Pneumatic Brake Control for trains, locomotives and freight cars

Now also available for regional, commuter rail and high-speed trains.

Knorr-Bremse made rail engineering history with the decentralized Brake Control System Family originally known as EP2002. Featuring new functionalities, the rebranded CubeControl Family is now ready to write the next chapter. The new deceleration control system ensures reproducible braking distances even in rapidly changing environmental conditions. New Ethernet specifications enable condition-based maintenance. The new Wheel Slide Protection algorithm reduces braking distances even under extremely low adhesion. And all this is now also fully available for the mainline sector.

System benefits

Fully integrated and standardized solution concentrated in a compact underfloor-ready cube. Direct EP brake control for service and emergency brake with 2-channel WSP.

Operations

• Reduced operational costs
• Operational gains in line capacity and operational stability thanks to Reproducible
• Braking Distance (RBD)
• Overhaul period of up to 12 years
• Reduced spare parts needed in stock
• Brake pipe and distributor compatibility

System properties

• Failure-resilient brake architecture
• Optimized braking performance
• Light & compact to maximize passenger space
• Faster installation and commissioning

Hardware & software

• Control external auxiliary functions
• Integrated service tool software tracks system status
• Inbuilt data storage capability
• Optional support for external distributor for indirect backup brake

Extended operational functionsn

• RBD included – new advanced functionality
• Brake disk temperature monitoring
• DNRA function for high-speed trains

Buildup

• Per-bogie control
• Electro-Pneumatic design: compact, lightweight & highly integrated
• No external WSP valves required

SMART functions

• Cybersecure Ethernet train-bus communication
• Integrated CBM functionality
• Remote accessibility and diagnostics
• Webserver based tooling

Applications

• Metro
• Regional & commuter trains
• High-speed trains

The flexible and powerful FlexControl system family provides mainly brake cylinder pressure control, especially for central (per-car) & decentral (per-bogie) control. It can integrate indirect brake via brake pipe and distributor valve ranging from simple backup up to full UIC compliance. Wheel slide protection function as well as different auxiliary control functions can be integrated as an option. Its modular design of electronic and pneumatic modules allows configuration for most train applications.

Customer benefits

• Market-proven discrete but highly integrated components & technology
• Pneumatic portion optimized to be controlled with KB SysControl
• Flexible and extensible system layout for numerous system configurations
• Maximum economy thanks to standardization, modularization, and common parts share
• Straightforward service and easy maintenance concept
• Proven concepts for low LCC

Applications

• High-speed trains
• Metros
• Regional & commuter trains

Exemplary standard pneumatic units with FlexControl module kit

• based on highly-integrated electro-pneumatic modules
• optimized design for lower life cycle cost & improved overhaul
• Optional modules achieve outstanding functional integration, e.g.
• Parking Brake Control
• Magnetic track brake pneumatic control
• integration of distributor valve (indirect brake)
• Options for underfloor integration of electronics
• Further extendable by PLUS modules

FlexControl Modular

• Core function: brake cylinder pressure control with continuous load correction

FlexControl Lite

• Core function: brake cylinder pressure control with pneumatic load limitation

PLUS modules

• Standardized extension panels for various auxiliary functions, e.g. Sanding, Pantograph, Magnetic-Track-Brake, Wheel-Slide-Protection, Air Suspension, ... or any special function required

Integration of electronics: optimized to be controlled with Knorr-Bremse SysControl

Detached electronic unit …

• … allows separate positioning of pneumatic & electronic units in tight installation space situations
• Electronic unit can be placed in an underfloor or indoor housing

Attached electronic unit …

• … allows compact all-in-one solutions to minimize final-assembly (cabling) effort
• Different underfloor electronic units keep pacewith the functional variability

Applications: Freight Cars | Locomotives | Passenger Coaches | Multiple Units

New generation distributor valve KE for UIC market

When the first KE Classic valve entered service in 1953, its engineers had written a new chapter in railroad history. The KE Classic was the first distributor valve capable of always filling the brake cylinder within the prescribed time, regardless of size and piston stroke. It replaced high-maintenance mechanical slide valves by reliable rubber membranes and seat valves. Furthermore, the entire design was based on a modular principle.

After over six decades in operation, the KE distributor valve kit was re-engineered from the ground up. The new generation offers a high level of standardization which enables a lean spare part and stock management. It is complemented by newly developed relay valves featuring single stage, two-stage and load-dependent types.

Again, a new standard has been set: solid sand-cast designs have been replaced by state-of-the-art hot-pressed aluminum parts, resulting in significantly reduced installation space and weight.

The standard version now fits vehicles with limited installation space – such as low-floor cars – without any special modifications. And the ready-for-future tag is no advertising gimmick – the valves have been designed to be ready for the digitalization of freight cars.

Universal common parts strategy lies at the heart of this approach. The requirements of a wide range of vehicle types can be met flexibly with just one distributor valve and a handful of relay valve variants.

Furthermore extensive endurance testing was conducted to preserve at least the same or even higher mission reliability and long overhaul intervals of the existing generation. All wear parts of the new KEf have been designed for best-in-class durability. When a valve needs to be overhauled, the bracket simply remains on the car. The lightweight valves are easily detachable from the bracket.

