High speed air fuel coating for corrosion resistance of conductors

Abstract

A work machine (100), such as a conveyor at a mining site, includes a conductor rod (106) housing a concentric metal tube for receiving power from a contactor sliding on a power rail. Electrical connectivity between conductors within the conductor rod (106) is provided using a conductive liquid. A corrosion barrier layer is used to protect the conductors while maintaining electrical connectivity between the conductors.

Description

Technical Field

[0001] The present disclosure generally relates to systems for providing power using a conductive liquid as an electrical interface. Background Art

[0002] Heavy work machines, such as earth-moving vehicles or transport trucks, require significant power to perform their functions. The machines themselves may be very heavy, and moving their loads requires a lot of power. Diesel engines typically provide this power, but they may have disadvantages. For example, in some embodiments, heavy work machines may need to travel long distances across rough terrain. For example, at remote mining sites, groups of these machines are often used to transport extremely heavy loads along roads or transportation routes that extend between various locations within the mining site. The supply of diesel fuel may be far from these locations, or difficult to deliver to these locations. In addition, groups of diesel machines can generate significant pollution.

[0003] Electricity has been used to supplement these diesel engines while the work machines are moving. In some environments, electricity is delivered from lines above the transport route to pantographs on the work machines as the machines travel along the transport route, much like a cable car. However, overhead wires cannot reliably provide enough electrical energy to power heavy work machines during longer moves. Overhead delivery also cannot provide enough current to simultaneously charge the backup batteries for the motors. As a result, electricity via overhead lines is typically a supplement to diesel engines in heavy work machines, not a replacement.

[0004] Alternatively, a ground-based power rail can provide power to a heavy work machine. For example, an axially movable cylindrical rod includes an interface with the work machine at one end, and a connection to a power rail at the side of the transport route at the opposite end. In some cases, the interface with the work machine can not only provide power from the rod to the work machine, but also transfer pressurized air from the work machine to the rod for powering pneumatic controls. In addition, it may be necessary for electrical sensors or controls to transfer signal data between the rod and the work machine. It may be challenging to accommodate these interfaces in a cylindrical rod that handles high-voltage electricity.

[0005] For example, as the distance between the power rail and the work machine changes, these electrical interfaces extend and retract to maintain electrical and physical contact between the work machine and the power rail. In instances where the surface of one electrical contact slides against the surface of another electrical contact to accommodate movement of the work machine relative to the power rail, various techniques can be used to maintain electrical contact. For example, carbon brushes / carbon pads can be used, whereby the carbon brushes / carbon pads are designed to be at least partially conductive to maintain electrical contact while allowing different surfaces to move relative to each other.

[0006] Another example is the use of a liquid metal medium as a conductive medium. The liquid metal medium is formed by various metals and alloys that are liquid at or near the operating temperature, and the liquid metal medium will experience this operating temperature at the electrical interface. Some of these metals and alloys include gallium alloys, gallium indium alloys, gallium indium tin alloys, gallium indium tin zinc alloys, bismuth alloys, lead bismuth alloys, bismuth indium tin alloys, bismuth indium tin zinc alloys, etc. However, these liquid alloys will usually quickly and significantly corrode most types of typical electrical conductors, such as copper, aluminum, iron and their alloys. Therefore, in order to prevent corrosion, a barrier layer is usually deposited between the liquid metal and the electrical conductor. The barrier layer protects the electrical conductor from the corrosive effects of the liquid metal medium while being conductive itself.

[0007] Chinese Patent Application Publication No. CN108273713 ("the '713 Application") describes a method for providing a barrier layer. The '713 Application describes a process for depositing a high temperature resistant coating onto an electrical conductor. The process requires sandblasting, shot blasting, or grinding the surface of the electrical conductor to a certain degree of smoothness, and then applying the high temperature resistant coating to the surface. The coating can be formed from silicon, phosphate powder, or zinc powder. According to the '713 Application, once the coating is cured, a conductive coating is formed that acts as a corrosion barrier layer between the electrical conductor and the liquid metal. However, this process requires multiple steps, such as sandblasting / grinding, applying the barrier layer, and a curing period. In addition, when sandblasting is used, the size or area of ​​the parts that can be processed is generally limited by the internal volume of the sandblasting chamber. Finally, the density of the coated and cured layer may be limited by the available solvent / solute ratio, thereby potentially limiting the range of applications to which the layer can be applied.

