Use Case II
Retrofit – Brake control switch for Berlin S-Bahn

Initial situation

In rail transport, the maintenance of older systems often presents a particular challenge: Critical components are often worn out, while original parts are no longer available.

This was also the case here: Defective components of a brake control system had to be replaced, even though no standard replacement parts were available. The required one-off production of a small quantity – limited to a few brake light switches that needed to be refurbished – made the project a challenging task balancing maintenance and economic viability.

Typical challenges:

1

High safety requirements for critical components that are worn out and no longer available

2

Cost-effectiveness despite one-off production

What is needed is an individual solution that allows for the cost-effectiveness of one-off production while adhering to the strictest safety requirements.

To the solution

1

Functional analysis of the original component

2

Sustainable mix of remanufacturing repairable components with functional reconstruction of irreparable components

The EBK Group met the challenge with a well-thought-out solution: Through a comprehensive functional analysis of the original component, intact parts could be refurbished and reused. Non-functional parts, on the other hand, were newly developed, precisely manufactured, tested, and integrated into the existing system. In this way, the smooth continued operation of the plant was ensured while meeting the stringent safety requirements.

Reference project: Brake control switch for Berlin S-Bahn.