Rigid Overhead Contact Line System for Mass Transit

Saitong Railway Electrification (Nanjing) Co., Ltd.

Build the world-class, domestic advanced railway electrification system integrator

GIS /

SAP
R/3
2006 5 15 GB/T19001-2000 idt ISO9001:2000 GB/T24001-2004 idt
ISO14001:2004 GB/T28001-2001 idt OHSAS18001:1999

SAITONG Railway Electrification (Nanjing) Co., Ltd. (SAITONG) is a joint venture co-invested by Siemens Ltd., (China) and
DAQO Group Co., Ltd on January 19th, 2005, whose registered is 52nd Tianyuan Road Scientifical Park Jiangning Zone
Nangjing. We have 158 employees, including 42 technical personnel and 7 masters. Currently, SAITONG occupies 18000
square meters and its factory is possessed of 14000 square meters.
SAITONG focuses on designing, manufacturing and selling aluminum steel conductor rail system, rigid overhead contact
Line system for mass transit, components of overhead contact line system, GIS switchgear, indoor monopole vacuum circuit
breaker and unipolar / bipolar outdoor isolating switch for railway electrification. All of our products has adopted and
combined the international advanced technology.
SIEMENS AG is one of the leading international suppliers in the railway industry. As single source supplier and system
integrator, SIEMENS AG has four main business divisions: Automation and Power Supply, Locomotive Vehicles, Turn-key
System and Integrated Service, which offers a whole range of products covering form signaling and control system, traction
power supply to rolling stock for mass transit, regional and main line services. Its extensive project management experience
and forward-looking service concepts consolidate the company's comprehensive strength.
DAQO Group Co., Ltd. (formerly Jiangsu Changjiang Electrical Group Co., Ltd.), one of the biggest power-supply equipment
manufacturers in China, is engaged in manufacturing high and low voltage switchgears, components, power automation
system and environmental protection installations. DAQO Group owns highly qualified and experienced staff, advanced
production technology and efficient quality assurance system.
At the beginning of establishment, SAITONG has been devoting to becoming one of the best suppliers of railway
electrification. An integrated management system and efficient operation mode is built in SAITONG. The advanced SAP
system realizes rapid transmission and information management within purchase, inventory, production, financing and sales.
All of these improve the efficiency of operation and realize a successful interface with the R/3 system of SIEMENS.
On May 15th, 2006, we won three main authentication certificates together, including GB/T19001-2000 Quality Management
System, GB/T24001-2004 Environment Management System and GB/T28001-2001 Vocational Health and Safety
Management System.
By integrating the advantages of Siemens and DAQO, SAITONG supplies specialized products in the fields of railway
electrification and mass transit and at the same time provides its customers with advanced technology and the best services.
 Products Brief 1

Typical Installation Structure 3

Additional Elements 4

SAC2200 SAC2200 Current Bar Profile 5

Connect Joint 8

End-ramp 9

Transition Bar 9

B Steady Clamp B type 11

C Steady Clamp C type 11

Electrical Connection Clamp 12

Earth Clamp 13

Mid-anchor Clamp 13

Contact Wire Insertion Device 14

Applicable Standards 15

Test Report 16
 Products Brief

Rigid catenary system is a new power supply mode of

electrification railway, comparing with the traditional flexible

catenary system, it has below advantages.

1 more capability of current carrying

With large cross section current bar profile clamping contact wire, current bar profile and contact wire clamped in

the draw-back collet current bar profile can permit high level current passing. Further more it can effectively reduce the

radiation problem which caused by high level current

2 No risk of breaking-off, more security

As there is no traction stress, it allows more contact wire wear without risk of breaking-off in rigid catenary system,

the only limitation is that the pantograph can not touch the current bar profile.

3 Easy operation and maintenance

As the contact wire allows more wear and its installation and replacing is easy in rigid catenary system, the

maintenance cost is greatly reduced. Periodical control of the current bar profile connectors tightening and cleaning up

of the isolators are the only maintenance operations to be carried out

4 less tunnel clearance, less construction cost

Rigid catenary system reduces great tunnel clearance against standard catenary system, so the construction cost is

greatly reduced.

1
 1 EN755-2/9 EN573

Rigid catenary System made by Saitong Railway Electrification(Nanjing) Co.,Ltd, has been introduced, absorbed

and digested the advanced overseas technology, meanwhile, it combines the technical features of internal rail traffic

with the characteristic of similar products to optimize the design of key components. The whole series of products are

homebred to meet the construction and operation condition much better.

