Schaeffler Solutions for Rail

We Present Products and Services for the Railways of Tomorrow

As a component supplier to the railway sector, Schaeffler makes a sustained contribution to improving the competitive edge of the railway sector with respect to other modes of transport. We are therefore investing heavily in digitalization and thus optimizing the entire supply chain.

Join us on the journey to the future of rail. Under our motto “Reliable, Predictable, Sustainable – Schaeffler Solutions for Innovations in Rail” you will find new product solutions and pioneering systems for the entire powertrain of rail vehicles. Discover all the economic and ecological advantages the progressing digitalization of the railway sector will provide.

Do you have any questions about our products or solutions? Feel free to contact us anytime!

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Reliable Products for Safe and Efficient Railway Operations

What do we mean by reliability at Schaeffler? Careful product design and high-quality manufacturing offer significant benefits for manufacturers and operators. The approach includes optimized functionality, a high level of energy efficiency, a particularly long service life, and extended maintenance intervals for our components – features that make operation safe and ensure optimized availability.

An example of our versatile portfolio is the improved Y25 housing with optimized WJ/WJP bearings. The housing is a new design that allows an axle load of up to 25 tons. As a result of the redesign, the weight has been reduced by 14% compared to its predecessor. Due to the associated lower unladen weight, higher payloads can be transported. With the unique Y25 housing, Schaeffler supports market trends in freight transport with regard to extended maintenance intervals and CO₂ reduction.

Efficiency through reliability is also demonstrated by the new, high-performance rolling bearings for the internally mounted drive wheelsets as well as our traction motor and gearbox bearings for high-speed trains. With the inbound bearings, we have not only met but exceeded the market requirements for higher power density, weight reduction, and limited installation space.

Schaeffler offers solutions for the entire “railway system”
The Schaeffler portfolio does not only consist of mechanical components such as axlebox, traction motor, and gearbox bearing supports: Our solutions go beyond the drive train of rail vehicles. For high-speed, freight, and local transport applications, Schaeffler is also presenting systems for digital condition and process monitoring of components and modules for railway vehicles. Maintenance processes can be optimized in combination with intelligent service modules. The interplay between Schaeffler’s understanding of systems and digitalization enables a sustainable circular economy for the operation of all railway applications.
You can learn more about our solutions with our digital showroom.
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System components for increased efficiency in freight transportation
Our optimized Y25 housing for freight transportation applications is rated for an axle load of up to 25 tons and has 14 percent less weight than its predecessor and already includes the new WJ/WJP bearings. The reduction in tare weight allows the transport of higher payloads. The new WJ/WJP cylindrical roller bearings can be used separately or in combination with the Y25. The bearings are characterized by high-quality materials and an optimized cage design. This gives an increased rating life and extended maintenance intervals. The bearings are marked with a data matrix code (DMC) at the manufacturing plant.
You can learn more about our Y25 housings and the DMC Code in our digital showroom.
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Seals designed by Schaeffler for use in railway applications worldwide
Our Class K seals and the corresponding TAROL axlebox bearings, have the AAR standard certification in addition to the standard certification in accordance with EN 12080. Schaeffler therefore combines both worlds of standards and the seals can be used in Europe and in the USA, Australia, India, Southeast Asia, and many other countries worldwide.
You can find out more about our seals in our video.
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Insert bearings for reliable and resource-saving urban transport
In the context of passenger and local public transport Schaeffler offers new insert bearings for the independent wheel sets in low-floor streetcars. The user-friendly and precise setting of the bearing support simplifies mounting in the wheel unit and ensures an optimum load distribution and a significantly increased rating life. The compact design of the insert bearings made of resistant and low-wear materials results in extended maintenance intervals and a sustainable reduction in CO₂.
Bearing supports and systems for reliable operation of railway applications
In addition to rolling bearing solutions for the drive train, Schaeffler’s product portfolio also in-cludes components for further applications such as braking, door, and entry. Our linear actuators, that can be flexibly configured to meet specific requirements, are an example of linear bearing supports for door guidance and step systems.

Planning Reliability through Dynamic Condition and Process Monitoring

Our new solutions pave the way for the digital future of rail transport. A future that has already begun. The high reliability of all Schaeffler products is not only guaranteed by their design but also their future-oriented digital features. The basis for this innovation boost is our longstanding industry expertise and our high level of system understanding.

