Introduction to Workshop Bogie Technology
In modern rail vehicle workshops and production facilities, efficiency is closely tied to the flexibility of handling systems. When regular bogies need to be removed for overhauls, wheelset replacements, or reconditioning, workshop bogies come into action.
As accommodation bogies, they temporarily support the weight of the car body. They ensure that vehicles without their own running gear can be safely parked inside workshop halls or precisely shunted between individual stations. Valuable workshop space can thus be optimized while car bodies or locomotive bodies can be stored elsewhere.
Halberstadt Konstruktionstechnik manufactures equipment to the highest Heavy Duty Standards. A durable welded construction, top-grade components, and careful assembly alongside after-sales service maximize operating life and reduce operating costs. Depending on vehicle geometry and workshop configuration, highly specialized designs are utilized.
Design Advantages of Halberstadt Workshop Bogies
Our systems stand out through specific, practical engineering features that make demanding daily workshop operations noticeably safer and more flexible:
1. Original Wheel Flanges
Optimal rail guidance through the use of standardized original wheel flange geometries.
2. Turnout Compatible
Smooth and safe passing through switch lines and crossings across the entire workshop and plant premises.
3. Curve Compatible
Our swivel function allows negotiating even the tightest curve radii, even on demanding track curves.
4. Lateral Inclination Compensation
Safe load distribution and compensation for lateral track inclinations through a well-engineered leveling system.
5. Ramp Compatible
Safe negotiation of inclines, declines, and hall transitions without bottoming out or loss of traction thanks to longitudinal tilt rockers and high ground clearance.
6. High Ground Clearance
Sufficient space beneath the frame to prevent collisions with workshop equipment or track magnets. Ground clearance also plays a key role on concrete elevations or ramps.
7. Retention of Coupler Height
The car body remains precisely at nominal coupler height, allowing effortless shunting using standard equipment. Replacing individual bogies within trainsets is equally seamless.
8. No Stick-Slip Effect
Unlike solutions with sliding surfaces, our central ball bearing prevents the buildup and sudden release of forces—the infamous stick-slip effect. This provides exceptional derailment safety and gentle transport.
9. Three Degrees of Freedom in Movement
- Freely rotatable around the vertical axis, providing superior handling characteristics in curves
- Tilt function around the transverse axis, enabling lateral compensation of track inclinations and stress relief on the car body
- Tilt function around the longitudinal axis to compensate for gradients in the track bed
Modular Structure of Our Workshop Bogies
Our accommodation bogies follow a smart, three-stage modular system. This enables us to flexibly combine standardized, proven assemblies with customer-specific requirements:
1. Running Gear / Chassis
The solid foundation of your system. Choose from various basic chassis types between 15 and 60 tons load capacity to suit your load requirements and workload.
2. Crossbeams
Available in various widths and spacing for precise attachment of dogs or coupling brackets. Equipped with an integrated tilt function to reliably compensate for lateral inclinations and unevenness in the track bed.
3. Adapters
The flexible interface to the vehicle. Adapters are securely mounted onto the crossbeam and can be exchanged or adapted for new vehicle types at any time. With over 70 different vehicle adapters in our existing portfolio, we likely already have the matching geometry ready for your fleet.
Overview of Our Product Solutions
Tailored to the specific requirements of different vehicle classes and workshop shunting concepts, we offer the following system solutions:
1. Workshop Bogies for Locomotives
Engineered for extremely high point and axle loads. Locomotive accommodation bogies must safely support the heavy deadweight of robust frame structures and drive units.
- Payload capacities up to 60 tons and more per bogie
- Massive, torsionally rigid structural steel frames
- Special high-strength mounting plates for locomotive frame geometries
2. Workshop Bogies for Power Cars & Multiple Units
Specially adapted to the weight distribution and geometric interfaces of modern multiple units (e.g., ICE, regional trains). They enable stable handling despite uneven load distribution caused by built-in drive components.
- One chassis fits multiple vehicle types
- Compensation rockers for stress-free transport
- Optimized for rapid installation and removal cycles
3. Workshop Bogies for Jacobs Configurations
Special designs for articulated trains where two car bodies share a common bogie (Jacobs bogie). These accommodation bogies feature dual mounts to support both car ends simultaneously in coupled condition.
- Simultaneous support of two adjacent car bodies
- Maintains trainset integrity during workshop rotation
- Accepts various coupler types centered at the support point
4. Split Workshop Bogies for Vehicle Separation
These flexible auxiliary bogies are used when fixed trainsets need to be uncoupled. They reliably support the articulation and coupling areas of the separated car segments.
- Facilitates uncoupling and pulling apart on track
- Operable coupled or individually
- Can also be used under standard car bodies
5. Platform Bogies for Transporting Whole Vehicles
Large heavy-duty platforms designed to carry entire vehicles or stripped body shells. They serve as a universal transport base across extensive plant grounds.
- Extremely wide and stable support surface
- Suitable for various track gauges
- Frequently used in new construction and bodyshell manufacturing processes
6. Driven / Powered Workshop Bogies
Self-propelled shunting solutions. These bogies feature integrated electric or hydraulic drives (often battery-powered) and can be operated via radio remote control without external shunting vehicles or cable winches.
