Telescoping Arm Assembly for Reliable Mobile Power Coupling

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Solution Overview

Problem

Existing power systems for industrial machines, such as overhead lines, are not practical for remote and uneven environments, and there is a challenge in reliably coupling freely-steerable industrial machines to a power source.

Innovation Solution

An electricity-conducting connector assembly that includes a boom assembly, an arm assembly with multiple longitudinally extendable or telescoping arms, and a contactor assembly, which allows a free-steering mobile machine to connect to a stationary electricity source while moving, with the arm assembly's conductivity dependent on its telescoping position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If overhead electricity-conducting lines are used to power industrial machines, then power supply is reliable, but the system is not practical for remote and uneven environments and freely-steerable machines

Engineering Contradiction:

Improvepower supply reliabilityVSAvoidadaptability to remote and uneven environments

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent employs a dynamic arm assembly with multiple degrees of freedom that can extend, retract, and articulate to maintain electrical contact with overhead lines while the machine moves freely. The arm assembly includes telescoping sections and articulation joints that allow it to adapt to varying positions and terrain, enabling reliable power transfer without constraining machine mobility or requiring fixed routing.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The arm assembly acts as an intermediary mechanical element between the mobile machine and the overhead electricity-conducting lines. It serves as a flexible conduit that bridges the gap between the stationary power source and the moving machine, accommodating terrain variations and machine movement while maintaining continuous electrical connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a rigid electricity-conducting arm is used to connect mobile machine to power source, then electrical connection is stable, but the system cannot accommodate freely-steering movement and terrain variations

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidfreely-steering capability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The arm assembly is divided into multiple segmented sections that can extend and retract independently. These telescoping segments allow the arm to lengthen or shorten as needed, accommodating the machine's movement and positioning requirements while maintaining stable electrical connection through each segment's internal conductors.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The arm assembly incorporates multiple articulation joints and degrees of freedom that allow it to dynamically adjust its configuration. The arm can bend, extend, and reposition itself to follow the machine's movements and maintain contact with overhead lines, enabling both stable electrical connection and free-steering operation.

Inventive Principle:

Principle #15Dynamics

3Use of energy by moving object

If the arm assembly is extended to reach overhead lines, then electricity transfer is enabled, but the risk of electrical discharge increases during extension and retraction

Engineering Contradiction:

Improveelectricity transfer capabilityVSAvoidelectrical discharge risk

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The system establishes preliminary electrical contact through brush contacts or sliding contacts with the overhead lines before the arm assembly fully extends. This ensures that the electrical circuit is already closed and current is flowing through the arm's internal conductors before the outer shell completes its extension, preventing arcing or electrical discharge during the extension process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces traditional mechanical switch contacts with a continuous electrical connection system where current flows through the arm assembly's internal conductors throughout the extension and retraction process. This eliminates the need for mechanical make-and-break contacts that could cause sparks or electrical discharge, providing continuous electrical connection without interruption or arcing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250178444A1Arm assembly for energy transfer system

Publication Date: 2025.06.05 CATERPILLAR INC

AI summary

An electricity-conducting connector assembly for connecting a free-steering mobile machine to a stationary electricity source while moving includes an electricity-conducting boom assembly including a proximal end and a distal end, the proximal end of the boom assembly movably connected to a body of the mobile machine; an electricity-conducting arm assembly including a proximal end and a distal end, the proximal end of the arm assembly connected to the distal end of the boom assembly; and an electricity-conducting contactor assembly connected to the distal end of the arm assembly. The arm assembly includes at least three longitudinally extendable arms arranged parallel to one another.