Flexible solutions for rail vehicles

Transcription

1 Flexible solutions for rail vehicles 6200uk/1/07/12/1 Witzenmann GmbH Östliche Karl-Friedrich-Str Pforzheim, Germany Phone (0) Telefax (0) wi@witzenmann.com

2 ON THE MOVE FOR YOu AROuND THE WORLD Worldwide America brazil usa Asia China India Korea Europe Austria belgium Czech Republic France Germany Great britain Italy Poland Russia Slovakia Spain Sweden "Managing flexibility" is both a claim and a vision of the Witzenmann Group. In 1885, Heinrich Witzenmann founded the metal hose and expansion joint industry with the invention of the metal hose. Today, the Witzenmann Group is one of the world's leading manufacturers of flexible metallic elements. In 2009, over 3000 employees at 23 locations worldwide generated a turnover of 320 million euros. As a technology leader in this sector, we are in high demand internationally with customers active in the automotive industry, plant engineering and construction, technical building equipment and many other areas, including the aerospace industry. For this reason, our customers include all major manufacturers of rail vehicles. Witzenmann is an expert partner for development projects ranging from design to series production be it to create flexible metal elements as components or to jointly develop complex systems. Quality and reliability from the technology leader. 2 3

3 ENGINEERING MADE by WITZENMANN System developer Our global network ensures that our customers around the world receive what Witzenmann stands for: optimal solutions of the highest quality. We achieve this in close cooperation with the customer and by means of the most stringent test programs: electrodynamic vibration test stands, hot gas and durability testing facilities, and corrosion testing equipment, to name but a few. Our customers now include all major international manufacturers of rail vehicles. When it comes to economical and dependable system solutions, Witzenmann is the first choice. Worldwide. 6-axis test stand Wherever there is a need for flexible connections that are exposed to pressure, movement, and high or low temperatures, manufacturers turn to Witzenmann. In rail vehicles, this applies to the following areas: Transformers Refrigeration systems Air-conditioning units Power transmission (gearboxes) brake systems Exhaust systems A long service life and high operating reliability are important product features. Witzenmann is also an industry leader when it comes to quality standards. We therefore have all relevant approvals and certifications, such as EN Engineering made in Germany, of course. A glance at our references: Transformers: Voith Turbo, bombardier, Siemens Refrigeration systems: Alstom, Mahle behr Industry, Vossloh Air-conditioning units: bombardier Power transmission: Vossloh Brake systems: Siemens, bombardier Exhaust systems: bombardier-france, Vossloh, Eminox Cold-warm test stand 4 5

4 TRANSFORMERS OIL CIRCuIT ExHAuST SYSTEMS Application examples Application examples Oil pipe connecting a transformer Decoupler in exhaust systems with a cooling tower Flexible metal bellows/expansion joint Annularly corrugated hose with external braiding Design according to customer specifications Design according to customer specifications Connectors according to customer specifications Connectors according to customer specifications Use of one or more flexible elements, Use of one or more flexible elements, depending on requirements depending on requirements With or without insulation With or without insulation Complete system with bent stainless steel Expansion joint in the exhaust system. pipe and welded annularly corrugated hose as transformer oil pipe. Compensation of vibrations, Compensation of vibrations, thermal expansion and installation tolerances thermal expansion and installation tolerances Gas-tight element meets the most stringent Temperature-resistant thanks to selection exhaust gas regulations Temperature-resistant thanks to selection Corrosion-resistant thanks to selection Corrosion-resistant thanks to selection Low weight Pressure-resistant Low weight Diffusion-resistant 6 7

