First introduced at the InnoTrans fair 2024, the PAD 41 passenger alarm handle has been developed as the direct successor to Schaltbau’s proven PAD 40 series to address increasing requirements from rail operators for longer inspection intervals, improved serviceability and greater functional flexibility. At the same time, PAD 41 maintains full mechanical compatibility with existing PAD 40 installations, so that devices can be replaced without reworking the mounting surface. This allows straightforward retrofitting in existing fleets as well as integration into new vehicle platforms. 

A central enhancement of PAD 41 is its increased B10d value, which enables substantially extended inspection cycles for the passenger alarm handle. The B10d value, a reliability metric that describes the number of actuations at which fewer than 10% of devices are expected to experience failure, led to recommended inspection cycles of 6 months for PAD 40. With a B10d value of 30,000 actuations, the successor PAD 41 now supports inspection intervals aligned with regular vehicle maintenance cycles of two to three years, depending on operating conditions. As a result, both maintenance effort and vehicle downtime are reduced without compromising safety. 

 “Passenger alarm handles are rarely actuated in service, but they must function reliably after years of exposure. PAD 41 is designed for use in passenger rail vehicles where predictable inspection cycles, simplified maintenance and long-term reliability are critical selection criteria,” says Helmut Pusch, CEO of Schaltbau GmbH Group. “For operators, PAD 41 offers a clear transition path: a direct replacement for PAD 40 with no interface changes, but with measurable improvements in inspection cycles, service effort and configuration flexibility.” 

PAD 41 introduces a modular design, in which housing components and handles can be replaced independently without fully dismantling the device. Maintenance is further simplified through maintenance-free plain bearings which do no longer require regular lubrication as well as plug-in bolt mounting for snap-action switches. In contrast to PAD 40, the PAD 41 supports up to four S826 or S870 snap-action switches. 

Schaltbau’s PAD 41 passenger alarm handles are available in numerous customer-specific variants and options, including two housing designs (a classic version and a version with rounded outer edges), an emergency hammer with interlock hammer holder, LED indicator lights, individual labelling or an optional remote reset, allowing both manual reset and reset via electrical input.   

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“Battery electric and hybrid propulsion are no longer technology visions — they’re already delivering real benefits today. We know, for instance, that electric trains can emit up to 65% less CO₂ in service compared to diesel counterparts, depending on the local electricity mix,” said Helmut Pusch, CEO of Schaltbau Group. “That’s a transformative efficiency gain, and it’s exactly what Schaltbau’s contactors are enabling across modern rail systems.”

Rooted in technologies proven across demanding rail applications for decades, Schaltbau’s CP and CF series of high-power contactors deliver robust performance in both propulsion and battery-train contexts. Featuring advanced arc-extinguishing chambers, modular configurations, and bi-directional switching, they are now available in new variants.

The CP Series, ranging from 600 A to 2,000 A (new variants rated at 800 A, 1,000 A, and 1,500 A), are designed for seamless heavy load operation, minimal energy losses and maximum uptime and thereforekey to reducing total cost of ownership (TCO) in demanding rail applications. At the same time, the new modular, multipole CF contactor series configurable up to 400 A with AC/DC switching capability isideal for integrating traction units and onboard energy storage. Both solutions significantly enhance the performance and safety of battery-train architectures by effectively managing high-current conditions during battery connection and disconnection cycles.

In addition to its contactor portfolio, Schaltbau will also showcase further product highlights including connectors, precision-engineered snap-action switches, and electrics for rolling stock including driver desks and displays of its daughter company, SPII.

CP Series – High-Power Traction Contactors 
The expanded CP series offers high-power contactors designed specifically for demanding rail applications. Now featuring three newly developed variants—rated at 800A, 1000A, and 1500A—these additions fill critical gaps in current offerings, optimizing size and cost for applications requiring higher current capacity. 

"At Schaltbau, we prioritize innovation that anticipates the future needs of the modern railway industry. The CP contactor series shows our commitment to developing high-quality, future-proof solutions that drive efficiency and reliability in critical power applications”, says Steffen Munz, CEO of Schaltbau. "We are proud to showcase this versatile technology at InnoTrans 2024." 

