LightningBlu | Gigabit Internet for Rail

Lightning-fast track to train communications, keeping passengers seamlessly connected at 250+ kph. Day in and day out.

Ever tried to work on a train, only to battle with frozen video calls, failed emails, and endless buffering? You’ve experienced how the 5G mobile ‘revolution’ has left train passengers behind.

Blu Wireless had the communications expertise to fix it, and engaged us to deliver the technology from the lab bench into the real world – with rugged, visually refined enclosures built to withstand the harsh demands of railway travel.

Highlights

Engineering design
Thermal modelling
Design for manufacture
IP68 waterproofing
Rapid prototyping
Aerodynamic analysis

Blu Wireless high speed train internet communications - looking out of the window with lady and laptop on board train context

A Network of 3 Technical Enclosures

Working through a two-year development process, we created a family of three precision-engineered units, to safely house Blu Wireless’ sophisticated mmWave transceiver technology and withstand extreme environmental conditions.

Diagram Image of Blue Wireless Train 5 G System, showing the 3 components of and how they are connected

2 years of design and development, from initial concept sketches to production engineering drawings

Aerodynamics: For travel over 250 kph

The train top unit required careful consideration of the aerodynamics to reduce drag, eliminate noise and minimise dirt build-up. The performance was simulated using Computational Fluid Dynamics (CFD) before high speed trials and wind tunnel testing at UWE Bristol.

Thermodynamics: Keeping a high powered system cool

High powered radio electronics kick out a lot of heat and need to be cooled to stay alive! Good thermal management was considered all the way through the design process. The central metal part is designed to act as a heat sink.

Initially, 3D printed prototypes were used to check the form and fit. Later CNC-machined prototypes were manufactured to test the thermal performance against our FEA analysis.

IP Protection: Ensuring nothing gets through apart from data

IP68 water resistance was achieved using hidden O-ring seals, and specific non-metallic materials were needed for the radio windows so as not to hinder signal transmission. All units are made from solid aluminium to extract heat efficiently.

Safety & Compliance: Fully certified to EN50155 Meeting the highest of standards

Full environmental rail certification to EN50155. Extensive research ensured we’d meet the rigorous railway safety standards, fire resistance (V0), impact protection, UV stability at extreme temperatures were all considered to guarantee long-lasting performance.

Rolling out across railway networks worldwide

From San Francisco to London. The designs have enabled Blu to secure contracts with multiple operators. Passengers can stream high-quality video without dropouts, conduct uninterrupted video calls and stay productively connected throughout their journey.

Realise have consistently delivered across every project we’ve worked on together. They’re fast, responsive and handled the technical challenges with real expertise. Their knowledge of manufacturing processes meant we could get very professional looking and robust trial units out on the track quickly – exactly what was needed to launch successfully.

Jonathan Rogers

Director of Systems & Platforms