[0008] Examples of the present disclosure are directed to overcoming these and other deficiencies of such systems. Summary of the invention

[0009] In one aspect of the disclosed subject matter, a work machine is disclosed. The work machine includes an electric engine, a traction device configured to move the work machine when powered by the electric engine, and a conductor bar configured to transmit electrical energy to the work machine during movement of the work machine, the conductor bar having a first end and a second end. The conductor rod includes: a barrel, the barrel including a barrel conductor having an inner diameter and a longitudinal center defining an axis between a first end and a second end; and an arm, the arm including a cylindrical conductor, the cylindrical conductor being arranged to be concentrically and slidably engaged into the barrel conductor around the axis; a liquid space, the liquid space being configured to accommodate a conductive liquid, the liquid space being defined by an inner surface of the cylindrical conductor and an outer surface of the cylindrical conductor; a first corrosion barrier layer along the inner surface of the cylindrical conductor and a second corrosion barrier layer along the outer surface of the cylindrical conductor, the first corrosion barrier layer and the second corrosion barrier layer comprising a metal alloy having chemical resistance and low permeability to the conductive liquid accommodated in the liquid space; and a liquid junction, the liquid junction being formed by the liquid space, the first corrosion barrier layer, the second corrosion barrier layer and the conductive liquid, the liquid junction being configured to electrically connect the barrel conductor to the barrel conductor.

[0010] In another aspect of the disclosed subject matter, a conductor rod is disclosed. The conductor rod includes: a barrel, the barrel including a barrel conductor having an inner diameter, and a longitudinal center defining an axis between a first end and a second end; an arm, the arm including a cylindrical conductor, the cylindrical conductor arranged to be concentrically and slidably engaged into the cylindrical conductor around the axis; a liquid space, the liquid space configured to contain a conductive liquid, the liquid space being defined by an inner surface of the cylindrical conductor and an outer surface of the cylindrical conductor; a first corrosion barrier layer along the inner surface of the cylindrical conductor and a second corrosion barrier layer along the outer surface of the cylindrical conductor, the first corrosion barrier layer and the second corrosion barrier layer comprising a metal alloy having chemical resistance and low permeability to the conductive liquid contained in the liquid space; and a liquid junction, the liquid junction being formed by the liquid space, the first corrosion barrier layer, the second corrosion barrier layer and the conductive liquid, the liquid junction being configured to electrically connect the barrel conductor to the barrel conductor.

[0011] In yet another aspect of the disclosed subject matter, a method of manufacturing a conductor rod is disclosed. The method includes: applying a first corrosion barrier layer to at least a portion of an inner surface of a cylindrical conductor using a high velocity air-fuel process, the first corrosion barrier layer comprising a first matrix of nickel-chromium alloy (Ni-20Cr) and aluminum oxide (Al2O3) particles; applying a second corrosion barrier layer to at least a portion of an outer surface of a cylindrical conductor using the high velocity air-fuel process, the first corrosion barrier layer comprising a second matrix of nickel-chromium alloy (Ni-20Cr) and aluminum oxide (Al2O3) particles, and wherein the inner surface of the cylindrical conductor and the outer surface of the cylindrical conductor define a liquid space for containing a conductive liquid; inserting the cylindrical conductor into the cylindrical conductor to form a conductor rod; and filling at least a portion of the liquid space with the conductive liquid. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 An isometric view of a work machine within an XYZ coordinate system is shown as one example suitable for carrying out the principles discussed in this disclosure.

[0013] Figure 2 A longitudinal cross-section of a conductor rod having arms disposed in a barrel is shown according to one or more examples of the present disclosure.

[0014] Figure 3 A liquid space containing a conductive liquid using a corrosion resistant barrier layer according to various examples of the disclosed subject matter is shown.

[0015] Figure 4 is a cross-sectional view illustrating a corrosion barrier layer according to various examples of the disclosed subject matter.

[0016] Figure 5 is an exemplary HVAF system for depositing a corrosion barrier layer on an inner surface of a cylindrical conductor according to various examples of the disclosed subject matter.

[0017] Figure 6 is a flow chart depicting a method of constructing a conductor rod that may be used in a work machine using a liquid conductor corrosion barrier layer according to various examples described herein. DETAILED DESCRIPTION

[0018] Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Figure 1An isometric view of a work machine 100 in an XYZ coordinate system as an example of the principles discussed in the present disclosure is shown. The exemplary work machine 100 travels parallel to the X axis along a road (also referred to as a transport route 101), usually traveling from a starting point to a destination within a work site. In one embodiment as shown, the work machine 100 is a transport machine that transports loads within or from a work site in a mining operation. For example, the work machine 100 can transport excavated ore or other earthwork materials from an excavation area to a dump site along the transport route 101, and then return to the excavation area. In this arrangement, the work machine 100 can be one of many similar machines configured to transport earthwork materials in a transporter arrangement. Although in this case it is a large mining truck, the work machine 100 can be any machine that carries a load between different locations within a work site, examples of which include articulated trucks, off-highway trucks, highway dump trucks, wheeled tractor scrapers, or any other similar machinery. Alternatively, work machine 100 may be an off-highway truck, an on-highway truck, a dump truck, an articulated truck, a loader, an excavator, a pipelayer, or a motor grader. In other embodiments, work machine 100 need not transport a load and may be any machine associated with a variety of industrial applications including, but not limited to, mining, agriculture, forestry, construction, and other industrial applications.

