Transportation Market

1. Applications & Innovations
Transportation
Market

2. We’re committed to the
Transportation Market
The companies of Altra Industrial Motion offer many critical
drivetrain products utilized in transportation applications including
engineered bearing assemblies, linear actuators, clutches, heavy
duty gearing and gear drives.
Altra Brands Deliver Value Throughout the Drivetrain
Altra Industrial Motion is positioned to provide OEMs with
exceptional drivetrain value by ensuring component compatibility
and optimized performance combined with time-saving,
single-source convenience.
Extensive Technical Experience in Transportation
Applications
Major OEMs routinely rely on the vast transportation application
knowledge of Altra’s engineering teams that collaborate to
thoroughly analyze specific customer applications and then apply
the latest technologies in design, materials and manufacturing.

3. Trains

4. Nuttall Gear Provides Reliable
Gearing Solutions for Mass
Transit Propulsion Drives
Application ProfileApplication Profile

5. • For more than 25 years, major traction drive OEMs have chosen to
work with Nuttall for a wide range of gearing solutions – from stand
alone gear sets to full, multicomponent gearbox assemblies.
• Nuttall Gear to consistently meets OEM high quality and reliability
expectations when manufacturing new traction drive designs as well
as rehabilitating/reverse engineering older drive gearing components.
• In-house test stands allow Nuttall to quickly and efficiently perform
required testing of each new gearbox before it is shipped.
• Nuttall Gear has successfully supplied gearing and gearbox solutions
for various rail car programs in the United States, including the New
York Metropolitan Transportation Authority (MTA), including New
York
City Transit, Metro-North and Long Island Railroads, Massachusetts
Bay Transit Authority (Boston), Maryland Transit Administration
(Baltimore), the Southeastern Pennsylvania Transit Authority
(Philadelphia), and the Chicago Transit Authority.
Nuttall Gear Provides Reliable Gearing
Solutions for Mass Transit Propulsion Drives
www.AltraTransportation.comP-7841-NG.pdf

6. Advanced Coupling Technology from Twiflex
Provides Enhanced Flexibility in Commuter
Rail Traction Applications
Application ProfileApplication Profile

7. • For more than 45 years, Twiflex has been recognized by rail traction
OEMs worldwide for their superior coupling technologies.
• Twiflex Layrub couplings are specifically designed to meet the
requirements of modern traction systems:
- Coupling design based on a standard rubber component which can
be configured and adapted into housings for varying light rail, metro,
commuter and regional train bogie applications.
- Units feature enhanced torsional flexibility and damping. The
coupling’s sophisticated sub-assembly is capable of handling
relatively large angular and axial misalignments.
- Available in a range of configurations including close-coupled,
telescopic or fixed shafts, and combined with CV joints to meet the
wide range of individual bogie design specifications.
- Proven record of toughness, reliability and long service in climates
and track conditions ranging from the Arctic wastes of Northern
Scandinavia to the arid conditions of the Australian outback.
Advanced Coupling Technology from Twiflex
Provides Enhanced Flexibility in Commuter
Rail Traction Applications
www.twiflex.comP-7845-TF.pdf

8. Locomotive Hybrid
Transmission
Problem:
A major European manufacturer of power transmission
systems for locomotives needed a customized clutch to
integrate with its new hybrid transmission. positioned between
the electric drive system and the diesel engine, the clutch
allows the diesel engine drive to engage when the electric
drive’s battery power is low.
Solution:
Warner Electric worked closely with the OEM to develop a
customized E220 electromagnetic clutch to meet the
challenging locomotive application requirements.
• Max. torque rating of 3685 lb.ft. (5000 Nm)
• Max. speed rating of 3000 rpm
• 50,000 hour operating life without maintenance
• Specialized friction face material
• -40°C to 100°C operating temperature range
Application Profile
Custom E220 Clutch

9. Application Profile
Transit Rail Cars
Problem:
After years of rugged service, some of the gearing inside the
gearboxes of New York City subway cars needed to be
replaced due to normal wear. Each transit car has four traction
drive gearboxes which are mounted to the axles and driven by
electric motors.
Solution:
Nuttall Gear was selected to provide replacement gear and
pinion sets for the transit car gearboxes.
• Superior machining capabilities and exceptional quality
control procedures allow Nuttall to produce the complicated
gear/pinion sets which were custom-engineered by the traction
drive OEM.
• Precision hardened gear and pinion sets
• Manufactured to original OEM standards and specifications
Custom Heavy-Duty Gearing

