Current collector unit with sensor system

Abstract

The present invention relates to a current collector unit (100) for transmitting current between a rail system (150) having a conductor line (151) and an electrical load (160). The current collector unit (100) has a sliding contact carrier (104) with a sliding contact unit (102) which can be coupled to the conductor line (151) in order to form a sliding contact, and a sensor system (120) which is designed to measure a position of the sliding contact unit (102) relative to the conductor line (151).

Description

[0001] Current collector unit with sensor system

[0002] Technical field

[0003] The present invention relates to the field of electrical current collectors. In particular, the present invention relates to a current collector unit and a method for current transmission between a rail system with a conductor rail and an electrical consumer. Furthermore, the present invention relates to a current collector system comprising at least one current collector unit for current transmission between a rail system with a conductor rail and an electrical consumer.

[0004] Background of the invention

[0005] Electrical power transmission systems, especially those with pantographs, are crucial for the efficient and reliable operation of various transportation and industrial applications, particularly in industrial manufacturing facilities. These systems are designed to maintain continuous electrical contact with overhead or side-mounted conductor rails, thus ensuring a stable power supply for moving vehicles or machinery.

[0006] One challenge in this area is the wear of sliding contacts, such as carbon brushes, which are subject to constant friction and pressure against the conductor rails of the busbars. The pressure exerted on these brushes is important because excessive pressure leads to excessive wear, while insufficient pressure can result in poor electrical contact and potential power loss. Monitoring and maintaining the optimal pressure can therefore be helpful in extending brush life and ensuring consistent performance.

[0007] It is an object of the present invention to provide a current collector unit with which the functionality of the electrical transmission system can be monitored using a current collector unit.

[0008] This problem is solved with a current collector unit and a method for current transmission between a rail system with conductor rail and an electrical consumer, and with a current collector system according to the independent claims.

[0009] According to a first aspect, a current collector unit for current transmission between a rail system with a conductor rail and an electrical load is described. The current collector unit has a sliding contact carrier with a sliding contact unit, which can be coupled to form a sliding contact with the conductor rail, and a sensor system designed to measure the position of the sliding contact unit relative to the conductor rail.

[0010] According to another aspect, a current collector system with at least one current collector unit as described above is provided. The current collector system has a mounting bracket on which the current collector unit is arranged and to which the electrical load can be attached. The mounting bracket is movable and can be coupled to the rail system.

[0011] According to another aspect, a method for current transmission between a rail system with a conductor rail and an electrical consumer with a current collector unit described above is provided. The method includes the step of measuring the position of the sliding contact unit relative to the conductor rail using the sensor system.

[0012] The current collector unit is designed to travel along a rail system, which is arranged, for example, on the floor, along a side wall or along the roof of a production hall.

[0013] The current collector unit is configured to draw electrical current from a conductor, such as a conductor rail of a rail system, and supply it to an electrical load, such as a vehicle motor, a production system in a manufacturing hall, a power supply unit in an electric vehicle, or a transport system in a manufacturing hall. Current is also drawn along the rail system to drive the current collector unit itself.

[0014] The current collector unit can have a base carrier to which the sliding contact carrier is attached. The sensor system can be arranged on the sliding contact carrier and / or the base carrier. The base carrier has a support structure to which the components of the current collector unit are attached. Examples of a base carrier are a plate-shaped carrier, a frame, a housing, or a similar structural element. The mounting bracket consists, for example, of a stable support or mounting plate to which one or more current collector units with their base carriers can be arranged. The mounting bracket is coupled to the rail system in a force-transmitting manner. The mounting bracket has, for example, rollers or wheels by means of which the mounting bracket can move along the rail system.Furthermore, the mounting bracket can, for example, have a corresponding (electric) drive motor which generates a driving force to propel the current collector system along the rail system. In particular, the drive motor can drive the rollers described above.

[0015] Furthermore, the current collector system can be driven along the rail system via an inductive drive. The mounting bracket can also consist of several detachable units. For example, one unit of the mounting bracket can support the current collector system or the electronics box and the current collector units, while another unit (e.g., designed as a mounting plate) can support an electrical load, the rollers, and the drive motor.

[0016] The sliding contact unit forms a current collector head configured to establish and maintain a sliding electrical contact with a conductor, such as the conductor rail, in order to draw electrical current from the conductor rail. The sliding contact unit can, for example, carry one or more sliding contacts. Examples of sliding contacts include carbon elements (so-called carbons), a metal shoe, or a similar conductive element. Specifically, two current contact elements are provided. These can be placed on a pivoting rocker to compensate for irregularities along the conductor rail during operation.

[0017] The sliding contact carrier serves as a support structure for the sliding contact unit. Specifically, the sliding contact carrier is positioned between the base carrier and the conductor rail. The sensor system can be mounted on the sliding contact carrier.

[0018] The sensor system comprises one or more sensors of the same or different design. The sensors are configured to detect, measure, or monitor various physical quantities or conditions and provide corresponding output signals. In particular, the sensor system measures parameters or physical quantities that indicate the position of the sliding contact unit relative to the conductor rail. This can be implemented, for example, using position sensors, distance sensors, angle sensors, and / or optical sensors as described below. Furthermore, measuring the position of the sliding contact unit relative to the conductor rail indicates a change in the contact pressure between the sliding contact unit and the conductor rail.For example, the sensor system can include sensors that detect the position of the sliding contact unit relative to the base carrier. Based on this knowledge of the sliding contact position, inferences can be drawn about the contact pressure of the sliding contacts on the conductor rail. Furthermore, force sensors can also be incorporated into the sensor system to directly measure the contact pressure of the sliding contacts on the conductor rail, or indirectly via force generation systems, such as the contact spring described below, to measure the corresponding forces and thus infer the contact pressure of the sliding contact unit. Conversely, the contact pressure provides information about the position of the sliding contact unit relative to the conductor rail. Examples of a sensor system therefore include a position detection system, a force sensor system, or a similar arrangement of sensors.

