Emek R&D - Summer Practice Report

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METU Department of
Mechanical Engineering ME400
Summer Practice Report
by
Samet Baykul
October 17, 2017

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ME 400 Summer Practice Report October 18, 2018
I hereby declare that all information in this document has been obtained
and presented in accordance with academic rules and ethical conduct. I also
declare that, as require by these rules and conduct, I have fully cited and
referenced all material and results that are not original to this work.
Name, Last Name : Samet Baykul
Signature :

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TABLE OF CONTENTS
1. Description of the company ....................................................................... 1
1.1. Company Name and Location............................................................................ 1
1.2. Organizational Structure of the Company..................................................... 1
1.3. Engineers and Their Duties ............................................................................... 3
1.4. Main Area of Business ......................................................................................... 3
1.5. History of the Company ...................................................................................... 3
2. Introduction ................................................................................................... 5
3. Report .............................................................................................................. 6
3.1. General R&D Cycle............................................................................................... 6
3.1.1. Contract, Specifications & Standards ............................................................. 6
3.1.2. Conceptual Design............................................................................................ 7
3.1.3. Requirement Review ........................................................................................ 7
3.1.4. Preliminary Design and Review ...................................................................... 7
3.1.5. Critical Design and Review.............................................................................. 7
3.1.6. Production of Prototypes and System Verification......................................... 8
3.1.7. Test Readiness Review..................................................................................... 8
3.1.8. Test Verification & Assent............................................................................... 8
3.1.9. Final Design Review ........................................................................................ 8
3.1.10. Production Readiness Review.......................................................................... 8
4.2. Projects of Emek R&D ......................................................................................... 9
4.2.1. Introductions .................................................................................................... 9
4.2.2. Project 1: Inverted Current Transformer...................................................... 10
4.2.3. Project 2: Smart Disconnector ....................................................................... 10
4.2.4. Project 3: Pantograph Disconnector .............................................................. 12
4. Conclusion .................................................................................................... 19

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5. Appendices …………………………………………………………………………………
A.1. Map Location ................................................................................................................ i
A.2. Organizational Structure Chart of the Emek Arge ................................................... ii
A.3. Organizational Structure Chart of the Emek Electric Inc. ...................................... iii
B.1. General R&D Cycle Diagram......................................................................................iv
C.1. Disconnectors................................................................................................................v
C.2. Inverted Current Transformers..................................................................................vi
C.3. Radial electrical power distribution systems........................................................... vii
C.4. Smart Disconnector Principle .................................................................................. viii
C.5. Smart Disconnector Prototype....................................................................................ix
D.1. Technical Drawings of Pantograph Disconnector......................................................xi
D.2. Pantograph Mechanism ............................................................................................ xii
D.3. Electrical Contact Problem between Moving Mechanical Components ................ xiii
D.4. Geometry of Multilam ...............................................................................................xiv
D.5. Different Types of Multilam Connectors...................................................................xv
D.6. Cost of Prototype of Pantograph Disconnector ........................................................xvi

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1. Description of the company
This section is intended to give a general idea about the company, Emek Arge.
1.1. Company Name and Location
Full Name of the Company
EMEK Araştırma Geliştirme Danışmanlık Sanayi ve Ticaret A. Ş
Address of the Company
Ü̈niversiteler Mahallesi. İhsan Doğramacı Bulvarı. No: 33. Halıcı Binası. No: K1-4.
Teknokent Çankaya/Ankara
Tel: 0312 221 64 00-01
Faks: 0312 221 64 02
E-posta: info@emekarge.com.tr
Web: www.emekarge.com.tr
The location of the company office is provided in Appendix A.1.
1.2. Organizational Structure of the Company
Although Emek Arge has a small organizational structure consisting of five
employees, it carries out highly effective research and development activities and
achieves great works according to its size.
In order to see overall organizational chart of Emek Arge please look at the chart
in Appendix A.2.

