The present invention relates to the railway industry and, more particularly, to a wireless charging system for a railcar or railway vehicle.
Wireless charging is the process where electrical energy is transmitted from a power source to an electrical load across an air gap using devices such as inductive coils. Wireless charging or wireless power transfer (WPT) offers convenience to operators in railway vehicles. It not only eliminates a manual operation of plugging and unplugging electrical equipment, but it also permits charging where grease, dust, or corrosion could prevent suitable electrical contact. In some cases, wireless charging may enable safer charging in a hazardous environment where an electrical spark could cause an explosion. Wireless charging can be durable and does not wear out the contacts on multiple insertions. However, most of the wireless charging systems or devices developed and available to date are primarily involved with and applicable to the automotive industry.
Conventional approaches to improving the power transfer efficiency require major infrastructure modifications. However, these approaches may be problematic for many in the railway industry for various reasons. Accordingly, there is a need for an improved system for wirelessly charging a railway vehicle that can be installed and used without necessitating modification(s) to the existing infrastructure.
Aspects of this disclosure relate to a wireless charging system for charging a battery of a railway vehicle and a corresponding method of use. The wireless charging system may comprise a fixed coil assembly installed between a set of tracks of a railway and a mobile coil assembly affixed to a bottom side of a railway vehicle. The railway vehicle may comprise a locomotive, a railcar mover, and/or another type of railway vehicle. In various embodiments, the fixed coil assembly may comprise at least one primary coil, and the mobile coil assembly may comprise at least one secondary coil. When the railway vehicle is positioned over the fixed coil assembly, electrical power may be transferred between the fixed coil assembly and the mobile coil assembly to charge the railway vehicle. In various embodiments, electrical power may be transferred via the primary coil and the secondary coil without the primary coil physically contacting the secondary coil.
In various embodiments, the fixed coil assembly may be detachably installed between the set of tracks. For example, the fixed coil assembly may be pressure mounted between the set of tracks of the railway. In some embodiments, the primary coil may be mounted on a base of the fixed coil assembly, and the fixed coil assembly may comprise one or more adjustment portions configured to adjust a position of the base between the set of tracks of the railway. In some implementations, the fixed coil assembly may further comprise mounting members configured to interface with an interior side of each of the set of tracks of the railway. In various embodiments, the secondary coil may be mounted on a base of the mobile coil assembly, and the mobile coil assembly may comprise one or more adjustment portions configured to adjust a position of the base relative to the bottom side of the railway vehicle. In various embodiments, the secondary coil may be suspended from the bottom side of the railway vehicle and oriented parallel to the primary coil. In some implementations, the mobile coil assembly may further comprise a brush configured to remove debris on a surface of the primary coil as a railway vehicle passes over a fixed coil assembly.
In various embodiments, when the railway vehicle is positioned over the fixed coil assembly, the mobile coil assembly may be configured to interface with or move within a proximity of the fixed coil assembly. For example, the fixed coil assembly and the mobile coil assembly may each comprise one or more slide portions. In such embodiments, at least one slide portion of the mobile coil assembly may be configured to engage at least one slide portion of the fixed coil assembly to adjust (or maintain) a distance between the primary coil and the secondary coil. In some embodiments, the primary coil of the fixed coil assembly may be oriented such that it faces upward away from the tracks of the railway. In such embodiments, the secondary coil may be oriented such that it faces downward away from the bottom side of the railway vehicle, and thus may face toward the primary coil. In other embodiments, the primary coil of the fixed coil assembly may be oriented such that it faces downward towards the tracks of the railway. In such embodiments, the secondary coil may be oriented such that it faces upward towards the bottom side of the railway vehicle, and thus may face toward the primary coil.
These and other objects, features, and characteristics of the systems and/or methods disclosed herein, as well as the methods of operation and functions of the related elements of structure and the combination thereof, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. As used in the specification and in the claims, the singular form of “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
The present invention is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which:
These drawings are provided for purposes of illustration only and merely depict typical or example embodiments. These drawings are provided to facilitate the reader's understanding and shall not be considered limiting of the breadth, scope, or applicability of the disclosure. For clarity and case of illustration, these drawings are not necessarily drawn to scale.
