Rail cars are being contemplated with functionality that requires electrical power to operate. Prior attempts to provide electrical power include the use of solar and battery power. However, solar power is not easily implemented on all types of rail cars, and further is subject to vandalism, such as graffiti. Batteries are expensive and need periodic replacement or recharging. There have been attempts to electrically connect cars within an assembled train. Given the existing fleet of cars within the industry and the random nature of cars in a train, where cars go through classification yards and are re-assembled randomly, there is no practical way to provide a continuous electrical connection within or among the cars of an assembled train. Within rail cars the wheel/axle assemblies wear over time and are frequently replaced. As such the wheel/axle assembly must easily detach from the car. In fact, the wheel/axle assembly is held in place by a bearing adapter within the side frame, with no secure means of attachment. The entire rail car can be lifted off of its axles without any disassembly.
Hot bearing journals on the axle can be a significant cause of derailment and the industry has thousands of hot bearing detection systems installed along the rail right of way. These detectors scan the underside of the bearing on the axle as the car passes over the detector. As such, the underside of the bearing must remain clearly visible to the detector. The axle is held loosely in place by a bearing adaptor which is held in the side frame, loosely as well. Because of the flexible nature of the positioning of the axle within the adaptor and side frame, there will be variations of the position of the axle relative to adjoining parts of the truck assembly.
The present inventor proposes a generator that is rigidly mounted on an axle of a rail car. In particular, the generator can have a rotor assembly coupled to rotate with the axle of the rail car. Such coupling can be accomplished by a shaft, such as a stub shaft, which can be connected back to the axle via an axle end plate, for example. The generator can be configured to move along with the axle relative to stationary portion(s) of the rail car. As used herein the term “stationary portion(s)” is used to connote any portion of the rail car that is non-rotating during operation (movement of the rail car down the track). Thus, the stationary portion(s) are non-rotatable portions (i.e. portions of the wheel bearing, wheel bearing adaptor, side frame, etc.). Additionally, the generator is not rigidly connected or otherwise affixed to the stationary portion(s) but is rather provided with a flexible connection that is only used to restrain any rotation of the generator that could result from rotation of the axle. However, this flexible connection can allow for variation in the position of the generator relative to the stationary portion(s) of the rail car. Thus, as used herein the term “flexible connection” or “flexible linkage assembly” connotes a connection or assembly that allows for some degree of variation in the position of the generator relative to the stationary portion(s) of the rail car. Therefore, the generator can be supported entirely by the axle via the stub shaft.
The generator can include a stator assembly having one or more components such as a set of coils (positioned to interface with a set of magnets carried by the rotor assembly) and an electrical conductor. One or more bearings can maintain a precise dimensional relationship between the set of coils and the set of magnets. A linkage assembly can extend from the stationary portion(s) of the rail car to closely interface with the stator assembly. The linkage assembly can be used to maintain a position of the stator assembly (e.g., prevent the stator from rotating with the rotor assembly). However, as discussed above and according to one embodiment, the generator can be supported entirely by the shaft, which is coupled to the axle rather than the stationary portion(s) of the rail car.
The present inventor recognizes that a generator(s) mounted to rail cars can provide electrical power to car supported electronics. Such electronics can include a microprocessor based controller to be used for sensing the condition of the car, identification of the car, and other functions requiring power to operate. In one embodiment, electrical pulses from the generator(s) can be counted by the electronics to help identify a broken axle or other conditions. Still further, the electronics may be used to release air from airbrakes to engage the brakes on each car upon electrical or wireless command from an operator.
In the following description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments which may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural, logical and electrical changes may be made without departing from the scope of the present invention. The following description of example embodiments is, therefore, not to be taken in a limited sense, and the scope of the present invention is defined by the appended claims.