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Emek Arge works as an R&D department for Emek Electrical Industry Inc. But
Emek Arge and Emek Electrical Industry Inc. have separate legal entities. Therefore,
some information about Emek Electrical Industry Inc. is also included in the report.
In order to see overall organizational structure of Emek Electrical Industry Inc.,
please look at the chart in Appendix A.3.
The company manager is Bora Balya. He was graduated from ODTÜ
Mechanical Engineering. He is responsible for general order of the company.
Team leaders are Mehmet Fatih Sayılır and Nurkan Aktaş. They are both electric
and electronics engineers. They are both experienced in the power transmission
industry. They manage the development of the research projects.
Research and development engineer is Adem Duygu. He is a mechanical
engineer. He is responsible for the current development in the power transmission
industry and writing regular development reports about the industry. He is also
responsible for the mechanical designs for the products such as pantograph
disconnectors and smart disconnectors. He uses SolidWorks® and AutoCad® as CAD
software for the mechanical designs. He uses also ANSYS® for the mechanical design
analysis.
Administrative affairs supervisor is Mine Akgül, is responsible for the
financial transactions of the company. She also regulates the communication of the
company.

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1.3. Engineers and Their Duties
Table 1 : Number of Engineers
Engineer Number
Mechanical
Engineer
2
EE Engineer 2
Almost all products which are developed in the company are electro-mechanic. In
this reason, interdisciplinary cooperation is necessary in electricity and mechanics
sides.
Bora Balya and Adem Duygu are mechanical engineers. They are responsible for
mechanical designs for the projects.
Mehmet Fatih Sayılır and Nurkan Aktaş are electrical and electronical engineers.
They are responsible for electrical designs for the projects.
1.4. Main Area of Business
Design and development of instrument transformers, power capacitors, high
voltage alternating current disconnectors and earthling switches in the power
transmission industry.
1.5. History of the Company
Emek R&D was established in 2014 by an effective team of engineers for the
purposes of giving consultancy services in electro mechanic, energy and defense
industries. The thought behind the foundation was to put Emek Electrical Industry
Inc. one level up in the power transmission industry by making research and

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development studies.
Emek Electrical Industry Inc. is a medium scale factory that is built on 23
kilometers away from Ankara. Today, the plant comprises of 10,835 m² covered area
and 20,183 m² open area.
In 1978, Emek Test Laboratory has been accredited according to TS ISO EN 17025
by TURKAK in 2011.
In 1982, Emek realized the first export of instrument transformers, when 145 kV
current and voltage transformers were exported to WAPDA, Pakistan.
In 1998, Initial public offering of Emek Electricity's shares was realized.
Emek gives importance to quality on all stage of processes. Emek has
ISO9001:2008 certificate from ABS Quality Evaluations INC.
In Emek all processes have been designed and implemented to regard
environmental improvement. All related regulations and legislations are traced and
implemented.

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2. Introduction
This report includes all my personal observations and actions in Emek R&D as a
mechanical engineering student during 20 business days.
My personal observations:
1. General R&D Cycle: It covers how Emek Arge handles a research project and
intermediate steps.
2. Projects of Emek R&D: Information about past and current projects of the Emek
R&D.
My personal actions:
1. Factory Tour: Some images and videos of products and environment of the
manufacturer company. All related digital media will be provided on demand.
2. Staubli Meeting: Notes on the related meeting are compiled in this section. All
the related information about the meeting was compiled in an extra document.
But some important actions were included in this report as well.

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3. Report
3.1. General R&D Cycle
General Manager Bora Balya gave us a brief information about research and
development in the company in a meeting. In this section, this process will be
explained. If you would like to see General R&D Cycle please look at Appendix B.1.
All R&D steps are showed as follows:
1. Contract, Specifications and Standards,
2. Conceptual Design,
3. Requirement Review,
4. Preliminary Design and Review,
5. Critical Design and Review
6. Production of Prototypes and System Verification,
7. Test Readiness Review,
8. Test Verification and Assent,
9. Final Design Review,
10.Production Readiness Review.
3.1.1. Contract, Specifications & Standards
Contract, professional or technical services means services that are intellectual in
character, including consultation, analysis, evaluation, predication, planning, or
programming, or recommendation, and result in the production of a report or the
completion of a task. (mmd, n.d.)
Specification, is a technical contract and it includes Performance, Visual and
Functional articles.

