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Content
Cable
Practical cable solutions made to
international standards 12
Product properties that stand for safety,
cost advantages and high user benefit 13
BETAtrans® GKW 14
BETAtrans® GKW FE 180 15
BETAtherm® ENgine / BETAflam® ENgine 16
UIC train cable and train bus cables 17
Special Cables
Customised special cable
for rolling stock engineering 18
Application-specific cable solutions 19
– Highly flexible power and supply cables
– Highly flexible hybrid cables
– Fiber optic cables (POF & glass fiber)
Cable Systems
Engineering services 20
Feasibility and design studies 21
Carriage bridging systems / Inter-car jumper systems 22
High-voltage roof jumpers 24
Build-to-Print / Refurbishment 25
Global presence 26
Edition April 2011 References 26
Subject to change and error. LEONI – The Quality Connection 27
Address 28
4 www.leoni-traffic.com
Having the ability to produce cable for rolling stock means Areas of application
being at home in many technical disciplines and having a Q Communication links
broad product range. The requirements are not only technically Q Infotainment
demanding but also exceptionally complex. On the one hand Q Seat wiring
this field requires numerous products that are sometimes very Q Driver’s control panel wiring
different; on the other hand extreme operating conditions and Q Coiled radio cables
tricky installation problems will frequently have to be tackled. Q Drive systems
LEONI is one of the few cable manufacturer and system provi- Q Motor connection cable
der able to fulfil all these requirements. Q Switch cabinet and control panel wiring
Q Air conditioning, ventilation and heating systems
What makes this possible is LEONI’s unique value chain, which Q Sensor and component connections
stretches from thin copper wire to multi-core special cables Q Brake systems
and through to the ready-to-install cable system. All cable com- Q Door and footboard controls
ponents and products are developed and produced in house, Q Electric railcar jumper
which guarantees optimally harmonised solutions. We offer you Q High-voltage roof-mounted jumpers
earth straps, standard cables made to national and international Q Train safety systems
standards, application-specific special cables, ready-to-connect Q Train radar
assembled cables, sub-systems as well as complete system solu-
tions for rolling stock applications such as high-speed trains,
locomotives, trams, Metros, diesel and electrical multiple units
and freight cars.
6 Engineering & Support www.leoni-traffic.com
Product development
Process-related support
Being resolutely focused on your Q On-site consulting Q Prototype building under near
core business means finding better Q One-stop shop for customised mass-production conditions
solutions faster and moreefficiently. and standardised solutions Q Planning and execution
Q Development of new materials for of separate and integration tests
Do benefit to the best possible cables intended for special operating Q assessing of optimisation potential
extent from our support services and conditions Q Design and building of special testing
technologies, and thus focus on your Q Development of system solutions facilities for system fatigue tests to
core business. based on prescribed interfaces demonstrate the required durability
Q Layout and design of tailor-made cable Q In-house equipment to test the layout
solutions of moving cable systems
Q Development of concepts for railcar Q Engineering science-based calcula-
jumper solutions through the early tions of durability using stress
stages of new vehicle platform designs modelling
Q Design of mechanical connections for Q Finite element calculations for cable
railcar jumper systems carrier and guide systems
Q Precise layout of lengths into the Q Climate and lifecycle tests for cables,
moving part of the cables according to system components and cable sys-
the specific relative movements of the tems; own fire test lab in house
car ends
Q Costing of maintenance and operation
across the entire lifecycle (lifecycle
costs) of railcar jumper systems
(LCC/RAM analysis)
Q Design to cost
www.leoni-traffic.com Engineering & Support 7
Implementation
Q State-of-the-art technology to produce Q Customer-specific logistics solutions Q Management of spare parts for com-