5 REFRIGERATION SYSTEMS brake SYSTEMS Flexible elements in transformer oil cooling circuits Pipe with flexible metal bellows With and without internal sleeve With and without insulation With and without braiding, inside and outside Design according to customer specifications, preferably with flexible section Connection with flange, V-End or according to customer specifications Optionally segment and/or bare pipe elbow (up to DN 150) from our own production Compensation of thermal expansion and installation tolerances, decoupling of vibrations Technically gas-tight thanks to metal bellows Heat and pressure-resistant thanks to selection and multi-layer construction Resistant to corrosive media or media constituents thanks to selection of suitable materials Geometric and technical properties and connection technique can be adapted to suit customer-specific installation situation Application examples AECMA-EASE certified bellows solution designed as a flexible Aerocert connection certificate, pipe, EN9100 assembled (including according responsibility for development) to customer specifications and ready to install. Listed in the IAQG OASIS database Approved as per DVS2718, defence technology welding approval JAR/EASA Process and product audits as per SAE AS 7003 (NADCAP) The HYDRA product brand stands for products that meet the most demanding quality standard processes, which are regularly audi- the aerospace industry has begun to define requirements. Corresponding with our claim ted and certified at the respective suppliers of quality leadership, Witzenmann quality according to SAE AS 7003 (NADCAP) and management is firmly anchored in all processes Application according examples to the relevant process specifications of the independent Performance Review Compensation of installation and structures, tolerances and in hence secures brake systems uniformly high quality standards within the Institute (PRI) of the SAE. Witzenmann works Witzenmann Group on a global basis. on both levels and therefore is one of the few companies worldwide which are able Annularly corrugated Quality hose at the with system external level braiding to conduct an entirely in-house qualification Design according The certification to customer of specifications the quality management process for e.g. metal hose programs as per Connectors system according pursuant to customer to the specifications ISO 9001 and TS AS1424. Use of one or more standards flexible elements, forms the basis for a process-oriented depending on requirements quality assurance program for Quality at the product level With and without the entire insulation Witzenmann Group. In addition, Flexible an annularly In order to corrugated address all hose requirements for when annual audit by an IAQG accredited certification company according to EN9100 is carried tionality and materials, we make use of our compensation verifying of installation product properties tolerances. in terms of func- Compensation out of specifically vibrations, for thermal the special expansions requirements very extensive testing facilities. Hydraulic and installation of the tolerances aerospace industry. and electrodynamic vibration test stands, hot Technically oil-tight gas and durability testing facilities, and corrosion testing equipment are just a few of the Temperature-resistant Quality at the process level Corrosion-resistant In view of the small batch sizes in the aerospace industry, the focus is on 100% quality extreme conditions. The effects of all types of stations we use to test our products under Pressure-resistant Diffusion-resistant inspection for individual and final parts. As operating conditions on the metallic product a result, investigations regarding equipment or component structure are investigated in capability and automatic Statistics Process our own materials laboratory, including the Control (SPC) that would be applied to large use of scanning electron microscopy. series are replaced by elaborate customerspecific process qualifications. In this vein, 8 9