These robust design enhancements allow the CP series to perform seamlessly under heavy load conditions, ensuring optimal performance and a longer operational life. Additionally, Schaltbau will introduce the Smart-CP contactor, a next-generation intelligent switching device. Equipped with integrated sensors, real-time monitoring, and self-diagnostic capabilities, this device brings intelligence into critical power applications, improving energy management and reducing downtime. 

CF Series – Modular Multipole Contactors
The CF series introduces a modular approach to rail contactors, with the latest 400A variant adding versatility to an already adaptable system. These contactors are available in both NO (normally open) and NC (normally closed) configurations, handling currents up to 400A and voltages up to 3kV. The CF series' ability to switch both AC (up to 400Hz) and DC makes it an ideal choice for high-demand rail applications. 

"Our High-Power Contactor Initiative is a forward-thinking approach to high-energy applications that require greater reliability and precision," adds Munz. "Schaltbau has always been at the forefront of technological advancement, and we look forward to introducing the next generation of intelligent devices to bring new levels of performance and safety to high-power systems." 

Visitors to InnoTrans 2024 will have the opportunity to experience not only the high-performance contactors but also new products in the field of snap-action switches, railway devices and cockpit solutions from the subsidiary SPII at the Schaltbau stand. The company's experts will be on site to provide insights, answer questions and provide detailed advice on how Schaltbau solutions can be tailored to the specific needs of their customers.

Technical details:

Key technical highlights of the CP series include: 

• Current range: 600A to 2000A, with the three new versions rated at 800A, 1000A, and 1500A. 
• Voltage range: Nominal voltages of 1.5kV to 3kV, suitable for both AC and DC loads. 
• Switching capability: The contactors are designed to handle DC, fully bidirectional DC, and AC loads, ensuring exceptional electrical lifetimes. 
• Mechanical life: Over 1 million switching cycles for NO and NC contacts, making them highly durable in harsh operating conditions. 
• Configuration flexibility: The CP contactors feature 3 arc chamber types (A, B, D) and come with a monostable drive system, ensuring broad applicability and easy customization for specific rail systems. 
• Operational efficiency: These contactors incorporate larger fixed contacts and split contact bridges, which improve current distribution and contact reliability, reducing wear and tear. 
• Integrated permanent magnet system that eliminates critical current issues, resulting in lower total cost of ownership (TCO), as well as easy contact inspection and reduced maintenance requirements.

Technical features of the CF series include: 

• Current ratings: Available in 200A, 300A, and now 400A models, providing a scalable solution for different power needs. 
• Switching chambers: Each variant is built with up to six poles (for 200A/300A models) or four poles (for the 400A model), with fully bi-directional switching for both AC and DC loads. 
• Breaking technology: Advanced arc-suppression features, including polyamide, steel, and ceramic extinguished element inserts, ensure reliable switching and extended contact life. 
• Mechanical life: With over 1 million cycles, the CF series delivers longevity, reducing the need for frequent maintenance. 
• Operational flexibility: The modular design supports up to four auxiliary contacts (S870 or S826), enhancing its applicability across a variety of operational conditions. 
• Critical current resilience: The CF series is engineered to handle high short-circuit withstand currents of 4kA without critical current range issues. 
• The CF series' modular and bi-directional switching capabilities make it an exceptional solution for complex rail systems, where versatility and reliability are paramount. 
   

The numbers speak for themselves – rail travel and freight account for a mere 1% of transport emissions, a staggering contrast to road traffic (74.5%), aviation (11.6%), and shipping (10.6%).¹ This environmental edge is fueling a resurgence in rail's popularity, as passengers and freight operators alike seek out more sustainable mobility options. However, there's still work to be done since challenges such as the high energy consumption and the complex power distribution within trains remain. 

Electrification lies at the heart of sustainability in rail. The industry's global energy mix is shifting, with electricity accounting for more and more of the share . Currently, the International Union of Railways (UIC) estimates that approximately 50% of current global rail energy use comes from electricity.² This transition, coupled with the integration of renewable energy sources, is a game-changer for emissions reduction. 
Despite being comparably small, electromechanical components play their role in the electrification journey Solutions that have less weight, less resistance, consume less power and have a longer lifetime contribute to more energy savings and sustainability at any electrical connection within the train. In addition, advancements in traction motors, power electronics, and control systems are enhancing the performance and efficiency of electric and hybrid trains, expanding their range and capabilities. 

