Worldwide on Track – ZF’s Innovations at InnoTrans 2016

* Intelligent Transmission Concept for Railway Traffic * Potential recognized – IoT@ZF * Six Speeds and Integrated Reversing Function: ZF Premieres the New DMU Transmission ZF EcoWorld * More rail traffic safety with ZF aluminum crash absorbers

Digitization is a trend that is changing the industry. This fundamental technological change provides us with an opportunity to conquer new markets and make rail traffic significantly more comfortable, economical and safe. These are the important industry objectives ZF Friedrichshafen AG focuses on when the company presents its portfolio for rail vehicles at InnoTrans in Berlin from September 20 to 23, 2016. In Hall 20, Booth 320, ZF will be presenting trailblazing driveline and chassis technology and show visitors how the company connects mechanical technology and the digital world.

2_ZF_Condition_Monitoring_en
With its intelligent transmission concept for railway traffic, ZF presents a series of innovative approaches including state-of-the-art sensor technology and data analysis tools.

Intelligent transmission concept for railway traffic – “smart transmission” of the future

With its intelligent transmission concept for railway traffic, ZF presents a series of innovative approaches including state-of-the-art sensor technology and data analysis tools. This increases the efficiency and reliability of rail vehicles and the corresponding infrastructure.

Included here are a range of interesting functions:

Vibration Monitoring: The function allows for remote monitoring, the analysis of transmission functions, the analysis of the transmission condition and the detection of any faults that may occur.

Determining oil level and temperature behavior: The installed technology makes it possible to monitor various oil parameters. These can then be specifically linked with the current temperature behavior of the rolling bearings and transmission oil.

Data transfer: Operators can access the current information from all installed sensors via the mobile network or various data transfer stations along the route virtually in real time or in batch mode.

3_ZF_IoT
Internet of Things: The intelligent combination of mechanics, electronics and digital technologies is crucial when developing suitable solutions for the mobility trends of the future.

Internet of Things: The intelligent combination of mechanics, electronics and digital technologies

The Internet of Things enables the total utility of simple components, which is both greater than the sum of the single components and much greater than their previous use.

ZF has recognized the potential of this development, and is implementing the new technology based on the following pillars.

  • Connectedness of the supply and manufacturing chain in production using IoT technology and the Industry 4.0 approach.
  • Enrichment of products with sensors that are adapted from the automotive sector to the specific requirements.
  • Facilitation of new digital business models that are based on existing hardware and solve problems for manufacturers and operators, for which there has been no satisfactory solution up to now.
4_ZF_EcoWorld
The new, innovative ZF EcoWorld six-speed transmission system features an integrated reversing function.

EcoWorld – Six speeds and integrated reversing function

The new six-speed transmission system is designed for a maximum input torque of 2,500 Nm. It achieves maximum efficiency and is equipped with a powerful torque converter. The transmission system only needs one electric interface directly on the control unit.

The integrated primary retarder, which only requires a small installation space, provides for strong braking power even at low speeds. In addition to the oil cooler that has been integrated into the transmission, a heat exchanger contributes to the high cooling performance of the EcoWorld. The improved heat management extends the oil change intervals and service life, making the transmission even more reliable and easier to service. This keeps the life cycle costs low.

7_ZF_Aluminum_Impact_Absorbers
ZF aluminum crash absorbers absorb collision forces from minor to heavy collisions.

Aluminum crash absorbers– safe and light

With its crash system for rail vehicles, ZF offers a modern crash absorber that complies with standards for Category II + III type rail vehicles, for subway vehicles, light rail vehicles, and regional and urban-suburban rail systems.

With a total weight starting from 45 kg, the aluminum crash absorber offers a weight reduction of approximately 50 percent compared to similar solutions. A high-quality aluminum alloy is used to absorb lateral or climber forces which can occur in the event of an impact. Its material characteristics mean that the alloy is comparable to steel.

Due to uniform tube forming, the ZF aluminum crash absorber offers a uniquely high level of efficiency. As a result, the installation length of the ZF crash absorber is considerably reduced in comparison to folding crash boxes. Long protrusions on the front of the rail vehicle can thus be avoided by using ZF aluminum crash absorbers.