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Reliably closing doors secure underground railway operation of the VAG Nürnberg - chainflex® cables prevent expensive failures and meet strict fire protection standards


Profile

  • What was required: Fire-resistant energy supply system with high reliability
  • Requirements: Small bend radii, frequent unroll cycles, halogen-free and flame-retardant according to IEC 60332-1-2, CEI 20-35, non-toxic according to EN 50305-9.2 & low smoke density according to EN 61034-2 
  • Product: chainflex cable CFSPECIAL.414 
  • Field of application: Railway technology, rail vehicles
  • Success for the customer: The availability of vehicles is thus the ultimate goal, to have the timetable under control. Each door has to cope with around 70,000 open/close cycles per year.

About underground railway door systems: Particularly in operations under the earth's surface, strict fire safety guidelines and their compliance guarantee that a safe operation is ensured and disasters can be potentially prevented.  This is especially true for the automatically closing and opening doors, when the cables have to cope with extremely small bend radii and frequent unrolling operations. Every ten years, a door is therefore completely repaired in order to continue to ensure functionality and safety in the long-term.

chainflex secure underground railway doors

chainflex cables in railway technology

Challenge

To ensure a smooth operation of the vehicle, all used components are subjected to an ongoing inspection. This is especially true for the automatically closing and opening doors, when the energy supply systems have to cope with extremely small bend radii and frequent unrolling operations. Robert Meier of the subway automotive engineering division explains: "Since 2010, automatic subway vehicles have been running on two of the three lines, in which the handling of the vehicles is also automatically carried out, apart from individual stations in the rush hour. A new vehicle arrives at the station every 100 seconds, and the stay is a maximum of 30 seconds. If doors fail here, the whole process is disrupted. " The availability of a total of 46 newly purchased vehicles is thus the ultimate goal, to have the timetable under control.
 
Furthermore, high fire safety requirements for rail vehicles in recent years have led to the creation of necessary standards to prevent smoke development and limit the spread of smoke.


Solution

Here igus relies on its chainflex cables, which have been designed for moving applications in energy chains. They extend the maintenance intervals in this area up to 16 years, as could be verified through tests. The CFSPECIAL.414 was specially developed for moving applications on railway vehicles. Its jacket material is halogen-free and flame-retardant according to IEC 60332-1-2, CEI 20-35. Moreover, it proves to be non-toxic in accordance with EN 50305-9.2 and has a low smoke density in accordance with EN 61034-2. Thus the cable meets the high requirements in terms of fire protection for railway vehicles.
 
The bend radius also meets the requirements of the VAG, the cables are suitable for up to two million cycles in the energy chain, which means that there is still sufficient reserve for a service life of 20 years.
 

Straight to CFSPECIAL.414

Underground railway doors project team Increasing demands on the doors led to further exchanges between the VAG executive Robert Meier (centre) and the igus sales manager Werner Pecher (left) and product manager Andreas Muckes (right).
Underground railway doors with CFSPECIAL.414 The chainflex cable CFSPECIAL.414 used at present was specifically designed for moving applications in railway vehicles. In the trains of the VAG Nürnberg, it is moved safely and reliably in compact energy chains of the E2.15 series.