10. Application Profile
Long Island and
Metro-North Railroad Cars
Problem:
A major fleet upgrade was undertaken by The Metropolitan
Transportation Authority of New York in 2002. A large quantity
of new M7 electric rail cars were delivered as replacements for
aging fleets on the Long Island Rail Road and the Metro-North
Railroad. Each car required four gearboxes which were
mounted to the axles and driven by electric motors.
Solution:
Due to their extensive experience with mass transit propulsion
drive gearboxes, Nuttall Gear was selected to produce the
complex gearboxes, which were custom-engineered by the
traction drive OEM for the new cars.
• Nuttall delivered complete gearbox units including the
gearbox,
coupling, suspension (anti-rotational device), ground brush
assemblies and grounding connections.
Custom Gear Drives

11. BR High Speed Trains (HST)
Problem:
High speed trains needed to increase efficiency while
ensuring accuracy and dependability in their braking systems.
Solution:
Laylink couplings employ pre-compressed rubber blocks in
a link type configuration, and type laylink 6/340 couplings
were arranged circumferentially between the driving and
driven flanges.
• Reduced traveling time by 25%
• The laylink’s torsional stiffness allows it to transmit
particularly large torques and support heavy floating shafts
• Link configuration allows the coupling to accommodate large
levels of misalignment and movement between the driving
and driven units
Application Profile
Laylink Coupling Type LB 6/340 & Cardan
Shaft

12. Queensland Railway Trains
Problem:
Trains need to cope with angular, axial and radial mis-
alignment while meeting stiffness and damping specifications.
Solution:
Able to fit large mis-alignments, the Layrub coupling type 100
5/10 has a large volume of rubber blocks which gives it a
relatively low torsional stiffness, making it perfect for this
application.
• Torque ratings up to 64 kNm
• Unique design includes good damping characteristics
• Able to fit large misalignments
• Reduced traveling time between Brisban and Rockhampton
by five hours
Application Profile
Twiflex Layrub Coupling Type 100 5/10

13. LRV for Mass Transit
Administration
Problem:
Maryland’s MTA needed to improve its mass transit system
and required braking specifications for a transit maximum
speed of 89 km/h with a continuous power of 640 kW.
Solution:
Twiflex Layrub 70 type 5/10 couplings were installed to
provide a uniquely customized design that accommodates
large misalignments.
• Covers low to medium power ranges up to 64 kNm
• Helps provide the continuous and shock torque necessary
to make this transit successful
• All cars equipped with regenerative braking
Application Profile
Twiflex Layrub 70 Coupling Type 5/10

14. Suburban Train Class X10
Problem:
In order to service the growth in suburban rail traffic, the
Swedish State railway introduced two car units of the
X10 design. Each consists of one motor car and one
driving trailer.
Solution:
Twiflex 70 Layrub couplings are installed because they
are particularly suitable for the control of torsional vibration,
and the compactness of the couplings make them ideal for
high speed operation.
• Continuous torque 1320 kNm
• Maximum coupling speed 4000 rpm
• Meets continuous power requirements of
1140 kw (4 drives)
Application Profile
Twiflex Layrub 70 Couplings Type 5/10

15. Electric Locomotives
Problem:
Transporting coal from the vast reserves of Queensland,
Australia’s Blackwater Valley to the port of Gladstone calls
for a massive investment in rail haulage and braking.
Solution:
The electric locomotives used on the railways are built with
Twiflex Layrub 120 type 2/4 couplings to ensure low
torsional stiffness and high-quality damping characteristics
• Continuous torque 21 kNm
• Shock torque 54 kNm
• Maximum coupling speed 500 rpm
Application Profile
Twiflex Layrub 120 Coupling Type 2/4

16. Modern Rail Traction
Problem:
Rail traction systems have undergone a change from the
traditional use of DC motors to the use of more compact AC
systems. These motors are lighter, require less maintenance,
operate at higher speeds and provide braking to stopping
conditions; however they also carry the penalty of greater
torque “ripples” and generate higher shock torques.
Solution:
Twiflex Laylink and Layrub couplings are installed to absorb
greater movements and mis-alignments.
• Designed and adapted into housings to meet varying
requirements
• Certified to ISO 9001
• Proven record of toughness, reliability and long service
Application Profile
Twiflex Laylink and Layrub Couplings

17. Automotive

18. Custom Kilian Bearing and Detent Design
Solutions Provide Reliable Performance in
Automotive Powertrain Applications
Application ProfileApplication Profile

