Flexible housing systems for inter-car jumper

Reducing complexity and standardisation are key factors in improving process efficiency. When HARTING developed the VarioShell, the aim was to create a standardised and expandable system capable of meeting all the challenges associated with inter-car connections.

Ideally, rail vehicle manufacturers should be able to transmit very high power, high-speed data and even other media via the VarioShell through a single standardised cut-out in the wagon wall. This standardisation reduces the number of cut-outs in the car body and enables manufacturers to increase efficiency not only in terms of electrical cabling but also in metalworking.

At first glance, standardisation does not sound like it offers a great deal of flexibility. But quite the opposite, in fact. The VarioShell is an open system and creates a new benchmark for flexibility. The housing system can be used as a classic surface mounted housing or bulked mounted housing.

The largest variants, VarioShell 24 and 34 are the typical inter-car jumper housings between wagons or for the end-of-car-jumper. They are available in a dual row configuration and can be flexibility equipped with connectors for the transmission (high) power, data and signal. Equipped with 4x Han® HPR Compact EasyCon, connectors can also be rotated by 90 degrees. This ensures the highest density for signal and data for jumper connections. The EasyCon hood enables optimised assembly- and cable management inside of the hood and easy access to the cables in case of repairs or retrofit.

Alternatively, the VarioShell housings can also accommodate single poles for power distribution. The most powerful VarioShell solution for jumper cables to date can carry eight individual poles with up to 700 A/4 kV at a temperature of 40 degrees.

The two-piece housing achieves IP69K using a counter pressure frame, thanks to the all-round internal seal. As the cover is removable, the housing can be equipped from the interior of the vehicle as well as from the outside. Cables can easily be routed through the wall, which leads to additional weight reduction due to shorter cable runs.

Easy accessibility also reduces the effort required for operation, service and maintenance. Not all connections have to be interrupted in the event of a fault. Instead, it is possible to open the housing cover to identify and replace the faulty conductors or contacts.

As an open system, the Han® HPR VarioShell also features counter pressure frames, cable managers and shielding plates for routing and accommodating cables of various diameters.

The VarioShell forms a robust alternative for distribution boxes, for example on the roof of the vehicle, on the outside wall or on the bogie. The new single-row ‘Mini’ versions, available in sizes 6, 10, 16 and 24, offer additional flexibility for very tight installation conditions.

The well-known benefits can now also be utilised when the installation team is faced with very confined installation spaces such as bogie connections. Large cable bend raii can be prevented, as the cables can be routed smoothly through the VarioShell. 90° connections can be made much more easily.

Access from all directions, made possible by the removable cover, makes initial set-up and maintenance easier for installation and maintenance teams. The optional cable manager can also help to keep cables organised.