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Maintenance depot Fulda

Your competence centre for the maintenance and reconditioning of rail vehicle brake parts

The Fulda maintenance depot, with its production unit in Delitzsch, has many years of experience in the maintenance and overhaul of brake parts on rolling stock. The depot was opened in 1867 as "Werkstättenamt Fulda".

The Fulda depot is also responsible for Deutsche Bahn AG's workshops for disabled employees. At four locations around Germany, around 110 employees with disabilities contribute to creating value for DB Fahrzeuginstandhaltung.

Reconditioning, inspection and repair of brake components and control equipment

The Fulda depot is responsible for the reconditioning, inspection and repair of mechanical, pneumatic and electropneumatic brake components and other rail vehicle control equipment.

 

The following brake components are covered by the depot's specialist knowledge:

  • Control and relay valves
  • Driver's brake valves
  • Brake containers, brake modules and brake equipment panels
  • Brake cylinders, brake callipers and compact brake callipers
  • Slack adjusters
  • Magnetic track brakes
  • Small parts (e.g. pressure reduction valves, air shut-off cocks, release valves, windscreen wiper drives, hose connections, load-proportional valves, wheel slide protection valves, solenoid valves, check valves, etc.)
  • Brake valves for historical rail vehicles

 

Retrofitting and upgrade of brake components

By changing parameters (e.g. pressure behaviour) or assembling/taking apart attachments, new variants can be manufactured within a group of components. The Fulda depot ensures that brake components are state of the art by improving products continuously in consultation with the manufacturers.

 

Advice on complete systems and maintenance strategies

The Fulda depot is the ideal partner for those who wish to establish a customised strategy for maintaining rail vehicle brake components, as it has many years of experience in reconditioning brake parts.

 

Test dismantling and diagnostics

When a customer has defective brake components or wishes to lengthen service durations (spread of inspection intervals), the depot can dismantle the components for testing or carry out diagnostic tests. In test dismantling and diagnostics, the components are given an optical assessment on receipt, inspected on modern testing equipment and dismantled by experts, who then record the degree of contamination and appraise the parts subject to wear. The results are summarised in a findings report.

 

Development and construction of testing equipment

The Fulda maintenance depot develops and builds its own testing equipment. This enables staff  to enter specific parameters quickly and flexibly into the WiFi-linked testing infrastructure. Fast reaction times and independence from manufacturers are unique selling points for this depot.

 

Development, building and servicing of brake trial and test units from the Pdr family of test pressure controllers

The brake trial and test units at the Fulda depot are used throughout Europe and the world, as for instance in Germany, Russia, Cuba, Algeria, Italy, Israel and Switzerland.

 

Pdr 1-N/Pdr 1-N1:

This brake testing equipment carries out brake trials on freight trains/passenger trains without a locomotive. The equipment is attached to a fixed compressed air system and connected to the wagon with the main brake pipe. It is also possible to mount the equipment on a tripod.

 

Pdr 1-NF with remote control:

The Pdr 1-NF with remote control can be used to upgrade an existing Pdr 1-N unit for the remote-controlled application/release of the brakes.

 

Pdr-Z brake measuring kit:

This is used to provide digital documentation to record, archive and analyse pressure and brake force values on rail vehicles. The compact measuring kit, which runs on rechargeable batteries, is ideal for mobile use and allows all measured values to be depicted simultaneously in a scatter chart over time. The software can be installed on as many computers as needed.

 

Brake test unit Pdr 5 (with RailTab option):

Highlights: Testing in compliance with UIC 540, guideline 900.0080, VPI_07, external power supply from T pressure via additional device

 

Documentation: Analogue values transferred to printed form, time measurement with stopwatch function

 

With RailTab option:

  • Visualisation of brake test sheets
  • Digital documentation of brake test sequences
  • Automatic archiving of brake test sheets
  • Specific adaptation of brake test steps and sheet content
  • Removable handles
  • Operates on rechargeable batteries
  • Connection box for measurement of brake force (block/disc brake) suitable for mobile use

 

Brake test unit Pdr 6 with RailTab:

The brake test unit Pdr 6 enables:

