Boom and tow arm control system for dynamic energy transfer

Abstract

A boom (210) and tow arm control system (500) includes an electronic control module (502), multiple sensors, and a rail connector assembly (200) having a boom (210), an arm assembly, and a contactor assembly (250), the rail connector assembly (200) being configured to connect to multiple conductor rails (112). The control system (500) also includes an input receiver for the electronic control module (502), configured to receive input to extend the rail connector assembly (200) from the frame (140) of a mobile machine (120). The electronic control module (502) is configured to generate commands to extend the boom (210) and arm assembly.

Description

Technical Field

[0001] This disclosure relates generally to an energy transfer system for a mobile machine, and more specifically to a control system for a connector assembly including a boom and a drag arm. Background Technology

[0002] Mobile industrial machinery, such as earthmoving machines, can be quite heavy and may bear enormous loads, thus requiring significant power. Many industrial machines are powered by internal combustion engines. However, internal combustion engines have disadvantages such as high fuel costs, difficulties in fuel transportation, and harmful engine emissions. Therefore, powering large mobile industrial machinery has shifted towards hybrid or all-electric power systems.

[0003] While hybrid and all-electric power systems for industrial machinery offer advantages in reducing fuel costs and emissions, they also present challenges. For example, using hybrid or all-electric power systems in the industrial sector requires substantial infrastructure investment, particularly due to the location of industrial work sites. While overhead power lines are a solution for powering vehicles following predetermined routes or terrain conditions (e.g., trains, subways, buses), they are not practical for all machines or work sites, such as freely steerable industrial machines and work sites with uneven terrain. Therefore, existing power systems, such as overhead lines, are generally not used in remote and uneven environments. Other issues include the ability to safely deliver current to moving industrial vehicles. Therefore, it is beneficial for industrial machines to have control systems capable of quickly deploying or retracting connector assemblies, whether manually or automatically, with minimal assistance from the machine operator, if any.

[0004] International Patent Application Publication No. WO 2020 / 186296 A1 (“'296 Publication”), published on September 24, 2020, describes an electrical delivery system for supplying power to a moving vehicle. The system described in '296 Publication depicts an electrical delivery system for use in a mining facility for a mobile vehicle, wherein two conductors are anchored to a repositionable roadside barrier. To charge the mobile vehicle, the delivery system requires a retractable arm that must precisely engage with an electrical connector embedded in a horizontal channel within the roadside barrier. While the system described in '296 Publication may be helpful in some situations, it does not describe a system that facilitates connecting the electrical delivery system to the roadside electrical conductors.

[0005] The aspects of this disclosure can solve one or more of the problems set forth above and / or other problems in the art. However, the scope of this disclosure is defined by the appended claims, and not by its ability to solve any particular problem. Summary of the Invention

[0006] In one aspect, a method of operating a track connector assembly of a mobile machine may include receiving a request to extend the track connector assembly (which includes a boom, a drag arm assembly, and a contactor assembly) from the frame of the mobile machine, and a request to extend the drag arm assembly to electrically connect to a plurality of conductor tracks. The method may further include generating a movement command to operate the track connector assembly, and using a continuity sensor connected to the contactor assembly to determine the presence of electrical energy along the plurality of conductor tracks.

[0007] In another aspect, a mobile machine power system may include: an electronic control module having an input receiver; multiple sensors; and a track connector assembly having a boom, an arm assembly, and a contactor assembly. The track connector assembly may be configured to connect to multiple conductor tracks, and the input receiver may receive input to extend the track connector assembly from the frame of the mobile machine. The electronic control module may be configured to generate commands to extend the boom and the arm assembly.

[0008] In another aspect, a method for disconnecting a connector assembly of a mobile machine from a plurality of conductor rails may include: receiving operator input from a control system to disengage the connector assembly from the plurality of conductor rails; and generating a connector assembly command via the control system. The connector assembly command may include: a first command for controlling a plurality of magnets and a plurality of extendable brushes of the contactor assembly; a second command for controlling the towing boom assembly; and a third command for controlling the hydraulic system of the boom. The method may further include securing the connector assembly to the frame of the mobile machine. Attached Figure Description

[0009] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various exemplary embodiments and, together with this specification, serve to explain the principles of the disclosed embodiments.

