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Cable connection

Cable Bonding Methods

Electrical connection system for signalling, return traction and earthing applications within the Rail industry.
Pinbrazing, Safebond, Rail Bond, Safeplug, Track Shunting Devices

Electrical connection system for signalling, return traction and earthing applications within the Rail industry.

Pinbrazing, Safebond, Rail Bond, Safeplug, Track Shunting Devices


The only producer of a complete range of modern application systems

SAFETRACK is the leading manufacturer of Pinbrazing Systems. Have developed the unique SAFEBOND Method. Produces a temporary Rail Bonds System and Track Shunting Devices. And have now also introduced a new connection system with drill plugs, SAFEPLUG.

Click on following cable bonding methods.

Low heat brazing methods: PinBrazing and SafeBond® Drill plug system: Screw based bonding:
Pinbrazing Safebond Safeplug

Broken Rail Detection

Important advantages of the PinBrazing/SAFEBOND® method Vs drilling methods

1) If a broken rail arise (often where they have drilled for the fish plate), with Pinbrazing/SAFEBOND® on the rail head will the signal transference break and they will discover they have something wrong with the track and go out to check, then they see they have a broken rail and can repair without any derailment of trains. With the drilled connection they will presumably still have signal through BUT a broken rail and trains that is passing.

2) Lowest possible transition resistance because Pinbrazing/SAFEBOND® is the only methods that have a brazed, silver connection between the rail and the copper wire itself(unique manufacturing method). Not a mechanical connection.

3) Economy. When using a drilled connection you must use expensive plugs + larger area on the cable because a longer rail bond is needed around the fish plate+several times longer time to complete a connection. A comparison shows that the drilled connection can be several hundred percent more expensive than Pinbrazing/SAFEBOND® connections.

Time for operation of cpl. rail bond:

Pinbrazing/SAFEBOND®: 1-2 minutes (Every time).
Drilling: 4-6 minutes (Depending of rail hardness and how many drillings with the same drill).

Pinbrazing/SAFEBOND® Drilling
Pinbrazing/SAFEBOND® Drilling

4) Forces. When drilling a hole in the rail (ø19mm), the forces that affect the rail must be concentrated around the hole so the stress is higher on that part of the rail.

5) Fractural impression. A drilled hole leaves an uneven surface in the drill surface. This irregularity will be a possible start for cracks and a broken rail during the years.

6) Wear of drills. Modern rails is getting harder and harder. This will of course increase the required time to drill the holes but also decrease the number of holes before one have to replace the drill. If the drill not is replaced in time will the hole be oval and also the irregularities increase.

7) Cooling. If the cooling of the operation fail there is a huge risk of creating martensite.

8) Chamfering. It is necessary to chamfer the edge on the hole on both sides otherwise a dangerous concentration of forces will stress the rail. This operation is often neglected.

9) Checking. A drilled hole with mounted plug and cable is not possible to inspect visually that the drilling procedure have been made correctly, chamfering etc.

10) Versatility. Pinbrazing/SAFEBOND® can attach cables anywhere on the rail, either removable or fixed joints. Drill plugs can only be used in the web and as removable joints.

11) Environment. In opposite of Pinbrazing/SAFEBOND®, that is battery driven, is the drilling method powered by petrol. Large amount of cooling liquid is also used.

12) Vibrations and temperature changes. A screwed joint reinforcement that is affected by vibrations (passing trains) and temperature changes (winter and summer) could change over the years. Especially temperature changes are a very important factor because these changes affect the surface pressure between the drill plug and the hole.

13) Drilling Equipment. A lot of heavy drilling equipment have to be brought out to the work site:

-Drilling machine.
-Templates for different rail sizes.
-Calibration tool.
-Hydraulic tool.
-Coolant unit.
-Petrol can.
-Tools for spark plugs and mounting of cables.
-Heavy drill plugs. For ex: One drill plug= 180g. (100pcs=18kg) + heavier cables Compare to: One Pinbrazing pin with ferrule=10g. (100pcs=1kg)

14) Maintenance. With drilling methods a large need of maintenance of drills and machines are needed. Pinbrazing/SAFEBOND® needs more or less only to be recharged either from the mains or a vehicle.


What is a patent?

A patent is an exclusive right for an inventor during a period of 20 years to:


...a specific technique.

It is worth noting that only by using a patented technique that is not supplied from the owner of the patent is an infringement of the patent and may result in a lawsuit.

Safetrack develope, manufacture and marketing application methods on a worldwide basis and owns several dozens of patents.

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