Perspectives

Environmental Newspaper for Voith Turbo

DIWAhybrid for modern city buses
Peter Edelmann, Board Member of Voith AG, Chairman of the Board of Voith Turbo

2010/2011

Eco-Friendly Drive Alternative

Dear Readers,
Our nature lies in movement, this is what the French mathematician and philosopher Blaise Pascal stated in the 17th century. Nothing much has changed. But the predicted increase in mobility also requires new thinking, in order to ensure that this mobility stays in harmony with the environment and nature. The protection of resources is therefore at the heart of our considerations when we design new drive concepts and develop technologies that are fit for the future. For Voith Turbo, the main challenge is to make drive technology more efficient. Please read about our latest developments with environmental impact.

Best regards,

Peter Edelmann

DIWAPack for Rail Vehicles

With the introduction of the DIWAPack as a drive system, Voith Turbo has developed a DIWAhybrid variation for rail vehicles. It consists primarily of a parallel hybrid utilizing advantages such as the power-split principle in the starting range, the secondary retarder and the E300 electronic control. These benefits are added by a low-loss asynchronous electric motor supporting the diesel engine during starting and accelerating. During braking, the asynchronous machine acts as a generator. Electric energy is added to energy storage systems so-called Supercaps via a Voith inverter. This storage system provides 1,34 kWh of electric energy for operating the rail vehicle.

Since the summer of 2010, 22 buses have been driving with the diesel-electric and eco-friendly drive system DIWAhybrid. At the US bus manufacturer Gillig, the DIWAhybrid transmission has successfully passed several tests and is now on the roads of Concord, California. Fuel consumption has been reduced up to 15 percent, depending on the route. Serial production will start in April 2011.
The DIWAhybrid is a further development of the proven DIWA transmission and presents a genuine alternative over conventional drives with combustion engines in terms of economy and emissions: Simulations and actual measurements have shown fuel saving potentials of up to 20 %. These are accompanied by corresponding reductions of CO2emissions. These are benefits that have also convinced the bus manufacturer Solaris Bus & Coach, who decided in favor of the DIWAhybrid systems when looking for an innovative drive solution. In the DIWAhybrid an asynchronous electric motor complements the diesel engine when the vehicle is starting and accelerating. During braking, the asynchronous machine serves as a generator and acts as a primary retarder that optimally supplements the DIWA secondary retarder. This protects the service brake, reduces brake wear and minimizes fine dust pollution. The energy that is recuperated during braking is stored in a Supercap system weighting only 410 kg. opment phase will end with the certification of the vehicle in the fall of 2010. Afterwards, a pre-series vehicle will have to prove itself in everyday operation. The Ministry assumes that up to 50 Solaris buses with DIWAhybrids could go into operation by in the first half of 2011.
Solaris Urbino 18 DIWAhybrid: allows the use of a smaller diesel engine provides an input power of up to 290 kW and input torque up to 1600 Nm runs on a Cummins engine with 184 kW electric component of the DIWAhybrid is rated at 150 kW has up to 51 seats, and can carry up to 161 passengers

DIWAhybrid part of future mobility solutions

The German Ministry of Transport has decided to run a pilot project with ecofriendly drive systems. As part of the project, various test vehicles will be examined for suitability in practical operation among them Solaris Urbino articulated buses with the parallel DIWAhybrid drive from Voith. The devel-

Morning traffic in a megacity rush hour for public transportation.

DIWA Excellence: Tailor-Made Services for all Operators

Less Fuel and Increased Availability

DIWA Excellence is the worldwide service and after-market program all around the DIWA transmission. Individually configured for any bus operator, DIWA Excellence allows fuel savings, reduces emissions and increases vehicle availability.

Depending on the route profile, up to 6 percent less fuel is possible by the use of SensoTop.