As shown in
The shaft 114 can be a stub shaft that connects to or can be an integral part of the axle end cap 110. The axle end cap 110 can be removeably connected to the axle 102 via one or more fasteners 111 (only two are shown in
The stator assembly 118 can be disposed outward of the shaft 114 and a set of magnets (illustrated but numbered and shown in further detail subsequently) carried by the rotor assembly 116. The stator assembly 118 can be disposed to interface with and surround the rotor assembly 116. The stator assembly 118 can be coupled to the rotor assembly 116 via the one or more bearing assemblies 120. More particularly, the stator assembly 118 can be mounted on one or more bearing assemblies 120. The one or more bearing assemblies 120 can be mounted on the rotor assembly 116 and/or shaft 114. The linkage assembly 122 can interface with the stator assembly 118. Such interface may not comprise a rigid connection but rather can have a small gap to allow for some small degree of relative movement between the stator assembly 118 and the linkage assembly 122. The linkage assembly 122 can connect to the bearing adaptor 108 or other stationary portion(s) of the rail car and can be configured as subsequently shown to prevent rotation of the stator assembly 118. In particular, the linkage assembly 122 can be configured to connect to a lift ear 124 of the bearing adaptor 108.
In operation, the rotor assembly 116 rotates with the axle 102 via the shaft 114. This can turn a set of magnets (illustrated but numbered and shown in further detail subsequently) that are mounted to the rotor assembly 116. The stator assembly 118 can include the set of coils supported by portions of the stator assembly 118. This set of coils can be located proximate the set of magnets with a gap therebetween. This gap can be maintained by the one or more bearing assemblies 120. Rotation of the rotor assembly 116 with respect to the stator assembly 118 causes electrical current to be generated via the interaction of the coils, which may have ferrite cores, with the magnet fields generated by the magnets. The magnets can comprise permanent magnets. An electrical conductor (illustrated but numbered and shown in further detail subsequently) can be coupled to the set of coils, which are also electrically coupled to each other to provide the generated electricity to the rail car. The conductor may include a harness with plug connector or quarter turn connector to allow ease of coupling to distribute power to a rail car.
Referring now to
Referring to
The strut 132 can extend from the yolk 130 inward above the axle end cap 110. The strut 132 can be configured to couple to the bearing adaptor 108 via the lift ear 124 as previously show in
In abbreviated recap, the linkage assembly 122 can include the strut 132, which can be received by and interface with the yoke 130. In turn, the yoke 130 can be a portion of the stator assembly 118. The liner 133 can be disposed within the yoke 130 between the yoke 130 and the strut 132. The strut 132 can be configured to couple with the lift ear 124 (
The rail car 200 may be supported on a side frame 201 by gravity, without the use of special fasteners. Such support makes it easy to replace the side frame 201 and allows for some degree of shifting of the bearing 106 (
The electrical conductors 202 can provide electrical power to car supported electronics 204, which may include a microprocessor based controller to be used for sensing the condition of the car, identification of the car, and other functions requiring power to operate. In one embodiment, electrical pulses from the generators 112 can be counted by the electronics 204 to help identify a broken axle or other conditions. Still further, the electronics 204 may be used to release air from airbrakes to engage the brakes on each car upon electrical or wireless command from an operator.
In various embodiments, each generator 112 can be capable of operating as a single device, or with combinations of more than one, within a rail car truck or within multiple trucks within the rail car 200. Further still, when the rail car 200 is not moving the generator 112 will not be providing pulses/electrical energy to the electronics and will allow the electronics go into a sleep mode, and other electrical devices to be de-activated, such that a reduced level of energy will be drawn from the battery. When the rail car 200 begins to move the pulses/electrical energy from the generator 112 will provide energy to the electronics and will cause the electronics to awake and go into normal operational state and other electrical devices will be operational.
In one embodiment, a microprocessor in the electronics 204 receives a pulse count representative of pulses from one or more generators for the rail car 200. If no pulses are received after a predetermined amount of time, such as one minute or more for example, the microprocessor may enter a sleep mode or other reduced power consumption mode. Such a mode may include the processor performing a reduced set of functions, such as simply monitoring for pulses from one or more generators. Other functions that occur in a normal mode of operation that may or may not be performed in the sleep mode include but are not limited to RF transceiver functions, temperature sensing, acceleration sensing, and others. When an event, such as a pulse or multiple pulses are detected, which normally correspond to the associated car moving again are detected, the microprocessor may wake up and operate in a normal power consumption mode.
In a further embodiment, the microprocessor may receive indications of pulses from one or more generators, count the pulses, and compare the number of pulses per unit of time to each other or to a known speed of the car/train. Such pulses counts can be used to determine the speed of each corresponding wheel and can indicate faults, such as an axle not rotating at the same speed as the car is going. A sudden change in speed can also be detected, such as going rapidly from a normal speed, such as 60 miles per hour to zero. Such a change can be indicative of a frozen brake or a generator fault, and can be communicated to a locomotive via the RF transceiver.