[0019] refer to Figure 1 , the exemplary work machine 100 includes a frame 103 powered by an electric engine 102 to rotate a traction device 104. The traction device 104 is typically four or more wheels with tires, but may also be tracks or other mechanisms for engaging the ground along the transport route 101. As will be described in further detail below, the electric engine 102 operates on an external power source to provide mechanical energy to the work machine 100. Examples of mechanical energy provided by the electric engine 102 include propelling the traction device 104 to move the work machine 100 along the transport route 101, but the electric engine 102 also includes components sufficient to power other auxiliary operations within the work machine 100. For example, in some embodiments, the electric engine 102 includes a device for converting electrical energy to provide pneumatic or hydraulic action within the work machine 100. Although the electric engine 102 is configured to operate on an external power source, the electric engine 102 typically includes one or more batteries for storing electrical energy for auxiliary or backup operations.

[0020] In accordance with the principles of the present disclosure and in connection with the presently disclosed subject matter, work machine 100 also includes a conductor bar 106 configured to receive power from a power rail 108. In some examples, power rail 108 is one or more metal beams arranged substantially parallel to the ground and a distance above the ground. Figure 11, the power rail 108 is positioned substantially parallel to the X-axis and the direction of travel of the work machine 100. The support mechanism holds the power rail 108 in place at a distance to the side of the transport route 101 for the work machine 100 to pass through. The support mechanism and the power rail 108 can be of modular construction, allowing them to be disassembled and reassembled at different locations, or allowing them to be relocated along an existing transport route 101. In addition, although the power rail 108 is viewed from the perspective of an operator sitting in the cab of the work machine 100, the power rail 108 is not Figure 1 The power rail is shown as being located on the left side of work machine 100, but the power rail may also be located on the right side of work machine 100 or at other locations suitable for a particular embodiment.

[0021] The power rail 108 provides power for the work machine 100 as AC or DC. In some examples, the power rail 108 has two or more conductors, each of which provides voltage and current at different electrodes. In one embodiment (for example, an embodiment in which the power rail 108 includes three conductors), one conductor provides a positive DC voltage, a second conductor provides a negative DC voltage, and a third conductor provides 0 volts relative to the other two conductors. The two power supply conductors in the power rail 108 provide +1500VDC and -1500VDC. These values ​​are exemplary only, and other physical and electrical configurations of the power rail 108 are also available and within the knowledge of those of ordinary skill in the art. In addition, it should be understood that the voltages described herein are exemplary only, as various AC voltage levels and combinations of AC and DC voltages can be used depending on the specific configuration.

[0022] Conductor rod 106 provides electrical connection between work machine 100 and power rail 108, including during movement of work machine 100 along transport route 101. Figure 1 In the example shown in FIG. 1 , the conductor rod 106 is an elongated arm similar to a rod. Figure 1 The conductor rod 106 is shown positioned along the front side of the work machine 100 relative to the direction of travel of the work machine 100 in the X-axis direction. Figure 1 , the conductor bar 106 is positioned substantially along the Y axis in the YZ plane, with the first end 107 near the right side of the work machine 100 and the second end 111 located at the left side of the work machine 100. The conductor bar 106 can be attached to any convenient location within the work machine 100, such as to the frame 103, in a manner that couples the conductor bar 106 to the power rail 108. The conductor bar 106 is located at the Figure 1 106 as extending to the left side of work machine 100 toward power rail 108, but the conductor bar may alternatively be arranged to extend to the right side and at any desired angle to work machine 100 so that conductor bar 106 can be coupled to power rail 108 to obtain power.

[0023] like Figure 1 As embodied in FIG. 1 , the conductor rod 106 includes a cylinder 109 mounted to the frame 103 of the work machine 100. The cylinder 109 has a hollow interior and may be a conductive metal having suitable mechanical strength and elasticity, such as aluminum. The arm 110 is held within the cylinder 109. Figure 1 1, the arm 110 is engaged within the conductor bar 106 along the Y axis. The length of the conductor bar 106 roughly spans the width of the work machine 100. The joint 112 acts as a joint or interface between the arm 110 and the barrel 109 (which is the body of the conductor bar 106). When the arm 110 is fully retracted or contracted into the barrel 109, the joint 112 essentially becomes the left edge of the conductor bar 106. On the other hand, when the arm 110 is extended from the barrel 109 of the conductor bar 106, the arm 110 can extend from the work machine 100 to the near side power rail 108 on the side of the transport route 101.

