TRANSPORTATION

Mechanical gearboxes
and gear wheels for mass
transportation
Wikov 2012 - 01
Content
Gearbox designing - process
Gear units for:
Trams
Metro
Monorail system
EMUs
DMUs
Locomotives
Trolleybuses & Electro-buses & Hybrid-buses
Gearbox testing
Bevel gear sets
Gearbox overhauls
Spare parts
Point machines
Licences and Know how
Certificates
Contacts


Gearbox designing - Process

1) Customers submission
2) Draft calculation of gear toothing
and bearings
Gearbox designing - Process

3) Draft preliminary design +
preliminary dimensional drawing
4) Consultation and precising
customers submission
5) Final calculation of gear toothing
and bearings

Gearbox designing - Process

7) Calculation of gear box rigidity
and stiffness Finite Element
Method
Areas of load action
Definition of bolted connection of
split face
Breakdown of force reactions
Von Mises stresses on shafts
Shafts deformation by load action
Contact pressure distribution over
bolted connection in the split face
Tension on gear casing
Gear casing deformation
Drive suspension calculation
Gearbox designing - Process

8) Draft and optimization of toothing
modifications
9) Final drive design (SolidEdge)





Profile corrections
Longitudinal corrections
High floor trams gearbox type AWBD-H
Gearbox type
One stage bevel (hypoid)
axle drives AWBD-H
Description
One-stage bevel gearbox
transmits torque from
engine to the axle.
Gearbox connection with
an engine is via cardan
shaft. Axle is a
component of gearbox.
Vehicle type RT8D5M, T6A5
Nominal power 40 - 85kW)
Max. speed of input shaft 1,946rpm
Max. torque moment on
input shaft
640Nm
High floor trams gearbox type AWDD-N
Gearbox type
Two stage bevel-helical
axle drives with
cyklopaloid gearing
Klingelnberg AWDD-N
Description
Two-stage bevel-helical
gearbox transmits torque
from engine to the axle.
Gearbox connection with
an engine is via cardan
shaft. Axle is a
component of gearbox.
Vehicle type T6A2, KT4D
Nominal power 54kW
Max. speed of input shaft 4,350rpm
Max. torque moment on
input shaft
980Nm
High floor trams gearbox type AWDD-N
Gearbox type
Two stage bevel-helical
axle drives with
cyklopaloid gearing
Klingelnberg AWDD-N
Description
Two-stage bevel-helical
gearbox transmits torque
from engine to the axle.
Gearbox connection with
an engine is via cardan
shaft. Axle is a
component of gearbox.
Vehicle type T8M-700IT
Nominal power 110kW
Max. speed of input shaft 2,580rpm
Max. torque moment on
input shaft
609Nm
Partially low floor trams - gearbox type AWHD-Z
Gearbox type
Helical axle drives with
solid shaft for partially
low-floor trams AWHD-
Z
Description
Two-stage helical
gearbox transmits torque
from engine to the axle.
Gearbox connection with
an engine is via flexible
coupling. Axle is a
component of gearbox.
Vehicle type
KODA 03T, 13T, 14T,
16T
Nominal power 90kW
Max. speed of input shaft 4,500rpm
Max. torque moment on
input shaft
1,100Nm
Destination
Ostrava, Olomouc, Most,
Plze, Brno, Praha,
Wroclaw
Partially low floor trams - gearbox type AWHD-Z
Gearbox type
Helical axle drives with
solid shaft for partially
low-floor trams AWHD-
Z
Description
Two-stage helical
gearbox transmits torque
from engine to the axle.
Gearbox connection with
an engine is via flexible
coupling. Axle is a
component of gearbox.
Vehicle type
KODA-Inekon 10T,
Inekon TRIO 12
Nominal power 90kW
Max. speed of input shaft 4,500rpm
Max. torque moment on
input shaft
1,100Nm
Destination
Portland, Tacoma,
Seattle, Washington
Partially low floor trams - gearbox type AWHD-Z
Gearbox type
Helical axle drives with
solid shaft for partially
low-floor trams AWHD-
Z
Description
