Overhead Conductor Rail With Undercut Recess for Sag Reduction
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Solution Overview
Problem
Existing conductor rails in catenary systems suffer from sagging due to insufficient moment of inertia and require complex assembly processes, which complicates installation and maintenance.
Innovation Solution
The conductor rail features a recessed upper carrier with undercut longitudinal sides, allowing for easy attachment using connecting elements like hook-head screws, enhancing moment of inertia while simplifying assembly and reducing sag through strategic placement of connecting elements at zero moment points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the moment of inertia is increased to reduce sag, then the weight of the conductor rail increases, but the assembly effort and installation complexity remain high
Solution Approach 1:
The conductor rail is divided into multiple segments that can be assembled separately and then connected using connecting elements. The upper carrier is segmented with specific geometric features (recesses, undercuts) that facilitate modular assembly, allowing the rail to achieve high moment of inertia through optimized segment geometry rather than increasing overall weight
Solution Approach 2:
The upper carrier incorporates a longitudinal recess with undercut sides, creating a three-dimensional geometric feature that engages with connecting elements. This dimensional change allows the structure to achieve higher moment of inertia through optimized cross-sectional geometry rather than simply increasing mass
2Reliability
If complex assembly processes are used to ensure proper installation, then the reliability of installation improves, but the assembly effort and time increase
Solution Approach 1:
The upper carrier features self-aligning geometric characteristics including longitudinal recesses with undercut sides that automatically guide connecting elements into proper positions. The hooked head screws engage with the undercut recesses to create self-centering connections, eliminating the need for complex alignment procedures or specialized assembly tools
Solution Approach 2:
Connecting elements serve as intermediaries between the upper carrier segments and the support structure. These intermediaries (hooked head screws, clamping elements) simplify the connection process by providing standardized engagement features that reduce assembly complexity while ensuring reliable mechanical connections
Data Source
AI summary
The invention relates to a conductor rail for overhead contact line systems and to an overhead contact line system with conductor rails. The conductor rail 1 according to the invention is characterized in that the upper support 2, in its installed position, has a longitudinally extending recess 3 on its upper surface, which is undercut on the opposite longitudinal sides. The longitudinally extending recess 3 in the support 2 allows the conductor rails to be attached to the cantilevers of the overhead contact line system by means of connecting elements that engage in the recesses to create a positive-locking connection. In a preferred embodiment, the recess 3 of the upper support 2 is designed to receive the hook head 9 of a hook-head screw 8, with which the conductor rail can be attached to the cantilever in a particularly simple and cost-effective manner.Furthermore, the conductor rail, with its special upper support design, is characterized by a relatively high moment of inertia at a relatively low weight. This allows for a reduction in sag or an increase in the longitudinal span.