Air Supply

Compressors
Air treatment
Complete systems

Center
of
Competence

KNORR-BREMSE
Systems for Rail Vehicles
 Knorr-Bremse AG with its
divisions Systems for Rail
Vehicles and Systems for
Commercial Vehicles
gather their know-how
in Centers of Competence
geared to produce
purpose-built systems.

Focusing
corporate know-how
on
custom-engineered
2
solutions
 AIR SUPPLY

Traditionally in the lead

Knorr-Bremse manufactures brake systems for road and rail
vehicles. Our name stands for innovative solutions and a measure of
technological expertise that makes us a natural choice for vehicle
builders and operators throughout the world.

The legendary Knorr KE standard brake was given UIC approval in 1953. Its
subsequent success in over 40 countries has established Knorr-Bremse
as an international leader in innovative brake system engineering.

Knorr-Bremse designs and builds space- and weight-saving air

supply systems for modern rail vehicles running on mass transit and
long-distance services. These systems ensure the very highest level of
safety, reliability and efficiency, and are today setting the standards in rail
vehicles – in every corner of the world.

Integrated know-how – Leadership through

technical competence
To effectively support our customers in innovation and
planning, we have created an "Air Supply” CoC (Center of
Competence) as an overall organisation for our worldwide
activities in this field. To the customer, this means
development and manufacture according to KB-standardised
rules.

The customer benefits significantly from concentrated

product- and system-specific know-how, and from
dedicated co-operation by all divisions. Development,
manufacture, logistics and quality assurance contribute
globally towards the ultimate product.

3
The Knorr-Bremse Centers of Competence (CoC) The CoC gives competent support and advice to all parties
involved in conceiving the best brake system for the builder and
operator of a specific rail vehicle. The united efforts of our customers,
designers and sales engineers yield top quality, maximum flexibility,
accelerated processing and competitive costing.
 Compressed air supply
in a modern trainset

Ensuring
you’ll never
run out of air
4
With a modular system
to fit every situation
 AIR SUPPLY

Systematically powered
Diesel and electric locomotives are planned and
designed on the basis of central air supply concepts,
using Knorr-Bremse piston compressors. Long delivery
lines with numerous couplings connect a train’s air
consumers to the compressed air reservoirs, and
these again to the central air supply system.
Rapid technical progress, and the introduction of new
and individual types of rail vehicle, especially on mass
transit services, necessitate the use of smaller, modular
subsystems to round off or replace the central sy-
Precisely connected
The demands on effective air supply system engineering are growing
worldwide. Rising customer requirements, increasing differentiation
and ever shorter innovation cycles call for new forms of co-operation
on the part of customer and manufacturer. In creating our "Air Supply”
CoC, we have chosen to work in partnership with every single
customer. Our combined expertise in the field of air supply has been
effectively integrated in this CoC, making concentrated, corporate
know-how on compressors, air supply and complete systems
available to the engineering departments at every stage of every
project. Major spending on R&D, and investments in technologically
demanding test and trial equipment enable us to offer our customers
state-of-the-art compressed air technology for use in rail vehicles.

SING
stems.
CHA
PUR
S
Compactly built IS TIC
Installation becomes ever more complicated as the LO G
REP
MAN

AIR
UFA

proportion of compact, lightweight vehicles increases

CEN
CTU

TER
RE /

and space decreases. The air consumers creep up on the

DES

S
ASS
IGN

air supply equipment, aggravating the size, noise reduction

EMB
/ DE

LY

and reliability requirements, and exacerbating the safety RS

/ TE
VEL

RY E
STIN

D
OPM

demands on distributed air supply systems. The S/ AIR

G
ENT

S SOR ERS
designer is challenged today by the need to address an PRE I LT
CO M O IL F
unremitting increase in safety and performance while ESH ORS
CRO
M
L L ECT
accounting for continuously decreasing component MI E CO
E N SAT
sizes. Knorr-Bremse’s modern air supply concept is CON
D
YS T
EMS
AN CE 5
SUR
T E S
PLE S
engineered to satisfy stringent international standards,
CO M IT YA
promoting the development of present and future generations Q UA L
of vehicles, such as trainsets and low-floor cars.