[0019] With the current collector unit of the present invention, the position of the sliding contact unit relative to the conductor rail and, consequently, the contact pressure, in particular the change in contact pressure over time, can be measured by means of the sensor system while the current collector unit travels along the rail system. This sensor data on the position of the sliding contact units and the contact pressure, or its change, can be read and processed in real time or for predetermined periods. By evaluating the change in the position of the sliding contact units, conclusions can be drawn about the wear of the sliding contacts. Furthermore, damage to the rail system can be detected, since when the unit passes over a defect in the rail system, the position and, accordingly, the contact pressure of the sliding contact units change at the point of damage.The current collector unit according to the invention thus allows maintenance times to be determined more precisely and efficiently. Furthermore, damage to the current collector unit itself can be detected.

[0020] According to another exemplary embodiment, the sliding contact carrier has a mounting foot (which is, in particular, attached to a base carrier) and a tilting arm (connecting arm) which is pivotably attached to the mounting foot about a pivot axis, with the sliding contact unit being attached to the tilting arm. The mounting foot forms a mounting foot or a base mounting structure that is attached to the base carrier and is configured such that the movable tilting arm can be arranged. In addition to a tilting arm configuration, a connecting arm can also be provided that is movably arranged translationally between the sliding contact line and the mounting foot, for example, by means of a corresponding rail or cam guide. Furthermore, the connecting arm can be pivotably attached to the mounting foot as a tilting arm, as described in more detail below. The connecting arm, orThe tilting arm can be moved, for example, by means of an electric actuator or by means of a mechanical, in particular spring-based, drive, in order to generate a corresponding contact pressure between the sliding contacts and the conductor rail or to set a desired position.

[0021] The tilting or swiveling arm is configured to allow the sliding contact unit to rotate or tilt relative to the mounting base around a pivot axis, thus generating the appropriate contact pressure between the sliding contacts and the conductor rail. The pivot axis is specifically designed to be perpendicular to the direction of travel of the current collector unit along the rail system.

[0022] According to an exemplary embodiment, the tilting arm has a cantilever section extending from a pivot axis at the mounting base to the sliding contact unit. In an exemplary embodiment, the cantilever section includes an installation space for arranging functional units, in particular a sensor board for processing the sensor data from the sensor system.

[0023] Furthermore, in an exemplary embodiment, the boom section can additionally or alternatively include an installation section extending from the pivot axis at the mounting base to a free end. This installation section provides one or more additional installation spaces for arranging functional units, in particular a sensor board for processing the sensor data from the sensor system. Integrating the sensor system or its components into the mounting base, and especially into the installation space of the tilting arm, results in shorter cable runs and a reduced distance between the power supply and the sensor system. Integrating components of the sensor system into the mounting base can also achieve low dynamic stress on the cables and the sensor system. According to an exemplary embodiment, the sensor system includes a rotary angle sensor configured to measure a swivel angle.The angle of rotation of the tilting arm relative to the mounting base is measured, particularly for measuring the change in the swivel angle over time. The swivel angle indicates the position of the sliding contacts or the sliding contact unit relative to the conductor rail. The angle measurement provides information about the position and, consequently, the contact pressure of the sliding contact unit, and thus about the wear of the sliding contacts. Furthermore, any deflection of the tilting arm outside of specifications can be detected. Irregularities in the rail system – e.g., improperly installed rail joints – are also identified.

[0024] According to an exemplary embodiment, the rotation angle sensor is arranged in the installation space (either in the boom section or in the installation section) of the tilting arm, wherein the mounting base has a (particularly immovable and rigid) reference element that extends at least partially from the pivot axis alongside the installation space. The rotation angle sensor is configured to determine a rotation angle relative to the reference element. Alternatively, the reference element is arranged in the installation space (either in the boom section or in the installation section) of the tilting arm, wherein the mounting base has the rotation angle sensor that extends (particularly with the excitation coils and receiver coils described below) at least partially from the pivot axis alongside the installation space.

[0025] According to an exemplary embodiment, the rotary angle sensor comprises an excitation coil. The reference element is made of an electrically conductive material, in particular metal (for example, a foil-like metal, e.g., a copper foil), wherein the excitation coil and the reference element are arranged relative to each other such that, depending on the position of the reference element relative to the excitation coil, a specific voltage can be detected in an excitation coil, in particular in two excitation coils, of the rotary angle sensor, which is indicative of a rotation angle of the tilting arm.

[0026] The reference element is configured to define fixed or known reference points or values ​​for the coils of the rotary angle sensor.

[0027] With the described embodiment, the angle measuring system integrated in the installation space of the tilting arm can monitor the angle of rotation. This provides information about the position of the sliding contact units and about the changing contact pressure and, for example, the wear of the carbon brushes, since the wear height decreases over time, which in turn leads to changes in position or angle. An advantage of the present invention is that the principle of inductive position detection can be implemented with an excitation coil for generating an alternating magnetic field and two receiver coils for measuring the voltage ratio proportional to the target position, using a metallic reference element, e.g., a thin copper foil, as the reference point.

[0028] According to another exemplary embodiment, the rotary angle sensor comprises a sensor board on which at least one excitation coil and / or receiver coil is mounted. The sensor board is detachably attached to the installation section. The sensor board is a sensor circuit board (PCB) configured to serve as a mounting platform for various sensor components and associated electronic circuits. By installing the sensor board in the installation space, the sensor board, with its excitation coils and receiver coils, moves relative to the reference element, which is attached to the mounting base, particularly to the pivot axis. The reference element, for example, a metallic body (target) in the mounting base, serves as the reference point for the measurement. This enables inductive position detection.An excitation coil on the circuit board generates an alternating magnetic field which, depending on the position of a metallic target or reference element, induces different voltages in two receiver coils. The voltage ratio is proportional to the target position of the reference element.

[0029] According to another exemplary embodiment, the current collector unit has a shielding element arranged on a surface of the mounting base, with the reference element being arranged on the shielding element so that a magnetic field induced by the excitation coil can be shielded into the mounting base. The current collector units are typically arranged in a confined space due to the spacing of the power supply rails. To prevent the respective sensors from interfering with each other, the shielding element minimizes the electromagnetic radiation induced by the measurement itself. Interference affecting the respective measurement is thus minimized.

