Safety Efficiency Reliability. Energy Weight Space. Heating solutions for rail technology RAIL

Transcription

1 Safety Efficiency Reliability Enery Weiht Space Heatin solutions for rail technoloy

2 CONTENTS 1. Heatin solutions for rail technoloy Heatin cable in SeamLess Technoloy series WKS Silicone heatin mats Series WOS Silicone heatin jackets series WOS Heatin foils series WOFS Heated hoses and heated pipes series WSKS Temperature controller and reulator type WR Insulation made of silicone Winkler GmbH Enlerstraße 24 D Heidelber Tel.: Fax: sales@winkler.eu 2

3 1. Heatin solutions for rail technoloy The riht heatin at sensitive points plays an important role for safety, reliability, comfort and economical operation in rail technoloy. This applies for application in rollin stock, as in infrastructure. Time and time aain, snow, ice, extreme chanes in temperature and moisture cause partial or complete failure of mechanical, hydraulic, pneumatic or electrical systems. Such faults and the resultin problems in rail operation and even personal injury can be avoided with specially developed heatin solutions, the appropriate controllers and thermal insulation parts. Heatin solutions from Winkler are always tailored for the respective application in coordination with the customer. Our heatin solutions are space-savin and are also well suited for retrofittin. As a result of the justifiably hih safety standard and the applicable industrial standards for products used in rail technoloy, we also continuously develop our products and meet all the relevant industrial standards. Here we are able to call upon a wide rane of technoloies and over 30 years of experience. Industrial standards and reulations Flammability testin for German rail traffic DIN , ISO Toxicity DIN , DIN Fire behaviour and side effects Fire testin in accordance with DIN Overview imae fire assay Flammability testin for European rail traffic CEN/TS Winkler GmbH Enlerstraße 24 D Heidelber Tel.: Fax: sales@winkler.eu Flammability testin for French rail traffic NF F : 1988 Flammability testin for Italian rail traffic UNI CEI : 2005 Electronic equipment used on rollin stock DIN Shock and vibration tests EN 6173 SIL (Safety interity level) Certified accordin to CEN/TS Certified accordin to DIN and DIN Smoke as toxicity in accordance with DIN , Appendix C Overview imae, condition after testin 3

4 2. Heatin cable in SeamLess Technoloy series WKS Winkler is constantly on the search for better materials, new manufacturin processes and innovative desin concepts in order to make its products more durable and reliable. This is particularly important in rail technoloy, where hih reliability over a lon period and under the harshest conditions really matters. Electrical heatin devices in rail technoloy are usually subjected to environmental influences, such as temperature fluctuations, moisture and sometimes even chemicals. The also experience hih levels of electrical and mechanical stress, especially due to vibrations, under extreme conditions also due to projectiles. If, despite all precautions, failures occur in such applications, the causes may also be found at the transition between the heat conductor and connectin cable (cold conductor). Irrespective of whether this transition is realised with a separate clamp, a crimp connection, a plu or a soldered or welded joint, it is always an electrical connection and therefore a potential vulnerability. For this reason, Winkler deploys SeamLess Technoloy in demandin applications, This desin principle foroes an additional electrical connection, the cold connectin cable is already interated in the heatin cable. The connection between the heat conductor and connectin cable is uninterrupted, invisible from the outside, i.e. "seamless". SeamLess Technoloy Dayliht photoraphy of the heatin cable SeamLess Cold tail Transition zone Heatin cable Technoloy Thermoraphy Structure Outer jacket made of silicone Metal braidin Insulation made of silicone Heatin with spiralled heat conductor Glass silk Features and benefits of SeamLess Technoloy Consistently homoeneous material structure Robust structure made of hih quality materials No ap and no seal in the outer jacket No chane in cross-section (thickenin) at transition Spiralled heat conductor No additional electrical connections / heat conductors / cold ends Customer-specific lenths and properties of heatin conductors and cold ends Wide selection of heat conductor values 4 HEATING cables ideal performance with temperature fluctuations lon service life, hih reliability hih resistance to moisture and other environmental influences low risk due to friction and chafin no lenth variation with temperature chanes ideal behaviour with mechanical loads (especially vibrations) Different power distribution over the lenth possible (see Graphic 1, p. 5) Selective heatin of only certain zones possible (see Graphic 2, p.5) individual heat conductors, operatin voltaes and lenths can be achieved Technical data WKT1 heatin cables Perm. operatin temperature max. 150 C Perm. ambient temperature -50 to +80 C Operatin voltae max. 800 V AC/DC Test voltae 2,000 V AC Power max. 40 W/m (selectable in sections) Protection class IP68 Lenth min. 1 m to max. 50 m Outer diameter 5 mm Bendin radius min. 25 mm Weiht 50 /m

