Railroads

Railways throughout Europe are equipped with faigle assembly parts. The plastics technology from faigle is used in locomotives, passenger carriages and freight wagons, and even in track laying.

Examples:

Plates for wagons

Fabrication Process:	Machining
Material:	PAS-PTFE+Graphite; PAS-LXY
Customer:	Railway administrations and local transport services, producers and maintenance

Component Description, Application Area, Function:

The sliding plates are inserted into designated recesses in the bogie and carry the weight of the body once this has been positioned. They ensure safe operation by means of a defined, low coefficient of friction. With the development of these types of bogies, the material PS-PTFE +Graphite proved to be the most suitable. It has a very low coefficient of friction and a usable abrasion resistance, however only average stability. In operation of the up to 200 km/h passenger carriages it proved to be very good, only the maintenance intervals are not long enough. The new development of the material PAS-LXY and trials give hope of a successful step in the direction of better wear behaviour. Both materials are suitable for all-weather use.

Design, Material Selection, Manufacturing Process:

The customer wish here was also to reduce lubrication as far as possible or even to do away with it. As with other similar applications, by means of using the material PAS-LXY and the design of a slotted version of the bearing ring, it was possible, apart from a one-off assembly lubrication with IGOPAS Paste 3713, to completely do away with further lubrication intervals.

Even in this application, after 270,000 km in more than 2 years the bearing rings made of PAS-LXY are without measurable wear. In the meantime, the same bearing rings have already been in use for almost another 2 years without problem. With its integrated dry lubricants, the material has an extremely low coefficient of friction, high stability and excellent wear behaviour.

Particular Customer Benefits:

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• Low component costs
• Safe application over its lifetime
• Favourable overall costs for this design method
• Fast replacement (from stock)
• Special shapes possible
• High loads possible with PAS-LXY

Sliding inserts for freight wagons

Fabrication Process:	Injection moulding, subsequent machining
Material:	PAS-60X
Customer:	Railway administrations, repair workshops

Component Description, Application Area, Function:

The center pivot liner is integrated into the swivel ring of the bogie for freight vehicles. The center pivot liner carries the weight of the body once this has been positioned as well as the load and, with a defined coefficient of friction, ensures safe running of the bogie when running straight as well as in curves. In addition, the center pivot liner must also take up the shock loads which occur on starting, braking and shunting. The application area is outdoors at temperatures of -40 to +60 degrees in rain, snow and sunshine.

Design, Material Selection, Manufacturing Process:

The design of the center pivot liners resulted from the shape of the swivel ring and the opposite piece on the body. Demands on the material were the right coefficient of friction, low wear, high mechanical stability, no stick-slip, freedom of lubrication, chemical resistance, weathering resistance, high strength. These demands are well fulfilled by means of the materials PAS-60X and PAS-85X. Approvals from the administrations of different railways and use for over 25 years confirm the outstanding characteristics of these materials. Of course the center pivot liners are also approved by the DB. Fabrication is done by injection moulding – the moulded blank finished by machining and heat treatment.

Particular Customer Benefits:

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• In comparison with earlier solutions, lubrication is done away with completely
• The component is cheaper
• Installation takes place in the shortest time
• The durability of the product is dependent on the application conditions, however, as a rule, corresponds to the service interval (6 years)
• Conserves the fundamentally more expensive counterparts on the body and the bogie
• With the omission of lubrication, the environment is conserved and, by means of the slow wear of the swivel ring insert, no harmful substances emerge or are released.

Bogie Pin Guide Bush

Fabrication Process:	Machining
Material:	PAS-LXY
Customer:	Transport companies with underground railway networks, bogie producers and maintenance companies

Component Description, Application Area, Function:

The guide bush serves as a bearing between the bogie pin of the superstructure and the bogie of an underground railway wagon. Assembly takes place on the bogie, the bush, in a slotted design, is inserted into the drill hole and, after assembly, has the right inner diameter for acceptance of the bogie pin. Before positioning the superstructure, the bush has to be lubricated once only with IGOPAS Paste 3713. Further maintenance work over and above the service interval is no longer necessary. Operation is the whole year round and with all weather conditions.

