Since 2023, Honrock has delivered 213 sets of high-performance end door locks, through direct and indirect cooperation channels, for the new intercity train fleet operated by Polish State Railways (PKP) on the Warsaw Central Rail Loop (Warszawska Średnicowa Kolejowa). This supports the upgrade of urban rail transit in a core European metropolitan area.

I. Project Background

• Line Significance:

• The Warsaw Central Rail Loop is a key commuter line connecting Warsaw's core urban area, satellite towns, and the international airport.

• With a daily ridership exceeding 150,000 passengers, it is a critical artery in the Polish capital's transportation network.

• Vehicle Upgrade Requirements:

• PKP initiated a project for 40 new, modern intercity train sets (including standard coaches, first-class coaches, barrier-free coaches, bistro cars, and control cars).

• Components must rigorously adapt to Poland's typical continental climate: severe winter cold (-25°C), freeze-thaw cycles, high humidity, and de-icing salt corrosion.

• Stringent Standards:

• Design and manufacturing simultaneously comply with European Union (EN 16372) and Polish National Railway (PKP CLC) standards.

• Locks must maintain ultra-high reliability and safety under extreme low temperatures, high-humidity freeze-thaw conditions, high-frequency operation, and emergency scenarios.

II. Pain Point Analysis & Solutions

1. Dual Challenge: Extreme Climate & High-Frequency Usage

• ✅ Pain Points:

• Severe cold causing metal embrittlement and greasesolidification, increasing the risk of bolt rebound failure.

• Freeze-thaw cycles + de-icing salt erosion accelerating metalcorrosion and coating delamination.

• High-frequency commuting (thousands of daily operations)intensifies mechanical wear, impacting lifespan and emergency escapefunction reliability.

• ✅ Solutions:

• Triple Reinforcement Process:
  ▶ Core lockcomponents made from low-temperature toughness specialty alloy steel +multi-layer composite anti-corrosion coating, passing -30°C impact testsand 1000-hour salt spray validation.
  ▶Transmission system filled with wide-temperature range (-40°C to +80°C) syntheticlubricating grease.
  ▶ Specificreinforced bolt structure enhances fatigue and impact resistance.

2. High-Frequency Operation with Short Maintenance Windows DemandsUltimate Reliability

• ✅ Pain Points:

• The line operates 24/7 at high density, leaving extremelylimited time for maintenance.

• Low-temperature failure or wear-related faults in traditionallocks would cause carriage shutdowns with significant impact.

• Frequent manual maintenance is costly and difficult toimplement.

• ✅ Solutions:

• Ultra-Long Life Maintenance-Free Design:
  ▶ Enclosedreinforced gear transmission structure isolates external contaminantsand reduces internal wear.
  ▶Lifetime-sealed lubrication system + ultra-wear-resistant compositematerial bearings ensure ≥100,000 operations maintenance-free.
  ▶ Specialheat treatment process increases hardness of critical components towithstand high-frequency impacts.

III. Product Delivery Overview

• A total of 213 sets of end door locks weredelivered for this project.

• Primary Application: End doorlocks for critical passageways such as inter-carriage connection doors anddriver's cab access doors within the train sets.

• Products have passed rigorous certification and fieldoperational testing by the Polish National Laboratory (ILiM), fullycomplying with EN 16372 and PKP CLC technical specifications.

IV. Project Highlights & Collaborative Value

• Deep Customization: lockperformance in low temperatures and wear resistance was directionallyoptimized based on Warsaw's climate characteristics and operationalintensity.

• Efficient Collaboration: Rapidcompletion of EU standard technical adaptation, localization ofcertification documentation, and batch production & delivery.

• Agile Validation: Completedfull suite of accelerated tests (low-temperature cycling, salt spraycorrosion, 100,000-cycle lifespan) within 28 days.

V. Conclusion

Honrock's deep involvement in upgrading the core rail transit system of Poland's capital with 213 end door locks demonstrates its comprehensive capabilities in product design for extreme cold environments, integration of EU standards, and rapid localization certification. Honrock will continue to deepen its presence in the Central and Eastern European market, providing foundational technological assurance for the "zero-failure, high-availability" operation of modern rail transit equipment.