interrail1

Since the change-over of railway transport from token communication systems to automatic interlocking systems, a necessity of special connection of rails between each other has appeared to provide flow of current along them with minimum transient resistance in rail butts. The structure was named as a "rail chain".

Almost from the 50-s of the last century till present stable operation of rail chains has been provided by a method of electrical contact welding of rail bonds to the rail head. This leads to formation of "head cracks at welding point of rail bonds" — as per the Classification of Rail Defects NTD/TsP-1-93 and development Fig. 38.1 as per Rail Defect Catalogue NTD/TsP-2-93.

In order to solve the described problem, the specialists of our company performed metallographic examinations of interaction of rail steel with different metals and alloys, marketing researches and came to a conclusion that the most optimum solution for this operation would be use of low-temperature soldering of rail bonds.

 

SAFETRACK low-temperature soldering is intended for installation of electrical bonds between rails by soldering. It is an easily moving pin-soldering module with two transport rubber wheels, as well as wheels for movement along rails. When in upper position, the wheels easily move above railway switches and cross-pieces, and when in lower (parking) position, the wheels act as a stabiliser. The system is equipped with three sealed high-duty batteries that require no maintenance and enclosed in a cassette. Use of cassettes helps enlarging the capacity, as well as performing their separate charging. The system is supplied complete with a patented automatic soldering gun and uses pins with solder metal without any melting wire. Peculiar features of the set of infrastructure for low-temperature soldering of rail bonds:

 

  • No special preparation of performers is required;
  • Compact and mobile device;
  • Self-contained power supply (one charging of batteries is enough for 60-100 soldering processes);
  • Simple and practical use;
  • Short soldering time (2-4 seconds).

 

Creation method of electrical bonds by means of soldering is not only one of the most safe methods for an operator and workers who stay nearby, but also the most cost-effective method because one soldering process requires a very short period of time (2-4 seconds), working groups can work under any weather conditions — either rainy, snowy, cold or hot.

 

Our company offers the range of electrical bonds with different cross-sectional area (25 to 120 sq. mm), of any length and different materials.

An anti-vandal bond made from bimetallic steel-copper wire has been designed.

The new bond has much higher strength and considerably longer service life in comparison to the copper one at comparable flexibility and elasticity and is protected against non-ferrous metal scrap thefts.

Resistance of individual wires of PBSME conductor to mechanical impacts (vibrations of rail ends, snow removal, rail track works, impacts of Ballast at train movement) exceeds resistance of thinner and weak copper wires of MG conductor by many times.

RAILBONDS

Copper and steel-copper rail bonds are used for electrical connection of individual rail links in railway sections with automatic interlocking, electric traction and electric centralization of railway switches.interrail2

The following types of rail bonds are produced:

Description

Remark

Copper bond

25 mm2 L = 200 mm

Copper bond

50 mm2 L = 200 mm

Copper bond

70 mm2 L = 200 mm

Copper bond

95 mm2 L = 220 mm

Copper bond

120 mm2 L = 200 mm

Steel-copper bond

70 mm2 L = 200 mm

Steel-copper bond

90 mm2 L = 200 mm

Steel-copper bond

95 mm2 L = 200 mm

New steel-copper bonds (See the figure) have acceptable electrical parameters and completely exclude the major disadvantage of a copper bond. A bimetallic bond, the so-called anti-vandal bond, is not only much more reliable in operation, but it also has considerably long service life and is protected against being stolen.

Specifications:

  • Voltage 36 VDC;
  • Number of solderings per charging 60-100;
  • Weight 50 kg;
  • Overall dimensions (LхHхW) 800 x 380 x 350 mm

The following is used as consumable material:

  • Rail bonds;
  • Soldering pins;
  • Ceramic rings;