Rail...
Solutions for the rail industry

Tech up, Cost down. It´s our job.
www.igus.eu/railway

®

Your technical innovator and cost reducer,

Thorsten MerschIndustry Manager Rail Industry
Phone: +49 2203 9649-7038
e-mail: tmersch@igus.net
www.igus.eu/railway

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Advantages of motion plastics® for the rail industry● Maintenance and corrosion-free● Many products according to EN 45545● Vibration dampening● Compact for confined installation spaces● Long service life
● Cost-effective● For temperatures from –50 °C up to +250 °C

www.igus.eu/railway

Flame-retardant
motion plastics
for the rail industry
according toEN 45545 and
NFPA 130igus® motion plastics®: Cost-effective high-performance polymers and cables
for extreme operating conditions ensure greater reliability and comfort intrains and trams.
The number of passengers on public transport has been increasing steadily for
20 years. This is confirmed by figures from the Association of German TransportCompanies. Good news for the industry, but also an increasing load on the rail
network, trains, trams and equipment. Durable components are required that canwithstand the high requirements and yet meet stringent fire safety standards. But
how about reducing maintenance effort and costs or making regular lubrication
unnecessary? Is that impossible? Not at all! igus® has given the name motion
plastics® to these components, which simplify many applications wherever
movement is involved; tram doors is a typical example. www.igus.eu/railway

Tested in the laboratory, proven in the field.
igus® will help you master your challenges with outstanding properties that have beensuccessfully tested in the igus® test laboratory, the largest in the industry, and provenin the field. Here igus® polymer bearing technology, energy chains and fail-safe cables
are tested. Numerous igus® products meet Hazard Level 3 according to EN 45545.
This includes bearings made from high-performance polymers and durable cables.
Special plain bearing materials meet the R22/R23 test requirement, and certain cables fulfil R15/
R16. Another benefit of using motion plastics® is to save weight because heavy metals are replacedby lightweight and long-lasting polymer components. Due to their special material properties, they
are resistant to dirt, heat, cold, moisture and road salt. That's why they are used inside and outside
in rail bound traffic and transport.
Reliable entry-level systems. When boarding a tram or train, passengers encounter the firstigus® components. chainflex® cables, dryspin® lead screw technology and energy supply systems
are used to make door systems maintenance-free and, above all, reliable.
Maintenance-free and clean applications in the passenger compartment. iglidur® polymer
plain bearings and drylin® linear guides ensure clean adjustment, low coefficient of friction andsilent movements without the need of additional lubricant. This is due to the incorporated dry
lubricants, which are within the igus® materials.
motion plastics® are in use everywhere, from the driver's cab to the braking system. The
properties of motion plastics® also benefit the control elements of the train. drylin® linear guides
are installed in the brake levers, for example. For high wear resistance, bearings in control panelsand emergency brakes are equipped with iglidur® G plain bearings. iglidur® plain bearings are also
incorporated in the brakes themselves, ensuring perfect function in the event of bumps and dirt.
They are also corrosion-free.

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dryspin® lead screw
systems: trouble-free
operation in dirt, roadsalt and rain

www.igus.eu/railway

Reduce cost and improve
technology in the rail industry

®

Insulating high-performance polymers in pantographs.
As igubal® spherical bearings are made of nonconductive high-performance polymers, they canbe used as insulating components on pantographs.
iglidur® plain bearings are also installed in brakes,
because they allow trouble-free operation in theevent of bumps. They are also corrosion-free andare unaffected by dirt. The materials are suitable foruse in extreme temperatures, from as low as -100°C
to as high as +250°C.

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www.igus.eu/railway

Maintenance-free
and weatherresistant - motion
plastics outside®

● High media resistance● Lightweight● Cost-effective● Corrosion-free
www.igus.eu/H2

igubal KGLM sphericalbearings in pantographs:
insulating and extremely
flexible®

● Compensation of misalignment errors● Resistant to edge loads● High vibration-dampening
www.igus.eu/KGLM

iglidur TX in couplings:
reliable under shock anddirty conditions®

● Resistant to high edge loads● Dirt-resistant● High wear resistance

8-9

www.igus.eu/railway

iglidur H2 in brake calliper:
resistant to vibration®

Many different forces act in all directions on thetransitions and rotating joints between individual
carriages.
These include push and pull forces, impacts andcontinuous vibrations. For such applications, robust
and reliable bearings are especially important.
iglidur® plain bearings are a preferred choice forsuch use because of their high contact pressure,which can be up to 150MPa. The robust iglidur®
materials withstand even high edge loads without
breaking. The wide variety of iglidur® materials
makes is possible to find exactly the right plain
bearing for every possible application.
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www.igus.eu/railway