[0030] The shielding element can be designed as a metallic body (e.g., thin metal foil). The shielding element can, for example, be positioned on the opposite side of the metallic reference element at the mounting base. In particular, a housing can be provided to enclose the excitation coils.

[0031] According to another exemplary embodiment, the current collector system includes a frequency control element designed to control the frequency of the excitation coil (which may be part of a resonant circuit), so that the excitation coil can generate a magnetic field with a predetermined frequency that can be used to determine the position of the reference element. The ratio of, for example, the amplitudes of two receiving coils (sine and cosine) changes depending on the position of the reference element. The excitation coil is accordingly coupled to the frequency control element.

[0032] Due to the close proximity of inductive position sensors (rotary angle sensors) and their induction coils to each other (especially between the individual current collector units), there is a mutual interference of the alternating magnetic fields generated by the inductive position sensors. To prevent this, the magnetic fields (especially from the individual excitation coils) can be minimized or eliminated by placing the shielding element, particularly between two rotary angle sensors and / or two current collector units. For example, electrically conductive metallic plates / films can be inserted between two rotary angle sensors as a shielding element.

[0033] Similarly, a ferrite material (e.g. in the form of a foil) can be used as a shielding element to deflect the field lines.

[0034] Furthermore, the rotation angle sensors of adjacent current collector units can be operated with different frequencies for the alternating magnetic fields, i.e., for the excitation coils. For example, two different frequencies can be used for adjacent rotation angle sensors. The excitation coil and the frequency control element of one current collector unit are coupled such that a predetermined frequency (fl) of the generated magnetic field can be used to determine the rotation angle, thus determining the position of the reference element and, consequently, the rotation angles. The excitation coil and the frequency control element of another adjacent current collector unit are coupled such that a different predetermined frequency (f2) of the generated magnetic field can be used to determine the rotation angle, thus determining the position of the reference element and, consequently, the rotation angles.The frequency control elements of adjacent rotary angle sensors therefore do not evaluate the same frequency (e.g., in the case of four current collector units arranged side by side).

[0035] Rotation angle sensor 1. Current collector unit =fl,

[0036] Rotation angle sensor 2nd current collector unit =f2,

[0037] Rotation angle sensor 3. Current collector unit =fl,

[0038] Rotation angle sensor 4. Current collector unit =f2, etc.)

[0039] However, any number of frequencies can be assigned to one or more rotary angle sensors. This also reduces mutual interference without the need for a shielding element.

[0040] According to another exemplary embodiment, the sensor system includes a position sensor, in particular an accelerometer, configured to determine the position of the sliding contact unit relative to the conductor rail, i.e., the position of the connecting arm relative to the mounting base. The position of the connecting arm relative to the mounting base indicates a change in the vertical displacement of the conductor rail or the contact pressure between the sliding contact or the sliding contact unit and the conductor rail. The position sensor is configured to detect and measure the linear or angular position of the tilting arm relative to a reference point or a coordinate system. The position sensor can, for example, be located in the installation space of the tilting arm, such as on the sensor board. Rail transitions of the rail system can be monitored using the position sensor.Furthermore, vibrations at rail crossings can be detected. Based on the detection of the tilting arm's position, it can be determined, for example, whether the current collector unit is installed incorrectly, e.g., at an angle. According to one exemplary embodiment, the current collector unit has a contact spring arranged between the base support and the sliding contact carrier, the contact spring generating a contact force to press the sliding contact carrier against the conductor rail. According to another exemplary embodiment, the contact spring is arranged, in particular, between the tilting arm and the mounting foot. The contact spring generates the necessary contact pressure of the sliding contacts on the conductor rail. The contact pressure influences the wear of the sliding contacts; that is, higher contact pressure means higher wear.

[0041] The clamping spring is a compression or tension spring configured to apply a spring force to the tilting arm or the translationally displaceable connecting arm. Examples of clamping springs include a coil spring, a leaf spring, or a similar resilient element that exerts a spring force. The clamping spring can be positioned, for example, between the base support or mounting foot and the boom section, thus functioning as a compression spring. Alternatively, the clamping spring can also be positioned between the base support or mounting foot and the installation section, thus functioning as a tension spring. Furthermore, the clamping spring can be positioned on the pivot axis and function as a torsion spring to preload the tilting arm.

[0042] According to an exemplary embodiment, the sensor system includes a spring force sensor configured to measure the spring force of the contact spring, in particular the changes in spring force over time. The spring force is a parameter indicative of a change in the contact pressure between the sliding contact or sliding contact unit and the conductor rail. Furthermore, the measured spring force is a parameter indicative of the position of the sliding contact unit relative to the conductor rail, since the position of the sliding contact unit can be inferred from the magnitude of the spring force. Examples of a spring force sensor include a load cell, a force-resistance sensor, a pressure sensor, or a similar force measuring device.

[0043] The spring force sensor is used primarily to monitor the compressive / tensile force of the pressure spring. By using the spring force sensor, for example, material fatigue and breakage of the pressure spring can be detected. Furthermore, deviations of the tilting arm outside of specifications, as well as irregularities in the rail system, such as improperly installed rail transitions, can be detected.

[0044] According to one exemplary embodiment, the spring force sensor is arranged in the mounting base or the tilting arm and coupled to the clamping spring. Integrating the sensor in the mounting base offers the advantage of shorter cable runs and a smaller distance between the spring force sensor and the power supply. Furthermore, the dynamic loads on the power supply cable are lower than in the tilting arm.

[0045] According to an exemplary embodiment, the current collector unit has an electric actuator which moves the connecting arm relative to the mounting base in order to generate a contact force for pressing the sliding contact carrier against the conductor rail. The electric actuator can also function as part of the sensor system, since a change in the contact pressure during the movement of the current collector unit generates a movement of the connecting arm, which in turn can be measured as a change in the drive torque in the electric actuator.

