Reliable Technology for Chinese High-Speed Trains

Bipolar Fork Connector (GSR2.5)
Application: connection between busbar and laminated busbar in IGBT

High power transmission
Vibration resistance
Stable performance
Fast and safe mount and dismantling

Customer benefits:

Safe long-term operation in challenging conditions, proven by tailor-made tests
Innovative high-performance solution
Improved efficiency in operation for customer clients

Connection Solutions for The Railway Industry

Electrical Connector

Stäubli Bipolar fork connector (GSR2.5)

China is home to the largest and most extensively used network of high-speed trains in the world. Based in Beijing, the Chinese Academy of Railway Sciences (CARS) is the leading research and development institute, supporting this important industry with its specialised subsidiary, the Beijing Zongheng Electro-Mechanical Technology Development Co. Stäubli Electrical Connectors helped to develop a traction converter for the latest generation of Chinese high-speed trains, while building up a partnership.

China’s network of high-speed railways covers a total of over 22,000 km of tracks. Just imagine: if you could put these rails in a straight line, they would take you halfway around the globe – and even a little further. Every day, thousands of Chinese people use high-speed trains, running at 250 to 350km/h. The possibility of fast travel and commuting has profoundly transformed the country’s economy and society.

CARS: A Key Player in China’s Railway Industry

When China launched its first high-speed trains, they were imported or built under technology transfer agreements with foreign train-makers. Since this initial technological support, Chinese engineers have re-designed train components and started building indigenous trains. Thanks to generous funding from the government, a dynamic local industry has developed over the past 15 years. An important player in this market is the China Academy of Railway Sciences (CARS). Based in Beijing, CARS offers scientific and technological education as well as strategic consultation and certification services for the Chinese railway industry. A focal theme is research and the testing of new materials, products and technology.

Chinese high speed train technology

The Chinese Academy of Railway Sciences (CARS) and Stäubli cooperation

A Traction Converter for the New Generation

In 2010, CARS updated an existing traction converter for use in the latest generation of Chinese high-speed trains. The connector, fixed on the water-cooled board, contains two poles and connects the IGBT module (insulated gate bipolar transistor) to the bus bars in the converter cabinet. High-power transmission connectors were needed, fulfilling demanding requirements of the client for a safe and reliable solution. The higher the travelling speed of the trains, the greater the physical forces, therefore, the vibration resistance and stability are also critical. During maintenance, the module must be disconnected and replaced very rapidly to minimise costly downtime.

Jianhua Cheng, Senior Engineer at CARS, explains:

“I remembered having met Stäubli Electrical Connectors at an event in Beijing the year before. I was impressed with their MULTILAM technology, and thought they could help us find a solution.”


Thus talks started between the two companies and a joint development project was initiated.

Building Trust

Step-by-step, trust was built up through joint workshops, technical seminars and a lot of internal testing.

In close cooperation with CARS, Stäubli developed a customised GSR2.5 bipolar fork connector, which realises the connection between busbar and laminate busbar. The use of high-performance insulation materials ensures the product can meet the tough industry requirements of mechanical stability and long-term ageing.

Jianhua Cheng adds:

“What finally convinced me was a third-party test, where Stäubli’s solution showed a highly stable performance over 300,000 km of high speed. The solution is simple and easy to handle while ensuring safe and reliable operation of the train services. And our customers really appreciate the increase in productivity due to the fast connection and disconnection in maintenance.”


Connections: A Key Link in the Railway Transport Chain

As an industry partner and key supplier in the international railway sector for more than 30 years, we have a clear insight into your challenges and expectations, such as service continuity, extreme weather conditions and mechanical stresses. We provide an effective response with optimized solutions, whether for high-speed, main-line, suburban or regional trains, or tramways and underground railways.

Contact Stäubli Electrical Connectors

Use the form opposite to get in touch with Stäubli Electrical Connectors directly to discuss any requirements you might have.

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Railway Electrical Connector Systems

Stäubli Electrical Connectors is a leading manufacturer of advanced contact technology and sophisticated solutions, (formerly Multi-Contact). The Stäubli Electrical Connectors product range extends from miniature to high-current railway electrical connectors systems for energy transfer of several thousand amperes. The systems are used in a wide range of applications, such as railway and transport technology, the automotive industry, shipbuilding, aerospace, industrial technology, telecommunications, automation and robotics, power transmission and distribution, mechanical engineering, test & measurement, inspection and control technology, research and development, and military technology. Stäubli Electrical Connectors has become the global market leader in cabling systems for photovoltaics. The heart of most of the products is the unique MULTILAM technology, which has been awarded several patents. Numerous MULTILAM copper elements ensure efficient energy transfer with low performance loss, and ensure long product service life. Stäubli Electrical Connectors specializes in the development and production of customized designs at a high technical level. A specific customer requirement is often the trigger for a new standard product. George Freudiger, Head of Research & Development at Stäubli Electrical Connectors: “Because we get the best inspiration for new products from our customers, we can be sure that we can meet the needs of the market as accurately as possible.” [gallery ids="12118,12119,12120"]

