conductor rail documents
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Railtech Alu SingenRailtech International and Alcan Singen GmbH:
A COMBINATION OF STRENGTHSCOMBINATION OF STRENGTHSfor the benefit of the customer...
RailtechRailtech International:International:- leader in rail technology- worldwide flexibility-core business: insulators and third rail components
- strong references formass transit electrificationsystems & composites
3rd rail system
AlcanAlcan Singen GmbH:Singen GmbH:- leader in aluminium technology- large group + resources- core business: conductor rail- strong references forsupply of coextruded 3rd rail
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1. References1.1 References for coextruded conductor rail1.2 References for insulators1.3 References for 3rd rail systems
2. Conductor rail
3. 3rd Rail ComponentsSplice joint assemblies - Expansion jointsAnchor assemblies - General arrangementLow speed ramp cable terminals - covers
4. Testing of 3rd
TABLE OFTABLE OFCONTENTS:CONTENTS:
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1.1 REFERENCES: COEXTRUDED CONDUCTOR RAIL1.1 REFERENCES: COEXTRUDED CONDUCTOR RAILTransit System: Year: Quantity:Berlin Underground 1978 - 1995 20.480 mHamburg Rapid Transit 1978 - 1984 3.300 mOsaka South Port - Town Line 1979 34.000 mMetro Barcelona 1980 - 1982 8.000 mLondon Docklands Light Railway 1984 - 1995 89.500 mVienna Underground 1984 - 2000 49.050 mSMRT Singapore 1985 - 2001 223.150 mMetro North New York 1985 - 1999 8.400 mBerlin Rapid Transit 1986 - 2001 401.000 mTokyo Monorail 1986 4.000 mBritish Rail Portsmouth 1988 8.000 mMunich Underground 1992 - 1998 39.100 mTRTC Taipei 1992 - 1999 66.350 mLRTS Kuala Lumpur 1994 - 1996 41.200 mBTS Bangkok 1996 - 1998 60.870 mNuremberg Underground 1997 - 1998 9.100 mPeople Mover Turin 1999 3.400 m
1.068.900 m
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1.2 REFERENCES: INSULATORS1.2 REFERENCES: INSULATORSTransit System: Year: Quantity:A) Railway TrackSNCF Paris since 1936 92.000 pcs.RATP Paris since 1972 95.000 pcs.Tunis since 1933 18.000 pcs.Barcelona 1973 - 1978 25.000 pcs.Caracas 1980 - 2001 78.500 pcs.London 1985 - 1986 11.500 pcs.Lisboa 1995 4.500 pcs.Kuala Lumpur 1996 - 1999 24.000 pcs.MRTS Bangkok 2001 11.000 pcs.Athenes 2003 2004 7000 pcs.B) Special Track for TyresRATP Paris 1961 - 2001 74.000 pcs.Marseille 1977 - 1998 46.000 pcs.Lyon 1977 - 1998 67.500 pcs.Santiago de Chile 1976 - 1999 67.500 pcs.Mexico 1986 - 1993 7.500 pcsMontreal 2003 - 2004 8000 pcs.
617.500 pcs.approx. 2.000.000 m
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1.3 REFERENCES: 3rd RAIL SYSTEM1.3 REFERENCES: 3rd RAIL SYSTEMTransit System: Year: Length:Disney Monorail 1970 11.000 mBART San Francisco 1977 14.000 mBarcelona Metro 1973 - 1978 50.000 mCaracas Metro 1980, 1992, 2001 187.000 mBC Transit Vancouver 1987 - 1992 128.000 mToronto Transit 1986, 1999 32.000 mDetroit Transit 1986, 1999 20.000 mKuala Lumpur 1997 120.000 mMRTA Bangkok 2001 56.000 mWuhan (China) 2003Athenes 2003 2004 36.000 mTransRapid (test track) 2003
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2. COEXTRUDED CONDUCTOR RAIL:2. COEXTRUDED CONDUCTOR RAIL:ManufacturingManufacturing processprocess
High temperatures, high pressure: metallic bondLowest interface resistance, longterm stability (-> comperative testing)
Stainless steel coilDie
Press
Aluminium billet
Extrusion stamp
The stainless steel strip is rolled on a coil and feed to the extrusion press. Twocoils are used, one on the left side andone on the right side of the extrusion press since a duplex profile is extruded. The aluminium billet (pushed by theextrusion stamp) and both stainless steelstrips are extruded through the tooling(die) which gives the shape for theconductor rail.
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2. COEXTRUDED CONDUCTOR RAIL:2. COEXTRUDED CONDUCTOR RAIL:Design Design featuresfeatures of of steelsteel stripstrip
Bent and punched stainless steel strip;X6Cr17 = high chromium steel (17%)thickness 4,5mm minimum.
Lateral punchings; filled withaluminium during extrusion process.Steel strip is one piece & not subjectof delamination due to wear.
