The railway industry in Europe is facing fundamental change. Many vehicle fleets are technically outdated, while at the same time the requirements for safety, availability and environmental compatibility are increasing. New fire safety regulations, stricter approval standards and the growing demand for digital monitoring and control systems are further increasing the complexity of vehicle construction. Manufacturers and operators must therefore plan for the longer term. Components must function reliably for decades, remain low-maintenance and be integrable into increasingly complex systems. There is also political and social pressure to expand rail transport as a forward-looking mobility solution.
The Leon diesel multiple unit is a prime example of how the Romanian railway sector is addressing these requirements. For the first time in over 80 years, Leon is a passenger train that was developed and built in Romania. The project was realised by the Romanian company Electroputere VFU, based in Paşcani. With Leon, the long-established maintenance and vehicle construction company took a step from modernising existing vehicles to manufacturing its own train platforms. When it comes to connectivity technology, Electroputere VFU relies on solutions from LAPP, the global market leader for integrated solutions in the field of cable and connectivity technology. The cables used form the backbone of the electrical infrastructure in the vehicle and help to meet the high requirements for fire protection, reliability and service life in daily railway operations.
A long way from vehicle concept to standard-compliant implementation
The Leon diesel multiple unit was designed as a multi-purpose vehicle for regional and interregional passenger transport. The aim was to develop a fully type-approved rail vehicle that complies with current European safety and operating requirements while remaining robust and economical under real operating conditions. The three-carriage train has a total of 145 seats, including a small business area, and is designed for a maximum speed of 120 km/h. Two diesel engines, each with an output of 390 kW, provide the power.
Subsequent testing showed whether the concept also works under real conditions. Before the train went into passenger service, it completed more than 30,000 kilometres of test runs. These tests focused not only on handling and mechanical adjustments, but also on stress testing the electrical systems in continuous operation. This revealed the biggest challenges of the project: the electrical equipment had to meet high standards of safety, reliability and ease of maintenance.
In addition, as a passenger vehicle, the Leon must comply with relevant European standards, particularly with regard to smoke development, toxicity and flame spread. Accordingly, attention was paid to fire protection.
At the same time, strong vibrations, temperature fluctuations and mechanical stresses affect the connectivity technology in railway operations. Oily environments in the drive train area and tight installation spaces make clean and safe cable routing even more difficult.
Specialised connectivity technology for rail transport: ÖLFLEX® TRAIN
In order to meet these requirements fully and in the long term, Electroputere VFU opted for connection solutions from LAPP for the Leon’s electrical equipment. Cables from the ÖLFLEX® TRAIN portfolio, specially developed for rail vehicles, are used. They perform key functions in the power supply as well as in control and monitoring systems, thus forming the functional backbone of the vehicle’s electrical infrastructure. Single-core, flame-retardant and halogen-free cables are used for fixed installations, while flexible multi-core cables are used where moving installations or confined spaces require high bending strength.
The cables used are designed to withstand the particular stresses of railway operations. These include high fire protection requirements as well as mechanical stress from vibrations, temperature fluctuations and dynamic forces. The cables comply with the European fire protection standard EN 45545, are halogen-free and reduce smoke development and toxicity in the event of a fire. At the same time, they are resistant to oil and permanent mechanical stress and are designed for a wide temperature range from –50 °C to +120 °C.
Working together for the future of rail in Romania
For Electroputere VFU, the collaboration with LAPP was a key factor in the success of the Leon project. LAPP’s experts have many years of experience in international railway projects and were able to provide ideal support in dealing with safety-related standards and complex approval processes. This expertise was incorporated into the design of the electrical infrastructure at an early stage of the project and supported a standard-compliant and practical implementation.
The Leon diesel multiple unit shows that the development and manufacture of modern rail vehicles in accordance with European specifications is also picking up speed again in Romania. This is made possible by the combination of local engineering expertise and the proven technological expertise of international partners such as LAPP. For the Romanian railway industry, the Leon project marks a return to independent vehicle development and underlines how much stable industrial partnerships can achieve in the renewal of sustainable rail transport.