Electrical interface system

Abstract

An electrical interface system may include a base frame (242) having a plurality of through holes (253) and a plurality of conductor terminals (262). Each of the plurality of conductor terminals (262) includes a fixed piston (266), a fluid bag assembly, and a movable brush. The electrical interface system may also include a plurality of bus assemblies, each of the plurality of bus assemblies including at least one terminal hole aligned with at least one through hole of the base frame (242), wherein each of the plurality of through holes (253) and the aligned terminal hole receives a portion of a respective conductor terminal.

Description

Technical Field

[0001] This disclosure relates generally to an electrical interface system for mobile machines, and more specifically to a contactor assembly for engaging a conductive rail system. Background Technology

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

[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 systems in the industrial sector requires significant infrastructure investment, particularly due to the location of industrial construction sites. While overhead power lines are a solution for powering vehicles with predetermined routes or terrain (e.g., trains, subways, buses), they are impractical for all machines or construction sites, such as freely maneuverable industrial machinery and uneven terrain. Therefore, existing power systems, such as overhead lines, are generally not used in remote and uneven environments and / or on variable routes. Furthermore, properly aligning and connecting such power lines to the machines for proper energy transfer can be difficult. Such problems can lead to project delays and machine downtime.

[0004] International Patent Application Publication No. WO 2020 / 186296 A1 (“'296 Publication”), published on September 24, 2020, describes a system for supplying electricity to a moving vehicle. The system described in '296 Publication includes an electrical delivery system for a moving vehicle in a mining facility, in which two conductors are anchored to a roadside barrier that can be repositioned. To charge the moving vehicle, the delivery system provides an arm extending from the vehicle that aligns 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, connecting the roadside conductors to the vehicle's interface can have disadvantages.

[0005] The aspects of this disclosure can solve one or more of the problems described 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 contactor assembly for connecting a mobile machine to a plurality of conductor tracks includes: a base frame including a plurality of through holes; a plurality of conductor terminals, each of the plurality of conductor terminals including a fixed piston, a fluid bag assembly and a movable brush; and a plurality of busbars, each of the plurality of busbars including at least one terminal hole aligned with at least one through hole of the base frame, wherein each of the plurality of through holes and the aligned terminal hole receives a portion of an individual conductor terminal.

[0007] On the other hand, a contactor assembly for connecting a mobile machine to a plurality of conductor tracks includes: a base frame including a plurality of through holes; a plurality of conductor terminals, each of the plurality of conductor terminals including a fixed piston, a fluid bag assembly and a movable brush; and a plurality of busbars, each of the plurality of busbars including at least one terminal hole aligned with at least one through hole of the base frame, wherein each of the plurality of through holes and the aligned terminal hole receives a portion of an individual conductor terminal, and the piston further includes a tube fixed to an outer surface of the piston and a base plate fixed to a distal end surface of the piston.

[0008] In another aspect, a contactor assembly for connecting a mobile machine to a plurality of conductor tracks includes: a base frame including a plurality of through holes; a plurality of conductor terminals, each of the plurality of conductor terminals including a fixed piston, a fluid bag assembly, and a movable brush; and a plurality of busbars, each of the plurality of busbars including at least one terminal hole aligned with at least one through hole of the base frame, wherein each of the plurality of through holes and the aligned terminal hole receives a portion of an individual conductor terminal, and wherein each of the conductor terminals further includes a conductive fluid electrically connecting the fixed piston to the movable brush. 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, the electrically mobile machine including a track connector assembly for connection with a conductive track system.

[0011] Figure 2 This is a perspective view of the contactor assembly of the rail connector assembly.

[0012] Figure 3 yes Figure 1 and Figure 2 Top view of the contactor assembly.

[0013] Figure 4 This is a cross-sectional view of a section of the contactor assembly.

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

[0015] Figure 6 It is a cross-sectional view of each conductor terminal in a retracted configuration.

[0016] Figure 7 It is a cross-sectional view of each conductor terminal in an extended configuration. 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 stated values.