Structure of the
"Air Supply” CoC
Concentrated know-how –
instantly accessible
worldwide
 Compressed air
Products generators
The CoC supplies compressors, Our compressors have been Noise emission to the outside
air supply equipment, and specially designed and devel- environment is also reduced.
complete air systems for oped for the requirements of An additional advantage of this
powering rail vehicles. railway working. They are all working principle is that air
These products satisfy the flange-mounted, self- delivery is practically free
highest demands made by supporting sets of compact from pulsation. The flexibility
builders and operators around construction. with which the coolers can be
the world, thanks chiefly to The compressors can be driven fitted permits excellent
compact design and ease of optionally by DC, three-phase adjustment to the many
maintenance. or hydraulic motors. Growing different forms of installation
competition among public specified today.
transport operators places
ever greater significance on
passenger comfort. Noise
levels have been reduced by
the use of low-vibration
SL series screw compressors,
as these generate a lower
internal and external sound
pressure level.

6
SL 6K screw compressor

SL 22 screw compressor VV 120 piston compressor


Air treatment
As well as screw compressors, An air supply system in a modern
we supply a range of four basic rail vehicle would be inconceiv-
piston compressors for all able without air drying and
pneumatic applications. These micromesh oil filtering. Our
VV models represent the air treatment systems meet the
results of many years of requirements of ISO Standard
continuous evolution from the 8573-1 in this respect.
first Knorr-Bremse piston
compressors ever installed in Compressed air supply systems
diesel and electric locomotives. will only work safely and
Being specially designed for efficiently if the relative
railway operation, these humidity in the system is kept
compressors are characterised below 35%. Humidity in
by great reliability, long life compressed air systems can
and extraordinary lead to corrosion, and
ruggedness. They require no sometimes even to freeze-ups
special lubricants, and have an that would mean a total system
attractive price/performance breakdown. Malfunctions and
ratio. premature wear and tear on
pneumatic valves and
equipment are unavoidable in
such cases. The air dryers
offered by our "Air Supply” CoC
reliably reduce relative
humidity to an insignificant
residual level – and that, at any
outside temperature that might
be encountered during
operation. They work on the
cold-regenerative desiccant
adsorption principle, which
has proved the most economic
OEF 2 micromesh oil filter method for rail vehicles.
LTZ 015 air dryer
KSA 70 condensate collector
AIR SUPPLY
The air dryers have two chambers
which are shuttled alternately
by a cycle timer to work in
drying and regeneration mode.
The system includes an oil
separator, too.
Improved purity of air delivery
is an additional requirement
now placed on manufacturers
of air supply systems. Micromesh
oil filters installed downstream
of the air dryer reduce still
further the residual oil content
of the compressed air. They
serve additionally as watchdogs
permanently monitoring the
amounts of oil extracted from
the compressor and air dryer.
The quantities of oil and water
removed by the oil filter and air
dryer are accumulated in a
condensate collector which
meets the rules and requirements
laid down for ecologically
friendly collection and
disposal.
7
 Complete systems
Our “Air Supply” CoC can supply
components either singly or in
integrated, compact installations.
Complete systems consisting
of compressor and all the
necessary air supply equipment
are available for the
international range of rail
vehicle engineering.
SL 22 screw compressor
as used in the tilting trainset
on Queensland Railways
8
Designed to meet the customer’s
demand for accelerated
disassembly and assembly, they
help cut the cost of maintenance
and enhance availability.
For this reason, the components
of such complete systems are
mounted on a common chassis.
SL 25 screw compressor
as used in the Italian S220
Pendolino trainset
 AIR SUPPLY

This arrangement simplifies If specified by law or requested

inspection and maintenance by the customer, we can
by the customer. To cater for optionally supply our complete
rapid removal and installation, systems with additional
our complete systems have just soundproofing covers.
one defined mechanical
interface and only a few
electrical interfaces with the
remainder of the train system.