Sensorized systems and digital twins based on the Data Matrix Code (DMC) enable predictive maintenance and reduce the risk of breakdowns and accidents. To make this possible, components are permanently marked with an individual code on which product-specific characteristics are stored. Over the course of the product life cycle, this data is complemented with further information on transport, assembly, operation, and maintenance. In this way, the DMC is laying the foundation for digitalization in the rail sector and ensures a seamless exchange of information between component suppliers, vehicle manufacturers, and operators.

Having a look into our innovative research projects and cooperations further enriches the insight into the Schaeffler portfolio.

You can learn learn more about our predictable digitalized solutions in our digital showroom.

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Digitalization in the railway sector with data matrix code
Schaeffler’s DMC lays the foundation for a digitalized supply chain in the railway sector. The unique product identification enables the creation of a digital twin for Schaeffler’s railway products. Product-specific data are stored in this throughout the entire lifecycle of the component. Manufacturers and operators can access and analyze product information at any time and from anywhere in the world using the standardized GS1 EPCIS (Electronic Product Code Information Services) interface. The electronic data exchange allows a reduction of the maintenance costs and downtimes.
Learn why the DMC drives digitization for rail in our video.
Find out directly from our experts about the benefits of digitalization for OEMs and rail operators in our video.
Uniting industry knowledge for the digital future of railways
At InnoTrans 2022 in Berlin, Schaeffler presented the results from the cooperation with ZF to im-prove condition monitoring of axlebox bearings that was initiated in 2018. Since that time, a joint-ly developed system has been tested by a number of operators and has been continuously refined. Schaeffler’s ConditionAnalyzer accesses the existing sensors and onboard unit gateways via a con-dition monitoring system from ZF that records vibration data. With analysis software specifically designed for bearing maintenance, the data are automatically analyzed and used for the predictive planning of bearing maintenance and upkeep work. As a result, there is no need for vehicle opera-tors to install separate onboard systems. The software from Schaeffler can also be combined with systems from other providers independently of the joint solution with ZF.
Operational safety thanks to predictive maintenance with the Railway Condition Monitoring System (RCMS)
Also at InnoTrans 2022 Schaeffler presented its Railway Condition Monitoring System (RCMS). The sensorized RCMS makes digital monitoring of individual axlebox bearings, com-plete wheelsets, and power and trailer bogies possible. Data on acceleration, rotational speed, and temperature are analyzed with the help of special software. The rail operator receives a condition diagnosis of the relevant components through the analysis of the vibration data. This allows maintenance processes to be optimized and running performance to be improved. Thanks to the early defect analysis, accident risks can be avoided and components and systems can be continuously developed for sustainable railway operations.

Sustainability in Railway Operations through Optimized Circular Economy

The mobility sector plays an essential role in achieving global climate goals. That is why achieving the highest environmental standards is an essential part of Schaeffler’s 2025 Roadmap. Schaeffler promotes sustainability at all levels of its products and services. Resources are saved through the development of material and weight-optimized components for example. A particularly high level of technological maturity extends the service life of all our products and thus saves operators additional material and energy.

Another approach is optimized product cycles: Schaeffler helps customers to save valuable resources by systematically reconditioning axlebox bearings to the highest quality standards. Compared to the production of a new bearing, reconditioning saves up to 93% energy and 97% water. Our 100% return service enables the immediate provision of replacement bearings and a simplification of maintenance processes. This leads to improved availability of trains and maximizes their performance. For our 100% return model, Schaeffler was awarded the Railsponsible Supplier Award in the category of Climate Change and Circular Economy in 2021.

Our services and technologies combine cost efficiency and climate protection.

