 10 years.
No effort is too much for our experienced
project specialists, no task too difficult. Whether
it be complex power management systems,
reliable solutions for preheating and lowtemperature-protection
of diesel engines, onboard
power supplies, battery chargers or
power converters, the A.S.T. Gruppe is a centre
of competence which is capable of taking over
the management of complex projects and is on
hand with help and advice during every phase
of planning and implementation.
© Bombardier Transportation
We take on the overall responsibility for our
systems. But the A.S.T. Gruppe is far more than
just a system house. If we are unable to procure
a component on the global market in the
quality that we require, we develop it and
manufacture it ourselves. It goes without saying
that our highly motivated team of hardware
and software specialists, designers and planners
makes use of cutting-edge 3-D CAD and
simulation systems. Our own CNC machines
and an SMD assembly line ensure that we are
in a position to manufacture even projectspecific
components without long delivery
times, and to deliver them just-in-time directly
to our customers' assembly shops or to the
construction site.
The A.S.T. Gruppe.
That stands for Systems. Conceptions. Solutions.
For transportation engineering. From a single
source. From a reliable partner with years of
experience and technical expertise.
And if you think that's just our advertising
department exaggerating again, simply ask
some of our customers.
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Preheating of rail coaches
Warm and welcoming:
Power management systems for parked rail coaches.
It's a cold winter's morning. The train comes
straight from the siding to the platform. You
open the doors and a cosy warmth envelops
you. How? Because during the night our power
management system has been working hard to
ensure that the train remains frost-free overnight
and is at a comfortable temperature when
it sets off in the morning.
With our systems, energy savings of up to 40%
are possible over manual preheating and airconditioning
of parked rail coaches, meaning
that the systems pay for themselves extremely
quickly, generally within 12 to 24 months. For
example, Deutsche Bahn's annual energy consumption
for preheating and air-conditioning
its rail coaches is so high that it could make
savings of the order of 70,000,000 kWh annually
if it adopted our systems for all its coaches.
Testing auxiliary facilities of electric locomotives
without overhead line.
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The construction of power management
systems for parked rail coaches is a multidisciplinary
task: it is a highly complex subject area
requiring specialist knowledge of fields ranging
from design engineering to civil engineering,
from switch and control gear to process
Preheating system in Garmisch-Partenkirchen
(Bavaria).
computers. We can offer you a thoroughly
well-conceived solution from a single source.
A specific contact person is assigned to each
project, to provide advice and practical support
whenever it is needed, right from the preliminary
planning stage. You reap the benefits in
terms of smooth project coordination during
the construction phase and thorough, costeffective
telephone support when technical
problems arise, even years after commissioning.
1

System components
+ 1 Medium voltage switch gear
with circuit breaker
+ 2 Transformer
oil-cooled or resin-encapsulated
+ 3 Switch gear for heating outlets
1 - 24 branches
+ 4 Process computer
tried, tested and extremely reliable
+ 5 Control Pillar
intuitive operation
+ 6 Predetermined breaking point with heating cable
according to UIC/RIC standards
+ 7 Dummy socket holder
with monitoring contact
Benefits at a glance
+ energy savings of up to 40%
+ significant reduction in operating costs
+ pays for itself in 12 - 24 months
+ optimum passenger comfort
+ reliable sub-zero temperature protection
for trains
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5
2
6
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References
More than 180 systems and altogether more
than 4500 outlet boxes are in service with, for
example, the following railway authorities:
+ German National Railways (DB)
+ Iraqi State Railways (IRRE)
+ Luxembourg State Railways (CFL)
+ Mattherhorn Gotthard Railways (MG)
+ Norwegian State Railways (NSB)
+ Austrian Federal Railways (ÖBB)
+ Swedish State Railways (SJ)
+ Swiss Federal Railways (SBB)
+ Slovak State Railways (ZSR)
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Power electronics
Exclusively tailored or modular design:
Auxiliary power supplies, inverters, battery chargers.
No matter whether the speed of a fan needs to
be regulated, a compressor needs to be supplied
with power, an onboard battery needs to
be charged, or the battery voltage needs to be
stabilised against massive voltage dips, you can
rely on our equipment. Even under the worst of
conditions. So it's no surprise that customers
are increasingly entrusting us with critical tasks.
