ZF - Damping Systems for Rail Vehicles

Damping Systems for Rail Vehicles

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High-Tech for the Future on Rails

3Worldwide on TrackContinuity is a key element of our company philosophy: Since 1953, the Sachs brand of dampers have advanced to become a significant player in the rail market and have consistently kept pace with the requirements of rail traffic.

With the integration in the ZF Group, the engineers were able to continuously expand the product portfolio and adapt it to various applications. Today, rail vehicles around the world are equipped with our vibration dampers to the satisfaction of customers from the USA to Europe and further to Russia and China.

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Contents

Preface Page 3

Milestones Page 4

Competence Center Rail Vehicle Dampers Page 6

A Single Source for Complete Damping Systems Page 8

Twin-Tube Dampers Page 10

Yaw Dampers Page 12

Electrically Switchable Yaw DampersInter-Car Dampers Page 14

Research and Development Page 15

Innovations Page 16

Market Overview References Page 18

Wide Range of Services Page 19

The ZF Group an Overview Page 20 Always Close to the Customer Worldwide Page 22

5Milestones

Since 2002, Sachs is marketed under the umbrella of ZF Friedrichshafen AG a globally operating Group charac-terized by future-oriented technolo-gies. It is their aim to surpass even the highest customer expectations.

This holds true for all markets and product segments where ZF is active:

passenger and commercial vehicles, Formula 1 race cars, and of course rail vehicles.

We are proud of our significant, more than 60-year contribution to the advancement of rail traffic. Our suspension components are characterized by long service life, high functionality, and reliability. In 1953, the "Uerdinger Rail Bus" was the first vehicle on the rail market that featured dampers from Sachs.

Sachs is founded by Karl Fichtel and Ernst Sachs

Boge is founded

First rail vehicle damper project "Uerdinger Rail Bus"

First yaw damper in the "Airport Express"

Since 1991 High-speed trains in the "ICE1" and "ICE3" series (2000)

High-speed train "Velaro"

High-speed train "ZEFIRO China 380

Crash system "Vossloh streetcar"

Acquisition of Sachs by Mannesmann

Acquisition of Boge by Mannesmann

Sachs and Boge merger

Acquisition of Sachs by ZF

Development Center SchweinfurtChange of corporate name to ZF Friedrichshafen AG

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1895 1931 1987 1991 1993 1996 2002 20111953 1972 1991 2004 2012

High-speed train "Velaro China"

2006

High-speed train "Velaro Russia Sapsan"

2009

The product name Sachs has been synonymous for quality and innovative capacity for more than 100 years this has also been the case for rail vehicles for over 60 years: vibration damper applications over the course of time.

In 1992, the "Center of Excellence" for rail vehicle dampers was established in Eitorf. The correspond-ing basic development is pooled in the Development Center Schweinfurt. Consolidated experience and extensive know-how in combination with global pres-ence and high innovative capacity make ZF an expert in the field of rail vehicle dampers. We thereby pur-sue a clear goal: to prove to our customers each and every day, that they have made the right choice.

Copyright: Vossloh, Siemens, Bombardier, Deutsche Bahn AG,SNCF / Velaro is a registered trademark of Siemens AG

7This also includes global technical approvals like the SNCF (France), the Deutsche Bahn Classification Q1 (Germany), and the North American AAR (USA).

Modern Production Technologies

ZF has decades of experience and profound know-how in the production of rail vehicle dampers. A highly qualified team which competently masters all production processes, works in the "Rail Vehicle Damper" segment. We integrate production plan-ning, logistics, and quality assurance right from the start. The flexible production structure and the high degree of automation guarantee maximum efficiency and prompt, on schedule damper production: Mod-ern, future-orientated technology is used for produc-tion and quality assurance, and configured accord-ing to the flow principle. And finally, the painting

process fulfils special requirements: It ensures that our rail vehicle dampers receive a finish that is both corrosion-resistant and in compliance with environ-mental standards.