With SensoTop up to 6 Percent Less Fuel

With DIWA Excellence, Voith Turbo is making a significant contribution to the eco-friendliness of bus transmissions. This has been proven by the fuel savings achieved with the topography-dependent gear-shifting program SensoTop. All gear-shifting points of the DIWA transmission are automatically and optimally adapted to the prevailing load condition and the route profile. The transmission control recognizes instantly whether a vehicle is driving on a level road with full load, or whether it is on an uphill road, operating only at part load. The results are quite impressive: At Arriva in Brescia, Italy, fuel consumption and CO2-emissions were reduced by 4.4 percent compared to vehicles using a conventio-

nal acceleration-dependent gear-shifting program. Depending on the route profile and the vehicle operation, this result can even be surpassed. In the Ruhr Region, savings of up to 6 percent were achieved with Mercedes-Benz Citaro vehicles and at stra in Hanover vehicles fitted with SensoTop also use less fuel: here, - 3 percent was measured. Even in large cities such as Berlin and Munich where buses drive almost exclusively on level roads 2 percent less consumption and lower emission were recorded.

buses of Dubai and Abu Dhabi, plays an important role here. In both cities of the United Arab Emirates, high vehicle availability has top priority. Therefore, Voith Middle East services and maintains more than 1 650 transmissions on the basis of life cycle cost agreements. The fleet is constantly under observation: With DIWA SmartNet, the transmissions are permanently monitored via GSM (Global System for Mobile communications) and subject to regular maintenance planning. Failure reports are instantly transmitted to the Voith service employees in Dubai. As a result, transmission damage can be detected and eliminated at an early stage, ensuring trouble-free and efficient operation of the buses.

DIWA Excellence DIWA Excellence the worldwide service and after-sales program for DIWA transmissions covers the following modules: For daily operation: Evaluation of operating data Optimization of fuel consumption Training programs for operators For maintenance: Health check and transmission condition monitoring Worldwide availability of service exchange transmissions and original spare parts Service and life-cycle cost agreements

Eco-Friendly From Day One

Eco-compliant and cost-efficient operation across the entire service life of the transmission this is the goal of DIWA Excellence. Permanent condition monitoring, as carried out in the city

First Voith Engine for Rail Vehicles

Future Emission Limits Already Undercut

Since March 2010, Voith Turbo is now also an engine producer. The first Voith diesel engine is based on a new MAN engine series. During the joint development activities between Voith Turbo and MAN-Nutzfahrzeuge AG, special attention was paid to rail suitability, the reduction of emissions, as well as reliability and economy. The new V8 diesel engine achieves an output of 500 kW and a torque of 2 750 Nm. The combination with a maintenance-free particle catalyzer allow that emission values prescribed from 2012 (Stage IIIB) are already undercut. This can be achieved without an additional fuel medium.

EcoConsult and Hybrid Drive

Eco-Friendly Rail Traffic

Higher efficiency and improved environmental protection when operating rail vehicles this is what Voith Turbo pursues with technical developments such as EcoConsult, the basis tool for lower lifecycle costs and reduced fuel consumption, as well as the hybrid drive DIWAhybrid for rail applications.
EcoConsult is the toolbox from Voith Turbo for operating diesel and hybrid rail vehicles more efficiently and ecologically. As a tool for basic analysis, it helps already with the initial question: Which vehicle can I use in which way on a certain route? The decision, which driveline fits best to a track and load profiles or whether a rail vehicle should be operated with a hybrid drive or whether it would be more advantageous to install eco-components, is made significantly easier by EcoConsult. A proportion of the toolbox consists of transparent operating data. EcoConsult can perform measurements (for example fuel consumption) in order to identify savings potentials. As part of worldwide route data compilations, drive simulations on the basis of realtime routes help optimize timetables and reduce energy consumption. The driver assistance segment within EcoConsult is a control and display system that is integrated into the vehicle: EcoScout provides the driver with recommendations for resource-efficient ways of driving. In total, Voith EcoConsult presents a reliable basis for vehicle configurations and reduces life-cycle costs, as well as fuel consumption.

Voith EcoConsult covers fuel measurements as well as worldwide route data recording and recommendation of systems components and driving operation.