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Standards is used for a level of quality or attainment.
3.1.2. Conceptual Design
Conceptual Design includes literature search and indicating system’s needs.
3.1.3. Requirement Review
All requirements and limitations are described loud and clear. Report of input and
acceptance conditions is prepared. Project output has to satisfy the conditions.
Conditions that are not described in this document are not required to actualize the
conditions.
3.1.4. Preliminary Design and Review
Alternative products are designed. In the review part, different designs are
evaluated to determine if they satisfy economical and technical conditions. For
different concepts, pro-con matrices are made. Risks are determined, preliminary
calculations and assumptions are made.
3.1.5. Critical Design and Review
In this phase, designed models are analyzed and tested.
In the review part, detailed calculations are examined. Following topics are viewed:
• Needs, project goals, important requirements, general design, functions of
lower-segments, assumptions, designs from previous projects and comparison
to rival companies,
• Each necessities and supplies,
• Models and sketches,
• Tests, analyses and computations,
• Assumptions,
• Elimination of blurred topics,
• Project plan,
• Budget,
• Suitability for mass production,

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• Tests of present design or alternative designs or termination of the project.
3.1.6. Production of Prototypes and System Verification
Prototypes are manufactured and system is evaluated.
3.1.7. Test Readiness Review
Tests for each prototype are planned. Proper ways for testing that satisfy all
requirements are planned.
3.1.8. Test Verification & Assent
Tests are done, if everything goes well, product is verified and accepted.
3.1.9. Final Design Review
If the product succeeds tests, necessary changes are done in this stage. If the
product fails the tests, process starts again from Design phase. After all changes,
design process is frozen.
3.1.10. Production Readiness Review
It is viewed if the company is ready for mass production and if equipment is enough,
preliminary is made.

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3.2. Projects of Emek R&D
3.2.1. Introductions
In this part, some industrial components are introduced in order to explain the
following projects better.
Disconnector
A disconnector can be considered as a special type of switch. It is also called as
disconnect switch or isolator switch. It completely de-energizes an electric circuit. It
is used for service or when a malfunction occurred in sub-station and maintenance is
needed. Until the problem is solved, disconnector keeps the circuit open hence any
possible damage to people is prevented. It is mostly used in electrical distribution and
industrial applications. There are different types of disconnector such as,
• Center-break disconnector,
• Double-break disconnector,
• Pantograph disconnector,
• Horizontal break knee disconnector.

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Emek Arge is working on pantograph disconnectors. They are responsible for
research and development of the prototype of this type of disconnector. After the R&D
project finish, they will continue to assist on mass production for Emek Electrical
Industry Inc. Please look at the Appendix C.1. to see different types of disconnectors.
3.2.1. Project 1: Inverted Current Transformer
The Project is related to design and production of prototypes of new generation
inverted type current transformers according to IEC standards and receive test
certificate.
The main goal of this project is to produce a product that holds the market and
is not offered in Turkey, by using local resources. Another aim is to satisfy the Internal
Arc Test to decrease damage on nearby equipment and personnel during malfunction
or explosion in sub-station. Lastly, to produce safer products for electric line which
means mechanical endurance to earthquake. In Appendix C.2, different types of
products are shown.
3.2.2. Project 2: Smart Disconnector
Smart disconnector systems increase continuity of supply in energy transmission
line.
Since the electrical distribution companies are privatized, continuity of supply has
become more important. Especially in the areas where land conditions are tough and
radial electrical power distribution systems are used.
The problem of energy continuity transmitted to the end user with radial
distribution systems has been continuing for many years. In radial systems, when a

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fault occurs in any of the branches fed from the main line, all users in the main line
remain without electricity until the fault point is detected and repaired by the source
in case of failure.
Long-term and costly detection of defective branches in difficult terrain is the
disadvantage of these systems. Some figures about the Radial electrical power
distribution system are showed in Appendix C.3.
In radial electrical power distribution systems to prevent consumers from losing
electricity when a fault occurs in the system, this project would be very helpful by
isolating problematical branch from distribution line because the other branches on
the line are not affected by the malfunction. In order to see the comparison of the
systems with and without smart disconnectors, please look at Appendix C.4.
The project was finished in 2017 by Emek Arge. Manufacturing is continuous.
Some pictures were placed about the prototype in Appendix C.5.