[0024] In the barrel 109 (and possibly including the barrel), the conductor rod 106 includes a series of electrical conductors that are longitudinally transmitted from at least the head 122 at the proximal end of the conductor rod 106 to the tip 124 at the distal end of the conductor rod 106. Typically, the conductors in the conductor rod 106 are formed of a metallic material and are rigid. In some instances, the conductors are concentric tubes or hollow cylinders of solid metal (such as copper, aluminum, gold, silver, nickel, zinc, or alloys thereof) that are nested together and sized to provide enough electrical capacity to power the work machine 100. Other conductive materials may also be used, such as graphite, and are considered to be within the scope of the subject matter disclosed herein. The tubular conductors in the arm 110 are engaged with the corresponding tubular conductors in the barrel 109 to provide electrical continuity. In other instances, one or more concentric copper (rather than aluminum) tubes of different diameters may be used as tubular conductors. Other types of conductive tubes may be used and are within the scope of the subject matter disclosed herein. In some instances, conductivity between the tubular conductor within the arm 110 and the corresponding tubular conductor within the barrel 109 is provided using various liquid metals such as gallium alloys, gallium-indium alloys, gallium-indium-tin alloys, gallium-indium-tin-zinc alloys, bismuth alloys, lead-bismuth alloys, bismuth-indium-tin alloys, bismuth-indium-tin-zinc alloys, etc., as described in more detail in the accompanying drawings below.

[0025] Back to Figure 1 At tip 124, connector assembly 114 provides an interface with power rail 108 via trailing arm 116 and contactor 118. Power rail 108 is typically arranged along the side of transport route 101, and work machine 100 is maneuvered so that it traverses transport route 101 substantially parallel to power rail 108. Thus, referring to Figure 1, the power rail 108 and the travel path of the work machine 100 are substantially parallel to each other and parallel to the X-axis. The contactor 118 is configured to maintain electrical connection with the power rail 108 while sliding along the surface of the power rail in the X-axis direction as the work machine 100 moves. In some examples, the trailing arms 116 are conductors coupled to the contactors 118, each of which conducts voltage and current at a different electrode and corresponds to a conductor within the conductor bar 106. In operation, power is taken from the power rail 108 via the contactor 118, which maintains contact during movement of the work machine 100, and the power is conducted into the connector assembly 114 through the trailing arms 116.

[0026] From the connector assembly 114, power is transmitted at the tip 124 through the nested tubular conductors within the arm 110 and barrel 109 to the head 122 of the conductor bar 106, and to the work machine 100 through the head end interface 120. The head end interface 120 provides at least an electrical connection between the conductor bar 106 and the work machine 100 for powering the electric motor 102 and otherwise enabling operations within the work machine 100. In some examples, the head end interface 120 may also provide an interface for input to control mechanical operations of the conductor bar 106.

[0027] As discussed above, the tubular or cylindrical nature of the conductor rod 106 imparts greater rigidity to the conductor rod 106 than a solid conductor of similar or lesser mass or weight, since the moment of inertia of the hollow tube is greater than that of a solid rod of similar mass. Thus, by forming the conductive material into a hollow tube rather than a solid rod, the conductor rod 106 can provide a mechanism for conducting electrical power from a source to a load over an unsupported distance with similar conductive properties. As discussed above, the trailing arms 116 are conductors coupled to the contactors 118, with each trailing arm conducting voltage and current at a different electrode and corresponding to a conductor within the conductor rod 106. The liquid metal provides an electrical interface to allow the tubular conductors within the arms 110 to move relative to corresponding tubular conductors within the barrel, which is described below. Figure 2 Shown in more detail in .

[0028] Figure 2 A longitudinal cross section of a conductor rod 206 having an arm 210 disposed in a barrel 209 according to one or more examples of the present disclosure is shown. The arm 210 includes a cylindrical conductor 222 of tubular shape, i.e., a hollow cylinder. In this example, from an axial center AB extending along the center of the cylindrical conductor 222 toward the barrel outer surface 224, the cylindrical conductor 222 is concentrically positioned along the axial center AB of the barrel 209 (i.e., the longitudinal axis of 209), and is a tubular conductor made of aluminum or a similar metal having a desired conductivity and a desired mechanical strength. When connected to a power source 226 (such as Figure 1When power is supplied to the power rail 108 of the cylinder 209, power from the power source 226 flows into the arm electrical contacts 228A and 228B. The arm electrical contacts 228A and 228B are mechanically connected to the barrel conductor 222 at electrical contact points 230A and 230B, respectively. In addition to providing an electrical path from the electrical contacts 228A and 228B to the barrel conductor 222, the electrical contacts 230A and 230B also secure the barrel conductor 222 to the arm end cap 232. Therefore, as will be described in more detail below, when the barrel conductor 222 changes position within the barrel 209, the barrel conductor 222 and the arm end cap 232 move as a single unit.