Design, Material Selection, Manufacturing Process:

The requirements of the faigle technicians was a bush which readily withstands hard use over many years and which reduces the maintenance costs. Based on the application, the design of a slotted bush was chosen in order to guarantee a constant bearing clearance over the entire temperature range. For the material selection, PAS-LXY had already proved itself for such applications and, even in this application after 270,000 km in more than two years, resulted in no measurable wear. In the meantime, the same bushes have already been in use for almost another 2 years without problem. With its integrated dry lubricants, the material has an extremely low coefficient of friction, high stability and excellent wear behaviour.

Particular Customer Benefits:

Based on the above-mentioned benefits and the results of long-term trials, one can do away with lubrication (apart from the assembly lubrication).
This not only saves working time and lubrication costs but the laying of lines and nipples necessary for lubrication on the bogie can also be omitted.

In this way, apart from the savings in costs, a contribution is also made to the environment.

Spacers for Secondary Spring

Fabrication Process:	Injection moulding, machining
Material:	PAS-LXY
Customer:	Transport companies with underground railway networks, bogie producers and maintenance companies

Component Description, Application Area, Function:

The spacers for secondary springs have the task of taking up the movements of the secondary spring in the bogie of an underground railway wagon at a lowest possible coefficient of friction. Assembly takes place on the bogie, the spacer, in a slotted design, is plugged onto the seat and, after assembly, has the right outer diameter for acceptance of the contra-rotating piece. Before positioning, the bush has to be lubricated once only with IGOPAS Paste 3713. Further maintenance work over and above the service interval is no longer necessary. Application is the whole year round and with all weather conditions.

Design, Material Selection, Manufacturing Process:

The customer wish here was also to reduce lubrication as far as possible or even to do away with it. As with other similar applications, by means of using the material PAS-LXY and the design of a slotted version of the spacer, it was possible, apart from a one-off installation lubrication with IGOPAS Paste 3713, to completely do away with further lubrication intervals.

Even in this application, after 270,000 km in more than 2 years, the spacers made of PAS-LXY are without measurable wear. In the meantime, the same spacers have already been in use for almost another 2 years without problem.
With its integrated dry lubricants, the material has an extremely low coefficient of friction, high stability and excellent wear behaviour.

Particular Customer Benefits:

Based on the above-mentioned benefits and the results of long-term trials, one can do away with lubrication (apart from the assembly lubrication).
This not only saves working time and lubrication costs but the laying of lines and nipples necessary for lubrication on the bogie can also be omitted.

In this way, apart from the savings in costs, a contribution is also made to the environment. With this component, high maintenance costs also now only occur at longer time intervals.

Skid plate, side sliding

Fabrication Process:	Extrusion, injection moulding, machining, thermal treatment
Material:	PAS-80X
Customer:	Railway administrations and repair workshops world-wide, new design

Component Description, Application Area, Function:

The side bearers are mounted laterally onto the bogie of a goods wagon and support the body. With the turning movement of the bogie, the swivel ring inserts and the two lateral sliding plates work together – in this way, over a defined coefficient of friction and a specified turning moment, safe travelling operation can be guaranteed. Application is outdoors and therefore subjected to the seasons with their temperature fluctuations and precipitations.

Design, Material Selection, Manufacturing Process:

The side bearers are rectangular plates with thicknesses from 6 – 20mm and variable fixing holes which are taylored to customer wishes. As with the center pivot liners, here the lubrication and maintenance freedom was also a specification. With the material PAS-80X, this task could be excellently solved – this is proven by a decade of use as well as the approval of the "springloaded side bearer" by the DB AG. In this way, faigle is in the position of supplying all plastic parts for a freight vehicle bogie which are exactly adapted to one another. Further parts are bearing plates for draw hooks and brake linkage bushes made from faigle plastics. The side bearers are prefabricated with the extrusion and injection moulding processes and subsequently machined. Afterwards, heat treatment and several days are necessary in order to achieve the characteristics of this material.

