Rolling stock

AB Connectors-at the forefront of innovation

AB Connectors, part of TT Electronics Plc, is recognised as a market leader in the design and manufacture of connectors and interconnection systems for the harsh environments found in the rail industry, where high performance and reliability are crucial. It supplies bespoke, custom engineered solutions to many of the major players in the sector, including Bombardier, Alstom, Knorr-Bremse, Thales Communications and Wabtec.

With over 50 years as a pioneer in the sector, AB Connectors has exceeded the exacting requirements of the traction market. through continuous research and product development, extensive testing, manufacturing investment and industrial competence. By working with state of the art CAD/CAM facilities, rapid prototype techniques and modern CNC equipment, coupled with strong technical expertise, AB Connectors uses its comprehensive product range as a platform to provide custom engineered solutions, significantly reducing customer development time, costs and risks.

The company has particular experience in designing connectors and harnesses for inter-car jumpers for onboard electronics such as passenger information systems. Such systems are becoming vitally important in today’s rail industry as they provide important safety and security advice and form a crucial part of many operators’ safety policies. They also improve passengers’ travelling experience by giving real time information on station stops, destinations and onboard facilities and many travellers have come to expect them onboard. Indeed, functioning audio-visual passenger information systems are now a legal requirement for all new build trains and many operators and leasing companies are also investing in retro-fit programmes to increase the appeal and life expectancy of existing rolling stock.

AB Connectors was recently appointed by turnkey enhancements provider Transys Projects to design harnesses for ONE Railway and HSBC Rail. The harnesses were required for inter-car jumpers to allow data to be fed smoothly between carriages in order to update passenger information systems and onboard CCTV monitoring.

Working in close contact with the Transys Projects’ engineering team, AB Connectors created a unique single-harness design with a 90 degree elbow-fitted fixed plate on the car face, allowing the cable conduit to drop away vertically. This differs from standard formations of one fixed jumper with one harness or one fixed jumper with two fixed harnesses, creating a low profile which dramatically reduces the intrusion within the inter-vehicle space and achieving considerable cost savings.

The design delivers high speed data transfer whilst withstanding oscillations in temperature, corrosion from the elements, extreme weather conditions, water, salt and dust ingress and flying ballast. The critical inter-car coupling is extremely robust and will not disengage as a result of the vibration and motion of the train. Like all AB Connectors designs, the connectors incorporate low fire hazard thermo-plastic insulators and are manufactured using zero halogen rubber, a material which does not produce toxic fumes in the event of a fire.

The harness has major advantages in terms of railway performance. Interconnection systems have traditionally been a weak spot in train reliability. With trains carrying more and more electronics, the failure of a basic component can completely halt a service, resulting in a knock on impact on passenger experience, reputation and operating profits. However, AB Connectors’ design uses innovative features and advanced materials to ensure durability, strength and complete resistance to the harsh environments and rigours of rail applications.

Onboard staff and passengers will also benefit directly from the ability of the harness to provide effective and reliable PIS and CCTV, both of which significantly enhance safety and security and make a vital contribution towards creating a more user friendly, accessible and efficient railway.

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