In the following description of various examples of the invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example structures, systems, and steps in which aspects of the invention may be practiced. It is to be understood that other specific arrangements of parts, structures, example devices, systems, and steps may be utilized, and structural and functional modifications may be made without departing from the scope of the present invention. Also, while the terms “top,” “bottom,” “front,” “back,” “side,” and the like may be used in this specification to describe various example features and elements of the invention, these terms are used herein as a matter of convenience, e.g., based on the example orientations shown in the figures. Nothing in this specification should be construed as requiring a specific three-dimensional orientation of structures in order to fall within the scope of this invention.
The invention described herein relates to a wireless charging system that facilitates the wirelessly charging of a battery of a railway vehicle without requiring any modification to the existing infrastructure by using a primary coil apparatus (or assembly) installed between the tracks on a railway and a secondary coil apparatus (or assembly) installed on the bottom side of a railway vehicle. For example,
In some embodiments, components of wireless charging system 100 may be welded or securely fixed to rail tracks 60. Alternatively, in some embodiments, components of wireless charging system 100 may be press fit using fastening techniques that does not require welding or holes on rail tracks. For example, components of wireless charging system 100 (e.g., primary coil assembly 200, described further herein) may be pressure mounted between tracks on a set of rail tracks 60. As depicted in
In various embodiments, at least one primary coil 210 may be securely mounted on base 205 configured to be positioned between the rail tracks 60. The position of base 205 may be adjusted using horizontal adjustment portions 230 and/or vertical adjustment portions 240. For example, the horizontal adjustment portions 230 and/or vertical adjustment portions 240 may comprise threaded rods, hex coupling nuts, and/or other types of threaded rods configured to affix mounting member 220 to rail tracks 60.
In various embodiments, mounting member 220 may be configured to securely attach base 205 (and primary coil assembly 200) to the rail tracks 60. In various embodiments, mounting member 220 may be rigidly mounted to a side of rail via selectively detachable fasteners using a compression mechanism. In various embodiments, mounting member 220 may be configured to securely attach primary coil assembly 200 to rail tracks 60 by one or more fastening techniques describes herein or otherwise known or future developed. For example, a compression flange may be utilized on a side of rail 60 to attach mounting member 220 to rail tracks 60. While mounting member 220 is described herein, it should be understood that a combination of features may be used to secure primary coil assembly 200 to rail tracks 60.
In some embodiments, primary coil assembly 200 may further include one or more reinforcing components configured to secure primary coil assembly 200 to rail tracks 60. For example, in some embodiments, one or more reinforcing components may be configured to secure base 205 to rail tracks 60 along lower portions of rail tracks 60 and inside of rail tracks 60. In some embodiments, one or more reinforcing components may be configured to cover lower portions of rail tracks 60 to improve vertical stability of primary coil assembly 200 with respect to rail tracks 60.
In various embodiments, at least one primary coil 210 of primary coil assembly 200 may be mounted on base 205 “horizontally” (i.e., on the x-z plane) such that primary coil 210 may be facing upwardly and generally parallel to at least one secondary coil 310 mounted on a base 305 of secondary coil assembly 300. In various embodiments, vertical adjustment portions 240 and vertical adjustment portions 340 may be positioned to allow primary coil 210 mounted on base 205 and secondary coil 310 mounted on base 305 to be adjusted to or within a relatively parallel position (e.g., to improve conditions for transferring power from the primary coil assembly 200 to secondary coil assembly 300). For example, as depicted in
As depicted in
One aspect of the disclosure is that wireless charging system 100 may be configured to adjust a distance between the at least one primary coil 210 and the at least one secondary coil 310 automatically without any modification to the existing infrastructure. In various embodiments, base 205 of primary coil assembly 200 may include slide portions 215a, 215b. In some embodiments, the slide portions 215a, 215b may be symmetrical in shape. In other embodiments, the slide portions 215a, 215b may be asymmetrical in shape. In various embodiments, base 305 of secondary coil assembly 300 may similarly include slide portions 315a, 315b. In some embodiments, slide portions 315a, 315b may be symmetrical in shape. However, in other embodiments, slide portions 315a, 315b may be asymmetrical in shape.
In various embodiments, slide portions 215a, 215b may be bent to form a v-shaped base 205 that allows base 205 to include a different height at different points along base 205. Similarly, slide portions 315a, 315b may be bent to form a v-shaped base 305 that allows base 305 to include a different height at different points along base 305. By utilizing a combination of the different levels of height created by v-shaped base 205 and v-shaped base 305, wireless charging system 100 may be configured to position primary coil 210 underneath secondary coil 310 so that a distance between primary coil 210 and secondary coil 310 is automatically adjusted only based on mechanical means without any modification to the existing infrastructure.