  • Testing in compliance with UIC 540, guideline 900.0080, VPI_07
  • External power supply from T pressure via integrated electropneumatic pressure controller
  • Visualisation of brake test sheets
  • Digital documentation of brake test sequences
  • Automatic archiving of brake test sheets
  • Customer-specific adaptation of brake test steps and sheet content
  • WiFi-linked control of pressure input and test sequences
  • Operated from driver's cab or from working group
  • Connection box for measurement of brake force (block/disc brake)

 

Brake test unit Pdr 7 with RailTab:

Highlights:

  • Testing in compliance with VPI_07, VPI_08, guideline 900.0080, UIC 540, UIC 543
  • Automatic testing
  • Comparison of target and actual status
  • Integrated printer
  • External power supply from T pressure via integrated electropneumatic pressure controller
  • Visualisation of brake test sheets
  • Digital documentation of brake test sequences
  • Automatic archiving of brake test sheets
  • Specific adaptation of brake test steps and sheet content
  • WiFi-linked control of pressure input and test sequences
  • Operated from driver's cab or from working group
  • Connection box for measurement of brake force (block/disc brake)

The test sequence is fully automatic. Any necessary action by the operator is prompted visually. The operator uses a keyboard/mouse, a touchscreen or the WiFi-linked remote control.

 

Upgrade of existing devices Pdr 5, Pdr 6 and Pdr 7 with RailTab:

Brake test units Pdr 5, Pdr 6 and Pdr 7 have received a comprehensive facelift in the form of an innovative, portable RailTab designed in accordance with industry standards. This modification offers a high level of user friendliness while minimising data entry thanks to the following functions, among others:

  • Visualisation of brake test sheets
  • Digital documentation of brake test sequences
  • Automatic archiving of brake test sheets
  • Specific adaptation of brake test steps and sheet content
  • WiFi-linked control
  • Connection box for measurement of brake force (block/disc brake)
  • Existing devices can be converted at any time

 

Mobile on-site service and delivery service

The Fulda maintenance depot guarantees:

  • Consultation and information at the maintenance locations
  • Local assistance and service on site
  • Attractive conditions, correct and timely invoicing
  • Upholding of clear and concise order details and reasonable delivery dates
  • Flexibility with respect to changes in deliveries and services
  • Information about necessary changes to production provided early on
  • Information regarding logistical problems and changes to delivery dates communicated immediately
  • Immediate processing of complaints

 

Brake component logistics centre

  • Components delivered straight from warehouse (exchange pool)
  • Procurement and exchange of complete brake component sets for vehicles such as ER 20, Class 66, Lint, FLIRT, Traxx, DE 6400, double-deck wagons, etc.
  • No brake components are stored unused for too long

The services offered by the workshop for disabled employees are market-compliant, forward-looking and encompass several different areas. The workshop sites are located with the product portfolio in mind, as follows:

Hanover: Screen printing

Cologne-Nippes: Manufacture of warning horns and stamps

Ingolstadt: Metalwork and manufacture of fire extinguishers

Wanne-Eickel: Manufacture of magnetic track Brakes

Numerous customers repeatedly orders for these products. Many of these customers have long trusted in the capabilities, dependability and quality of the integration workshops' performance.

Several certifications of conformity and audits testify to the high quality of the services rendered. As of 2004, for example, the workshops have been DIN EN ISO 9001 compliant and have acquired all the certificates required to carry out special inspection activities.

Repair of brake components in the Br 3 brake inspection, as for example for the following vehicles and customers:

  • Desiro Mainline II (Mittelrheinbahn, Siemens Deutschland)
  • LE 7400 (Siemens Portugal)
  • LE 5600 (Siemens Portugal)
  • FLIRT (Cantus)
  • FLIRT (SOB)
  • Lint 41 (Arriva)
  • Type WZK 67 (Arriva)

To ensure the achievement of quality targets, the Fulda depot provides its staff members with professional training. Particular attention is paid to train young people in a variety of areas of expertise. The depot currently employs around 12 vocational trainees in the areas of mechatronics, industrial mechanics and warehouse logistics.

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