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3.2.3. Project 3: Pantograph Disconnector
3.2.3.1. Introduction the Pantograph Disconnector
The pantograph disconnector is single break and vertical reach type disconnectors
mounted on a post insulator operated through an operating rod insulator. The divided
support disconnectors are mounted directly on the structure. A technical drawing of
a prototyped pantograph disconnector is placed in Appendix D.1.
The disconnectors and/or earthling switches can be single-pole or three-pole
operated by means of a motor-operated drive mechanism or a manual-operated drive
mechanism.
In case only one drive mechanism is used for three-pole operation, the poles are
interconnected by means of adjustable coupling rods. The drive mechanism also
houses the auxiliary contacts for position indication. (Hapam, 2018)
An overview of the mechanism is showed in Appendix D.2.
3.2.3.2. Introduction the Project
Developing a new pantograph disconnector design which is used in sub-stations in
power transmission industry. All technical problems should be solved before
manufacturing begins. In this report, only one specific problem related with the
project will be discussed. I was assigned this problem personally during my
internship. My responsibilities for the problem were as follows:
1. Investigation of the problem,
2. Search for possible solutions to the problem,
3. Making the necessary calculations for the solution,
4. To submit a report about the related subject.

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3.2.3.3. Introduction the Problem
As a mechatronic system, in disconnectors, high voltage current passes through
the moving mechanical parts between the main frame and the shafts. In this region,
there is an extra component which has an electrical contact. This term can be used
for a separable connection between two current-carrying conductors which are
pressed together by a mechanical force. The supporting area created by this force
(apparent contact area) does not, however, correspond to the effective contact area (a-
sports) that is available for the transmission of current.
Please look at the Appendix D.3. to see the details of the technical problem.
3.2.3.4. Approach
The effective contact area, depends on a number of parameters as follows;
• Contact force Fk,
• Pollution layer (dirt, oxidation, etc.),
• Roughness (surface characteristics),
• Material characteristics,
• Operating temperature
Since the effective contact area is substantially smaller than the apparent area,
the lines of flow are confined to the individual contact points, resulting in an increase
in resistance which is known as the constriction resistance.
According to the contact model of R. Holm, the constriction resistance Re is
defined as follows;

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To this are added the effects of a possible pollution layer on the contact
material.
According to the formula:
With increasing force and constant hardness, the contact area can be enlarged
and thin pollution layers can be broken through. The force and constriction formula
determines the correlation between the constriction resistance, the contact force and
the surface hardness of the contacts.
Consequently, it is necessary to use a resistant part which can be resists a
certain mechanical load and high voltage current between the main frame and the
rotating shaft. Therefore, we requested a meeting with Stäubli Inc. In 5.9.2018, I
attended this meeting with general manager Mr. Balya and research engineer Mr.
Duygu at the factory of Emek Electrical Industry Inc. We talked with Mr. Yavuz and
Ms. Gözübüyük who are sales engineers from Stäubli Inc. They informed us about the

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solution of the problem.
Stäubli (in English usually written as Staubli) is a Swiss mechatronics
company, primarily known for its textile machinery, connectors and robotics products.
Staubli offers mechatronics solutions for electrical connectors, liquid and gas
couplings, robots and textile machinery. (Wikipedia, Staubli, n.d.)
3.2.3.5. Solution: The Multilam Technology
Although a plug connection is not a stationary contact, it is subject to the same
theoretical principles. Multilam are made from specially shaped contact strips (of
copper, copper-beryllium alloy or copper alloy), and according to application they are
plated with silver, gold or nickel and mounted in a slot. (Staubli Catalogue, 2018)
The Multilam creates parallel contact points between the two surfaces from
which each individual Multilam louver serves as an independent, resilient "bridge"
for the transmission of current, thus substantially reducing the contact resistance. On
the basis of the contact force of each Multilam louver, its geometry and spring
characteristics, as well as the known hardness and character of the surface material,
it is possible to reliably calculate the contact resistance. (Staubli Catalogue, 2018)
Please look at the Appendix D.4.
The constant spring pressure of the Multilam louvers ensures a permanent
contact with the contact surfaces which results in a low constant transmission
resistance. (Staubli Catalogue, 2018)
They have a high current-carrying capacity in both short-time and continuous
operation, and ensure a dependable performance over a wide temperature range as
well as a long life. (Staubli Catalogue, 2018)
The geometry of the individual Multilam louvers is designed for a long life, i.e.
their permanent deformation is small and the louvers in the contact zone, which are