[0029] The power received from the cylindrical conductor 222 flows into the cylindrical conductor 234, through the cylindrical electrical contacts 236A and 236B and flows to one or more electrical loads 239. The cylindrical conductor 234 is concentrically positioned along the axial center AB of the cylinder 209 (i.e., the longitudinal axis of 209), and is a tubular conductor made of aluminum or other metals having desired electrical conductivity and desired mechanical strength. The cylindrical conductor 234 includes an outer surface 238 and an inner surface 240. At least a portion of the outer surface 238 abuts the inner surface 242 of the cylinder. At least a portion of the inner surface 240 abuts the outer surface 244 of the cylindrical conductor 222. The cylindrical electrical contacts 236A and 236B are mechanically and electrically connected to the cylindrical conductor 222 at electrical contact points 246A and 246B, respectively. In addition to providing an electrical path from the electrical contacts 236A and 236B to the electrical load 239 , the electrical contacts 246A and 246B also secure the barrel conductor 234 to the barrel end cap 248 .

[0030] The arm 210 is substantially cylindrical, and its outer diameter D1 is smaller than the inner diameter D2 of the barrel conductor 234, thereby allowing the arm 210 to be slidably engaged in the barrel 209. "Sliding" means that as the arm 210 moves axially relative to the conductor rod 206, the arm 210 can move longitudinally along the AB axis in the barrel 209. Figure 2 Move from left to right toward B on the AB axis to extend, and Figure 2 The result of the sliding movement is to increase or decrease the overall length of the conductor rod 206 via the arm 210.

[0031] As the arm 210 moves longitudinally along the AB axis within the barrel 209, electrical connectivity between the power source 226 and the electrical load 239 is maintained by the liquid junction 250. The liquid junction 250 includes a conductive liquid located at a conduction location 252. The conductive liquid located at the conduction location 252 provides conduction of electricity and is a metal alloy that is liquid at a specific temperature (such as room temperature). An example of a metal alloy is GALINSTAN. GALINSTAN is a brand name for a eutectic alloy composed of gallium, indium, and tin that melts at -19C (-2F) and is therefore liquid at room temperature. However, it should be noted that other metal alloys having properties similar to GALINSTAN, such as gallium alloys, gallium-indium alloys, gallium-indium-tin alloys, gallium-indium-tin-zinc alloys, bismuth alloys, lead-bismuth alloys, bismuth-indium-tin alloys, bismuth-indium-tin-zinc alloys, etc., may be used, and these alloys are considered to be within the scope of the presently disclosed subject matter.

[0032] However, in some instances, a eutectic alloy such as GALINSTAN used as the conductive liquid at the conduction location 252 can corrode and substantially destroy the crystalline matrix of the metal exposed to the conductive liquid at the conduction location 252. For example, GALINSTAN can react with aluminum to form an aluminum-GALINSTAN mixture, which can not only structurally destroy the aluminum, but in some cases (if water or water vapor is present) can also release hydrogen. In order to protect the various components of the conductor rod 206 from the chemical and physical effects of the conductive liquid at the conduction location 252, the conductive liquid is contained within a liquid space 254. The liquid space 254 is a space defined by an inner surface 256 of the cylindrical conductor 222 and an outer surface 258 of the cylindrical conductor 234. The liquid space 254 is surrounded by a corrosion resistant barrier layer, which is formed in the liquid space 254. Figure 3 Described in more detail in .

[0033] Figure 3 A liquid space 254 is shown containing a conductive liquid at a conduction location 252 using a corrosion resistant barrier layer according to various examples of the disclosed subject matter. Figure 3254. Liquid space 254 is a space defined by inner surface 256 of cylindrical conductor 222 and outer surface 258 of cylindrical conductor 234. In order to reduce the probability of corrosion due to contact between the conductive liquid located at conductive position 252 and inner surface 256 of cylindrical conductor 222 or outer surface 258 of cylindrical conductor 234, corrosion barrier layers 302 and 304 are provided. Corrosion barrier layer 304 is a conductive chemically inert material layer deposited on inner surface 256 of cylindrical conductor 222 within liquid space 254. Corrosion barrier layer 302 is also a conductive chemically inert material deposited on outer surface 258 of cylindrical conductor 234. In the examples described herein, corrosion barrier layer 302 and corrosion barrier layer 304 are each a material layer deposited using a high velocity air fuel (HVAF) process. It should be noted that other deposition processes may be used and are considered to be within the scope of the presently disclosed subject matter, including but not limited to high velocity oxygen fuel (HVOF), plasma arc spraying, or twin wire arc spraying. The High Velocity Oxygen Fuel (HVOF) process is a period of time during which fuel and oxygen are delivered to a combustion chamber and ignition and combustion are continued. The fuel can be a gas (hydrogen, methane, propane, propylene, acetylene, natural gas, etc.) or a liquid (kerosene, ethanol, etc.). Plasma arc spraying is a process in which a high temperature plasma stream and a powder coating are delivered to a surface for deposition via an electric arc. Twin wire arc spraying is a process that uses an electric arc as a heat source between two consumable electrodes of the surface material. Compressed gas atomizes the molten material and propels it to the surface for deposition.