5 Desin examples STANDARD Heatin cable with one heated section and one heatin power Graphic 1 Connectin cable with cold tail Heatin cable Heated surface SPECIAL DESIGN Heatin cable with two heated sections and two heatin powers Graphic 2 Connectin cable with cold tail Heatin conductor with low power Heatin conductor with hiher power Cold line Applications 1. For heatin lare surfaces in floors and wall panels with meanderin routin. Application example 2. For heatin (hollow) profiles by drawin in or lonitudinal routin Heatin floors with SeamLess heatin cable. The heatin cable is drawn in to the aluminium sandwich panel from Metawell GmbH. 3. For heatin pipes and hoses with spiralled routin (ø > 50 mm) with double-sided and sinle-sided connection HEATING cables 5

6 3. SILICONE heatin mats SERIES WOS Silicone heatin mats are two-dimensional heatin elements. They consist of a heat conductor, embedded between two thermally and mechanically resistant silicone layers with additional lass fibre inlays. The heat conductor can be desined as a wire or etched conductor track. Vulcanisation to form a homoeneous unit protects the entire element aainst moisture. As a result of their structure, silicone heaters have mechanical, electrical and thermal advantaes that play an important role in rail technoloy or infrastructure applications. The flexible silicone structure allows ood contact to the components heated, even on curved surfaces. The individual layout of the heat conductor enables hiher powers, combined with fast heatin and response times. Shape, power profile and the number of heatin zones can be larely matched to the specific application. Individual contours and recesses can be punched out. Technoloy Thermoraphy Vertically routed heatin meander in etchin technoloy Thermoraphy Horizontally routed heatin meander in windin technoloy Structure Recess Connectin cable Insulation made of silicone foam Etchin technoloy Heat conductor tracks etched out of a metal layer; only economical in lare batch sizes Fixation hook Silicone layers Heatin cable Windin technoloy Heatin wire routed by hand; small batch sizes possible. Features and benefits Healin conductor embedded between two layers protected aainst moisture flexibility with hih mechanical strenth of vulcanised silicone Application-specific shape and accurate fit individual heat conductor layout specific and uniform heat distribution Thermal insulation with silicone foam no additional insulation expenditure possible after installation Wide rane of fixation options simple and safe installation for continuous available (self-adhesive foil, operation hooks, eyes, Velcro strips) Interation of temperature sensors, as well as temperature easy connection and easy interation switches and fuses possible 6 silicone heatin mats Technical Data WOS silicone heatin mats Perm. operatin temperature max.180 C Perm. ambient temperature -50 C to +80 C Operatin voltae max. 800 V AC/DC low voltae possible Test voltae 1,500 V AC Power max. 0.6 W/cm² Protection class IP65 Lenth max. 2,800 mm Width max. 900 mm Thickness approx. 1.5 mm Weiht approx.3.0 k/m 2

7 Applications Heatin of customer-specific contours Heatin of surfaces Heatin of cylindrical containers Application examples Silicone heater with insulation foam for heatin fire extinuishers Silicone heater with silicone foam insulation for heatin a windscreen wiper motor Silicone heater for heatin tram entrance areas silicone heatin mats 7

8 4. SILICONE heatin jackets series WOS Silicone heatin jackets are three-dimensional heatin devices. They differ from silicone heatin mats in that the heatin element is adapted to the eometry of the component heated. In addition, silicone heatin jackets are manufactured as a unit with thermal insulation and a mechanical outer skin. Functional elements like sensors, cables and fixation options can also be interated. Silicone heatin jackets are always supplied as a ready-to-connect complete solution. To produce silicone heatin jackets the riht tools are required, which we manufacture on the basis of the customer drawin. Technoloy Heatin Thermal insulation Fixation Thermoraphy Structure Heatin with silicone heaters or with heatin cables in SeamLess Technoloy Connectin cable silicone SeamLess Technoloy Sensor Insulation silicone foam Small batch sizes possible Features and benefits Interation of all functional elements in a sinle unit Optionally, the heatin jacket can be vulcanised onto the object to be heated. Application-specific shape and individual heat conductor layout Heatin elements in SeamLess Technoloy possible Wide rane of fixation options available (velcro strips, hooks, eyes) 8 Silicone heatin jackets Outer jacket silicone, washable simple installation and interation extremely robust and durable bond of all components accurate fit specific and uniform heat distribution various lenths and diameters possible no electrical connections within the jacket very hih reliability easy and safe installation for durable operation Fixation Technical Data WOS silicone heatin jackets Perm. operatin temperature max. 180 C Perm. ambient temperature -50 C to +80 C Operatin voltae max. 800 V AC/DC Test voltae 2,000 V AC Power max. 0.6 W/cm² Protection class IP65 Lenth min. 1 m - max. 50 m Outer diameter 5 mm Bendin radius min. 25 mm