Durable, robust
and tough motion plastics
in wagonconstruction®

● Space-saving and lightweight● Resistant to dirt and humidity● Corrosion and maintenance-free
www.igus.eu/E2.1

iglidur J in emergency door:
guaranteed to function safely
and reliably at all times®

● Maintenance-free● Large standard range● Extreme wear-resistancewww.igus.eu/J

www.igus.eu/railway

E2.1 e-chain in battery boxes:
robust, space-saving andweatherproof

igubal coupling joint in pressure
protection cap: maintenancefree and dirt-repellent®

● Angle compensation● Dirt-resistant● Maintenance and lubrication-free
www.igus.eu/double-joint
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®

The dryspin® lead screw systems are used toopen and close doors.
Their self-lubricating high-performance polymer leadscrew nuts eliminate the need for extra lubrication,
reducing maintenance and cleaning costs. The drivefor the lead screw systems can be igus® DC motors
or stepper motors. E2-micro e-chains®, chainflex®
cables and dryspin® lead screw systems are also
used in the sliding step under the door because theyremain unaffected by dirt, road salt and rain.

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www.igus.eu/railway

Please climb on
board – motion
plastics in door
systems®

● High static loads● Low adjustment forces● Long service life
igus.eu/rollers

dryspin lead screws in doors:vibration-free operation®

● Dry operation● Dirt-resistant● Various designs
www.igus.eu/dryspin

iglidur Q in ramps: long-lastinghigh load capacity®

● For high loads - wear-resistant on many shafts● Excellent wear resistance, especially for extreme loads● Recommended for extreme pv values
www.igus.eu/Q

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www.igus.eu/railway

iglidur high-performance rollers
in door guidance system®

● Small bend radius of less than 4xd● Service life of over 30 million double strokes, at least 20 years● Tested for 450,000 door cycles in the lab without any interruption

Guarantee

www.igus.eu/chainflex*Avoid failures, guaranteed – more than 2 billion test strokes and 1.4 million electricalmeasurements per year. For more than 25 years, igus® has been carrying out tests in theindustry's largest laboratory for moving cables and energy chains.

month guarantee

Robust high helix lead screws
and nuts in sliding steps● Very robust, reliable and durable● Designed for temperatures down to -25°C● 1 million cycles tested with no problems or failures
www.igus.eu/dryspin

E2.1 micro e-chain :reliably closing doors of
the VAG Nuremberg®

● 70,000 open/close cycles per year
● Weather-resistant● chainflex® cable CFSPECIAL.414, halogen-free and flame-retardant
www.igus.eu/E2.1
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www.igus.eu/railway

chainflex CF98 control cable- safe trap detection®

The properties of motion plastics® also benefit
the driver's controls for operating the train as
well as in the interior. drylin® linear guides are
installed in brake levers, for example. For high wear
resistance, bearing points in control panels andemergency brakes are equipped with iglidur ® G plain
bearings. igus® plain bearings and linear technology
are also used where they need to be clean and a highlevel of comfort is required, such as in the passenger
compartment. iglidur® G is used in adjustablearmrests, folding tables and folding seats. These
plain bearings are wear-resistant and available, fromstock, in a wide range of shapes and sizes.
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www.igus.eu/railway

Comfortable andquiet – motion
plastics interiors

®

● Resistant to high edge loads● Dirt-resistant● High wear resistance● Cost-effective
www.igus.eu/dryspin

iglidur M250 in switchgear:
high pitches possible®

● Excellent vibration dampening● Resistant to edge pressure● High impact resistancewww.igus.eu/m250

iglidur J in folding seats®

● Lightweight● Low-noise● Cost-effective
www.igus.eu/J

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www.igus.eu/railway

dryspin in height adjustment
for foot platforms:
extremely wear-resistant®

● Easy movement with roller support● Wide range of sizes and options● For exact re-positioning
www.igus.eu/info/low-profile-guide-drylin-ndrylin W in windows:
ergonomic operator control,smooth operation and silent®

● Dirt-resistant● Corrosion-free
www.igus.eu/drylinW

iglidur M250 MDM in seatsystems: rattle-free positioning®

● Tolerance compensation possible● Suitable for e-coating● High static load up to 120MPa
www.igus.eu/MDM

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www.igus.eu/railway

drylin pre-defined positional
systems in head-rests: lightweight, defined positioning®

Lifting platforms made to be long-lasting with little
need for maintenance. The vehicle fleet requires
regular maintenance. The lifting platforms and thecables connected to them are therefore subjected
to continuous stress. If the cables are not guided
securely, wear is accelerated and failures can occur.
If the cables are guided with e-chains® from igus®,
the service life of the cables increases. What's more,
the danger of accidents due to exposed cables isruled out. The e-chains® are also of help with regard
to cable management: cables can be arranged and,in the event of a failure, can be replaced easily andquickly.
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www.igus.eu/railway

