Alternator system for rail car electronics

Abstract

A drive system and mounting system for an vehicle mounted alternator is provided wherein such an alternator system may be mounted to the structure directly above the axel/bearing combination by means of a mounting plate and associated spacers that are is adaptable to a wide range of rail freight cars, associated bearing adapters, bearing sizes and types, and side frames. This alternator system employs automatic tensioning devices similar to those in automobiles and is enclosed to provide protection from the elements and vandalism.

Description

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX

Not applicable

BACKGROUND OF THE INVENTION

TMA has been investigating methods of providing power to monitoring systems, both for maintenance and security purposes of individual rail freight cars of a variety of types. Reliable power generation for such systems has been a problem for such systems.

There is no industry commitment to a standard to be implemented via cables from the locomotive. This invention provides an individual freight car with power for such monitoring systems and other ancillary functions by charging a battery by providing an external retrofit kit for many types of freight rail cars and associated bearing types and wheel sizes. It does so while providing a more compact enclosed system that fits at the end of an axel and provides some protection from the elements and casual vandalism.

It should be noted that several patents have addressed similar problems going as far back as 1903 and as recently as 1979. A Timken, internal to the bearing generator, requiring bearing change was put on trial in 2004. None of these has been accepted by the industry.

SUMMARY OF THE INVENTION

A self contained alternator system is mounted in close proximity to one bearing of a rail freight car by attachment to the outside of the bearing adapter, The alternator package provides a low profile allowing use on a wide variety of freight cars and provides power in either direction of train movement. It is belt driven and employs tension pulleys, similar to those in autos to provide constant tension over a limited range of movement between the bearing adapter and bearing. It can provide power to a battery or directly to an electronic system such as a monitoring system.

The Alternator System employs two different mounting sub-systems “floating” independently of each other within a limited range (The Axel and Bearing in relation to the Adapter and Side Frame. An automatic pivot tensioning system mounted to the support plate is employed to absorb this variation. The alternator itself is mounted to the support plate. The cover encloses both mounting systems and is easily removed for belt replacement and installation and maintenance activities.

DRAWING DESCRIPTIONS

FIG. 1—Typical Rail Freight Car Truck—This figure provides the structure to which the self contained alternator system is appended. (for explanation of the patent application)

FIG. 2—Front View—Self Contained Alternator System for Rail Car Electronics This view depicts the relationship of the major elements of the patent application to each other, the takeoff drive wheel, the tension pulley, the alternator and the mounting arrangements to the adapter and bearing cover.

FIG. 3—Left Side View with Cover—Self Contained Alternator System for Rail Car-Provides view of the system with the cover on and attachment method

FIG. 4—Right Side View—Self Contained Alternator System for Rail Car Electronics—This view depicts the relationship of the major elements of the patent application, the depth of the unit and the relation to the bearing and bearing adapter to each other.

DESCRIPTION

FIG. 1 provides basic information as to the freight car structure on which this apparatus will be mounted. This invention is a device that mounts on an Bearing Adapter and the Bearing Cover Plate of a rail car truck system at either end of any axel. (See FIG. 1.) It provides electricity to charge a battery that supplies power to a variety of electronics modules that may be employed on the rail car. The apparatus may be employed over a range of wheel, bearing and related bearing adapter sizes by the utilization of different mounting holes in the support plate 1 and take-off pulley 21 and an adjustable support plate.

FIG. 2 provides a good embodiment of the drive apparatus which is intended to drive an electric alternator or generator. This is carried on a rail freight car truck shown in FIG. 1. The attachment to the rail car truck system is by mounting of the support frame (reference number 1) to the bearing adapter by means of four bolts, 5A,B,C and D into drilled holes in the Bearing Adapter Face shown in FIG. 1. (The hole locations may vary for each bearing adapter size.)

The support plate 1 is primarily supported by an adjustable support foot 2 which is attached to the support plate 1 by means of two machine screws, 3A and B. The support foot employs an elastomeric shock absorbent material between it and the bearing adapter lug 31 beneath it. A slot 32 in the support plate 1 allows for a range a wheel sizes and associated bearings and adapters.

The support plate has a hole 33 cut in it to allow for larger freight car wheel and bearing sizes and for momentary change in relationship of bearing (32 and 33, FIG. 4) to bearing adapter 34 due to large bumps when the bearing retainer mounted to the side frame and under the bearing, is not installed (as shown). This opening is covered by an elastomeric gasket 8 to provide protection from the elements and is held in place by a gasket retainer 9 held in place by six machine screws 10A-F attached to the support frame 1.

A lateral stand off between the apparatus and the side frame (FIG. 1) is provided for these momentary dislocations by two stand off bumpers 11A and B, made of compressible elastomeric material.

The power takeoff is directly from one wheel bearing on the rail car by means of a pulley 21 attached to bearing cover plate 32FIG. 4. An elastomeric belt 19, ribbed or cogged, is used to drive an alternator 12. A tension pulley17, as employed in automobiles, maintains belt tension.

The take off pulley 21 is mounted directly to the bearing cover 32 in the case of smooth bearing covers (s in Brenco bearings) as shown in FIG. 4, or over a spacer (not shown) in case of bearing covers with “ears” (such as with Timken provided bearings.)