[0010] Figure 1 This is a perspective view of an electrically mobile machine according to various aspects of this disclosure, which is connected to a conductive rail power source via an extended connector assembly.

[0011] Figure 2 This is a side view of an electrically powered mobile machine, with the connector assembly in a retracted position.

[0012] Figure 3 This is a side view of an electrically powered mobile machine, with the boom of the connector assembly extended and the drag arm of the connector assembly retracted.

[0013] Figure 4 This is a side view of an electrically powered mobile machine, in which a connector assembly engages with a conductive rail power source.

[0014] Figure 5 This is a cross-sectional view of the conductor terminals housed within the contactor assembly.

[0015] Figure 6 This is a block diagram of an exemplary machine control system.

[0016] Figure 7 This is a flowchart illustrating a method for controlling a track connector assembly, based on various aspects of this disclosure. Detailed Implementation

[0017] The foregoing general description and the following detailed description are merely exemplary and illustrative and do not limit the claimed features. As used herein, the terms “comprises,” “comprising,” “has,” or other variations thereof are intended to cover non-exclusive inclusions, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but may also include other elements not expressly listed or inherent to such process, method, article, or apparatus. In this disclosure, unless otherwise stated, relative terms such as, for example, “about,” “substantially,” and “approximately” are used to indicate possible variations of ±10% in the stated values.

[0018] Figure 1 A mobile machine power system 100 according to various aspects of this disclosure is depicted. The mobile machine power system 100 includes a conductive track system 110, a mobile machine 120 having a track connector assembly 200, and a control system 500 including one or more sensors and an electronic control module (“ECM”) 502. The mobile machine 120 is freely steerable and includes an electric drive system 130 having at least one electric motor 132 and at least one battery system 134.

[0019] The electric drive system 130 rotates a set of ground engagement elements 136 (such as tires or continuous tracks) to propel and manipulate the mobile machine 120. The mobile machine 120 also includes a frame 140 and an external shelf 142. The external shelf 142 serves as a storage platform for the tow arm assembly 230 and the contactor assembly 250, and may be made of steel or any other suitable magnetic material.

[0020] During operation, the mobile machine 120 and its various systems are controlled by a machine operator located in an operator compartment 150, which may include multiple position indicators 152 present within the compartment 150. Examples of position indicators 152 include a camera feed, a turn signal indicator, a system representation or image of the position of the track connector assembly 200 relative to the conductive track system 110, etc. Displays within the operator compartment 150 may show the position indicators 152, system data, or other visual feedback.

[0021] like Figure 1 As shown, the mobile machine 120 may be a mining truck, such as a haul truck used for transporting materials in an open-pit mining environment. However, this disclosure is not limited to this, and other types of machines are also within the scope of this disclosure, including articulated trucks, asphalt pavers, backhoe loaders, cold milling machines, compactors, bulldozers, dragline excavators, drilling rigs, rope shovels, excavators, forestry machinery, hydraulic mining shovels, material handling machines, graders, off-highway trucks, pipelaying machines, road repair machines, skid steer and compact track loaders, telescopic forklifts, track loaders, underground mining loaders and trucks, wheel loaders, or other similar vehicles. Those skilled in the art will understand that the mobile machine 120 may utilize a hybrid or all-electric power system, and the conductive rail system 110 may be applied to either system.

[0022] An exemplary mobile machine 120 is configured to travel along a work route or path (e.g., in a free-turning manner), and a conductive track system 110 is positioned substantially parallel to that route or path. Figure 1 The conductive track system 110 includes multiple conductive tracks 112 connected to a power source (e.g., a power grid, generator, and / or energy storage device), multiple support posts 114 fixed to the ground 10, and a support assembly 116 attached to the top of each of the support posts 114 to maintain the multiple conductive tracks 112 in a safe elevated position. Although Figure 1 An example of multiple conductor rails 112 including three conductor rails is shown, but fewer or more rails 112 are also possible. In this example, two conductor rails provide power of different polarities, while the third conductor rail provides a 0-volt reference voltage. The conductor rail system can alternatively be incorporated into a three-phase power system that utilizes a three-rail power circuit, except for a fourth conductor rail providing the 0-volt reference voltage.

