Elevated Power Rail Base With Nested Couplers for Uneven Haul Routes
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Solution Overview
Problem
Existing systems for providing electrical power to heavy work machines traveling on uneven or hilly terrain struggle to maintain a continuous connection due to steering deviations and unexpected changes in power rail position.
Innovation Solution
A modular support structure for power rails using barriers with nested couplers that adjust positioning in multiple dimensions, ensuring stable alignment and minimizing disconnections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If power rails are placed on uneven or hilly terrain, then the system can provide power to heavy work machines traveling on such terrain, but the connection becomes unstable and disconnections occur due to steering deviations and rail position changes
Solution Approach 1:
The barrier assembly incorporates nested couplers with degrees of freedom that allow dynamic adjustment to terrain variations. The inner coupler rotates about a first axis perpendicular to the barrier base, while the outer coupler rotates about a second axis parallel to the barrier base, enabling the power rail to adapt its position dynamically while maintaining stable electrical connection on uneven terrain
Solution Approach 2:
The coupling mechanism uses nested couplers where an inner coupler is positioned within an outer coupler. The inner coupler has a smaller diameter and provides rotation about the first axis, while the outer coupler has a larger diameter and provides rotation about the second axis, creating a nested structure that enables multi-axis adjustment for terrain adaptation
2Strength
If fixed rigid joints are used to connect barriers, then structural strength is improved, but the system cannot accommodate curvatures and slopes in the haul route
Solution Approach 1:
The nested coupler system replaces fixed rigid joints with dynamic, multi-degree-of-freedom connections. The inner coupler allows rotation about the first axis for accommodating curvatures, while the outer coupler allows rotation about the second axis for accommodating slopes, maintaining both strength and adaptability
Solution Approach 2:
The coupling mechanism introduces rotational degrees of freedom in multiple dimensions - the inner coupler rotates about an axis perpendicular to the barrier base, while the outer coupler rotates about an axis parallel to the base, adding dimensional flexibility to accommodate three-dimensional terrain variations
Data Source
AI summary
A modular structure supports elevated rail segments for delivering electrical power to a moving work machine, such as a hauler at a mining site. Opposite ends of a roadside barrier contain complementary tubular couplers arranged vertically, one having a first diameter supported by an arm and the other having a larger second diameter and a vertical slot. Couplers on adjacent barriers can be mated together concentrically along a central axis. The mated couplers help restrict longitudinal displacement, lateral displacement, slope change, and lateral rotation between adjacent barriers during placement. One barrier may be used as a temporary alignment structure to position barriers spaced alternatingly along a haul route for the work machine.