As depicted in
Another aspect of the disclosure is that wireless charging system 100 may include a brush 380 installed on the secondary coil assembly 300 to ensure optimal charging environment when transferring power from primary coil 210 to secondary coil 310. As the train including brush 380 approaches a charging station/area where the primary coil assembly 200 is detachably (or selectively) installed, brush 380 may remove (or brush away) any debris on a surface of primary coil 210, which may interfere with the transfer of power from primary coil 210 to secondary coil 310 without physically contacting each other.
Areas proximate to railways can be harsh environments in which electrical components (such as primary coil 210) may be exposed to stone, steel, dirt and/or dust. Indeed, such a harsh environment may affect the performance and/or longevity of the primary coil assembly 200. In various embodiments, by positioning brush 380 beneath a bottom side of base 305, wireless charging system 100 may provide a more optimal charging environment when transferring power within the harsh environment in which wireless charging system 100 is utilized. Accordingly, brush 380 may increase the reliability of primary coil assembly 200 by cleaning any debris and reducing exposure to the primary coil 210 mounted (and used) in a potentially harsh environment.
In various embodiments, primary coil 210 and/or secondary coil 310 (shown in
In various embodiments, primary coil 210 may include a single primary coil 210 or a combination of any appropriate number and/or size to facilitate the one or more features or functionality of wireless charging system 100 described herein. Similarly, in various embodiments, secondary coil 310 may include a single secondary coil 310 or a combination of any appropriate number and/or size to facilitate the one or more features or functionality of wireless charging system 100 described herein.
In various embodiments, base 205 may comprise a generally similar surface profile throughout base 205. In some embodiments, base 205 may further include one or more portions with a varying profile. For example, the varying profile may be present proximate to slide portions 215a, 215b and/or slide portions 315a, 315b to reduce friction extending along the x- and/or z-axes when slide portions 215a, 215b and slide portions 315a, 315b may be configured to slidably or wedgingly engage each other and to position at least one primary coil 210 and at least one secondary coil 310 facing generally parallel to each other at a predetermined distance.
In various embodiments, base 305 may comprise air gap heights h2 and h2′. Air gap height h2 may be defined by a distance between inflection point 315c of slide portions 315a and a top surface of at least one secondary coil 310. Air gap height h2′ may be defined by a distance between inflection point 315d of slide portions 315b and a top surface of at least one secondary coil 310. In an embodiment that includes symmetrical slide portions 315a, 315b, air gap heights h2 and h2′ may be similar in length and may be, for example, between 7-13 mm. In a particular example embodiment, air gap heights h2 and h2′ are 10 mm in length.
As the train approaches a charging station/area where the primary coil assembly 200 is detachably (or selectively) installed, if the primary coil assembly 200 and the secondary coil assembly 300 are at a desired (appropriate for wireless charging) height, slide portions 315a of the secondary coil assembly 300 will not collide or come in contact with slide portions 215b of the primary coil assembly 200. In such embodiments, desired air gap between a top surface of at least one primary coil 210 and bottom surface of at least one secondary coil 310 may be, for example, roughly 20 mm in length.
In various embodiments, secondary coil assembly 300 may include a biasing component 360 configured to work together with slide portions 215a, 215b and slide portions 315a, 315b utilizing a combination of the different levels of height created by v-shaped base 205 and v-shaped base 305. For example, if primary coil assembly 200 is not at a desired height (i.e., lower than a portion of secondary coil assembly 300), biasing component 360 may prevent a collision of the secondary coil assembly 300 against primary coil assembly 200. In some embodiments, biasing component 360 may allow secondary coil assembly 300 attached to the train to move upwards in response to contact with slide portions 215a, 215b of primary coil assembly 200, and then allow secondary coil assembly 300 to come back down and maintain an air gap between the secondary coil assembly 300 and the primary coil assembly 200. In various embodiments, biasing component 360 may comprise a spring. For example, biasing component 360 may comprise a wave spring, a compression force spring, or any other suitable type of spring.
