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InnoTrans 2012
September 18 - 21 - Berlin

Liebherr-Transportation
Systems

Liebherr-Aerospace

© DB AG, Air bus

22

Editorial

Francis Niss

Dear Reader,

InnoTrans in Berlin is an event of utmost importance for Liebherr. As in the past, we are participat-

ing with enthusiasm this year to present the products and the technologies we have developed

for the rail industry.

The industry is currently facing a downturn. Indeed, the global economic and financial conditions

restrain the implementation of new train projects and the replacement of rolling stock. Even in

China, the world’s most important market for the rail industry, several new programs have sud-

denly been frozen.

Nevertheless, we continue to experience sustainable growth thanks to our long-term develop-

ment strategy.

We have decided to concentrate our engineering skills at our main site in Korneuburg (Austria)

in order to consolidate efficiency. We have launched a promising process for product standard-

ization as well as for the reduction of lead-time and development cost. In Korneuburg, we are

establishing engineering and production expertise for highly efficient hydraulic systems derived

from the technologies we developed for the aerospace industry.

Of course, we continue to invest in environmentally friendly technologies such as air cycle and

CO

air conditioning as well as in other solutions for the reduction of noise emissions, on-board

2

weight and energy consumption.

A modern and competitive production center in Bulgaria and a joint venture in China complement

the Korneuburg site. Our customer service activities show substantial growth thanks to dynamic

commercial action and our global presence.

Thus, Liebherr is well prepared to meet the future challenges of the rail industry, which still shows

considerable growth potential in the medium and long term.

We hope you enjoy reading this new edition of our exhibition news and have a successful

InnoTrans 2012.

Best regards,

Francis Niss
President, Liebherr-Aerospace & Transportation SAS

Contents

33

Editorial 2

Liebherr-Transportation Systems 4

A Strong Network ................................................... 6

Air Cycle Air Conditioning Technology ..................... 8

Electro-Hydraulic Actuation .................................... 10

Saline Provides Services

for Rail Vehicle Industry ......................................... 12

News From Around the World ............................... 14

Liebherr-Aerospace 16

Major Investments 18

Liebherr-Aerospace in the Americas ....................... 20

A Supplier to Airbus from the Very Beginning ........ 22

CSeries: Landing Gear and

Air Management Systems .................................... 24

AW189, Global 7000 / 8000 Program .................... 25

Vast Array of Products for the Aviation Industry .... 26

Liebherr Group News 28

Growth in the Business Year 2011 ......................... 30

Domestic Appliances Receive Awards ................. 33

New Liebherr T 284 Mining Truck ......................... 34

Publisher’s Address .............................................. 36

© Bombardier Transportation

Liebherr-Transportation Systems

6

Transportation Systems

Liebherr’s Transportation Systems Division,
a Strong Network

The railway industry shows growth per-

spectives in the medium term, even if it

seems that the dynamics have slight-

ly slowed down in the last few months.

While countries that were hit particu-

larly hard by the current economic and

debt crisis cancelled or postponed sev-

eral projects, the railway industry as a

whole continues to grow.

The driving forces behind this growth

are new railway projects on the one

hand, and modernization measures in

the fields of long-distance traffic for

the main routes, subways and street-

cars on the other hand. Additionally,

this develop ment is supported by new

environmental protection requirements

and the highly congested transfer routes

in metropolitan areas.

Within its long-term strategy Liebherr-

Transportation Systems continues to

promote the expansion of its organiza-

tion in selected new markets or market

regions like North America, Russia or

Brazil with the aim of local presence. At

the same time Liebherr-Transportation

Systems has reinforced the sales

and service teams in its core markets

France, Germany and United Kingdom.

The process-based organization of

Liebherr-Transportation Systems has

been further developed in order to im-

prove smooth collaboration across the

different sites and to ensure that eve-

ry individual part of the organization re-

mains responsible for its tasks while

contributing to the achievement of the

company’s overall objectives. By en-

hancing simultaneous engineering the

lead time of the projects could be short-

ened even further. Thus, product quali-

ty, customer satisfaction and sustaina-

bility have been further increased.