Particular Customer Benefits:

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• Lubrication and maintenance free
• Inexpensive
• Durable over a service interval
• Physiologically safe

Bearing plates for draw hooks

Fabrication Process:	Injection moulding, machining
Material:	PAS-80Mo
Customer:	Railway administrations, repair works and bogie new design world-wide

Component Description, Application Area, Function:

The bearing plates are mounted in different designs as wear plates under (sometimes also additionally over) the draw hook. In this application, the coefficient of friction is of subordinate importance, it was of more importance, despite the omission of lubrication, to achieve a good wear behaviour. That is why the choice fell to PAS80Mo which is optimally suited for this application. Even the outside application in this case can not harm this material. Already in use for many years, there are also approvals here from the administrations of different railways.

Design, Material Selection, Manufacturing Process:

Because of the rough operation with this application, the parts are very solidly designed and replace the metal plates used up to now accurately to size. By selecting PAS80Mo, lubrication can be omitted. Apart from this, a sound deadening occurs. There are bearing plates for draw hooks in different designs whereby the standard types are fabricated with the injection moulding process and the special types by machining. The subsequent heat treatment guarantees a high impact resistance

Particular Customer Benefits:

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• Lubrication and maintenance free
• Large amounts of lubrication grease are saved and, in so doing, not only the budget but also the environment is conserved
• Noise reduction
• Inexpensive
• Durable over a service interval
• Physiologically safe
• Conserves the draw hook

Bushes for Brake Linkages of Bogies for freight wagons

Fabrication Process:	Injection moulding, extrusion, machining, heat treatment
Material:	PAS-80X
Customer:	Croatian National Railways, other railway administrations and workshops

Bauteilbeschreibung, Einsatzumgebung, Funktion:

Die Bremsgestängebuchsen werden in allen Lagers des Bremsgestänges eines Drehgestelles für Güterwagen eingebaut. Als Ausnahme gilt hier der Bremsschuh, da hier im Betrieb zu hohe Temperaturen für thermoplastische Kunststoffe auftreten. Wichtig war hier ein niedriger Reibwert bei exzellentem Verschleißverhalten – und das im Trockenlauf. Natürlich wie in fast jeder "Bahnanwendung" herrscht auch hier Ganzjahresbetrieb.

Konstruktion, Materialwahl, Fertigungsverfahren:

Die Konstruktion der Buchsen erfolgte durch faigle-Techniker, da Kunststofflagerungen anderen Gesetzen folgen als Lager aus Metall. Da sich PAS-80X in ähnlichen Lageranwendungen bereits bestens bewährt hatte, wurde dieses Material auch hier gewählt. Erste Versuche fanden schon vor mehr als zehn Jahren statt, seit mehreren Jahren laufen diese Buchsen in Serie in Kroatien, aber auch Prototypen bei anderen Bahnverwaltungen.

Anfang 2002 bekam faigle nach mehrjährigem problemlosen Probebetrieb die Zulassung der Kroatischen Staatsbahn- wir bemühen uns auch, weitere Serienzulassungen zu bekommen.

Gefertigt werden Bremsgestängebuchsen in verschiedenen Verfahren – natürlich darf auch hier die entsprechende Wärmebehandlung nicht fehlen.

Bei den Ausführungen gibt es den kompletten Satz für den Neubau, aber auch Reparaturbuchsen für bereits ausgeschlagene Lager – das gewährleistet, dass auch bereits gebrauchte Drehgestelle jederzeit auf die Buchsen aus PAS-80X umgestellt werden können. Für kleinere Stückzahlen können auch Halbzeuge geliefert werden – Beratung zur Dimensionierung bekommen Sie natürlich wie gewohnt bei unseren Anwendungstechnikern.