1. Design and manufacture according to international code, such as EN755-2/9, EN573.

2. Improve Chemical composition of aluminium alloy to enhance mechanical and electrical properties of current bar

profile.

3. Improve extruding process, achieves good dimensional tolerance, high precision.

4. Adopt advanced inspect &measure facilities to Control properties of aluminium alloy and improve products quality.

5. Design and provide special tools and fixtures to improve construction quality.

2
 Typical Installation Structure

7 4

5
6

Typical Installation Structure

1. Supports 5. Connect Joint

3
 Additional Elements

Rigid catenary system and fittings mainly include current bar profile, end-ramp, transition bar, connect joint,

protecting plastic cover, steady clamp, mid-anchor clamp, electrical connection clamp, earth clamp etc.

B
Steady Clamp B Style

Protecting Plastic Cover

C
Steady Clamp C style

SAC2200
Current bar profile

Earth Clamp

Connect Joint

Transition bar

End-ramp
Electrical Connection Clamp

Mid-anchor clamp

4
SAC2200 SAC2200 Current Bar Profile

3500A
π

12

This part is used for clamping and fixing contact wire, carrying and transmitting power supply, ensuring smooth

pantograph passing. Current carrying capacity is no less than 3500A.

The cross section of current bar profile is a " " section, on the bottom of it a flexible collet is designed to clamp copper

or copper alloy contact wire, and a platform for special contact wire insertion device running is designed on both sides of

the collet under the platform "V" style groove is designed for contact wire insertion device installing and replacing contact

wire. Meanwhile this design is good for improving heat extraction condition.

Standard manufacturing length is 12m, there are holes in both end of current bar profile for connecting.

Products Features

1 EN755 EN573
2
3 T6
4 DIN43670

1 Material code acc. to EN755 and EN573, have high mechanical and electrical properties.

2 Optimize Chemical composition to achieve good extruding properties.

3 Adopt water-cool heat treatment process, delivery condition achieves T6.

4 Electrical properties of current bar profile are in conformity with current measure section of DIN 43670.

5
SAC2200 SAC2200 Current bar profile

Tensity testing

SAC2200
(N/mm)

A
Figure A Tensity testing of SAC2200 current bar profile

Current-temperature Graph

SAC2200

B S A C 2 2 0 0
Figure B Current-temperature Graph of SAC2200 current bar profile

6
SAC2200 SAC2200 Current bar profile

1 Nominal Cross Section Area mm2 2213

2 Calculated weight kg/m 5.91

3 20 20 Resistance Ω.mm2/m 3.2 10-5

4 Linear Expansion Coefficient 1/ 2.4 10-5

5 Max. temperature rise of current bar profile 1

6 Continuous Current Carrying Capacity A 3500

12 1mm
7 Max. tensity of 12m length current bar profile flank unilateral opens N/mm 3.8
1mm N/mm

2.2mm
8 10
Max.times of current bar profile flank unilateral opens 2.2mm times

9 m 80
Min. manual bent radii of current bar profile on horizontal

10 m 45
Min. mechanical bent radii of current bar profile on horizontal

11 8 2

Horizontal Bent times of current bar profile times

12 Tensile Strength N/mm2 215

13 Yield Strength N/mm2 160

14 Elongation δ 12

15 Hardness of surface HB 65-90

16 Elasticity coefficient N/mm2 69000

7
1. - B
2.
3.

Notes:
1 Current-temperature Graph of SAC2200 current bar profile see figure B
2 The dimension of collet should meet the tolerance specified in drawings after current bar profile was bent.

3 Within the plane composed with center line of current bar profile, curve it to one side with the radius showed in graph

and recover, then curve it to the opposite side and recover, to see how many times of bending it can endure till the

current bar profile distorted

Connect Joint

3.0kN
1.5kN
25N.m

This part is used for connecting of following

parts: current bar profile and current bar profile,

current bar profile and endr-amp, current bar and

expansion joint etc. to ensure both their mechanical

and electrical propertiy are compatible.

Max. vertical working load is 3.0KN.

Max. horizontal working load is 1.5KN.

Tighten torque of the bolt is 25N.m

8
 End-ramp

SAC2200

This part is made by machining SAC2200 current bar profile, and it is used at the end of rigid catenary which can

expand and contract freely, to ensure smooth pantograph passing smoothly.

Transition Bar

SAC2200

M10
14KN

9
 This part, which is made by machining SAC2200 current bar profile, is used in transition section to the meet the

gradual transition between rigid catenary system and conductor rail system.

