Testing the Pantograph Power

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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.  




Location: 20/13C, Bagepalli Main Rd, B T, R Nagar, Hosur, Tamil Nadu 635126, India

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