Customised hydraulic and battery solutions for railway construction

Aug 12
3 min read

Updated: Aug 26

How Nencki AG and Paul Forrer AG jointly developed a reliable system solution for RBS

When developing new work and maintenance vehicles for railway construction, the highest standards of reliability, safety and durability are required. In addition to a robust design, the hydraulics, control system and battery technology must be perfectly coordinated.

In a current project for Regionalverkehr Bern-Solothurn AG (RBS), Nencki AG developed modern tipping bridge modules for a new generation of 50-foot flat wagons. Paul Forrer AG supported the project with its expertise in hydraulics, control technology and battery solutions. Together, the two companies developed a customised solution for demanding railway construction applications.

The challenge: A reliable solution for railway construction

As part of a public tender, RBS was looking for a partner to develop, supply and commission new tipping bridge modules, including documentation, training and spare parts supply.

As the modules were developed specifically for the project, the focus was not on standard components but on a solution precisely tailored to the customer’s requirements.

Nencki AG was responsible for developing the modules and relied on the technical support of Paul Forrer AG in the areas of hydraulics, battery technology and control systems. The aim was to create a durable, maintenance-friendly and reliable solution for daily use on the railway.

Choosing the right battery technology as a key to success

One of the most important decisions concerned the selection of the appropriate battery technology.

As Nencki had only limited experience with comparable applications in this field, the specialists from Paul Forrer AG were involved at an early stage of the project.

Together, the partners opted for lithium battery systems from Flash Battery. The key factors behind this decision included:

customised design
integrated heating and cooling systems
high operational safety
optimal integration into the overall system

Thanks to the close technical collaboration, a reliable solution could be defined at an early stage of the project.

High demands on hydraulics and control systems

Work vehicles in the railway sector are exposed to extreme environmental conditions throughout the year. Rain, heat, temperature fluctuations and condensation in tunnels place high demands on all components.

For this reason, high-quality hydraulic components, protected control units and corrosion-resistant enclosures were used. Stainless-steel versions were selected for areas exposed to particularly demanding conditions.

Only through the perfect interaction of hydraulics, control technology and battery systems could the required level of operational reliability be achieved.

From pre-assembly to commissioning

Following the pre-assembly of the modules at Nencki, the components supplied by Paul Forrer AG were installed, connected to the hydraulic system and electrically wired.

The specialists from Paul Forrer AG then commissioned the complete energy module together with Nencki’s project team.

Thanks to careful preparation, only a few adjustments were required before the modules became fully operational. Following successful factory acceptance, the modules were delivered to RBS, where final commissioning on the flat wagons was carried out.

Successful collaboration on complex engineering projects

Technical adjustments and scheduling challenges are part of everyday project work, particularly when developing prototypes and special-purpose solutions.

Close cooperation between everyone involved, short communication channels and the high degree of flexibility demonstrated by both companies were crucial to the project’s success. Despite high workloads, all milestones were met and the project was successfully completed.

System expertise from a single source

For Nencki, the combination of technical expertise, project support and a broad product portfolio was a key advantage.

From hydraulic components and hydraulic power units to control systems and modern battery technology, all essential components could be sourced through a single point of contact. This system expertise simplifies engineering projects and significantly reduces coordination efforts.