Segmented Collector Shoe Assembly for Conductor Rail
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Solution Overview
Problem
Rigid collector shoes for electrified conductor rails experience heat damage due to high current density at minimal contact points, leading to instability and signal loss during motion, and existing solutions with multiple shoes result in uneven load sharing and increased costs.
Innovation Solution
A segmented collector shoe assembly with movably positioned, independently sprung collector segments aligned in a support block, allowing for multiple contact points and even current distribution, which reduces heat generation and maintains signal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a rigid collector shoe assembly is used to carry electrical current, then the current carrying capacity is sufficient, but the contact points are minimal causing high current density and heat generation
Solution Approach 1:
The collector shoe is divided into multiple independent collector segments (at least three) that are spaced apart along the conductor rail. Each segment independently contacts the rail at different locations, distributing the electrical current across multiple contact points. This segmentation reduces current density at each individual contact point while maintaining sufficient total current carrying capacity.
2Reliability
If multiple collector shoes are installed to provide more contact points, then the current distribution improves, but the assembly length increases and load sharing becomes uneven
Solution Approach 1:
Multiple collector segments are integrated into a single unified assembly that is mounted to one spring-loaded arm. The segments are spaced apart within the same support structure, combining the benefits of multiple contact points while avoiding the problems of separate assemblies. This merging approach ensures even load sharing through the common spring mechanism and maintains a compact overall length.
3Device complexity
If a rigid collector shoe is used for signal transmission, then the structure is simple, but signal loss occurs due to changing contact resistance during motion
Solution Approach 1:
The collector segments are made movable relative to the support block through sliding surfaces, allowing each segment to independently adjust its position and contact pressure. The spring mechanism provides dynamic force distribution that adapts to variations in rail profile and contact conditions during motion. This dynamic adjustment maintains stable electrical contact resistance for reliable signal transmission.
4Stability of the object's composition
If the collector shoe is spring loaded to follow the conductor rail profile, then the contact stability improves, but the contact points remain minimal causing high current density
Solution Approach 1:
The spring-loaded mechanism is distributed across multiple independent collector segments rather than concentrated at a single point. Each segment has its own spring force distribution, and together they provide both stability through the spring mechanism and reduced current density through the segmented contact arrangement across multiple locations on the conductor rail.
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 segmented design effectively distributes current over multiple points, reducing heat and ensuring stable contact, preventing damage and maintaining reliable signal transmission while maintaining a compact and cost-effective assembly.
Implementation Method 1
A spring is associated with each of the collectors to yieldably urge the respective collector outwardly from the support block
Implementation Method 2
the outer end of the collector will be yieldably urged into sliding conductive engagement with the conductor rail
Data Source
AI summary
A collector shoe assembly for use with an electrified conductor rail is disclosed. A support block comprised of first and second housing members secured together which has a plurality of spaced-apart, spring-loaded collector shoe segments movably positioned therein, the outer ends of which are in engagement with the conductor rail.