The side frame 201 is configured to receive the axle and wheels as previously illustrated in
In the embodiment of
As shown in
The one or more bearing assemblies 120 can comprise ball bearings according to the illustrated embodiment. Thus, the one or more bearing assemblies 120 each include balls 410, an inner race 412 and an outer race 414. However, other types of bearings are contemplated in other embodiments such as tapered roller bearings, radial tapered roller bearings, and dual race roller bearings. Off the shelf, non-integrated bearing assemblies may also be used.
The first portion 416 of the stator assembly 118 is configured to interface with and be spaced from the rotor assembly 116. In particular, the first portion 416 of the stator assembly 118 supports the set of coils 418 in a spaced relationship from the set of magnets 402. The set of coils 418 can be positioned adjacent the set of magnets 402 but spaced therefrom by a desired gap. This allows for rotation of the set of magnets 402 with the rotor assembly 116. Electricity can be generated when the set of magnets 402 rotates relative to the set of coils 418. The radial distance, as measured from the set of coils 418 to the set of magnets 402, can be minimized to optimize interaction of the coils with the magnetic fields and hence generation of electricity due to relative motion between the magnets and coils.
The set of magnets 402 can comprise permanent magnets. Rotation of the rotor assembly 116 with respect to the stator assembly 118 causes electrical current to be generated via the interaction of the set of coils 418, which may have ferrite cores, with the magnet fields generated by the set of magnets 402. An electrical conductor 202 (previously illustrated in reference to
In the embodiment of
The housing 126 can include an interior cavity 424 (shown in
The linkages 702, 704 can extend both radially and/or axially to make a suitable engagement to desired portions of the rail car 200 that do not rotate with the axle. The linkages 702, 704 can be configured to prevent rotation of the stator assembly 118, while other portions of the assembly (including rotor portions of the generator 112) rotate with the axle.
A linkage (e.g., linkage assembly 122 and/or linkages 702, 704) that allows for some degree of movement of the stator assembly 118 relative to the rail car 200 can thereby be provided. This allows some degree of variation of position between the generator 112 and the non-rotating components of the rail car 200. The linkage allows for variation in position of the axle. The mounting of the generator 112 with some degree of freedom of movement via linkage can reduce stress on the wheel bearings 106 (
According to one example embodiment a method is disclosed. The method includes rotating an axle having a generator coupled to the axle via a stub shaft, rotating the stub shaft to rotate a set of magnets of the generator, preventing a stator assembly of the generator from rotating, and supporting a set of coils with the stator assembly proximate the set of magnets, the set of coils positioned to generate electricity as the set of magnets rotate proximate to the set of coils.
According to another example embodiment, a controller is disclosed. The controller includes an input coupled to a generator mounted to an axle for a rail car. The input provides pulses of electricity generated by the generator as the axle turns, electronic circuitry to execute a pulse counting module coupled to the input and performing a method including counting pulses per unit of time, placing the electronic circuitry in a sleep mode if no pulses or electrical energy in any form is received for a predetermined time, and waking up the electronics when one or more pulses are received while in sleep mode.
According to yet another example embodiment, a controller is disclosed. The controller includes an input coupled to a generator mounted to an axle for a rail car wheel. The input provides electrical energy generated by the generator as the axle turns and electronic circuitry coupled to the input to perform a method. The method includes detecting electrical energy provided on the input, placing the electronic circuitry in a sleep mode if no electrical energy is received for a predetermined time, and waking up the electronics when electrical energy is detected on the input while in sleep mode.
As shown in
In the embodiment of
As best shown in
The yoke linkage 1032 can be swung out and away from the lift ear 124 to facilitate disassembly of the assembly 1000 if desired. The yoke linkage 1032 can be independent of and not rigidly affixed to any stationary portion of the rail car. Thus, the yoke linkage 1032 allows for variations in relative positions of the axle 102, wheel bearing 106, and generator 112, and may only serve to interfere with and stop any rotation of the generator 112. The yoke linkage 1032 reduces components and simplifies the mechanics of obstructing the rotation of the generator 112 relative to prior linkage assemblies previously described.
