Efficient compressors for rail vehicles by Knorr-Bremse

Intelligent air supply unit

The intelligent air supply unit AirSupply Smart (iASU) is able to supply demand-driven compressed air according to the required situation. As a fully integrated system, it combines intelligent control with monitoring of operating conditions. In addition, the system is optimized in space, weight and lifecycle costs. Key functions allow the reduction of noise emission and energy consumption.

Customer benefits

• Integrated Pantograph mode (battery start-up)
• Integrated Boost mode (for fast fill-up)
• Integrated Silent mode / Night mode
• Integrated full system condition monitoring
• Anytime extendable functions
• Automatic mode - to adjust the volume flow to the real demand
• Improved energy efficiency
• Easy system integration
• Reduced LCC
• Reduced weight
• Downsizing potential

Applications

High-speed trains · Locomotives · Metros · Passenger coaches · Regional & commuter trains

System integration

AirSupply Smart provides the possibility to be integrated in all common installation situations with less effort: under floor installation, inside installation in car body, roof mount installation.

Optimized operation & control

The main idea of AirSupply Smart is the full system approach of air supply, utilizing an inverter to not only control the motor speed, but also to link all system components intelligently:

• Boost Mode: Increase the volumetric air flow of the compressor over its normal limits for a short period of time. This reduces the reservoir fill-up time always when it is needed or enables to downsize the compressor.
• Automatic Mode: Automatically adjustment of air delivery to the real demand.
• Silent Mode: The compressor will be actively set to a lower rotation speed and reduces the noise emission whenever no high air demand is required, e.g. at night. Compared to Boost Mode the sourced energy emission is reduced by AirSupply Smart.

Noise emission management

AirSupply Smart was specially developed to adjust to specific situations, so it is possible to reduce or even avoid noise when it is most relevant e.g. at the station or at night. Supporting functions are the Silent Mode (see above).

Improved energy management

Eco-friendlyness is becoming more and more important. Several functions enable AirSupply Smart to improve energy consumption:

• Soft start functionality: Avoids inrush current.
• Power converter: It enables AirSupply Smart to be supplied, appard from to the standard AC voltage, now also by stabilized DC voltage, this allows to reduce the size and the weight of the auxiliary power unit and enables the usage of a more energy efficient DC voltage backbone.
• Intelligent regeneration control: Adaptive air dryer control reduces regeneration air demand.

Flexible & lightweight design

Product and system modularity lead to space and weight saving:

• No auxiliary compressor: The ability to supply the main compressor temporarily from the car battery eliminates the need for a separate auxiliary air supply system.
• Downsizing potential: By using the Boost Mode it is possible to cover temporary demand peaks with a smaller or less compressors.

Digital communication

AirSupply Smart combines hardware with software from one source. The system interfaces features several options for communication and control. With its integrated monitoring network it collects crucial information of components and provides health status information.

• Anytime extendable functions: Gives the possibility to extend and update the functions installed on AirSupply Smart by an easy software update which enables the customer to benefit also from later developments / releases.
• Integrated condition monitoring: By combination of sensor data and inverter information, analysed and interpreted by inbedded software and algorythems, the iCM profides a full system health status monitoring.
  

AirSupply Smart with ScrewSupply Eco

Discover the future of rail transport with our efficient and reliable AirSupply Smart with ScrewSupply Eco, reducing operating costs as well as lifecycle costs. With easy overhaul and maintenance, it minimizes interruptions and maximizes efficiency. Featuring an improved oil separation system, it offers an environmentally responsible solution for a sustainable future. Our compressor supports global rail industry trends, leading your company forward.

Customer benefits

• Simplified service and maintenance friendly design that is easy to access
• New innovative oil separation system reduces Life Cycle Cost as well as oil carry over
• Overall lifecycle reduction by more than 40%
• Weight and installation space reduction due to new mechanical interfaces and housing
• Special electrical fan design for adaptive cooling protects parts from rapid wear and increases the reliability of the system
• Significantly reduced noise level
• Even more benefits with integration to AirSupply Smart

Key features

New oil separation system:

• Long exchange intervall for the oil separator
• Low oil carry over
• Simple oil level check and handling

New housing:

• Optimized mechanical pre oil separator to increase the lifetime of the oil separation system
• Simulation based weight optimization of all casting parts leads to increased reliability and robustness

New E-fan:

• Adaptive speed: Demand-dependent control based on the temperature instead of continuous operation
• Improved cooling performance: Higher ventilation power combined with a homogenous cooling air distribution over the radiator
• Accessiblity: Direct access to cooler for cleaning
  

Benefits of integration into AirSupply Smart & applications

• Boost Mode: Increase the volumetric air flow of the compressor over its normal limits for a short period of time. This reduces the reservoir fill-up time always when it is needed or enables to downsize the compressor
• Silent Mode: Set to a lower rotation speed and reduces the noise emission whenever no high air demand is required
• Pantograph Mode: Ability to use standard car battery with no additional effort on car builder side. No installation of auxiliary air supply unit needed. Without this and accesories means less weight and installation space
• Integrated Condition Monitoring with specialized imbedded algorithm judges sensor data

Applications: High-speed trains · Regional & commuter trains · Metros · Locomotives

ScrewSupply Eco – type and air delivery

iASU SL2.0: 920 - 2270 l/min

Oil-free piston compressor

The Knorr-Bremse oil-free piston compressor has created a paradigm shift in the rail industry. With no oil in the system, the compressed air output is clean and free of oil. The Knorr-Bremse oil-free piston compressor PistonSupply Eco (VV-T 2.0) offers an outstanding combination of high performance, low vibration and noise levels, combined with worldwide field experience. Continuous technical improvement has now led to the next generation oil-free piston compressors.