Customer Benefits:

• Overall weight reduction up to 30%, reduced installation space up to 50%
• (complete unit of bracket, distributor and relay valve)
• Valve portions lighter by up to 75% and more compact by up to 55%
• Long overhaul intervals, best-in-class durability of all wear parts, even better mission reliability compared to existing generation
• Pilot volumes of distributor and relay valve now integrated in bracket
• No valve modification required for low floor cars anymore
• Maintenance free, easy overhaul in long intervals

Life-Cycle Assessment – focus Product Carbon Footprint

Distributor valve, Type: KE saves 52% CO2-emissions during its lifetime
compared to the KE Classic distributor valve, Type: KE0dvKSL

Main features:
KE – for UIC market

• Distributor valve KE in conjunction with related relay valve family covers as valve kit all UIC market requirements
• Graduated application and release
• Certified according to UIC and TSI regulations and based on the proven design principles
• Seamless integration into various car types due to kit design
• Interchangeable with all UIC approved distributor valves
• Indirect EP brake possible
• Covers all existing KE classic distributor valve variants
• Improved spare parts & stock management - standard distributor valve
• Reduced installation space and weight
• Standardized car interface
• Working temperature -40 °C to +70 °C (low-temperature version for -50 °C available)

KE – for Multiple Units

• Dedicated variant for integration in EMU/DMU brake systems
• Graduated application and release
• Distributor valve with full EN15355 functionality
• Certified according TSI
• Optimized for EP systems
• Over 90% common parts with standard KE distributor valve, but smaller dimensions for easier integration
• Working temperature -40 °C to +70 °C

KE for Multiple Units (Backup)

• Dedicated variant for integration in EMU/DMU brake systems
• Graduated application and release
• Design and functionality optimized for backup
• No UIC or TSI certification
• Optimal for backup usage in EP systems Over 90 % common parts with standard KE distributor valve, even smaller dimensions than KE for Multiple Units
• Working temperature – 40 °C to + 70 °C

KE Classic – for UIC

• Former standard valve generation KEdv
• Proven in service around the world
• Superseded by new valve kit KE for UIC market (as above)
• KE Classic stays available, in particular for spare part service as well as for specific variants
• Working temperature -40 °C to +70 °C (low-temperature version for -50 °C available)

DB60 – for AAR freight market

• Standard valve for AAR freight trains
• Graduated application and direct release
• Designed for accelerated service brake signal transmission
• Improved control of long and heavy trains
• Separation of service and emergency brake portions
• Interchangeable with all AAR approved distributor valves
• Working temperature -40 °C to +66 °C

EP60 – for AAR freight market

• Electronically controlled pneumatic (ECP) brake system
• Graduated application and release
• Meets AAR performance and interoperability specifications per S-4200
• Simultaneous signal transmission through the train
• Load-compensated braking at each wagon
• Online diagnostics at each wagon
• Improved handling of long, heavy trains, providing shorter stopping distances and saving energy
• Working temperature -40 °C to +66 °C

Valve technology that can address the needs of the world's trains. Being able to serve a global market means delivering products to meet very specific and often demanding requirements – for example a valve with the ability to operate in extreme environmental and climatic conditions such as temperatures down to -50°C!

At the heart of pneumatic brakes is the distributor valve, reacting precisely to changes in brake pipe pressure. Modern valves are sophisticated pieces of technology, providing load-dependent braking for various specific brake types. Millions of these valves are in daily use all over the world, but they are not a "universal" product: various regions have different standards that have been established over the years and are not compatible with one another. All distributor valves have in common long overhaul intervals and low life-cycle costs and are characterized by their robust and reliable design.

The Knorr-Bremse KE distributor valve for example is extremely popular in the core European and Asian UIC market and having proved itself in operation, the valve has now become synonymous with absolute reliability.

In American and African markets, the Knorr-Bremse DB60 distributor valve is the standard valve which uses AAR technology. Also the Australian railways system ARA operates with Knorr-Bremse DB60 distributor valves, employed for trains carrying heavy ore.

Modular Brake System

MaxControl (former CCB3) is the designated successor to the proven CCBII product family for China. The core components and architecture are derived from the technical specifications of the latest generation brake developed by Knorr-Bremse, including the latest technologies in electronic components, system architecture and integration. MaxControl has been designed from the outset as a modular kit for complete locomotive brake systems which considers variations according to TJ/JW-100 standard.

Customer benefits

• Improved mission reliability
• Life-cycle cost reduction
• Improved diagnostics
• Improved configurability
• Shorter lead times
• Higher accuracy control
• State-of-art mechatronic LRUs
  

Locomotive Applications

• AAR China

Customer Benefits

Design and integration

• The local experience of Knorr-Bremse has been used to develop MaxControl for locomotive builders and operators in China
• The brake system interface to the locomotive can be standardized for individual loco builders
• Highly standardized modules with fewer variants
• Enhanced on-site configurability
• The pipework will always be on the rear for similarity of installation
  

Improved reliability and safety

• MaxControl offers significant improvement in mission reliability by using latest technology and sophisticated system architecture
• Meets EN5012x Safety Standard
  

Reduced life cycle costs

• Improved maintainability
• Standardized modules → less inventory
• Improved diagnostics and service access
• Unsurpassed support in the field
• Active obsolescence management
• Best-in-class overhaul