Two-stage helical
gearbox transmits torque
from engine to the axle.
Gearbox connection with
an engine is via flexible
coupling. Axle is a
component of gearbox.
Vehicle type KODA 06T
Nominal power 115kW
Max. speed of input shaft 4,800rpm
Max. torque moment on
input shaft
1,100Nm
Destination Cagliari Sardegna
Partially low floor trams - gearbox type AWHD-Z
Gearbox type
Helical axle drives with
solid shaft for partially
low-floor trams
AWHD380Z
Description
Two-stage helical
gearbox transmits torque
from engine to the axle.
Gearbox connection with
an engine is via flexible
coupling. Axle is a
component of gearbox.
Vehicle type Vario LF2Plus
Nominal power 90kW
Max. speed of input shaft 4,340rpm
Max. torque moment on
input shaft
519Nm
Partially low floor trams - gearbox type AWHD-Z
Gearbox type
Helical axle drives with
solid shaft for partially
low-floor trams AWHD-
Z
Description
Two-stage helical
gearbox transmits torque
from engine to the axle.
Gearbox connection with
an engine is via flexible
coupling. Axle is a
component of gearbox.
Vehicle type RT6N
Partially low floor trams complete drive with AWHC-Z gearbox
for Cold Climate Conditions
Gearbox type
Helical axle drives with
hollow shaft
AWHC419Z
Description
Gearbox transmits
torque from engine to the
axle. Gearbox
connection with an
engine is via flexible
coupling. Axle
connection with a
gearbox is via flexible
coupling mounted on
holow shaft of gearbox.
Jmenovit penen
vkon
125kW
Maximln otky
vstupnho hdele
4,032rpm
Maximln penen
kroutic moment na
vstupnm.hdeli
775Nm
Fully low floor trams gearbox type AWDC-N
Gearbox type
Bevel-helical gearbox for
standard axle bogie
AWDC-N
Description
Gearbox transmits
torque from engine to the
wheel. Gearbox
connection with an
engine is via flexible
coupling. Wheel/gearbox
connection is via flexible
coupling. Gearbox is
suitable for traction bogie
with conventional axles
Nominal power 100 kW
Max. speed of input shaft 4,500 rpm
Max. torque moment on
input shaft
700 Nm
Fully low floor trams gearbox type AWBC-Z
Gearbox type
Bevel final drive for
pivoting traction bogie
with indepedently
rotating wheels - AWBC-
Z
Description
Gearbox transmits
torque from engine to the
wheel. Gearbox
connection with an
engine is via flexible
coupling. Wheel/gearbox
connection is via flexible
coupling. Gearbox is
suitable for pivoting
traction bogie without
mechanical linkage of
independently rotating
wheels
Nominal power 45kW
Max. speed of input shaft 1,622rpm
Max. torque moment on
input shaft
400Nm
Fully low floor trams
epicyclic hub drive with flexible pin technology
Gearbox type
Epicyclic hub drive for
pivoting traction bogie
with indepedently
rotating wheels
Nominal power 45kW
Max. speed of input shaft 1,622rpm
Max. torque moment on
input shaft
400Nm
The hub drive is equipped with Hicks
Flexible Pins
A well proven design concept that
ensures load sharing between
planets and across tooth faces
Ideally suited for dealing with
dynamic torsion loads and structural
deflections induced by variable loads
The evolved Hicks pin uses
advanced design features to protect
against overload and enable helical
gears to be used
Flexible pins & multi-satelite technology
Flexible Pin provides:
Equal loads between planet wheels
Uniform load across face width of
teeth sun/planet & planet / annulus
contacts
Uniform loads on planet wheel
bearings
Uniform load under overload and
shock load conditions
Gear tooth loads are isolated from
gear case deflections imposed by
driven machine loads
Main features of flex pin and multi-
satelite technology:
High reliability
Increased life time
Reduced weight & dimensions