[0023] Multiple support posts 114 ground the conductive track system 110, specifically contacting the conductor track 112 which provides a reference voltage of 0 volts. Individual support posts 114 can be rods, pillars, piles, cylinders, supports, or similar structures, and have a length sufficient to levy and support the multiple conductor tracks 112. For example, multiple support posts 114 may each have a length sufficient to support and stabilize the multiple conductor tracks 112 at a height of at least eight feet above the ground. The support posts 114 are made of a dielectric material, such as pultruded glass fiber reinforced polymer (FRP) or other electrically insulating or dielectric materials.

[0024] To electrically connect the mobile machine 120 to the conductive track system 110, the mobile machine 120 includes a track connector assembly 200, which includes a boom 210, a trailing arm assembly 230, and a contactor assembly 250. The boom 210 includes a housing 212 having a busbar assembly that extends the length of the boom (not shown). The boom 210 also includes a hydraulic system 214 within the housing. The boom 210 is pivotally attached to a side surface of the frame 140 at its proximal end. The boom 210 pivots toward or away from the frame via the hydraulic system 214. The housing 212 (which provides protection to the internal components of the boom 210) may be substantially parallelepiped and made of a metallic material (e.g., steel) or other suitable material. Although boom 210 is shown attached to a mining tractor truck, boom 210 can be incorporated into various types of mobile machinery 120 by using interchangeable adapters (not shown) that are specific to the type of machine being operated and attached to housing 212.

[0025] The housing 212 includes a plurality of maintenance openings 224 positioned along the length of the boom 210. Figure 1 Maintenance opening 224 allows easy access to the internal systems of boom 210 without requiring complete removal of boom 210 from mobile machine 120. For example, maintenance opening 224 allows an operator or mechanic to replace components of hydraulic system 214 or pneumatic system 236, and also ensures proper connection of busbar assemblies within boom 210.

[0026] The boom 210 includes several different states, such as the extended state (in Figure 1 , Figure 3 and Figure 4 As shown in the diagram, in the extended state, the boom extends away from the moving machine; in the retracted state (as shown in the diagram), the boom extends away from the moving machine. Figure 2 (As shown in the diagram), in this retracted state, the boom rotates inward to abut against the frame 140 of the moving machine; and in the locked state (also shown in the diagram)... Figure 2 As shown in the diagram, in this locked state, the boom locks to the side of the frame in the retracted state. Figure 1As shown, when in the extended state, the boom 210 pivots horizontally outward from the mobile machine 120, making the boom perpendicular to the mobile machine 120. Figures 1 to 4 As shown, the boom 210 is attached to the frame 140 of the mobile machine 120 at a height greater than that of the conductor rail 112. The distance between the height of the boom and the height of the conductor rail 112 is represented by distance D0. Figure 2 ).

[0027] When in the locked state, the locking pin on the boom 210 is actuated to the locked state, and the boom 210 is fixed in the retracted state. Figure 2 When the unlocking sequence is initiated, the locking pin on boom 210 is actuated to the open or free position, allowing the boom to be manipulated or positioned by the user even while still in the retracted state. This unlocked but retracted position facilitates the maintenance of connector assembly 200 and allows for the removal or integration of additional components.

[0028] Figure 1 Also depicted is a trailing arm assembly 230 attached to the distal end of the boom 210 via a connector (not shown), which allows multiple trailing arms 232 (in...) Figure 4 (Best shown in the diagram) It moves with two degrees of freedom (e.g., horizontal and vertical) independently of the movement of boom 210. These multiple degrees of freedom provide the connector assembly 200 with lateral and vertical freedom to be adjusted relative to the conductive track system 110 during use of the moving machine 120. More specifically, the tow arm assembly 230 is adaptable to changes in the relative position of the multiple conductor tracks 112 to the moving machine 120 during travel (e.g., increasing or decreasing to a distance D0).

