Enhancing Pantograph Performance and Reliability in Addis Ababa Light Rail System:
A Study on Material Selection and Maintenance Strategies
Kirubel Moges
ID: GSR/4561/14
01 CHAPTER ONE
Content
Introduction
02 CHAPTER TWO
Literature Review
CHAPTER THREE
03 Methodology
CHAPTER FOUR
04 Analysis
05 CHAPTER FIVE
Content
Case Study
06 CHAPTER SIX
Result And Discussion
CHAPTER SEVEN
07 Conclusion And Recommendation
CHAPTER ONE
Introduction
Background
Addis Ababa Light Rail is Ethiopia's first urban high-speed
railway, aiming to solve traffic problems, reduce carbon
footprint, and provide knowledge and technology. The
project, initiated by the Ethiopian Railway Corporation in
2008, consists of two lines and 39 stations, covering 31.6
km (19.6 mi). The railway has a capacity of up to 60,000
passengers per hour and operates at peak times in 3-6
minutes. It is powered by the Ethiopian power grid, which
consists of hydro, geothermal, and wind power. The train
operates every 10 minutes, with destination and stop names
in both English and Amharic. The light rail system operates
on electricity, with various components working together to
ensure efficient transportation and reduce the city's carbon
footprint.
Pantographs are crucial parts of electric trains
(AALRT) because they allow electricity to be
transferred from overhead lines to power the
trains. This study aims to analyze the challenges
faced by pantographs in the Addis Ababa light rail
AALRT Train Pantograph system and provide solutions for improvement.
Study Material choice and maintenance procedures
significantly impact pantograph performance and
dependability. The findings will help enhance the
Addis Ababa light rail transportation system,
enhancing efficiency and efficacy, and fostering a
more reliable and sustainable transportation
system for citizens and visitors.
Problem Main Specific
Scope
Statement Objective Objective
Pantographs transmit electric This study's goal is to • Examining materials in The study focuses on material
energy from power sources to increase the pantograph and selection and maintenance
locomotives, but are performance and evaluating their impact strategies for pantographs in
susceptible to dependability of on rail system railway systems. It analyzes
environmental pressures Pantographs Addis performance. materials like carbon composites
and premature wear, Ababa Light Rail • Assessing wear, and Copper alloys considering
causing delays. To improve System through a fatigue, and durability, conductivity, weight,
efficiency and reliability, thorough analysis of environmental factors and cost-effectiveness. The
choose appropriate materials material choice and affecting pantograph research aims to create practical
and implement effective maintenance practices. performance. methods to increase pantograph
maintenance practices. • Understand pantograph dependability and reduce
Materials with excellent wear maintenance methods, breakdowns. It compares
resistance and fatigue life inspection, lubrication, condition-based, predictive, and
increase pantograph lifespan, and repair. preventive maintenance
while preventive • Make suggestions approaches, considering variables
maintenance helps identify like inspection frequency,
and fix issues before failure. lubrication procedures, and
replacement dates.
CHAPTER TWO
Literature Review
The Structure of the Pantograph
Pantograph Functionality
Collecting Energy Maintaining Contact
Collecting Energy
Collector shoes The pantograph
contact power lines, system adjusts the
transferring electrical height, angle for
Transmission
energy. constant power line C M
Power
Maintaining
contact.
Contact
Supporting Mobility Power Transmission
E
P S
The pantograph moves
vertically with support
The train’s electrical Z
system uses collected Supporting Mobility
arms and frame, electrical energy for
adjusting overhead propelling and
line height. operating.
Pantograph Common Problems
Electrical arcing
Caused by inadequate contact or
filthy or contaminated surfaces
Inconsistent Contact
Resulted in Constant contact with
the power lines This resulted
Mechanical Wear
mechanical wear from the collecting
shoes' constant movement and sliding.
Icing and Snow Build-Up
When it's chilly outside or
during the winter
Damage to Overhead Power Lines
can result in alterations or breaks in the
pantograph's operation.
Liu et al. (2021)
Researchers found that carbon strips and contact wires' wear rate increased
significantly at frigid temperatures, influenced by sliding velocity and contact
pressure. This has implications for railway system design and maintenance in
cold climates.
Previous Studies
On Pantograph Xiong et al. (2014)
Researchers studied the wear behavior of a carbon strip against copper under
Materials Wear continuous arcing conditions, revealing increased wear rate and arc erosion with
increasing electric current density. The findings can improve electrical contact
Rate. material design and performance.
M. O. Said (2017)
The study investigates cyclic loading-related fatigue behavior in pantograph
head materials using experimental tests and finite element analysis. Results
show contact pressure and material qualities significantly impact fatigue life.
Optimization techniques are suggested to prolong the fatigue life.
Wang et al. (2021)
Researchers studied carbon/carbon composites with copper impregnation at
different heat treatment temperatures, finding that fracture toughness and wear
resistance increased with higher temperatures, while flexural strength decreased.
This information can enhance design and performance for high-strength
applications.