[0046] According to an exemplary embodiment of the current collector system, it includes an electronics box, which is, for example, attached to the mounting bracket. The electronics box includes a power unit, wherein the power unit has a current input, which is coupled to the sliding contact unit for drawing current from the conductor rail, and a current output, which can be coupled to the load. The power unit is configured to partially divert or loop through the current from the conductor rail for the load. The power unit is configured, for example, to control current transfer between the conductor rail and an electrical load unit of the current collector system.The electronics box is electrically coupled to the sensor system of a current collector unit mounted on the mounting bracket in such a way that the sensor system can be supplied with electrical power from the conductor rail and signal exchange of sensor signals is possible. The electronics box serves to house and protect various electronic components, circuits, or subsystems. For example, the electronics box contains current transformers that convert the current from the conductor rail into the necessary voltage or current for the sensor system. Furthermore, communication elements, such as signal emitters or antennas, can be integrated into the electronics box. The term "loop-through" refers to the process of passing current from (especially one phase of) the conductor rail to a load. The load then draws the current required for its operation.Due to the current being looped through the control unit, various measurements can be performed. Additionally or alternatively, an additional current portion can be drawn from one phase of the conductor rail to supply electrical loads within the current collector system.

[0047] According to one exemplary embodiment, the current collector unit has a connecting cable that couples the electronics box to the sensor system. In another exemplary embodiment, the sliding contact carrier is pivotably mounted on the base carrier by means of a hollow shaft, with the connecting cable being guided through the hollow shaft. The use of a hollow shaft for cable guidance minimizes the stress on the connecting cable during rotational movements. The hollow shaft consists, for example, of a sleeve, particularly made of metal or plastic, and forms a sliding bearing sleeve around which a bearing element of the tilting arm conforms.

[0048] According to an exemplary embodiment, the connecting cable has a conductive plug which can be inserted into the hollow shaft as a socket and, in particular, locked into place. This allows the sliding contact carrier to be detachably attached to the base carrier and easily connected to the necessary power supply and data transmission. In particular, the connecting arm or tilting arm can also be detachably arranged on the mounting base and likewise easily connected to a necessary power supply. This, in particular, enables a power supply for the sensor board in the mounting base or in the connecting arm.

[0049] According to another exemplary embodiment, the electronics box can be detachably mounted on the base carrier. This allows for easy replacement of the entire electronics box, minimizing downtime of the current collector unit, for example, during maintenance. Furthermore, the base carrier can be detachably mounted on the mounting bracket. Alternatively, the base carrier and the mounting bracket can also be integrally formed as a single piece.

[0050] According to another exemplary embodiment, the base carrier has a connecting board with sliding contacts for contacting the electronics box, wherein the electronics box has electrical contact elements, in particular spring-loaded contact pins. The electrical contact elements are designed such that when the electronics box is mounted on the base carrier, the electrical contact elements are connected to the sliding contacts of the connecting board.

[0051] According to another exemplary embodiment, the connecting cable is electrically coupled to the connecting board. The connecting cable supplies the sensor board with power and the electronics box with measurement data from the sensor system. The connecting cable is guided, for example, through the hollow shaft of the sensor board in a strain-relieved manner and mounted at the connector of the base. Guiding the cable through the hollow shaft has the advantage of minimizing stress on the cable during rotational movements. The electrical contact elements form a sliding contact with the connecting board, which in turn is attached to the base carrier. The electronics box can, for example, be slid onto the base carrier using a snap-fit ​​connection, so that the spring-loaded contacts of the electronics box make contact with the sliding surfaces of the connecting board.Therefore, no manual connection is necessary; instead, the electronics box automatically enables electrical contact during the mounting process.

[0052] According to another exemplary embodiment, the current collector unit is movable along the rail system in a main direction of travel, with the sliding contact carrier being arranged in front of the electronics box in this main direction. The main direction of travel of a current collector unit along the rail system is the direction in which the current collector unit can only move, or in which direction the current collector unit moves predominantly, i.e., over 50%, and in particular over 70%, of its movements. It should be noted that the embodiments described here represent only a limited selection of possible embodiments of the invention. It is possible to combine the features of individual embodiments in a suitable manner, so that a multitude of different embodiments are to be considered obviously disclosed to a person skilled in the art with the embodiments explicitly described here.In particular, some embodiments of the invention are described by apparatus claims and other embodiments of the invention by method claims. However, it will immediately become clear to the person skilled in the art upon reading this application that, unless explicitly stated otherwise, in addition to a combination of features belonging to one type of subject matter of the invention, any combination of features belonging to different types of subject matter of the invention is also possible.

[0053] Brief description of the drawings

[0054] For further explanation and better understanding of the present invention, exemplary embodiments are described in more detail below with reference to the accompanying drawings. These show:

[0055] Fig. 1 shows a schematic representation of a current collector unit on a rail system according to an exemplary embodiment of the present invention.

[0056] Fig. 2 shows a schematic enlarged representation of a receiving foot with a tilting arm from Fig. 1.

[0057] Fig. 3 shows a schematic representation of a current collector system, wherein two or more current collector units according to the invention are attached to a mounting bracket, according to an exemplary embodiment of the present invention.

[0058] Fig. 4 shows a schematic representation of a current collector unit with a rotary angle sensor according to an exemplary embodiment of the present invention.

[0059] Fig. 5 shows a schematic representation of a current collector unit with a shielding element according to an exemplary embodiment of the present invention.

[0060] Fig. 6 shows a schematic representation of a sensor board with excitation coil and receiver coils according to an exemplary embodiment of the present invention.

[0061] Fig. 7 shows a schematic representation of a current collector unit on a rail system, in which a connecting cable and a hollow axle are shown at the receiving base, according to an exemplary embodiment of the present invention.

[0062] Fig. 8 shows a schematic representation of a current collector unit on a rail system, in which a plug connection for the connecting cable is shown, according to an exemplary embodiment of the present invention.

[0063] Fig. 9 shows a schematic representation of a plug connection for the connecting cable according to an exemplary embodiment of the present invention. Fig. 10 shows a schematic representation of a current collector unit with a connecting board, according to an exemplary embodiment of the present invention.

[0064] Fig. 11 shows a bottom view of the current collector unit from Fig. 10 with a connecting board, according to an exemplary embodiment of the present invention.

[0065] Fig. 12 shows a schematic representation of a locking plate as a base carrier for attachment to a mounting bracket, according to an exemplary embodiment of the present invention.

[0066] Fig. 13 shows a schematic bottom view of a current collector unit with a locking plate from Fig. 12 according to an exemplary embodiment of the present invention.

