How we improved tram heaters — the story of one project

Tram heaters resistant to mud, dust, stone impacts and low temperatures? It's possible! See how we designed the braking system solution.

Context and challenge - tram heaters

The tram manufacturer approached us with a request to design a heater for the braking system. Our task was to create an element mounted under the vehicle, which was supposed to heat the nozzles that spread sand on the track in front of the wheels of the tram. The key challenge was working in extreme conditions — the heater had to be resistant to mud, dust, stone impacts and low temperatures.

Together with the customer's design team, we created a new heater model that passed all the tests and was accepted. The prototype met the requirements, and after its acceptance, serial production began. Everything pointed to success, until the moment when, after almost a year of operation, the first heaters began to return to us due to breakdowns.

Analysis of the problem - what went wrong?

During a detailed analysis, it turned out that the heater itself worked correctly, however, the current wires were damaged. The problem lay in the mechanical damage resulting from the operating conditions. The cable outlets were not adequately protected against impacts and external factors.

We quickly determined that the customer's service personnel had modified the connections on their own, adding metal pegs and other elements that were not compatible with our design. These actions were aimed at protecting the wires, but in fact led to leaks and damage.

Moreover, at the very beginning of cooperation, during the design, it was agreed that the issue of connections will remain beyond our scope. This decision caused that we did not have a complete picture of the conditions of installation and subsequent operation.

Actions Taken

1. Design changes:
   Once the problem was identified, we made key modifications. The power lines were sheathed with steel pipes, lengthened and routed so that the final connection was inside the metal box of the tram. This provided protection against both mechanical and environmental factors.
2. Modernization of existing heaters:
   Heaters already in operation have been retrofitted or adapted to new customer service requirements. It was a complicated and time-consuming operation that could have been avoided if all aspects of the assembly had been determined at the design stage.
3. Communication and Arrangements:
   We have taken steps to better coordinate the cooperation between the customer's design department and their service department. In the future, this will allow the full life cycle of the product to be taken into account — from design, to assembly, to operation and service.

Effects of change

Thanks to the modifications introduced, the heaters have become fully resistant to mechanical damage and the influence of external factors. The solution eliminated the problem and restored the full functionality of the braking system.

Lessons for the Future

1. Understanding the full context:
   Even the smallest details, such as how to assemble or later service modifications, can be critical to the durability and reliability of a product.
2. Communication between departments:
   Key design decisions should involve not only the designers, but also the teams responsible for installation and service. The lack of this cooperation can lead to problems that are time-consuming and costly to solve.
3. Proactive approach:
   If connections were included in our scope of action from the beginning, the problem could be solved at the design stage.

summary

Designing tram heaters is more than creating a solid device — it's understanding the environment in which it will operate and taking into account all the factors that affect its operation. Thanks to our experience and flexible approach, we were able to make lasting corrections that met the customer's requirements.

We make sure that our products are not only functional, but also reliable in all conditions. If your project requires a comprehensive approach and consideration of the smallest details — contact us.