Copperhead Conductor Systems
The VAHLE Copperhead Conductor System can trace its history back to the last century. During the early 1900s, trolley wires and steel I-beams were used to transmit electrical current to steel mill cranes. Electrical engineer Paul Vahle identified several major problems with this approach: the trolley wires didn't provide secure contact and broke easily; steel I-beams are an inefficient electrical conductor; and the setup generated showers of sparks when the collector passed, creating a safety hazard.
In response to these problems, Paul Vahle developed the Copperhead Conductor System. Patented in 1912, the system consists of a copper conductor rolled onto a T-shaped steel section. The copper conducts electrical current with high efficiency and also provides good electrical contact, while the steel section adds sufficient rigidity and durability.
Advantages of Copperhead Conductor
The Copperhead Conductor System is the proven, reliable solution for mobile electrification. Use the Copperhead to overcome the limitations of trolley wires, steel angles and steel rails.
- Copperhead conductor rails ensure efficient and continuous electrical contact
- Increased safety due to elimination of sparking
- Cost savings from reduced maintenance requirements
- Significantly reduced component wear for increased component life expectancy
- Lower resistance between copper and pickup shoe of mobile component
- Lower weight means lighter support structures and reduced space needs
- Expansion joints used to compensate for expansion and contraction due to ambient temperature changes
- Curved Copperhead conductor rails available to your specifications
- Heating systems available for low-temperature environments
Today, VAHLE Copperhead conductor rails are the proven solution for safe power transmission in a variety of heavy-duty applications, including:
- Travelling cranes
- Loading bridges
- Container handling equipment
- Monorails
- Hoists
- Coking machinery
In addition, the Copperhead system has been expanded over the years for specialized needs:
- Fiberglass Copperhead conductor rails for highly corrosive environments
- Aluminum Copperhead conductor rails for lower weight and greater conductivity
- Solid copper conductor rails for heavy duty applications
For more information, please contact us.
| Profile | Type | Material of the carrier profile | Cross section of copper head [mm2] | Max. current intensity [A] Continuous operation / 35° C |
|---|---|---|---|---|
 |
L20 | Steel | 14-1000 | 220-444 |
| A20 | Aluminum | 14 | 445 | |
 |
F35 | Steel | 30 - 200 | 320 - 724 |
| A35 | Aluminum | 30 - 100 | 600 - 795 | |
 |
F45 | Steel | 50 - 600 | 495 - 1432 |
| A45 | Aluminum | 50 - 400 | 790 - 1451 | |
 |
C20 | Solid copper | 200 | 720 |
| C35 | Solid copper | 400 | 1080 | |
| C45 | Solid copper | 500-800 | 1240-1580 | |
| C60 | Solid copper | 1200 | 2360 |
Accessories for VAHLE conductor rails
- Expansion and fixed joints
- Retaining and connecting clamps
- Rail holders and rail supports
- Insulators for high and low voltage
- Current collectors