Rail – Electrification and Subsystems for Rail Vehicles
Rail vehicles for infrastructure and maintenance offer significant decarbonization potential. Rail operators and special-purpose rail vehicle manufacturers seek reliable partners for electrical subsystems, power supply, and system integration. As experts in electrification, we support OEMs and manufacturers in implementing systems for special-purpose rail vehicles as functional turnkey solutions.
Practical Requirements
Challenges
Thinking of Decarbonization in a Global Context
The electrification of special-purpose rail vehicles is part of a broader decarbonization strategy. This includes replacement procurement, retrofitting, and operational optimizations, as well as the further development of charging infrastructure and energy management. Anyone developing systems today must consider integration into the fleet, operations, and infrastructure.
Targeted Design for Diverse Application Profiles
Construction and maintenance vehicles, service cars with generators, as well as light and heavy shunting locomotives place different demands on performance, energy requirements, and autonomy. This is precisely the task of a solid system design: dimensioning batteries and subsystems so that they cover real-world applications reliably and economically.
Small Quantities, High System Responsibility
Special-purpose rail vehicles are usually custom-made with a high degree of technical individuality. At the same time, work functions, power supply, safety, and integration must function as a coordinated overall system. This requires partners who contribute system expertise and deliver well-thought-out subsystems.
Fire Safety and Electrical Certification
In the rail environment, high requirements apply to safety certifications regarding battery systems, power distribution, and compact electrical architectures. Manufacturers need partners who can deliver proven systems and provide the necessary documentation.
Long Service Life and Maintenance Obligations
Rail vehicles are designed for service lives of 20 years or more. This obligates system suppliers to ensure long-term maintainability. This makes monitoring, documentation, and serviceability an integral part of every solution.
Are these your challenges as well? We would be happy to develop the right solution for you.
Turning Complexity into a System
Rail Systems: Our Solution Expertise
The electrification of special-purpose rail vehicles is only possible within an overall context. It includes the sensible selection of use cases based on power and energy requirements, sophisticated operating modes, suitable charging infrastructure, and well-conceived storage strategies. Optimizing only individual components will miss the mark.
SUNCAR deliberately focuses on the field of special-purpose electric vehicles: construction trains, workshop cars, shunting locomotives, measurement trains, and infrastructure machinery. Our focus lies on electrical subsystems in the low-voltage and CE-relevant environment. Our services include power supply, battery integration, DC architecture, charging integration, and compact electrical system solutions.
Since 2020, we have implemented real-world projects in the Swiss rail environment. They range from battery systems and cable harnesses to the complete re-powering of shunting locomotives. In doing so, we act as a subsystem supplier with system responsibility: in close cooperation with control cabinet builders, inverter suppliers, and special-purpose manufacturers. We are Rail-Ready: with proven electrical architectures, verified fire safety, and experience from successful projects.
5 Reasons for SUNCAR
Why SUNCAR for Rail
For the construction of electrical subsystems, partners are required who bring real project experience and safety certifications in the rail environment.
Experience from Real-World Rail Projects
Since 2020, we have implemented projects in the Swiss rail environment. Our experience ranges from battery systems and cable harnesses to the complete re-powering of shunting locomotives. This experience is the foundation of our offering in the rail segment.
Focus on Special-Purpose Vehicles and Infrastructure Machinery
We deliberately address the area where specialized partners are in demand: construction trains, workshop cars, measurement trains, shunting locomotives, and fire-fighting trains. Here, we can create particular added value as a subsystem supplier.
Strength in the Low-Voltage and CE Environment
Our focus is on electrical subsystems in the low-voltage range, where secure power supply, battery integration, charging integration, and compact system architectures are crucial. Here, we contribute experience, system understanding, and implementation expertise.
Fire Safety and System Certification
We do not just deliver components; we also provide the necessary safety certifications. Especially in the rail environment, this is a decisive factor and an area where we actively relieve our customers.
Long-term Partnership instead of One-off Delivery
Long-term Partnership instead of One-off Delivery
Convinced? Then please get in touch with us. We look forward to supporting you with your project.
Success Stories
Reference Projects
Successful electrification projects from various industries
Tailor-made Solutions
Relevant Products and Technologies
Battery Systems and DC Architecture
Electric rail vehicles require robust architectures for power supply, distribution, and integration. We develop battery systems and DC architectures that are tailored to the respective application and fit into existing or new vehicle concepts.
DC Charging Interfaces
With INTERFLOW, we offer charging solutions that can be integrated into rail vehicles. This allows us to ensure efficient charging cycles in depots or on private rail networks. The integration of simple 50 Hz charging solutions is a central topic for many applications and creates flexibility.
AC Grid Distribution and Power Supply
In addition to traction, special-purpose vehicles require a reliable power supply for work functions, lighting, and auxiliary systems. We design and deliver AC distributions and electrical supply structures as part of the overall system. These replace previous generator-based solutions.
Thermal Management and Battery Climate Control
Battery systems in rail vehicles must function reliably over long operating periods. Targeted thermal management is crucial for performance, service life, and safety. We provide targeted support to customers in this area.
INSIGHT Monitoring
With service lives of up to 20 years, telemetric data plays a significant role. Our systems enable the monitoring of operating states, battery health, and system behavior as a basis for predictable maintenance and long-term availability.
Our Approach
Our Process
Structured development processes are the foundation of successful electric vehicle and system developments. We accompany OEMs, machine manufacturers, and industrial companies from the initial concept idea to series integration.
Analyze Application Profile
We analyze vehicle type, route profile, energy requirements, operating time, and charging infrastructure. Based on this, we evaluate which use cases are suitable for electrification.
Define System Architecture
We develop the architecture for the battery, DC system, charging integration, AC grid distribution, thermal management, and energy management. In doing so, we focus on the operational requirements.
Implement Integration
The subsystems are integrated into the rail vehicle mechanically, electrically, and on the software side. We cooperate closely with manufacturers and control cabinet partners.
Validate and Optimize
The subsystems are integrated into the rail vehicle mechanically, electrically, and on the software side. We cooperate closely with manufacturers and control cabinet partners.