[0067] Fig. 14 shows a schematic representation in which the connection of the current collector unit with the mounting plate is shown, according to an exemplary embodiment of the present invention.

[0068] Detailed of example

[0069] Identical or similar components in different figures are identified by the same reference numbers. The representations in the figures are schematic.

[0070] Fig. 1 shows a current collector unit 100 on a rail system 150 according to an exemplary embodiment of the present invention.

[0071] Fig. 2 shows a schematic enlarged view of a receiving foot 105 with a tilting arm 106 from Fig. 1. The current collector unit 100 is designed for current transmission between a rail system 150 with conductor rail 151 and an electrical load 160. The current collector unit 100 has a sliding contact carrier 104 with a sliding contact unit 102, which can be coupled to form a sliding contact with the conductor rail 151, and a sensor system 150, which is designed to measure the position of the sliding contact unit relative to the conductor rail.

[0072] The current collector unit 100 has a mounting bracket 300 by means of which the current collector unit 100 can be movably coupled to the rail system 150. The current collector unit 100 is attached to the mounting bracket 300 by means of a base bracket 101. Furthermore, electrical loads 160 can be attached to the mounting bracket 300.

[0073] The current collector unit 100 is designed to travel along a rail system 150, which is arranged, for example, on the floor, along a side wall or along the roof of a production hall.

[0074] The current collector unit 100 is configured to draw electrical current from the conductor rail 151 of the rail system 150 and supply the current to an electrical consumer 160, such as a motor of a vehicle or a production system in a manufacturing hall, a power supply unit in an electric vehicle, a transport system in a manufacturing hall, or in logistics applications, such as in a high-bay warehouse. Furthermore, current is drawn along the rail system 150 to drive the current collector unit 100.

[0075] The sliding contact unit 102 forms a current collector head configured to establish and maintain a sliding electrical contact with the conductor rail 151 in order to collect electrical current from the conductor rail 151. The sliding contact unit 102 in Fig. 1 carries two sliding contacts 103. These are positioned on a pivotable rocker arm 112, which is pre-tensioned by a rocker spring 113 to compensate for unevenness.

[0076] The sliding contact carrier 104 serves as a support structure for the sliding contact unit 102. In particular, the sliding contact carrier 104 is positioned between the base carrier and the sliding line 151. The sensor system 120 is arranged on the sliding contact carrier 104.

[0077] The sensor system 120 measures parameters or physical quantities that are indicative of the position of the sliding contact unit 102 relative to the sliding line 151. A measurement of the position or a change in the position is also indicative of a change in the contact pressure between the sliding contact unit 102 and the sliding line 151.

[0078] The sliding contact carrier 104 has a mounting foot 105 attached to the base carrier 101 and a tilting arm 106 which is movably attached to the mounting foot 105 between the base carrier 101 and the sliding line 151, with the sliding contact unit 102 being attached to the tilting arm 106.

[0079] The tilting arm 106 is pivotably attached to the mounting base 105 about a pivot axis 107. The tilting arm 106, or pivoting arm, is configured such that it allows a rotational or tilting movement of the sliding contact unit 102 relative to the mounting base 105 about a pivot axis 107, thus generating a corresponding contact pressure between the sliding contact unit 102 and the conductor rail 151. The pivot axis 107 is specifically designed perpendicular to the main direction of movement 110 of the current collector unit 100 along the rail system 150. The tilting arm 106 has a boom section 108 which extends from a pivot axis 107 at the mounting foot 105 to the sliding contact unit 102, and an installation section 109 which extends from the pivot axis 107 at the mounting foot 105 to a free end, in particular from the pivot axis 107 in the opposite direction to the boom section 108.In the exemplary illustration, installation section 109 has an installation space for arranging functional units, in particular a sensor board 124 for processing the sensor data of the sensor system 120. The installation space can also be formed in the boom section 108.

[0080] The sensor system 120 in Fig. 1 and Fig. 2 has a rotary angle sensor 121, which is configured to measure a swivel angle o of the tilting arm 106 relative to the mounting foot 105, in particular to measure the change in the swivel angle over time. The swivel angle o forms a parameter so that a position of the sliding contact unit 102 relative to the sliding line 151 can be measured.

[0081] The rotation angle sensor 121 is arranged in the installation section 109 of the tilting arm 106, wherein the mounting base 105 has a reference element 123 which extends from the pivot axis 107 at least partially next to the installation space or, in the illustrated example, next to the installation section 109. The rotation angle sensor 121 is configured to determine a rotation angle o relative to the reference element 123. The rotation angle sensor 121 has an excitation coil 122 for generating a magnetic field. The reference element 123 is made of a conductive, for example, metallic material, wherein the excitation coil 122 and the reference element 123 are arranged relative to each other such that, depending on the position of the reference element 123 relative to the excitation coil 122, a specific voltage can be detected in the two receiver coils 127 shown, which is indicative of a rotation angle α of the tilting arm 106.

[0082] The reference element 123 is configured to define fixed or known reference points or values ​​for a scanning or measuring system. Examples of reference elements 123 are optical markers, magnetic markers, or similar detectable elements used for calibration or position determination.

[0083] According to another exemplary embodiment, the sensor system 120 comprises a position sensor 125, in particular an accelerometer, which is configured to determine the position of the connecting arm relative to the mounting base 105. The position of the connecting arm relative to the mounting base 105 is indicative of a change in the contact pressure between the sliding contact unit 102 and the conductor rail 151. The position sensor 125 is configured to detect and measure the linear or angular position of the tilting arm 106 relative to a reference point or a coordinate system. The position sensor 125 is arranged in the installation section 109 of the tilting arm 106, for example, on the sensor board 124.

