Axtone offers Crash components for EMU/DMU multiple units providing passive protection of the vehicle in accordance with European standard EN 15227. The components are designed to cater for Customer's individual needs. They are characterized by excellent performance parameters resulting from the application of peeling technology. The following products illustrate just some of the possible solutions.  

EuroPad® shock absorbers
EuroPad® shock absorbers are produced from high performance thermoplastic polymer. AXTONE has a possibility of production of produces different types of elastomer shock absorbers, depending on application. The working parameters can be modified according to customer’s needs and designed for special applications.

Applications:

• Side buffers according to EN 15551;
• Central couplers for freight wagons e.g. SA3 according to GOST;
• Draw gears according to EN 15556;
• Secondary vertical suspensions;

KX-ZP5 Buffer

A light rail-vehicle buffer that meets the requirements of the EN15551 standard, the UIC 528 leaflet as well as the related leaflets (except the buffer disk size). The shock absorber unit consists of the preliminary absorber featuring disk springs and the main elastomer shock absorber. Both solutions have already proved their infallibility and functional reliability during many years of operation. The buffer is characterized by good working parameters and operational reliability within the temperature range from -40ºC to +50ºC. Free-flowing elastomer retains its properties for many years. The material is also recyclable.

KX-ZP2 Buffer
A passenger car buffer that meets the requirements of the EN15551 standard, the UIC 528 leaflet as well as the related leaflets. The buffer is characterized by good working parameters and operational reliability within the temperature range from -40ºC to +50ºC The buffer disk’s surface is hardened. High durability of the buffer has been confirmed by the operating tests conducted in accordance with the ERRI B51 guidelines. It has the EBA and Railway Transport Office certificates.

Keystone ES110 Buffer
A buffer for passenger car equipped with a combigard ES110 hydraulic shock absorber. The product meets the requirements of the EN 15551 standard and the UIC 528 leaflet as well as the related leaflets. The buffer is characterized by good working parameters and operational reliability within the temperature range from -40ºC to +50ºC. The buffer is available in in the following variants: a buffer disk with a plastic pad a disk without the plastic pad, as well as 360x660 and 360x720 disks. The buffer disk with a plastic insert extends the buffer’s service life and reduces the operating costs. The main advantage of this buffer is the simple structure which guarantees long usage and minimum scope of regular maintenance. The product has the EBA certificate.

Keystone S110 Buffer
A buffer for passenger car equipped with a shock absorber featuring elastic components made of solid elastomer. The product meets the requirements of the EN 15551 standard and the UIC 528 leaflet as well as the related leaflets. The buffer is characterized by good working parameters and operational reliability within the temperature range from -40ºC to +50ºC. The buffer is available in in the following variants: a buffer disk with a plastic pad a disk without the plastic pad, as well as 360x660 and 360x720 disks. The buffer disk with a plastic insert extends the buffer’s service life and reduces the operating costs. The main advantage of this buffer is the simple structure which guarantees long usage and minimum scope of regular maintenance. The product has the EBA certificate.

Keystone 15 kJ buffer with friction spring

A buffer for passenger car equipped with a set of friction springs. The product meets the requirements of the EN 15551 standard and the UIC 528 leaflet, as well as the related leaflets. The buffer is characterized by good working parameters and operational reliability within the temperature range from -40ºC to +50ºC. It is manufactured in two options: a buffer disk including a plastic pad and a disk without a pad. The buffer disk with a plastic pad extends the buffer’s service life and reduces the operating costs. The main advantage of this buffer is the simple structure which guarantees long usage and minimum scope of regular maintenance. The product has the EBA certificate.

Shock absorbers for automatic and semi-permanent couplers 

Elastomer shock absorbers for automatic and semi-permanent couplers have good working parameters and operational reliability within the required range of temperatures. The free-flowing elastomer maintains its properties for many years. The material is also recyclable.