SLC 1400 motor compressor set LAC 1400 air treatment system

9
 Design
and
development
A compressed air supply sy-
stem is embedded in an
environment containing digital
and analog control systems.
Being an integral constituent
of the overall train control sy-
stem, it is custom-engineered
for each operator and each
train system. Great attention is
paid to close co-operation
with the customer long before
the air supply system gets off
the drawing board.
"Supplier partnerships” bring
about a continual exchange of
information between the
experts – the customer and
manufacturer getting together,
as it were, at the same table.
This mutual learning process
makes for benefits in quality
and innovative thinking.
It is a practice-oriented
approach that delivers
solutions at the highest
possible technical and
economic levels , tailor-made
10 to operator requirements and
vehicle design specifications.
"Design and development” is a
particularly good example of
how our customers benefit
from the CoC structure we
use at Knorr-Bremse. This helps
us gather together
all the available information
resulting from our international
activities and commitments
in the field of compressed
air systems. And ensures
that know-how gained in
worldwide applications
is exploited immediately for
every new development.
Of course, we employ the very
latest CAD workstations for
true-to-life modelling of
equipment and components.
This has long been standard
practice in our CoC. Once in
possession of the available
data, our customers can embed
"virtual” models of new air
supply equipment in planned
applications – long before
these are ever finalised.
Manufacture
and
assembly
Our fast manufacturing
performance results from strict
adherence to the modular
principle, in conjunction with
well-proven and forward-
developed production
processes. Running a business
with such a multiplicity of
equipment, small batches
and the requisite manufac-
turing flexibility would not be
economically viable without
a planned hierarchy of part
families and standard
toolsets.

Assembling piston compressors

at the "Air Supply” CoC

Our specialised experience,
backed up by advanced
production facilities in Munich,
Florence and Madrid, guarantees
the highest possible degree
of quality.
We ensure that our equipment
is assembled in special shops
kept separate from the actual
manufacturing facilities.
Equipment is put together by
specialists working in teams.
All procedural instructions are,
of course, laid down in writing
in a binding form. Prior to
delivery, all our equipment
undergoes and is required to
pass acceptance tests on
largely automated serial
test beds working according
to the highly sophisticated
Knorr-Bremse quality
assurance program.
The operability of our
equipment and the precise
interaction of all components
are tested thus. A detailed
test report that comes with
the equipment gives an
objective and neutral account
of its serviceability and verifies
its compliance with customer
specifications.
AIR SUPPLY
Service
Center
The economic and organisational
deliberations behind the CoC
concept make the Munich
Service Center for air supply sy-
stems an attractive facility for
our customers. Maintenance,
repair and main inspections
are carried out there on all our
products by qualified
technicians. Performance of
such work in our Service Center
extends our warranty
provision.
Being a separate logistic entity,
the Service Center ensures fast
turnaround and redelivery by
the required dates.
The Service Center has obvious
advantages for our customers.
It maintains the value of
capital investments at a very
high level, makes for planned
cost accounting, and minimises
vehicle downtimes. Moreover,
the customer avoids investing
capital in setting up and running
his own repair shops.
11
 The figurative mark ” K” and the trademarks KNORR, KNORR-BREMSE, KE, ISOBAR, ESRA, Z-AK, WZK, RZK and RZS are registered in the name of Knorr-Bremse AG.
Subject to alterations. For projection and use of our products we recommend you request individual consultation and documentation. Reproduction, even in extracts, is not permitted. Printed in Germany
Knorr-Bremse Usines Dehousse S.A. Knorr-Bremse
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A-2340 Mödling Fax: +36 1 4 21 11 56 Rail Systems Far East Ltd.
Austria 1301 Mass Mutual Tower
Phone: +43 2236 40 90 New York Air Brake Corporation 38 Gloucester Road
Fax: +43 2236 40 93 00 748 Starbuck Avenue Wanchai
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IFE Industrie-Einrichtungen USA Phone: +852 28 61 26 69
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Phone: +43 7442 5 15-0 861 Baltimore Boulevard AUS-Cardiff, N.S.W. 2285
Fax: +43 7442 5 15-12 USA-Westminster, MD 21157-9300 Australia
USA Phone: +61 2 49 54 29 70
Westinghouse Brakes (UK) Phone: +1 410 8 75 09 00 Fax: +61 2 49 54 29 60
Foundry Lane, Chippenham Fax: +1 410 8 75 08 30
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England Knorr Brake Ltd. 27-29 George Street
Phone: +44 1249 44 20 00 675 Development Drive AUS-Concord West, N.S.W. 2138
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F-51100 Reims
France
Phone: +33 3 26 79 72-00
Fax: +33 3 26 79 72-01
P-1128-EN-W02 03.2001

KNORR-BREMSE
Systems for Rail Vehicles