[0084] The current collector unit 100 has a contact spring 111, which is arranged between the base carrier 101 and the connecting arm, wherein the contact spring 111 generates a contact force Fp for pressing the sliding contact carrier 104 against the conductor rail 151. The contact spring 111 is arranged between the tilting arm 106 and the mounting foot 105. The contact spring 111 generates the necessary contact pressure Fp of the sliding contact unit 102 against the conductor rail 151. In the embodiment of Fig. 1, the contact spring 111 is a compression spring. The sensor system 120 has a spring force sensor 126, which is configured to measure the spring force of the contact spring 111, in particular the change in the spring force over time, wherein the spring force is an indicative parameter for a position or change in position of the sliding contact unit 102 relative to the conductor rail 151.A corresponding change in position is indicative of a change in the contact pressure Fp between the sliding contact unit 102 and the sliding line 151. The spring force sensor 126 is used, in particular, to monitor the compressive / tensile force of the contact spring 111. The spring force sensor 126 is arranged in the mounting base 105 and coupled to the contact spring 111.

[0085] The current collector unit 100 further comprises an electronics box 130 in which current transmission elements 131, such as the power unit, are arranged. These elements are configured for looping through, measuring, and / or controlling current transmission between the conductor rail 151 and the electrical consumer unit of the sensor system 120. The electronics box 130 is attached to the mounting bracket 300 (see Fig. 3). The electronics box 130 is also supplied with power from the conductor rail 151. Furthermore, the electronics box 130 is electrically coupled to the sensor system 120 such that the sensor system 120 can be supplied with electrical power from the conductor rail 151 and signal exchange of sensor signals is possible. The electronics box 130 serves to house and protect various electronic components, circuits, or subsystems.

[0086] The current collector unit 100 is movable along the rail system 150 in a main direction of travel 110, with the sliding contact carrier 104 being arranged in front of the electronics box 130 in the main direction of travel 110. The power supply elements 131 are connected to the conductor rail 151 via a connecting line 132. Furthermore, the electrical consumers 160 are supplied with power from the electronics box 130 via a connecting line 161.

[0087] Fig. 3 shows a schematic representation of a current collector system, wherein several current collector units 100, 100', 100" according to the invention are coupled to the rail system 150 on a mounting bracket 300. The current collector units 100, 100', 100" are designed to travel along a rail system 150, which is arranged, for example, on the floor, along a side wall, or along the roof of a production hall. The current collector units 100, 100', 100" are configured such that they draw electrical current from the conductor rail 151 of the rail system 150 and supply the current to an electrical load 160, such as a motor of a vehicle or a production system in a production hall, a power supply unit in an electric vehicle, or a transport system in a production hall. Current is also drawn to drive the current collector unit 100 along the rail system 150.

[0088] The mounting bracket 300 is used in particular to attach the base carrier 101 of a current collector unit 100. The mounting bracket 300 also serves as a mounting platform for other common components of the current collector units 100, 100', 100", such as a common drive motor, and also for the consumer 160.

[0089] The mounting bracket 300, for example, consists of a stable support that couples the current collector units 100, 100', 100" to the rail system 150 in a force-transmitting and movable manner. The mounting bracket 300 has, for example, rollers or wheels by means of which the mounting bracket 300 can move along the rail system 150. Furthermore, the mounting bracket 300 can, for example, have a corresponding (electric) drive motor that generates a driving force to drive the current collector units 100, 100', 100" along the rail system 150. In particular, the drive motor can drive the rollers described above.

[0090] Fig. 4 shows a schematic representation of a current collector unit 100 with a rotary angle sensor 121 and Fig. 5 shows a shielding element 501 for the rotary angle sensor 121 according to an exemplary embodiment of the present invention.

[0091] In the illustrated embodiment, an integrated angle measuring system is arranged on the installation section 109 of the tilting arm 106 to monitor the rotation angle o. This provides information about the position of the sliding contact unit 102 relative to the conductor rail 151 and thus, for example, also about the changing contact pressure and, for example, wear of the sliding contacts 103, since the wear height decreases over time, which in turn leads to changes in the angle. The rotation angle sensor 121 operates on the principle of inductive position detection with an excitation coil 122 to generate an alternating magnetic field and to measure the voltage ratio proportional to the target position. This can be implemented with, for example, two receiver coils 127 and a conductive reference element 123, such as a thin metal foil, as a reference point.

[0092] The current collector unit 100 has a shielding element 501, which is arranged on a surface of the mounting base 105, so that a magnetic field induced by the excitation coil 122 can be shielded in the mounting base 105. The shielding element 501 can be designed as a metallic body (e.g., thin metal foil). The shielding element 501 can, for example, be arranged on the opposite side of the metallic reference element 12 on the mounting base 105. Fig. 6 shows a schematic representation of a sensor board 124 with a rotary angle sensor 121 with excitation coil 122 and two receiver coils 127. Furthermore, other sensors (e.g., position sensors) of the sensor system 120 (e.g., as semiconductors) can also be arranged on the sensor board 124. The sensor board 124 can be detachably attached to the installation space, e.g., in the boom section 128 or installation section 109. The sensor board 124 is a sensor circuit board (PCB).By installing the sensor board 124 in the installation space, the sensor board 124 with its excitation coils 122 moves relative to the reference element 123, which is attached to the mounting base 105, in particular to the pivot axis 107.

[0093] The reference element 123, for example a metallic body (target) in the mounting base 105, serves as a reference point for the measurement. This enables inductive position detection. An excitation coil 122 on the sensor board 124 generates an alternating magnetic field which induces different voltages in two receiver coils 127 depending on the position of the reference element 123.

[0094] Fig. 7 shows a schematic representation of a current collector unit 100 on a rail system 150, in which a connecting cable 701 and a hollow axle 702 are shown at the mounting base. The connecting cable 701 couples the electronics box 130 with the sensor system 120 to exchange electrical energy and / or sensor signals. The sliding contact carrier 104 is pivotably arranged on the base carrier 101 by means of the hollow axle 702 with its mounting base 105. The connecting cable 701 is guided through the hollow axle 702. The use of a hollow axle 702 for cable guidance minimizes the stress on the connecting cable during rotational movements. The hollow axle 702 consists, for example, of a sleeve, in particular made of metal or plastic, and forms a sliding bearing sleeve, against which a bearing element of the tilting arm 106 conforms.

