Main Caps Bolts

Main Caps Bolts

Railway Industry of Daqo Group

Product Introduction
OCS is the core power supply equipment in power supply system of electrical railway traction. Its function is to supply power to the running electric locomotive incessantly. Different from the ordinary power transmission line, it must be fixed on the right top of the rail, and then locomotive can get power incessantly through the slip friction between top pantograph and contact wire. So everywhere that electric locomotive running through should span catenary. All catenary installation is hypaethral and it is always affected by kinds of bad weather, as well as its working state is changed with the running of electrical locomotive and has no standby, so working environment for catenary is complex and the request for it is higher. OCS components manufactured by SAITONG introduces and adopts international advanced technology, and optimize the design of key components products according to the technology feature of domestic rail transportation and feature of parallel products. The whole series of products have been homebred, and this caters to the construction and operation of Chinese rail transportation better. Aluminum alloy and copper alloy are adopted much in our product forging, now we have two forging line, and the manufacturing capability hits 2000kms/year. SAITONG is making the core components of Siemens Re250km/h and Re350km/h in China and can produce all catenary components refer to Chinese railway standard; we have passed the test of P.R.C catenary components inspection station. we have the sales ability.

Functional Features
A. Cantilever steady components
Application and Scope
Cantilever steady equipment is used to locate contact wire in electrical railway canetary system. The material of cantilever can be charry-steel and aluminum alloy. Flat Cantilever composes the angle top of hinged cantilever structure, one end of flat cantilever support canetary through the messenger wires supporting clamp, and the other end is joint with strut insulator. Inclined cantilever supports the flat cantilever with binaural sleeve and the other end is joint with strut insulator. Typical installation structure as follow.
1. Cantilever
When the cantilever is made of carbon steel, seamless steel pipes which refer to the standard of GB/T8162 can be used, while the cantilever is made of aluminum alloy, alma Ilium pipes AlMgSilF31 that refer to the standard of DIN 9107 can be used.
Its min. horizontal breaking load is not less than 24.17kN, and min. vertical breaking load is not less than 15.0kN.
2. Inclined Cantilever binaural sleeve
Inclined Cantilever binaural sleeve is stable at the end of inclined Cantilever to join inclined cantilever and flat cantilever. It is made of the material of cast aluminum alloy EN AC-AlSi7Mg0.6 that refer to the standard of DIN EN 1706 and made by metal mould forging technology. Its working load is not less than 4.0 kN, the min. breaking load is not less than12.0kN, and tightening torques of clamp bolt is not less than 50Nm.
3. Canetary supporting clamp
Canetary supporting clamp is stable at flat cantilever to support and fasten copper alloy canetary that the cross-section is about 70-120 mm2.The top of it is used to support stable line and siding canetary,it can rotate around the horizontal axis free. Canetary supporting clamp is made of the material of cast aluminum alloy EN AC-AlSi7Mg0.6 that refer to the standard of DIN EN 1706,and made by metal mould forging technology. The working load is 6.0kN; the min. breaking load is less than 18kN; Tightening torques: 56Nm for bolt M12, and 70Nm for bolt M16U.
4. Cantilever support
Cantilever support fixes and supports flat and inclined cantilever, it joins with flat and inclined cantilever through Cantilever support binaural sleeve. Cantilever support can be made of carbon steel and aluminum alloy. When the cantilever support is made of carbon steel, seamless steel pipes GB/T8162 can be used, but when the cantilever support is made of aluminum alloy, alma Ilium pipes AlMgSilF31 that refer to the standard of DIN 9107 can be used. Its working load is not less than 9.4 kN; the min. breaking load is not less than28 kN.
5. Steady ring
Steady ring is fixed on the cantilever, it provide installation support to binaural sleeve components, such as cantilever support binaural sleeve and inclined cantilever. Steady ring is made of the material of cast aluminum alloy EN AC-AlSi7Mg0.6 that refers to the standard of DIN EN 1706, and is made by metal mould forging technology. The working load is 5.0 kN; the min. breaking load is not less than15 kN; Tightening torques: 70Nm for bolt M16U.
6. Steady Tube, Hook end fitting
Registration arm provides location support to positioner; one end is joint with registration arm while on the other end pipe cap is installed.
Hook end fitting is fixed in the bottom of registration arm to make it join with inclined cantilever.
Registration arm can be made of carbon steel and aluminum alloy. When the Registration arm is made of carbon steel, seamless steel pipes that refer to the standard of GB/T8162 can be used, but when the Registration arm is made of aluminum alloy, alma Ilium pipes AlMgSilF31 that refers to the standard of DIN 9107 can be used.
Hook end fitting is made of the material of cast aluminum alloy EN AC-AlSi7Mg0.6 that refers to the standard of DIN EN 1706, and is made by metal mould forging technology.
The working load is 2.5kN; the min. breaking load is not less than 7.5kN; Tightening torques: 70Nm for bolt M16U.
7. Steady Arm
Steady Arm has below three kinds, straight, angle and curved steady arm. It is used for clamping the contact wire and ensuring the wire is fixed towards the direction of the line under the request of design. In overlap and curve section of the line, angle and curved steady arm and corresponding bracket will be used.
Steady ear, hook end fitting, grooved stud and rectangular pipe are main components of Steady Arm.
Positioner uses CuNi2Si material that refers to the standard of EN 12165.
Hook end fitting uses EN AW-6082 material that refers to the standard of EN 755-2.
Rectangular pipe uses EN AW-6082 material that refers to the standard of EN 755-2.
Hook end fitting, grooved stud cover and Steady ear are produced with precision casting process for metal mold.
Its working load is 3.5kN and the minimum anti-destroy load is not less than 10.5 kN.
8. Drop bracket
Drop bracket is installed on the registration arm with U style bolt, and the hook at the bottom of it is used for the link of hook end fitting. The position of the steady arm can be adjusted by changing the location of U style bolt on registration arm.
Positioner bracket uses EN AW-6082 materials that refer to the standard of EN 755-2 and are made by metal mould forging technology.
Its working load is 3.5kN and the minimum anti-destroy load is not less than 10.5 kN.