Always safe on
track – motion
plastics inmaintenance®

®

● Robust and compact design● More cost-effective than most steel chains or elaborate gliding systems● Resistance to dust, cold and heat
www.igus.eu/flizz

www.igus.eu/railway

E4.1 e-chain with flizz troughsystem in track traversers

readychain and drylin SLW inwheelset maintenance machine:
immediately ready to install®

®

● Harnessing time is reduced by up to 95%● Reduction in manufacturing costs● Minimal amount of logistics work
www.igus.eu/readychain

E4.1 e-chain in train washingsystems: no corrosion®

● Highly stable in all axes
● Resistant to corrosion and chemicals● Moisture and temperature-resistant
www.igus.eu/E4.1

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®

Make the rail network weather-resistant withmotion plastics®. igus® products are not justused on trains and trams. Their properties are also
in demand on track-side equipment and provide
decisive advantages. iglidur® J plain bearings are
installed in wheel tensioners and hinged cantilevers.
In shunting switches, iglidur ® plain bearings areused to mount the rollers in the switching system.
Here high-performance polymer bearings offer
several benefits: they do not corrode and protect
the shaft against wear. Since the plain bearings
are temperature resistant, they can also withstandextreme weather conditions.
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www.igus.eu/railway

All weather –motion plastics
in theinfrastructure®

● Extremely long service life and UV-resistant● Lightweight and maintenance-free● Quiet, vibration-free operationwww.igus.eu/J

iglidur G in roller switchingsystem: shaft-friendly androbust®

● Corrosion and weather-resistant● Very good wear resistance● Good for edge loads● Vibration- and shock-resistant
www.igus.eu/G

www.igus.eu/railway

iglidur J in signal systems:
weatherproof and long-lasting

iglidur P210 in circuit breakers
and earthing switches: longlasting in applications involving
pivoting movements®

● Wear-resistant on most shafts● Very low coefficient of friction● Cost-effective and maintenance-free
www.igus.eu/P210
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®

In order to built new tracks for trains or trams,
complex machinery is needed.
Bearing points in track construction machines
are exposed to considerable mechanical forces,
vibrations, dirt and weather influences. All thesefactors are no longer a problem if iglidur® plain
bearings are used. Energy supply systems andchainflex® cables are also used in track construction
machines. Due to their special design, they are very
stable and durable. As a result, they also enable safeand reliable cable guidance and protection even in
extremely stressful environments.
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www.igus.eu/railway

Weatherproof
components –motion plastics
in special vehicles
and tools®

● Highly stable even when long unsupported lengths are used
● Reliable guidance and protection of cables and hoses● Corrosion, dirt and weather-resistant
www.igus.eu/E4.1L

www.igus.eu/railway

E4.1L e-chain in railway cranevehicle: secure guidance andprotection for cables

iglidur PRT in shunting vehicle:
the perfect solution for highmechanical forces®

● Slewing ring bearings for high loads● Easy adjustment by hand or by a motor● Low-friction and wear
www.igus.eu/PRT

E4/4 e-chain in ballast
machine: dirt anddust-resistant®

● High strength and lateral rigidity● Resistant to dirt, dust and water● Good damping where vibrations occur
www.igus.eu/E4-4
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®

● Maintenance and lubrication-free● Very low profile – small installation space● Resistant to dirt, dust and humidity

www.igus.eu/drylinN

Grinding machinewith trapezoidal lead screws● Lubrication and maintenance-free● Longer service life due to asymmetry● Self-locking● Corrosion-resistant
www.igus.eu/dryspin

Measuring machine withigubal rod end bearings®

● Maintenance-free dry operation● Weight reducing● Vibration-dampening
www.igus.eu/igubal

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www.igus.eu/railway

Platform gap measuring
device with drylin N

The service life of freight wagons can be much
longer than 30 years. Designed for rough weather,high loads and contact with chemicals, igus®
products are ideal for the achievement of thisservice life with only little maintenance work being
needed. The plain bearings and sliding plates that
we supply are part of the versatile solutions weoffer for tankers, car transporters and bulk freightwagons.

