PI 128-13 2013-12-13

Fly like a "martin" into the Winter Olympics in Sochi

Copyright: Siemens-Presspicture

Rexroth cooling systems ensure the correct operating temperature in Russian special trains.

“The gate to the future”: This slogan stands for the preparation of the XXII Olympic Winter Games that will take place in Russia's Sochi at the Black Sea starting on February 7th, 2014. Here, in the Caucasus, the most modern sport sites are currently being created along with an infrastructure ready for one million spectators. For this purpose, the Russian State Railways RŽD is also extending its railway system and is investing in the most modern train technology, such as new regional trains of the Desiro family from Siemens Rail Systems. For this project, Bosch Rexroth has developed cooling units specifically designed for the Russian climate and is delivering the modules ready to install to the assembly lines in Germany and Russia.

The new regional trains are already rolling into the Sochi train station. Besides the braking noises, the humming of the cooling system of the converter in the drive train of the five part electrically driven train is barely noticeable. Maybe it was in fact this silent elegance that lead to the Russian name: Lastotschka, Russian for “martin”, as the Russian State Railways RŽD officially calls the model.

The “martin” is an electrically driven train with a performance of 2,550 kW and a maximum speed of up to 160 km/h. In the transformation of the electrical energy from the aerial line into the rotary motion of the drive motor, heat is generated, which must be discharged through cooling.

Cooling systems for locomotives are always custom designed solutions for the individual product line and operation site. “In Russia, the cooling system must also reliably hold the operating temperature down to negative 40 degrees Celsius”, as Gunther Neidlein emphasizes, Director Industry Sector Transport Technology of Bosch Rexroth AG. “With the help of 3D flow simulations, we have designed the air flow in such a way that no additional heating is necessary for the air intake, even with snow.”

As the development and system partner of Siemens Rail Systems, Rexroth carries the responsibility for the engineering and the series production of the cooling system of the “martin”. For decades an established supplier for the railroad industry, Rexroth delivers the completely assembled modules to Siemens Rail Systems.

Light construction for higher energy efficiency

Energy efficiency is another key subject for the operators considering the life expectancy of 40 years and more, because they largely determine the life cycle costs. An important approach is the increasing light construction in railroad technology.

Rexroth has taken up these challenges and has designed a light-weight frame for the cooling system on the roof. The low temperatures and the large temperature variations present considerable challenges to the design. The material must permanently resist vibrations at all temperatures.

Regional regulations in the development taken into consideration

At Rexroth, this design is handled by a development department that is fully specialized in the design and layout of ventilation and cooling assemblies for electrical as well as for diesel engine driven locomotives and rail cars. The industry specialists take the regional regulations into consideration in the context of their work.

Spare parts supply secured over decades

“Railway carriers expect a spare parts supply over the course of 40 years”, Gunther Neidlein explains. Rexroth fulfills these requirements with systematic obsolescence management. If the production of components that are used in railway technology is terminated, Rexroth develops retro-fitted compatible follow-up products. This ensures that a spare part is always available.

216 cooling modules are delivered by Rexroth for the Russian “martins”, immediately ready to install to the assembly lines in Germany and Russia. There, the cooling systems are connected mechanically, electrically and with hydraulics. For the XXII Olympic Winter Games, Russia is opening the gate to the future and the new regional trains will take the spectators to the competition sites in Sochi reliably and quickly, even at the lowest temperatures.

Economical, precise, safe, and energy efficient: drive and control technology from Bosch Rexroth moves machines and systems of any size. The company bundles global application experience in the market segments of Mobile Applications, Machinery Applications and Engineering, Factory Automation, and Renewable Energies to develop innovative components as well as tailored system solutions and services. Bosch Rexroth offers its customers hydraulics, electric drives and controls, pneumatics, gear technology, and linear motion and assembly technology all from one source. With locations in over 80 countries, more than 37,500 associates generated sales revenue of approximately 6.5 billion euros in 2012.

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The Bosch Group is a leading global supplier of technology and services. In fiscal 2012, its roughly 306,000 associates generated sales of 52.5 billion euros. Since the beginning of 2013, its operations have been divided into four business sectors: Automotive Technology, Industrial Technology, Consumer Goods, and Energy and Building Technology. The Bosch Group comprises Robert Bosch GmbH and its roughly 360 subsidiaries and regional companies in some 50 countries. If its sales and service partners are included, then Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further growth. Bosch spent some 4.8 billion euros for research and development in 2012, and applied for nearly 4,800 patents worldwide. The Bosch Group’s products and services are designed to fascinate, and to improve the quality of life by providing solutions which are both innovative and beneficial. In this way, the company offers technology worldwide that is “Invented for life.”

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