Optimization of Production Processes

for Customer Added Value

The focus of our quality teams is to have all processes under control while continuously improving these. Under their scrutiny, processes from product design to production layout planning are constantly reas-sessed and critically examined. This creates a con-tinuous improvement process, which is pursued with dedication by our employees. Our customers benefit directly from the results and can fully rely on the quality of the dampers at any stage of the project.

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Competence Center Rail Vehicle Dampers

Our employees: innovative, qualified, quality-minded

Competent and motivated employees are paramount for success. For example, quality control is indepen-dently performed and accounted for by the assembly groups. This is closely coordinated with established training and advanced training programs. We also rely on teamwork: to achieve continuously improved processes, optimization, and greater precision in the individual work steps as well as in logistics.

Safe and Reliable Thanks to Certified Quality

We use modern technologies for quality assurance in all project stages from development on to produc-tion and inspection and further to sales and distri-bution. Only the perfect command of all of these processes ultimately leads to compliance with even strict internationally recognized standards: This is reflected in the certification awarded to ZF according to DIN EN ISO 9001:2000 and ISO/TS 16949:2002.

The quality of ZF technologies, processes, and products is based on a strong foundation: the people in our company.

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A Single Source for Complete Damping Systems

ZF supplies a complete portfolio of rail vehicle dampers: These range from vertical and horizontal dam-pers in primary and secondary applications on to yaw dampers for a variety of applications.

This portfolio is the basis for the development of innovative and efficient damping concepts in close cooperation with the customer.

ZF is the competent partner for state-of-the-art damping systems in modern rail vehicles worldwide.

Whether the issue at hand is driving stability or en-hanced driving comfort: No other type of vehicle currently requires such a diverse system of perfect-ly calibrated vibration dampers as high-speed rail vehicles. The high quality of the ZF damper models guarantees maximum service life and therefore maximum cost-efficiency.

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Fundamentals of Vehicle Dynamics

Secondary damper

Mass 2 Body

Mass 1 Bogie

Unsprung mass (wheel, axle)

Primary damper

Primary vertical damper Secondary vertical damper Yaw damper Secondary horizontal damper Inter-car damper Crash system

Without damper With damper

The basic bogie and body structure requires separate damping of vibrations, created by movement, to the bogie and body. ZF has developed dampers with optimal character-istic curves for both vibration systems. Path-dependent and special systems are available for special requirements. The primary damp-ers (axle dampers) are located between the axle and the bogie frame and can cope with extremely heavy loads. Vibrations of the vehicle body are reduced by the dampers (secondary vertical or horizontal damper) between the bogie and the vehicle body.

T50/20 Horizontal damper

T50/20 Vertical damper

T50/28 Vertical damper

T70 Yaw damper

Crash System

T60 Yaw damper

T60 Electrically switchable

yaw damperProduct portfolio

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Twin-Tube Dampers for Vertical and Horizontal Application

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BenefitsExtremely long service life Great characteristic curve variance due to the adjustable piston and bottom valvesPath-dependent characteristic curves Space-saving construction Integrated lift stop Standardized and modular design Easy overhauling

Horizontal damper Vertical damper

Twin-Tube Principle Horizontal damper

Examples of characteristic curve progressions:

Twin-Tube Principle Vertical damper

Direction of compression Direction of rebound

ZF supplies twin-tube dampers in two different sizes, depending on the load profile. Their standardized modular design makes production cost-efficient. An integrated lift stop is optionally available: This device holds the axle on the bogie and the bogie on the coach, whenever these vehicles are being put onto the rails.

Twin-tube dampers for horizontal installation have a specially designed bottom valve. It reliably prevents air from entering into the operating chamber even in this installation position, and therefore ensures that the damper always functions safely.

When the piston rod moves in (compression stage), the ring volume flows through the piston valve from the lower to the upper operating chamber. The oil volume relevant to the piston rod is pushed through the damping bottom valve into the compensating chamber. When the piston rod is moved out (rebound stage), only the piston valve gener- ates the damping effect. Simultaneously, the oil volume relevant to the outward moving piston rod flows back through the bottom valve.