[0018] As used herein, the terms “upstream” and “proximal” are intended to identify, in terms of location, parts, components, and systems that are closer to the frame / body of the mobile machine. Conversely, the terms “downstream” or “far side” are intended to identify, in terms of location, parts, components, and systems that are further away from the frame / body of the mobile machine.

[0019] Figure 1 A mobile machine power system 100 is depicted, comprising a mobile machine 140 having a conductive connector assembly 200 and a conductive track system 120 for supplying power to the mobile machine 140. The mobile machine 140 includes an electric drive system 142 having at least one electric motor 144 and at least one battery system 146. The electric drive system 142 drives a set of ground engagement elements 148 (such as tires or continuous tracks) for propulsion and maneuvering of the mobile machine 140. The mobile machine 140 also includes a frame / body 150 supporting the machine components (including the conductive connector assembly 200). The mobile machine 140 may include a hybrid power system or a fully electric power system, and the conductive track system 120 can be applied to either system. The mobile machine 140 and its various systems can be controlled via a machine operator located in an operator's cab 160, and / or the mobile machine 140 may be semi-autonomous, fully autonomous, or remotely operated.

[0020] The mobile machine 140 is free-steering, thereby allowing the machine operator (or autonomous control system) to freely control the machine's direction and route. Thus, the exemplary mobile machine 140 is configured to selectively (e.g., in a free-steering manner) travel along a construction route or path within the work site, wherein the conductive track system 120 is positioned approximately along that route or path. Figure 1 The mobile machine 140 is shown in the context of a mining truck, which is typically used to transport ore in mining environments. However, this disclosure is not limited thereto, and other types of machines are also within the scope of this disclosure, including articulated trucks, asphalt pavers, backhoe loaders, drilling rigs, rope shovels, excavators, forestry machinery, hydraulic mining shovels, material handling machines, graders, off-highway trucks, pipelaying machines, road repair machines, telescopic boom forklifts, track loaders, underground mining dump loaders and trucks, wheel loaders, wheeled tractor-scrapers, or other machines.

[0021] The conductive track system 120 includes multiple elevated conductor tracks 122 connected to a power source (e.g., a power grid, generator, and / or energy storage device, not shown). The conductor tracks 122 may be supported by multiple ground-attached support rods 124 and track support assemblies 126. Although Figure 1 An example of multiple conductor rails 122 comprising three conductor rails is shown, but multiple conductor rails 122 may comprise fewer or more rails. In this example, two conductor rails provide power of different polarities (e.g., one conductor rail is positive and one conductor rail is negative), while the third conductor rail provides a 0-volt reference (ground). The elevated conductor rails 122 may have a height, for example, ranging from 8 to 15 feet above ground level. Therefore, the conductive rail system does not form a pantograph-type overhead power system, nor does it form an under-machine or low-ground power system.

[0022] A conductive connector assembly 200 electrically connects a mobile machine 140 to a conductive track system 120. The conductive connector assembly 200 includes: a boom assembly 210 having a proximal end and a distal end; an arm assembly (such as a trailing arm assembly 220) having a proximal end connected to the distal end of the boom assembly 210; and a contactor assembly 240 connected to the distal end of the trailing arm assembly 220. As used herein, the term "towing" refers to a direction opposite to the direction of travel of the mobile machine 140. The boom assembly 210 houses: a hydraulic system 212 for pivotally extending, retracting, and locking the boom assembly 210; a pneumatic system 214 for generating and controlling fluid pressure on downstream components (e.g., the trailing arm assembly 220 and the contactor assembly 240); and an integrated busbar (not shown) for transmitting electrical energy along the length of the boom assembly 210. While the following disclosure will provide details of the pneumatic system 214, it should be understood that the pneumatic system 214 may alternatively be a hydraulic system.