prototypes through to customer-speci- (just in time) ponents and systems up to 20 years
fic series production Q Installation outsourcing Q Retrofit service provider for updating
Q Production application and market- e. g. technical support during installati- systems in existing rolling stock
specific standard and special cables on of the jumper systems and training
Q Cutting, insulation stripping, attaching of the assembling as well as the main-
(using assembly robots) tenance staff
Q Soldering
Q Crimping (with assembly machines)
Q IDC (insulation displacement connec-
tors)
Q EMC-compliant assembly
Q Fitting of electronic and mechanical
components
Q Fitting of complete components/sys-
tems including metal and plastic parts
Q Making of plastic injection moulding
parts
Q Cable extrusion (connectors, sockets)
Q Global production and service presence
as required by your value creation
concept
8 Engineering & Support www.leoni-traffic.com
Process-related support
Project management
… for efficient solutions, worldwide … with an eye for the big picture
Complex projects require clear structures and processes. Highly qualified, internationally experienced project managers
We define the project objectives together with our customer, with inter-disciplinary and inter-cultural capabilities plan and
taking into account the set time and cost parameters as well coordinate all the jobs related to electrical connection techno-
as the available resources. logy within your overall project with respect to quality, costs
The key especially to international projects is to harmonise and time, worldwide. In doing so we use the latest communica-
widely varying technical, commercial, cultural, legal and poli- tion and project management tools that also correspond with
tical input. This is where we can bring the experience we have the IT set-up of our customers.
gained from numerous international projects effectively into
play. Once determined, we ensure that the individual stages Our project management incorporates all the phases of deve-
are adhered to and that the overall project is realised. lopment, production and installation of cable systems for rol-
ling stock
Q Particularly the planning and execution of development work
through to all the review and verification stages
Q Prototype building and first sample testing with the customer.
www.leoni-traffic.com Engineering & Support 9
Technologically leading
LEONI has attained a leading position worldwide
with its products. Particularly in the rolling stock
engineering sector, LEONI pools all its know-how
into a perfect whole and to an extent that virtually
no other cable manufacturer is able to offer. In addi-
tion there is the fact that LEONI continually invests
in new technologies, systems and processes and,
if required, also itself develops machinery and pro-
cesses to produce and test cable as well as cable
system solutions.
Areas of application
Materials
E-Cu/OF-Cu as well as Cu alloys; plain, tinned, nickel-plated
or silver-plated
Materials
E-Cu, plain, tinned, nickel-plated or silver-plated
12 Cable www.leoni-traffic.com
Arrhenius-Diagramm
Areas of application
Q Cable systems
Q Switch panels and units
Q Control panels
Q Cable ducts and bundles
Q Control consoles
Q Braking resistors and brake units
Q Power and signal cables for AC and DC
Q Inverters
Q Mains power and battery cables
Q Communication systems (ORMR, PIS)
Q Monitoring and recording systems (CCTV)
Safety All railway cables are flame retardant, low smoke and
halogen free. No corrosive gases are released in the event
of a fire, and our railway cables boast a low toxicity index.
The low fire load reduces combustion heat to a minimum.
Long lifecycle under LEONI railway cables withstand even extreme ambient
extreme operating and operating conditions because of their strong resis-
conditions tance to aggressive media (oils, fuels, acids and alkaline
solutions), UV and ozone resistance as well as strong
resistance to abrasion.
Depending on the cable type and standard, temperature
resistance ranges from –40 °C to +120 °C; in the case of
BETAtrans® GKW from –55 °C to +120 °C. Another key
property is the corona and partial discharge resistance
under heavy electrical load during operation.