[0029] refer to Figure 4 Each tow arm in the tow arm 232 includes a plurality of telescopic links 234 having connection sockets (not shown) accommodated within the plurality of telescopic links. The plurality of telescopic links are used to extend and retract between different states of the tow arm assembly. In operation, the tow arm assembly 230 can be in a variety of configurations or states, including: a fully extended state (in... Figure 1 and Figure 4 (shown in the image); Collapsed state (in the image) Figure 2 (As shown in the diagram), in the retracted state, the tow arm assembly 230 extends slightly to allow the contactor assembly 250 to contact the shelf 142; and in the retracted state (in... Figure 3 As shown in the diagram, in this retracted state, the tow arm assembly retracts to allow the contactor assembly 250 to disengage from the shelf, and the tow arm assembly is positioned above the conductor rail 112. In the retracted state (as shown in the diagram), Figure 3(As shown in the figure), the contactor assembly 250 is not attached to or in contact with the conductor track 112.

[0030] The contactor assembly 250 includes a base frame 256 in which a plurality of conductive terminals 262 are fixed. In an exemplary configuration, nine conductive terminals 262 are arranged in a three-by-three matrix to provide redundancy and maintain electrical connection with conductor rails 112; however, the conductive terminals 262 can be arranged in different amounts and other configurations. In an exemplary rail configuration with three conductor rails 112 and utilizing a three-by-three conductive terminal matrix, the plurality of conductive terminals 262 are divided into three equal groups of three conductive terminals arranged linearly. Each of the three groups of linear conductive terminals 262 corresponds to one of a positive conductor rail, a negative conductor rail, and a conductor rail providing a 0-volt reference voltage.

[0031] like Figure 5 As shown, each individual conductive terminal 262 is fluidly connected to the pneumatic system 236 of the trailing arm assembly 230 via a conduit 270, wherein each conductive terminal 262 further includes a plurality of magnets (not shown) and an extendable brush 264. The contactor assembly 250 further includes a plurality of retaining features for maintaining the connection between the contactor assembly 250 and the plurality of conductor tracks 112. For example, the base frame 256 includes: a pair of lower flanges 258 ( Figure 2 The pair of lower flanges are located on opposite lateral sides of the base frame 256; and a pair of buffers 260 that separate the respective sets of conductive terminals 262 from each other. The individual sets of conductive terminals 262 are aligned with individual conductor tracks 112, and the individual buffers 260 are aligned with the gaps positioned between the conductor tracks 112.

[0032] While the tow arm assembly 230 provides multiple degrees of freedom and movement in the horizontal and vertical directions, the contactor assembly 250 can generally be constrained to pivot about the distal end of the tow arm assembly 230. Providing movement constraints can help prevent rubbing or unstable connection with the conductor rail 112 and provide a stable platform for the power system 100 to connect to the conductive rail system 110.

[0033] The connector assembly 200 of the mobile machine 120 is configured for electrical connection to the conductive rail system 110. For example, the contactor assembly 250 provides electrical connection via a plurality of conductive terminals 262, thereby allowing electrical energy to be transferred from the contactor assembly 250 to the tow arm assembly 230. Figure 1 As shown, electrical energy is then directed from the fully extended tow arm assembly 230 to the busbar assembly within the boom 210, and then transmitted to the motor 132 and / or the battery system 134.

[0034] As in Figure 1As best illustrated, connector assembly 200 can be controlled by control system 500, which can be operator-controlled or automatically generated. In the illustrated configuration, control system 500 includes ECM 502 and one or more sensors that provide angle, linearity, rotation, and proximity feedback, or other information, as inputs to ECM 502. Sensors of control system 500 may include: lock sensor 216 generating lock signal 514; angle sensor 220 generating angle signal 516; hydraulic sensor 222 generating hydraulic signal 518; tow arm position sensor 238 generating position signal 520; pneumatic sensor 240 generating pneumatic signal 522; voltage sensor 252 generating voltage signal 524; and / or ground sensor 254 generating ground signal 526.