For instance, the battery-supported power
supply of an emergency ventilator for the
passenger compartment of an underground
End-to-end onboard power supply concepts
From the overhead line to standard power
450...650 V DC
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750 V DC
Overhead line
230 V 50/60 Hz 1 AC
80...460 V 50/60 Hz 3 AC
Input stage (DC/DC)
supplied from overhead line 750 V DC
Power supply and drive
unit inverters
(DC/AC)
Frequency inverter (AC/AC)
for regulating the speed of motors,
fans and pumps
400...715 V DC
0...440 V 3 AC
0...460 V 3 AC
0...230 V 1 AC
0...400 Hz
train which would ensure the necessary circulation
of air in the train in the event of a power
failure in a tunnel.
Our well proven modules, equipped with
standardised interfaces, are perfectly matched
to each other and form a highly flexible building-
-block system for onboard power supplies. No
matter what input and output voltages you are
using and what output power you require,
we will give you well thought-out solutions
remarkably quickly and at attractive prices.
0...230 V 1 AC
0...50 Hz (16.7, 60, 400 Hz)
Battery chargers
600 V DC,
230 V AC,
400 V 3 AC,
16.7...66 Hz
Charging voltage regulator
24 V DC/110 V DC
Battery chargers
24/96/110/144/156/312/336 V DC
DC generator
Vehicle battery

Further products
+ Complete systems
e.g. for power supplies
in passenger trains
+ Special equipment
such as charging voltage
regulators for DC generators
+ Options for the products
display modules, remote activation/
deactivation, line input with PFC,
galvanic isolation, etc.
Benefits at a glance
+ modular concept or
+ tailored problem solution
+ planning security right from the start
+ short delivery times
+ sensible prices
+ complete control over costs
+ reliable
+ long-lasting
Battery supply
24 V / 110 V DC
24 V / 110 V DC
24 V / 110 V DC
66...200 V DC
Vehicle battery
∆ – 70%
+ 65%
∆ – 30%
+25%
Onboard power supply
stailizers (DC/DC)
prevent voltage dips when starting up
Power supply inverters (DC/AC)
e.g. for laptop sockets in trains
Drive unit inverters (DC/AC)
e.g. for compressors / fans and
convenience functions
Drive unit inverters (DC/AC)
e.g. for circulation pumps
∆ – 10%
+ 15%
And what if the installation space available is
too small, or project-specific requirements do
not permit modular design? Then we will
develop the perfect solution tailored to your
requirements. Enjoy the benefit from our years
of experience. Experience gathered from
modernisation projects for existing train equipment
or when integrating power converters
with an extremely high power density into
special slimline vehicles. From forklift trucks
through to camera dollies.
It doesn't matter whether you choose our tailored
solutions to your problems or whether you
prefer our proven modular approach, if you opt
for equipment from the A.S.T. Gruppe, you have
chosen to back the competence and experience
of 20 years' of power electronics in transportation
engineering. And we're as good as our
word. We calculate life-cycle costs and determine
the MTBF for assemblies and systems. We are
only too happy to provide technical support
during on-site system integration.
Put us to the test!
24 V DC
110 V DC
230 V 50 Hz
0...440 V 3 AC
0...230 V 1 AC
0...50 Hz (16,7 , 60, 400 Hz)
0...98 V 3 AC
0...230 V 1 AC
0...50 Hz
References
+ DB tour train
+ Regional rail double-decker coach DO97
+ Regional rail double-decker coach DO2003
+ Berlin metropolitan railway BR 481
+ InterCity (DB)
+ EuroCity
+ ICE-3
+ Harz narrow-gauge railway
+ Berlin underground
+ Guangzhou Metro
+ Chinese high-speed train
+ City-Night-Line AG, Basle
+ IC-2000 (SBB)
+ New Jersey suburban railway (USA)
+ Metro in Taiwan
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Preheating systems
Protected against freezing when parked:
Preheating and heat retention systems for diesel engines.
They reduce operating costs, increase the operating
life of the power units, reduce primary
energy consumption, limit emissions to an absolute
minimum and usually pay for themselves
within 18 to 36 months. Our heating systems
for completely automated preheating
and freeze protection of the cooling circuits of
diesel engines and auxiliary systems are truly
versatile.