The transition bar works as the medium between rigid catenary system and conductor rail system. With same cross

section and material to current bar profile, the transition bar is made up by slots with certain distance and gradual

change depth, so its rigidity gradually reduces, and its flex gradually increases, it can prevents hard area, so there is no

risk of contact wire breaking-off caused by metal fatigue. pantograph can smoothly passes through transition bar from

rigid catenary system into conductor rail system and vice versa.

There is several bolts M10 to fasten contact wire, ensuring certain tension in spite of the affect of cutting slots

on the transition bar, further more, there is special clamp, which can support all tension (14KN) from conductor rail

system and avoid the contact wire sliding. Contact wire embedded in transition component is anchored on tunnel cliff or

bridle. There is special anti-twist equipment to prevent contact wire from twisting, ensures pantograph passing smoothly.

There is a feeder clamp at the end of transition section, it provide feeder connection for message wire in conductor

rail system.

10
 B Steady Clamp B type

SAC2200 1.5kN
3.0kN 25N.m
This part is used to fix SAC2200 current bar profile on rigid catenary. Max. horizontal working load is 1.5KN. Max.

vertical working load is 3.0KN. Tighten torque of the bolt is 25N.m

C
Steady Clamp C type

SAC2200

1.5kN 3.0kN
44N.m

This part is used to fix

SAC2200 current bar profile on rigid

catenary. Max. horizontal working

load is 1.5KN. Max. vertical working

load is 3.0KN. Tighten torque of the

bolt is 44N.m

11
 Electrical Connection Clamp

1. 2.0kN
2. 25N.m
3. 750A

Electrical connection clamp is installed directly on current bar profile, and is used in all electric connection sections of

rigid catenary such as feeder network of disconnector, uninsulated overlap, turnoff, transition facility etc

1. The sliding load between electrical connection clamp and current bar profile is no less than 2.0kN.

2. Tighten torque of the bolt is 25N.m

3. Maximum permitted current is 750A

12
 Earth Clamp

(SAC2200 )
M10 25N.m
U 70N.m

Earth clamp is installed directly on current bar profile to earth while maintenance.

Tighten torque of the bolt M10 is 25N.m,

and 70N.m for the U bolt.

Mid-anchor Clamp

13
 SAC2200

1. 4.0kN
2. 3.0kN
3. M12 44N.m

This part which is installed directly on current bar profile applies to rigid overhead mid-anchor, and it’s uesd to fix and

control the temperature change offset in the section which rigid catenary can expand and contract freely.

1. The sliding load between clamp and current bar profile is no less than 4.0KN

2. Max vertical woking load is 3.0 kN;

3. Tighten torque of the bolt M12 is 44 N.m.

Contact Wire Insertion Device

The contact wire insertion device is used for installation and replacement of contact wire. It is easy to
operate, and it works efficiently.

14
 Regulations and Standards

The products contained in this catalog correspond to the standards listed and to the relevant provisions or guidelines

below:

EN 573-3 Aluminium and aluminium alloys-chemical and composition and form of wrought products
-part 3: Chemical composition

- 2
EN 755-2 Aluminium and aluminium alloys-Extruded rod/bar,tube and profiles-part 2: Mechanical
properties

TB/T 2073-2003
Technical specification of fittings for overhead contact system in electrification railway

TB/T 2074-2003
Test methods of fittings for overhead contact system in electrification railway

(1-600 mm)
GB/T 196-2003
General purpose metric screw threads-Basic dimensions

(1-355 mm)
GB/T 197-2003
General purpose metric screw threads-Tolerances

GB/T 700-1988
Carbon structural steel

GB/T 2828-1987 Part 1:Sampling procedures for inspection by attributes Sampling schemes indexed by
acceptance quality limit(AQL) for-lot-by-lot inspection

GB/T 3098-2001
Mechanical properties of fasteners

GB/T 6892-2000 Wrought aluminium and aluminium alloy extruded profiles£›Tolerances on dimensions and
shape

GB/T 7999-1987
Standard method for direct reading spectromertrie analysis of aluminum and its alloys

GB/T 16865-1997
Test pieces for tensile test for wrought aluminium£‹magnesium and their alloy products

GB/T 17432-1998 Methods of sampling for analysing the chemical composition of wrought aluminum and
aluminum alloy

GB/T 3190-1996
Wrought aluminium and aluminium alloys-Chemical composition limits

15
Test Report

16
Saitong Railway Electrification (Nanjing) Co., Ltd.

28
86 25 52164000 86 25 52160378
www.saitong.cn 211153

Add: No.28 Yinlong Road Jiangning Development Zone Nanjing, Jiangsu,P.R.C

This conpany reserves the right to revise this catalog. Subject to change without prior notice.