The function of the twin-tube principle

F [N]

F [N]

F [N]

v [m/s]

v [m/s]

v [m/s]

Linear characteristic curve

Degressive characteristic curve

Path-dependent damping

F [N]

F [N]

F [N]

v [m/s]

v [m/s]

v [m/s]




F [N]

F [N]

F [N]

v [m/s]

v [m/s]

v [m/s]




Nominal rebound and compression Reduced compression Reduced rebound

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In contrast to the twin-tube damper for vertical and horizontal installation, in the yaw damper there are additional sealing elements integrated in the rod guide of the piston specifically for small amplitudes (< 2 mm). There is also an oil-tight venting valve integrated in the rod guide. ZF supplies the yaw damper with twin-tube principle in two sizes. They feature exceptional symmetrical damping properties and system stiffness especially from a dynamic perspective.

The damper model, based on the recirculation prin-ciple, has the following special feature: If the piston rod moves in the rebound or compression direction, the oil flow is rectified in the piston and base areas by the non-return valves.

As a result of the special dimensioning of the piston rod and the cylinder tube, the surfaces for the piston rod and the toroidal chamber between the rod and the cylinder tube are the same size. This enables symmetrical compression rates and volume flows. Since the same damping valves are used for both the rebound and the compression settings, these also generate symmetrical damping forces. The characteristic curves of the damper are generated in the interchangeable valve cartridges. Since the valves are arranged at the base of the damper and are designed as cartridges, they can be quickly and easily exchanged. This is a great advantage for both the characteristic curve changes and overhauling.

This yaw damper variant operates on the principle of a syn-chronized cylinder. Due to the overall geometry and absolutely identical surface area ratio on both sides of the piston, ZF has

achieved maximum symmetry for the characteristic curve as well as for the system stiffness. This yaw damper model therefore meets the highest demands for dynamic performance.

Yaw Dampers According to the Recirculation Principle

Twin-Tube Principle

Yaw Damper with Continuous Piston Rod

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Direction of compression Direction of rebound

Yaw dampers minimize the sine mo-tion effects of the bogie. Specifically rail vehicles with medium and high speeds can be thereby securely kept on track. In order to provide the best possible adherence to market requi-

rements, we supply yaw dampers in a wide range of technical specifications: based on the twin-tube or recirculating principle, as well as a version equipped with continuous piston rod.

Yaw Dampers

Typical Characteristics of Yaw Dampers

Standard Characteristics,measuring stroke +/- 12,5 mm

Characteristics at small stroke +/- 1 mm

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T70 Yaw damper

Damping Characteristic

F [N]

v [m/s]

Compression

Rebound

s [mm]

F [N]

s [mm]

F [N]

Compression

Rebound

BenefitsExtremely long service life Equal damping force for rebound and compression settingsHigh damper stiffness Blocking safety Space-saving construction Standardized and modular design No venting required prior to installationPotential use of electrically engageable valvesEasy overhauling

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The yaw damper is not required for stable operation when maneuvering curves. Instead, the case is rather that wheel/rail forces resulting from the yaw damper often lead to wear on tracks and wheelsets.

For precisely this reason, ZF developed the electri-cally switchable yaw damper, which significantly reduces contact force between wheel and track. The maintenance costs for vehicles and track sections that are generated by wear are thereby considerably decreased.

Electrically Switchable Yaw Dampers

Inter-Car Dampers

Electrically Switchable Yaw Damper

Inter-car dampers are applied on the interfaces between the coach bodies, in order to equalize the movements among the rail car.

In this segment, ZF has an extensive product portfo-lio for various types of vehicles. In close cooperation with the customer, engineers design the dampers to meet the requirements of the relevant application and individually configure response and stiffness. Our tailor-made damper solutions thereby ensure comfort-able operational performance of the vehicles en-tirely without having to compromise on operational safety.

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Our goal: to create an efficient development process

in close cooperation with our customers

At ZF, expert teams in all rail vehicle damping sectors are available for the customers. By performing dynamic tests and calculations, the experts already ascertain all basic data required for optimal damper design at a very early stage of the project. Employ-ees in Engineering and Testing implement the specific customer requirements with the latest tech-nologies. The dampers are subjected to testing at modern test benches, in order to ensure optimal quality. ZF is consequently hallmarked by the valu-able alliance of expertise, technical know-how, and innovative capacity.

