Application of Cables in Automotive Air Conditioning Systems

1. Scene Introduction

With the continuous development and improvement of urban rail transit systems, the importance of train air conditioning system is becoming more and more prominent as a key system to ensure passenger comfort and the internal environment of the train. As a key component connecting air conditioning equipment, control system and power supply, the performance and quality of train air conditioning system cables are directly related to the stable operation of the air conditioning system and passengers’ riding experience. Therefore, professional rail transit train air conditioning system cable solutions are particularly important.

2. Pain point analysis

In the rail transit train air conditioning system, the use of cables often face the following pain points:

High weather resistance requirements: the train operating environment is variable, the cable needs to withstand the impact of different climatic conditions, such as high temperature, low temperature, humidity, etc., to maintain stable electrical performance.
High mechanical strength requirements: the train will produce vibration and impact in the process of traveling, the cable needs to have enough mechanical strength to cope with these challenges.
Signal transmission stability requirements: air conditioning system involves a number of control signal transmission, the cable needs to ensure accurate and fast transmission of signals to avoid signal interference or attenuation leading to system misoperation.

3.The train air conditioning system on the cable requirements

For the special needs of rail transit train air conditioning system, the cable needs to meet the following requirements:

Excellent weathering performance: able to operate stably in a variety of harsh climatic conditions, resisting the erosion of ultraviolet rays, high temperature, low temperature and other natural factors.
High mechanical strength: sufficient tensile, bending and vibration resistance to ensure stable operation during train travel.
Low impedance and low attenuation: Ensure efficient and stable transmission of power and signal, reduce energy loss and signal distortion.

4.Certification Standards

The cable products in this solution comply with the following international and domestic certification standards:

IEC 60349: the international standard for railroad vehicle cables, which strictly stipulates the electrical performance, mechanical performance and environmental adaptability of cables.
EN 50264 EN45545: European standard for cables used in rail transit, with specific requirements for flame retardancy, oil resistance and other aspects of the cable.
RoHS: A directive restricting the use of certain hazardous substances to ensure that cables are environmentally friendly during production and use.
GB/T 12706 is a Chinese national standard mainly applicable to extruded insulated power cables and their accessories with rated voltage from 1kV to 35kV.
TB/T 3159 is the Chinese railway industry standard, specifically for rolling stock cables.
In addition, TST CABLES products have been certified by quality management system (such as ISO 9001), environmental management system (such as ISO 14001) and product certification.

5.Cable Selection

According to the specific needs of the air conditioning system of rail transit trains, we recommend the following cable options:

Low smoke and halogen-free flame retardant cables: with special materials and structural design, they have excellent flame retardant performance and low smoke and halogen-free characteristics to ensure that the release of smoke and hazardous substances is reduced in emergencies such as fires.
High-strength flexible cable: with high flexibility and excellent mechanical properties, it can adapt to the requirements of train vibration and bending, and at the same time ensure the stable transmission of power and signal.

Selection parameters for reference (can be customized according to actual needs)
Temperature resistance: -50°C to 125°C
Rated voltage: 600V
Insulation strength: >10MPa
Elongation at break: >125%
Fire rating: HL3 according to EN45545-2 R15/R16
High-precision tinned copper, excellent conductivity and long service life.

6.Product characteristics

The cable products in this solution have the following characteristics:

Excellent weather resistance: special materials and technologies are used to improve the weather resistance of the cables and ensure stable operation under various climatic conditions.
High Mechanical Strength: The cable structure is sturdy enough to withstand train forces such as vibration, shock and bending, ensuring the integrity and electrical performance of the cable.
Low impedance and low attenuation: Optimized cable conductor and insulation materials reduce impedance and attenuation to ensure efficient transmission of power and signals.

Recommended Products

Vehicle air conditioning system cables are tensile resistant and well insulated, and are an important component for transmitting control signals and power between the air conditioning unit, temperature sensors and control module

7.Technical Tests

To ensure that the quality and performance of the cables meet the requirements of aircraft air-conditioning systems, TST CABLES conducts a series of rigorous technical tests. These tests include electrical performance tests, environmental adaptability tests, flame retardant performance tests, etc. to ensure that the cable meets or exceeds international aviation standards in all performance indicators.

8.Cable laying installation and commissioning

In the process of cable laying and installation of train air-conditioning system, TST CABLES will formulate a reasonable cable routing plan according to the layout and structure of the train air-conditioning system. Meanwhile, TST CABLES will provide professional commissioning guidance to assist customers in completing the connection and commissioning of the cables with the train air conditioning system to ensure the normal operation of the system.

9. After-sales maintenance & technical support

TST CABLES provides comprehensive after-sales maintenance and technical support services, including regular inspection, troubleshooting, repair and replacement of cables for train air conditioning system cables. Our professional team will provide technical support and solutions for customers at any time to ensure the stable operation of the train air conditioning system cable and customer satisfaction.

10. Actual Cases

In the subway projects of many large cities in China, TST CABLES provides high-performance data transmission cables for vehicle safety monitoring system.TST CABLES EN50264 series and EN50306 series cable products for rail transportation have obtained CRCC certification. Over 500,000 cables have been installed in more than 3,500 high-speed rail coaches, with a running mileage of over 6,000,000 kilometers. We have successfully applied the air-conditioning system cable for rail transit trains in this solution. After long-term operation verification, the cable shows excellent weather resistance, mechanical strength and signal transmission stability. Compared with traditional air-conditioning system cables, the failure rate of this cable has been reduced by 98% and the signal transmission efficiency has been improved by 97%. At the same time, due to its excellent flame-retardant properties, the project has achieved a significant improvement in fire safety.

In summary, this cable solution for rail transit train air conditioning system takes into full consideration the special needs and actual operating environment of train air conditioning system, and provides stable and reliable cable solution for train air conditioning system in rail transit industry through high-quality product selection, technical testing, and professional laying installation and commissioning services. We will continue to provide customers with better products and services to promote the sustainable development and safe and sound operation of the rail transportation industry.

Other solutions for cables in railway applications.


10 years of experience

Specializing in the production of railway cables for 10 years

Engineer-to-engineer one-on-one support

Engineers provide one-on-one service to assist with product selection and problem-solving

Customization according to requirements

With a strong R&D team, we support customized cables based on specific needs

Quality certification

Stringent adherence to industry standards, complete certification

Fully testing facilities

Various tests based on customer requirements

10,000 ㎡ factory

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