Six Factors You Should Know When Selecting a Track Switch Heater
A rail track switch heater is a critical component in ensuring the smooth and reliable operation of railway systems, especially during the wintertime. When ice and snow accumulate on rail tracks, they can cause significant disruptions, particularly at switch points where tracks diverge or converge. A good rail track switch heater addresses these challenges, ensuring that freight and transit trains operate safely and on schedule.
Six Factors to Consider When Selecting a Track Switch Heater
What makes a good rail track switch heater? There are several factors to be considered when looking to install a new system or upgrade your existing rail track switch heating infrastructure. These include:
- Efficiency in Heating
The primary function of a rail track switch heater is to melt ice and snow. Efficient heaters use energy effectively to produce sufficient heat to keep switch points clear. The use of advanced heating elements and smart control systems that optimize energy use based on real-time weather conditions enhance efficiency.
- Durability and Reliability
Rail track switch heaters are exposed to harsh environmental conditions, including extreme cold, snow, ice, and moisture. A good heater is built from robust materials that can withstand these conditions without degrading. Reliability is critical; heaters must consistently perform without failure to prevent rail disruptions.
- Smart Control Systems
Modern rail track switch heaters often incorporate smart control systems that can adjust heating levels based on current weather conditions. These systems can be automated to turn on the heaters when the temperature drops below a certain point or when snow is detected. Smart controls can also allow for remote monitoring and diagnostics, enabling maintenance teams to quickly address any issues.
- Energy Efficiency
Energy efficiency is a significant consideration, both for cost savings and environmental impact. High-quality rail track switch heaters use energy-efficient technologies that reduce power consumption while maintaining performance. This can include the use of low-wattage heating elements, efficient insulation, and systems that use energy in response to when heat is required.
- Ease of Installation and Maintenance
Switch heaters should be designed for easy installation and maintenance. This includes modular designs that allow for quick replacement of parts and clear, accessible layouts for maintenance crews. The availability of knowledgeable technical support, should any issues arise, is also key. Reducing the time and complexity of installation and repairs helps to minimize disruption to rail services.
- Safety Features
Safety is paramount in railway operations. Good rail track switch heaters include safety features, such as thermal cutoffs to prevent overheating, ground fault protection to avoid electrical hazards, and robust insulation to protect against accidental contact.
Proven Performance in Real-World Conditions
A good rail track switch heater has a proven track record of performance in real-world conditions. Hotwatt heaters are used by railroads and rail transit authorities throughout North America to keep tracks free of snow and ice, even in the harshest of conditions.
With more than 50 years of experience building rail switch heaters, our heaters are built-to-last and perform in the toughest environments. Whether you are investing in a new system or upgrading your existing switch heating infrastructure, Hotwatt can custom design a solution that works for you.
We provide comprehensive information on our rugged and cost-effective solutions for rail authorities, including details about the electric heaters we manufacture, including flat tubular, round tubular, crib heaters (switch rod heaters), moveable point frog heaters, running rail heaters, ballast heaters, and hollow steel ties on this comprehensive resource page about how we serve the railroad and rail transit industry.
Today we are discussing flat tubular and round tubular switch point heaters in more detail here. Both are built using the highest quality materials and a proprietary manufacturing process. These heaters are available in any size and length, and we have the largest selection of diameters and alloys available—including Incoloy® and 300 series stainless-steel sheath.
Flat Tubular Switch Point Heaters
The Hotwatt flat tubular heater delivers more heat into the rail than conventional round tubular heaters through its geometry. Flat switch point heating delivers more heat through thermal conductivity, and has ~40% surface-area contact with the rail; the round tubular heater has ~15% surface-area contact with the rail. This is constant wattage heating.
Other features of flat tubular heaters include:
Uniform Heating: The flat design allows for more uniform heat distribution over a larger surface area, making it suitable for applications that require consistent heat.
Customizable Shapes: Flat tubular heaters can be fabricated in various shapes and sizes to fit specific requirements. This makes them versatile and adaptable to different applications.
Easy Installation: The flat shape makes installation straightforward, especially in applications where space is limited or a specific form factor is needed.
Space Efficiency: Due to their flat profile, these heaters can be installed in tight spaces or where a low-profile heating element is needed.
Efficient Heat Transfer: The flat shape also enhances heat transfer efficiency, ensuring that heat is effectively transferred to the target area without significant heat loss. Flat heaters are effective for applications requiring quick heating.
Durability: Flat tubular switch point heaters are often robust and can withstand high temperatures, making them suitable for demanding environments.
Round Tubular Switch Point Heaters
Available in a variety of lengths and diameters, the round tubular heater performs in the harshest conditions and provides a cost-effective solution to switch point heating. This constant wattage heater has ~15% surface-area contact with the rail.
These heaters can be placed on the outside of the running rail, with wrap-around clips through rail braces, or on the inside of the rail via bolt on clips. Round switch point heaters are coiled for ease of transportation to the site and on the track. This switch point heater can be made of stainless steel or Inconel.
The Hotwatt round tubular heater performs in the harshest conditions and is the most rugged and longest-lived heater on the market; this, combined with an affordable price and customization, make it the optimal solution.
Other features of round tubular heaters include:
High Heat Concentration: The round shape enables these heaters to deliver high heat concentration to specific points or areas, making them suitable for applications that require focused heating.
Versatility: Round tubular heaters can be used in a variety of applications, transit and rail applications, as well as industrial processes, medical equipment, and plastic process and packaging, and equipment heating.
Rugged Construction: Round tubular heaters are typically durable and able to withstand harsh operating conditions, such as those found in rail and transit applications. They are well-suited for industrial applications that demand robust heating elements.
Easy Installation: The cylindrical shape allows for easy installation and replacement, as they can fit into standard mounting configurations.
Customizable: Round tubular heaters can be customized in terms of wattage, voltage, and sheath material to suit specific application requirements.
Both flat tubular and round tubular switch point heaters offer distinct advantages depending on the specific heating requirements of the application. Consideration of factors such as heat distribution needs, space constraints, durability, and customization options will help determine the most suitable type of heater for a particular application.
As mentioned above, our comprehensive range of heating solutions also includes switch rod heaters, moveable frog point heaters, running rail and ballast heaters. In addition, our sister company, NIBE North America, offers a patented dual-element heating system. The Blue Point switch heating system uses pulse width modulation (PWM) to dial in the exact wattage needed. In extreme conditions, heat—as much as 600 watts per foot—is applied to switch points to keep rails free of ice and snow.
What is most impressive is the PWM controller’s ability to modulate energy use, which can reduce energy costs by 90% or more. Combined with proactive monitoring, remote diagnostics, and a 10-year warranty, this is an excellent solution for transit authorities looking to boost performance and significantly reduce energy costs.
Custom Design Your Rail Switch Heater
A good rail track switch heater ensures that rail operations run smoothly and efficiently, even in the most extreme conditions. Precision heating, tight tolerances, and robust manufacturing are all critical to a dependable, efficient rail switch heating system. When you engage with us, our engineers work closely with your team to meet all physical, regulatory, and performance requirements.
Backer Hotwatt solves unique heating problems with custom designed and manufactured solutions that our competitors can’t—or won’t—provide. We’re here to help you create the best rail heater for your needs.
- We build heaters to any length and size.
- We have the largest selection of diameters and alloys available.
- Transit customers—both in the freight and passenger rail segments—buy directly from us.
- You receive better technical support and more customizable options.
How can we help you with your next rail switch heating project? Contact an engineer today to set up an exploration consultation. We look forward to helping you soon.