Bemo Rail Case Study: On The Right Track with Grayson BTMS

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Bemo Rail Case Study: On The Right Track with Grayson BTMS

Explore how Grayson partnered with Bemo Rail to equip their hybrid shunting locomotive with our advanced Battery Thermal Management System (BTMS), supporting greener industrial operations and showcasing the future of low-emission rail shunting technology.

Customer Profile

Customer Name: Bemo Rail

About Customer: Based in the Netherlands, Bemo Rail are a global specialist in the development, production, assembly, maintenance and repair of rails, crane tracks and shunting vehicles.

Sector: Rail

Location: Industrial Steel Factory

Application:Hybrid Shunting Locomotive

Products:

Grayson S1-400V AC BTMS

Requirement

In late 2022, Grayson was engaged by Bemo Rail, a pioneering rail solutions provider from the Netherlands renowned for advancing shunting technology since the 1980s.

The collaboration focused on supporting the development of a cutting-edge hybrid locomotive, designed for use in an industrial steel facility and signifying an important move toward quieter, lower-emission rail operations. The application combines electric power with a generator that handles peak demand and recharges the battery during lower-intensity activities.

A key challenge for Bemo Rail was to ensure the vehicle’s batteries were maintained at the correct temperature in varying environmental ambient conditions, from sub-zero temperatures to high heat loads, to deliver optimal performance consistently while preserving the health of the cells over time.

The Dutch shunting expert needed a durable and compact battery thermal management system capable of providing 14 kW of cooling and 5 kW of heating across a wide temperature range, from -10°C to 40°C, while operating on a 400V AC power supply.

Our Solution

To address the application’s requirements, Grayson proposed our BTMS S1-400V AC (part number: BC-6728-000). As part of our standard BTMS range, this pre-configured, plug-and-play system is both extensively field-tested and fully homologated. It combines reliable refrigerant-based cooling and heating in one compact unit, ensuring precise temperature regulation for the batteries.

Powered by our advanced ‘Grayson Intelligence’ controller, the BTMS integrates seamlessly with the shunter’s CAN network, adapting dynamically to operational demands with customisable set points. The system provides up to 14 kW of cooling capacity, enabling the hybrid shunter’s batteries to maintain peak performance and reliability, even in the harsh conditions of industrial settings.

Outcomes

The collaboration between Grayson and Bemo Rail successfully delivered a battery thermal management solution tailored to meet the unique demands of the hybrid shunter project. Grayson’s BTMS S1-400V AC played a critical role in ensuring the battery system operated efficiently, maintaining optimal temperatures across all conditions and safeguarding the long-term performance and lifespan of the battery pack.

The BTMS was extensively tested during Bemo Rail’s Site Acceptance Test (SAT), with results confirming the system’s reliable performance in the hybrid locomotive’s demanding operational environment. Its compact design seamlessly integrated into the locomotive’s layout, meeting Bemo Rail’s strict size and thermal management requirements. Since the system’s recent commissioning, Bemo Rail has expressed satisfaction with the BTMS’s performance and its ability to maintain the hybrid shunter’s operational efficiency.

In addition to the technical success, the project highlighted the strength of the partnership between Grayson and Bemo Rail. The collaborative approach ensured that Grayson’s technical expertise and support were available at every stage of the project. This close cooperation allowed for swift adaptation to project needs and a solution that delivered on all performance expectations.

Robin Okkerse, Project Manager at Bemo Rail, reflected on the project:

“From beginning to end, we are very pleased with the assistance and technical know-how of Grayson. During testing, we were also very pleased with the results of the BTMS and look forward to any other projects in the future.”

This first-of-its-kind hybrid shunter is one of the most compact locomotives in its class, combining exceptional pulling power, a sizable battery pack, and a centrally located cabin with enhanced field of vision and spacious interior design. It is the first of ten hybrid locomotives planned for delivery to the operator by 2026, all equipped with Grayson’s advanced BTMS.

Key outcomes

Reliable Performance Validated Through Rigorous Testing

Grayson’s BTMS S1-400V AC successfully passed extensive Site Acceptance Testing (SAT) by Bemo Rail, demonstrating its ability to meet the demanding thermal management requirements of a hybrid locomotive.

Optimised Battery Performance and Longevity

The BTMS provided a compact, high-performance solution that safeguarded the battery pack, ensuring optimal thermal regulation to enhance efficiency and extend battery lifespan.

Strong Collaboration and Technical Expertise

Bemo Rail praised Grayson’s collaborative approach and technical know-how, highlighting the seamless integration of the BTMS and the valuable support provided throughout the project.

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