Alternator system for rail car electronics
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.
Patent Application: Self Contained Alternator System for Rail Car Electronics. Patent Application No. 60/540,824—Customer #000037984
Work on this invention has been wholly funded by Transportation Monitoring Systems, LLP (TMS) an dall rights to it are retained by it.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIXNot applicable
BACKGROUND OF THE INVENTIONTMA 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 INVENTIONA 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
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,
A lateral stand off between the apparatus and the side frame (
The power takeoff is directly from one wheel bearing on the rail car by means of a pulley 21 attached to bearing cover plate 32
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
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.
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.
Type: Application
Filed: Jan 28, 2005
Publication Date: Aug 3, 2006
Inventors: Robert Martina (Shreveport, LA), Michael Asher (Keithville, LA), James Brannon (Keithville, LA), Carl Chance (Keithville, LA)
Application Number: 11/045,456
International Classification: B61F 5/00 (20060101);