Innovation in traction optimisation – the variable sanding system in practice
In conversation with Ross Orchardof Siemens Mobility, we explore the use of a speed-dependent sanding system in modern diesel railcar operations. The focus is on the GripMaster® from HANNING & KAHL, which sets new standards in traction optimisation thanks to its variable, infinitely variable dosing.
tram.news: The interview provides insights into the technical requirements, development and practical implementation in operation, and demonstrates how the collaboration between the two companies contributes to greater efficiency, safety and sustainability in rail transport.
Ross Orchard: Our partnership with HANNING & KAHL has shown what can be achieved when organisations combine their expertise to solve real operational challenges. Together, we've taken Variable Rate Sanding from an innovative concept to an award-winning technology that is delivering benefits for operators, maintainers and passengers alike. We're delighted to share some of that journey in this interview.
tram.news: What specific operational challenges in diesel railcar operations led to the introduction of the variable sanding system, and how has demand changed compared to traditional sanding solutions?
Ross Orchard: One of the biggest challenges for diesel railcars is dealing with changing adhesion conditions, particularly during autumn and winter. Traditional sanding systems typically operate at a fixed rate, which means they can't always respond effectively to the conditions the train is actually experiencing.
VRS was developed to address this by automatically adjusting the amount of sand delivered based on factors such as speed and braking demand. This helps improve braking performance while using sand more efficiently.
What we've seen over the last few years is a growing interest from operators and fleet owners who are looking for more than just a like-for-like replacement. They want solutions that can improve performance, reduce operational risk and deliver measurable benefits, and that's where VRS has really gained momentum.
tram.news: What measurable improvements (e.g. traction behaviour, braking distance, wheel-rail adhesion, sand consumption) have been observed in operation since the introduction of the GripMaster®?
Ross Orchard: The most significant improvement has been in braking performance during low-adhesion conditions. Rail Safety and Standards Board (RSSB) testing demonstrated that variable-rate sanding can reduce stopping distances by up to 50% compared with conventional fixed-rate systems in certain scenarios.
We've also seen improved wheel-rail adhesion and more consistent traction and braking behaviour, particularly in challenging seasonal conditions. Another key benefit is that sand is only delivered when and where it is needed, which helps optimise sand consumption and reduce unnecessary replenishment.
tram.news: What role does speed-dependent and continuous sanding play in optimising adhesion, particularly under changing weather and track conditions?
Ross Orchard: The key advantage is that the system can respond to the conditions the train is actually experiencing rather than applying a one-size-fits-all approach. As weather and rail conditions change, the sanding rate changes with them.
This helps maintain optimum adhesion throughout the braking cycle, improving performance and driver confidence while making more efficient use of sand.
tram.news: How do you rate the collaboration with HANNING & KAHL in terms of the development process, system integration and adaptation to specific vehicle requirements?
Ross Orchard: Very highly. Introducing an innovation like Variable Rate Sanding requires close cooperation between all parties, and Hanning & Kahl have been a fantastic partner throughout the journey.
From development and testing through to fleet integration, they've been responsive, pragmatic and always willing to work through the unique challenges that each vehicle type presents. That collaborative approach has played a major role in the success of the project.
We've been fortunate to develop strong relationships with the team at HANNING & KAHL beyond the day-to-day project work. Their hospitality, professionalism and positive approach to collaboration have helped create a real sense of partnership, which has been invaluable in delivering successful outcomes for our customers.
tram.news: What significance does the award at the 2024 National Rail Awards hold for the further scaling or deployment of the technology in future vehicle projects?
The award was a proud moment for the whole team and a great recognition of what can be achieved through collaboration and innovation.
Perhaps most importantly, it helped bring Variable Rate Sanding to the attention of a wider audience within the rail industry. As a result, we've seen increasing interest from operators and fleet owners who are keen to explore the benefits on their own fleets.
Kurzvita
Ross Orchard. Fleet Strategy Manager at Siemens Mobility, specialising in rolling stock asset management, innovation, digital transformation and customer-focused solutions that improve fleet performance, reliability and sustainability