At ZF, expert teams with vast professional experience

employ modern technologies to develop high quality

damper innovations.

ZF is a leading supplier of damper solutions for the future on rails. Today, our products and services are designed to meet the requests and requirements of our customers just as they have been for over 60 years.

The most recent findings from ZF research conse-quently flow into the further development of rail vehicle dampers. In addition, customers benefit from numerous synergetic effects at ZF, which are the result of basic research for road vehicle dampers.

Research and Development

Inter-Car Damper

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Innovations, Trends, and Challenges

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BenefitsFlexible rebound and compression stops Progressive spring characteristic possible Use possible even in extremely limited installation space Compensates tolerances due to adjustable in-vehicle lengths Cost-effective due to modular construction Completely maintenance-free

Inter-car dampers are applied at the interfaces between the coaches in order to compensate for the relative movement of coach bodies.

A special challenge was the develop-ment of a damping device with overlaid spring characteristics for rebound and compression, that can also be used in a very limited installation space. Damp-ing as well as the appropriate spring characteristics may be defined individu-ally to the requirements within a rather wide range.

Inter-Car Dampers with Integrated Rebound and Compression Spring

Crash System

ZF engineers rise to meet current and future challenges and to develop groundbreaking technologies for every type of rail vehicle.

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Reversible and Irreversible Damping Solutions

With the ZF Crash System

Since 2012, DIN EN15227 is the official mandatory standard for all rail vehicles requiring a high colli-sion safety grade. The ZF Crash System meets these demands on all levels. The highly efficient solution is based on high performance hydrodynamic impact absorbers, which absorb impact forces according to the force of the collision. Light pushing movements that can occur when maneuvering are absorbed in the reversible function range, whereas if strong colli-sions should occur, the dampers irreversible function range comes into action.

As a result of the modular design principle, the crash system can be customized for the individual applica-tion - both in regard to the level of force as well as towards the type of rail vehicle.

Inter-Car Dampers with Integrated Rebound and Com-

pression Spring Use also for Limited Installation Space

The main issue is to increase riding comfort and safety for rail vehicles. Improvements are focused on the chassis or drive, which is usually designed as a bogie. Of course, the interior furnishing and the tran-sition between coaches are also important factors. For the latter, ZF developed a damper suspension element to control relative motions in the transverse direction. This enables passengers to conveniently transfer from one passenger carriage to the next. Since the ZF in-novation with individually customized damping and suspension characteristics only permits gentle motion, unwanted abrupt jolts are effectively prevented.

BenefitsDeformation elements in compliance with EN 15227Reversible function according VDV 152 Integrated anti-climber protection EN 15227 High energy efficiency Customer-specific adjustable force level Tested by TV [German Technical Monitoring Association]Proven product

We continuously develop our products according to a variety of perspectives: Faster trains in con-nection with the ever-increasing transport traffic leads us to consider the growing safety concerns and requirements. Greater passenger traffic places higher demands for more comfort, as well as noise optimization. Increased mileage

and decreased operation costs can be reached by reducing weight, whichs lowers energy consump-tion and promotes greater transport capacity. The trend towards platform strategies gives rise to new tasks, both for rail vehicle manufacturers, and for ZF. In doing this, we not only support our custom-ers today, but also intensify our associations in the future.

The connection of the ZF Crash System to the power rail can either be done according to standard (EN 15551) or customer specification. This is also the case for the anti-climber, which can be implemented as a connecting element between the energy absorbers or as an individual body.

For the highest possible stiffness at a low weight, ZF also supplies the combination with a center support.

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Our Wide Range of Services

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Front Runner on the Track for Good Reasons

Copyright: ALSTOM Transport, Bombardier Transportation, Brush Traction, CAF Beasain, Plasser & Theurer-Bahnbaumaschinen-Industriegesellschaft m.b.H., Siemens AG Transportation Systems, Vossloh Locomotives GmbH, Deutsche Bahn AG

Locomotives

Rapid Transit and Light Rails

High-Speed Trains

Track Maintenance Vehicles

Intercity

Our references show: At ZF, customers can rely on sustainable innovations and optimal support in all sectors.