- Maximum independence during hall transfers
- Precise millimeter-level positioning
- Comprehensive safety sensor technology (Emergency Stop, various brake programs)
- Retrofitting of existing equipment possible, either by integrating a drive (see picture) or by attaching an external drive unit
7. Tram / Streetcar Bogies
Low-floor streetcars present unique challenges during bogie exchanges or maintenance when trainsets are uncoupled. For these applications, we have developed ultra-low platforms:
- Extremely robust
- Only 250 mm height
- 10-ton load capacity
- Fully configurable
8. Comprehensive Accessories
- Mechanical or hydraulic height adjustments
- Plug-in or foldable tow bars for tractor/shunter operation
- Heavy-duty polyurethane rollers (floor-run) or flange-guided steel wheels
- Integrated deadman brakes and locking mechanisms
9. Milling Machine on Workshop Bogie
For repairs under the car body:
- For operations in aluminum or steel
- Programmable
- Grooving, facing, drilling
- Horizontal or vertical operation
Commercial Aspects & Procurement Options
Beyond technical excellence, we offer maximum financial planning flexibility through adaptable procurement models:
1. Direct Purchase
The classic outright purchase for long-term workshop capacity and permanent operational readiness in your own fixed assets.
2. Rental / Hire
The ideal capital-preserving solution for project-based demands, temporary peak workloads, or during overhaul cycles of owned or third-party vehicles.
3. Hire Purchase
Combine flexibility with asset accumulation. Use the equipment immediately and acquire ownership after the agreed rental term expires.
4. Buy-Back Agreement
Maximum planning certainty for time-limited major projects via contractually pre-agreed buy-back guarantees upon project completion.
5. Used Equipment Sales
Budget-friendly alternatives featuring certified, workshop-inspected, and immediately available used workshop bogies from our inventory.
Previously Manufactured Vehicle Adapters & Series
Search specifically by manufacturer or class to check if we already have matching adapter solutions in stock:
| Manufacturer | Designation / Type | Category | German Class (BR) | Other Class / Desig. |
|---|---|---|---|---|
| Ausbesserungswerk Halberstadt | BDCM | Passenger Coach | - | - |
| Alstom | Coradia Continental | Regional Train | BR 440 / 1440 | - |
| Alstom | Coradia Lint 81 | Regional Train | BR 620 | - |
| Alstom | Coradia Lint 54 | Regional Train | BR 622 | - |
| Alstom | Lint 27 | Regional Train | BR 640 | - |
| Alstom | Coradia Lint 41 | Regional Train | BR 648 | - |
| Alstom | Coradia iLint | Regional Train | BR 654 | - |
| Alstom | Prima H3 | Locomotive | BR 1002 | - |
| Alstom | Regio Citadis, electric | Light Rail | BR 452 | - |
| Alstom | Regio Citadis, hybrid | Light Rail | BR 689 | - |
| Alstom Bombardier | - | Regional Train | BR 430 | - |
| Alstom Bombardier | Talent 2 | Regional Train | BR 442 / 1442 / 2442 / 3442 | - |
| Alstom Bombardier | Talent 3 | Regional Train | BR 6442 | - |
| Alstom Bombardier | TwinDexx | Regional Train (Double-deck) | BR 445 / 446 | - |
| Bombardier | Itino | Regional Train | BR 613 | Sweden: Y31 & Y32 |
| Bombardier | Talent | Regional Train | BR 643 | - |
| Bombardier | Talent | Regional Train | BR 644 | - |
| Bombardier | - | Locomotive | BR 145 | - |
| Bombardier | Traxx | Locomotive | BR 147 | - |
| Bombardier | Traxx F 140 | Locomotive | BR 185 | - |
| Bombardier | Traxx F 140 MS | Locomotive | BR 186 | - |
| Bombardier | Traxx F 140 AC 3 | Locomotive | BR 187 | - |
| Bombardier | Traxx MS3 | Locomotive | BR 188 | - |
| Bombardier | P160 DE ME | Locomotive | BR 245 | - |
| Bombardier | Traxx P160 DE | Locomotive | BR 246 | - |
| Bombardier | Traxx F 140 DE | Locomotive | BR 285 | - |
| Bombardier | Flexity Swift, low floor | Light Rail | K 4000 | - |
| Bombardier | Flexity Swift, low floor | Light Rail | K 4500 | - |
| Bombardier | Flexity Swift | Light Rail | K 5000 | - |
| CAF | Nexio WEG | Regional Train | BR 455 | - |