9 Applications SeamLess Technoloy Heatin of pipes, vulcanized Heatin of fittins Application examples Silicone heatin jackets for heatin sand pipes for the emerency brake Silicone heatin cap for heatin sand ejectors for the emerency brake silicone heatin jackets 9

10 5. HEATING foils series WOFS Heatin foils consists of etched conductor tracks, embedded between two thermally and mechanically resistant polyimide films thus protected aainst moisture. Complex desins may be built up of several heatin or insulation layers and therefore optimised for special applications. The minimal thickness reduces problems due to the heatin element's own weiht and space requirement. The low intrinsic mass allows rapid temperature chanes and thus uarantees ood control properties. Technoloy Heatin + Cold zone = Precise heat distribution Thermoraphy Structure Polyimide foil Features and benefits Etched heat conductor sealed between two thin polyimide films Minimum heat conductor separation attainable Application-specific shape and individual heat conductor layout Fittin with self-adhesive foil possible Polyimide foil Interated sensor with solder pads (optional) minimal thickness and low weiht rapid heatin time suitable for heatin the smallest surfaces several heatin circuits with different power densities possible complex surfaces heatable precise and uniform heat distribution simple installation Connection wire Technical data WOF heatin foils Conductor track etched Solder pads for connection wires Perm. operatin temperature max. 180 C Perm. ambient temperature -50 to +80 C Operatin voltae Power Lenth Width Thickness Weiht Pressure loadin capacity max. 230 V AC/DC 0.8 W/cm² max. 550 mm max. 300 mm 0.2 mm 0.05 /cm² 10 N/cm² 10 HEATING foils

11 Applications Heatin uneven surfaces Heatin surfaces - sandwich structure Application example Heatin foil for heatin displays in transport ticket machines HEATING foils 11

12 6. HEATED hoses and heated pipes series WSKS If temperatures drop below a certain value, there is a risk that hose or pipe connections freeze or the viscosity of the fluids contained increases sharply. Winkler heatin devices for hoses and pipes offer a reliable solution for this problem. A heatin cable ensures uniform heatin of the hose, a silicone insulation structure prevents serious loss of heat. The consistently used silicone material meets the rail standard requirements, is extremely durable and has hih mechanical strenth. The flexibility of the hose connection is not impaired by the heatin cable and the silicone insulation. Winkler heatin hoses and heated pipes are easy to interate into existin systems and can be used for retrofittin accordin to the customer's specifications. It is possible to heat hoses with a lenth up to 20 m and an outer diameter up to 1 m. The Winkler heatin devices are used in rail technoloy, e.. with hydraulic hoses in point drive units in cold climates. Technoloy Uniform heat distribution Structure Multi pole plu (standard), optionally with customer-specific desin possible Fittins Connectin cable Heatin with heatin cable Temperature sensor (optional) for controller operation Inner hose Silicone caps Features and benefits Helically wound heatin cable with hih quality insulation materials Insulation structure made of silicone foam with robust outer jacket Compact and ready-toconnect system Wide rane of lenths, diameters and fittins attainable 12 HEATED hoses flexibility uniform heat distribution ideal thermal insulation with hih mechanical strenth, hih flexibility, low bendin radius attainable simple and fast installation for reliable operation Termination accordin to customer requirements ideally suited for retrofittin Insulation structure with silicone foam hose Outer jacket made of silicone Technical data WSKS heated hoses Perm. ambient temperature -50 C to +80 C Operatin voltae max. 400 V AC/DC Test voltae 2,000 V AC Power min. 5 - max. 80 W/m Protection class IP55 Lenth max. 20 m Inner diameter mm Bendin radius min mm

13 Desin examples Type S1 Type S2 Type S3 ID DJ L: Lenth of the heated hose max. 20 m max. 10 m max. 6 m DC: Cap diameter 38 mm 48 mm 62 mm DJ: Diameter outer jacket 33 mm 43 mm 53 mm ID: Inner diameter 4-10 mm 6-16 mm mm LC: Cap lenth 110 mm LO: Clearance of the cable outlet 25 mm LCC: Lenth of the connectin cable accordin to customer requirements HC: Cap heiht incl. cable outlet 50 mm 64 mm 80 mm min. bend radius (dep. on ID) approx. 200 mm approx. 250 mm approx. 300 mm Dimensions LCC DC DJ Multi pole plu LO HC L LC Applications Heatin of hydraulic lines and water hoses Heatin of pipes HEATED hoses 13