6 Air-conditioning units Power transmission (gearboxes) Flexible elements in refrigeration systems for space cooling Annularly corrugated hose with external braiding Vibraflex vibration absorbers are chiefly used in cooling systems such as air-conditioning units, refrigeration plants and heat pumps. Vibraflex Stainless steel hose with factory-welded copper connections. Advantages: More stability through stainless steel hose Simple brazing into existing copper pipes directly at the construction site Stainless steel hose with welded stainless steel connection pieces. vibration absorbers prevent transmission of vibrations and have a sound-insulating effect. Vibraflex life. Designed for use with modern refrigerants The hose features high stability and a long service AECMA-EASE certified vibration absorbers are resistant to the usual refri-aerocergerants. Stainless steel must be used for R 717 (NH bility for Advantage: development) such certificate, as ammonia EN9100 (NH3). (including responsi- 3). Vibraflex vibration absorbers are frost-resistant. simple welding into steel pipes. Listed in the IAQG OASIS database All connections can be designed according Approved to customer as per DVS2718, specifications. defence technology welding approval Vibraflex is available in 3 models. JAR/EASA Application examples Bronze hose with copper connection Process and product audits as per SAE AS 7003 pieces. (NADCAP) For conventional applications in the area of refrigeration/air-conditioning technology. Simple and problem-free brazing with copper connection pieces. The HYDRA product brand stands for products that meet the most demanding quality requirements. Corresponding with our claim of quality leadership, Witzenmann quality management is firmly anchored in all processes and structures, and hence secures the aerospace industry has begun to define standard processes, which are regularly audited and certified at the respective suppliers according to SAE AS 7003 (NADCAP) and according to the relevant process specifications of the independent Performance Review uniformly high quality standards within the Application Institute examples (PRI) of the SAE. Witzenmann works Transmission oil Witzenmann pipe Group on a global basis. on both levels and therefore is one of the Quality at the system level few companies worldwide which are able to conduct an entirely in-house qualification Annularly corrugated The certification hose with of external the quality braiding management Design according system to pursuant customer to specifications the ISO 9001 and TS process for e.g. metal hose programs as per AS1424. Connectors according standards to customer forms specifications the basis for a process-oriented more flexible quality elements, assurance program for Use of one depending on the requirements entire Witzenmann Group. In addition, an annual audit by an IAQG accredited certification Quality at the product level In order to address all requirements when verifying product properties in terms of func- company according to EN9100 is carried Pressurised tionality pipes and for transmission materials, we oil. make use of our Compensation out of specifically vibrations, for the special requirements thermal expansion of the aerospace and installation industry. tolerances Technically oil-tight Temperature-resistant Quality the process level Corrosion-resistant In view of the small batch sizes in the aerospace industry, the focus is on 100% quality Pressure-resistant Diffusion-resistant inspection for individual and final parts. As a result, investigations regarding equipment capability and automatic Statistics Process Control (SPC) that would be applied to large very extensive testing facilities. Hydraulic and electrodynamic vibration test stands, hot gas and durability testing facilities, and corrosion testing equipment are just a few of the stations we use to test our products under extreme conditions. The effects of all types of operating conditions on the metallic product or component structure are investigated in our own materials laboratory, including the use of scanning electron microscopy. series are replaced by elaborate customerspecific process qualifications. In this vein, 10 11

7 SPRINKLER APPLICATIONS COMPONENTS IN ENGINE VICINITY RETuRN PIPES 12 High pressure pipes for water mist systems Heavy annularly corrugated hose with external braiding Design according to customer specifications Connectors according to customer specifications Available as complete system, incl. installation components AECMA-EASE certified Heavy model for higher fire protection classes Compensation of vibrations, thermal expansion and installation tolerances Temperature-resistant Corrosion-resistant High-pressure-resistant Maintenance-free Aerocert certificate, EN9100 (including responsibility for development) Listed in the IAQG OASIS database Approved as per DVS2718, defence technology welding approval JAR/EASA Process and product audits as per SAE AS 7003 (NADCAP) The HYDRA product brand stands for products that meet the most demanding quality requirements. Corresponding with our claim of quality leadership, Witzenmann quality management is firmly anchored in all processes and structures, and hence secures the aerospace industry has begun to define standard processes, which are regularly audited and certified at the respective suppliers according to SAE AS 7003 (NADCAP) and according to the relevant process specifications of the independent Performance Review uniformly high quality standards within the Application Institute examples (PRI) of the SAE. Witzenmann works Exhaust gas return Witzenmann pipes Group on a global basis. Pipes for exhaust gas return for use with petrol and diesel engines Quality at the system level Oil return pipes The certification of the quality management Pipes for oil return system for pursuant use with to the ISO 9001 and TS on both levels and therefore is one of the few companies worldwide which are able to conduct an entirely in-house qualification process for e.g. metal hose programs as per AS1424. petrol and diesel engines standards forms the basis for a process-oriented quality assurance program for the entire Witzenmann Group. In addition, an Quality at the product level In order to address all requirements when Design according annual to audit customer by an specifications, IAQG accredited certification verifying product properties in terms of func- corrugated company according section to EN9100 is carried Oil return tionality pipe in vicinity and materials, of engine. we make use of our preferably with Elbow as bare out pipe specifically elbow or for asthe special requirements a bend in the of corrugated the aerospace section industry. Connection with flange, V-End or according Quality to customer at the specifications process level With and without In view insulation of the small batch sizes in the aerospace industry, the focus is on 100% quality inspection for individual and final parts. As Compensation a result, of vibrations, investigations regarding equipment thermal expansion capability and and installation automatic tolerances Statistics Process Technically oil- Control and gas-tight (SPC) that thanks would be applied to large very extensive testing facilities. Hydraulic and electrodynamic vibration test stands, hot gas and durability testing facilities, and corrosion testing equipment are just a few of the stations we use to test our products under extreme conditions. The effects of all types of operating conditions on the metallic product or component structure are investigated in our own materials laboratory, including the use of scanning electron microscopy. to metal bellows series are replaced by elaborate customerspecific process thanks qualifications. to selection In this vein, Temperature-resistant Corrosion-resistant thanks to selection Low weight 13