[0035] Lock sensor 216 (in) Figure 1 (Best shown in the image) Attached to the frame 140 of the mobile machine 120. A locking sensor 216 is configured to sense the proximity of the boom relative to the side of the mobile machine 120. An angle sensor 220 for the boom 210 (in...) Figure 1 (Best shown in the image) Located at or near the attachment point between the frame 140 and the proximal end of the boom. Angle sensor 220 provides angle data to ECM 502, which is related to whether the boom 210 is fully extended (…). Figure 1 ) or whether the boom retracts to rest against the moving machine ( Figure 2 Correspondingly, the hydraulic sensor 222 on the boom 210 provides rotational data to the ECM 502, which can correspond to the control of the hydraulic components housed in the boom, the actuation of the hydraulic cylinder, and the rotational movement of the boom.

[0036] The tow arm assembly 230 may include one or more position sensors 238. Figures 2 to 4 The position sensor 238 is housed within each tow arm 232. The position sensor 238 provides vertical and horizontal position information of the tow arm 232 to the ECM 502 and is used to indicate the alignment of the tow arm assembly 230 with the conductive track system 110, and in particular the conductor track 112. The tow arm assembly 230 also includes a pneumatic sensor 240. Figures 2 to 4 The pneumatic sensor is used to adjust the extension and retraction of the tow arm and to engage or disengage the contactor assembly 250 from the conductor rail 112.

[0037] The contactor assembly 250 further includes a plurality of voltage sensors 252 and a plurality of ground sensors 254 (collectively referred to as "continuity sensors"). The continuity sensors communicate electrically with a plurality of conductive terminals 262 of the contactor assembly 250 and provide voltage information or other relevant data to the ECM 502. Data from the continuity sensors can be provided continuously (e.g., in real time), if desired. For example, during operation in an exemplary configuration, three conductive terminals 262 in separate groups are arranged in a line. The continuity sensors 252, 254 for the three conductive terminals 262 in each group continuously test the presence of voltage or ground (e.g., a 0-volt reference voltage) on their respective conductor rails 112. More specifically, for each group of three conductive terminals 262, the first two conductive terminals 262 test the presence of voltage or ground at the transition between the current segment of the individual conductor rail 112 and a new segment of another conductor rail 112, while the remaining conductive terminals confirm the presence of voltage or ground on the current segment of the conductor rail. The data provided by the continuity sensor can correspond to commands from the ECM 502 related to: the engagement of the contactor assembly 250, the response of the pneumatic system 236 to disengage the brush 264, and the transfer of electrical energy from the conductor track 112 to the battery system 134 of the mobile machine 120.

[0038] ECM 502 may be made from a single physical module or may include multiple physical modules, each associated with a specific task or function. ECM 502 may include a single microprocessor or multiple microprocessors configured to receive input and generate command-like outputs to control the operation of components of connector assembly 200. ECM 502 may include programming for calculating optimal operation of conductor assembly 200, generating outputs to be executed by connector assembly 200 and / or other components of machine 120, and performing the functions described herein.

[0039] Figure 6This is a block diagram illustrating an exemplary configuration of a control system 500, which includes an ECM 502 that can be programmed to perform the functions of a lock release module, a boom position module, a connector assembly position module, and an electrical connection monitor, as described below. Input receiver 504 of the ECM 502 receives inputs 510 from the sensors described above. Inputs 510 may include: operator inputs 512 from input devices (e.g., joysticks, pedals, control buttons, switches, etc.); pre-programmed sequences or routines for moving the machine; boom sensor information (e.g., lock signal 514, angle signal 516, and hydraulic signal 518); boom data inputs (e.g., position signal 520, pneumatic signal 522); and continuity sensor information obtained from the contactor assembly (e.g., voltage signal 524 and ground signal 526).

[0040] like Figure 6 As shown, output 550 may also include notifications, such as cabin indicators. Output 550 generated by control system 500 may also include: a lock command 552 for locking pins; a boom command 554 for hydraulic system 214; a tow arm assembly command 556 for pneumatic system 236 (thereby controlling multiple telescopic links 234 of multiple tow arms 232); a connector assembly command 558 for pneumatic system 236 (thereby controlling multiple extendable brushes 264); and a data display command 560, as described below.

[0041] Industrial applicability

[0042] The aspects of the control system disclosed above can be used to deploy and control rail connector assemblies at the work site, while simultaneously charging freely steerable mobile machines using a conductive rail system. For example, the accompanying drawings illustrate various engagement states of the connector assembly with the conductive rail system, and a block diagram of the rail connector control system.

