Abstract
This article presents the methodology, description, and results of experimental studies aimed at determining the impact of the copper concentration in a carbon–metal composite contact strip on the maximum temperature of the copper contact wire during a contact event when used for operation in the railway industry in Europe. Based on these tests, we determined the minimum percentage of copper that is required for the composite to meet the normative requirements for current loads. In addition to experimental research, a 3D FEM numerical model was also developed in which the contact strip and contact wire geometry were mapped, along with imposed loads resulting from the test for current loads mentioned above. Fifteen simulation variants were carried out for the established model, where the value of the thermal conductivity coefficient and the specific heat coefficient were varied. On this basis, we analyzed the sensitivity of thermal coefficients to the contact wire temperature and determined the minimum conductivity coefficient value, which allowed the maximum copper contact wire temperature of 120 °C to be obtained during the verification tests.
Highlights
The cooperation between the pantograph of a railway vehicle and the overhead contact line boils down to the contact between the contact plates of the pantograph and the contact wire. This essentially results in contact between two different materials—the carbon composite of strips with the copper of the railroad wire
In Poland, contact strips made of carbon rather than copper have been used since 2011 in an attempt to adapt to the requirements of the TSI [15]
We have carried out numerous certification [20] and operational [21] tests to assess the quality of cooperation between carbon contact strips and copper contact wire on rolling stock operated in Poland
Summary
The cooperation between the pantograph of a railway vehicle and the overhead contact line boils down to the contact between the contact plates of the pantograph and the contact wire. We have carried out numerous certification [20] and operational [21] tests to assess the quality of cooperation between carbon contact strips and copper contact wire on rolling stock operated in Poland In these studies, special attention was paid to thermal issues. One of the most visible changes in the use of new materials is the replacement of copper inlays from the start of the rail comprising carbon composite inserts with the addition of copper This resulted from the need to reduce wear of the contact wire as well as to eliminate graphite grease, which has an adverse effect on the environment. We earlier tested the concentration of metals used in contact wire and its effect on the resulting thermal resistance [21] as a basis for the current study
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