For a Better Eco-Balance

Voith SteamTrac a System to Recover Waste Heat in Rail, Industry and Marine Applications

Making Sure that Precious Energy Does Not Just Puff Out
When liquid or gaseous fuels are burned in combustion engines, over 60 percent of the energy in the fuel currently remain unused. This energy escapes as exhaust heat via emissions and the cooling water. The waste heat recuperation system SteamTrac developed by Voith Turbo redirects some of this energy back into the driveline. Voith SteamTrac builds on a closed steam circuit. In the hot exhaust stream of a diesel engine, steam is generated via a heat exchanger and fed to a piston expander. This means that exhaust heat created during the combustion process is converted into usable torque and redirected to the drive. As a result, fuel consumption and consequently CO2emissions can be significantly reduced and the engine output is increased without the need for extra fuel. A system, which can be used especially for offroad applications in rail vehicles, marine or industrial applications. The key difference to known thermal systems is that the SteamTrac has been developed specifically for the cyclical operation of vehicles. Especially with diesel-driven rail vehicles, the lower fuel consumption is clearly recognizable the savings amount to 4 to 12 percent, depending on the respective load profiles.

Voith SteamTrac for marine and industrial applications

The additional energy generated from waste heat via the SteamTrac can be used either as a supplementary power source for the diesel engine or for driving auxiliary units (e. g. generators). After extensive trials on the test stand, the system will now be tried out in a rail vehicle. The intended medium is a diesel railcar with two diesel-hydraulic

drive systems used in commuter traffic. Beyond applications in rail vehicles, the SteamTrac system will be installed in a pusher boat during the winter period. While efficient heat recuperation systems are already fairly established in high-performance engines, there is still no adequate technology for smaller marine applications. For combustion engines with a power consumption between 300 and 2 000 kW, a steam turbine would be ineffective. Apart from that, such an investment would also not be financially feasible. In industrial applications, the Voith SteamTrac is already used in landfill gas plants.

The PlanetSolar measures 35 meters in length and is 23 meters wide.

Worlds Largest Solar Catamaran Driven by Vector Propellers from Voith Turbo

A Ship Powered by Nothing but the Sun

Can a 75-ton ship be powered on the high seas by nothing but solar energy? The answer is yes. This is what the initiators of the project PlanetSolar want to prove not only during their current test runs in the North Sea, but also on a 140-day sailing trip round the world. And further more, they want to demonstrate that a solar catamaran is not only technically possible, but can also be built and operated at affordable cost. The boat is driven by two variable-pitch propellers, type Vector Prop, from Voith Turbo.
In April 2011, the worlds largest solarpowered catamaran PlanetSolar will start its circumnavigation of the world along the Equator. We wanted to prove that renewable energies and technologies enabling improved energetic efficiency have become reliable and powerful today, say the project initiators Raphal Domjan and Grard dAboville. The dimensions of such a solar-powered vessel are impressive. The PlanetSolar measures 35 meters in length and 23 meters in width (with flaps). The surface of the boat is fitted with saltwater resistant photovoltaic panels. With adequate sun radiation, the energy thus generated amounts to 103.4 kW (138.7 hp). In this way it is ensured that the entire drive energy of the 75-ton catamaran is won from solar power. Storage takes place in lithium-ion accumulators. The new drive concept comes with an additional environmental benefit: Made from carbon fiber, the boat moves through the water without any noise. The catamaran is powered by four electric motors, coupled in twos to both of the two drive systems. During maneuvering, it is therefore possible to achieve a short-term maximum output of 90 kW per system. During sailing, the system operates with an output of two times 10 kW, reaching a speed of 9 knots. Director of Voith Turbo Advanced Propeller Technologies GmbH & Co. KG. The Vector Prop is an equally extraordinary drive element and, as a surfacepiercing propeller, has a high efficiency. The compact propeller can be adjusted and therefore also serves as a steering system. The control hub of the Vector Props is water-lubricated, which underlines the ecological advantages of the vessel further. The extended Voith Turbo scope of supply includes the shaft, the bearings, components for water lubrication, the adjusting device, as well as the redundant steering system.

