Testing the Pantograph Power

Pantograph Load Testing for Electric Trains

A pantograph load test machine is a specialized system used to evaluate and simulate the performance of pantographs, which are critical components in electric trains.

Complex Environment and Challenges       

• The pantograph is the component of an electric train that makes contact with the overhead trolley wire (catenary system) to draw power.
• The environment where the pantograph touches the wire is incredibly complex:
  • Catenary systems exhibit varying vertical stiffness along their length.
  • The wires zigzag at intervals (typically 30 to 100 meters) to prevent grooving.
  • The force applied by the pantograph to the wire must stay within a well-defined range (usually between 70N and 120N).
  • Too little force results in loss of contact, arcing, and damage to the wire and contact bar.
  • Too much force causes premature wear on the wire and contact bar due to friction.
• Delivering the right amount of force requires variable vertical motion, especially at high speeds.

Testing Challenges:

• Recreating the dynamic pantograph environment in the lab is complex:
• Pantographs travel at speeds up to 350 kph (220 mph) and carry enough power to accelerate heavy rail cars.
• Traditional spin/slide tests using spinning discs and carbon specimens do not fully replicate real-world dynamics.
• These tests involve pushing a piece of carbon against a spinning wire, but they lack the full complexity of actual pantograph operation.

Advanced Testing Systems:

• New pantograph testing systems aim to simulate operational dynamics more precisely.
• These systems measure various parameters, including:
  • Contact forces: Load cells allow precise measurement of the forces exerted by the pantograph.
  • Lateral movement: Motor servo-actuators reproduce the catenary stagger, allowing to travel pantograph to achieve its maximum height up to 4000mm with respect to the central axis of the pantograph.
  • Frequency and acceleration: The system can operate at frequencies up to 1.5 Hz and accelerations of up to 2.7 g.
• The goal is to understand the interaction between the pantograph and catenary system accurately, ensuring safe and efficient rail operation.

TEST CASE

• Holding the pantograph in test in a fixed, known, repeated position near the testing machine
• Appling a pneumatic air to rise the pantograph lifting.
• Measuring 
• Applied static load
• Distance traveled pantograph height
• Observation and Adjustment of the pantograph by Graph with in the  limits.

DESIGN

•     Power supplies
•     Cabinet
•     Control Pc
•     Servo drives
•     Safety button

SOFTWARE

•     Operator Login Interface
•     Live data Graph Interface
•     Settings Interface   

FUTURE

    The Adjustment of the pantograph fine turning error message pop up will be provided.