The Art of Precision. A.S.T. GmbH, Mess- und Regeltechnik

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1 The Art of Precision Force transducers, amplifiers, mechanical constructions, software and systems for the quality control of railway vehicles A.S.T. GmbH, Mess- und Regeltechnik

The Art Of Precision measuring systems for the quality assurance of railway vehicles Today we are used to travel calmly at speeds in which former generations would never have believed high-speed

For somebody who lives in Hamburg and likes to travel to Berlin, the ICE express train starts at 8:06 o clock in the Hamburg central station and already 9:45 o clock rolls into the Berlin central

The driver by car who would like to travel as fast to Berlin would have to move constantly on the passing lane Intercity express passengers can drink their morning coffee in the board restaurant

2 The Art Of Precision measuring systems for the quality assurance of railway vehicles Today we are used to travel calmly at speeds in which former generations would never have believed high-speed trains make it possible. For somebody who lives in Hamburg and likes to travel to Berlin, the ICE express train starts at 8:06 o clock in the Hamburg central station and already 9:45 o clock rolls into the Berlin central station. The Intercity express masters the 280-kilometre-long distance into the capital in one hour and 39 minutes which corresponds to an average speed of 170 kilometres per hour. The driver by car who would like to travel as fast to Berlin would have to move constantly on the passing lane Intercity express passengers can drink their morning coffee in the board restaurant comfortably. However, no Intercity express user anticipates which manufacturing precision is necessary to be able to accelerate a mass of 365 tons of an average Intercity express train, safely on 300 kilometres per hour and more. Every single carriage must succeed for it in the work so perfectly that all of its four ground corner points are exactly at the same level, and that its bogies distribute the weight steadily to all wheels, otherwise the carriage would stand with high tension similar to a chair which stands on 4 legs with different lenghts: It would start to further contort under its weight, and this would entail huge material tensions again. Then extreme forces would press to the carriage in the running driving situation this would be an unacceptable risk! Therefore, high-speed trains assume just because of their mass and size an unbelievable exactness in dimension and manufacturing processes A.S.T. delivers the key for the highest precision: Starting from the single measuring cell, modules and measuring systems up to calibration units there comes the complete precision chain out of one hand.

System Components If you need to put up large components like machines, bridges or railway vehicles into a tension-free position, you have to know the force distributions precisely.

within the tension free position. The component HE401 is a robust, mobile and reliable lifting unit.

Application examples are: Semiautomatic car body force measurement system for railway cars Weighing and determining of center gravity of machines and components Controlled moving or deforming of

3 System Components If you need to put up large components like machines, bridges or railway vehicles into a tension-free position, you have to know the force distributions precisely. During this measurment every single measuring load cell transfers its value and is moved out of the levelled position if necessary, until the values are reached which correspond to the force values within the tension free position. The component HE401 is a robust, mobile and reliable lifting unit. It is suited especially to the measuring of heavy forces and can be lifted up to a maximum of 25 mm. Application examples are: Semiautomatic car body force measurement system for railway cars Weighing and determining of center gravity of machines and components Controlled moving or deforming of components As heart of the unit a force transducer is topped with a manual hydraulic jack. The force transducer converts the load into an electrical signal which is later processed transmitted and visualized by the on board indicator. The data is sent alternatively through a cable interface, a wireless radio system, or a data logger GPRS to the PC. To determine the displacement generated by the manual hydraulic pump a relevant optional sensor is available. Several units can be brought together with wireless or a serial interface to monitor and record the data. Lifting Unit with integrated Force and Displacement Measurement Interface (option) Mobile Loadcells MLE-F cable wireless GPRS (Datalogger) Options Remote PC-Software for monitoring and quality control Calibration Displacement measure For mobile applications you can use the mobile load cells MLE-F. Every load cell unit transfers the data wireless to the hand measuring instrument with remote control, which can evaluate the current value, maximum values and the point of center gravity. Application examples are: Weighing of machines Weighing of containers or similar loads Evaluation of the center gravity point The main component of the measuring system is the calibration unit with its functionality. We develop and produce the calibration unit for every system specifically. With our systems to enable the tension free position, each of the four force measuring units can be calibrated individually. For adjustment and recalibration, a defined strength on the measuring cell is given using the hydraulic unit together with special software functions. Thus you can check and adjust the accuracy of the system and the system components. Calibration Unit to check and adjust the accuracy of systems and system components

EKM 305-S EKM 305-SL Corner Load Measuring equipment for Rail Car Bodies to Automatically adjust tension free position.

For adjusting to the tension-free position, the four sensors move upwards to touch the car body and then lift up the car body from the test stand.

The correct corner forces are calculated following the newest standard DIN25043 which incorporates the position of the center gravity.

4 EKM 305-S EKM 305-SL Corner Load Measuring equipment for Rail Car Bodies to Automatically adjust tension free position. Suitable for Shell Production In the shell production the car body is sitting on a stationary fixed test stand which also serves as a levelling system. For adjusting to the tension-free position, the four sensors move upwards to touch the car body and then lift up the car body from the test stand. Now the software together with the precision lifting gear is controlling the height and displacement of each sensor until the correct force and tension free position is reached. The correct corner forces are calculated following the newest standard DIN25043 which incorporates the position of the center gravity. After the car body reaches its tension free position, you can measure the geometric dimensions. For finishing, like directing or welding, you lift down the car body back on to the robust, stationary stands. Thus you can keep to the demanded high-class standards from the beginning of the production to the end and you receive results with the highest precision linked with the greatest possible productivity as well as flexibility, scalability and robustness. Applications: Shell production Customized designs and constructions Coaches (EKM 305-S) Locomotives (EKM 305-SL)

EKM 305-F_ EKM 305-FL Corner Load Measuring System for Rail Car Bodies to Automatically adjust tension

Suitable for Finished Car Body Production After you have concluded the inside final assembly, the corner

The rigged design and the perfect workmanship ensure highest quality for the measuring process as well as

The software fully supports the comfortable levelling of the car body by rotation laser in order to meet

The measuring process runs off similar to the shell production with the EKM 305-S.

