Connectors Contribute to Safe Railways

Safe railways and rolling stock depend on a combination of data-driven design, integration of smart and sustainable technologies, and quality components that are built to perform in harsh railway environments.

Protecting passengers, cargo, and communities surrounding rail networks is a critical goal for designers of safe railways. Rail service, whether it’s a bullet train carrying passengers at speeds approaching 350 km/h or a regional network moving hazardous materials through residential areas, must deliver safety. That commitment includes a careful consideration of every element, including every connector and cable assembly, to ensure that each aspect of the global rail network is designed to prioritize protection as well as performance.

Potential risks to rail service include derailment, collision, fire, environmental contamination, and equipment breakdowns. Modern rail protection is a multi-faceted endeavor that involves strategic systems design and component selection that supports high power loads as well as the high-speed connections needed for AI-based technologies. Additional considerations for component selection include sustainability and regulations surrounding materials and fire safety. Achieving these complex safety objectives depends on collaboration between equipment designers and component suppliers. Companies like Schaltbau work closely with rail operators and transit authorities to address these challenges.

“One of the key issues today is the increasing focus on short-term cost reduction at the expense of long-term reliability. Many components on the market are designed with a lifespan of just a few years, often matching warranty periods, leaving operators to deal with the consequences of premature failures —unexpected downtime, higher maintenance costs, and safety risks,” said David Vaquero, rail sales director, Schaltbau GmbH.

“We take a different approach by focusing on total cost of ownership and long-term performance. Our contactors, for example, are designed for extended operational life, significantly reducing failures and ensuring continued safe operation. This is particularly important for transit authorities or operators dealing with frequent service disruptions, such as metro systems where propulsion failures can leave trains stranded in tunnels. By providing robust, maintenance-free solutions, we help operators enhance safety, reduce lifecycle costs, and improve service reliability.”

Schaltbau’s CP and CF contactors offer enhanced performance, reliability, and adaptability to various railway applications. The CP series is a family of high-power contactors designed for DC, bidirectional DC, and AC loads, covering current ranges from 600A to 2,000A and voltage levels between 1,500V and 3,000V (nominal). A key advantage of CP contactors is their ability to switch loads without critical current limitations, ensuring long electrical lifetime and operational safety.

At the 2024 edition of the rail trade fair InnoTrans, Schaltbau introduced the Smart CP contactor, a next-generation single-pole NO switch designed for rail applications with operating voltages of up to 1.5 kV and a current range of up to ±1 kA. This intelligent switching device brings significant advancements in railway safety and efficiency by integrating real-time sensing, self-diagnostics, and predictive switching capabilities.

Ruggedization has long been a key requirement for components used in rail systems, which are subject to environmental conditions, shock and vibration, and the stress of continuous operations. As trains achieve higher speeds, higher power is needed, as well as the ability to safely disconnect that power load. The company has focused on designs that safely manage energy across various platforms. Vaquero said the company is developing solutions for next-generation green railways, particularly in battery-powered electric locomotives and alternative propulsion systems such as hydrogen. These solutions include switches, relays, and interconnects for high-speed trains, locomotives, passenger coaches, trams, and metro systems.

Schaltbau’s HV series connectors feature solid power and signal contacts and are suitable for a wide range of high-current applications. The robust connectors have a modular design and protection against accidental contact. They are IP69K certified and designed for a high number of mating cycles. The HV connectors are perfect for the energy transmission between rail cars.

“These products are specifically designed to support sustainable and efficient railway solutions,” said Vaquero. “Schaltbau’s innovative solutions contribute to advancing the next generation of green railway systems worldwide, supporting a cleaner and more efficient future for rail transport.”

Rail technologies integrate AI

The rails remain a rugged environment for electronics, but the latest transportation technologies depend on high-speed data. Technologies like Positive Train Control (PTC), automated track inspection systems, advanced signaling systems, and video monitoring represent a multifaceted approach to railway safety. These technologies integrate real-time monitoring, automation, and data analytics into rail operations.

• PTC is designed to automatically stop or slow a train before accidents occur. It can prevent train-to-train collisions, derailments caused by excessive speed, unauthorized train movements, and movement through misaligned track switches. The system uses GPS, wireless communication, and onboard computers to continuously monitor train positions and speeds.
• Automated track inspection systems are another critical safety innovation. Traditionally, track inspections were conducted manually. Today, rail operators deploy autonomous vehicles or high-tech inspection cars equipped with sensors, cameras, and lasers to detect defects in tracks, switches, and infrastructure.
• Advanced signaling systems, such as the European Train Control System (ETCS) and Communications-Based Train Control (CBTC), offer real-time communication between trains and control centers. CBTC, commonly used in urban transit networks, enables driverless train operation and frequent, safe train service through constant data exchange.
• Video monitoring and AI-based surveillance are playing an increasingly important role in ensuring railway safety. Modern rail systems use high-resolution cameras and AI-powered software to monitor station platforms, level crossings, and rail yards for unauthorized access, suspicious behavior, or safety violations.
• Derailment Detection and Crash Energy Management (CEM) systems use sensors to recognize the moment a train leaves the tracks, triggering emergency protocols.

Binder is addressing the needs of these data-driven applications with M12-X-coded connectors that meet the rigorous requirements of rail environments. These components deliver cutting-edge solutions for applications such as Ethernet-based communication infrastructures, camera-based monitoring systems, and passenger infotainment services.

M12-X-coded connectors

“The rail industry and the transport sector are becoming increasingly digital. We are currently adapting the M12-X-coded connectors for the specific applications in these target markets. Our connectors will be used in backbone communication structures with high data rates as well as in passenger infotainment systems,” said Dieter Sandula, product manager at binder.

binder ensures reliable data transmission in line with the Cat6A standard, even under challenging conditions such as intense vibrations and shock loads. Connectors designed for demanding rail markets must adhere to stringent criteria, such as the DIN EN 61076-2-109 standard, which defines essential requirements, including mechanical durability, vibration resistance, and effective sealing for connectors used in industrial and harsh environments.

Connectors used for railway systems must undergo additional shock and vibration tests in accordance with DIN EN 61373. Passing these tests ensures that the connectors remain fully functional, even during short-term stresses like those encountered in shunting or coupling operations.

As rail networks expand and modernize, ongoing innovation in safety technology will remain vital for preventing accidents, improving reliability, and building public trust in rail transportation.

To learn more about the companies mentioned in this article, visit the Preferred Supplier pages for Schaltbau and binder.

Like this article? Check out our other Harsh Environment and Artificial Intelligence articles, our Transportation Market Page, and our 2024 and 2025 Article Archives. 

Subscribe to our weekly e-newsletters, follow us on LinkedIn, Twitter, and Facebook, and check out our eBook archives for more applicable, expert-informed connectivity content.