[0095] Fig. 8 shows a schematic representation of a current collector unit 100 on a rail system 150, in which a plug connection for the connecting cable 701 is shown. Fig. 9 shows a more detailed schematic representation of such a plug connection. The connecting cable 701 has a current-conducting plug 801, which can be inserted into the hollow shaft 702 as a plug socket and, in particular, locked into place. Thus, the sliding contact carrier 104 can be detachably attached to the base carrier 101 and easily connected to the necessary power supply. In particular, the connecting arm or tilting arm 106 can also be detachably arranged on the mounting foot 105 and likewise easily connected to a necessary power supply.

[0096] Fig. 10 shows a schematic representation of a current collector unit 100 with a connecting board 1001. Fig. 11 shows a bottom view of the current collector unit 100 from Fig. 10 with a connecting board 1001. The electronics box 130 is arranged on the mounting bracket 300. The base bracket 101 has the connecting board 1001 with sliding contacts 1101 for contacting the electronics box 130, wherein the electronics box 130 has electrical contact elements, in particular spring-loaded contact pins. The base bracket 101 of a current collector unit 100 to be mounted can be detachably attached to the mounting bracket 300, for example by means of a snap-fit / plug connection. At the same time, the electrical contact elements of the electronics box 130 are designed such that when the current collector unit 100 is attached to the mounting bracket 300, the electrical contact elements are connected to the sliding contacts 1101 of the connecting board 1001.The connecting cable 701 is electrically coupled to the connecting board 1001. Alternatively, the connecting cable 701 can be directly coupled to the electronics box, e.g., to the power unit. The connecting cable 701 supplies the sensor board 124 with power and the electronics box 130 with measurement data from the sensor system 120. The connecting cable 701 is, for example, guided through the hollow shaft 702 on the sensor board 124 with strain relief, or connected to the hollow shaft 702, which functions as a connector socket. The current-conducting connector 801 can be locked into the connector socket and leads another part of the connecting cable 701 to the electronics box 130. The electrical contact elements of the electronics box 130 form sliding contacts with the connecting board 1001.

[0097] Fig. 12 shows a schematic representation of a locking plate 1201 for attaching the base support 101 to the mounting bracket 300. The hollow axle 702, for example, is integrally formed on the base support 101. The base support 101 can, for example, be manufactured as a molded plastic part.

[0098] Fig. 13 shows a schematic bottom view of a current collector unit 100 with a locking plate 1201 as part of the base carrier 101. The current collector unit 100 can thus be slid onto the mounting carrier 300 with a snap-fit ​​connection, so that simultaneously the spring-loaded contacts of the electronic box 130 make contact with the sliding contacts 1101 of the connecting board 1001. Therefore, no manual connection is necessary; instead, the electronic box 130 automatically establishes electrical contact during the mounting process. The locking plate 1101 can be a molded part that, for example, integrally incorporates the hollow shaft 702. Furthermore, the locking plate has a locking element 1202, which is elastically deformable.The locking element can be pre-tensioned during movement of the base carrier to the predetermined position on the mounting carrier 300 and, when the current collector unit 100 is in the predetermined position, snaps into a receiving opening of the mounting carrier 300 to fix it in place. In the predetermined position, the contact pins of the electronics box 130 are also electrically coupled to the sliding contacts 1101 of the connecting board 1001.

[0099] Fig. 14 shows a schematic representation of a current collector system with a current collector unit 100, a mounting bracket 300, and an electronic box 130. The current collector system in Fig. 14 corresponds to that in Fig. 1, with the connection of the current collector unit 100 to the mounting plate 300 shown more clearly. In the intended position of the current collector unit 100, the locking elements 1202 engage with the section of the mounting bracket 300 that forms a locking plate 1201. In this position, the connecting board 1001 is inserted into the electronic box 130, and a sliding contact with corresponding contacts in the electronic box 130 is established. This provides a simple connection mechanism in which the current collector unit 100 can be easily mounted on the mounting bracket 300 and electrically connected to the electronic box 130.

[0100] It should also be noted that "comprehensive" does not exclude any other elements or steps, and "a" or "an" does not exclude a plurality. Furthermore, it should be noted that features or steps described with reference to one of the above embodiments may also be used in combination with other features or steps of other embodiments described above. Reference numerals in the claims are not to be considered as limitations. List of reference numerals:

[0101] 100 current collector unit 132 connecting cable with

[0102] 101 Base carrier conductor rail

[0103] 102 sliding contact unit 150 rail system

[0104] 103 Sliding contact 151 Sliding line

[0105] 104 sliding contact carriers 160 electrical consumers

[0106] 105 Mounting foot 161 Connecting cable with

[0107] 106 Tilting arm consumer

[0108] 107 Swivel axis

[0109] 108 Boom section 300 Mounting bracket

[0110] 109 Installation section

[0111] 110 Main direction of movement 501 Shielding element

[0112] 111 Pressure spring 701 Connecting cable

[0113] 112 rocker 702 hollow axle

[0114] 113 Rocker spring

[0115] 801 electrically conductive plug

[0116] 120 Sensor system 1001 Connection board

[0117] 121 Rotary angle sensor 1101 Sliding contact

[0118] 122 Excitation coil 1201 Latching plate

[0119] 123 Reference elements 1202 Snap-in element

[0120] 124 Sensor board

[0121] 125 Position sensor Fp On pressing force

[0122] 126 Spring force sensor o Angle of rotation

[0123] 127 Receiver coil

[0124] 130 electronic box

[0125] 131 Power transmission element

Claims

Patent claims 1. Current collector unit (100) for current transmission between a rail system (150) with conductor rail (151) and an electrical consumer (160), the current collector unit (100) comprising a sliding contact carrier (104) with a sliding contact unit (102) which can be coupled to form a sliding contact with the conductor rail (151), a sensor system (120) which is configured to measure a position of the sliding contact unit (102) relative to the conductor rail (151).

2. Current collector unit (100) according to claim 1, wherein the sliding contact carrier (104) has a receiving foot (105) and a tilting arm (106) which is pivotably attached to the receiving foot (105) about a pivot axis (107), wherein the sliding contact unit (102) is attached to the tilting arm (106).

3. Current collector unit (100) according to claim 2, wherein the tilting arm (106) has a cantilever section (108) which extends from a pivot axis (107) at the receiving foot (105) to the sliding contact unit (102).