In various embodiments, as depicted in
As depicted in
As depicted in
As depicted in
Finally, as depicted in
In an operation 702, process 700 may include installing a fixed coil assembly between a set of tracks of a railway. In various implementations, the fixed coil assembly comprises a primary coil. In various implementations, the fixed coil assembly may be detachably installed between the set of tracks. For example, the fixed coil assembly may be pressure mounted between the set of tracks of the railway. In various implementations, the primary coil may be mounted on a base of the fixed coil assembly, and the fixed coil assembly may comprise one or more adjustment portions configured to adjust a position of the base between the set of tracks of the railway. In some implementations, the fixed coil assembly may further comprise mounting members configured to interface with an interior side of each of the set of tracks of the railway. The fixed coil assembly may include a single primary coil or multiple coils including at least the primary coil.
In an operation 704, process 700 may include affixing a mobile coil assembly to a bottom side of a railway vehicle. In various implementations, the mobile coil assembly comprises a secondary coil. In various implementations, the railway vehicle may comprise a locomotive, a railcar mover, and/or another type of railway vehicle configured to move on tracks of a railway. In various implementations, the secondary coil may be mounted on a base of the mobile coil assembly, and the mobile coil assembly may comprise one or more adjustment portions configured to adjust a position of the base relative to the bottom side of the railway vehicle. In various implementations, the secondary coil may be suspended from the bottom side of the railway vehicle and oriented parallel to the primary coil. In some implementations, the mobile coil assembly may comprise a brush configured to remove debris on a surface of the primary coil as a railway vehicle passes over a fixed coil assembly. The mobile coil assembly may include a single secondary coil or multiple coils including at least the secondary coil.
In an operation 706, process 700 may include positioning the railway vehicle over the fixed coil assembly. When the railway vehicle is positioned over the fixed coil assembly, the mobile coil assembly may be configured to interface with or move within a proximity of the fixed coil assembly. In some implementations, the primary coil of the fixed coil assembly may be oriented such that it faces upward away from the tracks of the railway. In such implementations, the secondary coil may be oriented such that it faces downward away from the bottom side of the railway vehicle, and thus may face toward the primary coil. In other implementations, the primary coil of the fixed coil assembly may be oriented such that it faces downward towards the tracks of the railway. In such implementations, the secondary coil may be oriented such that it faces upward towards the bottom side of the railway vehicle, and thus may face toward the primary coil. In some implementations, the fixed coil assembly and the mobile coil assembly may each comprise one or more slide portions. In such implementations, at least one slide portion of the mobile coil assembly may be configured to engage at least one slide portion of the fixed coil assembly to adjust (or maintain) a distance between the primary coil and the secondary coil.
In an operation 708, process 700 may include transferring electrical power between the fixed coil assembly and the mobile coil assembly to charge the railway vehicle. In various implementations, electrical power may be transferred via the primary coil and the secondary coil without the primary coil physically contacting the secondary coil. In various implementations, the fixed coil assembly may be configured to wireless charge the railway vehicle. In various implementations, wirelessly charging the vehicle via the fixed coil assembly would comprise inductive charging. For example, in various implementations, a current may be passed through the primary coil at the fixed coil assembly to create an electromagnetic field. The electromagnetic field created by the primary coil of the fixed coil assembly may create an alternating electric current in the secondary coil of the mobile coil assembly, which may in turn be used to charge a battery or other power source/supply of the railway vehicle.
It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth herein. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Variations and modifications of the foregoing are within the scope of the present invention. It should be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention.
While the preferred embodiments of the invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made therein without departing from the spirit of the invention, the scope of which is defined by this description.
Reference in this specification to “one embodiment”, “an embodiment”, “some embodiments”, “various embodiments”, “certain embodiments”, “other embodiments”, “one series of embodiments”, or the like means that a particular feature, design, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of, for example, the phrase “in one embodiment” or “in an embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, whether or not there is express reference to an “embodiment” or the like, various features are described, which may be variously combined and included in some embodiments, but also variously omitted in other embodiments. Similarly, various features are described that may be preferences or requirements for some embodiments, but not other embodiments.
The language used herein has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. Other embodiments, uses and advantages of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. The specification should be considered exemplary only, and the scope of the invention is accordingly intended to be limited only by the following claims.
This application claims priority to U.S. Provisional Patent Application No. 63/505,919, filed Jun. 2, 2023, the content of which is hereby incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63505919 | Jun 2023 | US |