Customer benefits

• Service-proven product with more than 40,000 units sold
• Oil-free air is environmentally friendly and causes no downstream contamination
• Cold starts without preheating, down to -50 °C
• Specially optimized design to minimize noise and vibrations
• No oil exchange, no disposal of used oil, no contaminated condensate to collect

Key features

• Designed for railroad applications
• Continuously improved product based on long-term worldwide experience
• Less complex system with fewer interfaces than conventional compressor systems
• Robust design for underfloor mounting conditions as well as for standing installation, roof-mounted or interior

Applications & types

High-speed trains · Regional & commuter trains · Metros · Light rail vehicles · Monorails · Locomotives · Special vehicles

Optimized sound profile

Reducing noise emissions of rail vehicles is becoming an increasingly high priority. The PistonSupply Eco Silent (VV-T Silent) offers an optimized sound profile, using innovative development and simulation methods, that have enabled Knorr-Bremse to achieve noise emission targets previously unattainable for an non-capsuled compressor. This compressor is the result of our ongoing commitment to reducing our ecological footprint, innovating, implementing technical improvements, and maintaining the highest quality standards.

Customer benefits

• Quietest compressor without soundproofing encapsulation ever supplied in this output range
• Sound pressure reduction of up to -15 dB(A) - A 6 db(A) reduction in sound pressure is equivalent to a 50% reduction
• The noise reduction of the Silent valve system is overproportional achieved in combination with an AirSupply Smart in Silent Mode
• Also includes all the features of the PistonSupply Eco (VV-T 2.0)

Key features

• More robust design for harsh conditions
• Updated bearing system
• The new E-fan provides optimized bearing cooling airflow and a more homogeneous temperature distribution
• Reduced noise level with built-in E-fan and redesigned Silent valve system
• The noise reduction of the Silent valve system and E-fan is overproportional achieved in combination with an AirSupply Smart in Silent Mode

Integration into AirSupply Smart, applications & type

• Boost Mode: Increase the volumetric air flow of the compressor over its normal limits for a short period of time. This reduces the reservoir fill-up time always when it is needed or enables to downsize the compressor.
• Downsizing Potential: By using the Boost Mode it is possible to cover temporary demand peaks with a smaller or less compressors.
• Silent Mode: The compressor will be actively set to a lower rotation speed and reduces the noise emission whenever no high air demand is required, e.g. at night.

Applications: Regional & commuter trains · Metros · Light rail vehicles

Next generation air dryer

The Knorr-Bremse air dryer has turned into the next evolution for the rail industry. The DrySupply Compact (LTZ-C) offers an outstanding combination of high drying performance, compact design and digitally connectivity, combined with worldwide field experience. Continuous technical improvement and standardization has now led to the next generation of the Knorr-Bremse air dryer portfolio.

Customer benefits

• New compact design, optimization of installation space and weight
• Cold starts without preheating, down to -40 °C
• With SupplyControl Smart: fit for diagnostics and condition monitoring
• Simplification in assembly and maintenace
• Standardization, reduction of air dryer variants
• Reduction of Total Cost of Ownership and Life Cycle Costs

Key features

• Environmentally friendly design
• Designed for railroad applications
• Modular system to simplify the maintenance activities
• Improved maintenance – pit stop concept ready
• Continuously improved product based on long-term worldwide experience
• Reduced weight
• Standardized portfolio – one design covers whole compressor portfolio

Air Dryer solutions for multiple applications

Air Dryer System

DrySupply Smart Max, LD-1000, air dryer increases the availability of the entire train by providing clean, dry air with best-in-class life-cycle costs. Braking systems equipped with the Knorr-Bremse Air Dryer improve reliability as well as safety, so that freight rolling stock can keep up with the industry’s increasing demand for on-time arrival.

Customer benefits

• 10-year product life prior to major overhaul due to superior air dryer pre-filtration
• Lengthened life of all downstream components
• Low life-cycle costs
• Visual indication of the proper function of the air dryer through “Blue-Eye” humidity indicator
• Prevention of freezing within the locomotive and train brake system as a result of dry air
• Optimized closed-loop regeneration minimizes purge air losses, providing significant energy savings

Applications: Conventional locomotives · Heavy-haul freight locomotives

Technical data & key features

Key features

• Minimized purge air use as well as longer component life due to fewer valve operation cycles, both as a result of intelligent regeneration control
• Easy installation, interchangeable with typical AAR unit
• Single-valve block LRU in which all valve elements controlling the draining of the 3-stage pre-filtration and the switching of the desiccant circuits are co-located; replaceable as a single module
• Required service can be completed in less than 15 minutes without disturbing electronics or pneumatics