| Various | V60 | Locomotive | BR 362 / 363 | - |
| EMD | Class 77 | Locomotive | BR 266 | LT 42 CWRM |
| Kirow | KRC 1200 | Crane | BR 732 | - |
| Consortium | BCMZ | Couchette Coach | - | ÖBB 5991 |
| Consortium | BCMZ | Couchette Coach | - | ÖBB 5990 |
| Consortium Adtranz / Bombardier / Siemens | - | Regional Train | BR 424 | - |
| Consortium Adtranz / Alstom / ABB / LHD / Bombardier | - | Regional Train | BR 423 | - |
| Consortium Siemens / Bombardier / DWA | - | Regional Train | BR 425 | - |
| Consortium Siemens / Bombardier / DWA | - | Regional Train | BR 426 | - |
| Krupp, Henschel, Krauss-Maffei & AEG, BBC, SSW | - | Locomotive | BR 139 | - |
| Krupp, Henschel, Krauss-Maffei, MAK | V160 | Locomotive | BR 216 | - |
| Krupp, Henschel, Krauss-Maffei, MAK | V164 | Locomotive | BR 218 | - |
| LEW | V 100 Ost | Locomotive | BR 201 | - |
| LEW | V 100 Ost | Locomotive | BR 202 | - |
| LEW | V 100 Ost | Locomotive | BR 203 | - |
| LKM & LEW | V100 Ost | Locomotive | BR 202 / 204 | - |
| LTS Lugansk | Ludmilla | Locomotive | BR 232 / 233 | - |
| MaK | V100 West | Locomotive | BR 211 | - |
| MaK | V100 West | Locomotive | BR 212 | - |
| MaK | V100 West | Locomotive | BR 213 | - |
| MaK | V90 | Locomotive | BR 290 / 294 / 295 | - |
| MaK | V100 West | Locomotive | BR 212 / 213 / 714 | - |
| MaK | V 90 (Remodeled) | Locomotive | BR 294 / 296 | - |
| Mak Vossloh | G1206 | Locomotive | BR 266 | - |
| O&K | MB 10 N | Locomotive | xxx | - |
| Pesa | Link 1 | Regional Train | BR 631 | - |
| Pesa | Link 2 | Regional Train | BR 632 | - |
| Pesa | Link 3 | Regional Train | BR 633 | - |
| Plasser | - | Track Construction | BR 746 | - |
| Plasser | Various | Track Construction | Various | - |
| SGP / Jenbacher Werke | BM PZ Eurofima | Passenger Coach | - | ÖBB 2991 |
| Siemens | Eurosprinter | Locomotive | BR 152 | - |
| Siemens | Taurus 2 ES64U2 | Locomotive | BR 182 | - |
| Siemens | Taurus 3 (ES 64 U4) | Locomotive | BR 183 | - |
| Siemens | ES 64 F4 | Locomotive | BR 189 | - |
| Siemens | Vectron Smartron | Locomotive | BR 192 | - |
| Siemens | Vectron | Locomotive | BR 193 | - |
| Siemens | Eurorunner ER 20 | Locomotive | BR 223 | Class 2016 Hercules |
| Siemens | Vectron Dual Mode | Locomotive | BR 248 | - |
| Siemens | Vectron Light | Locomotive | BR 249 | - |
| Siemens | ER 20 | Locomotive | BR 253 | - |
| Siemens | ICE 1 | Locomotive | BR 401 | - |
| Siemens | ICE 2 | Locomotive | BR 402 | - |
| Siemens | ICE 3 | Long-distance Train | BR 403 / 406 / 408 | - |
| Siemens | ICE 4 | Long-distance Train | BR 412 | 4011 |
| Siemens | ICE T | Long-distance Train | BR 411 / 415 | 4011 |
| Siemens | Desiro HC | Regional Train | BR 462 | - |
| Siemens | Desiro ML | Regional Train | - | 4744/46/48 |
| Siemens | Mireo | Regional Train | BR 463 | - |
| Siemens | Mireo Plus H | Regional Train | BR 554 | - |
| Siemens | Mireo Plus B | Regional Train | BR 563 | - |
| Siemens | Desiro Classic | Regional Train | BR 642 | 5042 |
| SLM / ABB | EL 18 | Locomotive | - | - |
| Stadler | Flirt 1, three-car | Regional Train | BR 427 | - |
| Stadler | Flirt 1, four-car | Regional Train | BR 1428 | - |
| Stadler | Flirt 1, five-car | Regional Train | BR 429 | - |
| Stadler | KISS, Double-deck | Regional Train | BR 445 | 4110 / 4010 |
| Stadler | Flirt, Battery | Regional Train | BR 526 | - |
| Stadler | Flirt, H2 | Regional Train | BR 554 | - |
| Stadler | KISS | Regional Train (Double-deck) | BR 445 | - |
| Stadler | Regio Shuttle RS 1 | Regional Train | BR 650 | - |
| Stadler | Euro 9000 | Locomotive | BR 2019 | - |
| Stadler | Euro Dual | Locomotive | BR 159 | - |
| Stadler | Euro 9000 | Locomotive | BR 1018 | 2019 |
| Strømmens Verksted | WLAB | Passenger Coach | - | - |
| Talgo | ICE L | Long-distance Train | BR 230 | - |
| Voith | Gravita | Locomotive | BR 261 / 265 | - |
| Vossloh | G 1206 | Locomotive | BR 271 | - |
| Vossloh | G 2000 BB | Locomotive | BR 272 / 273 | - |
| Vossloh | G 1000 | Locomotive | BR 276 | - |
| Vossloh | DE 18 | Locomotive | BR 418 | - |