[0023] like Figure 1 As shown, the boom assembly 210 extends generally horizontally from one side of the mobile machine and connects to one side of the frame / body 150 of the mobile machine 140 around a pivot joint. The pivot joint is located at a height of more than 8 feet on the machine (above the ground 10). As previously mentioned, the conductive connector assembly 200 includes several different deployment states, including an extended state in which the boom assembly 210 extends generally horizontally outward from the side of the mobile machine 140 (e.g., Figure 1 (Shown) A retracted state (not shown), in which the boom assembly 210 rotates or pivots inward to rest against the frame / body 150 of the mobile machine (not shown); and a locked state, in which the boom assembly is locked to one side of the machine frame / body 150 by a hydraulically actuated locking pin (not shown) in the retracted state. Finally, although the boom assembly 210 is shown attached to a mining truck, the same boom assembly 210 can also be incorporated into various types of mobile machines 140 by using interchangeable adapters (not shown) specific to the type of machine being operated.

[0024] The tow boom assembly 220 forms a mechanical and electrical connection between the boom assembly 210 and the contactor assembly 240, and may include one or more booms. The one or more booms may be extendable and retractable, and may have multiple degrees of freedom to allow vertical and lateral pivoting about the boom assembly 210. In one arrangement, the tow boom assembly 220 may form a double parallel-bar linkage mechanism including three telescopic booms configured to form a current path in their fully extended state.

[0025] like Figure 2 and Figure 3 As shown, the contactor assembly 240 is electrically connected to the conductive track system 120 and includes a base frame 242, multiple conductor terminals 262, multiple busbar assemblies 306, and track interface features. The base frame 242 includes a composite structure comprising an upper skin layer 236, a bottom skin layer 237, and a high-density foam material 238 sandwiched between the two skin layers. Figure 4 Both the upper skin layer 236 and the bottom skin layer 237 can be made of multilayer resin-reinforced materials or fabrics (such as glass fiber or other electrically insulating materials). The base frame 242 can be formed using various composite fabrication techniques (such as vacuum-assisted resin transfer molding) to develop lightweight and substantially rigid composite structures.

[0026] The composite structure of the base frame 242 includes respectively in Figure 2 and Figure 3 The top side 230 and bottom side 231 are shown. The base frame 242 also includes a central platform 304 and a pair of opposing transverse sides 232. Figure 2 In the pedestal frame 242, each of the opposing lateral sides 232 includes a lateral strut 244 and a pair of lateral flanges or wings 246, the lateral struts extending outward from the central platform 304 at a downward angle. The pair of lateral flanges 246 are located on the distal ends of each of the lateral struts 244, wherein the lateral flanges are arranged substantially parallel to the central platform 304 of the pedestal frame 242. The lateral flanges 246 are configured to help position and hold the conductor rails 122 within the pair of lateral struts 244 by preventing excessive lateral movement of the conductor rails 122 relative to the bottom surface of the pedestal frame 242.

[0027] Multiple track interface features connected to the base frame 242 may include multiple support rollers 248, multiple wear pads 250, and multiple spacer buffer blocks 252. To facilitate sliding of the base frame 242 along the multiple conductor tracks 122, the multiple support rollers 248 are attached to the front and rear sides of the base frame 242 (see [link to documentation]). Figure 2 and Figure 3 Multiple wear-resistant pads 250 may be attached to the bottom side 231 of the base frame 242 at the transverse flange 246 (see...). Figure 3 Multiple spacer blocks 252 are attached to the bottom side 231 of the base frame 242 in a spaced-apart configuration to align with the gaps between the multiple conductor tracks 122. When traveling on the conductor tracks 122, the spacer blocks 252 help reduce excessive lateral movement of the base frame 242. The spacer blocks 252 can be as follows: Figure 3The strips are triangular in shape, but their size and shape can vary based on the characteristics of the base frame 242 and the spacing of the multiple conductor tracks 122.

[0028] The central platform 304 of the base frame 242 includes a plurality of through holes 254 extending vertically through it. Each through hole 254 receives a corresponding conductive terminal 262 and an annular magnet chamber 259. Figure 2 and Figure 3 As shown, the central platform 304 includes nine through holes 254 arranged in a 3×3 matrix, such that three sets of linearly aligned through holes 254 and corresponding conductive terminals 262 correspond to each of the three busbars 306 and conductor tracks 122. More or fewer conductive terminals 262 can be used, such as only three, six, or twelve conductive terminals 262. Although one through hole 254, conductive terminal 262, and associated feature will be discussed below, this description will equally apply to other through holes 252, conductive terminals 262, and associated feature.

