State-of-the-art train signals are all based on the same electro-mechanical architecture. There is a mechanical modular enclosure with some frontal holes (typically around 200mm) where the LED lights are located inside. Every LED light can represent only one color and due to this technical limitation, the signal need one independent LED light for each color that must represent. Consequently, one signal can represent only one aspect (color, route direction or speed limit).
Because of multiple signals must be installed on the field, every signal must be specifically manufactured for its specific function. Moreover, signals change from one country to another. So, as explained before, every Railway Administration has its own information representation codification: size, position, number of LED lights, information provided.
As a result, suppliers develop signals that are modular: they are composed of basic mechanical elements and, according to train Administration’s needs, they are integrated and adapted for fulfil the required features. This process entails a big cost of integration of parts during the production time (a lot of process and as well a big amount of big screwing elements) and usually to be done by a lot of manual operations.
Electrically, the currents Train Signals are managed very rudimentary, following the same architecture of an incandescent bulb base solution. All the energy to light on the LED lights are send from the Interlocking to the Train Signal with two cupper cables per LED light (several kilometers of distance is usual). It means that a LED light with 5 LED lights will need up to 10 wires with a relevant section because they transport energy for several kilometres.
Electrans’ LEDVAR-Z will provide the following advantages over the current antiquated systems:
- Fewer cables and reduced installation and maintenance costs. 30% less hardware will be needed at interlockings. Less space, fewer cables and fewer metres of cable will be necessary overall. This also means that the distance between signals can be greater. They are also vulnerable to vandalism, tampering/sabotage and theft. We can deliver a 90% reduction of cable links to interlockings, depending on the size and complexity of the installation. Reducing copper cables not only saves money but removes a potential target for theft, vandalism, tampering or sabotage, actions that have been responsible for great inconvenience and safety problems in the past.
- Reduced costs and limitations due to object controllers, as fewer will be needed. There is currently a limitation of some 5 or 6km in the connection distance between elements in the field and their controllers. To get around this, interlockings have object controllers that run all along the tracks. What limits the distance are the track circuits and the signals. In our solution, we use existing fibre optic cables from the interlocking to the signals. This way, it is not necessary to use object controllers every 5 or 6km but rather every 20km. This reduction will save some €20,000 per controller, so savings for an entire train line will be between €4,000-€10,000/km.
In fact, interlockings with a large number of control boards and controls for each signal will not be necessary.
- Greater adaptability, flexibility and scalability. Each LEDVAR-Z signal is able to show any aspect or pictogram, with the desired luminosity and colour, without pre-planning or separate manufacture for each symbol. Our high-quality LED signals reach safety standards that matrix-based signs have not been able to attain in the past and moreover, they can be easily adapted for use in any train system.
- A new supply paradigm: currently, rail companies have to order individual signals to be manufactured near the end of the planning stage of any system changes. Often the waiting time for these signals is long, creating delays and cost overruns. With our solution, rail companies can just order ONE PRODUCT (our adaptable LED signal) that can show any symbol that is needed. A reasonable stock level can be kept according to normal planning methods, as in other industries. This will create indirect but noticeable benefits for railway travellers, as the number of trains, their punctuality, the reliability of the system and the quality of service rely on smooth functioning of the installations.
- Reduced consumption of energy. We use the latest, cutting-edge LEDs and with our control system, the consumption of energy will not have to be artificially increased to match that of incandescent bulbs. Savings will reach 50% of current energy use.