5 EKM 305-F_ EKM 305-FL Corner Load Measuring System for Rail Car Bodies to Automatically adjust tension free position. Suitable for Finished Car Body Production After you have concluded the inside final assembly, the corner load measuring system EKM 305-F (for locomotives the EKM 305-FL) is pushed under the car body. The rigged design and the perfect workmanship ensure highest quality for the measuring process as well as for the geometrical measurement. The software fully supports the comfortable levelling of the car body by rotation laser in order to meet the high exactness requirements following the new DIN The measuring process runs off similar to the shell production with the EKM 305-S. Also, the well proven precision lifting gears are used to generate force. Besides, the construction is very adaptable concerning type of car and measuring place. Applications: Final assembly rail car production Service and maintenance Final inspection and testing Repair Special models and constructions Coaches (EKM 305-F) Locomotives (EKM 305-FL)

RAK 402-A Variable Length Wheel Load Measuring System For 1 Gauge and Bogies with 2 Axles RAK 402-B Variable Length Wheel Load Measuring System For 2 Different Gauges and Bogies with 2 Axles Using

You can design and adapt the modular hard and software configuration to meet your requirements with variation variety (axle and bogie distances) and planned measurements.

6 RAK 402-A Variable Length Wheel Load Measuring System For 1 Gauge and Bogies with 2 Axles RAK 402-B Variable Length Wheel Load Measuring System For 2 Different Gauges and Bogies with 2 Axles Using our special test systems for wheel load measuring you control the distribution of the weight on the axles as well as on the single wheels. You can design and adapt the modular hard and software configuration to meet your requirements with variation variety (axle and bogie distances) and planned measurements. The system modules are mountable on an adjustable measuring sledge. Thus you can adapt the system using center pieces to meet different distances of the bogies. You can also install several measuring modules at different places to be able to measure coaches with different lengths or different axle or bogie distances without rebuilding or hardware changes. The software automatically recognises the loaded modules. With the RAK systems you can determine and document all wheel loads and axle loads, the total weight and the position of the center gravity. RAK 403-A Variable Length Wheel Load Measuring System For 1 Gauge and Bogies with 3 Axles RAK 403-B Variable Length Wheel Load Measuring System For 2 Different Gauges and Bogies with 3 Axles While passanger coaches are mostly built with 2 axle bogies, locomotives frequently use also bogies with 3 axles. For these you can lay out the test systems and software accordingly, and similar to the system RAK 402 for 2 axles you can configure the system to meet your respective variation and variety. Since locomotives typically have less variations, you will lay out the system with several measuring segments and interpieces in such a way that the single measuring segments are mounted fixed and must not be altered with another distance of the bogies. The software automatically recognises the loaded modules. With the RAK systems you can determine and document all wheel loads and axle loads, the total weight and the position of the center gravity.

System modules The RAK measuring module with the track section is carried by four stable sensor elements.

We design the RAK of measuring modules and intermediate pieces in such a way that always exactly one wheel comes to a halt at one measuring module.

measuring modules with intermediate pieces and the construction of adjustable measuring sledges enables you the highest flexibility.

Then one measuring carries two rails and the opposite side one rail.

Application: Distribution of load on the individual wheels and/or axles, examination of the center gravity, two different gauges Measuring module and intermediate

Distribution of load on the individual wheels and/or axles, examination of the center gravity, two different gauges As with every measuring system the calibration

7 System modules The RAK measuring module with the track section is carried by four stable sensor elements. Every sensor element transfers the measuring values to a special integrated amplifier which delivers the correct sum to the PC. We design the RAK of measuring modules and intermediate pieces in such a way that always exactly one wheel comes to a halt at one measuring module. Measuring module and intermediate piece for the setting up of systems with firm or also freely adjustable axle- and bogie distances The free combination of the measuring modules with intermediate pieces and the construction of adjustable measuring sledges enables you the highest flexibility. If you want to build up systems with more than one gauge, you can realise this with our modular components RAK 402-B and RAK 403-B respectively. Then one measuring carries two rails and the opposite side one rail. Thus you can realise with a single system which allows the measurement of two different gauges. Application: Distribution of load on the individual wheels and/or axles, examination of the center gravity, two different gauges Measuring module and intermediate piece for the setting up of systems with firm or also freely adjustable axle- and bogie distances, used for systems with two different gauges Application: Distribution of load on the individual wheels and/or axles, examination of the center gravity, two different gauges As with every measuring system the calibration unit is a determining component which we develop and design for every system specifically. If you plan your system for locomotives, a higher calibration force is necessary and a larger unit is used. Calibration Unit to examining the accuracy and for the adjustment of the measuring modules By our complete developing work and technology as well as our own manufacturing of the components up to the system installation, we deliver the highest precision and the best quality to our customers.

8 A.S.T. GmbH, Mess- und Regeltechnik Marschnerstraße Dresden Germany Telefon +49 (0) Fax +49 (0) AST e

Railway Systems. The system to determine and adjust the rolling stock to torsion free position with integrated geometric measurement

Railway Systems. The system to determine and adjust the rolling stock to torsion free position with integrated geometric measurement Railway Systems The system to determine and adjust the rolling stock to torsion free position with integrated geometric measurement The system to determine and adjust position with integrated EKM 305 Systems