[0029] refer to Figure 4 and Figure 5 Each through-hole 254 in the base frame 242 can receive a radially outer tubular member 255 and a radially inner tubular member 257, which together form an annular magnet chamber 259 between them. The tubular members 255, 257 can be secured to the central platform 304 by any suitable means, such as using adhesives. In one example, the radially inner tubular member 257 may include a radially outwardly extending distal flange 256 located at the bottom side 231 of the base frame 242 to help secure the tubular member to the bottom skin layer 237 of the base frame 242. The annular magnet chamber 259 houses a magnet assembly comprising a plurality of magnets 258 circumferentially arranged within the magnet chamber 259. The plurality of magnets 258 are thus housed within the base frame 242 and help connect the base frame to the plurality of conductor tracks 122 of the conductive track system 120. An annular foam insert 261 may also be located above a plurality of magnets 258 in an annular magnet chamber 259. A radially internal tubular member 257 may include a top or proximal portion 260 extending beyond the top surface of the base frame 242 to allow mating engagement with an annular cutout portion 310 formed in the underside of the busbar assembly 306. The tubular members 255, 257 may be made of any suitable dielectric material, such as glass fiber or other similar electrically insulating materials.

[0030] refer to Figure 5Each conductor terminal 262 may include a piston assembly 264, a fluid bag or air bladder assembly 280, and various retractable brushes 300. The piston assembly 264 includes a piston 266, a cylindrical outer tube 274, and a bottom base plate 276. The piston 266 may include a plurality of pneumatic channels 268, 270, and 272 that are fluidly interconnected to guide pressurized fluid through each conductor terminal 262. For example, the piston 266 may include: a first pneumatic channel 268 extending horizontally through a first proximal end of the piston body; a second pneumatic channel 270 extending horizontally through the piston body at a middle portion; and a third pneumatic channel 272 extending vertically and connecting the first pneumatic channel 268 and the second pneumatic channel 270. The piston 266 may have a generally cylindrical shape, wherein the diameter of the top or proximal portion 265 is smaller than the diameter of the bottom or distal portion 267, and a horizontal step 269 is provided between the proximal portion 265 and the distal portion 267. The piston 266 may be made of any conductive material, such as aluminum alloy or other similar materials or alloys. In addition to the piston 266, the cylindrical outer tube 274 is hollow, having a plurality of through holes corresponding to the second pneumatic passage 270, and the dimensions of the cylindrical outer tube are designed such that the piston 266 is press-fitted and fixed within the cylindrical outer tube 274. The bottom base plate 276 is fixed to the bottom surface of the distal portion 267 of the piston 266 by friction welding. The bottom base plate 276 may have a diameter larger than the distal portion 267 of the piston 266 and the cylindrical outer tube 274. Both the cylindrical outer tube 274 and the bottom base plate 276 can be made of any corrosion-resistant metallic material, such as stainless steel alloy or other similar materials.

