Download the Complete Electromagnetic Relay Case Study

The Problem:

It is incredibly vital that signaling relays, used in train control systems, work under extreme conditions. A leading manufacturer of rail signaling systems was looking for a way to improve the reliability and long-term performance of several electromechanical relay components in order to improve the overall safety of rail traffic.

To function, these rail relays must have:

  • Low “magnetic remanence”
  • Resistance to aging
  • Control of “stack tolerance”

Filling all of these demands for such a specific application proved to be impossible for other manufacturers.

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Tell Us About Your Application

The Problem:

It is incredibly vital that signaling relays, used in train control systems, work under extreme conditions. A leading manufacturer of rail signaling systems was looking for a way to improve the reliability and long-term performance of several electromechanical relay components in order to improve the overall safety of rail traffic.

To function, these rail relays must have:

  • Low “magnetic remanence”
  • Resistance to aging
  • Control of “stack tolerance”

Filling all of these demands for such a specific application proved to be impossible for other manufacturers.

The Solution:

Our breadth of forging experience allowed our experts to provide the right manufacturing processes for improving the relay signaling system’s reliability.

Rail Relay Solution

Beginning with silicon iron, a traditional material used in magnetic circuits, we were able to:

  • Develop a complex manufacturing and supply change management process for the relay manufacturer
  • Upgrade the production process to assure an improved, consistent end result 
  • Meet specific magnetic requirements dictated by the position in the electromagnetic circuit
  • Manage all secondary operations to offer a completed component, ready for assembly on the customer’s line

We managed this entire process to assure highly consistent magnetic material properties for over a dozen critical components in a variety of sizes and configurations.

The Results:

Through innovative processing and continuous management of a complex supply chain, we were able to provide a cost-competitive solution, improving reliability and consistency.

The final product we were able to deliver:

  • A productivity increase from 80-90 to more than 450-500 finished standard relays per shift (more than a 400% improvement)
  • A value-added approach, allowing the customer to dramatically simplify their supply chain
  • Enhanced reliability of the electromagnetic relays for improved rail transportation safety

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