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slightly rounded, permit a large number of sliding cycles. The resistance values
undergo no major changes and remain constant over a long period.
Briefly, Multilam are specially formed and resilient contact elements. Because
of their constant spring pressure, Multilam louvers ensure continuous contact
surface, resulting in a constantly low contact resistance. The different Multilam types
are included in Appendix D.5.
After the meeting, we choose the LA-CU type Multilam. The reasons are as
follows:
• Very good electrical and thermal conductivity,
• Low but adequate contact force minimizes wear,
• Space-saving due to small width (smaller than LA-CUT type),
• High short-circuit current carrying capacity,
• This product allows rotation in both directions,
• Our competitor Güray Elektrik A.Ş. also uses this product. (Güray Elektrik
A.S.̧ manufactures their disconnectors under the patent permission from
Belgium.)
3.2.3.6. Calculations for Selection of Correct Product
All calculations and other details about the project are placed in another
document namely “Using Multilam in Pantograph Disconnectors, Meeting Notes” and
presentations.
I submitted this report which I compiled from my meeting notes and my
studies to the company during my internship period.
Briefly, calculation results are as follow:

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• If we choose LACU type Multilam, the required diameter of Multilam
connector should be minimum as 27 [mm].
• On the other hand, in recent design, mechanical restrictions increase
this number up to 35 [mm].
• With a new design this number can be reduced.
• As a result of calculations for LAIA Type Multilam, we saw the
calculations holds approximate pre-calculated values. Calculations seem
consistent.
3.2.3.7. Other Considerations
Fail History
• The selection of the connector model which cannot turn on both sides caused a
fail in Güral Elektrik A.Ş.
Warranty
• Final diameter values could be used for real operations. This means, these
numbers are in very safe zone for the test,
• Guarantee continuous after the test,
• Guarantee depends on number of the revolution or journey in km. It not
depends on time.
3.2.3.8. Cost Analysis
Cost Optimization
• Connector manufacturer in Sweden believes in technical accuracy is much
more important the price.
• They do not think any sale due to the recent exchange rate fluctuation.

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• Since the road warranty is quite tightly linked to the material quality, it affects
the final price significantly. For this reason, desired journey should be
optimum.
• As diameter increases, the journey increases as well. So, diameter should be
selected as optimum.
• Using standard products may be efficient for cost optimization. For example:
o Cost of 1000 products is 30% cheaper than cost of 100 products.
o Cost of 2000 products is 5% cheaper than cost of 1000 products.
• It is not very important at the beginning but cost is much more than linear
increasing with respect to the number of louver. For example:
o If number of louver = 10 -> 10$
o If number of louver = 15 -> >15$
• All prices are open to negotiations. All expectations and details of budget may
affect the final price.
Cost of the Prototype
A related table is given in Appendix D.6.

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4. Conclusion
During my summer internship at Emek Arge, I had some very valuable experiences
and I had the opportunity to develop many of my skills. I can sort some of these in the
following way:
• I increased my communication skills with people in a small office environment,
• I had the opportunity to attend an important meeting with sales
representatives from other companies. This gave me clues about how the
communication between companies took place. I even developed ideas about
continuing my after-school career as a sales engineer.
• As a machine engineer candidate, I learned better the importance of curiosity
and observation skills.
• I learned how much knowledge and experience gained during academic life can
make everything easier in professional life.
• I have witnessed the development of research and development stages closely.
• I have seen how programs such as ANSYS and SolidWorks are used.
During the internship, I was one of the most hard-working interns in the office.
When I presented my work to the general manager and project assistants, I enjoyed it.
I was happy to see that I could do something useful for the company for even a very
short time. It encouraged me for my future professional life. Thanks to the technical
knowledge provided by Mechanical Engineering Department in METU and the social
skills provided by METU campus, I can look forward to the future with more hopeful
and courage. I would like to thank all my managers and interns for a great summer
internship experience.