The rail industry is also leveraging regenerative braking and energy storage systems to minimize energy waste and boost efficiency. In modern systems, remaining energy loss is mostly the result of friction and electrical resistance. Regenerative braking systems capture and store kinetic energy during braking, which is then converted and reused for accelerating the train or powering onboard systems. Energy storage systems utilize mostly batteries to efficiently manage and store regenerated energy, reducing overall energy consumption and enhancing efficiency. 

Electromechanical connectors and contactors also contribute to sustainable rail infrastructures, enabling better power distribution and data/signal transmission with minimal energy losses. Innovative designs and materials contribute to this efficiency, ensuring precision, safety, and reliability in even the harshest operating conditions. Schaltbau’s electromechanical components contribute here by connecting or isolating the flow of energy with minimized losses (e.g.by contact resistance) and safe operation over the full range of demand. 

Sustainable Manufacturing: Paving the Way for a Greener Future 

Sustainability in the railway industry extends beyond operations and includes the industry's manufacturing processes. Pioneering companies are leading the way, embracing carbon-neutral factories, recycled materials, and other eco-friendly practices to minimize the environmental impact of rail production. We’re proud that our design and manufacturing processes guarantee precision and efficiency, use recycled materials and reduce environmental impact during production at our NExT Factory in Velden, Germany. 

The potential benefits of embracing innovative rail technologies are evident. By diversifying energy sources and providing more efficient mobility, the rail sector can further reduce transport-related emissions and help combat the global climate crisis.³ As the world becomes increasingly conscious of its environmental impact, the rail industry is positioned to play a pivotal role in the transition towards a greener, more sustainable future. 

Through the strategic implementation of electrification, energy-efficient infrastructure, smart technology, and sustainable manufacturing, the rail industry can drive this transformative shift. These topics and more will take center-stage at this year’s upcoming InnoTrans, the leading international trade fair for transport technology, taking place in Berlin on Sep 24-27. 

Join us there to learn more about how the latest advancements in electromechanical components can power the future of sustainable rail. Our team will be on hand to showcase our innovative products and solutions. We look forward to connecting with you there! 

Learn more about InnoTrans here!
 

References: 

1. Ritchie, H. (6. Oktober 2020). CO2-Emissionen aus dem Verkehr, 1990-2018. Unsere Welt in Daten. https://ourworldindata.org/co2-emissions-from-transport
2. Internationaler Eisenbahnverband (UIC). (2022). Global Rail Sustainability Reportr 2022 (S. 23). https://uic.org/IMG/pdf/global-rail-sustainability-report-2022.pdf
3. Internationale Energieagentur (IEA). (30. Januar 2019). Railways could provide much greater benefits for energy and the environment, according to IEA report. https://www.iea.org/news/railways-could-provide-much-greater-benefits-for-energy-and-the-environment-according-to-iea-report

Highlights will include new variants of the CP and CF contactor series that expands the high-power rail contactor portfolio. The company also will show a first prototype of their smart rail contactor. Additionally, Schaltbau will debut the PAD 41, a new emergency brake handle as well as a new snap-action switch. Together with their brand SPII, Schaltbau will also present intelligent rail interfaces such as master control systems and driver desks for intuitive and safe interaction.  

Visitors to InnoTrans 2024 can experience these innovations firsthand at Schaltbau’s exhibit located in Hall 2.2b, Stand 110. Schaltbau’s team of experts will be on hand to provide in-depth demonstrations and answer any questions about the new products. 

“At Schaltbau, innovation is a crucial element of our DNA," said Steffen Munz, CEO of Schaltbau. "We are diligently working to advance the industry with intelligent contactors and continually elevating our renowned rail technology for not only the highest standards of safety, but also to push the boundaries of innovation so that we contribute to the future of rail. We look forward to sharing this work at InnoTrans2024.”

Building on nearly a century of rail expertise, Schaltbau’s high-quality rail solutions have enabled safe, intelligent, and energy-efficient mobility on rail for generations—safely switching, connecting and controlling electrical systems in rail vehicle operation across the world. 

InnoTrans is a key event for the rail industry, bringing together global leaders and showcasing the latest advancements in transport technology. Schaltbau’s participation highlights its role as a global leader of rail solutions, dedicated to creating a safer, more efficient, and more connected rail network.