Multi-Tier Conductor Rod Interface for Stable Power Transfer
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Solution Overview
Problem
Existing systems for providing electrical power to heavy work machines, such as those used in mining and construction, face challenges in maintaining reliable connections and efficiently transferring high-voltage electrical power through conductive rods, leading to interruptions and inefficiencies.
Innovation Solution
A conductive rod system with a rigid outer tube and concentrically arranged tubular conductors separated by air and metallic rings, which provides a stable and efficient means of transferring electrical power and pneumatic control signals to work machines, ensuring continuous power supply and mechanical operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-tier interface with hydraulic or pneumatic cylinders is used to connect conductors to the vehicle, then the connection mechanism is simple, but the contactors pivot outwardly causing disconnection from roadside metal strips and interruptions in electrical power flow
Solution Approach 1:
The patent transitions from a single-tier interface to a multi-tiered interface structure. The first tier provides electrical connection through concentric conductive tubes, while the second tier provides pneumatic connection through separate conduits. This dimensional separation allows independent optimization of each connection type and eliminates the pivoting motion that caused disconnection in single-tier systems.
Solution Approach 2:
The interface is segmented into multiple independent tiers: electrical connectors are separated from pneumatic connectors. The electrical connection system uses nested concentric tubes that remain axially aligned, while pneumatic connections use separate conduits. This segmentation prevents the mechanical interference and pivoting issues experienced in integrated single-tier systems.
2Quantity of substance
If concentric conductive tubes are used within the rod, then multiple electrical conductors can be housed efficiently, but the structure becomes more complex and difficult to manufacture
Solution Approach 1:
The patent employs nested concentric conductive tubes where smaller diameter tubes are positioned inside larger diameter tubes. This nesting arrangement efficiently houses multiple electrical conductors within the limited cross-sectional space of the rod, maximizing conductor capacity while maintaining a compact external diameter.
Solution Approach 2:
Different regions of the rod structure are assigned different functions: the concentric tubes provide electrical conduction, while separate conduits provide pneumatic pathways. This local differentiation allows each component to be optimized for its specific function, simplifying manufacturing by allowing independent fabrication and assembly of electrical and pneumatic systems.
3Volume of moving object
If the interface accommodates both electrical power and pneumatic controls in a cylindrical rod, then space is efficiently utilized, but the structural complexity increases significantly
Solution Approach 1:
The patent separates electrical and pneumatic functions into different spatial dimensions and tiers. Electrical conductors are arranged concentrically around the central axis, while pneumatic conduits are positioned in separate radial zones. This dimensional organization efficiently utilizes the cylindrical volume while maintaining clear functional separation and reducing structural complexity.
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 system ensures reliable and continuous electrical power delivery to work machines, reducing interruptions and enhancing operational efficiency by maintaining a stable connection and supporting high-voltage transmission.
Implementation Method 1
A first conductor within the rigid outer tube includes a first metal tube surrounding and extending along the axis from proximate the first end to the first metallic endplate... A second conductor includes a second metal tube concentrically surrounding and separated from the first metal tube by an annular space
Data Source
AI summary
A work machine, such as a hauler at a mining site, includes a conductor rod housing concentric metal tubes for receiving electrical power from a contactor sliding on a power rail. A head-end interface of the conductor rod proximate the work machine includes multiple tiers to which terminal connectors are affixed. The tiers are at different heights above the base of the head-end interface, providing a distance or spacing between adjacent terminal connectors, thus reducing the need to increase a diameter of head-end interface to accommodate adjacent terminal connectors.