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March 8, 2011
Knorr-Bremse Group
Agenda
Knorr-Bremse Group 2
The Knorr-Bremse Group
Knorr-Bremse Group
Knorr-Bremse at a glance
Founded 1905
Experience 100 years of Innovation
Independence Family owned
Employees 14.432*
Sales 2,761 Mrd. EUR*
R&D expenses 5,5 % vom Umsatz*
Investments 101 Mio. EUR*
Locations More than 65 locations in 25 countries
Two Main Divisions Systems for Rail Vehicles, Systems for Commercial Vehicles
Product portfolio Global market- and technological leader with two main pillars:
– Brake systems for rail vehicles + On-Board Systems
– Brake systems for commercial vehicles + torsional vibration damper
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Corporate Vision of Knorr-Bremse Systems for Rail Vehicles
Worldwide
Worldwidesystem-partnership
system-partnership
Strong
Strongcommitment
commitmentto
toinnovation
innovation
Automatic Door Systems Other On-Board Systems (e.g.)
Broad,
Broad,safety
safetyrelated
relatedproduct
productrange
range
Platform Screen Doors
Superior
Superiorservices
services
Information Systems
“Best
“Bestin
inclass”
class”performance
performance
Knorr-Bremse Group 6
Knorr-Bremse the competent system supplier
(Example: Metro Madrid S 9000)
HVAC
HVAC Systems:
Systems: Power
Power Supply
Supply &
&
Roof-mounted
Roof-mounted unit
unit Distribution:
Distribution:
Contactors:
Contactors:
LTC250/1P
LTC250/1P
LTHS800/1P
LTHS800/1P
LTHS800/2P
LTHS800/2P
Door
Door Systems:
Systems: Brake
Brake Systems:
Systems:
RLS
RLS E2
E2 Air
Air Supply
Supply
Brake
Brake Control
Control
Bogie
Bogie Equipment
Equipment
Knorr-Bremse Group 7
Knorr-Bremse the competent system supplier
(Example: High-Speed EMU CRH3)
HVAC
HVAC Systems:
Systems: Windscreen
Windscreen Wiper
Wiper
Roof-mounted
Roof-mounted unit
unit
Door
Door Systems:
Systems: Brake
Brake Systems:
Systems:
DET
DET Air
Air Supply
Supply
Brake
Brake Control
Control
Bogie
Bogie Equipment
Equipment
Knorr-Bremse Group 8
Knorr-Bremse the competent system supplier
(Example: Alstom Citadis)
HVAC
HVAC Systems:
Systems: Power
Power Supply
Supply &
&
Roof-mounted
Roof-mounted unit
unit Distribution:
Distribution:
Contactors:
Contactors:
LTHS
LTHS
Resistors
Resistors
Door
Door Systems:
Systems: Brake
Brake Systems:
Systems:
RLS
RLS
Hydraulic
Hydraulic
Brake
Brake Control
Control
Bogie
Bogie Equipment
Equipment
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Applications
MT
Metros
Metro-North Railroad M7
(New York MTA)
Vancouver
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References in LRV Projects
JFK (New York / USA)
MBTA No. 8 Cars (Boston / USA)
PAAC (Pittsburgh / USA)
Vancouver BCT (Canada)
Hiawatha (Minneapolis / USA)
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Product Overview
Merak
Merak is
isone
oneofofthe
theworld
world leading
leadingcompany
companyspecialized
specializedin
inthe
the
design,
design, manufacture
manufactureand
and maintenance
maintenanceof ofAir
Air Conditioning
Conditioning
Systems
Systems (HVAC)
(HVAC)only
onlyfor
for railway
railwayvehicles
vehicles
Focused on railways since more than 40 years
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Main Components of Transit air conditioning system
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Duct work as necessary
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Exhaust air Unit
Exhaust air unit
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Overpressure protection damper system
Knorr-Bremse Group 17
Overpressure protection damper system
Technical Development
300
200
100
-100
p (Pa)
-200
-300
-400
-500
-600
-700
-800
0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6
t (s)
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Passenger area HVAC system
Knorr-Bremse Group 19
Merak Overview – Design Process
Knorr-Bremse Group 20
Transit Industry Requirements
Mechanical
Shock and Vibration Size and Weight
Mobile Environment
Environmental Maintainability
Sealing
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Mechanical Requirements
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Example of Frame design
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FEM (Finite Element Modeling) – Stress Analysis
Static Calculation
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Requirements- Vibration Testing
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Acoustic Noise Testing
6m
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Transit Industry Requirements
Thermal
External Conditions Interior Conditions
105/120 F Temp, humidity
System Design
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Transit Industry Requirements – Performance
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Transit Industry Requirements – Examples
“The control system shall be designed to automatically maintain the car interior
temperature, including both cabs, at the specified conditions, under any ambient
temperature from 22°F (-6°C) to 115°F (46°C), with a condenser air entering temperature
of up to 125°F (52°C), with or without variable internal heat loads such as passengers,
motors, lights and solar gain, when the auxiliary power supply (APS) is at its
nominal voltage”.
