The EPHY-MESS Modular Concept
Requirements for railway industry sensors
To ensure that production and operating costs are held within acceptable limits, the following requirements apply to rolling stock sensors.
- low construction costs
- safe operation
- low interference susceptibility
- high availability
- rapid and safe disconnection from vehicle during maintenance
- favourable price
In order to meet these needs, EPHY-MESS has developed a modular concept for sensors in rolling stock.
The modular concept is based on four main components:
The sensor must resist extreme vibrations over a long period of time. Available are 1 x Pt 100 (2-, 3- or 4-wire circuitry) or 2 x Pt100 (2-wire circuitry). Highly shock-proofed types are available with stainless steel protection tube from Ø 5 mm to 12 mm. The protection tube length, the size and position of fixing bores are specific to customer´s requirements.
EPHY-MESS speed sensors provide contact-free (Hall effect) measurements and generate signals as incremental impulses. By this means the rotational direction and speed of locomotives, multiple units and high-speed trains are monitored.
The cable connection is resistant to stone impact, cleansing liquids, salts, alkalis and other external influences. Halogen -and silicone-free shielded wires are used for this purpose optionally with an additional fabric protection hose, as well as polymer or metal corrugated hoses with specially sealed contact zones.
The plug connector needs increased corrosion protection. Heavy duty sealed plug types, for example Harting, Amphenol, ITT, HTS are offered. Adjusted to the specific requirements they ensure trouble-free signal transmission.
In addition to the assembly groups you will receive installation material that is specifically designed for the product and a service packet covering the product from first design to setting into operation.
The modular concept combines proven components. It ensures safe operation, excellent service quality and high reliability. The possibility of flexible combination of sensors, cable and plug connectors makes it possible to configure sensor systems that meet all the requirements of the railway industry.
Functionality of the Modular Concept
The conceptual design of a wiring harness for rolling stock can be accomplished very easily in a short time. Let us know which type of temperature sensor (preferably standard), and how many are required. Either you select the type of speed sensor, or we make a recommendation depending on your request. You will receive our proposal for the most suitable wiring harness for your project.
Combination of elements
The elements of the modular concept can be widely combined to create a customized sensor or wiring harness.
Each sensor consists of a measuring element, wiring and, if needed, a plug connection with tension release.
Temperature sensor, cable and plug
Two temperature sensors, cable and plug
Speed sensor, cable and plug
Temperature sensor, speed sensor, cable and plug
With one wiring harness up to four sensors can be combined to one main cable that is connected via one plug. Fixed intergration of components within the wiring harness is also possible, as well as the use of additional separating plugs which could be necessary for installation and service.
Usually each sensor cable is single shielded into the final plug to minimize the influence of electrical interferences.
The pictured example shows a cable system used in high speed trains, consists of the following system and sensor components:
three double-temperature sensors,
two temperature sensors equipped with separating plugs (for cable ducts)
separating plugs with defined angles installed in two levels
one speed sensor, steadily connected
single cable of all sensors combined to one system cable using waterproofed cable transition (IP65)
all sensor cables single shielded (also within the plug and transition)
unification of all signal wires into one system plug at exchange node
wiring system in protection class IP65 (waterproofed)