Rugged Railway Electrical Connectors

Electrical connections in railway engineering demand the utmost in contact quality. With the Railwayline range of products, Stäubli Electrical Connectors offers resilient contacts and connectors for highly demanding applications in the railway industry. Developing new products, the railway specialists at Stäubli Electrical Connectors benefit from deep knowledge and longterm experience on this particular sector. Where standardised products do not apply, they design custom solutions. Our broad railway electrical connectors product range is based on the unique MULTILAM Technology. Connectors equipped with MULTILAM are characterized by a high current carrying capacity, low contact resistance and minimum power loss. Their tried and tested vibration resistance qualifies these connectors for the use in the railway industry. Advantages of MULTILAM technology:

Connectors for Harsh Environments

The new system in the Powerline range provides excellent performance and safety, even in harsh environments, such as in mining or railway applications. The railway electrical connectors provide a reliable technical solution for the electrical connection between railway carriages. The connector in its sturdy cast aluminum housing is fitted with 32 signal contacts and an 8-pole bus connection. A special safety cap protects the interior from snow or damaging dust. The plug side of the coupling is flange-mounted and inclined to 15 degrees to reduce the mechanical load on the coupling cable. The system is designed to cope with rated voltages of up to 1000 V. Depending on the customer requirements, the railway electrical connectors can be fitted with different contacts for the application in question. The Stäubli Electrical Connectors specific MULTILAM contact elements guarantee long-term stability in terms of contacts, even in adverse weather conditions and under heavy vibration. [gallery ids="12121,12122,12123"]

Connectors for Busbars

Connectors in the CLIPLAM CL-T and HP-GSRD ranges are a superior solution for connecting busbars in every respect. And the best thing is that they can be fitted simply by plugging in, with no drilling or screwing required. Where there are inverters in railway vehicles, busbars are used to distribute the high currents. Screw-fitting the connections or branches on the copper busbars has considerable disadvantages, such as complexity of mounting, voltage losses as a result of increased contact resistance, and increased induction levels. With the CLIPLAM CL-T busbar connectors, the numerous sprung MULTILAM elements take over the contacts. The multitude of parallel power lines leads to a noticeable reduction in contact resistance and induction compared to a screw connection. The system is suitable for busbars of 2 to 5 mm in thickness. The connectors are simply clipped to the busbars in their plastic frames. When they are inserted into the busbars, the sprung contacts clean themselves to guarantee secure connections, even when jolted or vibrated. When the current levels are high, Stäubli Electrical Connectors can provide the HP-GSRD fork plug, which is a more heavy-duty connector system but just as easy to handle. The fork plug is designed for 15 mm busbars, and copes with currents of up to 3000 A. Here, too, a range of individual contact springs connected to sprung aluminum contact plates are responsible for conducting the current, and also give mechanical purchase to the busbar connections. The connectors comply with all applicable rail standards with respect to operating temperature, vibrations, and power conduction. Maintenance costs are reduced because the assembly and maintenance times are considerably cut.

CombiTac for Slide-in Systems

The new CombiTac modules CT-HE are perfectly suited for the use on rolling stock. The modular connector system CombiTac allows customized combinations of different contact types for countless applications. The rackable connectors are particularly interesting for slide-in systems; misalignments are compensated, so that the modules can be mounted without looking, e.g. in hidden and confined spaces. Up to 4 power contacts with a diameter of 12 mm and 400 A as well as up to 12 signal contacts with a diameter of 1.6 mm may be combined, for example to monitor battery systems. An earthing contact may be intergrated as well. The CombiTac for harsh environments fulfils the railway standards for operating temperature, shock, vibration and fire protection." ["post_title"]=> string(30) "Stäubli Electrical Connectors" ["post_excerpt"]=> string(0) "" ["post_status"]=> string(7) "publish" ["comment_status"]=> string(6) "closed" ["ping_status"]=> string(6) "closed" ["post_password"]=> string(0) "" ["post_name"]=> string(29) "staubli-electrical-connectors" ["to_ping"]=> string(0) "" ["pinged"]=> string(0) "" ["post_modified"]=> string(19) "2019-10-25 15:41:20" ["post_modified_gmt"]=> string(19) "2019-10-25 14:41:20" ["post_content_filtered"]=> string(0) "" ["post_parent"]=> int(0) ["guid"]=> string(60) "" ["menu_order"]=> int(60) ["post_type"]=> string(9) "suppliers" ["post_mime_type"]=> string(0) "" ["comment_count"]=> string(1) "0" ["filter"]=> string(3) "raw" }