RG 20F Draw-Gear
The RG20F draw-gear is designed for passenger cars. It meets the requirements of the EN 15566 standard, as well as the UIC 567-3, UIC 520 leaflet, and enables absorbing energy up to 20 kJ. The draw-gear is equipped with elastic components made of the EuroPad solid elastomer ensuring premium technical parameters (available also with TecsPak). The EuroPads are made of the finest quality materials which maintain their characteristics for many years. The material is also recyclable. Due to its compact structure, the device has relatively low weight. The draw gear has good working parameters and operational reliability within the temperature range from -40°C to +50°C. The product has EBA certificate.

RG 15F Draw-Gear

The draw gear type RG15 is designed for passenger cars .It meets the requirements of the EN 15566 standard, as well as UIC 567-3, UIC 520 leaflets, and enables absorbing energy up to 15 kJ. The draw-gear is equipped with elastic components made of the EuroPad solid elastomer ensuring premium technical parameters (available also with TecsPak). The EuroPads are made of the finest quality materials which maintain their characteristics for many years. The material is also recyclable. Due to its compact structure, the device has relatively low weight. The draw-gear has good working parameters and operational reliability within the range of temperatures from -40°C to +50°C. The product has EBA certificate.

KX-AM-3 Draw-Gear
The KX-AM-3 draw-gear is designed for passnger cars. It meets the requirements of the EN 15566 standard, as well as the UIC 520 leaflet, and  ensures energy absorption of 20 kJ. The device is equipped with elastic components made of the EuroPad solid elastomer ensuring premium technical parameters. The elastomer pads are made of the finest quality materials which maintain their characteristics for many years. The material is also recyclable. Due to its compact structure, the device has relatively low weight. The draw-gear has good working parameters and operational reliability within the temperature range from -40°C to +50°C. It has the Rail Transport Office and TSI certificates.

In multiple units (EMU and DMU) coil springs are used as primary suspension. Due to space and load requirements regarding the primary springs, linear spring sets are usually used. Linear coil spring means a cylindrical coil spring with constant diameter and constant wire diameter. The spring ends are either “closed and ground” or “taper rolled, closed and ground”. Linear spring set means that two linear coil springs with the same length are put together one into the other. Therefore the inner spring has a smaller outer diameter than the inner diameter of the outer spring. The inner spring also has a smaller wire diameter. The two springs of one set must have different coiling directions (one left, one right hand coiled). As in most cases low floor heights are requested for modern EMUs and DMUs, the space for the primary springs is very limited. The stress in such coil springs is thus usually rather high so that the springs for EMUs and DMUs require a high material grade and production quality.

Production of rings used for friction springs which meet the requirements of the chart UIC 827-2 takes place in the Czech company owned by the Group. The springs are manufactured in a wide range of various diameters from 80 to 400 mm. The rings are used in friction springs of Ringfeder type applied in buffers, tractive apparatuses, pull rod bars and automatic couplers.
Features:

• Hot formed, highest quality materials;
• Various shapes possible;
• Linear characteristic;
• Safe against overloading;
• Big damping due to friction;
• Characteristic independent of the speed;
• Characteristic independent of the temperature;
• Proven in rail applications.

Basic technical dates of friction springs:

Example of spring calculation
This spring consists of 4 elements type 19600:

• End force = 600 kN
• Stroke = 4 x 4,4 (Se ) = 17,6 mm
• Spring work (Absorbed energy) = 4 x 1300 (We) = 5200 J
• Spring length = 4 x 23,4 (he) = 93,6 mm

By adding additional elements, we increase the stroke (length of the spring), the absorbed energy (spring work) but the end force will remain the same. End force still 600 kN.

During the operation of the friction spring two thirds of the input energy is dissipated as frictional heat. The recoil force at any point on the diagram is approximately equal 1 / 3 of the relative compressive force F. The capacity of the spring is represented by the total area shown below the load curve.

Friction springs are generally designed to „block”, so it is therefore ensured that the admissible stresses cannot be exceeded and the friction spring will not be damaged.

Applications:

• Buffers;
• Draw gears;
• Draw bars;
• (Semi) automatic couplers