Clean Thanks to Water Lubrication

The PlanetSolar was designed by the New Zealander Craig Loomes (Lomocean Design). We have already had excellent contacts with him in the past. This is why our propulsion system was installed in this extraordinary boat, states Jrgen Friedrich, Managing

More Safety in Stormy Offshore Environments

Special Vessels with VSP Set up Wind Energy Plants in the High Seas
The utilization of wind energy will play a central role in the energy mix of the future. Offshore plants, which are being set up on the high seas in higher and higher numbers, are playing an important part in this development. Their installation is carried out by giant special vessels. In the second half of 2012, two such jackup vessels will be launched in Dubai. They are the first ships of this kind to receive three Voith Schneider Propellers each.
The economy of wind energy plants depends strongly on their location. The North Sea, together with regions such as Cape Horn and the southernmost tip of Argentina are among the windiest areas in the world. During 90 percent of the time, there are winds with speeds of more than four meters per second. This makes power generation with wind energy plants economically feasible. (see page 8). In order to set up such plants, special jackup vessels are required. The special ships come with impressive main data. They are approximately 131 meters long, 39 meters wide, with an installed power of 11.4 MW and take up maximum loads of 5 300 tons. There is also a 3 200 square meter operating deck and an installation crane for loads of up to 800 tons and 25 meters in height. Two jackup vessels with identical design will be built and delivered in May and September 2012 to Lamprell Energy in Dubai. Their future task: Transport and installation of offshore wind energy plants, especially in the North Sea, so the ship owner Fred Olsen Windcarrier AS in Norway says. High efficiency and maneuverability are two key requirements on the special vessels. Fred Olsen therefore decided in favor of a solution with Voith Schneider Propellers (VSP). Three VSP ensure propulsion, as well as exact positioning, and get the marine giants to speeds of 12 knots during transfer trips. into special effect. It only takes three seconds for the drives to reverse. This prevents the ship from making leeway, which is normally inevitable due to the swell of the sea. The moment when the legs are lowered to the seabed is particularly critical. During this transitional phase, the VSP delivers significantly better thrust than horizontal propulsion concepts. The VSP also allows a simple hull shape. The ships can thus be built with an hydrodynamically efficient design, which has a positive impact on consumption figures and emissions. In difficult weather conditions a frequent occurrence in stormy offshore wind parks the Voith Roll Stabilization (VRS) reduces the rolling motions of the vessel and ensures increased safety.

Hold Position with Extreme Precision

A typical design characteristic of these jackup vessels are the four columns or jackup legs, which can be lowered to the bottom of the sea, lift the vessel and turn it into a stable operating platform. For this process, the jackup vessels have to hold their position with extreme precision. This is where the advantages of the VSP in direct combination with the dynamic positioning system come

High Efficiency and Maneuverability

The up to 180 meter-high wind turbines are often 45 kilometers off the coast in 30 meter-deep water. The adaptation of the wind-generated fluctuating power to the requirements of the electric grid is ensured by the WinDrive the Voith drive concept for wind energy plants

The vessel is lifted from the sea by four columns of jackup legs and turned into a platform.

Voith Hydrodynamic Gear Box Operates in Chinese Wind Parks

Peak Performance for Wind Parks with WinDrive

A 10-gigawatt wind park is under construction in the Gansu province in north-west China. Some of the wind turbines will use the Voith WinDrive in the driveline.

Construction of a 10-gigawatt wind park near Jiuquan in the Chinese province Gansu has started. A proportion of the wind turbines in the park will be fitted with the Voith hydrodynamic gear box WinDrive. The same applies to an offshore wind park. This is what the Chinese energy giants Guodian and LEC have decided. The wind park on the ancient Silk Road in Chinas northwest is an example of the Chinese state energy policy mapped out in the 11th Five-Year Plan for Economic and Social Development.

Wind energy: Sustainability for the next generation.

The new wind park to be built in Jiuquan with a budget of 12.5 billion euros is the first of six huge parks in the gigawatt class. Designed for a power capacity of 5.6 gigawatt by the end of 2010 (planned: 12.7 gigawatt by late 2015), Jiuquan will be Chinas largest wind power station. Voith participates in this mega project through two strong local partners, Lanzhou Electric Corporation (LEC) and China Guodian Corporation. Guodian is Chinas largest energy producer and LEC is one of the leading manufacturers of electric drives and generators. Both have decided to use the Voith WinDrive for 2 and 3 MW wind turbines in their wind parks.

park in Jiuquan, the worlds largest onshore wind power project. LEC has decided in favor of the WinDrive as the exclusive drive solution. For this purpose, Voith has co-developed a new 2 MW turbine, and a series contract is already signed and sealed. The plan is to seriesproduce over 100 WinDrives per year. Alongside LEC, the Chinese energy producer Guodian, too, went for the Voith solution. Guodian intends to use the WinDrive in the drivelines of wind turbines for on- and offshore wind parks. For these new wind power stations, Guodian United Power Technology, a company set up specifically for the renewable energy segment, is developing a 3 MW turbine. Series production of the high-performance wind turbine with Voith drive technology starts in 2012, the planned number of units is initially 100 turbines per year.

