Railtech Alu Singen

Railtech International and Alcan Singen GmbH:

A COMBINATION OF STRENGTHS COMBINATION OF STRENGTHS
for the benefit of the customer...
Railtech Railtech International: International:
- leader in rail technology
- worldwide flexibility
-core business: insulators and
third rail components
- strong references for
mass transit electrification
systems & composites
3
rd
rail system
Alcan Alcan Singen GmbH: Singen GmbH:
- leader in aluminium technology
- large group + resources
- core business: conductor rail
- strong references for
supply of coextruded 3rd rail
1. References
1.1 References for coextruded conductor rail
1.2 References for insulators
1.3 References for 3rd rail systems
2. Conductor rail
3. 3rd Rail Components
Splice joint assemblies - Expansion joints
Anchor assemblies - General arrangement
Lowspeed ramp cable terminals - covers
4. Testing of 3rd
TABLE OF TABLE OF
CONTENTS: CONTENTS:
1.1 REFERENCES: COEXTRUDED CONDUCTOR RAIL 1.1 REFERENCES: COEXTRUDED CONDUCTOR RAIL
Transit System: Year: Quantity:
Berlin Underground 1978 - 1995 20.480 m
Hamburg Rapid Transit 1978 - 1984 3.300 m
Osaka South Port - Town Line 1979 34.000 m
Metro Barcelona 1980 - 1982 8.000 m
London Docklands Light Railway 1984 - 1995 89.500 m
ViennaUnderground 1984 - 2000 49.050 m
SMRT Singapore 1985 - 2001 223.150 m
Metro North New York 1985 - 1999 8.400 m
Berlin Rapid Transit 1986 - 2001 401.000 m
Tokyo Monorail 1986 4.000 m
British Rail Portsmouth 1988 8.000 m
MunichUnderground 1992 - 1998 39.100 m
TRTC Taipei 1992 - 1999 66.350 m
LRTS Kuala Lumpur 1994 - 1996 41.200 m
BTS Bangkok 1996 - 1998 60.870 m
NurembergUnderground 1997 - 1998 9.100 m
People Mover Turin 1999 3.400 m
1.068.900 m
1.2 REFERENCES: INSULATORS 1.2 REFERENCES: INSULATORS
Transit System: Year: Quantity:
A) Railway Track
SNCF Paris since1936 92.000 pcs.
RATP Paris since1972 95.000 pcs.
Tunis since1933 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 Tyres
RATP 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 pcs
Montreal 2003 - 2004 8000 pcs.
617.500 pcs.
approx. 2.000.000 m
1.3 REFERENCES: 3rd RAIL SYSTEM 1.3 REFERENCES: 3rd RAIL SYSTEM
Transit System: Year: Length:
Disney Monorail 1970 11.000 m
BART San Francisco 1977 14.000 m
Barcelona Metro 1973 - 1978 50.000 m
Caracas Metro 1980, 1992, 2001 187.000 m
BC Transit Vancouver 1987 - 1992 128.000 m
Toronto Transit 1986, 1999 32.000 m
Detroit Transit 1986, 1999 20.000 m
Kuala Lumpur 1997 120.000 m
MRTA Bangkok 2001 56.000 m
Wuhan(China) 2003
Athenes 2003 2004 36.000 m
TransRapid(test track) 2003
2. COEXTRUDED CONDUCTOR RAIL: 2. COEXTRUDED CONDUCTOR RAIL:
Manufacturing Manufacturing process process
High temperatures, high pressure: metallic bond
Lowest interface resistance, longterm stability (-> comperative testing)
Stainlesssteel coil Die
Press
Aluminium
billet
Extrusion stamp
Thestainlesssteel stripisrolledon a
coil andfeedto theextrusion press. Two
coilsare used, oneon theleft sideand
oneon theright sideof theextrusion
presssincea duplex profile isextruded.
Thealuminium billet (pushedby the
extrusion stamp) andbothstainlesssteel
stripsare extrudedthroughthetooling
(die) whichgivestheshapefor the
conductor rail.
2. COEXTRUDED CONDUCTOR RAIL: 2. COEXTRUDED CONDUCTOR RAIL:
Design Design features features of of steel steel strip strip
Bent and punched stainless steel strip;
X6Cr17 = high chromium steel (17%)
thickness 4,5mm minimum.
Lateral punchings; filled with
aluminium during extrusion process.