So it's hardly surprising that they can be found
on virtually all models of diesel locomotives
used on the German Railway. No matter
whether they are way up in the mountains with
freshly charged batteries one day or down on
the coast with the batteries almost empty the
next, our processor-controlled, dual-circuit heating
systems just keep on running. And an impressive
number of them have been doing so
for more than fifteen years.
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Temperature
sensor in cab
Temperature
sensor
Cab heating system
with ventilator 1
Thanks to their modular design, our preheating
systems can be adapted to suit any type of vehicle
without great difficulty, no matter
whether it be locomotives or trainsets or large
construction vehicles or watercraft. No matter
whether limited installation space means that
the boiler has to be installed vertically or
whether two boilers are to be used on a locomotive
such as the BR 219, we will provide you
with well thought-out planning along with appropriate
key components for retrofitting in older
vehicles right up to complete, ready-to-fit
solutions for series production.
Schematics
S6
S5
3-way mixing valve
Motor 1
Boiler circuit
pump
Boiler sensor
Safety temperature
limiter
Motor sensor 1
4-way mixing valve
with four integrated
temperature sensors
Boiler Burner
S2
Cooling
circuit 1
Boiler sensor 1 Boiler sensor 2
S1
Motor circuit
pump 1
Heat exchanger
Outside
temperature
Cooling
circuit 2
Process control system
Motor circuit
pump 2
Communication interface
Motor sensor 2
S4
3-way mixing valve
S3
Motor 2
Temperature
sensor
Cab heating system
with ventilator 2
Temperature
sensor in cab

System components
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2
3
4
5
6
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Heating curve
Outside temperature
Boiler supply
Boiler return
Engine temperature
Position of
4-way mixing valve
Temperature [°C]
+100
+80
+60
+40
+20
0
-20
+ Circulation pump
Integrated inverter
+ Low-pressure
hot water boiler
35, 50 or 85 kW
+ Oil burner
Two-stage,
integrated inverter
+ 4-way mixing valve
Integrated
temperature sensors
+ Sensor system
components
IP 65
+ Process control system
Extremely high reliability
+ Mini-terminal
Simple operation
in clear text
(A)
(B)
(C)
(D)
(E)
(F)
Valve position [%]
08.48 a.m 09.00 a.m. 09.12 a.m. 09.24 a.m. 09.36 a.m. 09.48 a.m.
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(G)
4
7
2
100
80
60
40
20
0
20
5
1
Benefits at a glance
+ high energy savings
+ no operator
+ no antifreeze agent
+ no cold starts
+ minimal emission levels
+ literally stand-alone
References
More than 1500 preheating
systems in use, for instance on
the following models:
+ BR 202/203/204
+ BR 212
+ BR 216/217/225
+ BR 218
+ BR 219/229
+ BR 232/233/234
+ BR 241/242
+ BR 290/294
+ BR 291/295
+ BR 298
+ BR 344-347
+ SVT 675
+ BR 708/714
+ SVT 675
+ VT 618/619 (LIREX®)
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Weighing systems for railway car bodies
Precise, reliable and in use across the world:
Measurement systems for QA in rail vehicle manufacturing and refurbishment.
Weighing systems for railway car bodies
These systems for measuring corner loads
provide proof of uniform transmission of inertia
forces over the bogies to the wheelsets and
ultimately onto the track. The ultra-precise
measurements delivered by our systems help
you to detect and eliminate uneven running of
rail vehicles before they ever leave the shop.
Our systems are in use every day with many
major manufacturers and maintenance companies
for rail vehicles. One reason is that in addition
to the generally recognised measuring
method in accordance with DIN 25 045, our
systems also support the considerably more
precise measuring method based on "nominal
forces". This latter method may be able to
establish itself as an international standard in
the coming years, since, unlike the method laid
down in DIN 25 045, it also takes account of the
longitudinal position of the centre of gravity of
the body.
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Our car body weighing system is also capable
of setting the tension-free position in accordance
with DIN 25 043 – even fully automised.
All aspects of the design of our system are geared
towards high precision while at the same time
maintaining maximum operational safety.
The precision lifting gear is self-locking, which
means that the positions of the corners are
kept constant over long periods of time. The lifting
displacement of the vehicle is measured
by contactless inductive encoders.
