E³: From pioneering achievement to innovative standard
The greening of track maintenance emphasizes the ecofriendly image of the railway. Alternative drive systems in track construction must fulfil stringent requirements as they are now a key criterion in tenders issued by infrastructure managers. However, time-tested previous generations based on combustion engines set the standard in terms of reliability and performance. The potential for added value makes the switch to green machines more attractive.
In 2014, Plasser & Theurer set the course for E3. Looking back today, this stands out as a pioneering achievement. The decision for alternative drive systems for track construction and maintenance machines was made with three objectives in mind: “Economic, Ecologic, and Ergonomic” – which is what E³ stands for. The highest performance class for mechanized track maintenance was chosen for the first prototypes. A 09-4X Dynamic 4-sleeper tamping machine and the BDS 2000, known as the ballast saving machine, received the affix “E³”. Electricity from the overhead contact line was used as an energy source by converting it to provide the tried-and-tested hydraulic supply for the work units.
Ecological track maintenance pays off
Krebs Gleisbau has recognized the potential and opted for a Unimat for track and turnout maintenance with E³ in Switzerland back in 2016. This machine provided data which quickly proved how acting environmentally friendly can also be cost-effective. It saved €177 of operating costs per hour of use.
Technological milestones for electrified machines
From then on, things continued at a rapid pace. The electrification of the drives resulted in a reduced need for complex hydraulics and in a more direct utilization of the high efficiency of electric motors. This included drives on the bogies and rotating actuators for the work units. In addition, a prototype for overhead contact line construction with innovative battery technology was launched in 2017: the HTW 100 E³. The technology has been successfully tested under tough conditions. In the climatic wind tunnel, the material was exposed to temperatures from -30 to +50 degrees Celsius.
Quiet construction and maintenance
Thanks to the significant added value it provides, it did not take long for E3 technology to become well accepted. Track maintenance often takes place at night when train operation is at a standstill. In addition, tracks to be maintained often pass through populated areas. Pollutant emissions are particularly critical when work is done in tunnels. Noise reductions of up to 20 dBA benefit everyone near the worksites, be it residents or employees.
Ready for series production thanks to a ten-year technological edge
Solutions like E³ are urgently needed today in 2024. The ten-year technological edge manifests itself in many years of experience with 14 highly customized individual solutions and translates into a scalable offering for emission-free track maintenance. Plasser & Theurer is currently manufacturing over 60 E³ machines. The offering with new E³ drives includes vehicles and machines for overhead contact line construction and maintenance, track and superstructure maintenance, tamping machines for plain-line track and turnouts, ballast management, and dynamic track stabilization. There are also offerings for greening existing fleets, such as retrofits with electric tamping units, retrofitting frequency control systems or drive systems with alternative fuels such as HVO100 – they also contribute significantly to reducing CO₂ emissions and operating costs.
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10 Jahre E3: https://www.plassertheurer.com/de/machine/yellow-machines-go-green/klimafreundlicher-bahnbau/der-gruene-weg-10-jahre-e3