Modular Conductor Rail Assembly with Form-Fitting Head Profile
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Solution Overview
Problem
Existing conductor rails for mobile electricity consumers, such as electrically driven rail vehicles, face complex installation and dismantling processes due to the need for welding and intricate connections, which increases assembly and disassembly efforts and reduces flexibility.
Innovation Solution
A conductor rail design featuring a carrier profile composed of two elements and a head profile that form a form-fitting and non-positive connection, allowing for easy assembly and disassembly by changing the positional relationship of the carrier profile elements within the head profile, and facilitating axial coupling of busbars through offset ends and conductive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding and intricate connections are used to assemble conductor rails, then the structural strength and reliability are improved, but the assembly and disassembly complexity and effort increase significantly
Solution Approach 1:
The conductor rail is divided into modular sections with standardized interfaces. Each section can be independently assembled and disassembled using simple connection elements rather than welding, maintaining structural integrity while enabling easy reconfiguration and maintenance.
Solution Approach 2:
Connection elements serve as intermediaries between conductor rail sections. These standardized mechanical connectors replace welding operations, providing reliable structural joints that can be easily assembled and disassembled without specialized equipment or processes.
2Strength
If welding and intricate connections are used to assemble conductor rails, then the structural strength is improved, but the installation time and productivity are reduced
Solution Approach 1:
Connection elements and conductor rail sections are pre-configured with standardized interfaces during manufacturing. This preliminary preparation eliminates the need for complex field assembly operations, allowing rapid installation by simply connecting pre-matched components.
Solution Approach 2:
The conductor rail system is segmented into standardized modules that can be quickly assembled using simple mechanical connections. This modular approach replaces time-consuming welding operations with fast-connect interfaces, significantly improving installation speed while maintaining structural strength.
3Stability of the object's composition
If complex connections are used in conductor rail design, then the structural stability is improved, but the flexibility and adaptability for different installations are reduced
Solution Approach 1:
The connection elements are designed with universal interfaces that can accommodate various conductor rail configurations and orientations. The same standardized connection mechanism provides stable structural joints while enabling adaptation to different installation scenarios without requiring custom-designed components.
Solution Approach 2:
The connection system incorporates adjustable and reconfigurable elements that allow the conductor rail structure to be dynamically adapted to different installation requirements. Components can be easily repositioned and reconnected, providing both structural stability during operation and flexibility during installation and modification.
Data Source
Figure 1~2
Figure 3a~3c
Figure 4a~4c
AI summary
The invention relates to a power rail (10) for movable power consumers, in particular for electrically driven vehicles, preferably rail vehicles, having a carrier profile which comprises a first carrier profile element (12) and a second carrier profile element (14) which are coupled to one another along a surface (13a, 13b) which is partially curved, and a head profile (16) which has a first lateral section (16a) and a second lateral section (16b) lying opposite, and which is connected in a positively engaging and/or frictionally engaging fashion to the first carrier profile element (12) and to the second carrier profile element (14), wherein an end of the surface (13a, 13b) which faces the head profile (16) is arranged closer to the second lateral section (16b) than to the first lateral section (16a). The power rail according to the invention is characterized in that the two carrier profile elements (12, 14) are coupled to one another in a positively locking fashion and/or frictionally locking fashion along the surface (13a, 13b) by means of the head profile part (16). Furthermore, the invention relates to a corresponding method for mounting or dismounting a power rail (10) and to a system composed of multiple axially combined power rails.