moklansa

E3SElectronic Rail Lubrication System

moklansa

moklansa

E3SElectronic

Rail Lubrication System

Wear and Noise in Curves and Points

Points and curves are the nerve centre of railway traffic. Increased wear on rails, switch tongues, check rails and wheels is accompanied by noise pollution which can at times be considerable. Intelligent lubri-cation of the guiding surface, leading edge and, if necessary, a thin film applied to the rail head offers some remedy.

Wear to wheels, rails and switch tongues can be substantially reduced by the instal-lation of the moklansa E3S. Maintenance work, such as build-up welding of the rail flanks or reworking of the tyre is reduced, while extending the life of the tracks and points.

Effective noise reduction is to the benefit of residents and helps to improve the accep-tance of rail traffic.

Controlled Lubrication

moklansa E3S - The Electronic Rail Lub-rication System has established itself over the years in continuous use at DB AG (Germany Railways Ltd) as well as rail operators, local traffic services and the industry at home and abroad. The basic prin- ciple is compelling: lubricant precisely dosed to specific requirements is applied exactly between the wheel flange and the rail flank, the passing wheel picks up the lubricant, rolls it over and thus distributes it automatically along the critical points of wear.

This process comprises three system components: The installation core controls the lubri-cation process and contains the inter- changeable grease reservoir.

The sensor station registers the approa-ching rail vehicle and notifies the control centre in the installation core, which then triggers the lubrication process.

The lubrication path with lubrication channels or lubrication ridges applies the lubricant to pinpoint accuracy be- tween flange and rail flank.

The EBA approval certificate is available for the moklansa E3S (EBA = German Federal Railway Office).

Lubricated to Straight to the Point

The moklansa E3S system is suitable for all common rail profiles and wheel flange types.

Lubrication channelsThanks to a special drilling technique, the rail can be equipped with lubrication chan-nels, the outlets of which are located pre-cisely on the rail flank, leading edge or on the rail head. Lubrication ridges are inte-grated at the check rails, if required later on, for wheel lubrication. In addition, mo- bile (feedable) lubrication ridges are availab-le. They can be used in combination with grooved rails, even on covered tracks.

By aligning the lubrication channel con-nections towards the centre of the track, high-pressure pipes can be safely installed under protective cover strips, in inspection boxes or in connector boxes.

Bus SystemDue to the high reaction speed of the bus system, there is almost no delay between process activation (grease request by the rail vehicle) and the emergence of grease at the grease channels. In combination with a minimum quantity output, the multiple lubri-

cation of each and every bogie of a vehicle with the smallest of grease quantities has been solved in the best way.

Multiple lubrication paths can be supplied with track lubricant at any time or simulta-neously, as well as separately. Due to the long distances between lubrication path and installation core (up to 80 metres), double-track curves, complete Y-tracks or entire track harps are supplied with track lubricant by only one installation core.

Grease switchSystems with grease switch are suitable for branches, e.g. the tip of an Y track. Here too, an installation core supplies the lubri-cation paths for two tracks independently.

Film Lubrication of the Track The precise dosage by the moklansa E3S enables even the most accurate moistening of driving surfaces. In combination with the lubrication of the rail flank, the moistening of the contact surface of the inner curved rails enables quiet driving in bends. Before starting the moistening of the contact sur-faces, brake tests according to BOStrab are recommended.

Arrangement of lubrication channels

on grooved rail profile

Arrangement of lubrication channels

on vignol rail profile

Arrangement of lubrication ridges

on the check rail

Arrangement of the mobile lubrication

ridge for wheel lubrication

Optimized for Grooved and Vignol Rails

Installation core Cabinet design

Installation core Box design

Lubric

atio

n pat

h

Sensor station

Lubric

atio

n pat

h

moklansa

E3SElectronic

Rail Lubrication System

Geometric Precision

The quantities of grease moklansa E3S supplies to the respective lubrication chan-nels are absolutely identical, and are not influenced by differences in hose length or fluctuations in temperature. The required flow rate can be adjusted with precision and kept constant at all times. The stored-program control of moklansa E3S proces-ses all relevant operating parameters. Lu- bricant flow rate, lubrication intervals, even the number of lubrication impulses per vehicle are infinitely variable. The system can be adjusted individually to the respec-tive operating requirements. The settings and operating conditions are shown in a display panel.

