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.”
Rugged Railway Electrical Connectors
Electrical connections in railway engineering demand the utmost in contact quality. With the Railway line 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 long-term 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 use in the railway industry.
Advantages of MULTILAM technology:
- High current-carrying capacity
- Very large number of mating cycles
- Minimal contact resistance
- Minimal power loss
- High temperatures up to 350 C possible
- Resistant to corrosion and salt spray
- Good toleration of fluids such as oils, acids and alkalis
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’s 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.
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 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 integrated as well. The CombiTac for harsh environments fulfils the railway standards for operating temperature, shock, vibration and fire protection.