Deployable Power Rail Connector for Ground-Based Mining Power

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Solution Overview

Problem

Existing mining trucks configured to collect electrical power from overhead trolley lines are costly and complex to install and maintain, and there is a need for more efficient and cost-effective strategies to supply electric power to electric machinery in mining operations.

Innovation Solution

A power rail connector with a linkage system that adjusts from an extended, current-collecting configuration to a collapsed configuration, allowing for flexible electrical connection to an external power rail using a fold and lift joint mechanism, supported by a movable support arm and rail contactor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If an overhead trolley line system is used to supply electric power to mining trucks, then electric power can be supplied to enable continuous operation on uphill grades, but the installation and maintenance costs become expensive and complex

Engineering Contradiction:

Improveelectric power supplyVSAvoidtrolley system complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

Instead of having the mining truck reach upwardly and outwardly to contact an overhead trolley line, the invention inverts the approach by placing the power rail on the ground and having the collector mechanism contact it from above. This eliminates the need for overhead infrastructure while maintaining continuous power supply capability.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention extracts and eliminates the overhead trolley line infrastructure from the system, replacing it with a ground-based power rail. This removes the complex overhead support structure, wiring, and safety concerns associated with high-voltage overhead lines while preserving the essential function of continuous power supply.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If a mechanism is designed to reach upwardly and outwardly from a mining truck to electrically contact an overhead trolley line, then power collection is enabled, but installation and maintenance costs increase significantly

Engineering Contradiction:

Improvepower collection capabilityVSAvoidinstallation and maintenance cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention inverts the traditional trolley system configuration by placing the power conductor on the ground rather than overhead. The collector mechanism on the truck reaches downward to contact the ground-based power rail, which dramatically simplifies installation and maintenance while maintaining reliable power collection.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The ground-based power rail system uses simpler, more durable components that are easier and cheaper to replace if needed. The power rail itself can be standard electrical conduit or rail available off-the-shelf, eliminating the need for custom overhead infrastructure and reducing both initial installation cost and ongoing maintenance expenses.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Power

If an overhead trolley line system is implemented at a mine site, then electric power supply for mining trucks is enabled, but the installation cost becomes expensive

Engineering Contradiction:

Improveelectric power supply capacityVSAvoidinstallation cost

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

The invention removes the expensive overhead trolley line infrastructure from the system and replaces it with a ground-based power rail. This extraction of the overhead component eliminates the need for tall support structures, complex aerial wiring, and extensive safety clearances, dramatically reducing installation cost while preserving full power supply capacity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The ground-based power rail can serve multiple functions: it provides electrical power, defines a travel path for the mining trucks, and can be integrated with existing ground infrastructure. This multi-functionality reduces the need for separate infrastructure elements, lowering overall installation cost while maintaining high power supply capacity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12522078B2Deployable power rail connector for electric machine and method

Publication Date: 2026.01.13 CATERPILLAR INC

AI summary

A power rail connector for an electric power system in an electric machine includes a linkage having a lower link and an upper link, and a rail contactor coupled to the lower link and including electrical contacts positioned to electrically connect to a power rail. The linkage includes a fold joint, a lift joint, and a pivot, and is adjustable from an extended, current-collecting configuration to a collapsed configuration via rotation of the lower link relative to the upper link and rotation of the upper link relative to the pivot. Related machinery and methodology is also disclosed.