[0031] The airbag assembly 280 includes an airbag 288, an airbag chamber 285, and a reservoir forming hub 290. As noted above, the airbag assembly 280 may alternatively be used with a fluid other than air, such as a fluid bag assembly using hydraulic fluid. The airbag 288 may have a substantially tubular or spherical shape and may be formed of one or more layers of compressible material, such as rubber. The top or proximal portion of the airbag 288 is securely attached to the outer diameter of the piston assembly 264 between a first attachment point (via a first retaining ring 284) and a second attachment point (via a second retaining ring 286) using a first annular clamp 287. Both the first retaining ring 284 and the second retaining ring 286 may be snap rings or other suitable fastening devices, wherein the second retaining ring 286 includes a tapered shape that fits within the inner surface of the upper wall 293 of the reservoir forming hub 290. The second positioning ring 286 is aligned with the second pneumatic passage 270 of the piston assembly 264 and includes a plurality of holes to allow pressurized fluid to travel from the second pneumatic passage to the airbag chamber 285. Additionally, the airbag 288 also includes a distal or bottom portion 282, which is securely attached (via a second annular clamp 283) to the outer circumferential surface of the reservoir forming hub 290. (As in...) Figure 6 and Figure 7 As best illustrated in the movement of the airbag, the airbag chamber 285 may be supplied with air to cause the reservoir to form a hub extending distally along the piston assembly 264, thereby causing the retractable brush 300 to extend distally along the longitudinal axis 278. When supplied with air from the pneumatic system 214, the radial movement of the airbag 288 may be constrained by the rigidity of the walls and upper or proximal cover 312 of the airbag, the radially internal tubular member 257, and / or the busbar assembly 306.

[0032] The reservoir forming hub 290 is an annular member having a proximal or upper wall 293 and a distal or bottom base 295. The bottom or distal end of the base 295 of the reservoir forming hub 290 is securely attached to the top or proximal surface 301 of the retractable brush 300 in any suitable manner. The upper wall 293 may include one or more piston rings 303 to allow the reservoir forming hub 290 to move along the piston assembly 264 during the extension and retraction of the retractable brush 300. The reservoir forming hub 290 extends circumferentially around the piston assembly 264 and forms an inner chamber 294 and a reservoir chamber 292. The inner chamber 294... Figure 7The reservoir is best shown in the diagram and is formed by the gap between the piston assembly 264, the upper wall 296 of the reservoir forming hub 290, and the top surface 301 of the retractable brush 300. The reservoir chamber 292 of the reservoir forming hub 290 is formed by an annular channel 307 in the top surface of the bottom base 295 of the reservoir forming hub 290. The reservoir chamber 292 is fluidly connected to the inner chamber 294 via a plurality of angled connection passages 298. The inner chamber 294 includes a conductive fluid 311 to facilitate electrical connection between the piston assembly 264 and the retractable brush 300 as the retractable brush extends and retracts relative to the fixed piston assembly 264. The reservoir chamber 292 is configured to receive excess conductive fluid 311 during movement of the retractable brush 300 and associated volume changes occurring in the inner chamber 294. Thus, the piston assembly 264, the retractable brush 300, and the reservoir forming hub 290 together form a reservoir for the conductive fluid. When the retractable brush 300 approaches the retracted position ( Figure 6 When the retractable brush 300 is nearly fully extended, the reservoir chamber 292 can receive the conductive fluid 311. Figure 7 When the liquid is discharged, the reservoir chamber discharges conductive fluid 311. The reservoir forming hub 290 may be made of a corrosion-resistant material (such as stainless steel, ceramic or other similar materials). The conductive fluid 311 may be any flowable conductive material that is liquid at room temperature, such as gallium-based or mercury-based liquid metal alloys.

[0033] Return to reference Figure 5 Enlarged view of the respective conductor terminals 262 of the piston assembly 264, the airbag assembly 280, and the retractable brush 300. As noted above, the retractable brush 300 is housed within the base frame 242 and includes various extended or retracted states based on the amount of pressurized fluid (e.g., air) present in the airbag chamber 285. For example, different extended or retracted states may include: a fully retracted state ( Figures 4 to 5 In the fully retracted state, the retractable brush 300 is fully retracted within the contactor assembly 240, while the pressurized fluid of the contactor assembly is discharged to the atmosphere; in the operating state (not shown), the retractable brush extends slightly during attachment to contact the top surface of the conductor track 122; and in the fully extended state ( Figure 7In the fully extended state, the retractable brushes extend to their maximum length. In the fully retracted state, the pressure of the fluid in the airbag chamber 285 is insufficient to overcome the preset shape of the airbag 288, and therefore the airbag causes the retractable brushes 300 to enter the fully retracted state. In the operating state, the bottom surfaces of the plurality of retractable brushes 300 extend slightly from the base frame 242 and are configured to slide along the top surfaces of the plurality of conductor tracks 122 to collect electrical energy. For example, the retractable brushes 300 conduct electrical energy from the plurality of conductor tracks 122 through the body of the retractable brushes to the piston assembly 264 via the conductive fluid 298. Note that the conductive fluid 311 is in fluid communication with the airbag chamber 285.

