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:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     Patent Application: Self Contained Alternator System for Rail Car Electronics. Patent Application No. 60/540,824—Customer #000037984  
                                                 U.S. Pat. Documents                                731382   June 1903   McElroy   322/42       732239   June 1903   Turbayne et al   322/43       768392   August 1904   Moskowitz   322/42       1319066   October 1919   Grob   322/42       1389463   August 1921   Turbayne   322/43       2743679   May 1956   Lofton   74/242       3306121   February 1967   Jenkins   74/242       3702570   November 1972   Stikkers   74/242       3924483   December 1975   Walker et al   74/242       4165466   August 1979   Stikkers   290/3; 322/42; 474/117                  
 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     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 APPENDIX  
       [0003]     Not applicable  
       BACKGROUND OF THE INVENTION  
       [0004]     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.  
         [0005]     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.  
         [0006]     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  
       [0007]     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.  
         [0008]     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  
       [0009]      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)  
         [0010]      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.  
         [0011]      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  
         [0012]      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  
       [0013]      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.  
         [0014]      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,  5 A,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.)  
         [0015]     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,  3 A 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.  
         [0016]     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  10 A-F attached to the support frame  1 .  
         [0017]     A lateral stand off between the apparatus and the side frame ( FIG. 1 ) is provided for these momentary dislocations by two stand off bumpers  11 A and B, made of compressible elastomeric material.  
         [0018]     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   FIG. 4 . An elastomeric belt  19 , ribbed or cogged, is used to drive an alternator  12 . A tension pulley 17 , as employed in automobiles, maintains belt tension.  
         [0019]     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.)  
         [0020]     The retaining cap screws  23 A-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  23 A-C is reutilized to stop cap screw rotation.  
         [0021]     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 frame 2  utilizing an appropriate spacer to insure alignment with the takeoff pulley  21 .  
         [0022]     The alternator  12  is mounted on shaft  26 A retained by a shaft retainer  26  on the back of the support frame  2 . An alternator stator mounting plate  21 A 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).  
         [0023]     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.  
         [0024]     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.  
         [0025]      FIG. 3  provides a left view the un-mounted unit with the cover  29  which is attached by  4  screws  24 ,  25  and  28 A and B. Four small drain holes in the bottom of the cover are not shown.  
         [0026]      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.  
         [0027]     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&#39;s models, and rail car wheel sizes by means of a mounting back plate with several sets of mounting holes associated with bolts  5 A-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.  
         [0028]     The attachment to the axel and bearing is carried out with a pulley with a set of mounting holes  23 A-C that varies according to the axel diameter.  
         [0029]     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.  
         [0030]     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.