Moreover, Liebherr-Transportation Systems

has started to concentrate all heating,

ventilation and air conditioning (HVAC)

product development activities at its

main site in Korneuburg (Austria). The

aim is to benefit from synergies that

the utilization of engineering resourc-

es and infrastructure, the standardiza-

tion of business processes, the existing

in-house production as well as test fa-

cilities offer.

Furthermore, the collaboration with

the development and project manage-

ment departments is being improved

in order to meet customer needs in an

even more suitable manner and to im-

plement the sales and service strategy,

which was defined for the entire trans-

portation field. Here the standardiza-

tion of processes across all Liebherr-

Transportation Systems sites has

especially proven its worth.

The organizational alignment of the

hydraulic systems area has been com-

pleted: Liebherr-Transportation Systems

further established its responsibility re-

garding marketing, sales and customer

service (including repair and overhaul) of

hydraulic systems and equipment,

in the framework of a close collabo

with Liebherr-

GmbH (Ger

ment of the manufacturing network,

which was kicked off some years ago,

was also further advanced.

Aero space Lindenberg

many). The strategic align-

with-

ration

Transportation Systems

Liebherr-Transportation
Systems GmbH & Co KG
in Korneuburg, Austria

7

The manufacturing site of Liebherr-

Transportation Systems in Radinovo

(Bulgaria) has expanded its operation.

The local company called Liebherr-

Transportation Systems Marica EOOD

is in charge of the series production of

all large-scale European HVAC projects.

The joint venture in China’s Zhejiang

province, Liebherr Zhongche Transportation

Systems Co., Ltd., has successfully in-

creased its production program in the

field of HVAC systems for Chinese car

manufacturers, who contribute to pro-

jects in and beyond China.

In addition, the plant of Liebherr-

Transportation Systems GmbH & Co KG

in Korneuburg has been further devel-

oped in order to optimize performance

and quality, flexibility and high-speed re-

action time, which contributes to the di-

vision’s competitiveness. The range of

products manufactured in Korneuburg

is subsequently being enlarged.

Liebherr-Transportation Systems is be-

ing prepared to launch the assembly

and test of hydraulic products in the

near future, which will complement

the traditional HVAC systems railway

application.

All employees work hard to make one

vision come true: that of Liebherr-

Transportation Systems becoming a

global player and a worldwide reference

in the fields of HVAC, hydraulics and

power supply systems for the railway

industry. A major achievement in this

context was the renewal of the IRIS (Inter-

national Railway Industry Standard) cer-

tification of the Liebherr- Transportation

Systems’ sites in Korneuburg, Mannheim

and Radinovo in autumn 2011.

Service specialists
checking an air
conditioning unit

8

Transportation Systems

The Eco-Friendly Solution
for Air Conditioning in Trains

Liebherr’s air cycle air conditioning sys-

tem simply uses air as refrigerant to pro-

vide a comfortable climate for passen-

gers. The system operates with an open

loop process and draws the air required

for the cooling process from the environ-

ment. The air expands and thus cools.

Then the cool air runs through the heat

exchanger and is subsequently returned

to the ambience.

Fresh Air

Filter

When developing the system, Liebherr

took advantage of its long-term expe-

rience in the aircraft industry: air cycle

air conditioning systems made by

Liebherr have been installed on board of

numerous aircraft.

The system for application in rail vehicles

complies with all common passenger

comfort requirements such as UIC 553,

Exhaust

Process Air

Heater

MCT

EN13129 and EN14750, and – as a real

alternative to chemical refrigerants –

helps to reduce the greenhouse effect

according to worldwide HFC regulations.

As the system does not use any other re-

frigerant than air, there is no risk of refrig-

erant leakage and the compliance with

any future legislation regarding refriger-

ants in air conditioning systems is abso-

lute and unlimited.

Supply Air

Fan

Return Air

Filter

Fresh Air

Fresh Process Air

Return Air

Fan

Heater Heat Exchanger

Supply Air

Liebherr’s Air Cycle Air Conditioning Technology
Gives Proof of its Qualities

Liebherr-Transportation Systems’ cut-

ting-edge eco-friendly technology for air

conditioning of railway vehicles – the air

cycle air conditioning system – has prov-

en its outstanding performance in dai-

ly service. During the past seven years,

application in ICE 3 high speed trains

has demonstrated that this future-proof

technology derived from Liebherr’s

aerospace branch is superior to tradi-

tional vapor cycle air conditioning con-

cepts in terms of eco-friendliness, total

cost of ownership and enhanced pas-

senger comfort.

