INDUSTRY FOCUS RAIL
CONNECTORS: SUPPORTING RAIL INFRASTRUCTURE TRANSFORMATION
As the global rail industry accelerates towards full automation, the supporting technologies behind the scenes are just as vital as the software that guides the trains. Connectors are playing a crucial role in delivering the reliability, safety and performance required by Rail 4.0. Karen James, product manager at PEI-Genesis, comments
Bahn is trialling fully automated trains in Hamburg; and the East Japan Railway Company (JR East) is advancing plans to introduce driverless Shinkansen bullet trains by the mid- 2030s. Such efforts – which signal a wider shift towards rail systems built around AI, real-time analytics and high-speed communication – depend on reliable interconnect technology
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SOLUTIONS THAT WITHSTAND HARSH CONDITIONS Rolling stock and trackside hardware often have to face harsh conditions. They are exposed to constant vibration, temperatures from -55˚C up to +200˚C, humidity, and exposure to contaminants such as dust, oil and de-icing agents. Added to this, electromagnetic interference (EMI) generated by traction drives and overhead cables can jeopardise signal integrity unless connectors are effectively shielded. To withstand such conditions, the connectors designed for rail applications must be ruggedised to meet stringent international standards such as EN 50155 and EN 45545-2, NFPA 130, VG 95234 and MIL-DTL-5015. These define the connector’s ability to withstand shock, vibration, fire exposure and long-term environmental stress. RoHS and REACH variations, along with corrosion resistant platings, make for rugged and reliable interconnect solutions in the harshest environments. For autonomous trains, the connectors must also be capable of supporting high-speed data transmission protocols such as Gigabit and
38 DESIGN SOLUTIONS JUNE 2025
cross the world, rail operators are making significant investments in digitalisation and automation. In Germany, Deutsche
10-Gigabit Ethernet (typically Cat 6A and Cat 7), USB 3.1 and fibre optic interfaces. These protocols are essential for handling real-time data streams from sensors, LiDAR systems, onboard diagnostics and communication networks. Data rates in these environments can exceed 10 Gbps, especially when multiple high- bandwidth systems, such as video surveillance, telemetry and predictive maintenance sensors, are operating concurrently. Another factor is mechanical resilience. Connectors generally incorporate bayonet or threaded coupling systems to maintain secure connections under vibration; and contact retention mechanisms are designed for longevity, often rated for thousands of mating cycles. Contacts are generally gold- plated to minimise corrosion and offer low contact resistance for a prolonged time, but these are also available in silver-plated versions. Another crucial factor is ease of maintenance,
particularly for retrofit applications. Modular connector designs and coding schemes enable simple installation and error-proofing, while quick-disconnect configurations ensure quick field servicing with minimal downtime.
FUTURE-PROOFING RAIL CONNECTIVITY As Rail 4.0 evolves, so too must the technology that supports it. Upcoming innovations in train autonomy and electrification demand connectors with greater bandwidth, higher power ratings and smarter integration capabilities. As an example, the development of distributed
traction systems and battery-electric multiple units (BEMUs) introduces new requirements for high-voltage, high-current connectors that can
handle regenerative braking energy and rapid charging. These connectors must include safety interlocks, arc suppression features and compliance with standards such as IEC 61373 for shock and vibration. In addition, increased deployment of real-time
diagnostics and condition monitoring means that connectors must support multiple sensor interfaces. Emerging designs now incorporate built-in diagnostics, enabling connectors themselves to report on temperature, contact resistance, or mechanical wear, turning passive components into intelligent assets. Another key trend is modularity. Future rail
systems will demand flexible, reconfigurable architectures to accommodate upgrades and regional customisations. Connectors that support daisy-chaining, backplane mounting and tool-less assembly are increasingly favoured to reduce downtime and simplify system expansion.
MEETING RAIL STANDARDS Meeting rail industry requirements, PEI- Genesis’ portfolio includes high-power solutions designed to handle demanding electrical loads, as well as high-speed data connectors used in communications and control systems. These connectors are designed to meet strict global rail standards, including EN 50155. With modularity and rugged design as core
principles, the company’s connectors support applications ranging from onboard control systems to trackside signal units, playing an essential role in powering the next generation of autonomous rail technology.
PEI-Genesis
www.peigenesis.com/en/rail
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