ZF has announced an extension of its partnership with Irish Rail to upgrade existing rail vehicles with modern drivetrains, a process referred to as “repowering.” This initiative, designed to enhance fleet efficiency while minimizing costs and service disruptions, was formalized with a Memorandum of Understanding during the InnoTrans trade show in Berlin. The focus will be on ZF’s EcoWorld 2 six-speed powershift transmission, which aims to reduce fuel consumption, enhance ride comfort, and lower maintenance requirements.
“Repowering allows us to offer all the advantages of new vehicles to our customers while reducing costs and service interruptions,” explained Stephen Brew, Key Account Manager for Rail Drive Systems at ZF. He highlighted that, while extending the lifespan of older vehicles is a key benefit, newer models also see significant returns on investment through fuel savings. “Updating the driveline earlier leads to compounded savings and a reduction in carbon emissions.”
At InnoTrans, ZF presented the EcoWorld 2 powershift transmission for diesel multiple units (DMUs), which has already spurred a new project. In 2018, ZF assisted Irish Rail in retrofitting power packs for its national railway system using the predecessor of the EcoWorld 2. Jim Meade, CEO of Irish Rail, expressed enthusiasm about the collaboration’s continuation after experiencing the improved performance of ZF’s driveline technology.
Since September 2020, Irish Rail has been testing a repowered three-car DMU equipped with EcoWorld 2. The ongoing trial has seen the train cover over 650,000 km, demonstrating exceptional reliability and achieving fuel consumption reductions of up to 20%. Both ZF and Irish Rail view these results as compelling reasons to pursue large-scale fleet repowering, with a potential project launch in 2025 involving the delivery of over 230 EcoWorld 2 transmissions over three years.
The EcoWorld 2 model offers systemic improvements that enhance performance, fuel efficiency, and CO2 emissions reduction by 20% or more while improving acceleration. Its updated design includes a revised weight distribution and a new Transmission Control Unit (TCU), which reduces strain on the brake system, leading to lower maintenance needs. Additionally, the specialized gear design allows the engine to operate at lower RPMs, reducing noise levels for passengers and nearby residents while minimizing heat generation and wear on the cooling system.
ZF’s EcoWorld 2 can be retrofitted in either a power pack or installed separately from the engine via a driveshaft, using a specially designed transmission housing and flywheel cover called “EcoBell.” The Aftermarket Division at ZF provides a comprehensive range of solutions, from individual components to complete systems with technical support, ensuring they meet customer needs.
With the EcoWorld 2 featuring an integrated Electronic Control Unit (ECU) and TCU that support full CAN systems, it is also compatible with stop-start and hybrid technologies, making it a strategic option for operators aiming to meet climate targets. Furthermore, it can be combined with ZF’s “connect@rail” condition monitoring system to facilitate predictive maintenance.