19. • For more than 25 years, Kilian has built an excellent reputation for
providing customized bearing and detent design solutions to major auto
transmission/transfer case OEMs around the world.
• Kilian’s global expertise in this market focuses primarily on shift detents,
shift forks, planetary gear sets for actuators and assemblies used to
control hydraulic pressure.
• Kilian specializes in identifying the best materials, heat treatment,
lubrication, bearing type and part geometry that will provide the optimum
performance at the lowest overall cost.
• Co-located design and manufacturing engineers work together to ensure
that a product design not only meets the specific application
requirements
but also considers “Design for Manufacturability” (DFM).
• As a custom bearing and assembly designer, Kilian can easily adapt to
specification and design changes.
• A complete in-house prototype department allows Kilian to provide
production-intent designs to the customer in approximately 4 weeks.
Custom Kilian Bearing and Detent Design
Solutions Provide Reliable Performance in
Automotive Powertrain Applications
www.kilianmanufacturing.comP-7842-KM.pdf

20. Steering Column Tilt Lock
Application Profile
Unitized Thrust Bearing
Problem:
A leading manufacturer of automotive steering columns
needed an replacement custom bearing solution for use on
their line of tilt-adjustable steering columns. The customer
was using a competitor bearing that was expensive and easily
fell apart during shipping and installation, causing production
delays and associated costs.
Solution:
Kilian engineers modified the part design to develop a
custom unitized precision bearing assembly that fit within the
tight space envelope.
• Through-hardened, high carbon steel rollers positioned
within a custom polymer retainer cage.
• Two heat-treated carbon steel thrust washers snap into the
retainer to securely hold the assembly together during
shipping and installation.

21. Minivan Folding Seat
Problem:
A major seating manufacturer that supplies products to one
of the world’s bestselling minivans needed a unique bearing
to fit into a folding seat assembly that allows the second and
third-row seats to be folded flat into the floor in less than
30 seconds.
Solution:
Kilian Manufacturing’s engineers worked closely with the
manufacturer to develop a custom precision bearing solution.
• Bearing material needed to accommodate tremendous
loads, high stress and excessive torque
• Prototype was delivered in less than two weeks
• In-house testing included torque-to-rotate, push-out force,
durability testing and environmental testing for corrosion-
resistance and grease retention
• Bearing design met strict automotive regulations
Application Profile
Customized Roller Bearing Assembly

22. Automotive Transmission
Problem:
A major manufacturer of automotive transmissions and
transfer cases needed a custom shift detent mechanism for
a smooth shift engagement in their new system. The
customer’s engineering team contacted Kilian early in their
development process and began working closely with their
design engineering counterparts at Kilian.
Solution:
After several prototype iterations, the Kilian team ultimately
developed a heat treated, high-carbon material housing that
was greased in the final assembly.
• Kilian engineers performed comprehensive testing and
supported the customer with critical data.
• The new material selection satisfied the applications
press fit and the smooth rolling performance exceeded
customer expectations.
Application Profile
Custom Shift Detent Mechanism

23. OEM Transmission Drive
Application Profile
Custom Thrust Bearing
Problem:
Kilian worked with an automotive OEM that had been
purchasing expensive bearings for their transmission
drives – bearings that did not meet their needs or suit their
drive units.
Solution:
Kilian team engineered a significantly cost-effective custom
bearing design. The Kilian solution incorporated three
stamped components with installed rollers.
• New money-saving thrust bearing surpassed the
customer’s expectations.
• Innovative design enhanced the overall end product
quality and performance

24. Automotive Transmission
Problem:
Kilian worked with a global automotive producer of engine
and drivetrain systems to help develop a unique, high-
volume assembly for a new, “cutting-edge” transmission.
Although the new assembly was not a bearing, the
customer quickly saw that Kilian possessed the core
expertise to take on this extremely challenging project.
Solution:
Combining Kilian’s strength in engineering development,
precision machining, molding, assembly, quality systems,
testing and project management, Kilian was able to
achieve the demanding quality and program targets to
successfully launch the new system.
• Unique, custom engineered solution
• High-volume assembly
Application Profile
Custom Component

25. Pickup Truck Door Checker
Application Profile
Custom Needle Bearings
Problem:
A major U.S. automotive manufacturer contacted Kilian for a
special door hinge bearing assembly that was needed for their
newly designed pickup trucks. The bearing allows the truck
doors to open smoothly, with minimum effort as it “clicks through”
the range of motion, from “full-close”, to “halfway”, to “full-open”.
The originally specified bushing-style bearing design was failing
durability tests and door efforts were too high.
Solution:
Kilian developed a custom bearing solution utilizing needle
rollers for this high-load application. Materials were specifically
selected for each of the bearing components to optimize durability
and system loading.
• Seals were integrated to protect the bearings from
outside contamination
• Machined knurls for snug fit
• Zinc plating and grease added for enhanced corrosion protection