Save resources, costs, and time with the remanufacturing of railway bearings
Schaeffler offers OEMs and railway operators an ecological and economical service for axlebox bearing reconditioning. The service includes the condition inspection of all relevant bearing components and, if required, the professional reconditioning of axlebox bearings to the highest quality standards. In this way, they achieve many times their basic rating life without sacrificing operational reliability. Reconditioning bearings can save up to 93 % in energy, 96 % in CO₂, and 97 % in water.
This video explains Schaeffler’s professional and economical bearing reconditioning service and opens up opportunities to start digitizing your existing fleet today.
Digital data exchange provides for sustainable optimization of rail transport
Exchanging data industry-wide using the standardized GS1 EPCIS offers numerous advantages in vehicle manufacturing and maintenance. Through the globally recognized, manufacturer-independent interface standard, data can be exchanged between component manufacturers, OEMs, and rail operators. In combination with the DMC and a trackside monitoring device, this makes informative condition monitoring possible even without the need for retrofitting a separate sensor system in the vehicle. At InnoTrans 2022 in Berlin Schaeffler demonstrated in a proof of concept together with Stadler Rail AG and a Swiss rail operator how exactly this data link supplies information for the planning and execution of bearing maintenance.
Sustainability is part of Schaeffler’s DNA
Schaeffler assumes ecological and social responsibility all along the value chain. The company pays special attention to ensuring responsible and careful use of natural resources. As part of its eight sustainability goals, Schaeffler will achieve climate-neutral business operations (Scopes 1 and 2 as well as Scope 3 upstream) by 2040. To achieve this goal, the company will already make in-house production climate-neutral by 2030. The company transparently reports on the individual steps needed to achieve these goals as well as already achieved successes in the annually published sustainability report.
Reduced downtimes with the 100% return service
Schaeffler combines the ecological and economic potentials of reconditioning in its 100 percent return service, which is tailored flexibly to the respective customer requirements. Every axlebox bearing that is sent to Schaeffler for reconditioning as part of maintenance intervals will be directly replaced by a remanufactured and fully functional bearing or a new bearing, regardless of its condition. If required, both new and existing bearings can be marked with a DMC to enable fast, plannable, and resource-saving maintenance.
Customers can choose between two service models.
In the case of Model 1, the bearings sent in to Schaeffler are returned following reconditioning. Any defective bearings are replaced with new ones.
Model 2 also significantly reduces the throughput time for vehicle maintenance. The bearings to be inspected are registered for reconditioning in advance. The customer immediately receives the same number of reconditioned or new bearings from a rolling bearing pool.

Services

Testing Laboratories

High testing capacities for axlebox bearings

State-of-the-art test standards and extensive capacities for our railway customers
Schaeffler is a reliable partner worldwide for the development of customized rolling bearing solutions for rail vehicles. Demand for axlebox bearings for freight wagons as well as for local and long-distance passenger rail transport (including high-speed trains, rail cars, and locomotives) is particularly high. Railway customers benefit from our unique rolling bearing expertise, decades of application experience, and a complete range of products from a single source: from engineering through to approval inspections for field testing in our independent accredited test laboratories.

Nine test rigs offer above-average capacities
We are continuously investing in our test laboratory equipment to ensure we are always up-to-date and further expand testing capacities for our railway customers. With a new test rig put into operation in December 2019, our location in Schweinfurt now offers a total of six test rigs. We have three further test rigs in our laboratory in Anting, China. These nine test rigs enable us to offer significantly high capacities on the market. In view of the high demand for testing facilities, this can be a decisive factor for our customers’ time to market.

Accredited independent test laboratories with flexible scope of category III
Our Conformity Assessment Body (CAB) “Railway Test Facility” comprising two test laboratories in Germany and China is accredited by the National Accreditation Body for the Federal Republic of Germany (DAkkS). The accreditation confirms that both laboratories as independent testing facilities have the required expertise according to DIN EN ISO/IEC 17025 to carry out tests of the performance capability of axlebox bearings for railway applications.

We immediately implement changes to test standards by making technical adjustments to our test rigs. Additionally, our laboratories have an accreditation with a flexible scope of category III. This means that they are also permitted to carry out test procedures without prior notification and approval by DAkkS if a revised standard has been issued.

Stories and Publications

Working Together to Digitalize Rail

Customer Success Story

In partnership with Schaeffler, Swiss Federal Railways (SBB) has made significant progress with the digitalization of its fleet. The basis for the new life cycle management of bearing data is a data matrix code (DMC) on the axlebox bearings that allows data on the bearing history – from production to operation and maintenance – to be retrieved and shared between various companies worldwide.

Learn more about the data matrix code and how it helped our customer here.

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Insutect A coating for current-insulated bearings - Reliable protection against damage caused by current passage
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Housing for freight car wheel sets in Y25 bogies - Lighter, stronger, and more reliable

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New single-piece cage for cylindrical roller bearings in traction motors
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Railway Bearing Reconditioning and Digitalization
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Railway Drive Bearings
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Rolling Bearings in Traction Motors
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Axlebox Rolling Bearing Arrangements
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Tapered Roller Bearing Units TAROL Mounting, Maintenance, Repair
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Axlebox Generator for Railway Applications
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Axlebox Bearing Generator for Railway Applications
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Condition Monitoring System for Railway Applications
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System Solution for Streetcars Slewing Ring Combined with a Central Joint
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