Boom and Trailing Arm Control for Dynamic Rail Power Connection

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Solution Overview

Problem

Existing power systems for industrial machines, such as overhead electricity-conducting lines, are not practical for remote and uneven environments, and there is a need for a control system that can quickly deploy or retract a connector assembly to safely deliver electricity to a moving industrial vehicle.

Innovation Solution

A control system for a mobile machine power system that includes an electronic control module with sensors and a rail connector assembly with a boom, an arm assembly, and a contactor assembly. The system generates commands to extend and retract the connector assembly, determines the presence of electrical energy along conductor rails using a continuity sensor, and securely connects the mobile machine to an electrically-conducting rail system for charging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If overhead electricity-conducting lines are used to power industrial machines, then power delivery is achieved, but the system becomes impractical for remote and uneven environments

Engineering Contradiction:

Improvepower deliveryVSAvoidadaptability to remote and uneven environments

Core Design Contradiction:

Use of energy by moving objectVSAdaptability or versatility

Solution Approach 1:

The connector assembly is designed with dynamic, movable components including a boom assembly with multiple articulated segments and a trailing arm assembly that can extend, retract, and articulate to adapt to varying terrain and positions of the mobile machine, enabling operation in remote and uneven environments

Inventive Principle:

Principle #15Dynamics

2Use of energy by moving object

If a retractable arm system is used to connect to roadside electrical conductors, then electrical connection is achieved, but the system lacks ease of connection and requires precise engagement

Engineering Contradiction:

Improveelectrical connectionVSAvoidease of connection

Core Design Contradiction:

Use of energy by moving objectVSEase of operation

Solution Approach 1:

The control system automatically controls the extension and retraction of the boom assembly and trailing arm assembly, and the engagement and disengagement of the contactor assembly with the conductor rails, eliminating the need for manual operation and precise manual engagement by the operator

Inventive Principle:

Principle #25Self-service

3Use of energy by moving object

If manual deployment of connector assembly is used, then connection is achieved, but it requires significant operator assistance and time

Engineering Contradiction:

Improveconnection capabilityVSAvoiddeployment time

Core Design Contradiction:

Use of energy by moving objectVSLoss of time

Solution Approach 1:

The control system replaces manual mechanical deployment with automated electronic control, where the control system receives operator input and automatically generates movement commands to operate the boom assembly, trailing arm assembly, and contactor assembly, significantly reducing deployment time and operator effort

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If continuity sensor is used to detect electrical energy, then safety is improved, but system complexity increases

Engineering Contradiction:

Improvesafety in electrical connectionVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The continuity sensor provides feedback to the control system about the presence of electrical energy along the conductor rails, enabling the control system to make informed decisions about when to engage or disengage the contactor assembly, ensuring safe operation

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The control system enables safe and efficient connection of a mobile machine to an electrically-conducting rail system, allowing for automated deployment and engagement of the connector assembly, continuous testing for electrical presence, and quick disengagement when necessary, thereby addressing the challenges of remote and uneven environments.

Implementation Method 1

determining a presence of electrical energy along the plurality of conductor rails using a continuity sensor connected to the contactor assembly

Methodology Applied

Scientific EffectElectrical conductivity detection: Conduction (electrical)

Data Source

PatentUS20250178442A1Boom and trailing arm control system for dynamic energy transfer

Publication Date: 2025.06.05 CATERPILLAR INC

AI summary

A boom and trailing arm control system includes an electronic control module, a plurality of sensors, and a rail connector assembly with a boom, an arm assembly, and a contactor assembly, the rail connector assembly configured to connect with a plurality of conductor rails. The control system also includes an input receiver for the electronic control module configured to receive an input to extend the rail connector assembly from a frame of a mobile machine. The electronic control module is configured to generate commands to extend the boom and arm assembly.