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The VAHLE Copperhead Conductor Rail System can trace its history back to the last century. In 1912, electrical engineer Paul Vahle identified several major problems with traveling wires used for powering trolleys: they didn’t provide a very secure contact for passing current; they generated a lot of sparks, which can be a real safety hazard; and the flexible wire broke easily.

In response to these problems, Vahle developed the Copperhead Conductor Rails System: a copper bar mounted onto a T-shaped steel section. The copper bar transfers the electrical current, and the T-bar provides greater strength and more reliable electrical contact.

Copperhead Conductor Rails Advantages

The copperhead conductor rail system is the proven, reliable solution for mobile electrification. Use the Copperhead rails to overcome the limitations of trolley wires, steel angles and steel rails.

  • Conductor rails ensure efficient and continuous electrical contact
  • Increased safety due to elimination of sparking
  • Cost savings from reduced maintenance needs
  • 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
  • Standard expansion joints used to compensate for expansion and contraction due to temperature changes
  • Curved or bent conductor rails are available on request and customized to your precise specifications
  • For low-temperature environments, heating systems available for all rails

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 Rail system has been expanded over the years for specialized needs:

  • Fiberglass conductor rails for highly corrosive environments
  • Aluminum Copperhead systems 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
Copperhead Conductor Bar System L20 Steel 14-1000 220-444
A20 Aluminum 14 445
Copperhead Conductor Bar System F35 Steel 30 - 200 320 - 724
A35 Aluminum 30 - 100 600 - 795
Copperhead Conductor Bar System F45 Steel 50 - 600 495 - 1432
A45 Aluminum 50 - 400 790 - 1451
Copperhead Conductor Bar System C20 Solid copper 200 720
C35 Solid copper 400 1080
C45 Solid copper 500-800 1240-1580
C60 Solid copper 1200 2360