Liebherr's air cycle air conditioning tech-

nology features significantly reduced life

cycle costs compared to common vapor

cycle systems. Life cycle costs of tradition-

al air conditioning systems consist of sev-

eral items, the most significant ones be-

ing the direct maintenance on the system,

unscheduled vehicle downtime due to

system failure, spare part administration

and power consumption. Additional oper-

ating costs related to the refrigerant circuit

such as refrigerant handling and disposal,

retrofit of refrigerant in order to comply

with future regulations, or refrigerant emp-

tying / refilling times also contribute to the

high life cycle costs of traditional techno-

logies, increasing the attractiveness of the

air cycle technology.

Transportation Systems

9

Thanks to the reduced number of its

key components, which is based on the

fact that the refrigerant channel does

not need to be sealed, the system offers

higher reliability. Moreover, failed com-

ponents can be isolated and exchanged

much faster on an air cycle system than

on a traditional system, which normally

requires the replacement of the complete

cooling unit. Therefore maintenance op-

erations are significantly simpler.

In all, the reliability of Liebherr’s air cy-

cle air conditioning system helps to save

direct maintenance costs and leads to

considerably reduced vehicle down-

times. In the case of maintenance the

reduced number of parts in the system

ease any maintenance and repair, while

simplified accessibility guarantees effi-

cient time-saving service. Maintenance

does not require EG 303/2008 refriger-

ant-trained and certified personnel any-

more. Moreover, storage, handling and

future accounting of refrigerant on site

are no longer necessary. Furthermore,

with a view to a future ban of chemical

refrigerants, the air cycle air condition-

ing units will not need to be retrofitted or

adapted, thus accounting for an addition-

al cost advantage when compared to va-

por cycle units.

A key advantage of the air cycle sys-

tem technology is its ability to continue

operating even when external tempera-

tures are extremely severe and beyond

normal operating conditions. For exam-

ple, it even continues generating cool

air under high external temperatures. In

contrast to this, the vapor cycle system

stops operating due to the refrigerant

overpressure switch. This key feature

guarantees that the air cycle air condi-

tioning systems works when it is most

needed, thus preventing inside cabin

temperatures from exceeding outside

temperatures.

Other benefits this technology offers to

passengers are the low measured noise

and vibration levels in the car and on

the platform. Liebherr-Transportation

Systems is the only supplier in the industry

to develop the air cycle machine / cooling

turbine in-house, which guarantees the

long-term availability of this next genera-

tion technology for railway applications.

From September 18 - 21, 2012, Liebherr-Transportation Systems will present

numerous innovative solutions at InnoTrans in Berlin (Germany) at booth no. 232

in hall 3.1. Energy-efficient and environmentally friendly air conditioning systems,

reliable hydraulic actuation systems and electronic compo-

nents, or a high-performance railroad excavator with rail bo-

gies – the variety of products and services on display represent

Liebherr’s comprehensive know-how in the transportation

sector.

Outdoor display
at InnoTrans

10

Transportation Systems

Electro-Hydraulic Actuators −
an Intelligent Solution for Rail Transport

Electro-hydraulic actuators (EHA) work

as compact, high-performance “pow

houses” in rail vehicles, and are pro-

duced by Liebherr to meet specific cus-

tomer requirements in a wide range of

applications.

Twindexx Express

These applications include active lateral

suspension and active lateral centering

systems, car positioning systems, ac-

tive radial control, active wheelset control

and tilt technology. Among other attrib-

utes, EHA make a valuable contribution

to reducing the burden on the environ-

ment and preventing wear while increas-

ing performance.

Liebherr performs their assembly, fill-

ing and final testing under extremely

er

clean conditions and thus ensures they

will achieve many years of service in the

tough environment of rail transport. The

car manufacturer fits the Liebherr EHA

© Bombardier Transportation

to the vehicle and installs the cable con-

nection for the energy supply and con-

trol systems. The time-consuming in-

stallation work required on conventional

hydraulic systems to route the lines, fill

and vent the circuit is thus eliminated.

