Rolling stock benefits from weight reduction due to lighter connectors and cables

Manufacturers of railway vehicles continuously try to reduce the energy consumption per passenger-kilometre driven. In addition to increasing capacity utilisation and using drives that are more efficient, weight is one of the most important levers in this respect.

When you think of connectors, you might wonder how such small components can help to reduce weight. In railway engineering, connectors can be quite complex and heavy systems. Even minor adjustments can lead to a weight saving of a few kilograms. However, even small connectors can actually save a few kilograms per wagon if used in sufficient numbers.

Furthermore, optimised cable routing with short cable runs offers significant potential for weight reduction.

With the introduction of the Han® 4 HPR, HARTING has expanded its Han® HPR range of industrial connectors to include a further housing size between 3 and 6. The HPR series is suitable for very harsh operating conditions where solutions that are shock- and vibration-resistant, as well as salt-spray-resistant, are required. Bogies are one example of this.

The new connector size 4 allows 50% weight savings (approx. 300g per connector) compared to the previous standard size 6. This is achieved, amongst other things, by replacing the module’s metal frame with a plastic version. The solution continues to meet high standards for durability and protection rating (IP68/IP69) and is certified in accordance with IEC 45545 and UL 1977.

Depending on the number of connectors per locomotive or wagon and the respective connector configuration, switching from size 6 to size 4 can result in a weight saving of several kilograms per wagon. Calculated over a 40-year service life, every kilogram saved can lead to savings of several thousand euros in energy costs. Size 4 features an integrated PE connection. With over 150 different connector inserts, it offers a future-proof solution.

It is not only smaller and lighter connector hoods and housings that can help to reduce the overall weight of the interfaces in railway vehicles. Choosing the right connector inserts can also influence the choice of connection solution.

The Han-Modular® Domino modules are ideal for applications where space is limited. They enable users to combine different media in a single connector module slot, where a conventional modular connector would previously have required two slots. Power, signals, data or compressed air, as well as male and female contacts, can now be combined in a single module. Connectors up to 50% smaller can be selected for the same application.

Overall, the number of interfaces required per rail vehicle or railcar can be reduced. The connection technology is becoming smaller and lighter, meaning that more modules and module types than before can fit into a single connector.

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Switching from metal to plastic connectors in the interior of the vehicle, for example, inside of the locomotive for cabinet applications, is also an option to increase the energy efficiency.

Manufacturers have been able to reduce connector housing weight for trams and trains up to 50% between one generation and the next – this is the significant difference in weight between the classic Han® aluminium die-cast and the Han-Eco® high-performance plastic housing for the same size.

Due to the modularity and the many different uses, the Han® 1A is applicable wherever small drives, sensors and devices need to be supplied. In the field of train vehicle engineering this implies e.g. the supply of door drives and entry systems, lighting, headlights, loudspeakers, screens, scoreboards, warning and alarm lights, push buttons, wipers or signal generators.

The Han® HPR VarioShell was developed as a highly flexible housing system for inter-car connections. It can be used as a classic surface mounted housing or bulked mounted housing - and forms a robust and light-weight alternative for distribution boxes, e.g. on the roof of the train, on the outside wall or on the bogie.

The housing consists of two parts and, thanks to the counter-pressure frame and the circumferential internal seal, achieves protection class IP69K. The removable cover allows service teams to install the system from both inside the vehicle and from the outside. The cables can be easily routed through the wagon wall. This enables additional weight reduction due to short cable runs.

Passenger information systems and other comfort systems are increasing the demand for higher data transmission capacity on board trains. More and more data cables need to be routed in an ever-increasing number of areas within the rail vehicle. Ethernet networks are becoming increasingly complex, as is the cabling infrastructure inside the wagon. This presents rail vehicle manufacturers with logistical challenges in both new trains and retrofit projects.

Single Pair Ethernet (SPE) is a high-performance data infrastructure for railway and stationary applications that is reduced to just two copper wires. Compared with conventional 8-wire data cabling, SPE offers significant advantages in terms of weight, space requirements, fire load and resource consumption.

Thanks to SPE cables, railway vehicle manufacturers can reduce weight by up to 40% compared with conventional data cables. This means that less weight needs to be accelerated during operation, resulting in lower energy costs. At the same time, SPE rail cables have a diameter that is up to 35% smaller, which helps to solve the additional problem of confined installation spaces. More data cables can be accommodated in narrow cable ducts, both in new installations and in retrofits.

More efficient energy consumption and reduced complexity are major trends in the railway industry. Manufacturers of railway vehicles are always looking for ways to reduce the weight of their vehicles.

The Han® HPR TrainPowerLine replaces existing solutions such as UIC, power or Y-distributors for train busbars. The complexity of the application was reduced considerably at the customer's request: a uniform solution now replaces the many variants that were previously required for busbar construction.

The result of developing the TrainPowerLine is a uniform connector design for the entire underbody distribution of a train. The advantages are obvious and range from shortened installation times to more economical use of materials, weight reduction and standardised processes in assembly. It is tailored to modern trains running in a network and offers weight advantages of up to 10 kilograms per wagon compared to previous standards in the market. Very little space is required to reliably supply all the electrical equipment and systems of the train.