4. Current collector unit (100) according to claim 3, wherein the boom section (108) has an installation space for arranging functional units, in particular a sensor board (124) for processing the sensor data of the sensor system (120), and / or wherein the tilting arm (106) has an installation section (109) which extends from the pivot axis (107) at the receiving foot (105) to a free end, wherein the installation section (109) has the installation space for arranging functional units, in particular a sensor board (124) for processing the sensor data of the sensor system (120).

5. Current collector unit (100) according to one of claims 2 to 4, wherein the sensor system (120) has a rotation angle sensor (121) which is configured to measure a rotation angle (o) of the tilting arm (106) relative to the receiving foot (105), in particular to measure the change over time of the swivel angle, wherein the swivel angle is indicative of a position of the sliding contact unit (102) relative to the sliding line (151).

6. Current collector unit (100) according to claim 4 or 5, wherein the rotation angle sensor (121) is arranged in the installation space of the tilting arm (106), wherein the receiving foot (105) has a reference element (123) which is arranged spaced apart from the pivot axis (107), wherein the rotation angle sensor (121) is configured to determine a rotation angle (o) of the tilting arm (106) relative to the reference element (123).

7. Current collector unit (100) according to claim 6, wherein the rotation angle sensor (121) has an excitation coil (122), wherein the reference element (123) is made of an electrically conductive material, in particular of metal, wherein the excitation coil (122) and the reference element (123) are arranged relative to each other such that, depending on the position of the reference element (123) relative to the excitation coil (122), a certain voltage can be detected in at least one receiver coil (127), in particular in two receiver coils (127), which is indicative of a rotation angle (o) of the tilting arm (106).

8. Current collector unit (100) according to claim 7, wherein the rotation angle sensor (121) has a frequency control element which is designed to control the frequency of the excitation coil (122) so that a magnetic field with a predetermined frequency can be generated with the excitation coil (121) which can be used to determine the position of the reference element (123).

9. Current collector unit (100) according to claim 7 or 8, wherein the rotary angle sensor (121) has a sensor board (124) on which the excitation coil (122) and / or receiver coil (127) is formed, wherein the sensor board (124) is in particular detachably attachable to the installation section (108).

10. Current collector unit (100) according to one of claims 6 to 9, further comprising a shielding element (501) which is arranged on a surface of the receiving base (105), wherein the reference element (123) is arranged on the shielding element (501) so that a magnetic field induced by the excitation coil (122) can be shielded in the receiving base (105).

11. Current collector unit (100) according to any one of claims 1 to 10, wherein the sensor system (120) comprises a position sensor (125), in particular an acceleration sensor, which is configured to determine a position of the sliding contact unit (102) relative to the conductor rail (151).

12. Current collector unit (100) according to any one of claims 1 to 11, further comprising a base carrier (101) to which the sliding contact carrier (104) is attached 13. Current collector unit (100) according to claim 12, wherein the sensor system (120) is arranged on the sliding contact carrier (104) and / or the base carrier (101).

14. Current collector unit (100) according to claim 13, further comprising a pressure spring (111) which is arranged between the base carrier (101) and the sliding contact carrier (104), wherein the pressure spring (111) generates a contact force (Fp) to press the sliding contact carrier (104) against the conductor rail (151).

15. Current collector unit (100) according to claim 14, wherein the clamping spring (111) is arranged between the connecting arm and the receiving foot (105).

16. Current collector unit (100) according to claim 14 or 15, wherein the sensor system (120) has a spring force sensor (126) configured to measure the spring force of the clamping spring (111), in particular the change of the spring force over time, wherein the spring force sensor (126) is arranged in the receiving foot (105) or in the tilting arm (106) and is coupled to the clamping spring (111).

17. Current collector system comprising at least one current collector unit (100) according to one of claims 1 to 16, a mounting bracket (300) on which the current collector unit (100) is arranged and on which the electrical consumer (160) can be attached, wherein the mounting bracket (300) can be moved and coupled to the rail system (150).

18. Current collector system according to claim 17, further comprising an electronics box (130), wherein the electronics box (130) is attached to the mounting bracket (300), wherein the electronics box (130) has a power unit, wherein the power unit has a current input which is coupled to the sliding contact unit (102) for drawing a current from the conductor rail (151), and a current output which can be coupled to the consumer (160), wherein the power unit is configured to partially divert or loop through the current from the conductor rail for the consumer (160).

19. Current collector system according to claim 18, wherein the power unit is electrically coupled to the sensor system (120) in such a way that the sensor system (120) can be supplied with electrical power from the conductor rail (151).

20. Current collector system according to claim 18 or 19, further comprising a connecting cable (701) which connects the electronics box (130) to the Sensor system (120) couples.

21. Current collector system according to claim 20, wherein the sliding contact carrier (104) is pivotably arranged on the base carrier (101) by means of a hollow shaft (702), wherein the connecting cable (701) is guided through the hollow shaft (702).

22. Current collector system according to claim 21, wherein the connecting cable (701) has a current-conducting plug (801) which can be inserted into the hollow shaft (702) as a plug socket and in particular can be locked in place.

23. Current collector system according to one of claims 18 to 22, wherein the electronics box (130) is detachably arranged on the mounting carrier (300).

24. Current collector system according to one of claims 18 to 23, wherein the base carrier (101) of the current collector unit (100) has a connecting board (1001) with sliding contacts for contacting the electronics box (130), wherein the electronics box (130) has electrical contact elements, in particular spring-loaded contact pins, wherein the electrical contact elements are designed such that when the base carrier (101) is attached to the mounting carrier (300) the electrical contact elements are connected to the sliding contacts of the connecting board (1001).

25. Current collector system according to one of claims 18 to 24, wherein the current collector system is movable in a main direction of travel along the rail system (150), wherein in the main direction of travel the sliding contact carrier (104) of the current collector unit (100) is arranged in front of the electronics box (130).

26. Method for current transmission between a rail system (150) with conductor rail (151) and an electrical consumer (160) with a current collector unit (100) according to one of claims 1 to 17, wherein the method includes the step of measuring the position of the sliding contact unit (102) relative to the conductor rail (151) by means of the sensor system (120).

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