Cross-section of conductor rail;showing detail of interlocking.
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2. COEXTRUDED CONDUCTOR RAIL:2. COEXTRUDED CONDUCTOR RAIL:ExampleExample and design and design detailsdetails
Detail: Steel strip and interlockingConductor rail Metro North New York
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3. :33. :3rdrd RailRail ComponentsComponentsSpliceSplice jointjoint assembliesassemblies ((examplesexamples))
Splices Berlin UndergroundSplices MRTA Bangkok
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3. :33. :3rdrd RailRail ComponentsComponentsExpansion Joint (Expansion Joint (examplesexamples))
Expansion joint - MRTA Bangkok Expansion joint cover MRTA Bangkok
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3. :33. :3rdrd RailRail ComponentsComponentsExpansion Joint (Expansion Joint (examplesexamples))EJ BTS Bangkok
EJ - TransRapid
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3. :33. :3rdrd RailRail ComponentsComponentsExpansion Joint (Expansion Joint (examplesexamples))
EJ - Athens
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3. :33. :3rdrd RailRail ComponentsComponentsAnchorAnchor AssemblyAssembly ((examplesexamples))
Anchor design for MRTA Bangkok
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3. :33. :3rdrd RailRail ComponentsComponentsAnchorAnchor AssemblyAssembly ((examplesexamples))
Anchor design BTS Bangkok
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3. 3. 3rd 3rd RailRail ComponentsComponentsGeneral General arrangementarrangement, , bracketbracket & & insulatorinsulator
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3. 3. 3rd 3rd RailRail ComponentsComponentsGeneral General arrangementarrangement, , bracketbracket & & insulatorinsulator
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3. 3. 3rd 3rd RailRail ComponentsComponentsExampleExample MRTA Bangkok,MRTA Bangkok, mechanicalmechanical analysisanalysis
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3. 3. 3rd 3rd RailRail ComponentsComponentsLowLow speedspeed rampramp, high , high speedspeed rampramp, , applicationsapplications
Ramp design BTS Bangkok
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3. 3. 3rd 3rd RailRail ComponentsComponentsCABLE TERMINALSCABLE TERMINALS
Power feed Berlin Rapid Transit
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3. 3. 3rd 3rd RailRail ComponentsComponentsExamplesExamples of of existingexisting applicationsapplications
Power feed MRTA Bangkok
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3. 3. 3rd 3rd RailRail ComponentsComponentsStandard cover, distance holder, Standard cover, distance holder, specialspecial partsparts
Cover design MRTA Bangkok
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4. TESTING OF 3rd RAIL:4. TESTING OF 3rd RAIL:LongitudinallyLongitudinally cuttingcutting & & TensileTensile testtest
Result:Metallic bond breaksat 15 kN.Interlocking ok 22-24 kN.Delamination at 25 kN.-> very good results
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4. TESTING OF 3rd RAIL SYSTEM:4. TESTING OF 3rd RAIL SYSTEM:Short Short circuitcircuit testtest
Result:100 kA for 1 s successfully passed!
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4. TESTING OF 3rd RAIL SYSTEM:4. TESTING OF 3rd RAIL SYSTEM:InsulatorInsulator TestingTesting
Tests usually performed on the insulators:
Mechanical tests
High voltage test
Non propagation of flame
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A high experience in Railway application with the most exacting customers
A design department to propose you a complete third rail solution adapted atyour needs
A world wide flexibility
The guarantee of two major companies :
Strong references in third rail application
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1.1 REFERENCES: CONDUCTOR RAIL SINCE 1978...1.1 REFERENCES: CONDUCTOR RAIL SINCE 1978...
Berlin Rapid Transit
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1.1 REFERENCES: CONDUCTOR RAIL SINCE 1978...1.1 REFERENCES: CONDUCTOR RAIL SINCE 1978...
Vienna Underground
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1.1 REFERENCES: CONDUCTOR RAIL SINCE 1978...1.1 REFERENCES: CONDUCTOR RAIL SINCE 1978...
Nuremberg Underground Munich Underground
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1.1 REFERENCES: CONDUCTOR RAIL SINCE 1978...1.1 REFERENCES: CONDUCTOR RAIL SINCE 1978...
LRTS Kuala LumpurSMRT Singapore
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1.1 REFERENCES: CONDUCTOR RAIL SINCE 1978...1.1 REFERENCES: CONDUCTOR RAIL SINCE 1978...
BTS Bangkok
TRTC Taipei
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1.3 REFERENCES: THIRD RAIL SYSTEM1.3 REFERENCES: THIRD RAIL SYSTEM
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Athenes Athenes
Athenes
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1.3 REFERENCES:1.3 REFERENCES: THIRD RAIL SYSTEMTHIRD RAIL SYSTEM
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Trans Rapid
Trans Rapid
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1.2 REFERENCES:1.2 REFERENCES: INSULATORSINSULATORS
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Athenes Trans Rapid