An excellent grid-feeding quality

The WinDrive is to demonstrate its advantages especially against the background of stricter grid-feeding legislation. While the absence of failureprone electronics will increase the availability and the energy output of the plant. The WinDrive also allows for the first time that power station-tested synchronous generators can be used. This generator type stands out by excellent grid-feeding quality and does not require additional electronic components such as condenser banks, voltage drop compensators or transformers inside the wind park. The improved availability and reduced maintenance requirements will result in lower power production costs compared to conventional drive concepts.

Series-production of over 100 WinDrives per year

LEC is based in Lanzhou and one of the contractors of the 10-gigawatt wind

Front ends made of lightweight fiber compounds offer ecological advantages: lower CO2-emissions and lower energy consumption.

New Rail Vehicle Heads Made From Fiber Compound Plastics and New Horizontal Buffers

Efficiency and Safety Best Combined

Voith Turbo Scharfenberg has developed two new head elements for rail vehicles. They offer ecological advantages and increase vehicle safety. The horizontal buffer increases impact protection and helps to prevent derailing and overriding of the carriages in the event of a rail accident. The new composite rail vehicle heads of the GALEA series also increase protection during collisions. Thanks to their low weight, they reduce energy consumption and vehicle wear and contribute to more efficient rail operations.
Apart from design and safety advantages, lightweight fiber compounds also offer ecological advantages over conventional materials: lower CO2-emissions and lower energy consumption. The lower weight also results in higher energy efficiency, less wear and better economy. Additionally, the transport efficiency of the traffic system is increased, as more passengers can be moved. Frontends have to withstand high operating loads and, in the event of a collision, even maximum loads. This requires special structural and energy absorption elements, which ensure higher passive safety for the vehicle driver and the passengers. Voith Turbo Scharfenberg is currently producing two prototypes of fiber compound heads for multiple units, railcars and control cars with operating speeds of up to 200 km/h which are used in regional and intercity traffic. The new vehicle heads are built in compliance with the crash norm EN 15227, as well as in line with Fire Protection for Rail Vehicles referring prEN 45545. Additional material requirements due to higher structural stiffness and additional energy-absorbing elements can be compensated by the utilization of fiber compound materials. Complex geometries and free-forming surfaces, which are necessary for the modern design of Voith frontends, would hardly be possible without fiber-reinforced plastics. helps prevent carriages from derailing and overriding in the event of a train accident. For this reason, the UIC/RID regulations for rail vehicles make crash buffers compulsory for all newly built tanks cars carrying hazardous goods. The collapsible element of the crash buffer has an energy absorption capacity of approx. 400 kJ per horizontal buffer. This high degree of energy absorption prevents overloads on the vehicle during serious collisions and therefore offers higher protection against derailing, overriding of the carriages and, in a worst-case scenario, the explosion of hazardous materials. During a collision, the approximately 130 kilogram-cash buffer does not immerse into the vehicle body and therefore reduces repair costs after accidents. Further advantages are less downtimes and faster re-availability of the vehicles after a collision.
Publisher: Voith Turbo GmbH & Co. KG September 2010 Editorial head office: Marion Jooss Voith Turbo GmbH & Co. KG Corporate Marketing/PR P.O. Box 20 30 89510 Heidenheim, Germany Phone +49 7321 37 2802 Fax +49 7321 37 7110 info.voithturbo@voith.com www.voithturbo.com Text: ecomBETZ PR GmbH, Schwbisch Gmnd Layout: Eberle GmbH Werbeagentur GWA, Schwbisch Gmnd

Higher Protection, Less Downtimes

Apart from these new frontends, Voith Turbo Scharfenberg is also developing a horizontal crash buffer (SK400) for locomotives, freight cars and tank cars. It makes rail transports of chemicals and other hazardous goods safer, as it increases impact protection and

PR 0002 September 2010 Reproduction and copying are subject to the express approval of the editorial head office.