Application of Cables in Vehicle Sensors

Application of Cables in Vehicle Sensors

1.Product industry background

With the rapid development of the rail transportation industry, the level of vehicle intelligence and automation is constantly improving, the sensor as the vehicle senses the external environment, to achieve accurate control of the key components, the stability and reliability of its performance is directly related to the safe operation of the vehicle. Sensor cable as a bridge connecting the sensor and vehicle control system, its quality and performance is also critical. At present, there is a growing demand for high-performance, high-reliability sensor cables in the market, especially in the field of high-speed rail, subway, light rail and other rail transportation.

2. The pain point analysis

In the application of sensor cables for rail transit vehicles, the following pain points exist:

Poor environmental adaptability: rail transit vehicle operating environment is complex and variable, the cable needs to withstand high temperature, low temperature, humidity, vibration and other harsh conditions.
Serious electromagnetic interference: the complexity of the electromagnetic environment within the vehicle, the cable needs to have a good anti-electromagnetic interference capability to ensure stable signal transmission.
High security requirements: the sensor cable is directly related to the safe operation of the vehicle, so the cable fire, flame retardant and other safety performance requirements are extremely high.

3.The vehicle sensor cable requirements

For the above pain points, TST CABLES vehicle sensor cables need to meet the following requirements:

1. excellent environmental adaptability, able to work stably in a wide range of temperatures, and has excellent anti-vibration, anti-shock properties.
2. Good electromagnetic compatibility, can effectively inhibit electromagnetic interference, to ensure the accurate transmission of signals.
3. High safety performance, cable materials need to meet the fire, low smoke, halogen-free flame retardant and other safety standards to reduce the risk of fire.

4.Certification standards

Vehicle sensor cables need to meet the relevant certification standards at home and abroad, such as UL, EN, cUL, CSA, VDE, CCC, IATF 16949, ISO 9001, ISO 14001 ROHS, CRCC, REACH certified, etc., in order to ensure that the products are safe, environmentally friendly and compliant. At the same time, it is also necessary to meet the specific standards of the rail transportation industry, such as IEC 60332, EN 50264, EN 50306, EN 50382, EN45545-2, etc., to ensure that the cable is safe for application in the field of rail transportation.

5. Cable Selection

According to the specific requirements of vehicle sensor cables, TST CABLES recommends the selection of comprehensive sheathed cables with excellent performance. The cable adopts high-quality insulation materials and sheath materials, with good electrical performance, mechanical properties and environmental adaptability. At the same time, the cable structure is compact, easy to install and maintain, and can meet the diversified needs of sensor cables for rail transit vehicles.

Selection parameters for reference (can be customized according to actual needs)
Temperature resistance: -40°C to 125°C
Rated voltage: 750V (test voltage: 3500V/5min)
Fire resistance: conform to EN45545-2 R15/R16 HL3
Insulation strength: >12Mpa
Sheath strength: >10Mpa
Cable bending radius: 6 times the outer diameter (6D)

6. Product characteristics

The vehicle sensor cable in this solution has the following characteristics:

Excellent electrical performance: low resistance and low capacitance, ensuring high efficiency and accuracy of signal transmission.
Strong environmental adaptability: high and low temperature resistance, vibration resistance, shock resistance, to ensure stable operation in a variety of harsh environments.
Excellent electromagnetic compatibility: effectively inhibit electromagnetic interference to ensure stable signal transmission.
High safety performance: the application of fireproof and flame retardant materials reduces the risk of fire and ensures vehicle safety.

Recommended Products

Vehicle sensor rear-end cables are well insulated, high temperature resistant, bend without deformation, and are key components of modern vehicles

7.Technical Test

To ensure the performance and quality of the sensor cable, we have conducted a series of rigorous technical tests, including electrical performance tests, environmental adaptability tests, electromagnetic compatibility tests and safety performance tests. The test results show that the sensor cable in this solution meets or exceeds the industry standards and customer needs in all performance indicators.

8.Cable laying installation and commissioning

In the cable laying and installation process, we will follow industry norms and standard operating procedures to ensure that the cable layout is reasonable, fixed and reliable. At the same time, we will provide detailed commissioning guidelines to assist customers to complete the cable and sensor, control system connection and commissioning work to ensure the accuracy and stability of signal transmission.

9.TST CABLES after-sales maintenance and technical support

TST CABLES provides comprehensive after-sales maintenance and technical support, including regular inspection of cables, troubleshooting, repair and replacement services, etc. TST CABLES professional team will be ready to provide customers with technical support and solutions to ensure the stable operation of vehicle sensor cables and customer satisfaction.

10. Practical examples

This solution has been successfully applied in the vehicle sensor cable system of many high-speed railroads and subway lines in China.TST CABLES EN50264 series and EN50306 series cable products for rail transportation have obtained CRCC certification. At present, more than 500000 cables have been installed in more than 3500 high-speed railway coaches, with a running mileage of more than 6,000,000 kilometers. In the actual operation of rail transit, TST CABLES sensor cables show excellent environmental adaptability and stability, accurate and reliable signal transmission, which effectively improves the level of vehicle intelligence and operational efficiency. Taking Shenzhen metro lines as an example, after adopting this solution, the failure rate of vehicle sensors has been reduced by 100%, and the error rate of signal transmission has been reduced by 99.99%, which provides a strong guarantee for the safe and stable operation of the metro.

To sum up, TST CABLES vehicle sensor cable solution has excellent product performance, strict quality control and comprehensive technical support, and can meet the demand for high-performance, high-reliability sensor cables in the rail transportation industry. We will continue to be committed to providing customers with better quality products and services to promote the sustainable development 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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