[0034] As used herein, "high speed" generally refers to a deposition process that deposits material using a propellant that accelerates the deposited material to a spray rate of about 800 m / s to 1400 m / s, but velocities slightly above or below this range may also be used and are considered within the subject matter disclosed herein. The HVAF process as used herein is a thermal spray process used to deposit coatings to protect parts, containers, and structures from wear, erosion, and corrosion. The HVAF process operates using a fuel gas such as propane, propylene, or natural gas (supplied at 140 psi from a gas cylinder or gas line) and compressed air (supplied at 125 psi by a 400 CFM air compressor). Added to the HVAF stream is a mixture of a nickel-chromium alloy such as Ni-20Cr. In some instances, aluminum oxide (Al2O3) particles are added to the nickel-chromium alloy (such as Figure 4 254). The sealing rings 306A and 306B seal the conductive liquid at the conductive position 252 in the liquid space 254. The sealing rings 306A and 306B can be made of various materials such as rubber, silicone, carbon, etc., which act as a fluid barrier layer to prevent the conductive liquid at the conductive position 252 from leaking from the liquid space 254.

[0035] As cylindrical conductor 222 is extended and retracted along the length of cylindrical conductor 234, electrical conductivity between cylindrical conductor 222 and cylindrical conductor 234 is maintained by the conductive liquid located at conductive location 252. The physical and material structure of corrosion barrier layer 302 and corrosion barrier layer 304 are designed to provide a conductive path while also protecting the respective surfaces on which corrosion barrier layer 302 and corrosion barrier layer 304 are deposited. Examples of the physical and chemical composition of corrosion barrier layer 304 are described in Figure 4 Shown in.

[0036] Figure 4 is an illustration of various examples of the subject matter of the present disclosure along Figure 3 25 . The inner surface 256 of the cylindrical conductor 222, the corrosion barrier layer 304, and the conductive liquid located at the conduction location 252 are shown. The corrosion barrier layer 304 is made of a Ni-20Cr matrix 402 in which Al2O3 particles 404 and 406 (as an example) are dispersed. Although various thicknesses can be used, in some examples, the Ni-20Cr matrix 402 has a thickness of approximately 50 μm to 600 μm. The cylindrical conductor 222 can be composed of various metals, including but not limited to 6061 aluminum. In order to provide a physical (and therefore chemical) barrier layer between the conductive liquid located at the conduction location 252 and the cylindrical conductor 222, the corrosion barrier layer 304 has a low porosity, or a low proportion of the void volume to the total volume of the Ni-20Cr matrix 402.

[0037] HVAF provides low porosity due to the high temperature and high velocity experienced by the Ni-20Cr and Al2O3 particles 404 during deposition. The high velocity and high temperature not only substantially compact the Ni-20Cr and Al2O3 particles 404 in the Ni-20Cr matrix 402, the high velocity of the Ni-20Cr and Al2O3 particles 404 also impacts the inner surface 256 of the cylindrical conductor 222, filling a majority of the surface deformations of the inner surface 256. Surface deformations such as surface deformations 407 and 408 are caused by the kinetic energy of the Ni-20Cr and / or Al2O3 particles 404 impacting the inner surface 256. The velocity of the Ni-20Cr and Al2O3 particles 404 causes the Ni-20Cr and Al2O3 particles 404 to form and fill the surface deformations 407 and 408. Thus, the HVAF process using Ni-20Cr and Al2O3 particles 404 to produce the Ni-20Cr matrix 402 for the corrosion barrier layer 304 has a relatively low porosity, thereby reducing the probability of the conductive liquid at the conductive location 252 contacting the inner surface 256. In addition, the Ni-20Cr and Al2O3 particles 404 provide a certain degree of conductivity, thereby allowing electricity to move between the barrel conductor 222 and the barrel conductor 234. In some examples, where the Ni-20Cr matrix 402 has a thickness of about 50 μm to 600 μm, the resistivity of the Ni-20Cr matrix 402 can be in the range of 0.0004 ohms to 0.0013 ohms. As described above, as Figure 5 As shown by way of example, in order to achieve low porosity and relatively low resistivity of the Ni-20Cr matrix 402, a high speed process is used to form the Ni-20Cr matrix 402.

