Industrial and Traction Technology

Carbon Sliding Stripsfor Pantographs and Trolley Pole Systems

Schunk Kohlenstofftechnik

Page

Sliding Strips 3

Grades – Current Load 5

Sliding Strips Catenary Current Collection 6

Design Variations – Complete Collector Strips 7

Sliding Strips Catenary Current Collection 8

Design Variations – Special Design 9

Sliding Strips – 3rd & 4th Rail 10

Grades – Designs 11

Carbon Inserts – Trolley Pole Systems 12

Grades – Current Load Design Variations/Collector Shoe 13

Worldwide Location 14

Certificate 15

Contents

2

Sliding Strips

3

It is an imperative prerequisitefor the safe and economic opera-tion of both – Light and HeavyRail transit vehicles – to assureuninterrupted and complete cur-rent collection from the catenary– or the power rail.

It is Schunk’s worldwide objectiveto design, manufacture, and pro-vide a variety of individual com-ponents to support efficient railand road operations.

We Supply

complete pantographs carbon current collector strips

for roof pantographs carbon current collector strips

for 3rd & 4th rail applications carbon current collector inserts

for trolley pole systems

Why Carbon?

The excellent physical propertiesof carbon have been exploited formany decades to transmit powerfrom overhead contact wiresand/or power rails to electricallyoperated vehicles. Some of thoseproperties are:

an excellent sliding capability great electric and heat conduc-

tability high mechanical strength good damping properties no tendency to weld formation of protective coating

(patina) largely corrosion proof stable contact conditions prevention of radio interference

As the result of the advancesmade in the design of electricallyoperated traction units, greaterdemands have been placed on thecontact material, which conse-quently facilitated the worldwideintroduction of carbon compo-nents for current transfer. Themost important demands are:

increased vehicle performanceexpectancy

superior comfort higher speeds reduced operating costs

Schunk supplies appropriate car-bon grades, and suitable carriermaterials, for almost all require-ments.

Yarra Tram, Melbourne

Sliding Strips

Operating Reliability

excellent temperature resistance stability up to the wear limit emergency operating features resistance to corrosion safe current collection under all

conditions

Long Usable-Life

long usable-life of catenary orpower rail

high resistance to burnup no fusing with catenary or

power rail

4

Electrical Load Capacity

low contact resistance to count-er material

low resistance to carrier material uniform current distribution

within the carbon strip low electrical power loss good contact under different

climatic effects

Environmental Protection

multiple use of components low noise sliding contact no radio interference lead-free metal impregnation

possible and recommended

Maintenance Friendly

easy installation maintenance-free during entire

life of carbon strip complete components

Loco 1016 “Taurus”,

Austrian Railways

Grades – Pantograph Sliding StripsMaterials for Local and Long Distance TrafficPhysical Properties

Grade Type of Spec. El. Apparent Flexural Hardness TypicalCarbon Graphite Resis- Density Strength Rockwell Load atField of tivity OperationApplication µΩm g/cm3 Mpa HR 5/150 A/mm

SK85 Pure carbon graphite 34 1.71 30 085 05 – 08

SK85W = SK85 protected 34 1.73 30

085

05 –

08

against water

SK85S = SK85 for higher 32 1.75 35

095

05 –

08

mechanical stress0

SK85Cu = SK85 impregn. with (SK85M) metal for higher electr. 05 2.18 50 110 10 – 14

stress. LEAD FREE

SK85CS = SK85 impregnated with bearing alloy. 10 2.22 55 120 10 – 14LEAD FREE

SK95 Pure carbon graphitefor rough catenary 34 1.69 40 100 05 – 08conditions

SK95CS = SK95 impregnated with bearing alloy. 09 2.25 65 125 10 – 14LEAD FREE

SK01 Pure carbon graphite for special 34 1.71 30 090 05 – 08applications

SK01CS = SK01 impregnated with bearing alloy. 09 2.25 50 120 10 – 14LEAD FREE

BH424 Pure carbon graphite 34 1.71 30 085 05 – 08

BH424C = BH424 impregn. withmetal for higher electr. 05 2.18 50 110 10 – 14stress. LEAD FREE

BH424D = BH424 impregnatedwith lead-bronze 0

3 2.30 55 110 10 – 14

Grades – Current Load

Guide-Line for Current Load – Pantograph Sliding Strips

All values mentioned are calculat-ed per mm sliding strip width.

Operating Currents above thegiven range will result in shorterlifetime.

Standstill currents are subject ofvarious factors i.e.: material,cross sectional area, type andstate of the catenary, permissiblecatenary temperature, mean con-tact force per strip and last but

not least the carbon grade in use.Further details will be given byour engineering department orany subsidiary listed on page 14in this brochure.

