Background
The End-of-Train device (ETD) is a critical rail safety system. Mounted on the final car of a freight train, this device monitors brake pipe pressure and transmits vital telemetry data to the locomotive cab. Seeking to optimize this system, Siemens Mobility partnered with Porticos to redesign the manifold architecture for their Trainguard EOT.
Challenges
To power these systems, an internal air manifold harnesses pressure from the train’s pneumatic brake lines to drive a miniature generator turbine. For this project reworking the manifold design, Siemens Mobility tasked Porticos with a difficult engineering paradox: double the power and cut the cost. Specifically, Siemens wanted to trim production costs by reducing the physical complexity and component count of the existing manifold, while at the same time increasing electrical power to support next-generation electronics. Adding to the challenge was the need for these devices to function through brutal northern winters.
To achieve the project goals, Porticos used computational fluid dynamics (CFD) to optimize the turbine design, delivering a simplified architecture that slashed manufacturing costs while successfully doubling generator power. The improved performance was fully validated under extreme environmental testing down to -40°C.
Outcome
The project was a resounding success.
In fact, the improvements were so successful that the design over-performed. The new manifold achieved such a massive leap in pneumatic efficiency that Porticos had to intentionally scale back the turbine blade design to prevent overloading the ETD’s existing electronics. Siemens Mobility received a lower-cost, highly reliable product with performance headroom for future electronic upgrades.