[0038] Figure 5 2 is an exemplary HVAF system 500 for depositing a corrosion barrier layer 304 on the inner surface 256 of a cylindrical conductor 222 according to various examples of the disclosed subject matter. The HVAF system 500 includes a nozzle 502 that receives a mixture 503 of propane 504, air 506, Ni-20Cr 508, and Al2O3 510. The mixture 503 enters the nozzle 502. A burner 512 (such as a spark plug or other ignition system) ignites the propane 504, thereby generating a high pressure within the nozzle 502. Depending on the fuel gas and the igniter design, the combustion temperature is in the range of 1200-1800C. The combustion temperature within this range can provide for gradually heating the Ni-20Cr 508 and Al2O3 510 to or slightly above the melting temperature of the metal. The high pressure accelerates the mixture 503 through the nozzle 502 at a speed from about 800m / s to over 1400m / s, thereby generating a flame 514. Ni—20Cr 508 and Al 2 O 3 510 within the flame 514 are deposited onto the inner surface 256 of the cylindrical conductor 222 .

[0039] Figure 6 A method 600 for constructing a conductor bar 206 that may be used in a work machine 100 using a liquid conductor corrosion barrier layer according to various examples described herein is shown. Figure 6 As shown in FIG. 6 , at step 602, a HVAF process (such as Figure 5 The HVAF system 500 of FIG. 4A ) applies the corrosion barrier layer 304 to the inner surface 256 of the cylindrical conductor 222. The corrosion barrier layer 304 is composed of a Ni-20Cr matrix 402, which is composed of Ni-20Cr and Al2O3.

[0040] In step 604, a HVAF process (such as Figure 5 The HVAF system 500 of FIG. 4A ) applies the corrosion barrier layer 302 to the outer surface 258 of the barrel conductor 234. The corrosion barrier layer 304 is composed of a Ni-20Cr matrix 402, which is composed of Ni-20Cr and Al2O3.

[0041] In step 606, if Figure 2 As shown in FIG. 2 , the cylindrical conductor 222 is inserted into the cylindrical body conductor 234. From the axial center AB extending along the center of the cylindrical conductor 222 toward the cylindrical outer surface 224, the cylindrical conductor 222 is concentrically positioned along the axial center AB of the cylindrical body 209.

[0042] In step 608, liquid space 254 is at least partially filled with a conductive liquid located at conduction location 252. Liquid space 254 is a space defined by inner surface 256 of barrel conductor 222 and outer surface 258 of barrel conductor 234. Liquid space 254 may be filled with a conductive liquid located at conduction location 252 using a variety of techniques, which are considered to be within the scope of the presently disclosed subject matter.

[0043] In step 610, barrel conductor 234 and barrel conductor 222 are attached to electrical contacts. Arm electrical contacts 228A and 228B are mechanically connected to barrel conductor 222 at electrical contact points 230A and 230B, respectively. In addition to providing an electrical path from electrical contacts 228A and 228B to barrel conductor 222, electrical contacts 230A and 230B also secure barrel conductor 222 to arm end cap 232. Barrel electrical contacts 236A and 236B are mechanically and electrically connected to barrel conductor 222 at electrical contact points 246A and 246B, respectively. In addition to providing an electrical path from electrical contacts 236A and 236B to electrical load 239, electrical contacts 246A and 246B also secure barrel conductor 234 to barrel end cap 248.

[0044] At step 612 , conductor bar 206 is electrically and physically connected to work machine 100 and power rail 108 via trailing arm 116 and contactor 118 to provide power to work machine 100 .

[0045] Those skilled in the art will also recognize that the principles of the present disclosure are not limited to the specific examples discussed or shown in the figures. For example, although conductor bars 106 and 206 are shown as having two conductors, three or more conductors may be employed in accordance with the principles explained in the present disclosure. In addition, the disclosed principles are not limited to implementation on work machines. Any mobile vehicle that obtains power from a ground-based conductor rail may benefit from the disclosed and claimed examples and techniques.

[0046] Industrial Applicability

[0047] The present disclosure provides a corrosion barrier layer for use with a conductive liquid in a system for a mobile machine having a conductor rod configured to receive electrical energy from an energized rail to the mobile machine, wherein the conductor rod extends and retracts. As described above, a conductive liquid containing a gallium alloy, a gallium-indium alloy, a gallium-indium-tin alloy, a gallium-indium-tin-zinc alloy, a bismuth alloy, a lead-bismuth alloy, a bismuth-indium-tin alloy, a bismuth-indium-tin-zinc alloy, etc. is used to maintain an electrical connection between a power source and a working machine. In order to protect the conductors within the conductor rod from the corrosive effects of the conductive liquid, a non-porous conductive corrosion barrier layer is deposited onto a surface that may come into contact with the conductive liquid. Using a high-speed process such as HVAF, Ni-20Cr with Al2O3 particles is deposited onto the surface. The use of a corrosion barrier layer allows the use of a conductive liquid while reducing the probability of the conductive liquid coming into contact with the conductor surface.

[0048] Unless expressly excluded, the use of the singular to describe a component, structure, or operation does not prevent the use of a plurality of such components, structures, or operations or their equivalents. As used herein, the word "or" refers to any possible arrangement of a group of items. For example, the phrase "A, B, or C" refers to at least one of A, B, C, or any combination thereof, such as any of the following: A; B; C; A and B; A and C; B and C; A, B, and C; or a plurality of any items, such as A and A; B, B, and C; A, A, B, C, and C, etc.