BETAtrans® GKW
Product portfolio
Performance in case of fire
Standard Level of pro- Level of protection
tection inside outside vehicle
vehicle
BS 6853 Ia, Ib, II Ia, Ib, II
DIN 5510 1, 2, 3, 4 1, 2, 3, 4
NF F 16-101 A1, A2, B A1, A2, B
Classification C/FO
BETAtherm® ENgine
and BETAflam® ENgine
Product portfolio
permits ≥25 % higher current carrying capacity and incre- EN 50306-4 1E 300V MM 105 EN 50264-3-1 600V M
ases the longevity to three to four times that of chemically EN 50306-4 1P300V MM 105 EN 50264-3-2 600V MM
BENEFITS for OEMs and operators LEONI UIC cables are developed and produced to UIC specifica-
Q Halogenfree and flame retardant tions. They provide the ideal conditions for use as connection
Q Low smoke density and corrosiveness of fumes cables between the cars and as either through connections or
Q UV and ozone resistance supply cords inside the cars.
Q Heat pressure resistant and abrasion proof
Q Resistant to oil, acids and alkaline solutions They transmit both analogue and digital signals, e.g.
Q Flexible when cold Q For train crew voice communication
Q Remote control of train components (e.g. doors)
Q For power supply and controlling the electro-pneumatic
brake
Details will frequently determine the performance and safety Our additional services
of a cable. Special cable solutions by LEONI are matched pre- Q Production of short lengths (starting at 100 m of cable)
cisely to their intended purpose in a function-optimised way, Q Prototype cables
no matter whether that involves a flexible or fixed-installed Q Implementation of cable design
application. Q Through to finished cable within a few weeks
Q Patented solutions for power cables operating with high
Such individual cable design as well as the use of specially currents at higher frequencies through to rectangular current
developed sheath and insulation materials provide strong dura- flow (optimised for skin effect and EMC)
bility under thermal and mechanical strain. LEONI special cable
solutions are developed and produced to national and interna-
tional standards for the railway industry.
www.leoni-traffic.com Special Cables 19
Because of their special properties, fiber optic cables are used LEONI provides two types of FO cable:
in rolling stock projects especially where rapid and disruption- Q Pure FO cables that contain nothing but either glass or poly-
free communication is required, such as in operator and control mer fibers (halogen free and flame retardant pursuant to IEC
panel connection. 60332-1 and IEC 60332-3)
Q Fibre optic cables also available as customised hybrid cables
20 Cable Systems www.leoni-traffic.com
Engineering services
Areas of application
This can result in the design solutions which have very different
requirements, because train operators transfer the respon-
sibility for the availability of rolling stock to our customers,
according to country-specific specifications. This resulted, for
example, in the creation of completely new inter-car jumper
systems concept for high-speed trains. Based on frame condi-
tions given by the customer, several options were developed
and discussed, evaluated in terms of profitability and incorpora-
ted into the specifications by the customer.
The requirements for inter-car jumper systems range from the In this feasibility study, the end users requested, amongst other
electrical characteristics to the resistance to severe environ- things, a very high capacity to absorb vertical forces. To meet
mental conditions and the mechanical strength of the systems this design specification, our engineers developed a special
themselves. strain relief system that can be tailored to the particular moun-
ting interface and be validated as a complete system.
22 Cable Systems www.leoni-traffic.com
LEONI manufactures roof jumpers as a double helix, which BENEFITS for OEMs and operators
thanks to the sophisticated cable design and the use of spe- Q Full compensation of the three-dimensional relative
cially developed jacketing and insulation materials ensures movements at the fixing points
excellent bending strength and flexibility even when subject Q High operational reliability through redundant design
to the highest mechanical, physical and chemical strains. The (double helix), electrically or mechanically
highly flexible cable system compensates for permanently Q Available in different cross sections depending on power
occurring oscillations and changes in length of up to ± 1000 mm. supply
A high hydrolytic stability, good rebound properties at tempe- Q Thanks to its intrinsic performance, fail-safe insulation
ratures from – 30 °C to + 80 °C are also achieved, as is high UV distance to gangway bellow underneath, even in the event
resistance. The cable meets the requirements of IEC 60332-1. of one or both spirals is ruptured
Q Mounting on insulators or terminals
Q Customer-/ application specific connection
Q Product qualification and validation through life testing
Engineering at LEONI (analysis, design)
www.leoni-traffic.com Cable Systems 25
Build-to-Print Refurbishment
The cable systems are manufactured or assembled in our Modernization, general overhaul, upgrading
factory, based on the 2D illustration taken from the design- When managing refurbishment projects, project managers
to-build process. The term Build-to-Print describes the cable and system engineers cooperate closely with the experts from
assembly (Build) with the help of the Print on the cable boards. manufacturing and production. As part of this cooperation, we
Q Cutting analyse the specific needs of the installation situation, looking
Q Marking for solutions that meet the existing conditions and then imple-
Q Assembling menting the optimal solution.
