References

Development and technological implementation
of the world’s first rail vehicle in
a carbon-fiber-intensive lightweight design.

References

Development and technological implementation of the world’s first rail vehicle in a carbon-fiber-intensive lightweight design. ​

CETROVO Project

CETROVO is the world’s first lightweight metro train made almost entirely of CFRP components.

The CG Rail GmbH team developed the vehicle for the world’s largest rail vehicle manufacturer, CRRC, using carbon fiber composite materials to produce the essential main systems, including the front cab, car body, underfloor cladding, and bogie frame. The innovative lightweight concept enables weight reductions of more than 30 percent, contributing to a resource-efficient, high-performance local public transportation system.

CFRP front cab

  • Innovative lightweight design with ultra-large CFRP structures
  • Reduced number of individual parts combined with a high level of functional integration
  • Modern cab design with complete separation of cab and car body without a continuous underframe
  • More than 30 percent reduction in mass compared to a metal design

CFRP-Car body

  • The world’s first car body composed of more than 70 percent CFRP structures
    CFRP-Structures
  • Reduced number of individual parts combined with a high level of functional integration
  • Modern cab design with complete separation of cab and car body without a continuous underframe
  • More than 30 percent reduction in mass compared to a metal design

CFRP-Cladding prototypes

  • Innovative lightweight design with a CFRP content of more
    than 90 percent
  • Highly efficient and reproducible production technologies, such as pultrusion of CFRP profiles
  • Mass optimized impact protection through multi-material composites

CRP-Bogie frame

  • World-first CFRP bogie frame in an innovative differential design with longitudinal and cross beams
  • Highly efficient production using automated, series-capable technologies, including automated preforming by braiding and winding
  • Successful cyclic test in accordance with DIN EN 13749   – more than 12 million load cycles at a load level up to 60 percent higher than the normal operating load (corresponding to a service life of more than 33 years)
  • More than 40 percent mass savings compared to the conventional steel design
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