[0049] Although various aspects of the present disclosure have been particularly shown and described with reference to the above embodiments, it will be understood by those skilled in the art that various additional embodiments may be conceived by modifications to the disclosed machines, systems, and methods without departing from the spirit and scope of the disclosed content. Such embodiments should be understood to fall within the scope of the present disclosure as determined by the claims and any equivalents thereof.

Claims

1. A working machine (100), comprising: An electric motor (102); a traction device (104) configured to move the work machine (100) when powered by the electric engine (102); A conductor bar (106) configured to transmit electrical energy to the working machine (100) during movement of the working machine (100), the conductor bar (106) having a first end (107) and a second end (111), the conductor bar (106) comprising: a barrel (109) comprising a barrel conductor (234) having an inner diameter and a longitudinal center defining an axis between the first end (107) and the second end (111); and an arm (110) comprising a cylindrical conductor (222) arranged to be concentrically about the axis and slidably engaged into the barrel conductor (234); a liquid space (254) configured to contain a conductive liquid, the liquid space (254) being defined by an inner surface of the cylindrical conductor (222) and an outer surface of the cylindrical conductor (234); a first corrosion barrier layer (302) along the inner surface of the cylindrical conductor (222) and a second corrosion barrier layer (304) along the outer surface of the cylindrical conductor (234), the first corrosion barrier layer (302) and the second corrosion barrier layer (304) comprising a metal alloy having chemical resistance and low permeability to the conductive liquid contained in the liquid space (254); and A liquid joint (250) is formed by the liquid space (254), the first corrosion barrier layer (302), the second corrosion barrier layer (304) and the conductive liquid, and the liquid joint (250) is configured to electrically connect the cylindrical conductor (234) to the cylindrical conductor (222).

2. The work machine (100) of claim 1, wherein the first corrosion barrier layer (302) and the second corrosion barrier layer (304) comprise a matrix of a nickel-chromium alloy (Ni-20Cr).

3. The work machine (100) according to claim 2, wherein the first corrosion barrier layer (302) and the second corrosion barrier layer (304) further contain aluminum oxide (Al2O3) particles.

4. The work machine (100) of claim 2, wherein the first corrosion barrier layer (302) or the second corrosion barrier layer (304) is deposited using high velocity oxygen fuel (HVOF), plasma arc spraying, or twin wire arc spraying.

5. The working machine (100) according to claim 1, wherein the conductive liquid comprises a gallium alloy, a gallium-indium alloy, a gallium-indium-tin alloy, a gallium-indium-tin-zinc alloy, a bismuth alloy, a lead-bismuth alloy, a bismuth-indium-tin alloy, a bismuth-indium-tin-zinc alloy, or GALINSTAN.

6. A conductor rod (106), comprising: a barrel (109) comprising a barrel conductor (234) having an inner diameter and a longitudinal center defining an axis between a first end (107) and a second end (111); and an arm (110) comprising a cylindrical conductor (222) arranged to be concentrically about the axis and slidably engaged into the barrel conductor (234); a liquid space (254) configured to contain a conductive liquid, the liquid space (254) being defined by an inner surface of the cylindrical conductor (222) and an outer surface of the cylindrical conductor (234); a first corrosion barrier layer (302) along the inner surface of the cylindrical conductor (222) and a second corrosion barrier layer (304) along the outer surface of the cylindrical conductor (234), the first corrosion barrier layer (302) and the second corrosion barrier layer (304) comprising a metal alloy having chemical resistance and low permeability to the conductive liquid contained in the liquid space (254); as well as A liquid joint (250) is formed by the liquid space (254), the first corrosion barrier layer (302), the second corrosion barrier layer (304) and the conductive liquid, and the liquid joint (250) is configured to electrically connect the cylindrical conductor (234) to the cylindrical conductor (222).

7. The conductor rod (106) of claim 6, wherein the first corrosion barrier layer (302) and the second corrosion barrier layer (304) comprise a matrix of nickel-chromium alloy (Ni-20Cr) and aluminum oxide (Al2O3) particles.

8. The conductor rod (106) according to claim 7, wherein the matrix has a thickness of about 50 μm to 600 μm.

9. The conductor rod (106) of claim 6, wherein the first corrosion barrier layer (302) or the second corrosion barrier layer (304) is deposited using a high velocity air fuel process, high velocity oxygen fuel (HVOF), plasma arc spraying, or twin wire arc spraying.

10. The conductor rod (106) of claim 9, wherein the high velocity air-fuel process deposits the nickel-chromium alloy (Ni-20Cr) and the aluminum oxide (Al2O3) particles at a velocity of 800 m / s to about 1400 m / s.

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