A temperature-dependent quantity output is also an option. All adjustable operating parameters are selected individually with three independent temperature bands.

Economical, Safe and Reliable

The moklansa E3S dispenses the well-adhering lubricant extremely sparingly, which was specially developed for this system. The grease supply is used eco-nomically, so that soiling to the track bed and vehicle are avoided. Of course, the moklansa E3S can also be monitored via the operating control centre. Furthermore,

external information can be processed, for example a rain sensor shuts down the sys-tem.

A robust gear pump is responsible for con-veying the lubricant and for the generation of pressure. This pump, which has been modified for the conveyance of lubricants has been applied in the field of oil hydrau-lics many hundreds of thousands of times – moklansa has been using it successfully from the beginning for stationary rail lubri-cation systems.

Maintenance-friendly Thanks to Exchangeable ReservoirsIt couldn‘t be simpler to refill the moklansa E3S: The refillable grease reservoirs can be replaced in no time, with no mess or spil-lage. Breakdowns due to contamination or air locks can be practically ruled out.

To refill the grease reservoirs, many cus-tomers make use of the moklansa grease refill centre. However, we also provide filling stations for self-fillers as an accessory.

The new refillable pressure reservoirs with modified membrane technology further increase economic efficiency. The higher fil-ling pressure reduces the remaining quan-tities and optimises the process sequence. The reservoirs are available in two sizes.

no more no less

More Grease for Longer Running Times

The following moklansa E3S versions are available:

box design with one or two grease reservoirs - Assembly next to the track system on a base or jig

- Assembly under the ground in the ground box in the middle of the track or next to the track system

cabinet design with up to three grease reservoirs

The cabinet design is set up next to the track system at a distance of not more than 80 metres from the lubrication path. The reservoirs are emptied simultaneous-ly. 3-Container cabinets can also be deli-vered with „Single emptying in succession“ option.

With the moklansa E3S as a multi-reservoir system, larger quantities of lubricant can be made available, allowing less frequent and more flexible refill intervals. Equipped with two to three exchangeable reservoirs connected in series, the empty reservoirs can even be changed while the system is running. In due time before the complete emptying of the grease reservoirs, a war-ning message appears on the display that is transferred to the master display with remote maintained systems.

The display of the control unit has a text display that indicates operating states and settings. That facilitates the setting of the system as well as the modification of indivi-dual operating parameters.

moklansa

E3SElectronic

Rail Lubrication System

and all that goes with it

System planning

Our consultant engineers will assist you right from the design phase and the selec-tion of a suitable location, bringing with them extensive experience from a variety of projects.

CAD support in the planning phase ensu-res the optimum positioning of all system components, taking the local conditions into account.

Service On Site

moklansa E3S is delivered ready for ope-ration, then installed and connected. This includes fitting the lubrication channels into the rail section. The level of precision required for this is achieved with a specially developed drilling implement.

With our Full Service Package we offer not only inspection and maintenance, but also assure the uninterrupted operability of your system.

We train your specialists either in our trai-ning rooms in Dortmund or else in Inhouse seminars.

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261.03

260.89

261.05

258.50

258.39

258.60

258.80

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259.92

259.95

259.86

260.22

260.14

259.86

259.81

259.91

259.81

259.06

258.98

259.01

258.66

258.39

258.51

258.43

258.50

258.77258.77

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258.40

258.55258.35

258.32

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258.60

258.46

258.36

258.36

258.17

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259.46

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258.39

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260.33

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260.37

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260.52

261.28

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261.68

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261.52

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266.40

265.56

265.55

265.45

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265.72

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265.75

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264.53

264.44

264.61

264.66

264.80

264.67

264.75

264.30

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258.59

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258.39

258.33

258.26

258.34

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Gertrud u. GertrudeKubin

EZ 289

Dr. Brigitte Moerkelsberger

EZ 110

EZ 272

EZ 272

der Stadtgem. LinzForster Margarete

(Landesstrassenverwaltung)

Land Oberoesterreich

EZ 483

Stadt LinzEZ 49

(Bundesstrassenverwaltung)

Republik Oesterreich

EZ 197

Linz

Stadtgem.

