Safe and maintenance-free electrical connections are critical for the cost-effectiveness of modern rolling stock. PFISTERER, the international quality leader in electrical connection technology for energy infrastructure with headquarters in Germany and more than 100 years of experience, shows how plug-in solutions make the entire train construction process more efficient – from components to service.
Contacting train components such as transformers, traction motors, rectifiers, or air conditioning units are key tasks with a far-reaching impact on the entire life cycle of a train, from electrical testing in the component manufacturing phase to the construction of the train as well as quick replacement during servicing. PFISTERER develops, produces, and sells solutions for insulating and connecting electrical conductors for power grid interfaces and supplies technology for efficient and safe connections for rolling stock, such as the CONNEX connector system on the primary side and the PLUG connector system on the secondary side. The benefits and savings potential of these plug-in solutions compared to traditional screw technology are evident throughout the entire train manufacturing process and beyond.
Efficiency from the start: how plug-in connection technology makes train construction more economical:
Plug-in connection technology enables standardized, error-free, and cost-efficient processes from the planning and production phase of a train. The PFISTERER solution separates the mechanical fastening from the electrical contact, increasing operational reliability and reducing the operator’s responsibilities. Thanks to clear coding, only matching plugs and sockets can be connected to each other, making it impossible to mix them up. Power cables are supplied fully assembled and tested by the cable harness manufacturer. This reduces the train manufacturer’s workload to a simple insertion process, keeping costs down significantly.
Designed for easy installation – fast assembly with minimal risk:
When actually assembling the train, manufacturers and system integrators benefit from the plug-and-operate logic with pre-assembled cables: transformers and other components can be connected very quickly without the need for specialist personnel or time-consuming on-site testing. The reduction to simple, intuitive mechanical fastening steps not only accelerates the assembly of the vehicle, but also minimizes sources of error that can arise from complex cable work on site. This not only saves time, but also reduces complexity for the worker, with less rework required.
Compact design – more room for functionality:
PFISTERER’s plug-in technology also creates new freedom when it comes to transformer design. The connections can be integrated directly into the housing, removing the need for additional enclosures or oversized housing shapes. This saves installation space and simplifies the design. At the same time, the number of sealing points is reduced, increasing safety and reliability.
Durability included – maintenance-free for decades:
Another benefit reveals itself during operation: tested and maintenance-free connections ensure no planned replacement over the entire service life of a train – often over 30 years. This means fewer service call-outs and minimizes the total cost of ownership (TCO) in the long term. Dr. Thomas Schilla, Key Account Manager at PFISTERER, sums up the benefits of the company’s connection technologies:
“Our plug-in solutions not only enable quicker and safer installation for train manufacturers, they also save rail operators significant costs over the entire life cycle.”
Product Expertise: Pfisterer | This Product Expertise is a part of our Latest Magazine: Subscribe to our Magazine Today!
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