In abbreviated recap, the linkage assembly 1022 can include the yoke linkage 1032, which can be directly coupled to the stator assembly 118 at a first end portion with the fastener(s) 1002. In turn, the yoke linkage 1032 can couple in a non-rigid manner with the lift ear 124 at the coupling portion 1033 (
As discussed above, the generator 112 of
Example 1 is a generator for a rail car. The generator can comprise: a shaft rigidly coupled to a rotatable axle of the rail car for rotation therewith; a set of magnets coupled to the shaft for rotation therewith; and a stator assembly mounted on one or more bearing assemblies and disposed outward of the shaft and the set of magnets, wherein the stator assembly is independent of a stationary portion of the rail car so as to be moveable relative thereto with movement of the axle. The stator assembly can include: a set of coils supported by the stator assembly and positioned proximate to the set of magnets to generate electricity when the set of magnets rotates; and an electrical conductor coupled to the set of coils to provide the generated electricity to the rail car.
In Example 2, the subject matter of Example 1 optionally includes wherein the stator assembly interfaces with a flexible linkage assembly connected to the stationary portion of the rail car, the linkage assembly is configured to restrain the stator assembly to prevent rotation of the stator assembly but can change position relative to the stator assembly with movement of the stationary portion of the rail car.
In Example 3, the subject matter of Example 2 optionally includes wherein the linkage assembly is connected to one or more of a lifting ear of a bearing adaptor or a side frame of the rail car.
In Example 4, the subject matter of Example 3 optionally includes wherein the linkage assembly includes a strut that is received by a yoke of the stator assembly, and wherein the strut and yoke interface with but are not rigidly connected to one another so as to allow for movement of the stator assembly relative to the rail car.
In Example 5, the subject matter of Example 4 optionally includes wherein the strut extends from the yoke to affix to the lifting ear of the bearing adaptor.
In Example 6, the subject matter of any one or more of Examples 1-5 optionally include a rotor assembly configured to connect to the shaft and support the set of magnets in a spaced relationship from the shaft; and the one or more bearing assemblies disposed between the rotor assembly and the stator assembly and configured to maintain a desired gap between the set of magnets and the set of coils.
In Example 7, the subject matter of any one or more of Examples 5-6 optionally include wherein the stator assembly includes a split housing configured to capture a portion of the stator assembly and the one or more bearing assemblies.
In Example 8, the subject matter of any one or more of Examples 1-7 optionally include an axle end cap having a plurality of spaced apart tapered holes; and a plurality of fasteners each having a tapered shaft configured for insertion into one of the through holes.
In Example 9, the subject matter of any one or more of Examples 1-8 optionally include wherein the shaft comprises at least one of: a part of a rotor assembly and is configured to connect to an axle end cap of the rail car; a stub shaft connected to the axle end cap; or a part of an intermediate component that is coupled to the axle end cap.
In Example 10, the subject matter of any one or more of Examples 1-9 optionally include inches.
Example 11 is a generator mountable to a rail car via an axle end cap. The generator can comprise: a shaft rigidly coupled to a rotatable axle of the rail car via the axle end cap for rotation therewith; a rotor assembly configured to connect to the shaft and support a set of permanent magnets in a spaced relationship from the shaft; and a stator assembly coupled to the rotor assembly via one or more bearing assemblies, wherein the stator assembly is independent of a stationary portion of the rail car so as to be moveable relative thereto with movement of the axle. The stator assembly can include: a set of coils supported by the outer race assembly and positioned proximate to the set of magnets to generate electricity when the inner race rotates; and an electrical conductor coupled to the set of coils to provide the generated electricity to the rail car.
In Example 12, the subject matter of Example 11 optionally includes wherein the stator assembly interfaces with a flexible linkage assembly connected to the stationary portion of the rail car, the linkage assembly is configured to restrain the stator assembly to prevent rotation of the stator assembly but can change position relative to the stator assembly with movement of the stationary portion of the rail car.
In Example 13, the subject matter of Example 12 optionally includes wherein the linkage assembly is connected to one or more of a lifting ear of a bearing adaptor or a side frame of the rail car.
In Example 14, the subject matter of Example 13 optionally includes wherein the linkage assembly includes a strut that is received by a yoke of the stator assembly, and wherein the strut and yoke interface with but are not rigidly connected to one another so as to allow for movement of the stator assembly relative to the rail car.
In Example 15, the subject matter of Example 14 optionally includes wherein the strut extends from the yoke to affix to the lifting ear of the bearing adaptor.
