Application of Cables in Rail Transportation Lighting Systems

Application of Cables in Rail Transportation Lighting Systems

1.Scene Introduction

With the rapid development of urban rail transit construction, the lighting system, as an important part of rail transit infrastructure, has an irreplaceable role in enhancing passenger experience and ensuring traffic safety. Lighting system cable as a link between power supply and lighting equipment, its performance and quality are directly related to the stability and reliability of the lighting system. Therefore, professional lighting system cable solution for rail transit is especially critical.

2. The pain point analysis

In the practical application of rail transit lighting system, cable products often face the following pain points:

Insufficient weather resistance: lighting system cables are exposed to the outdoor environment for a long time, and are susceptible to temperature, humidity, ultraviolet rays and other natural factors, resulting in cable aging, cracking, affecting the lighting effect.
Unstable electrical performance: some cables, after a long period of operation, the conductivity decreases and the insulation performance weakens, which may lead to lighting equipment failure or safety hazards.
Installation and maintenance difficulties: rail transit lighting system cable laying environment is complex, limited installation space, maintenance difficulties, the flexibility and reliability of the cable puts forward high requirements.

3. The rail transit lighting system on the cable requirements

For the characteristics of the rail transit lighting system, the cable needs to meet the following requirements:

Excellent weather resistance: able to operate stably for a long time under a variety of harsh environmental conditions, resistance to temperature, humidity, ultraviolet radiation and other factors.
Stable electrical performance: with good electrical conductivity and insulation properties, to ensure stable power supply of the lighting system.
High flexibility: adapt to complex laying environment, convenient installation and maintenance.

4.The certification standards

In order to ensure that the performance and quality of the rail transit lighting system cable meets the industry requirements, the cable products in this solution fully comply with the following international and domestic certification standards:

IEC 60349: the international standard for rail transit 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 actual demand of rail transportation lighting system, we recommend the following cable selection:

Low-smoke halogen-free flame retardant cable: low-smoke halogen-free flame retardant materials are used to reduce the risk of fire, and at the same time reduce the emission of harmful gases.
Flexible weather-resistant cables: with high flexibility and excellent weather-resistant performance, adapting to the use of various harsh environmental conditions.

Selection parameters for reference (can be customized according to actual needs)
Temperature resistance: -40-90°C
Voltage resistance level: 600V (test voltage 3500V/5min)
High precision tin-plated copper, good conductivity, long service life
Conductor: silver-plated copper conductor class 5 structure
Insulation: irradiated cross-linked polyolefin
Winding: mica tape
Insulation: irradiated cross-linked polyolefin

6.Product characteristics

The cable products in this solution have the following characteristics:

Excellent weather resistance: designed with special materials, it can resist the erosion of UV rays, humidity and other natural factors to prolong the service life.
Stable electrical performance: the conductor is made of high-quality copper, and the insulation layer is made of high-performance materials to ensure that the cable has good electrical conductivity and insulation properties.
High flexibility: the cable has a small bending radius, adapting to complex laying environments and facilitating installation and maintenance.
Low-smoke halogen-free flame retardant cable: with low-smoke, halogen-free and flame retardant properties, it can reduce the production of smoke and toxic gases in case of fire and improve the safety of evacuation.

Recommended Products

Rail transit lighting cables are high temperature resistant and have a rated voltage of 600V. They are an important part of the lighting provided in various areas of the rail transit system (including passenger compartments, platforms and stations).

7. Technical Test

To ensure the performance and quality of the cable products, we conduct a series of strict technical tests, including:

Weathering test: The cables are subjected to high temperature, low temperature, humidity and other harsh environments for a long time to verify their weathering performance.
Electrical Performance Test: Test the electrical parameters of the cable such as conductivity, insulation resistance, voltage resistance, etc. to ensure compliance with the design requirements.
Flexibility test: simulate the actual laying environment, test the performance of the cable in different bending radius.

8. Cable laying installation and commissioning

In the process of cable laying and installation, TST CABLES will formulate a reasonable cable routing plan according to the layout of the lighting system and the structure of the rail transit facilities. At the same time, TST CABLES provides professional commissioning guidance to assist customers to complete the connection and commissioning of the cable and train lighting equipment to ensure the normal operation of the lighting 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 rail transit lighting system cables. Our professional team will provide customers with technical support and solutions at any time to ensure the stable operation of the lighting system cables and customer satisfaction.

10.Actual Cases

In the expansion project of Shenzhen metro line, due to the problems of aging and high failure rate of the original lighting system cable, it was decided to adopt the rail transportation lighting system cable solution provided by TST CABLES. The project covers the upgrade of the lighting system in many areas such as subway platforms, tunnels and station halls.

During the project implementation, TST CABLES first conducted a comprehensive assessment of the existing lighting system to determine the scope and quantity of cable replacement. Subsequently, a detailed cable laying plan was developed based on the layout of the lighting system and the structural characteristics of the metro station. For cable selection, we chose cable products with excellent weather resistance, high flexibility and low-smoke halogen-free flame retardant properties to ensure the stability and safety of the lighting system.

In the cable laying and installation phase, we sent a professional technical team to provide on-site guidance to ensure that the cable laying complies with the specifications and is well connected to the lighting equipment. At the same time, we also carried out comprehensive technical tests on the installed cables to ensure that their performance met the design requirements.

The effect of using TST CABLES Railway Lighting System cables:

Reduced failure rate: After the upgrade, the lighting system cable failure rate of this metro line was significantly reduced. Compared with the original cable, the failure rate of the new cable is reduced by about 90%, which greatly improves the stability and reliability of the lighting system.

Improved lighting effect: The excellent electrical performance of the new cables ensures stable power supply to the lighting equipment, which significantly improves the lighting effect of subway platforms, tunnels and other areas. Passengers can enjoy a brighter and more comfortable lighting environment when traveling on the subway, which improves the travel experience of passengers.

Lower maintenance costs: Due to the higher durability and reliability of the new cables, the number of maintenance visits and repair costs due to cable failures are reduced. According to statistics, maintenance costs for the retrofitted lighting system have been reduced by approximately 50%, resulting in significant operational cost savings for the metro operator.

Improved safety: The low-smoke, halogen-free flame-retardant material used in the new cables effectively reduces the production of smoke and toxic gases in the event of a fire, improving safety in metro stations. At the same time, the high flexibility of the cable also reduces the safety risks caused by improper installation.

In summary, through the actual application examples and the display of relevant data, it can be seen that the cable solutions for rail transit lighting systems provided by us have achieved remarkable results in actual projects, providing a reliable solution for upgrading the lighting systems in the rail transit 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

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