Previous Studies
On Pantograph Li et al. (2021)
The study examined copper/sintered-carbon composites for pantograph sliders,
Materials Wear revealing improved mechanical properties and wear behaviors. Higher copper
content composites had higher compressive strength, tensile strength, electrical
Rate conductivity, and lower friction coefficients. This led to a stronger, more wear-
resistant composite, providing valuable insights into the design and performance
of Cu/SC composites.
Research Gap
• Research on carbon strip wear
behavior under specific
circumstances remains
unclear. Such as sliding speed
and contact pressure
• On a small selection of
• Some of the studies did not
materials, certain research was
consider the effects of humidity
undertaken. The study's findings
or other environmental factors
may not generalize well to other
on wear behavior.
types of material.
Research On The Influence of Environmental
Factors On Pantograph Performance
55% 75% 35% 90%
Temperature Humidity Rain Wind
Reduces Increases wear, Causes arcing, Increase
Contact force, Causes arcing, icing vibration, can
increases wear Pitting and cause
grooving might pantograph to
appear on these derail
surfaces over
time
Maintenance Practices and their impact on
pantograph reliability and Lifespan
Prevents further damage and
ensures proper operation
Replacement Addresses
Helps to prevent of worn or problems that have
wear and tear damaged parts
Corrective already occurred
Lubrication
maintenance
Helps to identify Regular Scheduled
and correct Inspection Preventive maintenance that is
problems before And maintenance performed to
Maintenance
they cause damage. Cleaning prevent problems
Practices
from occurring
Review of condition monitoring systems and
predictive maintenance approaches for pantographs
CHAPTER THREE
Methodology
Research Design
Data Collection Methods
Note: Data Analysis Technique that i used to did this is Statistical analysis.
Variables and Measurements
CHAPTER FOUR
Analysis
Pantograph Specification AALRT
Nominal Speed 120 km/h
Nominal System Voltage 150 VDC (Max. bearing voltage)
Operating Current 1050 A
Static Contact Pressure 100 N (Adjustable from 60 to 140N)
Pantograph rise/fall time <= 10s
Max. Working Hight 2400mm (Including Insulator)
Min. Working Hight 380+/-10mm (Including Insulator)
Insulator Hight 80 mm
Slider-length 1047 mm
Slider-spacing 300 mm
Slider-material Metal-impregnated carbon
Control Voltage 24 VDC
Control Current Max. 13 A
Sample Maintenance Data Record of Pantograph on
AALRT Light Rail Train
Monthly
Train No. 201 202 204
Operation km MC1: MC2: MC1: MC2: MC1: MC2:
420683 km 420684 km 378760 km 378762 km 420571 km 420572 km
Content 1st Carbon 2nd Carbon 1st Carbon 2nd Carbon 1st Carbon 2nd
Strip Strip Strip Strip Strip Carbon Strip
Left End (mm) 4.4 4.4 4.7 4.7 4.5 4.5
Position one (mm) 11 11 11 10.7 11 11 Annual inspection
Position Two (mm) 13.9 13.7 13.9 13.8 14 14 include Uprising
Time (< 10s),
Position Three (mm) 9.8 10.7 9.7 9.4 13.5 12.7 Lowering Time
(<10s) , And
Position Four (mm) 8.4 8.4 8.4 9.3 12.9 12.9
Contact Pressure
Position Five (mm) 8.2 8.7 9.2 9.2 14 13 (+/- 100 NM)
Position Six (mm) 14 13.7 14 14 14 14
Position Seven (mm) 11 11 10.5 10.8 11 11
Right End (mm) 4.5 4.5 4.4 4.5 4.5 4.5
Min. Thickness (mm) 8.2 8.4 8.4 9.2 11 11
Wear Rate of Strip
Wear rate
No Train Thickness Wear Current Maintenance
No. Difference Rate Collector Frequency
Max-Min (mm/cm) Efficiency
1 201 7.3 0.070 93.9% 4
2 202 6.6 0.063 94.9% 5
3 204 8.3 0.079 91.2% 6
4 205 8.4 0.080 90.5% 7
5 208 9 0.086 85.2% 3
6 209 8.7 0.083 87.3% 5
7 210 8.8 0.084 86.1% 8
8 212 6.4 0.061 95.3% 6
9 213 8.8 0.084 86.1% 4
10 216 4.6 0.043 97.2% 7
11 217 8 0.076 93.2% 6
12 218 4.3 0.041 98.5% 6
13 219 7.7 0.073 92.5% 7
Count Mean Std. Dev Min Max
Wear Rate 13 0.071 0.0145 0.041 0.086
(mm2/N)
Material Selection
The strip makes direct contact with the contact wire because it is a component of the head.