This also removes the risk of contaminat-

ing the hydraulic fluid through incorrect

installation work and, as a result, dam-

aging the actuator. The system could

almost be described as having ‘plug and

play’ functionality.

EHA from Liebherr are fundamental-

ly maintenance-free. If, nevertheless, a

fault should occur, the entire unit can be

quickly replaced without any hydraulic

expertise, thus avoiding prolonged vehi-

cle downtime.

The innovative EHA systems are regulat-

ed by a controller which communicates

with the vehicle control unit via CAN bus.

This controller was also developed by

Liebherr.

Liebherr’s EHA can be adapted for all

customer requirements and ensure fast,

comfortable, and above all safe arrivals

at the destinations.

At train speeds of up to 350 km/h EHA

have to move heavy loads of several tons

into the position specified by intelligent

control units, or counteract vibrations

occurring on the vehicle. They not only

make faster train speeds possible, but

also increase passenger comfort.

A further key advantage of EHA is that

they reduce car and infrastructure wear

enormously. Initially rather high invest-

ment costs are recouped very quickly

through lower maintenance expenses,

reduced total energy costs and higher

carrying capacity compared with con-

ventional hydraulic systems. EHA are

self-contained hydraulic systems.

Above: Active yaw
damper system
Below: Actuator for
tilting technology

The new Bombardier

V300 ZEFIRO high-speed train

© Bombardier Transportation

New Generation of Compact,

Transportation Systems

11

Reliable and Service-Friendly Actuators

Last year, Liebherr-Transportation Systems

developed a new type of electro-hydraulic

drive system for rail vehicles for

Bombardier Transportation. In the first

stage, concepts for two versions of this

new actuator type were drawn up. One

version is used for active roll compensa

on the new InterCity double-decker

coaches of Swiss Federal Railways

(SBB). The other version is used for active

yaw compensation on Bombardier’s new

V300 ZEFIRO Italia high-speed train.

The new actuator type is part of a new

platform strategy, for which Liebherr is

developing customer-specific actuators

for as broad a range of applications as

possible. These include elements for

active rotational damping, active later-

al suspension, lateral compensation, tilt

technology and level control.

The new generation of actuators differs

from the electro-hydraulic actuators de-

veloped by Liebherr in the past in that

the electronics are now integrated into

the device. They now assume the task

of regulating and monitoring the individ-

ual actuator. The computer in the vehi-

cle is merely responsible for coordinating

the individual actuators among each oth-

er. Communications with this computer

are conducted using a robust CAN bus

tion

signal, allowing the number of electrical

connections needed in the overall system

to be substantially reduced. Another ad-

vantage of bus communications is that

the parameters specific to the vehicle

or the actuator can be made available

through the bus system. Therefore an ac-

tuator can, for example, be used in dif-

ferent vehicles without any modifications

to its software. Equally, it is possible to

change the mechanical or hydraulic para-

meters of the actuator without software

modifications.

Another feature of Liebherr's new actu-

ator type is the complete integration

the bogie frame. The actuator is sim

sideways into the opening provided in

the frame. This guarantees optimal ac-

cessibility to the actuator when it is in-

stalled, and allows the complete elec-

tronics or individual hydraulic valves to

be exchanged within a very short space

of time without removal of the device.

Direct thermal contact means that the

bogie frame can also act as a cooler for

the actuator.

Not only in its installation attention was

paid to optimal service friendliness, but

also in its design. For example, all com-

ponents which could potentially fail can

be quickly and simply replaced. The num-

p ly slid

ber of parts subject to wear has been re-

duced to small assembly modules, and

a paint finish has been deliberately omit-

ted, keeping the follow-on costs incurred

during an overhaul to a minimum.

With the new generation of compact,

reliable and service-friendly actuators,

Liebherr-Transportation Systems has

developed a highly versatile basis for a

wide range of future applications. Funda-

mentally, these are configured as highly

dynamic, power-regulated components.

Versions with travel control circuit are,

however, also possible. The design was

configured to allow additional expansion

into

stages to be realized. That permits the

actuator to be expanded by a second

controlling element, for example, retain-

ing use of many individual components.

One actuator controlling element can

thus tilt the coach frame while the sec-

ond radially adjusts the axis to the spe-

cific radius of the bend.