Improving the Reliability of Current Collectors in Electric Vehicles

This article presents a mathematically grounded approach to increasing the operational reliability of current collectors in electric transport systems by ensuring a constant contact force between the collector shoe and the power rail. The core objective is achieved through the development and analysis of a mechanical system incorporating spring and cam elements, which is specifically designed to provide a nearly invariant contact pressure under varying operating conditions. A set of equilibrium equations was derived to determine the stiffness ratios of the springs and the geometric conditions under which the contact force remains constant despite wear or displacement. Additionally, the paper introduces a method for synthesizing the cam profile that compensates for nonlinear spring deformation, ensuring force constancy over a wide range of movement. The analytical results were validated through parametric simulations, which assessed the influence of wear depth, rail inclination, and external vibrations on the system’s force output. These simulations, executed within a numerical framework using scientific computing tools, demonstrated that the deviation of the contact force does not exceed a few percent under typical disturbances. Experimental verification further confirmed the theoretical predictions. The study exemplifies the effective use of mathematical modeling, nonlinear mechanics, and numerical methods in the design of energy transmission components for transport applications, contributing to the development of robust and maintainable systems.