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UIC Noise Workshop June 11, 2013 LL Block Manufacturing Becorit GmbH Dr. Juergen Schroeder

UIC Noise Workshop June 11, 2013 LL Block Manufacturing Becorit GmbH Dr. Juergen Schroeder. Agenda. ….. 11 years of LL testing and field test support ! Noise, Winter conditions, Shuntage , Fussible Conicity , ERS, Sweden field tests, Eurotrain

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UIC Noise Workshop June 11, 2013 LL Block Manufacturing Becorit GmbH Dr. Juergen Schroeder

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  1. UIC Noise WorkshopJune 11, 2013LL Block ManufacturingBecorit GmbH Dr. Juergen Schroeder

  2. Agenda • …..11 years of LL testing and field test support ! • Noise, Winter conditions, Shuntage, FussibleConicity, ERS, Sweden field tests, Eurotrain • Homologation June 2013, time to concentrate on implementation! • Product Requirements • Production Process • Quality Management • LL Implementation from Manufacturing View

  3. Technical Requirements • Noise reduction • Good wet & winter performance • No wheel lock up‘s • Reduction of LCC • Low dispersion of friction values • Shuntage ( effect on track circuit operation ) • Thermo mechanical behavior (fusible) • Requires advanced production • and process control system !

  4. Step1: Weighting Mischen Container system Fixed Storage Production of LL Shoes Balance system • QC controlled raw materials • Binder System, Fillers, • Lubricants, Friction Modifiers • Bar Code system • Computer controlled balance • Automatic non conformity stop • Backwards traceability Step 2: Mixing Mixing • Controlled System: Time, Temperature, Energy, • Record of all Parameters • 100% Mix Quality Control • First in / first out • Backwards traceability

  5. Curing Oven Production of LL Shoes Step 3: Pressing Pressen • QC controlled steel back plates • Record of pressing parameters • Computer Validation • required vs actual • Automatic non conformity stop • Backwards traceability Step 4: Curing Process • Controlled System: Time, Temperature, Energy • Record of all Parameters • required vsactual • Automatic non conformity stop • Backwards traceability

  6. Production of LL Shoes Step 5: Finishing & Marking • Record of finishing parameters • required vsactual • Automatic non conformity stop • Backwards traceability 123 Step 6: Quality Control • Dimension Control • Mechanical Control • Chemical Control • Conformity of Process Parameters, Statistics • Additional QC Testing

  7. Becorit - Additional QC Tools QM Certification: IRIS Rev1/Rev 2   2009=>                          ISO 9001       1994=>                          ISO14001      2000=>                          DIN EN 15085  2005=>   QC Shuntage (UIC homologated procedure)

  8. Darstellung des gemessenen Radprofiles Profilhöhe in [mm ] Rad: L01 Messort: we013 rs1+12 li 40 Radprofil in [ mm ] QR Linie SD Linie SH Linie RB Linie SH Linie H SDH 38 7 80 6912 007-9_L01_07-10-2008_15-28-17.txt 36 34 SH= 30,51 mm 32 30 28 26 24 22 20 18 16 14 12 10 8 SD1= 30,82 mm 6 RB= 137,1 mm 4 2 0 -2 QR= 9,16 mm -4 -6 -8 -10 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 Profilbreite in [ mm ] Becorit - Additional QC Tools Laser System Control of Wheel Profiles QC Winter Performance ( UIC homologated procedure)

  9. Project Overview & Implementation Phase 1:Phase 2: Development Extended Field Tests & Testing & Production Setup Phase 3:Phase 4: Production Extended Production Planning & Invest & Implementation Provisional Certification System Approval Delivery Plan Investment 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 Extended Production Capacity

  10. Status Projekt StepStatus • System Homologation done • Production setup (limited volume) done • Investment scenario (volume extension) done • Commitment of Railways and private Operators open • (type/volume/timing) • Binding Contracts / Long Term Delivery Plan open/T0 • Investment approval open/T0+1 • Investment realization ( 12 months) open/T0+13

  11. Conclusions • Manufacturing is prepared to produce smaller up to medium volumes to ensure first 2013/2014 requests acc. delivery plan • Volume and delivery time are depending on the overall request, shoe type and size ( approx. 6-10 weeks delivery time ) • For high quantities scenarios are prepared, but need clear commitment from operators (frame contract, LTSA) to justify further investment • Implementation of extended machinery needs 13 months

  12. Please contact us for individual questions ! • Becorit GmbH • Rumplerstrasse6-10 • D-45659 Recklinghausen • Mail: info@becorit.de • Fon: +49 (0)2361 / 666-6 • Fax: +49 (0)2361 / 666-740 Thank you for your attention !

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