Torque Advantage from Multiple Planets
Torque capacity 166%
3 planets 5 planets
Metro gearbox type AWHC-Z
Gearbox type
Helical axle drives with
hollow shaft AWHC-Z
Description
Gearbox transmits
torque from engine to the
axle. Gearbox
connection with an
engine is via flexible
coupling. Axle
connection with a
gearbox is via flexible
coupling mounted on
holow shaft of gearbox.
Metro gearbox type AWHC-Z
Gearbox type
One-stage helical
gearbox AWHC365Z
Nomiinal power 200kW
Max. speed of input shaft 3,600rpm
Nom. torque moment on
input shaft
958Nm
Monorail
Gearbox type
Gearbox for monorail
system
Description
Two-stage helical
gearbox transmits torque
from engine to the axle.
Gearbox connection with
an engine is via cardan
shaft. Gearbox
connection with drive
wheel is via flexible
coupling.
Vehicle type Project Monorail J akarta
Nominal power 100kW
Max. speed of input shaft 3,500rpm
Max. torque moment on
input shaft
643Nm
EMUs gearbox type AWHD-Z
Gearbox type
Helical axle gearbox
AWHD-Z
Description
Two-stage helical
gearbox transmits torque
from engine to the axle.
Gearbox connection with
an engine is via flexible
coupling. Axle is a
component of gearbox.
Bogie type
6Ev, narrow-gauge
version
Nominal power 85kW
Max. speed of input shaft 4,800rpm
Max. torque moment on
input shaft
562Nm
Destination Locarno
EMUs gearbox type AWHD-Z
Gearbox type
Helical axle gearbox
AWHD365Z
Description
One-stage helical
gearbox transmits torque
from engine to the axle.
Gearbox connection with
an engine is via flexible
coupling. Axle is a
component of gearbox.
Nominal power 340kW
Ratio 3.86
Max. speed of input shaft 4,200rpm
Max. torque moment on
input shaft
3,528Nm
EMUs gearbox type AWHC500Z
Gearbox type
Helical axle gearbox
AWHC500Z
Description
Gearbox transmits
torque from engine to the
axle. Gearbox
connection with an
engine is via flexible
coupling. Axle
connection with a
gearbox is via flexible
coupling mounted on
hollow shaft of gearbox.
Nominal power 180kW
Ratio 7.117
Max. speed of input shaft 4,360rpm
Max. torque moment on
input shaft
1,522Nm
EMUs
gearbox type AWHC595Z 500kW, up to 160 km/h
Gearbox type
Helical axle gearbox
AWHC595Z
Description
Gearbox transmits
torque from engine to the
axle. Gearbox
connection with an
engine is via flexible
coupling. Axle
connection with a
gearbox is via flexible
coupling mounted on
holow shaft of gearbox.
Nominal power 500 kW
Ratio 4.857
Max. speed of input shaft 5,257 rpm
Max. torque moment on
input shaft
4,450 Nm
EMUs
gearbox type AWHC595Z 500kW, up to 160 km/h
EMUs gearbox type AWHD-R
Gearbox type
Helical axle gearbox
AWHD404R
Description
Two-stage helical
gearbox transmits torque
from engine to the axle.
Gearbox connection with
an engine is via flexible
coupling. Axle is a
component of gearbox.
Nominal power 340kW
Ratio 4.79
Max. speed of input shaft 6,200rpm
Max. torque moment on
input shaft
2,865Nm
EMUs axle wheels and pinions
EMU type 471 and 671 (575)
CityElefant (KODA)

DMUs gearbox type AWDD-N / AWBD-N
Shunting diesel-electric locomotives
One-stage helical gearbox for
shunting locomotive (CZ Loko)







Shunting diesel locomotives gearbox type AWHD-Z
Gearbox type
Two-stage helical
gearbox AWHD-Z for
shunting locomotive with
hydrostatic drive
Description
Two-stage helical
gearbox transmits torque
from hydraulic motor to
the drive axle of shuting
locomotive. Gearbox
connection with hydraulic
motor is via disc clutch.
Axle is a component of
gearbox.
Vehicle type CMI (project)
Nominal power 91kW
Max. speed of input shaft 3,453rpm
Max. torque moment on
input shaft
1,523Nm
Electric locomotives
Drive type
Electric locomotive drive
with helical one-stage
gearbox
Description
Axle drive with
transverse traction motor
connected with gearbox
via input membrane
coupling. Wheel-
set/gearbox connection
is via jointed coupling
Vehicle type Electric locomotive
Nominal power 1,200kW
Max. speed of input shaft 3,625rpm
Nominal torque moment
on input shaft
6,486Nm
Electric locomotives
Axle wheels and pinions for electric
locomotives
Diesel-electric locomotives spare parts
Trolleybuses
One-stage helical gearbox with
output shaft option left or right