Gut der

oeffentl.

EZ 267

Mag. Marlene Potye

Leitner

Robert u. Maria

Robert u. Maria

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EZ 61

EZ 60

EZ 60

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Gertrud u. Gertrude

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Donaubauer Artur

EZ 38

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Ground box for installation

in the centre of the track

Ground box for installation

next to the track

Inspection box for installation

on grooved rails

Remote monitoring

The moklansa E3S enables remote moni-toring and data transfer via mobile radio. Operating parameters can be accessed and set and malfunction messages can be forwarded via text message or e-mail. Modified operating parameters are auto-matically sent to a preset fax address for documentation purposes.

Power Supply

The moklansa E3S system is connected to the 230V/AC mains supply. No further sources of power are required.

If the locations are far from the power sup-ply, the following variants are available:

solar energy current transformer interchangeable battery pack

Accessories

A comprehensive range of accessories is available, allowing moklansa E3S to be adapted for individual site conditions and operating parameters:

mid-track, low-level ground boxes, con-nector boxes and distributor boxes

protective cover strips attached to the lower flange of the rail

photovoltaic driving terminals DC/DC transformer battery pack rain sensors breeze concrete plates underframes filling stations

Filling station

DC/DC transformer

Solar energy

Power supply with battery pack

Short overview

DimensionsBox design housing box B 800 x T 600 x H 350 1 or 2 reservoirs mounted on foundation base, mounting frame or fitted in a ground box.

Cabinet design housing box B 800 x T 450 x H 1100 1 or 2 reservoirs assembled on base, concrete slab or breeze concrete plate

Cabinet design housing box B 1100 x T 400 x H 1100 3 reservoirs assembled on base, concrete slab or breeze concrete plate

Power supply 230 V/AC, 24 V/DC, DC/DC transformer 600 V/24V solar technology or interchangeable battery pack

Control compact PLC with key operation, operating states and inputs can be read on the display. Function diodes, potential-free contact for remote transmission.

Vehicle detection Inductive approach initiators, installed in a sensor terminal box or a sensor station.

Alternative: By external signalling.

Grease reservoir two-chamber reusable container (DIN 4807), effective volume 9 litres each or refillable pressure reser-voir, effective volume 4 resp. 9 litres each

Lubricant transfer Directly on the contact surfaces by special lubrication channels integrated into the rail or check rail or for the lubrication of the wheel with feedable lubrication ridges.

Rail flank lubricant KUB 2 K-20 – established over many years, specially designed for rail flank lubrication.

KUB 1 K-30 – with further improved moistening proper- ties. Is particularly suitable for moistening the head if the dosage is accordingly small.

If external products are used, we recommend a compa-tibility test with the polymers used.

Options Temperature-dependent quantity and cycle control. BCD-coded interfaces for data exchange.

Complete data exchange including alarm chain with GSM technology.

moklansa GmbH

Gottlieb-Daimler-Straße 15 59439 Holzwickede

Tel: +49 (0) 23 01-94 93 68-0 Fax: +49 (0) 23 01-94 93 68-9

info@moklansa.de www.moklansa.de

Maschinen- und Anlagenbau

moklansa

E3SElectronic

Rail Lubrication System

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Our sales and distribution partners:

VTEC - Gesellschaft für den Vertrieb von innovativen Produkten für den Oberbau, Vertriebsberatung mbH

Westfalendamm 265 D-44141 Dortmund

Tel: +49 (0) 231- 5 65 59 95-0 Fax: +49 (0) 231- 5 65 59 95-5

info@vtec-gmbh.com www.VTEC-GmbH.de

Your contact in Switzerland:

RTS Swiss AG Zugerstr. 74 CH-6340 Baar

Tel: +41 (0) 4 17 69 35 82 Fax: +41 (0) 4 17 69 35 84

info@rtsag.ch www.rtsag.ch

moklansa

Railtechnik Swiss AG