[0043] Figure 7 This is a flowchart illustrating an exemplary method 600 for operating a connector assembly 200 of a mobile machine power system 100 according to various aspects of the present disclosure. Before performing method 600, the connector assembly 200 may be in a state where… Figure 2 The state shown in the diagram. In this locked state, the tow arm assembly and the contactor assembly are held in place on shelf 142 due to the magnetic force generated by the magnet (not shown) housed within the base frame 256 and the combined mass of the tow arm assembly 230 and the contactor assembly 250. Figure 2 The tow arm assembly 230 and the contactor assembly are oriented vertically relative to the ground 10. Additionally, before unlocking the boom 210, the lock sensor 216 ( Figure 1 The signal 514 is provided to the control system 500 to indicate that the locking pin is in the locked state.

[0044] Step 610 may include unlocking boom 210 from frame 140 of mobile machine 120. For example, ECM 502 receives a request from extension track connector assembly 200 (e.g., a request from extension tow arm assembly 230), determines that boom 210 is locked, and in response, initiates unlock or open command 552 to the actuator for the locking pin, thereby moving the locking pin to the open or free position. The requests from extension track connector assembly and extension tow arm assembly may be single requests generated by an operator pressing a button in operator compartment 150, or may be automatically generated based on the geographic location of machine 120, such as that determined by a Global Navigation Satellite System (“GNSS”).

[0045] As part of step 610 or in a subsequent step, ECM 502 can be used to generate a tow arm command 556 to cause multiple telescopic links 234 to retract from their retracted state. Figure 2 Retract to the retracted state ( Figure 3 ECM 502 initiates contactor assembly command 558, thereby signaling the pneumatic system to provide fluid pressure to actuate the extendable brush 264 in the contactor assembly. Figure 5 As shown, the retraction of the tow arm away from the shelf 142 and the extension 266 of the extendable brush 264 in the direction 268 (opposite to the shelf 142) generate a combined force of gravity and magnetism greater than that required to hold the contactor assembly 250 on the shelf, thereby changing from a retracted state (in which the contactor assembly 250 rests on the shelf 142) to a retracted state (in which the tow arm assembly 230 is slightly retracted from the shelf 142), and the combination of the tow arm assembly and the contactor assembly enables the boom 210 to travel freely.

[0046] Step 620 of method 600 may include: extending the boom 210 from the retracted state by generating a boom command 554 that extends the boom 210 from the retracted state to the fully extended state, such as... Figure 1 As shown. Step 620 can be performed in response to operator input 512 received by input receiver 504, thereby extending the track connector assembly 200. In step 620, ECM 502 provides boom command 554 to hydraulic system 214, thereby signaling boom 210 to extend outward from the side of mobile machine 120. As boom 210 extends, retracted trailing arm assembly 230 rotates outward at the distal end of boom and is oriented vertically relative to ground 10, as shown. Figure 3 As shown. When the boom 210 has been fully extended, the angle sensor 220 provides an angle signal 516 to the input receiver 504, thereby indicating that the boom 210 has reached its maximum outward position.

[0047] In step 630, the control system 500 may extend the tow arm 232 in response to a request to extend the tow arm assembly 230 (e.g., via operator input 512). The ECM 502 then generates a tow arm command 556 for the actuator of the pneumatic system (e.g., upon monitoring actuation via a signal 522 from the pneumatic sensor 240). This allows the pneumatic system 236 to supply pressurized fluid to the plurality of telescopic links 234 to fully extend the plurality of tow arms 232. The tow arms 232 extend fully from the distal end of the boom 210 in a direction generally toward the ground 10, wherein the connection sockets of the links 234 each form an electrical connection to conduct electrical energy along the length of the telescopic arm 232.

[0048] In its fully extended state, the trailing arm assembly 230 extends to a length L greater than the distance D0. Figure 4 Therefore, upon encountering the conductive track system 110, the tow arm assembly 230 rotates rearward in a direction opposite to the direction of movement of the mobile machine 120, causing the contactor assembly 250 to be dragged behind the boom 210. Figure 4 The tow arm assembly 230 can extend when the mobile machine 120 is in motion during operation, or when the mobile machine is stationary or stopped.