Vehicle type Trolleybus
Nominal power 240kW
Ratio 1.85

Nom. torque moment on
input shaft
1,307Nm
Electro-buses epicyclic drive with flexible pin technology
One-stage epicyclic gearbox with
flexible pin technology designed by
ORBITAL2
Main features of flex pin and multi-
satelite technology:
High reliability
Increased life time
Reduced weight & dimensions


Vehicle type Electro-bus
Nominal power 145 kW
Maximal motor power 241 kW

Ratio 4.00

Testing Full load test
with continuous control of torque and motor speed
Continuous control of torque and
motor speed
Simulating the torque characteristic of
rail vehicle driving cycle
Testing the gearbox behaviour in
almost realistic conditions
Recorded speed, torque or
temperature curve
Possible cooling of gearboxes by air
flowing through special fans, which
simulates the air flow around the
gearbox in the real environment of
the vehicle
Test results are immediately applied
to the gearbox design, including, e.g.:
gear modification adjustment,
gearbox cooling or further noise
reduction
The entire system is software-
protected against overloading

Testing Full load test
with continuous control of torque and motor speed
Testing Cold Climate Test
Test of complete drive (gearbox +
couplings + motor) for rail vehicles
operating in CCC (Cold Climate
Conditions)
Modular system of Climate
Chamber
2 compressors 2 x 26kW + electric
fans
Gradually cooling of gearbox up to
- 45C (air temperature -50C)
Hard starting-up of the drive
Measuring temperatures inside of
gearbox; measuring pressures,
output torque, speed and vibrations

Testing Cold Climate Test
- AWHD365Z gear unit
Bevel gear sets with spiral gearing
Hypoid gearing Gleason - lapped
Hypoid gearing Klingelnberg HPG
method
Non-hypoid cyclopalloid gearing
Klingelnberg lapped or HPG

Gearbox overhaul
We offer repairs and overhauling of
gearboxes for rail vehicles
Tram axle gearboxes of type KD
and KODA
Others types of rail vehicles
gearboxes
Spare parts
We offer deliveries of spare parts for
gear units such as:
Gear wheels and pinions parallel
or bevel gear sets
Gearbox housings

Point machines
Example of successful production
transfer from Great Britain to the
Czech Republic:
Production of point machines
designed by Alstom company
Production since 2003
Produced more than 3500 pcs.

Licences & Know How
KD (Siemens Kolejov vozidla)
The company Wikov MGI a.s. is the
exclusive manufacturer and exclusive
seller of the below stated gearboxes
and components of KD (Siemens
Kolejov vozidla) railway vehicles
production:
Dieselelectric locomotives:
Gearboxes, gear wheels
Bevel pinions
Gearboxes for auxiliary drives
Tram types (including all subtypes):
T3, K2, KT4, T4, KTNF8, T5C5,
KT8D, KT8D5, T6A5, RT8D5M,
T6C5, RT6N-1

Licences & Know How
KODA
(KODA TRANSPORTATION a.s.)
Wikov MGI a.s. is exclusive
authorized licensed producer and
supplier of axle gearbox spare parts
and big gear wheels for electric
locomotives - KODA and axle
gearboxes for trams KODA-
INEKON


Licences & Know How
esk drhy, a.s. (Czech Railways)
Wikov MGI a.s. is certified as
technically qualified supplier by the
D Certification Centre for:
Production of gearboxes for traction
rail vehicles
Production of auxiliary drives for
traction rail vehicles
Production of gear wheels and
pinions for traction rail vehicles



ISO 9001:2008
Bureau Veritas ISO 9001:2008 -
certification
Contacts

Wikov MGI a.s.
Zbenk 356, CZ-549 31 Hronov
www.wikov.com

Michal Stuchlk tel. +420 491 488 426 e-mail: mstuchlik@wikov.com