B. Electrical Connection Component
Application and Scope
Electrical connection joins catenary and contact wire and conveys power in power line to contact wire. It includes the electrical clamp for messenger wire and for contact wire and parallel connecting clamp
1. Electric connecting clamp for Messenger wire
Electric connecting clamp for messenger wire is used for the joint of electrically connector and catenary, it uses E-Cu material that refers to the standard of EN 1787 and is made by forging technology.
The gripping load shall not be less than 4.0 kN. The continuous carrying capacity shall not be less than 540A, with the 5min overload carrying capacity not less than 760A.The tightening torque for the bolt is 25Nm.
2. Electric connecting clamp for contact wire
Electric connecting clamp for contact wire is used for the joint of electrically connector and messenger wire, it uses E-Cu material that refers to the standard of EN 1787 and is made by forging technology. The gripping load shall not be less than 2.0kN. The continuous carrying capacity shall not be less than 500A, with the 5min overload carrying capacity not less than 700A.The tightening torque for the bolt is 44Nm.

C. Integral Dropper Components
It is suitable to hung copper alloy or copper contact wire on copper alloy catenary in overhead contact system for electrified rail, to adjust the tension of contact wire. Dropper structure shall adopt thimble type. Body of dropper is U type structure; press-jointed connection will be used for connecting contact wire and dropper. Press-jointed shall be done in site and actual length will be defined according to construction requirement .dropper length can be adjusted. To avoid to be hurt by current, reliable electrical connection and prevention measure between dropper and messenger wire and contact wire shall have reliable electrification connection and protective measures. Max vertical work load of integrated dropper is 1.3kN. Tensile failure load of integrated dropper assembly shall not less than 4.0kN. Slide load between integrated dropper and contact wire and messenger wire shall not less than 1.0kN.
1. Dropper clamp for messenger wire
It is covered and clamped on canetary to connect dropper wire of hanger contact wire, the material is CuNi2Si that refers to the standard of EN12165 and is made by stamping technology. Tightening torque of bolt is 32 Nm; tensile failure load is not less than 3.9kN.
2. Dropper clamp for contact wire
Clamp the contact wire and join with dropper clamp for messenger wire with dropper wire, the material is CuNi2Si that refers to the standard of EN12165 and is made by stamping technology. Tightening torque of bolt is 32 Nm; tensile failure load is not less than 3.9kN. It is well-matched with pantograph and not hurt pantograph under the -30 offset condition.