Q Retention Test (test for proper engagement of the crimp
contact inside the connector)
Q Electrical Continuity Test (network test), insulation, dielectric
strength, four-terminal measurement where required by the
customer
Q Examination (visual inspection for obvious defects)
Local presence is a key to success for us. Our customers include a large number of companies
Our worldwide presence makes it easy for our partners to
use all our services quickly and straightforwardly. Q Alstom Transportation Q MVG (Münchner Verkehrs-
Q Global production and service network Q Bombardier Transportation gesellschaft GmbH)
Q Assurance of high product availability Q BVG (Berliner Verkehrs- Q Österreichische Bundes-
Q Local process monitoring as well as process and product betriebe) bahnen
optimisation Q CAF Q RhB Rhätische Bahnen
Q Customised logistics solutions Q CMKS Q Schweizerische Bundes-
Q On site installation Q CNR Changchun Railway bahnen
Q Spare parts management Vehicles Ltd. Q Siemens Mobility
Q CNR Tangshan Railway Q Skoda
Vehicles Ltd. Q Stadler Rail
Q CSR Zhuzhou E.L.W. Q Vossloh Kiepe GmbH
Q Deutsche Bahn Q Windhoff Bahn- und An-
Q Gmeinder Lokomotiven- lagentechnik GmbH
fabrik GmbH Q ZOS Trnava
Q Graz-Köflacher Eisenbahn
Q HYUNDAI Rotem
Q Matisa Materiel
www.leoni-traffic.com 27
Service
Engineering
Cable systems / Wiring Systems
LEONI is a worldwide system and development provider for Success in a variety of markets
wire, cable and wiring systems. Employing over 50,000 people As well as products for the automotive, commercial vehicle
in 36 countries, the Group achieves excellent results on the and supplier industries, LEONI’s services in the “Wire & Cable
basis of solid financial management and offers quality of the Solutions” division include copper wires and strands, cables and
highest technical standard in all areas. We implement our special cables, as well as cable systems and services in line with
“Quality Connection” motto by always developing the best customer specifications.
quality solution for our customers and by seeking to provide End users are companies in the automotive, communication
the best possible service in every project we work on. We sup- and infrastructure, industry and health, domestic appliances as
ply products and solutions to leading German industrial busi- well as wires and strands markets.
nesses and many market leaders in their respective areas.
LEONI is actually the world market leader for vehicle cables. Our
Market leader and leading system provider wire products have made us a leading system provider for the
The Wiring Systems Division is one of the two business areas of special cable and component industry. The particular strength
the worldwide LEONI Group. LEONI is the market leader in the of LEONI within the cable business is its ability to manufacture
wiring systems sector in Europe and is ranked number 4 in the both standardised cables and customer-specific special cables
global league. We aim to lead our competitors in terms of cost and assembled systems. We work with different processes
and are one of the few providers with a global network of pro- used in all technologies. This is your opportunity to make use
duction and development locations. of these unique synergy effects and to tap into the enormous
potential available within the LEONI Group.
LEONI Elocab GmbH Industriestraße 27
Business Unit Traffic 91187 Röttenbach
Deutschland
Phone +49 (0)9172 6844-0
Fax +49 (0)9172 6844-29
E-mail rollingstock@leoni.com
www.leoni-traffic.com