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Appendices
All related data, tables and drawings should be given in this section.
A.1. Map Location
Figure 1. Location of Emek Arge. Map shows ODTÜ Teknopolis, Ankara

ii
A.2. Organizational Structure Chart of the Emek Arge
Figure 2. Organizational Structure of Emek Arge

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A.3. Organizational Structure Chart of the Emek Electric Inc.
Figure 3. Organizational Structure of Emek Electric Inc.

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B.1. General R&D Cycle Diagram
Figure 4. Research and Development Stages on Emek Arge

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C.1. Disconnectors
Figure 5. Different Types of Disconnectors which are used in Power Transmission Industry. Left to right: 1. Center-break
disconnector, 2. Double-break disconnector, 3. Pantograph disconnector and 4. Horizontal break knee disconnector

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C.2. Inverted Current Transformers
Figure 6. Different Types of Current Transformers designed by Emek Arge and
manufactured by Emek Electrical Industry Inc. These are: Cast-head Inverted Type, Welding
Head Inverted Type, Tank Type and Bushing Type.

vii
C.3. Radial electrical power distribution systems
Figure 7. Radial Electrical Power System
Figure 8. Malfunction Occurs in Radial Electrical Power System

viii
C.4. Smart Disconnector Principle
Figure 9. Radial Electrical Power System without Smart Disconnector
Figure 10. Radial Electrical Power System with Smart Disconnector

ix
C.5. Smart Disconnector Prototype
Figure 11. Design of Coil for Measurement Transformer
Figure 12. Tests of the Smart Disconnector. Left: Disconnector is closed, circuit is active.
Rİght: Disconnector is open, circuit is break.

x
Figure 13. Finished Product of the Project

xi
D.1. Technical Drawings of Pantograph Disconnector
Figure 14. Technical Drawings of Pantograph Disconnector. Designed by Adem Duygu from
Emek Arge.

xii
D.2. Pantograph Mechanism
Figure 15. Technical Drawing of a Pantograph Disconnector while Moving
Figure 16. Moving Steps of a Pantograph Disconnector

xiii
D.3. Electrical Contact Problem between Moving Mechanical Components
Figure 17. Effect of Pollution Layer on Electrical Contact Area
Figure 18. Actual Electrical Contact Area is different than Ideal Contact Area

xiv
D.4. Geometry of Multilam
Figure 19. Geometry of Multilam, a Special Type of Electrical Connector which is Used in
Moving Mechanical Parts as an Electrical Bridge
Figure 20. Electrical Resistance of each Multilam Louver

xv
D.5. Different Types of Multilam Connectors
Figure 21. Different Multilam Connectors on the Stäubli Catalogue

xvi
D.6. Cost of Prototype of Pantograph Disconnector
Table 1. Cost of the Prototype of Pantograph Disconnector which designed by Emek Ar

xviii
References
Hapam (2018, October 18), Pantograph disconnectors type GSSB,
http://www.hapam.nl/products/pantograph-disconnectors-type-gssb/
Staubli Inc. Catalogue (2018, September 5)
International Conference on Large High Voltage Electric Systems (1984, August 29 –
September 6)
MMD (n.d.)
http://www.mmd.admin.state.mn.us/mn05000.htm
Wikipedia, Staubli (n.d.),
http://www.wikizeroo.com/index.php?q=aHR0cHM6Ly9lbi53aWtpcGVkaWEub3J
nL3dpa2kvU3TDpHVibGkjY2l0ZV9ub3RlLWJlaXNlLTE

Emek R&D - Summer Practice Report

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