Completely on Track for Safe and Relaxed Travel

October 2010At work between the rails and the passenger compartment, ContiTech air springs reliably contribute to the safety of humans and machines – in high-speed trains barreling through the countryside at 190 miles an hour, in trams, metro and rapid-transit systems and in regional trains all around the world.

Trains run by Germany's national rail company, Deutsche Bahn, are so fast that getting to early-morning out-of town business meetings is no longer a problem. The trains can get up to a speed of 190 mph. This does not, however, in any way prevent passengers from immersing themselves in their work. They know that this means of transport is quite simply safe all around. A study published in February by the German Pro-Rail Alliance – made up of environmental and passenger associations – shows that it is almost a hundred times safer to go by rail than by car. And ContiTech is making a major contribution here with its suspension system for rail vehicles.

All around the globe, railway operators are increasingly focusing on high-speed trains, thus providing an interesting alternative to flying or travel options. With their speed, comfort and passenger capacity, high-speed trains are even competitive for medium- and long-distance hauls. In Europe, high-speed routes now also link international metropolises like Paris and London. Primarily the major players in the sector – Bombardier, Alstom and Siemens – are supplying the fast trains circulating on the world’s railway lines. And the suspension technology they use is often also the same. The very high speeds attained by today’s swiftest trains impose strict demands on technology, above all in terms of safety. There can be no compromising in this regard, which is why leading rail vehicle and bogie manufacturers rely on ContiTech quality.

Underneath the passenger seating area, down close to the rails, ContiTech air suspension systems simultaneously carry out the most diverse tasks. At work where wheel and rail are constantly in contact, they allow curves to be negotiated with generous freedom of movement between the carriage and the bogie. The air spring systems reliably and comfortably absorb and dampen jolts and vibrations. Frequencies of more than 200 hertz are no rarity – more than 200 superbly cushioned movements per second, in other words. This tour de force goes largely unnoticed in the coach seating area, but in the bogie below, it requires a gargantuan exertion – under all weather conditions, hot or cold, all year round and under great strain. Each individual air spring must, in fact, support up to 12.5 tonnes.

Top safety research team

The responsibility to maximize passenger safety rests heavily on the shoulders of all involved. This is why ContiTech Railway Engineering (CRE) maintains a development department, in which its large team of specialist engineers is completely devoted to the search for new solutions and the ongoing upgrading of existing products. CRE also exploits to the hilt the potential to be derived from the research and development activities underway throughout ContiTech, all of which is underpinned by the very best in calculation, simulation and testing technology. In the course of testing, the air springs are subjected to massive pressure and are stretched, compressed, loaded, shaken and supercooled. These trials yield key data for current and upcoming developments.

Air Spring Systems engineers have, for example, come up with an ultrasound sensor that makes it possible to optimally adjust air springs for even greater comfort. They have also bridged the gap to the digital world by integrating a transponder chip in air suspension systems. It stores production, durability and service data. This “thumbprint” data can be used to clearly identify each individual air spring and provide information of value for those maintaining and servicing the bogies. The data likewise protects customers and their passengers from inferior pirate reproductions and thus from undesirable consequences as well.

Comprehensive material expertise is also vital to safety. Unlike many of its competitors, ContiTech uses only compound formulas and air suspensions systems produced in-house, giving it complete control over product quality. This is of evidence in day-to-day use, particularly under extreme situations. Since ContiTech air springs function smoothly and safely at either -40 °C or +40 °C, you will find them in trains traveling through regions as diverse as Siberia and Saudi Arabia.

Tracked for safety all around the world

Worldwide presence, quality, safety and good service go down well everywhere, be it in high-speed or regional trains or in metropolitan transit systems. That's why ContiTech isn't just currently equipping 50 new high-speed trains in China with air suspension systems, but also working to ensure that trams, subways, light rail systems, metros and regional trains are safe.