New interfaces for power distribution in rail technology

Details: Released: 01.07.2021; Last updated: 05.11.2023; Hits: 9345

The Connectors for the energy distribution im Rail vehicle must be particularly robust, quick to install and easy to maintain. For rail technology Harting therefore developed new interfaces. They withstand the demanding environment in rail traffic and also remain interoperable in the sub-distributions. And passengers are also taken care of with a new mini Ethernet interface for infotainment systems.

Contents

Trends for the rail vehicle in rail technology
New interfaces for power distribution
Mini Ethernet interface for infotainment
Success story for a user

Trends for the rail vehicle in rail technology

High-speed data transfer, Weight reduction and the lowering of CO₂ Footprints are one of the most important trends in the rail industry. In the field of power distribution, too, there is currently a very high level of dynamism with increasing power density and increased efficiency. High electrical currents and voltages must be transmitted safely. Here Harting relies on system concepts that specifically cover these needs.

Single Pair Ethernet | for IIot and Industry 4.0

The focus is clearly on the safety and longevity of the entire electrical infrastructure. The new developments are part of an overall system for the cabling of rail vehicles moving from Vehicle Roof extends to the distributors in the underfloor area.

New interfaces for power distribution

The new Han HPTC P800 transformer connector is usually placed near the pantograph. The new Han HPR Varioshell housing system is a solution for jumper cables. The Y-distributor Han HPR TrainpowerLine (TPL) replaces existing solutions. Last but not least, Harting is expanding its offering specifically for infotainment and passenger information systems with a new cable assembly consisting of the IX Industrial data interface and Etherrail cable.

Transformers connectors for outdoor use

The transformer connector Han HPR HPTC (High Performance Transformer Connector) meets all requirements for electrical railway technology. housing and Glanden were optimized for outdoor use of the rail vehicles. The connectors are so robust that the connection between pantograph, transformer and train line is stable over the long term. The existing contours on the transformer can continue to be used. No changes need to be made to the design.

Cable protection with integrated screw connection for railway technology

The connector for railways is easily configurable, consists of a few components and is extremely secure. On the cable side, a crimped contact is inserted into a three-part, touch-safe insulating body. A cable gland protects against dust and moisture. It is also part of the shielding and absorbs differential currents, which it transfers to the housing.

With previous transformer connections, the outer shells Plastic used. This could shorten the service life under the harsh conditions on the roof of rail vehicles. The HPTC, on the other hand, offers a completely pluggable energy distribution solution that enables significantly longer lifetimes compared to plastic housings. This is due, among other things, to the robust housing, which is on the manufacturer's own High Pressure Rail Way (HPR) standard for railways based.

With that all around metallic contacting housing the cover and bottom are connected to one another over the entire contact surface. This is unique on the market, because so far there has been no other transformer connector specifically for shielded connections. Thanks to the two separate contact areas, the Han-HPR HPTC P800 picks up residual currents and diverts them via the housing. The connector is connected directly to the flange housing via a surface on the underside. On the top there is a thread for a potential flag, which dissipates the remaining differential currents.

Components for rubber metal buffers for vibration protection on the rail

The installer does not have to shrink or tape for assembly. The interfaces are quickly prepared: Crimp contacts, Insert the insulator with the shield in the housing, close the cover and the cable side is ready. There are several options for coding. Two coding elements in the add-on housing open up 16 different combinations. One type of connector is sufficient for connecting the transformer. The rest can be regulated via coding. A risk of confusion is excluded.

The new interface is available in the performance classes 400, 850 and 1400 A. Voltages of up to 3,6 kV / 4,8 kV can be transmitted. An IP degree of protection up to IP69K is realizable.

Housing system for jumper cables

The Han HPR Varioshell is a housing system for rail vehicles that was specially developed for jumper applications. The two-part housing achieves IP69K using a counter pressure frame with a circumferential internal seal.

Thanks removable lid the housing can be fitted from the inside of the car and from the outside. The easily accessible housing reduces the work involved in operation, maintenance and service. Not all connections have to be interrupted in the event of an error. The maintenance technician only has to open the housing cover in order to find and replace the faulty conductors or contacts.

The Housing contour the Varioshell do not leave any deposits or rust. Special lines, for example, lead water away from the screwsthat fix the housing. Curves on the top ensure that snow and ice drain off and slide down the sides. Because they do not exert any pressure on the housing, the service life of the interface increases.

The Varioshell is a open system. It also offers counter pressure frames, cable managers and shield plates to guide and support cables of various diameters. As a classic base housing or add-on housing, the Varioshell is a robust alternative for distribution boxes on the outside wall of the wagons, on the wagon roof or on the bogie, among other things.

Interface for the sub-floor

So far, systems for power distribution in the underfloor area have used the UIC 552 interface. The various interfaces of these systems each require their own installation technology and require separate stocks. The Han HPR TPL (Trainpowerline) interface to energy distribution replaces existing UIC, power or Y-distributors for train busbars. It is designed for modern trains running in a network and is up to 10 kg lighter per wagon compared to previous standards. The interface requires little space to reliably supply all electrical devices and systems on the train.

The complexity of the application was greatly reduced at the customer's request. Now a uniform solution replaces the many up to now for the Structure of busbars required variants. The number of components used has also been reduced. Safety is also a top priority. Electrical pin and socket contacts are designed to be safe to touch. Ground potentials exist on the top and bottom of the housing. As with the Han-HPR Varioshell, the contours used on the TPL also lead away dirt and ice to the sides.

So far they were Interfaces for the underfloor area mostly hard-wired. With the TPL, all connection points are now pluggable. The housings are equipped with Han-HC Modular high-current contacts. The transmitted power is 800 A / 5100 V DC / 3000 V AC. The housing, made of corrosion-resistant die-cast aluminum, is based on the design of the Han HPR. The TPL is therefore ideally suited for rough outdoor use.

With Kuka from the Harting connector to robot connectivity

The interface was promoted in cooperation in a customer application. The result is a uniform connector design for the entire underbody distribution of a train. Welcome side effects are shortened installation times, reduced use of materials, weight reduction and standardized assembly.

Mini Ethernet interface for infotainment

Harting brings new developments onto the market especially for infotainment and passenger information systems and thus builds the miniature data connector product line IX Industrial further out. A combination of data interface IX Industrial and Ether Rail cable enables a cable assembly with a Cat.6A performance of up to 10 GBit/s. This is approved for the requirements of the railway industry and is ideally suited for infotainment and passenger information systems in trains and buses.

The plug connection is significantly smaller and lighter than comparable round plug connectors common in rail vehicles. The Snap-in mechanism for locking is very stable and can be connected quickly and without tools to switches, monitors, onboard systems and other devices.

Success story with a user

The Stadler Bussnang AG has been building trains for over 75 years. Harting supplies the connection technology for the transmission of data, signals and power, including Ethernet backbones and data infrastructures such as sensors and passenger information systems.