[0034] When fully extended, due to the expansion of the air bladder 288, the retractable brush 300 extends downward from the bottom surface of the base frame 242 toward the top surface of the plurality of conductor rails 122, wherein the pneumatic extension force 302 is guided in the same downward extension direction (e.g., Figure 7 (As shown). In the fully extended state, the retractable brush 300 is used to push the contactor assembly 240 away from the conductor track 122, sufficient to overcome the magnetic force of the plurality of magnets 258. In this fully extended state, the conductive fluid can be disconnected from the piston assembly 264 (as shown). Figure 7 (As shown). Multiple retractable brushes 300 may be constructed from carbon-based or metal-based composite materials. For example, graphite-based composite materials may be used. (As exemplified) Figure 5 As shown, each retractable brush 300 is typically disc-shaped and sized to fit within a through-hole 254 formed in the base frame 242. Furthermore, the retractable brushes 300 of the contactor assembly 240 are located together in a common plane for contacting the top surfaces of the plurality of conductor tracks 122.

[0035] Refer again Figure 5Each conductor terminal 262 is removably secured to the central platform 304, busbar assembly 306, and proximal cover 312 of the base frame 242 via a pin connector 320. In the illustrated arrangement, the pin connector 320 forms the only or sole connector for removably connecting the conductor terminal 262 to the contactor assembly 240 and extends horizontally through the top portion 265 of the piston 266. To remove the conductor terminal 262, the pin connector 320 is withdrawn from the top portion 265, and the conductor terminal 262 is pushed distally away from the proximal cover 312 and the respective through holes 254 of the base frame 242. The busbar assembly 306 is mounted to the upper skin layer 236 of the base frame 242 and includes a plurality of terminal holes or through holes 308 for receiving the top portion 265 of the piston assembly 264. As will be explained in more detail below, the busbar assembly 306 may be made of any conductive material, such as aluminum, copper, brass, or other similar materials. Each busbar assembly in busbar assembly 306 is generally rectangular in shape, and a plurality of through holes 308 extend vertically through them. As discussed above, busbar assembly 306 includes a plurality of annular cutout portions 310 on the bottom surface of busbar assembly 306, which surround each of the through holes 308. The annular cutout portions 310 thus form steps for receiving the top portion 260 of the radially inner tubular member 257. The terminal holes or through holes 308 are thus aligned with the respective conductor terminals 262 and align busbar assembly 306 with the upper skin layer 236 of base frame 242. The plurality of through holes 308 are also sized to receive the conductor terminals 262 extending therethrough. Busbar assembly 306 can be secured to the upper skin layer 236 of base frame 242 by applying adhesive without the use of additional machine fasteners. However, machine fasteners may be additionally or alternatively included for connection and positioning purposes.

[0036] Each of the multiple through-holes 308 in the multiple busbar assemblies 306 includes a proximal cover 312 that effectively secures each conductor terminal 262 within the base frame 242. Figure 5As shown, the proximal cap 312 may include a generally annular and tubular shape, having an annular opening 314 extending through the proximal cap, an internal retaining flange or step 326, and an external retaining flange 316 surrounding a central portion of the piston assembly 264. The annular opening 314 is shaped to receive a top portion of the piston assembly 264 such that the internal retaining flange 326 abuts a horizontal step 269 in the piston 266, thereby separating the smaller-diameter proximal end of the piston 266 from the larger-diameter distal portion 267 of the piston 266. The proximal or top portion of the cap 312 includes a pneumatic passage 318 aligned with a first pneumatic channel 268 of the piston 266. The pneumatic passage 318 may include a fitting 324 for connection to a pneumatic supply conduit 322. The pneumatic passage 318 and the pneumatic supply conduit 322 facilitate the transfer of pressurized fluid to and from the air chamber 285 during brush extension and retraction. The external retaining flange 316 includes a bottom surface that is placed on the top surface of the busbar 306 and completely covers each through hole 308. Figure 4 and Figure 5 The proximal cover 312 also includes a lower portion located below the external retaining flange 316 and within the respective through holes 308 of the busbar assembly 306. In operation, the lower portion of the proximal cover 312 can contact the airbag 288 before and during inflation. The external retaining flange 316 includes a plurality of fastener holes for attaching the flange to the busbar assembly 306 using a plurality of machine fasteners.