Knorr-Bremse Group 29
Transit Industry Requirements – Examples
The Heating, Ventilation, and Cooling system (HVAC) shall provide automatic
control of interior temperatures as required herein at any ambient temperature
from -18°F to +105°F at the specified wet bulb conditions, with or without solar
gain or variable internal heat loads such as passengers, miscellaneous electrical
apparatus, and lights. Unless otherwise specified herein, the HVAC shall be
powered by the Auxiliary Power System (APS) and shall start and operate within
the voltage and frequency ranges specified in Section 1.3 and Section 17.
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Introductions to Load Calculations
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Load Calculation Output - Overview
Parameter Inputs
Results
Knorr-Bremse Group 32
Load Calculation - Overview
Outside:
Baseline: 41oC (11%RH) – Tucson Spec
Option 1: 41oC (25 %RH)
Option 2: 41oC (50% RH)
Passengers:
Baseline: 115 (AW2)
Option 1: 154 (AW3)
Knorr-Bremse Group 33
Load Calculation - Overview
Based on Vehicle
Parameters (LxWxH)
Transmission gains
from Data Base
Internal gains
115 Passengers
14 kW (50,000 BTU/hr)
Knorr-Bremse Group 34
Load Calculation – Key Parameter Output
Total Cooling
Required per Total Airflow
Car (11 tons) per Car
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Load Calculation – Key Parameter Output
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Systems Design
Operating Voltages
– Power : 208/3ph/60 Hz
– Control: 37.5 VDC nominal / 120 VAC (26 VDC – 42 VDC)
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System Overview - General Design Features – example
Design Features
– Unitized Roof mounted package
– Stainless steel support frame with aluminum walkable covers and access doors
– Refrigerant control compartment easily accessible from the inside of the vehicle
– Control Panel, pressure controls, gauge ports, sight glass within return air plenum
– Microprocessor control
– Cooling modes from 50°F to 125°F
– Refrigerant R-134a
– Hermetic Scroll Compressors
– PTE access through car locker
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Mechanical System Schematic – Piping
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Transit Industry Requirements
Electrical/software
Power and Power Train communication
supplies
Onboard Power
Rail Power
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Typical System Interface – Electrical
PTE
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Typical System Interface – Electrical
F- End F- End
230 Vac 3
Low (compressors,
Voltage blowers, fans)
700 Vdc
(control,
(OH sensors,
Heater) feedback)
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Transit Industry Requirements
Manuals, training
Full Manuals Parts Catalogs
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Manuals
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Special Tools and Test Equipment
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HVAC Technology and Innovation
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HVAC Technology and Innovation
1
y = 1,8 m Air discharge
y = 1,65 m 2
5 4 3
y=1m
Comfort parameters
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Merak test facilities
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Merak test facilities
Test Facilities
Thermodynamic Laboratory
Airflow test (equipment & Mock-up) Extreme conditions testing
Software de
de Control
Control
Diseñado
Diseñado por
por Merak
Merak en
en base
base aa la
la herramienta
herramienta LabView
LabView
Control
Control Equipo de Ensayo Humidificadores Cálculo de Capacidad:
- Método Entálpico
- Método de Potencia
Registro de Medidas
Temperatura aire seca y húmeda-Presión aire-Consumos eléctricos
Presión refrigerante-Temperatura refrigerante
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Typical PTU Interface
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Transit Industry Requirements
Refrigerants
R- 22 R-134 a
R-407c Future ??
Knorr-Bremse Group 52
Transit Industry Requirements
Refrigerants
Refrigerant Past Present Future
R-22
R-407c
R-134a
R-744 1
R-410a 2
HFO-1234yf 3
Knorr-Bremse Group 53
Knorr-Bremse Group 54