With world-renowned expertise across mechanical, fluid, and electrical disciplines, Stäubli Group has become a trusted partner across multiple market sectors where end-to-end fluid, gas and electrical connection solutions are required.
The rail sector, whether it is urban or intercity rail transport, passenger, or freight, faces significant environmental and demographic challenges in today’s fast changing world. Rail users are increasingly demanding services that offer superior comfort, safety, and speed, while operators continue to raise their demands for performance, productivity, and reliability.
Rail Sector Technology & Expertise
Rail vehicles are constantly subject to different types of stress. Service availability expectations are high, with little or no tolerance for disruption. This means that quick replacement for specific types of components during preventative or remedial maintenance procedures is essential if the anticipated availability targets are to be met. In addition, the mechanical and electrical components used on today’s rail vehicles need to be compact and lightweight in design to meet demanding specifications without any trade-off in performance.
As an industry partner and key supplier in the international rail sector for over 30 years, Stäubli has a clear insight into the sectors’ unique challenges and expectations, such as service continuity, extreme weather conditions and mechanical stresses. This close partnership with the sector during this time has been the catalyst for the development of a series of connector products which are now generally recognised by many as industry standard solutions.
Stäubli designs and manufactures reliable, lightweight and compact quick-release couplings that are very easy to use, even in confined spaces, thereby minimising equipment maintenance processes and subsequent rolling stock downtime. The rail sector fluid and electrical applications covered by Stäubli’s connector technology include cooling of on-board electronic circuits, body-to-bogie and inter-body connections, hydraulic circuits, braking systems, battery pack connections and converters.
A key element of the Stäubli product offering to the rail sector is the Modular Power Connector (MPC) range, which facilitates electric connectivity between the various functions that are part of the electric traction chain on different types of rolling stock. The Modular Power Connector (MPC) range has the advantage of delivering a universal multi-application, compact and modular solution, through the rationalisation and the standardisation of common components.
Thanks to the modular nature of the connector design, combined with a series of options, a complete customised solution can be configured for each specific application. The MPC connector solutions offer a range of benefits including the fact that all on-board power applications can be connected, the same system can be used for every power connection plus the fact that the range offers easy and fast assembly and maintenance. Stäubli connectors are certified for high voltage and high current applications and are tested to rail sector standards IEC 62847 – EN 61373 and EN 45545-2.
Stäubli MPC Connectors In Action
The Appenzell Regional Railway offers convenient schedules and new rolling stock for efficient connections onward to long-distance transport. The new low-floor trains used on this route were produced by Stadler, the innovative Swiss train manufacturer. For the first time, these narrow-gauge trains have been fitted with the proven MPC (modular power connector) from Stäubli Electrical Connectors to deliver an easy-to-maintain electrical connection between the vehicle and the traction unit.
The low-floor design of the new trains for the Appenzell Railway ensures that all passengers have barrier-free entry and exit. In addition, the wide doors enable quick passenger changes to keep trains running to schedule. All the trains are air conditioned and offer a first-class carriage. Applying its innovation, passion, and flexibility as well as its knowledge of the respective local conditions, Stadler puts the best possible vehicle on the track for its customers, and this is where their aspirations meet those of Stäubli Electrical Connectors.
The partnership began with a Stäubli solution for earthing blocks for high-performance Stadler double-decker interurban trains to meet the train builder’s safety requirements. Over the next few years this collaboration continued and grew. Stäubli Electrical Connectors was able to build trust and together with the company’s engineering team for gear, narrow-gauge and specialty vehicles, evaluated best-in-class solutions for safe, fast, and vibration-resistant power supply connectors for a variety of applications.
As a result of the collaboration with Stäubli Electrical Connectors, Stadler decided to compare the existing screwed connections with the compact and space-saving MPCs between the car and the drivetrain on the bogies. In railway operations, maintenance must be completed as quickly as possible to minimise rolling stock downtime, and therefore pluggable connections are considered to be the ideal solution for efficient maintenance.
Proven Quality Based Upon Tailor-Made Tests
Durability and low-loss energy transmission for high currents, maximum shock, impact and vibration resistance and high robustness - even in extreme climatic conditions - are required for all components in railway technology. The route and elevation profile of the track in Appenzell were all considered when tests were conducted to ensure that the MPC could transmit the required power over the acceleration sections after the halts, and that the bespoke cable assemblies could withstand even tight curves and steep hills. On completion of the tests Stäubli was able to prove that the MPC range could meet the customer’s high expectations in all areas.
A combination of expert advice, excellent supply availability and close collaboration during all phases of the project resulted in the installation of the new Stäubli connectors in the Appenzell trains. Pascal Duvoisin, Installation Planning Team Leader commented: “The electrical tests carried out specifically for the Appenzell Railway project prove the outstanding suitability under the required conditions. This ensures that we can offer our customers the safety and operational warranty they need. The MPC allows for speedy handling and contact reliability during maintenance periods, which brings the entire train back into operation and back on the rails faster.”