[0037] Industrial applicability

[0038] The aspects of the contactor assembly disclosed above can be used for electrical connection to a conductive rail system, along which the contactor assembly slides for charging a freely steerable mobile machine during operation at the work site, and disengages from the conductive rail system. For example, the figures generally depict a contactor assembly located at the distal end of a conductive connector assembly, which includes a plurality of conductive terminals for collecting electrical energy and a busbar assembly, the plurality of conductive terminals being held within a base frame, the busbar assembly being attached to the base frame via multiple top portions of a plurality of radially internal tubular members.

[0039] To operate the mobile machine 140, the mobile machine is remotely or autonomously controlled by an operator in operator room 160. Upon approach to the conductive track system 120, a conductive connector assembly 200, including boom assembly 210, trailing arm assembly 220, and contactor assembly 240, is deployed and attached to multiple conductive tracks 122, such as... Figure 1 As shown. The contactor assembly 240 is attached to multiple conductor tracks 122 in two ways. First, the base frame 242 of the contactor assembly 240 includes multiple magnets 258 (such as...). Figure 4 and Figure 5 As shown, multiple magnets extend circumferentially around multiple conductor terminals 262, generating a downward magnetic force toward the multiple conductor rails 122. Additionally, the mass of the contactor assembly 240 generates a gravitational force, which also facilitates engagement between the contactor assembly and the multiple conductor rails 122. While the downward magnetic force and gravitational force help attach the contactor assembly 240 to the multiple conductor rails 122, as discussed above, the contactor assembly 240 also includes multiple rail interface features for maintaining its connection to the rails.

[0040] When in the engaged state, the retractable brush 300 of the contactor assembly 240 extends partially from its fully retracted state and slides along the conductor rail 122, transferring electrical energy from the conductor rail 122 to the mobile machine 140. Each of the three rows of conductor terminals 262 and the bus assembly 306 is electrically connected to the respective conductor rail 122, thereby forming a positive electrical connection, a negative electrical connection, and a neutral or ground connection. To aid in proper connection to and maintenance of the connection with the conductor rail 122, the contactor assembly 240 may utilize a pair of transverse flanges or wings 246, multiple support rollers 248, multiple wear-resistant pads 250, and multiple spacer buffer blocks 252, such as... Figure 2 and Figure 3 As shown.

[0041] During the connection process in the engaged state, electrical energy from multiple conductor tracks 122 travels through multiple retractable brushes 262 to the conductive fluid 311 (e.g., ...). Figure 5 (As shown). Electrical energy is transferred from the conductive fluid 311 to the piston 266 (via the cylindrical outer tube 274 and the bottom base plate 276). The piston 266 transmits electrical energy along its length toward the proximal cover 312. The electrical energy can then be transferred to a plurality of bus assemblies 306, which are connected to upstream components of the conductive connector assembly 200 (e.g., the tow arm assembly 220 and the boom assembly 210).

[0042] Once the operator initiates the disengagement procedure, the pneumatic system 214 generates a pneumatic extension force 302 capable of extending the plurality of retractable brushes 300. As noted above, the pneumatic system 214 in the boom assembly 210 can be controlled to pressurize fluid to downstream components of the conductive connector assembly 200. The pressurized fluid is transferred from the pneumatic system 214 of the boom assembly 210 to a pneumatic supply conduit 322. The pneumatic supply conduit 322 is fluidly connected to a plurality of conductor terminals 262, each of which includes a piston assembly 264. The piston assembly 264 includes a piston 266 and a plurality of pneumatic channels 268, 270, 272 that internally connect the pneumatic supply conduit 322 to an airbag assembly 280, which contains pressurized fluid in an airbag chamber 285.