In Example 16, the subject matter of any one or more of Examples 11-15 optionally include wherein the shaft comprises at least one of: a part of the rotor assembly and is configured to connect to the axle end cap of the rail car; a stub shaft connected to the axle end cap; or a part of an intermediate component that is coupled to the axle end cap.
Example 17 is a generator mountable to a rail car. The generator can comprise: a shaft rigidly coupled to a rotatable axle of the rail car for rotation therewith; a rotor assembly configured to connect to the shaft and support a set of permanent magnets in a spaced relationship from the shaft; and a stator assembly coupled to the rotor assembly via one or more bearing assemblies, wherein the stator assembly is independent of a stationary portion of the rail car so as to be moveable relative thereto with movement of the axle; and a linkage assembly. The stator assembly can include: a set of coils supported by the outer race assembly and positioned proximate to the set of magnets to generate electricity when the inner race rotates; and an electrical conductor coupled to the set of coils to provide the generated electricity to the rail car. The linkage assembly can interface with the stator assembly, wherein the linkage assembly is connected to the stationary portion of the rail car, the linkage assembly is configured to restrain the stator assembly to prevent rotation of the stator assembly but can change position relative to the stator assembly with movement of the stationary portion of the rail car.
In Example 18, the subject matter of Example 17 optionally includes wherein the linkage assembly is connected to one or more of a lifting ear of a bearing adaptor or a side frame of the rail car.
In Example 19, the subject matter of Example 18 optionally includes wherein the linkage assembly includes a strut that is received by a yoke of the stator assembly, and wherein the strut and yoke interface with but are not rigidly connected to one another so as to allow for movement of the stator assembly relative to the rail car.
In Example 20, the subject matter of Example 19 optionally includes wherein the strut extends from the yoke to affix to the lifting ear of the bearing adaptor.
In Example 21, the subject matter of any one or more of Examples 17-20 optionally include wherein the shaft comprises at least one of: a part of the rotor assembly and is configured to connect to an axle end cap of the rail car; a stub shaft connected to the axle end cap; or a part of an intermediate component that is coupled to the axle end cap.
In Example 22, the subject matter of Example 21 optionally includes wherein the stub shaft comprises one of an integral part of the axle end cap or a separate component that is connected to the axle end cap.
In Example 23, the subject matter of any one or more of Examples 17-22 optionally include inches.
In Example 24, the subject matter of any one or more of Examples 1-23, wherein the linkage assembly includes a yoke linkage that that rigidly couples to the stator assembly and couples with the lifting ear of the bearing adaptor non-rigidly such that the yoke linkage is configured to allow for movement of the stator assembly relative to the rail car.
Example 25 is a method that can comprise: rotating an axle having a generator coupled to the axle via a stub shaft; rotating the stub shaft to rotate a set of magnets of the generator; preventing a stator assembly of the generator from rotating; and supporting a set of coils with the stator assembly proximate the set of magnets, the set of coils positioned to generate electricity as the set of magnets rotate proximate to the set of coils.
Example 26 is a controller that can comprise: an input coupled to a generator mounted to an axle for a rail car, the input providing pulses of electricity generated by the generator as the axle turns; electronic circuitry to execute a pulse counting module coupled to the input and performing a method comprising: counting pulses per unit of time; placing the electronic circuitry in a sleep mode if no pulses are received for a predetermined time; and waking up the electronics when one or more pulses are received while in sleep mode.
In Example 27, the subject matter of Example 26 optionally includes wherein the electronic circuitry is coupled to multiple inputs from multiple generators on the rail car and detects faults based on counted pulse rates from the multiple generators.
In Example 28, the subject matter of any one or more of Examples 26-27 optionally include wherein the pulse counts are converted to a speed and compared to a known speed of the rail car.
Although a few embodiments have been described in detail above, other modifications are possible. For example, the logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. Other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Other embodiments may be within the scope of the following claims.
The following statements are potential claims that may be converted to claims in a future application. No modification of the following statements should be allowed to affect the interpretation of claims which may be drafted when this provisional application is converted into a regular utility application.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/546,942 filed on Aug. 17, 2017, the benefit of priority of which is claimed hereby, and which is incorporated by reference herein in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/US18/46969 | 8/17/2018 | WO | 00 |
Number | Date | Country | |
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62546942 | Aug 2017 | US |