Steel strip is one piece & not subject
of delamination due to wear.
Cross-section of conductor rail;
showing detail of interlocking.
2. COEXTRUDED CONDUCTOR RAIL: 2. COEXTRUDED CONDUCTOR RAIL:
Example Example and design and design details details
Detail: Steel strip and interlocking Conductor rail Metro North New York
3. :3 3. :3
rd rd
Rail Rail Components Components
Splice Splice joint joint assemblies assemblies ( (examples examples) )
Splices Berlin Underground
Splices MRTA Bangkok
3. :3 3. :3
rd rd
Rail Rail Components Components
Expansion Joint ( Expansion Joint (examples examples) )
Expansion joint - MRTA Bangkok
Expansion joint cover MRTA Bangkok
3. :3 3. :3
rd rd
Rail Rail Components Components
Expansion Joint ( Expansion Joint (examples examples) )
EJ BTS Bangkok
EJ - TransRapid
3. :3 3. :3
rd rd
Rail Rail Components Components
Expansion Joint ( Expansion Joint (examples examples) )
EJ - Athens
3. :3 3. :3
rd rd
Rail Rail Components Components
Anchor Anchor Assembly Assembly ( (examples examples) )
Anchor design for MRTA Bangkok
3. :3 3. :3
rd rd
Rail Rail Components Components
Anchor Anchor Assembly Assembly ( (examples examples) )
Anchor design BTS Bangkok
3. 3. 3rd 3rd Rail Rail Components Components
General General arrangement arrangement , , bracket bracket & & insulator insulator
3. 3. 3rd 3rd Rail Rail Components Components
General General arrangement arrangement , , bracket bracket & & insulator insulator
3. 3. 3rd 3rd Rail Rail Components Components
Example Example MRTA Bangkok, MRTA Bangkok, mechanical mechanical analysis analysis
3. 3. 3rd 3rd Rail Rail Components Components
Low Low speed speed ramp ramp, high , high speed speed ramp ramp, , applications applications
Rampdesign BTS Bangkok
3. 3. 3rd 3rd Rail Rail Components Components
CABLE TERMINALS CABLE TERMINALS
Power feed Berlin
RapidTransit
3. 3. 3rd 3rd Rail Rail Components Components
Examples Examples of of existing existing applications applications
Power feed MRTA Bangkok
3. 3. 3rd 3rd Rail Rail Components Components
Standard cover, distance holder, Standard cover, distance holder, special special parts parts
Cover design MRTA Bangkok
4. TESTING OF 3rd RAIL: 4. TESTING OF 3rd RAIL:
Longitudinally Longitudinally cutting cutting & & Tensile Tensile test test
Result:
Metallic bond breaks
at 15 kN.
Interlocking ok 22-24 kN.
Delamination at 25 kN.
-> very good results
4. TESTING OF 3rd RAIL SYSTEM: 4. TESTING OF 3rd RAIL SYSTEM:
Short Short circuit circuit test test
Result:
100 kA for 1 s successfully passed!
4. TESTING OF 3rd RAIL SYSTEM: 4. TESTING OF 3rd RAIL SYSTEM:
Insulator Insulator Testing Testing
Tests usuallyperformedon theinsulators:
Mechanical tests
Highvoltage test
Non propagation of flame

A highexperiencein Railwayapplication withthemost exactingcustomers

A design department to propose youa completethirdrail solution adaptedat
your needs
A worldwideflexibility
Theguaranteeof twomajor companies:
Strongreferencesin thirdrail application
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 Lumpur
SMRT 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 SYSTEM 1.3 REFERENCES: THIRD RAIL SYSTEM
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Athenes Athenes
Athenes
1.3 REFERENCES: 1.3 REFERENCES: THIRD RAIL SYSTEM THIRD RAIL SYSTEM
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Trans Rapid
Trans Rapid
1.2 REFERENCES: 1.2 REFERENCES: INSULATORS INSULATORS
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Athenes Trans Rapid