[0043] Once the airbag chamber 285 of the airbag assembly 280 is filled with sufficient pressurized fluid, the reservoir forming hub 290 moves toward the fully extended position (e.g., Figure 7 (As shown). This expansion actuates multiple retractable brushes 300 that extend downward and abut against the top surface of the conductor rails 122. A pneumatic extension force 302 is directed toward the top surface of the conductor rails 122 in the same downward direction. In instances where the pneumatic extension force 302 exerted by the multiple retractable brushes 300 is greater than a combined force including the downward magnetic force and gravity acting on the contactor assembly, the contactor assembly 240 may disengage from the multiple conductor rails 122. The conductive connector assembly 200 may then complete the disengagement routine or attempt to reconnect to the multiple conductor rails 122 to continue charging the mobile machine 140.

[0044] According to this disclosure, a contactor assembly for mobile machinery allows a rail connector assembly to be securely attached to, slide along, and safely disengage from a plurality of conductive rails using a pneumatic system fluidly connected to a piston assembly. The contactor assembly also utilizes a plurality of annular grooves extending from the bottom skin layer of a base frame and projecting from the upper skin layer of the base frame, thereby allowing a plurality of machined busbars to be positioned and mated with the annular protrusions without the need for machine fasteners. Finally, the contactor assembly of the present invention provides a pneumatic pin connection interface for retaining conductor terminals within the annular grooves and allowing for quick replacement of conductor terminals as needed.

[0045] 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 contactor assembly (240) for connecting a mobile machine (140) to a plurality of conductor rails (122), the contactor assembly (240) comprising: Base frame (242), the base frame including a plurality of through holes; Multiple conductor terminals (262), each of the multiple conductor terminals including a fixed piston (266), a fluid bag assembly, and a movable brush; and Multiple busbars (306), each of the multiple busbars including at least one terminal hole aligned with at least one through hole of the base frame (242), Each of the plurality of through holes (253) and the aligned terminal holes receives a portion of a respective conductor terminal.

2. The contactor assembly (240) according to claim 1, wherein each of the respective conductor terminals is removably attached to the contactor assembly (240) via a single connector.

3. The contactor assembly (240) according to claim 2, wherein the single connector is a pin connector (320).

4. The contactor assembly (240) of claim 3, wherein the top portion of the piston (266) includes a pin hole for receiving the pin connector (320).

5. The contactor assembly (240) of claim 4, further comprising a cover associated with each conductor terminal, the cover being secured to the top of the associated busbar and including a passage for receiving the top portion of the piston (266), and the pin connector (320) abutting the top surface of the cover when the conductor terminal is secured to the contactor assembly (240).

6. The contactor assembly (240) according to claim 5, wherein when the conductor terminal is fixed to the contactor assembly (240), the cover includes a step that engages with a step of the piston (266).

7. The contactor assembly (240) according to any of the preceding claims, wherein the fluid bag assembly is an airbag assembly (280), and the airbag assembly (280) moves the brush between an extended position and a retracted position.

8. The contactor assembly (240) of claim 7, wherein the piston (266) includes a plurality of pneumatic channels extending through the body of the piston (266) to deliver air to and from the airbag (282) chamber of the airbag assembly (280).

9. The contactor assembly (240) of claim 7, wherein the airbag assembly (280) includes an airbag (282) having a proximal end and a distal end, and the airbag (282) is securely coupled to the piston (266) at the proximal end and securely coupled to a movable hub at the distal end.

10. The contactor assembly (240) of claim 9, further comprising a movable hub surrounding the fixed piston (266), wherein the piston assembly (264), the movable brush, and the movable hub form a reservoir for conductive fluid (298).

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