Mechanical Float Rail Connector for Uneven-Terrain Power Transfer
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Solution Overview
Problem
Existing power systems for industrial machines face challenges in delivering electricity safely and maintaining connections while moving, especially in remote and uneven environments, and require infrastructure investments for hybrid or all-electric systems.
Innovation Solution
A dynamic energy transfer system with a rail connector assembly that includes a boom, arm, and contactor assembly, utilizing hydraulic and mechanical float couplings to maintain contact with conductor rails despite vertical undulations, allowing for quick deployment and retraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If overhead electricity-conducting lines are used to power industrial machines, then power delivery is reliable, but the system requires extensive infrastructure investment and is not practical for remote or uneven terrain
Solution Approach 1:
The patent extracts the power delivery function from fixed overhead infrastructure and relocates it to a mobile rail connector assembly that can move with the industrial machine. This eliminates the need for extensive overhead line infrastructure while maintaining reliable power delivery through direct contact with conductor rails.
Solution Approach 2:
The system transitions from static overhead lines to a dynamic mobile connector assembly that can extend, retract, and position itself to maintain contact with conductor rails. The boom assembly and arm assembly provide dynamic adaptation to terrain changes and machine movement, eliminating infrastructure rigidity.
2Adaptability or versatility
If a retractable arm system is used to engage electrical connectors, then deployment is flexible, but maintaining stable connection during movement on uneven terrain is difficult
Solution Approach 1:
The arm assembly incorporates dynamic positioning capabilities with actuators that continuously adjust the contactor assembly's position to maintain stable electrical connection. The system adapts to terrain variations and machine movement in real-time, preserving both flexibility and connection reliability.
Solution Approach 2:
The system employs feedback mechanisms through sensors and control systems that monitor the contactor assembly's position and connection status. This feedback enables automatic adjustments to maintain optimal contact with conductor rails, ensuring stable power transfer during movement on uneven terrain.
3Device complexity
If manual deployment of connector assembly is required, then system complexity is reduced, but deployment time and operator assistance requirements increase
Solution Approach 1:
The patent replaces manual mechanical deployment with automated hydraulic or electric actuators that control the boom and arm assemblies. This substitution reduces deployment time and eliminates the need for operator assistance while the control system manages the complexity through integrated control circuits.
Solution Approach 2:
The connector assembly is designed to deploy and position itself automatically using onboard actuators and control systems. The system performs self-service functions including extension, retraction, and positioning without requiring external operator intervention, thereby reducing deployment time while managing complexity through automation.
Data Source
AI summary
A rail connector assembly for an electrically powered mobile machine includes a boom assembly with a first end and a second end, an arm assembly movable between a stowed condition and a deployed condition, the arm assembly having a first end coupled to the boom, and a second end, and a contactor assembly coupled to the second end of the arm assembly. The assembly also includes a hydraulic system controlling movement of the rail connector assembly. The hydraulic system includes a plurality of hydraulic actuators, wherein a first hydraulic actuators of the plurality of hydraulic actuators includes a mechanical float coupling.