Development of axle boxes
Brake disc Z type
- Fasteners special design
- Patent: EP2 733 377 A2
- Advantages:
- Time saving when replacing the disc
- No holes on the surface – better friction
- No accumulation of water in holes
- Less wear of brake pads
Freight brake discs Type QSK
- Cooling special design
- Weight reduction in disc by up to 19 kg (156 kg→ 135 kg)
- Extended wear limit of 10 mm
- Advantages:
- Better cooling efficiency
- Longer disc lifespan
- Lighter bogie – energy saving
Brake disc type NSK – NET technology
- Unique disc cooling system
- Patent: SI 23474 A
- Advantages:
- Better cooling efficiency
- Improved heat dispersion
- Longer disc lifespan
Project FUTURA
In the project Futura, two final prototypes were developed and manufactured – the first disc 170 mm wide prototype and the second 110 m wide prototype. Both of them were subject to demanding tests on a dynamometer according to UIC 541-3 and in a real environment on the wagon.
With final prototypes of DRFB discs, the emphasis was on safety, thermal performance, lowering of vibrations (due to accurate connection of crown and hub), as well as further reduction of mass of DRFB disc.
With the final design of DRFB disc 170 mm wide and in comparison to initial DRFB disc, the mass was reduced by 22,7 %, air resistance was decreased for 21 %, and the dissipation efficiency increased for 17,3 %.
Main characteristics of DRFB disc 170 mm of width
| Outer diameter | 590 mm (option 610) |
| Inner diameter | 325mm |
| Width | 170mm |
| Mass | 112kg |
| Ventilation losses | 372 W at 165 km/h |
| Connection crown/hub | Special patented design |
| Connection hub/axle | Shrunken/pressed |
| Material | Cast iron |
| Imbalance value | Max. 16 gm |
| Wear limit | 10mm |
In the final DRFB disc 110 mm wide prototype, the emphasis was on the additional reduction in the DRFB disc mass while maintaining the same level of safety and thermal efficiency. With this prototype, the mass was lowered for 34.5% compared to the original DRFB disk, air resistance was decreased for 34 %, and the efficiency of thermal dissipation increased for 32.7 %.
Main characteristics of DRFB disc 110 mm of width
| Outer diameter | 590 mm (option 610) |
| Inner diameter | 325m |
| Width | 110mm |
| Mass | 95kg |
| Ventilation losses | 311 W at 165 km/h |
| Connection crown/hub | Special patented design |
| Connection hub/axle | Shrunken/Pressed |
| Material | Cast iron |
| Imbalance value | Max. 16 gm |
| Wear limit | 10mm |
Consortium of four partners
The FUTURA project has received funding from the European Union`s Horizon 2020 research and innovation program under grant agreement No.700985
Development of axle boxes
K25 – New generation of axle boxes
- Geometrically improved and thus 15 % light bearing housing
- Completely replaceable with the existing axle box BA386
- Modernized way of mounting worn-on sheets – upgraded with new technologies of assembling of the materials (gluing)
- When the product’s own weight is lowered, rolling stock operators use not only less energy for freight transport but also save on maintenance costs.
15 % less weight
100 % replacement with axle box BA386
No additional replacement costs
Reducing acceleration energy consumption