It goes without saying that every measurement
is also documented in a detailed measurement
log. Open interfaces ensure easy data transfer.
Additional functions allow you, for example, to
deliberately tilt the body to a defined angle.

Load monitoring on the lifting jacks
In some potentially dangerous situations, traditional
safety equipment on lifting jacks does
not provide sufficient protection against the load
falling. Thus, for instance, dangerous situations
can quickly arise when operating unwieldy
systems because even the slightest change in
position of stiff vehicle bodies has a significant
impact on the distribution of forces over the individual
points of support.
Our load monitoring system brings safety for
people and vehicles back onto the shop floor.
This is achieved by securing to every pad a
compact load cell which independently and
precisely captures the inertia forces introduced.
Benefits at a glance
+ compliant with DIN 25 045
+ additional measurement method based
on “nominal forces”
+ high-precision measurement
+ efficient work methods
+ reliable and maintenance-free
+ modular concept – simple adaptation
to our customers' requirements
+ versatile
+ future-proof
+ open interfaces for data transfer
The benefits of measuring forces directly at the
transition point between the body and the
lifting jack:
- Reliable measurement
- Rapid installation
- Simple replacement of components
System features at a glance
+ standard measuring method in accordance
with DIN 25 045
+ adjustment of the tension-free position in accordance
with DIN 25 043
+ determination of the centre of gravity
+ measurement of the corner loads
+ determination of the overall weight
+ proof of uniform transmission of inertia forces
+ separate log for each measurement
+ optional calculation modules, for instance
for slider and spring forces
References
+ Siemens TS, Krefeld (4 systems)
+ Siemens SGB, Vienna
+ Siemens SKV, Prague
+ Zhuzou Electric Locomotive Works, China
+ Hellenic Shipyards, Athens
+ Bombardier plant, Görlitz (2 systems)
+ Bombardier plant, Bautzen
+ Bombardier plant, Ammendorf
+ ÖBB, Vienna
+ DB plant, Kassel (2 systems)
+ DB plant, Frankfurt
+ DB plant, Berlin
+ S-Bahn Berlin GmbH
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Special solutions
No matter what transportation engineering products you need:
Benefit from our experience and expertise.
Depot power supply for ICE-3 und ICE-T
3rd generation trainsets, i.e. the ICE-3 and ICE-T,
have a 670 V DC busbar. Auxiliary facilities and
air-conditioning units may be supplied
with power and tested in the depot using this
busbar, without the overhead line having to be
live.
We have designed an appropriate, short-circuit-proof
depot power supply; the trainset is
supplied with 670 V DC via a single special
connector. Continuous output is 250 kW. Our
control strategy ensures that the depot power
supply may be switched off within 100 ms
even under full load, so as safely to avert danger,
e.g. if the plug is unintentionally pulled out.
Auxiliary power supply for depot-testing
If an electric locomotive arrives at the depot for
maintenance and repair, our auxiliary power
supply for depot testing ensures that auxiliary
facilities and air-conditioning units can be
tested without overhead lines or main transformer.
Mobile aircraft weighing systems
In addition to our own mobile weighing system
for aircraft of the Airbus A300, A310, A320, A340
series, we have also incorporated in our range a
mobile aircraft weighing system for Boeing
aircraft (B737, B747, B757, B767, B777) from our
Japanese partner, Unipulse Corporation.
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Both systems use stable, compact platforms
with integrated, high-precision measurement
sensors in order to capture the measured values.
If required, data can be transferred between
the platform and the central analysis system
over a wireless communications link.
Both systems allow convenient determination
of the centre of gravity of an aircraft using a
menu system. This is of vital importance, not
only during flight testing, but also when
aircraft are recommissioned after significant
modifications have been made.
The modular concept behind the systems means
that it is no problem to measure aircraft
from a whole range of weight classes and with
anything from three to 20 axles.
References
+ EADS
+ JAL Japanese
Airlines
+ Air Canada
+ ANA (All Nippon
Airways)

Introducing A.S.T. Gruppe
A profile of the A.S.T. Gruppe:
Lithe. Dynamic. Your reliable partner.