Besonderer Kundennutzen:

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• Wartungsfrei über einen Serviceintervall – bei der Montage ist eine einmalige Einbauschmierung mit IGOPAS Paste 3713 vorgeschrieben.
• Lärmmindernd
• Kostengünstig, auch kleine Stückzahlen und Sonderabmessungen
• Physiologisch unbedenklich

Point Bushes, Bush Inserts

Fabrication Process:	Injection moulding, mechanical finishing
Material:	PAS-LGX
Customer:	Starting with the ÖBB further railway administrations and point works and therefore in use world-wide

Component Description, Application Area, Function:

The bushes are integrated into the drill holes for tracks, linkages and points systems. A long lifetime without greasing and in some cases, even the electrical insulation are expected. Both have been exceptionally well fulfilled for decades by means of the material PAS-LGX. Large forces are effective and in addition, the component made from PAS-LGX is exposed, practically unprotected, to the weather. However, with these bush inserts, a much longer serviceable life is achieved than with customary metal bushes.

Design, Material Selection, Manufacturing Process:

The design and choice of material took place more than 30 years ago by our application engineer, Mr. Manfred Menia. Since then, these bushes have been in use in Austria and, with their use in the VAE, in the whole world. The material PAS LGX braves all loads which occur with use in points. The material specially developed for this purpose combines a very high mechanical stability with good dry running characteristics and electrical insulating property. Exceptions are high temperatures on points with gas heating – even here there are bushes made from faigle plastics for high temperature applications which have proven themselves for years. The bushes are designed slotted and are mounted by means of a key. During trials with the DB a new bush was developed by faigle which is mounted with the minimum of effort and which has an even longer lifetime. By omitting the key, the costs for stocks and the component have also dropped. The new points bush, for which in the meantime the patent has been applied for, was approved at the beginning of 2002 by the EBA, in future, the points bushes used up to now will also be converted. At this point, we would also like to thank the above-mentioned companies for their support. Fabrication takes place chiefly with the injection moulding process with subsequent mechanical finishing. To make the holding of stocks and assembly easier, each points bush is labelled with the most important data.

Particular Customer Benefits:

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• By means of the omission of greasing, the environment is conserved, the operator has lower maintenance costs and the service intervals can be increased.
• Conserving the drill holes and bolts – repair bushes can be inexpensively supplied for already damaged bearings
• Fast and easy assembly
• Fast delivery thanks to a large stock at faigle – standard dimensions at short notice, special dimensions on request.

IGOSTRAP®-Hanging Strap

Safety in a new range of designs.

Faigle has taken up the challenge to produce a future-oriented transportation design and developed a new look for hanging straps.

Now for the first time hanging straps are an attractive interior design element for standing passengers in urban and underground railraods, trams, busses, commuter trains and mountain railways.

Whether you want to call passenger attention to safety by adding a coulour accent or you want to enhance interior design, the news IGOSTRAP® series by faigle offers almost unlimited possibilities. Special CI solutions are also possible.

The Advantages

• Quick fastener available in plastic or metal
• Hand strap available in 5 standard colors, fast delivery
• Best functionality - convincing haptics
• High tearing strength - supports loads up to 200 kg
• Preassembled for quick installation
• Microbe-resistant and easy to clean
• Complies with German and US fire safety standards

Top Adstrap - Hanging Straps

Multifunction at a glance:

The "top Adstrap" hanging straps from faigle offer passengers in underground trains, local buses and airport buses, trams, cable cars and other public means of transport the following benefits:

• Comfort and safety
• The antimicrobial plastic prevents the spread of germs.
• With an advertising area above the hanging strap mounting, the hanging straps also offer an attractive advertising space above head height which can be seen from a long way off.