26. Buses & Trucks

27. Bus Doors
Problem:
A major South American transit bus manufacturer required
economical, yet powerful linear actuators to open and close the
vehicle’s bi-fold doors. Two actuators are used to operate each
pair of doors.
Solution:
Warner Linear K2VL electric actuators were selected to meet
the application demands. Units are designed to meet vigorous
service requirements and have demonstrated superior
performance over competitive models in life cycle tests.
• Economical solution
• Up to 600 lbs. (2669 N) load capacity
• Factory-set ball detent overload clutch
• O-ring seals and protective coatings provide exceptional
corrosion resistance
Application Profile
B-Track K2vL Electric Actuators
Application Profile

28. Transit Bus Doors
Problem:
A leading U.S. manufacturer of metro transit buses needed a
reliable electric linear actuator solution for a new line of buses.
The actuators are used to operate the two sets of bi-fold doors
on each bus. The challenge was that the actuator needed to fit
in a very tight space envelope. A clutch design was also
required that would automatically and quickly open the doors
in the case of an obstruction.
Solution:
The Warner Linear I-Track actuator, featuring an in-line design,
was an ideal choice for this application since a parallel motor
type actuator would not fit in the limited space available.
• Up to 200 lbs. (90kg) load capacity
• Release clutch allows for easy manual operation if needed
• Nitrile impregnated gaskets for superior sealing
Application Profile
I-Track Electric Actuators
Application Profile

29. School Bus Engine
Cooling Fan
Problem:
A major school bus OEM required a reliable compact
electric clutch solution for the 24” dia. cooling fans on their
diesel engines.
Solution:
Warner Electric engineers worked closely with the customer to
develop a custom version of the FC-550 electromagnetic
on-off fan clutch with a torque rating of 150 ft.lb. to meet the
specific application requirements.
• Revolutionary, compact 8”dia. fan clutch design provides the
highest possible torque in a small package.
• Unlike viscous fan drives, which go from mostly “off” to mostly
“on” based solely on ambient temperature, the efficient
Warner Electric 12VDC fan drives are easily controlled using
sensors and on-board controls.
Application Profile
Custom Fan Drive Clutch

30. Coach/Transit Bus
HVAC System
Problem:
One of the World’s leading manufacturers of bus HVAC
systems required highly reliable compressor clutches for use
on air conditioning comfort systems designed for various
transit and coach bus types and sizes. The clutches are part
of a completely automated temperature control system.
Solution:
To meet the rigorous, continuous-duty demands of the
vehicle operation, the engineers at Warner Electric custom-
designed a clutch that mounts directly to the air conditioning
compressor shaft.
• The unit’s superior magnetic circuit design provides 30%
more torque than competitive models.
• All clutch components, including the armature disc, rotor
pulley assembly, field coil, springs and bearings, meet tight
manufacturing tolerances.
Application Profile
Custom Compressor Clutch

31. Truck Air Deflectors
Problem:
A global manufacturer of truck aerodynamic products required
reliable electric linear actuators for use on their cab-mounted
adjustable air deflectors. The actuators allow the driver to
remotely raise and lower the deflector panel to match the
varying heights of trailers and loads to achieve optimum
vehicle aerodynamics.
Solution:
Warner Linear supplied B-Track K2x actuators to meet the
application requirements.
• Units are weather-tight with integral O-ring seals
• 2,800 lbs. (1270kg) load capacity
• Patented screw end bearing guide
• Heavy-duty, sealed double ball bearing motor
Application Profile
B-Track K2X Actuator
Application Profile

32. Recreational Vehicles

33. RV Room Slide-Outs
Problem:
A company that supplies recreational vehicle manufacturers
with a mechanism used on RV room slide-outs was using a
precision track roller bearing as part of the assembly. The
bearings, by design, were through-hardened, which was
causing the track rollers to crack and fail.
Solution:
Kilian engineers inspected the bearings and the assembly
and created a customized track roller bearing.
• Modified Kilian bearing design saved significant costs
• Reduced downtime and warranty repairs
Application Profile
Custom Precision Track Roller Bearing

34. Travel Trailer Jack Stands
Problem:
A major RV manufacturer required a durable electric jack stand
actuator for use on their line of travel trailers. The jack stands
provide fast, reliable leveling while reducing sway of the
free-standing trailers when they are unhitched from their
towing vehicles.
Solution:
Warner Linear rugged duty, robust B-Track K2XJS Jack Stand
actuators were selected for this all-weather application.
• Models are specifically designed for jack stand usage
• Up to 2,800 lbs. (1270 kg) load capacity
• Integral load holding brake
• Units feature protective coatings, O-ring seals throughout and
incorporate a large diameter extension rod which provides
maximum offset load capability.
Application Profile
B-Track K2XJS Electric Actuator
Shown with
optional switch
box, direct drive
manual override
and footpad.