The A.S.T. Gruppe comprises a number of
medium-sized enterprises. We have been
developing and manufacturing systems,
modules and sensors for a wide variety of
different applications for almost 30 years and
over that time have focussed on power and
environmental technology. Our system solutions
rely on interdisciplinary cooperation within
a highly motivated team, whose members can
call on decades of experience in sectors as
diverse as
- Power systems technology
- Microprocessor control technology
- Measurement and control technology
- Machine technology
- Power electronics
- Microsystems technology
Under the common motto "Systems. Conceptions.
Solutions." the 200 or so employees of the
group generate annual sales of around 25
million euros in the group's three locations in
- Berlin (A.S.T. Leistungselektronik GmbH)
- Dresden (A.S.T. Mess & Regeltechnik GmbH)
- Wolnzach (A.S.T.Energie&Umwelttechnik GmbH)
The official representative of the A.S.T. Gruppe
is the holding company A.S.T. Angewandte
System Technik GmbH in Wolnzach. The A.S.T.
Gruppe is headquartered in the world-famous
hop-growing region of Hallertau between
Ingolstadt and Munich.
The market-oriented structure of the group
follows the lines of a classical matrix organization.
The products of the individual locations are
arranged by target group and marketed by a
total of five operational divisions:
+ Transportation Engineering
+ Industrial Automation
+ Power and Facilities Technology
+ Medical Technology
+ Communication Systems
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Get to know us.
The responsibility and skill of our staff:
Together with your specialists, we form an irresistible team.
In all our products for the transportation systems
sector, there are three aspects that form the
focus of our work:
- Safety
- Energy savings and environmental protection
- A significant increase in transport quality
The quality of our solutions is impressive; but
not only that, as a sort of welcome side-effect
they also reduce operating costs. For instance
as a result of lightweight construction, high
efficiency levels and extremely low maintenance
requirements. It goes without saying that the
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A.S.T. Gruppe has an ISO 9001-certified quality
management system. So it's no surprise that
we have been listed as a Q1 supplier to the
Deutsche Bahn for years.
Teamwork is the basis Standard of authenticated accuracy (force & weight)

Our years of experience and the skills an knowledge
of our staff, yes, and their responsibility
too; these are all things that we've emphasised.
That's the prerequisite. But solutions that deliver
considerable benefits for the operators,
that protect the environment by reducing
emissions, and that help to make travelling
safer, better, and more comfortable don't just
come from the drawing board. Many of our
products originated as very specific ideas from
our customers. The dialogue between us and
you as the user and operator is not only some-
Production at highest precision
thing that is very important to us, it is a prerequisite
for our work.
Working together with our customers' specialist
departments, we develop and implement
the very best solution. And to achieve that, we
invest all of our energy and creativity. For safe
high-speed trains, for safety on the shop floor,
for real cost benefits as a result of energy
savings and reduced emissions, for high levels
of comfort in passenger transportation and for
high levels of availability in freight traffic.
Visit us
at one of the trade fairs – or perhaps at one of
our plants. Get to know the people behind our
products.We would love to talk to you.
Maybe sample some of the local delicacies;
the Hallertau, Berlin and Dresden all have a lot
to offer.Welcome to the A.S.T. Gruppe!
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Locations in Germany
+ A.S.T. Leistungselektronik GmbH
Brook-Taylor-Strasse 10
D-12489 Berlin
Fon +49 (0) 30 63 92 57 00
Fax +49 (0) 30 63 92 57 09
+
+
A.S.T. Mess & Regeltechnik GmbH
Marschner Strasse 26
D-01307 Dresden
Fon +49 (0) 351 44 55 30
Fax +49 (0) 351 44 55 555
A.S.T. Energie & Umwelttechnik GmbH
Hagertshausen 7
D-85283 Wolnzach
Fon +49 (0) 84 42 67 0
Fax +49 (0) 84 42 67 111
+
Angewandte System Technik GmbH
Hopfenstrasse 28-30
85283 Wolnzach
Germany
Fon +49 (0) 84 42 67 200
Fax +49 (0) 84 42 67 111
verkehrstechnik@ast.de
www.ast.de
(C) 2004 A.S.T. Gruppe. 0904-100-GB Text & Conception: Ingenieurbüro für Marketing, Moosburg. Layout & Production: mediaPool, München