5

Permissible Peak Current Load

Among specific conditions dur-ing operation peak currents 50 %higher than the mentioned guide-line values are possible. Furtherdetails will be given by our engi-neering department or any sub-sidiary listed on page 14 in thisbrochure.

6

Note: Alternate suggestions toallow greater load than the abovemaximum ratings:

usage of higher load capacitygrades and designs

wider contact surface by em-ploying wider carbon profiles

more current collector strips(e.g. 4 strips instead of 2 strips,or 2 strips and one center, etc.)

more catenary wires acceptance of a higher wear

factor

The wear of the carbon currentcollector strips is influenced bytwo factors, the electrical and themechanical wear.

Limiting Quantities on Service Life

current load feeding back of braking cur-

rents the speed environmental influences

(i.e. rain, hoar-frost, ice, etc.) design of pantograph and/or

pan head design of current collector strip type of current

(i.e. AC, DC, or mixed current) condition of catenary/stagger construction of rail foundation pressure force mixed operation with metal

strips

Sliding StripsCatenary Current Collection

Loco 189, German Railways

Design Variations – Complete Collector Strips

7

A complete carbon current collec-tor strip consists of the carbonstrip (carbon profile) mountedonto, or into, a socket. The sockettakes on the role of conductingthe current, and stabilizing thecarbon profile against impactsand deflection. In order to beresistant against ambient influ-

Clamped Version Carbon Strip

socket material either steel orcopper

designs: riveting, bolting, flang-ing, soldering

multiple use possible for boltedversion

Soldered Version Carbon Strip

bottom surface of carbon pro-file metalized(e. g. copper sprayed, electro-plated)

low transfer resistance

ences, preferably aluminum, cor-rosion protected steel and cop-per, and in special cases stainlesssteel, are used as socket materi-als.

In the short distance- and longdistance traffic the followingdesigns are employed.

Composite Carbon Strip

carbon profile 3-sided encasedin copper

current transmission throughcopper part of carbon strip

carbon serves as lubricant high mechanical and electrical

loading capacity operating current approx. 800 A/

strip

Carbon strip

Copper layer

Electrically conduc-tive adhesive layer

Aluminium carrier

8

Adhesive Bonded Carbon Strip (ABCS)

large variety of light-metalsocket profiles

corrosion proof multiple chamber design with

high stability advantages in aerodynamic and

weight allow for high speeds highly electrical conductive

bonding of carbon profile andsocket

max. bending strength approx.3,500 N

All Carbon StripHoffmann Covered Carrier System (HCCS) high arcing resistance by means

of carbon jacket (application atfrost conditions)

for railway and light railways low thermal expansion recyclable extremely high corrosion resist-

ance excellent emergency running

properties increased lifetime due to lower

wear rates available with Automatic Drop-

ping Device (A.D.D.) integral construction possible

(with integrated run-off horn, alsoavailable with carbon coating)

hollow structure can be appliedas fracture and wear detector

Sliding StripsCatenary Current Collection

Carbon strip

Copper layer

Adhesive layer

Aluminium carrier

Electricallyconductive strip

Carbon SK 85

Aluminium contact plate

Mounting components

Cu flex.tube

Glass fiber reinforced plastic

Design of Hoffmann bonding system

Design of Schunk bonding system

Design of All Carbon

Strip, System HCCS

9

Special Design Carbon Strips

Carbon Strip with Integrated Horn

easy installation and disassem-bly

adaptability to all designs ofpan head

Carbon Strip with built-inWorking Condition Sensor

will react when carbon stripgets damaged

minimizes damage to panto-graph and/or catenary

Air duct for Automatic Dropping Device (A.D.D.)

Air duct for Automatic Dropping Device (A.D.D.)

Carbon Collectorand Holder Profiles

All designs in grade BH424, SK85and SK85S are available up to thelength of 1,300 mm. Metal im-pregnated variants can be manu-factured as an one-part-strip up

to the length of 1,150 mm. If necessary a multiple-part-stripmust be used. Other designs andspecial radiuses are available oncustomer request.

Design Variations –Special Design

Sliding Strips – 3rd & 4th Rail

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Guide-Line Values for Current Load – 3rd & 4th Rail

The 3rd Rail contact is a planecontact. Therefore the standardvalues are given as an area unit.The maximum permanent current-carrying capacity during opera-tion is 10 A/cm2 for plain carbongrades, for metal-impregnated ver-sions 12 A/cm2 and 15 A/cm2 forthe casted design.