14 7. TEMPERATuRE controller and reulator type WR Throuh our many years of experience in control technoloy in industrial and plant enineerin, we are also in a position to develop control units for rail technoloy. We develop the appropriate control system specific to the customer and project for complex heatin solutions in which precise temperature limit values or defined switchin and shutdown temperatures are required for smooth operation. As we match the controllers specifically to the respective application, there is no standard proramme here. The product requirement specifications are drawn up in close cooperation with our customers. Acceptance in accordance with SIL is possible on request. Structure (example) USB port Display Interface Mains connection S I L Heatin and alarm outputs Features and benefits Customer-specific solution Robust structure with hih quality components optimised for the respective application (e.. control of fire-fihtin systems) control of several independent heatin circuits monitorin of the proper function of heatin circuits temperature sensors are freely selectable monitorin of sensor function output of error messaes in the event of a fault connection to a superordinate monitorin unit possible operatin hours counter possible desined for continuous operation desin of housin and operatin unit in coordination with the customer Close cooperation with test institutes optimal throuhput times for projects Application example Control unit for heatin of fire extinuishers 14 temperature control unit

15 8. INSuLATION made of silicone Insulation caps and insulation plus made of silicone Applications: Thermal insulation of frost-sensitive components, such as valves, filters, pumps etc. To improve the efficiency of electric heatin devices. Protection aainst accidental contact and mechanical protection. Insulation cap to snap on Insulation cap to snap on Insulation plu with foam core Insulation jackets made of silicone foam Thermal insulation of frost-sensitive components with simple round eometry, such as fittins, pipes and joints. To improve the efficiency of electrical heatin devices, especially with spiralled heatin cables. Protection aainst accidental contact and mechanical protection while maintainin flexibility. Insulation jacket Anular insulation jacket Insulation jacket Insulation mats made of silicone Material properties: Closed cell silicone foam Water repellent Density approx. 260 k/m³ Thermal conductivity W/(m K) Available in rolls and mats of 980 mm width Machinin with water jet or punchin from CAD data Colours white Thickness Desin examples red rey-black Application example Fire extinuisher head without insulation 3-15 mm Fire extinuisher head with insulation HEATING cables 15

16 Winkler GmbH who we are and what distinuishes us Our work not only centres on the product itself, but also on developin complete solutions. It is with this belief in mind that our employees plan and manufacture electrical heatin devices - adapted precisely to your requirements as a customer. Your temperature problem is our inspiration. Our resourceful developers and skilled manufacturin specialists do everythin within their power to make your enquiry into a Winkler heatin solution. This way we can respond flexibly and quickly deliver you a ready-for-connection result from a sinle source. We re proud of that! There is not only enthusiasm for innovation in our 60 employees heads, but also comprehensive knowlede from a wide rane of technoloies. We have continuously transferred the experience ained since the company s foundation in 1979 into new product and application areas, such as explosion protection. This versatility allows us to supply customers in industry, in the laboratory and in railway technoloy worldwide. But no matter where: We are in close contact with every customer. Because the better we fulfil your requirements, the more convincin the results. And that is what matters for us! Our headquarter Our production site in Walldorf Your contact: Wolfan Weis Sales Manaer OEM Surface Heaters Tel: Fax: w.weis@winkler.eu Winkler GmbH Enlerstrasse Heidelber Deutschland Tel Fax sales@winkler.eu Our product rane Company presentation Heatin solutions for exhaust measurement technoloy Heatin solutions for rail applications ATEX heated lines Diital ATEX-Controller-Limiter- and Power Selector Combination Heated hoses for luein technoloy and for fillin and dosin systems Heatin solutions for chemical and thermal process enineerin Silicone heaters and heatin foils Prarallel heatin tapes Drum and IBC heaters Laboratory heaters Temperature control units Our aencies austria In. Wolfan Stipanitz, 4060 Leondin Tel Fax sales@winkler-austria.com FranCE André Weinzaepflen, Paris Tel Fax commercial@winkler-france.com Winkler GmbH Winkler, the Winkler-Loo, PILZ, the PILZ-Loo and the red dot are reistered trademarks of Winkler GmbH All rihts reserved