3P Front End Systems

As traffic volume increases, so too does the risk of accidents – particularly close to tram stops and crossings. The HÜBNER Group has more than 30 years of experience in the production of tram front ends made of polyurethane (PUR) foam. With this expertise it is possible to combine passive pedestrian protection with modern vehicle design to best effect.

Depending on  the requirements, our polyurethane components can be produced so as to be robust, heat-resistant and shock-absorbent. In addition to this they have outstanding thermal and acoustic insulating characteristics.

Depending on the desired components and other customer wishes, we process PUR in the following forms:

•     PUR flexible foam
•     PUR integral foam - flexible to semi-rigid
•     PUR integral foam - hard
•     PUR compact duromer
•     PUR RIM systems

Shock-absorbing front bumpers for more safety

For trams and streetcars, we produce paneling elements, head lights and special front bumpers. The "3P Front End System" (People Protection Products) for trams is made of flexible polyurethane foam and provides optimal protection for both pedestrians and the vehicle in the event of a collision.

The system consists of shock-absorbent polyurethane foam which absorbs the impact force in the case of a collision. With the use of this material, the HIC value (Head Injury Criterion) is brought substantially below the threshold value of 850.

The HIC value indicates the impact force that a person is subjected to in the event of a collision. Values up to 850 typically result in minimal or no injuries at all to the involved persons, while values over 1,300 typically result in serious injuries. Our front bumpers, vehicle paneling parts and headlights for tram vehicles have an impressive HIC value of 600. By contrast, traditional vehicle paneling parts typically have values substantially over 1,300.

HÜBNER is the first manufacturer worldwide to offer the tram vehicle front ends that fulfill the specifications of the new fire safety standard EN 45545.

The challenge was to find a way to be able to paint the material in accordance with customer wishes. In the past, the paint finishing together with the polyurethane foam were too highly flammable. We were able to solve this problem.

Bumper quickly returns to its original form

Polyurethane has a cellular structure This makes it so that the material deforms on impact and then in a short time returns to its original form again. Within just a few seconds after impact the front bumper regains its original contours.

In addition, the material does not splinter – in contrast to panel elements made of reinforced plastic fiber material. Such parts can inflict serious injuries to pedestrians through small flying splinters that are discharged on impact. The PUR foam technology is far superior to the traditional vehicle paneling components in this respect.

Economical modernization

Long years of use also make themselves felt in the appearance of tram vehicles. If trams are still delivering good service, however, and the technical features are only outdated in their appearance, then there is an another possibility besides the cost-intensive procurement of new vehicles. An economical alternative developed by HÜBNER is the installation of new bumper elements with pedestrian protection – available also for older tram models. A practical side effect: Vehicles that have taken on an outdated appearance shine again with a fresh new design. In addition, the bumper elements can provide space for other technical upgrades such as modern headlight systems.

Shock-absorbing vehicle paneling parts at a glance:

• Front bumpers, paneling elements and headlines made of shock absorbing polyurethane foam.
• HIC value: 600
• No splintering – more safety for pedestrians
• Unlimited design options with structured, silk-matte or high-gloss finishes