D. Anchor Components
Application and Scope
The clamp is applied in mid-point of one tension length with both sides of compensation in overhead catenary system (OCS) of the electrified railway to stable and connect canetary, mid-anchor junction and connecting wire, and this can prevent the leap between connecting wire and canetary caused by heat or cool and other factor.
1. Anchor clamp device for messenger wire
Connection Clamp is installed on the catenary of the mid-anchor section and the material is CuSn, made by metal mold forging process. The slide load is not less than42.35kN. The break load is not less than 54kN. Tightening torque is 56Nm.
2. Anchor clamp device for contact wire
The Mid-point anchor clamp for contact wire is installed on the contact wire of mid-anchor section and includes a clamping body for attachment to the contact wire grooves and two flaps for connection to one Mid-point anchor rope, one thimble and one compression connector to terminate the Mid-point anchor rope to the flaps. The body is made by metal mold forging process. The slide load is not less than54kN. Tightening torque is 46Nm.

E. Tensioning Device Components
Application and scope
Scope of application: The tensioning device is applied in both end of one tension length with both sides of compensation in overhead catenary system (OCS) of electrified railway to tighten catenary and contact wire.
Performance
The nominal transmission ratio: 1:3. The transmission efficiency is 97%. The working load of turnbuckle is 61.7kN. The min. failing load is 185kN. Calculated breaking load of wire is 74kN. The min. breaking load of connection fittings is not less than96kN.
Tension wheel
Tension wheel body is made of CtAl that refers to the standard of EN 1706, the maximum of its working tension is 40 kN, and drive ratio is 1:3. Connection fittings that join the body of tensioning wheel, wire and anchor Insulator are made by metal mould forging technology.

F. Anchorage Components
Application and Scope
Scope of application: The clamp is applied terminal anchoring point for copper alloy messenger wire and contact wire in overhead catenary system (OCS) of electrified railway.
1. Terminal Anchor Clamp for Messenger Wire
It is used to anchorage catenary at the end, adapting wedge type, and it is made of duralumin alloy material that refers to the standard of ISO 1637-87. It is made by metal mould forging technology. The Tightening torques is 80Nm; Sliding load is not less than 60.81kN; The min. breaking load is not less than67kN.
2. Terminal Anchor Clamp for Contact Wire
It is used to anchorage contact wire at the end, adapting wedge type, and it is made of duralumin alloy material that refers to the standard of ISO 1637-87. It is made by metal mould forging technology. The Tightening torques is 80Nm; Sliding load is not less than 60.81kN; The min. breaking load is not less than67kN.

G. Section Insulator
Application and Scope
It is used in overhead contact system for electrified railway to divide the contact system into some unattached electrical departments, and this is convenient for installation, test and maintenance.
Specification and Allocation
Section insulator is composed with insulator body and iron components, includes messenger wire, termination fitting for catenary, catenary insulator, junction components and section insulator suspension equipments. Section insulator is made of copper, stainless steel, copper nickel, and silicon alloy, Insulator on catenary is made of GFRP, conical termination fitting is made of albronze.
Performance
The contact between insulating body of section insulator and pantograph is directly sliding. The insulating body has sufficient ability for anti-arcing and self-cleaning, and has the function to guide the arcing. During the sliding passage of pantograph, no electric breaks appear. The material of section insulator has higher ability of anti-arcing in order to avoid any damage due to burning of all the parts of section insulators. The body of section insulator is made of light alloy material with high mechanical performance and polymerized material with high strength and anti-corrosion material. The assembly is light in weight. The metal connection parts and all the accessories, fastening pieces are made of anti-corrosion material. They can bear the working load reliably with efficient safety factor. The insulating parts of section insulator and MW (including insulating slider) are self-cleaning and water repelling. Service life of the whole set of the section insulator is not less than 15 years.

Technical Parameter
Power frequency dry withstand voltage is 163kV.
Power frequency wet withstand voltage is 132kV.
Full wave impulse withstand voltage is 40 kV. (Standard lightning impulse withstand voltage)
Power frequency pollution withstand voltage is 40kV. (Surface density of salt covering is 0.35mg/ cm2)
Creepage distance is ?1200mm.
Min. failing load is ? 90Kn.
the working load is ? 30Kn.
Performance of anti-vibration ? 2*106 times.
Performance of anti-wear (times of pantograph) is ? 5*105 times.
Minimum of air distance is ? 220 times.
Unit weight is 15.5kg.

About the Author

by Daqo Group

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