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Connected By Rails
By Roger E.
Rickey, Bishop & Associates Inc.
The global railroad
passenger vehicle industry includes production of new locomotives
and passenger cars, maintenance and refurbishment of old vehicles,
electrical/electronic control systems development, installation of
electrification devices, signaling services, and other equipment.
Unlike similar forms of commercial transportation, this market (by
value) increased at a compound annual growth rate of 9.1% from 2004
to 2009, is expected to accelerate at a 10.7% compound annual growth
rate (CGAR), and achieve revenues of $39.1 billion by 2015.
Geographically, Europe will remain the leader in the passenger rail
market, while Asia Pacific, with its population growth and resultant
higher passenger-to-kilometer ratio, will capture second place.
Russia is also modernizing its rail industry. During 2009, Russia
built 428 locomotives, 841 passenger, and 33,400 freight cars, which
achieved annual turnover of $5.6 billion, approximately 1.1% of its
GDP. It is anticipated that between 2010 and 2015, Russia will
produce an additional 7,504 locomotives, 8,540 passenger, and
485,500 freight cars to complete its rail transportation system
modernization project.
China is
significantly expanding its high-speed rail system, and especially
its highly successful ultra-high-speed Mag-Lev rail system. In the
next five years, China will surface as the largest high-speed train
market.
More stringent changes to global emission standards regulations will
hasten the growth of hybrid locomotives, which will demand creation
of a new generation of high-current, high-voltage electrical and
electronic interconnect systems. The hybrid locomotive market is
expected to become more prevalent later this decade, and achieve a
CAGR of 6.7% between 2010 and 2020.
U.S. Railway
Connector Market
Unfortunately for those people who would prefer to bypass the hassle
of airport security pat downs, the total North American passenger
railway industry is very likely to continue to lose its market
position because of the continuing popularity of personal passenger
cars, as well as the potential loss of rail subsidy funding. Since
2004, U.S. production of locomotives, passenger, and freight cars
has been on a steady decline, and regrettably, recovery is not
predicted for the near distant future. Historical volumes are
listed in the table below:
U.S. Railway
Vehicle Sales
U.S. Railroad Passenger Vehicles
Locomotives and passenger car rolling stock contain very complex,
high-mix, electrical systems that require a great variety of wire
harnesses, electrical connectors, and terminals. Unit volumes,
however, are quite low. Locomotive manufacturers include General
Electric, General Motors Electromotive Division, and Progressive
Rail Services (Caterpillar). American Car & Foundry (AMF),
Bombardier, and Siemens AG are the major passenger car
manufacturers. Leading wire harness and connector suppliers are
Northwest Rail Electric, Pyle-National, and
Stäubli
Group.
Railroad Electrical System Components
The
following depicts electrical components typically found in railroad
electrical systems that require a variety of electrical connectors.
1. Head-End Power System:
Railroad
passenger trains contain a head-end power source, usually the locomotive or a separate generator car, that generates all
electrical power needed by the train. Distribution to each passenger
car is achieved by using separable wire harnesses and connector
assemblies.
2. HVAC and Controls: Pictured below is a modular
HVAC control system assembled for use in controlling the heating,
venting, and air conditioning, and an under-car air conditioning
condenser unit.
Typical HVAC performance requirements are:
Operating
temperatures: -40°F to 110°F
Electric rating:
400 amps, 600 volt
Dielectric
strength: 2,000 volts
Body material:
DuPont Hypalon™ Rubber
Mating/unmating
force: 70 lbs. max.
3.
Communications
and Multi-Unit
Interconnect Systems
are typically not part of the head-end power system, but are used to
conduct power and signals to communications devices and other
electronic control modules.
4. Passenger Car Electric Locker Packages:
Electric locker packages usually include HVAC controls at the top,
120-volt circuit breakers in the middle, and 480-volt circuit
breakers at the bottom of the package.
5.
DC Control Systems:
Direct current systems power everything
from simple battery-powered lights to 32-volt DC air conditioning
systems, marker lights, ditch light systems, etc. More complicated
systems include battery charging, circuit breaker panels, and
voltage indication. DC control systems can also include a number of
solid-state DC-DC converters for a wide variety of voltages, ranging
from 12 to 72 volts. DC systems are typically a sub-set of the
electrical locker package.
6.
Circuit Breakers:
This DC circuit breaker panel includes
two-pole circuit breakers for a number of different loads, including
headlights, marker lights, the turbine generator, and a 32-volt DC
voltage indicator.
7.
Battery Chargers:
Used to convert 480 volt, three-phase power
from the head-end power system to charge 120-volt nickel cadmium
batteries.
8.
Custom PLC Control Systems:
Programmable Logic Controllers (PLCs)
are very common in railroad passenger cars for a wide variety of
destination sign controls, HVAC controls, data acquisition, and
management.
9.
Overhead and Baseboard Heaters:
480 volt, three-phase
configuration heater element capacity ranges from 18kW to 24kW.
Overhead heaters may be configured to operate on either 240 or 480
volts, use ring terminals for connection, and contain built-in
high-limit switches for controlling blowers and circuit breakers.
Baseboard heaters are 208 volt, low profile units with low watt
density heating elements to prevent overheating, and maximize
passenger comfort and safety.
Unlike the historical
decline of U.S. railroads, other countries demonstrate that internal
planning is assisting their railroad Industries to achieve
significant growth by implementing new rail technology, improving
infrastructure, as well as producing improved, low-cost
(passenger-per-kilometer) passenger rail transportation vehicles.
This, in turn, will provide major new opportunities for the global
connector industry.
References:
http://www.marketresearch.com/product/display.asp?productid=2553811
http://www.bharatbook.com/detail.asp?id=158973&rt=Global-Passenger-Rail-Market-2010-2015-Market-Size-Market-Share-and-Growth-Forecast.html
http://findarticles.com/p/articles/mi_m0BQQ/is_10_47/ai_n27419132
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Roger
E. Rickey, Market Director,
Automotive
and Non-Auto Transportation, Bishop & Associates Inc.
Roger E.
Rickey has more than 30 years experience in the automotive and
electronics industries, including four years experience as plant
manager with Chrysler Huntsville Electronics Division, a leading
electronics manufacturer. Most recently, as president of R.E. Rickey
& Associates Inc., he worked as an international management
consultant with several Fortune 500 clients, including major
automotive OEMs.
Rickey began his career in engineering with Ford Motor Co. and was
chief engineer and director of engineering with United Technologies
Automotive Products Division. He holds degrees from Eastern Michigan
University and Southern Illinois University, and served as an
officer with the U.S. Army in Vietnam. He holds two Bronze Star
Medals and an Army Commendation Medal. |
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