“The portfolio we are presenting at InnoTrans 2024 once again proves that sustainability is a powerful driver of innovation in the rail sector,” said Dr. Michael Holzapfel, Senior Vice President, Business Unit Rail at Schaeffler. “Our technologically pioneering products and services ensure greater energy efficiency, conservation of resources, and maximum uptime. In this way, Schaeffler not only supports our customers’ sustainability goals but also makes a strategically important contribution to their competitiveness.”
Products for greater reliability and availability Reliable and robust products – exemplified by Schaeffler’s TAROL axlebox bearings, one of Schaeffler’s main exhibits at InnoTrans 2024 – are crucial for ensuring maximum uptime and efficiency in rail transportation. Renowned for their long service life and significantly extended maintenance intervals, these exceptionally low-friction bearings are suitable for passenger trains, high-speed trains, freight and heavy goods transport, as well as locomotives, underground trains and trams.
Schaeffler manufactures its TAROL axlebox bearings on an application-oriented basis according to customer-specific design requirements. This includes, for example, adapting bearing dimensions and materials to the required payload and mileage. Special friction-optimised seals are available for freight transport locomotives (Class GG), while variants are also offered for heavy goods traffic (Class K), ensuring energy-efficient as well as safe operation.
At the same time, the DMC serves as the digital reference for data exchange between Schaeffler, OEM suppliers and railway operators. By alternately linking databases, condition monitoring systems can be set up to access data from existing fixed systems (wayside monitoring devices). At InnoTrans 2024, Schaeffler is presenting an entry-level model based on a feasibility study conducted in Switzerland. Schaeffler is also showcasing vehicle-based railway condition monitoring systems (RCMS), which further increase rail traffic safety.
Remanufacturing is more economical and sustainable
The closed-loop system is a key approach to sustainable management in rail transportation. To that end, Schaeffler has developed an extremely successful remanufacturing service for bearings that can achieve up to 95% resource savings, depending on the extent of reconditioning required. At the same time, Schaeffler offers the same quality and safety standards with its 100% return service, and the remanufactured bearings include the same warranty as new products. As a full member of the "Railsponsible" initiative, Schaeffler reaffirms its commitment to greater sustainability in the rail industry.
Current-insulated bearings and hybrid cylindrical roller bearings In rail vehicles, the operation of electric motors can cause unwanted electric currents in wheelsets, gearboxes and traction motors. This can damage raceways and rolling elements and cause lubricants to break down, resulting ultimately in premature and unexpected component failures. All of which translates into higher maintenance and repair costs, not to mention the added expense of machine downtime. Schaeffler offers a cost-effective and reliable solution to this problem with its electrically insulated bearings. These ceramic-coated bearings and hybrid bearings with ceramic rolling elements reduce maintenance costs and increase machine availability. Also on show at InnoTrans are Schaeffler’s high-capacity cylindrical roller bearings for traction-motors, featuring the new single-part “MP” solid brass cage.
Compared with the “M1” two-piece, riveted solid brass cage, this new cage offers higher strength under stresses caused by vibrations and shocks, even at higher rotational speeds. The new cage design also simplifies bearing reconditioning because the rollers can be removed without damaging the cage.
The benefits to customers include optimised operational reliability, longer service life, and reduced lifecycle costs and total cost of ownership (TCO). The longer service life also improves rail operators’ carbon footprint.
Smart maintenance tools
Between 10 and 20% of all bearing failures are caused by incorrect handling during maintenance. At InnoTrans 2024, Schaeffler is showcasing its Smart Maintenance Tools (formerly Bega Special Tools), an expanded range of solutions for the ergonomic, safe and material-friendly mounting and dismounting of powertrain components.
This includes self-centring hydraulic and mechanical extractors for small to medium-size components. For large rail and underground train bearings, couplings and wheels, Schaeffler is presenting the BETEX HXPM, which has a maximum pulling capacity of 150 tonnes, and the BETEX BPP, which has a maximum capacity of 100 tonnes. These tools are height-adjustable and easy to maneuvre, so they can be operated quickly, easily and safely – even by a single technician working on their own. Moreover, the intelligent tool design minimises the risk of damage to axles and to the bearings and wheels being mounted or dismounted.