The retaining cap screws 23A-C retaining the bearing covers are replaced by those ¼″ longer in the case of smooth bearing covers; longer ones (conforming with MR requirements) for those with “ears” requiring spacers. A cap screw retaining plate 22 for the pulley/bearing cover cap screws 23A-C is reutilized to stop cap screw rotation.

A commercially available tension pulley assembly 18 is mounted to the support frame 2 by a bolt and retainer 27 in at a distance from the support frame2 utilizing an appropriate spacer to insure alignment with the takeoff pulley 21.

The alternator 12 is mounted on shaft 26A retained by a shaft retainer 26 on the back of the support frame 2. An alternator stator mounting plate 21A is mounted to the support plate 2 and provides appropriate spacing for the alternator 2 for proper alignment with the take off pulley 21. Additional spacers or custom alternator stator mounting plates are required for takeoff pulley arrangements other than that shown to bearing size and type (with or without ears).

The electric regulator 15 is a weatherproof enclosure connected to the alternator 12 with a cable 14, and to a battery and or other supported electronic by a cable 16. Other commercial enclosures may be substituted.

The top of the support frame 2 supports the cover 29 and is a provision for providing additional internal support for the alternator and tension pulley if required.

FIG. 3 provides a left view the un-mounted unit with the cover 29 which is attached by 4 screws 24, 25 and 28A and B. Four small drain holes in the bottom of the cover are not shown.

FIG. 4 depicts the apparatus in relationship to the bearing adapter 11 to which the support frame 2 and all components except those related to the takeoff pulley 21 are mounted. FIG. 4 also depicts the takeoff pulley 21 associated components in relation to the bearing cover plate 32. A cross section of a bearing 33, bearing cover plate 32 and a bearing adapter 31 is provided and also shown with the apparatus mounted in dotted outline.

The apparatus may be added to the rail car truck during car manufacture or can be retrofitted to the rail cars in the field or repair shops. It will fit a variety of rail car types, freight car truck manufacturer's models, and rail car wheel sizes by means of a mounting back plate with several sets of mounting holes associated with bolts 5A-D, an adjustable support foot 2 and spacers for mounting of the three pulley assemblies and the by variable position of the automatic tensioned idler pulley.

The attachment to the axel and bearing is carried out with a pulley with a set of mounting holes 23A-C that varies according to the axel diameter.

The Alternator system will work in either direction of rail car travel and can provide power at several voltages depending on rail car needs by alternator substitution.

A cable assembly from the Alternator goes to the battery to be charged. Alternator System status signals may also be send via signal lines to a monitoring system. The associated battery housing and mounting is not included in this invention and may be mounted in several locations, depending on rail car and truck type.

Claims

1. A belt driven self enclosed alternator system mounted to the bearing adapter and bearing end plate—In a rail freight car having a frame structure and truck mounted thereon; an axle extending between and fixed to an associated set of wheels for rotation therewith, said axle with associated bearing serving as a rotateable driver shaft; an electrical alternator with a stator and driven rotor within the alternator housing; and a drive apparatus for said alternator comprising a driver sheave fixed to above said rotor bearing end plate, and belt means operatively connected between said drive sheave (pulley) to a driven sheave (pulley) of the alternator; the improvement in said apparatus comprising a mounting to the bearing adapter of said rail freight car side frame structure providing a common mounting for the said alternator and a belt tension pulley to provide a constant tension on the drive belt and allowing for precise alignment of these two pulleys (drive and driven) by means of mounts and spacers of the two pulleys.

2. On a rail freight car further improvement comprising a support structure to the said alternator support plate that allows for fit on the supporting bearing adapter ear/lug protruding from the face of the bearing adapter and bearing adapter face by means of slot in the alternator support plate and an adjustable support shoe, both mounted with machine screws; and a wide opening in the alternator support plate; and by use of mounts and spacers for pulley alignment. The alternator support plate slots, adjustable support shoe mounting arrangements and spacers and will allow use of the apparatus on most rail freight car types, wheel and bearing sizes, and bearing cover plates.

3. A largely enclosed system providing protection from weather, track dust and debris, and some protection from casual vandalism by means of: the alternator support plate employing an elastomeric gasket to cover a large portion of the opening in the alternator support plate below the bearing which allows the alternator system to float within a limited range within normal fluctuations between the bearing adapter and the bearing itself.

4. An opening in the support frame below the bearing to allow a large (abnormal) dislocation in the relationship of the bearing adapter and the with bearing without destruction of the apparatus when bearing retainers below the bearings are not properly installed.

5. A lower profile design (down lower dimension from said axle/bearing center) may be provided with less margin of safety for the apparatus where Rail Road companies so specify and assume responsibility for proper installation of bearing retainers. (A future improvement)

6. A lower profile design lower height from bearing center line but wider) utilizing a more serpentine belt and an additional idler pulley option (A future improvement)

7. A variety of mounting hole templates for the alternator support plate to allow use of said apparatus with most wheel and bearing sizes and associated bearing adapters, allowing use over a wide range of rail road freight car types.