[0049] In step 630, the contactor assembly 250 is aligned with the plurality of conductor tracks 112. During operation ( Figure 4 The combined mass of the tow arm assembly 230 and the contactor assembly 250 is subjected to gravity, and the magnetic force generated by the plurality of magnets (not shown) housed in the base frame 256 causes the contactor assembly 250 to be connected to the plurality of conductor tracks 112.

[0050] In step 640, the control system 500 determines whether the tow arm assembly 230 is aligned with the plurality of conductor rails 112 by: using a continuity sensor in the contactor assembly 250 to sense the presence of current and grounding in the plurality of conductor rails, and using a position sensor 238 housed within the plurality of tow arms 232 to sense the alignment of the rails. To determine the alignment of the tow arm assembly 230 relative to the rails, the position sensor 238 and the continuity sensor provide feedback to the control system 500, which generates appropriate movement commands as needed. The position sensor 238 is fixed near or inside the plurality of tow arms 232 and provides vertical and horizontal position data to the control system. Once the control system has received the position signal 520, the ECM 502 can generate display data 560 in the form of a position indicator 152 for the operator in the compartment 150. The position indicator may include: a camera image; a turning signal indicator for guiding the operator to position the tow arm assembly 230; an image representation of the connector arm assembly 200 relative to the conductive rail system 110; or other suitable representation. Similarly, continuous sensors (especially voltage sensor 252 and ground sensor 254) continuously test the presence of voltage or ground along the conductor track and transmit voltage and ground information to the control system.

[0051] In step 650, if the contactor assembly 250 is correctly aligned with the rails and the presence of current and grounding is confirmed, the electrical energy carried by the conductive rail system 110 is transferred from the plurality of conductor rails 112 along the tow arm assembly 230 via the busbar assembly within the boom 210 to the contactor assembly 250, and to the battery system 134 of the mobile machine 120. Electrical transfer from the conductor rails 112 to the battery system 134 can continue as long as necessary to fully charge the battery system 134, or as the operator deems necessary.

[0052] Step 660 includes determining whether a current or ground connection is missing (e.g., disconnected) and whether ECM 502 has received a command to retract the rail connector assembly 200. The determination in step 660 is "No" when current and ground are connected (as indicated by signals 524 and 526) and a retraction request has not been received by operator input 512.

[0053] However, if the connector assembly control system determines that the contactor assembly 250 is not properly aligned with the conductor rail 112, or that there is no current or grounding on the conductor rail 112, the determination in step 660 is "yes". Method 600 can then proceed to step 670, in which the control system 500 generates a contactor assembly command 558 to disengage from the plurality of conductor rails 112. The contactor assembly command 558 signals the pneumatic system 236 to generate fluid pressure in the plurality of extendable brushes 264 located in the contactor assembly 250, thereby producing a disengagement force greater than the magnetic force and gravity acting on the contactor assembly. The extendable brushes 264 will move in the downward direction 268 ( Figure 5 The brush extends toward the conductor track 112, wherein the brush extension 266 thereby disconnects the electrical connection between the conductive terminal 262 and the track.

[0054] Once the contactor assembly 250 has been disconnected from the conductor rail, step 680 can be performed by generating a tow arm command 556 to move the tow arm assembly 230 from its fully extended state. Figure 4 The tow arm is retracted to the retracted state. Specifically, the tow arm command 556 signals the pneumatic system 236 to retract the multiple tow arms 232, causing the tow arms 232 to be oriented vertically relative to the ground at the distal end of the boom 210, and the disconnected contactor assembly 250 to be suspended from the tow arm assembly above the conductor rail 112, as shown. Figure 3 As shown.

[0055] As part of step 680, ECM 502 may subsequently or simultaneously generate boom command 554, thereby signaling the hydraulic system 214 of boom 210 to move the boom from its fully extended state. Figure 3 Retract to the retracted state ( Figure 2 Angle sensor 220 communicates with input receiver 504 to provide an angle signal 516 when the boom is fully retracted. Once retracted, lock sensor 216 senses the proximity of boom 210 and provides a proximity indicator to the control system. ECM 502 generates a lock command 552 to the locking pin to actuate the locking pin, thereby locking boom 210 to the side of mobile machine 120.