You will enjoy comprehensive carefree operation with our products, comprehensively formulated instructions, and training.

We go from intercity to high-speed trains, to construction equipment: ZF is the leading supplier of tech-nologies for rail vehicle damping. Our products and services are equally reliable, powerful, and in-novative. We build customer trust with our employees competence,

The maintenance-free design of the rail vehicle dampers was our top priority from the very beginning: Even today, this valuable feature is characteristic for each new devel-opment in the extensive damper portfolio.

and continuity. With a global sales network in all parts of the world, we ensure that our customers receive the optimal support they deserve. Designed with quality, reliability, and cost effectiveness, our dampers are proven to be safe, prompt, and com-fortable whether they are transporting passengers or goods.

ZF also places great value on the corresponding processing for the specific design or further devel-opment of the individual damper components: This includes detailed text and video instructions to op- timally support customers with damper installation. On request ZF will of course also organize extensive product trainings at the company itself or on-site at the customer.

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ZF Group Overview

Worldwide, the ZF Group has 121 production companies and 8 main development locations in 27 countries. In addition, we have approx. 34 service companies and representative offices as well as 650 service partners. This enables ZF to provide a tight network of highly qualified contacts close to international customers at all levels and in all regions.

ZF is consistently expanding its global market presence. Both estab-lished market regions and new markets play very important roles.Particularly activities outside Eu-rope will gain more importance in the future. This applies not only to the established markets in North and South America, but especially

to the Asia-Pacific region and the new markets in Eastern Europe and India. Key aspects here are market development through adapting products to specific market requirements and best-cost- country considerations which play a decisive role in production and procurement. ZF supports the international expansion of established customers while also adding partners from new market regions to its customer portfolio.

Marken von ZF

We develop and manufacture innovative, high-quali-ty products and related technologies that improve the mobility of people and goods. Our products and services offer our customers clear added value

through leading technologies, quality, and service. Our passionate commitment to achieving greater efficiency and resource conservation has made us a trendsetter in new markets.

Powertrain Technology

Transmissions

Axle Drives

Powertrain Modules

Industrial Technology

Off-Highway Systems

Test Systems

Special Driveline Technology

Electronic Systems

Marine Propulsion Systems

Aviation Technology

Wind Power Technology

Chassis Technology

Chassis Systems

Chassis Components

Rubber & Plastics

Suspension Technology

Commercial Vehicle Technology

Truck & Van Driveline Technology

Bus Driveline Technology

CV Axle Systems

CV Chassis Modules

CV Damper Technology

CV Powertrain Modules ZF Lenksysteme GmbH is a joint venture of ZF Friedrichshafen AG and Robert Bosch GmbH.

Steering Systems

Passenger Car Steering Systems

Commercial Vehicle Steering Systems

Passenger Car Steering Columns

Global Aftermarket

ZF Services

Driveline and Chassis Technology

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Always Close to the Customer Worldwide

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ZF Friedrichhafen AG Rail Technology Bogestrasse 50 53783 Eitorf [email protected] +49 2243 12-383 Fax +49 2243 12-280

SFT Service und Fahrzeugteile GmbHFreiberger Strae 77-8301159 Dresden [email protected] +49 351 499 12 60Fax +49 351 499 12 61www.sftparts.de

RHIAG Group Ltd. Oberneuhofstrae 9 6341 Baar [email protected] I +41 41 769-5547Phone II +41 41 769-5555Fax +41 41 769-5595www.rhiag.ch

ZF Italia S.r.I. Via Donizetti, 11 ITA 20090 Assago (MI) [email protected] / [email protected] +39 02 48883 337 Fax +39 02 4884 3260

Europe Asia America

Sachs Automotive Components & Systems Shanghai Co., Ltd.Yuanjiang Road 4440 Minhang District Shanghai 201111 P.R. China (China, Korea, Hong Kong)[email protected] / [email protected] +86 21 2416 9544 Fax +86 21 2416 9402

ZF Japan Co., Ltd.Palazzo Astec 7,8F2-8-1 Higashi-Shimbashi, Minato-ku105-0021 [email protected] +81 3 4590 7700Fax +81 3 4590 7770