Modern METRO- and SUBWAY-Systems utilize 3rd Rail systemsto satisfy the current supply. Thepower rails consist mostly ofsteel, bronze, or aluminum alloymaterials. Typically the contactsare exposed to the followingloads:

Requirement Profile

mechanical impacts high starting and stopping cur-

rents high dust exposure

Compared to conventional cur-rent collection systems withmetal contacts, carbon gradeshave the following advantages forthose applications:

careful treatment of power rail excellent sliding property minimal arcing low noise level reduced weight

Due to the high mechanical wearand tear, grades with a high den-sity are preferably used. De-pendent on the electrical loads,carbon, or metal-impregnated car-bon, is utilized.

Application in Metro Systems

Grades – Designs

11

Designs

In one version the complete col-lector shoe consists of the carbonprofile, which is mounted onto acarrier/socket, which preferablyis made of zinc plated steel sheetmetal or aluminum.In another design carbon lubrica-tion elements are casted withmetals.

Grades for 3rd & 4th RailPhysical Properties

Grade Type of Spec. El. Apparent Flexural HardnessCarbon Graphite Resis- Density Strength RockwellField of tivityApplication µΩm g/cm3 Mpa HR 5/150

BH424 Pure carbon graphite34 1.71 30

085

extruded

BH424C = BH424 impregnated with metal for higher

05 2.18 50 110

electr. & mech. load;LEAD FREE; extruded

BH25 Pure carbon graphite 40 1.55 45 115*

BH25C = BH25 impregn. with metal for higher electr. 10 2.50 70 120*load

BH20C Carbon graphite impregn.with bearing alloy.LEAD FREE. For diff.

10 2.70 80 120*

cond. and high load

SK85 Pure carbon graphite;extruded

34 1.71 300

85

SK85CU = SK85 impregnated with metal for higher 0

5 2.18 50 110electr. & mech. load;LEAD FREE; extruded

SK85CS = SK85 impregn. with bear. alloy. LEAD FREE

10 2.22 55 120

SK95CS = SK95 impregn. with bear. alloy. LEAD FREE 0

9 2.25 65 125

SK01CS = SK01 impregnated with bearing alloy. 09 2.25 50 120LEAD FREE

Castedversion

*HR 5/40

Schunk supplies three main ver-sions:

design with metal end piece design as soldered version design as cast version

Special designs are available oncustomer request.

Carbon Inserts – Trolley Pole Systems

With electrically operated bussesthe current transfer from thecatenary to the vehicle is con-ducted by means of a current col-lector head, which is mounted tothe end of a trolley pole. Contactwith the catenary is achievedthrough a carbon insert, which isclamped exchangeable into ametalshoe.

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Grades – Trolley Pole Carbon Inserts

Grade Type of Material Specific Bending Rockwell Bulk RemarksElectrical Strength Hardness Density

ResistivityµΩm N/mm2 HR 5/40 g/cm3

BH25 Carbon graphite 40 45 115 1.55 standard grade,pressed to size capablefor normal load

BH504Z4 Carbon graphite 40 33 115 1.65 extruded grade withspecial impregnation,excellent sliding abilityat low humidity

BH304B Carbon graphite 15 55 120 2.40 extruded grade,metal impregnated excellent sliding ability

BH25B Carbon graphite 10 70 120 2.50 high loads, for poormetal impregnated catenary conditions

BH25C Carbon graphite 10 70 120 2.50 highest load, for extrememetal impregnated weather conditions

BH20C Carbon graphite 10 80 120 2.70 highest load,metal impregnated at high air pollution

BH20A Carbon graphite 10 80 120 2.70 highest load, for poormetal impregnated catenary conditions

BH26D Carbon graphite 7 80 120 2.60 highest load,metal impregnated for extreme

weather conditions

SK95Z4 Carbon graphite 35 50 110 1.75 extruded grade withmetal impregnated special impregnation,

for bad catenary conditions

Requirement Profile

high service life high mechanical strength protection of catenary low noise level during opera-

tion proper contact in collector shoe safe current transfer operation under ice and hoar-

frost conditions radio interference behaviour

Grades – Current LoadDesign Variations/Collector Shoe

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Design Variations

Schunk supplies carbon inserts inall of the above mentioned gradesfor all customary collector shoedesigns.

The double-wedge-shaped insertproved itself again and again, dueto its easy and safe installationand the great fit into the collectorshoe.By tailoring the insert to thecross sectional area of the cate-nary, an optimization of contactcondition can be achieved.

Standard Values for Current Load – Trolley Inserts

Grade max. Current Load per mm Contact Length

BH25, BH504Z4, SK95Z4F5 2.5 A

BH304B 3 – 4 A

BH25B, BH25C, BH20A, BH20C, BH26D 3 – 5 A

Collector Shoe

In our own foundry Schunk isable to manufacture nearly allcollector shoe designs employedworldwide.