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www.igus.eu/railway

Freight wagons

®

● Cost-effective● Protects against dirt and dust
● Longer service life
www.igus.eu/sg03

igubal spherical bearingsin opening flap®

● Angle compensation● Dry operation● No corrosion
www.igus.eu/eglm

igubal two-hole fixed flange
bearing for shaft bearing®

● Easy assembly● Angle compensation● Cost-effective
www.igus.eu/efom

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iglidur plain bearings withfelt-ring seal in manual
braking system®

We can also go your way: customised solutions,special designs and special materials - (virtually)
everything is possible.
Standard parts do not suit every application. Therefore,igus® also manufactures a number of customised
special designs. Structural and material specials
are equally possible, whether it is plain bearings
for multiple-edge shafts, bearings with reduced
clearance or anti-rotation features, special leadscrew support blocks and glide pads, and so on,igus® will adapt to your needs. Starting from medium
quantities we make almost everything possible.
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www.igus.eu/speedigus
www.igus.eu/barstock

www.igus.eu/railway

When it is all about
railway technology- igus catalogue
parts, special parts,
bar stock and 3D
printed solutions®

3D printing service – reduced
downtime through replacementof old components even without
original drawings
Two simple steps to 3D printed components - with instant price. We
print custom components using lubrication-free, wear-resistant iglidur ® highperformance polymers.
Upload the drawing in the STEP (STP) format, check the 360° view and selectthe filament material. Upon order, it is printed and shipped - depending on thecomplexity - from 24 hours.
Tested strength when compared to machined and injection-moulded parts
3D print materials from igus® are robust and composed of wear-resistant materials
made of iglidur® high-performance polymers, which are especially suited formoving applications. They guarantee a long service life as well as a high wear
resistance of custom-made parts.

3D printing service – for individual parts
made of high-performance polymers.
New: iglidur ® RW370 tribo-filament forhigh temperature applications.

igus® 3D printing service:
easy, fast and transparent
www.igus.eu/3dprintservice
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www.igus.eu/railway

New: iglidur
RW370
tribo-filament:
developed for
applicationsin the hightemperature
range

Fully-assembled,
ready-to-install:
www.igus.eu/readychain
Always the right harness for your application. Ready-to-fit, readychain®
e-chain system,® configured and delivered in 3-8 days. Possible due tothe large selection of energy chains for all kinds of motion, cables for e-chains®
with a 36-month guarantee plus the relevant connectors. Reduce the number ofsuppliers and orders by 75%. Maximise machine uptime. System guarantee –depending on the application.

● Service for fast, error-free installation● Specialised assembly team
www.igus.eu/assemblyLabellingBasic

e-chain® with fitted cables strain relief in the system

Standard

e-chain® with cables andrelevant connectors

Standard+

Harnessed e-chain systems® withassociated sheet metal parts

Premium

Ready-to-install complete system
mounted on transport rack
● Harnessing and labelling of the cableaccording to customer requirements

Engineering● Customised products● Many solutions from the "modular construction kit"
www.igus.eu/engineering
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The most usedharnessing in the rail
industryBasice-chain® with cables
and suitable connectors
marked and labelledaccording to your wishes.
www.igus.eu/RCbasic

www.igus.eu/railway

Fitting

Extensive
test
database

Long-term durability
10 billion e-chain® cycles
per year in the e-chains®
and chainflex® laboratory● Service life test for vibration● Test for energy chains and cables● Vibration levels from 30 up to 60Hz

Resistance to
low temperatures

Investigation ofcoefficient offriction● Extreme test in the cold chamber● Tested in motion in energy chain down to -40°C● More than 250 tests conducted in parallel in 58
test facilities● Constant load test
● Tests of wear and coefficient of friction● Test of functioning, service life, strength andfailure scenarios

High load test rig

Long-term durability CF298 data
cable with TPE outer jacket forthe smallest bend radius up to
4xd withstands more than 138
million strokes.
50-51● More than 3 billion test cycles per year
● Special test set-ups for specific industries● Further information at www.igus.eu/frontloadertest

From more than 15,000 tests
performed per year, we havecreated what is probably theworld's largest database. This
database gives us the ability toalways select the right productfor your specific application.
Individual tests for your industry
are also possible.
Polymer bearings in aheavy-duty test with amaximum load of 500kg

www.igus.eu/test

www.igus.eu/railway

Vibration ...

/9001:2015/16949:2016

igus® is certified in accordance with ISO
9001:2015 and ISO/TS 16949:2016 in the field ofenergy supply systems, cables and harnessing,as well as polymer bearings.

/14001:2015

igus® is certified according to ISO 14001:2015.
This accepted basis for environmental
management systems supports us on our way
to a CO2-neutral factory.

/newsletter

Get more information about motion plastics®
innovations and trends: exciting applications,videos, test results, online seminars and muchmore. Compact and free of charge. Register
here: www.igus.eu/newsletter/onlineYou can find out more about railway technology
at www.igus.eu/railway

igus® GmbH
Spicher Str. 1a51147 Cologne
Phone +49 2203 9649-800
Fax +49 2203 9649-222
info@igus.dewww.igus.eu
Published by igus® GmbH, Germany
MAT0072987.20 06/2020
Subject to technical alterations.

www.igus.eu/railway