High mechanical
strength, low
resistivity &
Moderate cost, Wear
Metal-impregnated carbon is the Resistance
best alternative for pantograph Heavy Weight, Low 90%
contact strips due to its high Resistivity
electrical conductivity and wear Moderate to Heavy . Metal-
resistance. However, copper and Weight, Low 70% Impregnated
copper alloys (Beryllium Copper Resistivity carbon
Powder
and Brass) are increasingly used 60% (Carbon, copper
Light Weight, High Metallurgy
due to their improved strength and Resistivity 15 – 30 %)
Pure Metal (sintered
corrosion resistance. The choice of
material depends on the rail Light Weight, Low 59% (Steel Strip, iron-based,
vehicle's requirements, operating Resistivity copper strip, the sintered
environment, and desired Pure copper-
53% 2 % of
performance characteristics. Carbon based type
Carbon)
Graphite
The following is the process used to make carbon strips
with metal impurities. Utilizing a mold, press carbon
Manufacturing powder onto a carbon-based strip. Place the strip in a
high-temperature sintering furnace and heat it for 48
Process hours at a temperature between 1200 and 400 °C while
maintaining a specific temperature gradient. To create a
molten alloy, melt lead, tin, and copper in a certain
ratio while extracting air from the carbon-based strip.
The final carbon-based strip should be dipped into the
molten alloy. Charge air to pressurize to (100-150) 98
MPa and hold for 0.5–1.0 hours to ensure that the
carbon-based strip is evenly distributed throughout the
molten alloy and impregnated with it. Once the carbon-
based strip impregnated with the molten alloy has
cooled, it should be transformed into a metal-
impregnated carbon strip with a circular arc at the
bottom.
Wear rate of carbon strips at different sliding speeds and contact
Comparison of Performance Metrics with Existing Standards pressures
No. Performance Addis Ababa Existing Sliding speed Contact pressure
Metrics Standard Standard Wear rate (mm³/km)
(m/s) (N/mm²)
1 Contact force 150 N 120-180 N
2 10 0.5
2 Contact 0.02 ohms 0.01-0.03 ohms
resistance 4 10 0.10
3 Leakage 1 mA 0.5-1 mA 6 10 0.20
current 2 15 0.7
4 Rise time 100 ms 80-120 ms 4 15 0.15
5 Fall time 100 ms 80-120 ms 6 15 0.30
2 20 0.10
6 Contact 20 ms 10-20 ms 4 20 0.20
bounce
CHAPTER FIVE
Case Study
Accident involving a pantograph and an overhead line close to
Littleport, Cambridgeshire
On January 5, 2012, a passenger train's
pantograph assembly fell from the roof, causing
the train to halt at a speed of 129 km/h. The train
body sustained minimal damage, but the
overhead wire apparatus sustained significant
damage. The pantograph arm struck a cantilever
overhead line support structure, causing the
assembly to fall from the roof. The pantograph
head lost contact with the overhead line due to
long-term movements and wind force, causing
line divergence from the intended location. The
rail accident investigation branch (RAIB) found
that the overhead line's maintenance was not
performed in accordance with Network Rail
standards, causing the line to be diverted from its
intended location. The RAIB has given Network
Rail two recommendations: evaluating and
reducing the risk of maintenance standards
violations and providing information to overhead
line maintenance managers to manage alignment
efficiently. The rail sector should consider using
polymeric or composite insulators for pantograph
support.
Computerized Maintenance Management Systems (CMMS)
The process of recording pantograph maintenance data can be automated using software tools. Work orders,
workflows, and the scheduling of manpower and materials can all be automated using computerized
maintenance management systems (CMMS), Additionally, condition-based maintenance can be enabled by
predictive maintenance solutions like OpenMAINT and can increase asset reliability.
CHAPTER SIX
Result And Discussion
Result And Discussion
The Addis Ababa Light Rail System's pantograph
performance and reliability were improved through
material selection and maintenance procedures.
Metal-impregnated carbon, a mixture of carbon and
copper, was chosen for contact strips due to its high
conductivity, corrosion resistance, low friction
coefficient, low wear rate, and strength. Copper alloys
like Beryllium Copper were used to enhance
performance. A comprehensive maintenance plan,
including preventive, predictive, and corrective
maintenance, was developed, focusing on routine
checks, cleaning, lubrication, and replacement of
worn-out parts. The study found that material
selection and maintenance procedures improved the
system's dependability and performance while
minimizing wear and damage by using suitable
materials for pantograph components.
CHAPTER SEVEN
Conclusion And Recommendation
Conclusion Recommendation
The study on improving pantograph The study suggests recommendations for
performance and reliability in the improving Addis Ababa Light Rail System
pantograph performance and reliability.
Addis Ababa Light Rail System
highlights the importance of material • Examine pantograph performance and
reliability using composites, as high-
selection and maintenance practices. quality materials improve reliability and
Adopting high-quality materials, such performance in the future.
as contact wires and carbon strips, • Develop preventative maintenance plans to
reduces maintenance costs and reduce pantograph failure risk by using
increases system reliability. Effective sensors to track performance and identify
preventive and predictive maintenance potential issues before they escalate.
techniques can prevent problems and • The study analyzed maintenance
extend equipment life. Environmental approaches for improving pantograph
factors like temperature, humidity, and performance and dependability but did not
wind also impact pantograph system evaluate their cost-effectiveness. Future
research should evaluate these procedures.
performance.
Future research could enhance pantograph
system performance and dependability in light
rail systems.
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