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GermanyHead QuarterSchunk Kohlenstofftechnik GmbHRodheimer Strasse 59 – 6135452 HeuchelheimTel.: +49 (0)641 608-0Fax: +49 (0)641 608-1223

Schunk Kohlenstofftechnik GmbHIngenieur- u. Vertriebsbüro DortmundBiesenwiese 5147167 DuisburgTel.: +49 (0)203 5181867Fax: +49 (0)203 5181868

Schunk Kohlenstofftechnik GmbHIngenieur- u. Vertriebsbüro DresdenEnno-Heidebroekstrasse 4 – 601237 DresdenTel.: +49 (0)351 270-9007/ 9008Fax: +49 (0)351 270-9009

Schunk Kohlenstofftechnik GmbHIngenieur- u. Vertriebsbüro HannoverAlbert-Schweitzer-Strasse 1531319 SehndeTel.: +49 (0)5138 617892Fax: +49 (0)5138 617792

Schunk Kohlenstofftechnik GmbHIngenieur- u. Vertriebsbüro KölnUnderhook 746499 HamminkelnTel.: +49 (0)2852 968055Fax: +49 (0)2852 968056

Schunk Kohlenstofftechnik GmbHIngenieur- u. Vertriebsbüro MünchenSchlossstrasse 2485406 ZollingTel.: +49 (0)8167 696126Fax: +49 (0)8167 696128

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EuropeHoffmann & Co., Elektrokohle AGAu 624823 Steeg/ÖsterreichTel.: +43 6135 400-0Fax: +43 6135 400-10 oder 12

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Schunk Praha spol. s r.o.vyrobni zavod Plzen Skladova ul.c. 1731705 Plzen/TschechienTel.: +420 19 7454111Fax: +420 19 7455498

Sirma Elektrik Kömürleri Persembepazan Cadd No. 41/280004 Karaköy-Istanbul/TürkeiTel.: +90 212 2789970Fax: +90 212 2703565

Schunk Romania SRLStr. George Georgescu nr. 40Sektor 4040133 Bukarest 4/RumänienTel.: +40 21 3372859Fax: +40 21 3351639

AmericaSchunk Graphite Technology LLCW 146 N9300 Held DriveMenomonee Falls/USA Wisconsin 53 051-1643Tel.: +1 262 2538720Fax: +1 262 2551391

Schunk Electro Carbón, S.A. de C.V.Acueducto del Alto Lerma No. 6Zona IndustrialOcoyoacac, Edo. de MexicoC.P. 52740Tel.: +52 728 282 7890 (Zentralbüro)Fax: +52 728 282 7141

Schunk do Brasil Ltda.Estrada do Embu No. 277706713-901 Bairro MoinhoVelho-Cotia, SPTel.: +55 11 46133200Fax: +55 11 47025659

AsiaSchunk United Carbon Co. Ltd.7/8 Moo 11 Soi Ramkhamheang 199Ramkamhang RoadMinburi, Bangkok 10 510/ThailandTel.: +66 2 517-6223-6Fax: +66 2 517-6267

Pichit Industrial Work Co. Ltd.143/1 Moo 1, T. NernmakokRuamchitbundarl Road,A BangmoonnarkPichit 66120/ThailandTel.: +66 56 632101-2Fax: +66 56 632229

Schunk General Carbon Ltd.Unit 1004Tsuen Wan Industrial Center220 Texaco RoadTsuen Wan N.T./Hong KongTel.: +852 2 4086688Fax: +852 2 4073409

Schunk Carbon (M) Sdn. Bhd.19, Jalan Serindit 2Bandar Puchong, Jaya47100 Puchong,Selangor Darul Ehsan/MalaysiaTel.: +60 3 58822970Fax: +60 3 58822915

Seung Lim Carbon Metal Co., Ltd.737-2 Wonsi-DongAnsan-City, Kyunggi-Do/KoreaTel.: +82 31 491-2722Fax: +82 31 491-2726

IndiaSchunk Metal & Carbon (I) PVT. LTD.54/2, Whitefield RoadMahadevapura PostBangalore 560 048/IndienTel.: +91 (80) 2851 6708Fax: +91 (80) 2851 6713

AustraliaSchunk (Aust) Pty. Ltd.47 Henderson RoadRowvilleVIC 3178/AustraliaTel.: +61 3 9753-3588Fax: +61 3 9753-3589

In almost all other countries Schunk is

represented by independent agents.

Worldwide Location

15

Schunk Kohlenstofftechnik GmbH

Rodheimer Strasse 5935452 HeuchelheimGermany

Tel.: +49 (0)641 608-0Fax: +49 (0)641 608 1748

www.schunk-group.cominfobox@schunk-group.com

16.10e/2004

Hoffmann & Co., Elektrokohle AG

Au 624823 SteegAustria

Tel.: +43 6135 400-0Fax: +43 6135 400-10

office@hoffmann.at