An aluminum power transmission rail product comprises a profile main component made from molten aluminum onto which a stainless steel cap has been co-cast. Preferably, this main component has a locking feature such as a down-turn on at least one edge of the stainless steel cap. The rail product is preferably cast on a casting unit selected from the group consisting of a horizontal caster, a horizontal DC caster, an MDC caster and a semi-solid casting unit.

A modular structure supports elevated rail segments for delivering electrical power to a moving work machine, such as a hauler at a mining site. Opposite ends of a roadside barrier contain complementary tubular couplers arranged vertically. A lower end of a dielectric post positioned in one of the tubular couplers has opposing dielectric plates at an upper end. A top edge of each plate has a creepage concavity between a pair of rail recesses. Another dielectric post of similar configuration is positioned in the other of the tubular couplers. Holes within the couplers and the posts ensure alignment of respective rail recesses in which conductive rails are placed. Dielectric inserts frictionally lock the rails into the rail recesses.

A simulation system for a current collecting surface of a C-shaped contact rail includes a double-headed rail and a limiting plate. A current collecting end surface of the double-headed rail has a same current collection area as an actual C-shaped contact rail. The limiting plate matches the inner contour of the C-shaped contact rail. A constructed test line can simulate the current collecting status of the C-shaped contact rail. The limiting plate and the existing double-headed rail are combined, and compared with reproduction of the C-shaped contact rail, the manufacturing cycle is short, the costs are low, and it is applicable to the test line.

A method of manufacturing an aluminum power transmission rail product with a metallurgically bonded stainless steel cap comprises providing molten aluminum in a tundish; providing a roll formed stainless steel wear cap; pretreating and preheating the stainless steel cap, then introducing that cap into the tundish; co-casting the aluminum and cap through one or more dies; and tensioning the stainless steel cap at an exit of the casting die and rapidly cooling the same. An aluminum-stainless composite product is also disclosed.

A modular structure supports elevated rail segments for delivering electrical power to a moving work machine, such as a hauler at a mining site. Opposite ends of a roadside barrier contain complementary tubular couplers arranged vertically, one having a first diameter supported by an arm and the other having a larger second diameter and a vertical slot. Couplers on adjacent barriers can be mated together concentrically along a central axis. The mated couplers help restrict longitudinal displacement, lateral displacement, slope change, and lateral rotation between adjacent barriers during placement. One barrier may be used as a temporary alignment structure to position barriers spaced alternatingly along a haul route for the work machine.

A modular structure supports elevated rail segments for delivering electrical power to a moving work machine, such as a hauler at a mining site. Opposite ends of a roadside barrier contain complementary tubular couplers arranged vertically. A lower end of a dielectric post positioned in one of the tubular couplers has opposing dielectric plates at an upper end. A top edge of each plate has a creepage concavity between a pair of rail recesses. Another dielectric post of similar configuration is positioned in the other of the tubular couplers. Holes within the couplers and the posts ensure alignment of respective rail recesses in which conductive rails are placed. Dielectric inserts frictionally lock the rails into the rail recesses.

A modular structure supports elevated rail segments for delivering electrical power to a moving work machine, such as a hauler at a mining site. Opposite ends of a roadside barrier contain complementary tubular couplers arranged vertically. A lower end of a dielectric post positioned in one of the tubular couplers has opposing dielectric plates at an upper end. A top edge of each plate has a creepage concavity between a pair of rail recesses. Another dielectric post of similar configuration is positioned in the other of the tubular couplers. Holes within the couplers and the posts ensure alignment of respective rail recesses in which conductive rails are placed. Dielectric inserts frictionally lock the rails into the rail recesses.