[0056] In addition to retracting the tow arm assembly 230 and locking the boom, step 680 may also include engaging the contactor assembly 250 to the shelf 142. For example, before or during locking the boom 210, a pneumatic sensor 240 in the tow arm assembly 230 sends a pneumatic signal 522 to an input receiver 504 to extend the telescopic link 234 of the tow arm assembly 230. The ECM 502 calculates and generates a tow arm command 556 that causes multiple tow arms to extend such that the contactor assembly 250 abuts the shelf 142. Once contact is established, the combined mass of the tow arm assembly 230 and the contactor assembly 250, along with the magnetic force generated by the magnet integrated into the base frame 256, effectively engages the contactor assembly 250 to the shelf 142 in the retracted state, as... Figure 2 As shown.

[0057] According to this disclosure, a control system for a track connector assembly for mobile machinery provides a series of conditions and calculations to securely and safely connect the mobile machinery to a conductive track system for charging. Furthermore, the control system provides automated deployment and engagement of the connector assembly along any route in an industrial work site without operator intervention. Finally, the control system provides additional safety by continuously testing the presence of current and grounding, and by rapidly disengaging from the conductor track in the event of a lack of current, lack of grounding, or improper alignment of the connector assembly.

[0058] It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed system without departing from the scope of this disclosure. Other embodiments of the system will be apparent to those skilled in the art upon consideration of this specification and the practice of the system disclosed herein. This specification and examples are intended to be considered merely exemplary, and the true scope of this disclosure is indicated by the following claims and their equivalents.

Claims

1. A method of operating a track connector assembly (200) of a mobile machine (120), the method comprising the steps of: Received using electronic control module (502): A request to extend the track connector assembly (200) from the frame (140) of the mobile machine (120), the track connector assembly (200) including a boom (210), a trailing arm assembly (230), and a contactor assembly (250), and A request to extend the towing arm assembly (230) to electrically connect to a plurality of conductor rails (112); The electronic control module (502) generates movement commands to operate the track connector assembly (200); and The electronic control module (502) uses a continuity sensor connected to the contactor assembly (250) to determine the presence of electrical energy along the plurality of conductor tracks (112).

2. The method of claim 1, further comprising generating a boom (210) extension command that causes a hydraulic system (214) to extend the boom (210), the boom being pivotally attached to the side of the mobile machine (120).

3. The method according to claim 2, wherein the boom (210) is attached to the mobile machine (120) at a proximal end of the boom (210) at a height greater than the height of the plurality of conductor tracks (112).

4. The method of claim 3, the method further comprising generating a tow arm extension command that causes a pneumatic system (236) to extend the tow arm assembly (230).

5. The method of claim 4, wherein the tow arm assembly (230) is rotatably attached to the distal end of the boom (210) and has a vertical orientation relative to the ground, wherein when the tow arm assembly (230) is fully extended, the length of the tow arm assembly (230) is greater than a first difference between the height of the proximal end of the boom (210) and the height of the plurality of conductor rails (112).

6. The method according to any of the preceding claims, the method further comprising rotating the towing arm assembly (230) in a rearward direction relative to the direction of travel of the mobile machine (120), such that the towing arm assembly (230) and the contactor assembly (250) tow the boom (210).

7. The method according to any of the preceding claims, the method further comprising receiving position data from a plurality of position sensors using the electronic control module (502) to determine the position of the tow arm assembly (230).

8. The method according to any of the preceding claims, the method further comprising determining the contactor assembly (250) and the plurality of conductor rails (112) based on the detected voltage.

9. The method of claim 8, wherein the contactor assembly (250) comprises one or more voltage sensors (252) and one or more ground sensors (254), and The method further includes receiving data indicating the presence of voltage and ground potential using the one or more voltage sensors (252) and the one or more ground sensors (254).

10. The method of claim 9, further comprising extending a plurality of extendable brushes (264) of the contactor assembly (250) based on the data received from the one or more voltage sensors (252) or the one or more ground sensors (254).

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