ZF Asia Pacific Pte. Ltd.11 Tuas Drive 1638678 [email protected] / [email protected] +65 6424 8787Fax +65 6424 8788www.zf.com/ap

ZF Sales & Service Malaysia Sdn. Bhd.No. 2 & 3, Lorong Teknologi BNouvelle Industrial Park, Kota Damansara47810 Petaling JayaSelangor Darul Ehsan [email protected] / [email protected] +603 6140 6058 Fax +603 6140 6055www.zf.com/my

Peter Renz sp. z o.o Piotr Dzieszkowskiul. Armii Krajowej 43 PL 05-600 Grjec [email protected] +48 48 6650618 Fax +48 48 6703531Mobile +48 601574200www.renz.pl

Jozef MihaliskoKetkovice 15166491 IvaniceCesk Republika(Czech Republic, Slovakia)[email protected] +420 725 773 328

ZF Services Nederland B.V.Postbus 5572600 AN Delft [email protected] +31 15 270 23 50Fax +31 15 270 23 51www.zf.nl

SKF Railways Business Unit, Nordic AreaCamilla Svensson, RKv-1SE-415 50 GteborgSweden(Denmark, Finland, Norway, Sweden)[email protected] +46 31 337 2146Fax +46 31 337 1610Mobile +46 730 224404

PTL Global Co., Ltd.Mr. Ki Hwan OhRoom No 624Unhyeongung SK Hub 102-dong89-4,Gyeongun-Dong, Jongno-Gu110-776 SeoulSouth [email protected] / [email protected] Phone I +82-2-3210-1337Phone II +82-70-8813-133Fax +82-2-3210-1338Mobile +82-10-3707-7551

Giant Motors International Co., Ltd. No. 48, Shuang-Lien Street P.O. Box 68 1758 Taipei [email protected] +886 2 2557-9557Fax +886 2 2557-7880

MG Worldwide Pvt. Ltd. 1004, 10th Floor, Hemkunt Tower 98, Nehru PlaceNew Delhi [email protected] I +91 11 26412284Phone II +91 11 26412285Fax +91 11 26412287www.mgworldwide.in

Tradimpex (Pvt) Ltd701-703 (7th Floor)Al-Qadeer Heights1 Babar Block, New Garden TownLahore 54700,[email protected] I +92 (0) 42 - 35866174 upto 78Phone II +92 (0) 42 - 35866172Fax +92 (0) 42 - 35866169 upto 71http://www.tradimpex.com/

ZF Services Espaa, S.A.U.Dpto. Vehiculos EspecialesAvda. Fuentemar, 11E-28823 Coslada (Madrid)SpainPhone +34 91 485 2721Fax +34 91 485 20109

John S. Mattheou Sons OENicholas J. MattheouManaging Director17 G.Olympiou st. Thrakomacedones13676 [email protected] I +30 210 2430152Phone II +30 210 2433996Fax +30 210 [email protected]

Alexander E. SivachenkoBor, Gorky Gasse 8Nizhny Nowgorod 606440 Russia(Russia, CIS)[email protected] +7 (831) 596 7500Mobile +7 910 886 1324

ZF Sachs Automotive of America 15811 Centennial Drive Northville MI [email protected] +1 734 582 8126Fax +1 734 582 8027Mobile +1 248 670 1289

Hadady Corporation510 West 172nd StreetSouth Holland, Illinois [email protected]@hadadycorp.comPhone +1 708 596-5168Fax +1 708 596-7563www.hadadycorp.com

Parts Direct OceaniaSuite 6, 84-85 River Street,PO Box 347Balina NSW [email protected] +61 2 6881 4587Fax +61 2 6681 4578Mobile +61 411 690 737

Australia

EN 0

000

750

180

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Driveline and Chassis Technology

ZF Friedrichshafen AGRail Vehicle DampersBogestrae 5053783 EitorfGermanyPhone +49 2243 12-383Fax +49 2243 12-280www.zf.com/rail

ZF - Damping Systems for Rail Vehicles

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