8 COMPONENTS IN ENGINE VICINITY ExHAuST ExPANSION ELEMENTS PROTECTIVE HOSES Exhaust gas: in front of and behind the turbocharger Charge air Application examples With and without internal sleeve With and without insulation Design according to customer specifications, preferably with corrugated section AECMA-EASE certified Connection with flange, V-End Expansion joints in exhaust systems. or according to customer specifications Aerocert certificate, EN9100 (including responsibility for development) Listed in the IAQG OASIS database Technically gas-tight thanks to metal bellows Temperature-resistant thanks to selection Approved as per DVS2718, defence technology welding approval and multi-layer construction Corrosion-resistant thanks to suitable JAR/EASA materials Process and product audits as per SAE AS 7003 Currently available in all standard nominal (NADCAP) diameters and lengths Geometric and technical properties and connection techniques can be adapted to suit customer-specific installation situation Pressure-resistant thanks to multi-layer design The HYDRA product brand stands for products that meet the most demanding quality requirements. Corresponding with our claim of quality leadership, Witzenmann quality management is firmly anchored in all processes and structures, and hence secures the aerospace industry has begun to define standard processes, which are regularly audited and certified at the respective suppliers according to SAE AS 7003 (NADCAP) and according to the relevant process specifications of the independent Performance Review uniformly high quality standards within the Application Institute examples (PRI) of the SAE. Witzenmann works Cable sheathing Witzenmann Group on a global basis. on both levels and therefore is one of the Quality at the system level few companies worldwide which are able to conduct an entirely in-house qualification Stripwound metal The certification hose with interlocked of the quality profile management Sealed and unsealed system pursuant models to the ISO 9001 and TS process for e.g. metal hose programs as per AS1424. With or without PVC standards coating forms (liquid-tight) the basis for a process-oriented galvanised steel, quality stainless assurance steel program for Available in Quality at the product level or brass the entire Witzenmann Group. In addition, an In order to address all requirements when Special hoses annual for glass audit fibres by an (of IAQG aluminium) accredited certification verifying product properties in terms of func- according company to customer according specifications to EN9100 is carried Protective tionality hoses of and various materials, types we depending make use of our Connectors Use of one or out more specifically flexible for elements, the special requirements on the application very extensive area. testing facilities. Hydraulic depending on of the requirements aerospace industry. and electrodynamic vibration test stands, hot gas and durability testing facilities, and corrosion Quality at the process level Very flexiblein view of the small batch sizes in the aerospace strength industry, and resistance the focus is on 100% quality High tensile to transversal inspection pressure for individual and final parts. As High crushing a result, strength investigations regarding equipment Temperature-resistant capability and automatic Statistics Process Corrosion-resistant Control (SPC) that would be applied to large testing equipment are just a few of the stations we use to test our products under extreme conditions. The effects of all types of operating conditions on the metallic product or component structure are investigated in our own materials laboratory, including the use of scanning electron microscopy. From DN 3 to series DN 50 are (depending replaced by on elaborate type) customerspecific process qualifications. In this vein, 14 15