New Vehicles for BVG – with Braking Systems from HANNING & KAHL

Berlin’s transport company Berliner Verkehrsbetriebe (BVG), the biggest public transport provider in Germany, carries millions of passengers through the capital every day. Their vehicles must not only be reliable, they must also be state-of-the-art. HANNING & KAHL’s  braking systems are installed in the next tram vehicle generation, the Urbanliner. By Carsten Stapke

In the past, HANNING & KAHL had a successful partnership with Bombardier (at that time) working on different platforms like Flexity and Flexity Classic in projects for Zürich, Vienna and Frankfurt. On account of these positive experiences, Bombardier approached us early about the “BVG 2020“  project in order to work together on the development of a new motor bogie and a trailer bogie for Berlin trams.

Development began in 2016. In 2018 we compiled the first calculation and quotation on the basis of a preliminary parts list. Over the years, numerous adjustments were made including technical improvements and the integration of bespoke wishes. One particular challenge was the tight installation space available in the bogies, for which we specially developed two new brake components: a compact HYS 150 with 6 kN brake force for the motor bogie and a newly developed  HYS 202 with 22 kN for the trailer bogie.

Another special point was the request for brake pads with wear detection – technically, an easily solvable requirement, but rather unusual in tram operations. After numerous iterations, the fourteenth and final parts list was compiled in January 2022. The same month we submitted the final quotation to car builder Alstom who had taken over the project from Bombardier. In spite of the very tight scheduling – in particular for cast parts with long lead times – together with the customer, we managed to initiate orders early and to deliver on time.

Today we can look back on a successful project: braking systems for around 20 vehicles have already been supplied; the first new trams went into operation in 2025. 

The first vehicles are in test operation in Berlin and are to start transporting passengers this year. Altogether, the order could encompass up to 90 vehicles. As of today, BVG has ordered the 65 vehicles of the minimum call-off order. Supply of our braking systems is likely to continue until 2028 and beyond.