FIELD OF THE INVENTION
The present invention relates to a method of mounting a dual pulley high power alternator in space constrained bogies of railway vehicles and like transits and methods thereof.
BACKGROUND OF THE INVENTION
It has been seen that there are not many proposals in the past regarding mounting arrangements for alternators in space constrained railway bogies.
Description of Prior art
The Indian Railways coaching stock employs low speed ICF bogies to form trains. The ICF bogies uses axle coupled rotating generators/alternators to provide electrical power inside the trains for the passengers. The ICF bogies being a low speed design makes use of an alternator arrangement with a suspension hanger and bracket arrangement. The alternator is hung beneath the bogies frame also called the transom, through a brackets and secured with a pin and cotter members. This method of mounting is also known as the transom mount. The alternator pulley and the axle’s drive pulley is coupled via V-belts and belt tensioning long adjust screws are used to push /pull the alternator away from the drive pulley at a desired distance where appropriate belt tensioning is achieved. The Brushless alternators in these bogies had been working for the past 40+ years and with satisfactory reliability, with more than 60’000 units operational in the Indian railways till date. However; in the year 1993-94, the Indian Railways decided to look for a new passenger coach design which would be lighter and capable of higher speeds compared to their existing coaches. In 1995, after a global selection
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process, Alstom-LHB received the order from Indian Railways to design and develop a new passenger coach under a transfer of technology agreement. The RCF Kapurthala began to manufacture LHB bogies and other variant designs, from the year 2001 to 2002, and rolled out its first rake in December 2002. The first such a rake was introduced for Mumbai-New Delhi Rajdhani Express in December, 2003. In the year 2001, the RCF kapurthala undertook initiatives to develop self- generating versions of the LHB coaches. The RDSO thereafter examined the various alternatives for self- generating coaches of LHB design as under;
1) Belt drive system identical to existing self-generating AC coaches.
2) Cardan shaft drive arrangement.
3) Gear drive system-proposal of M/S FIAT.
4) RCF’s development of permanent magnet alternators (mid-axle type).
5) Belt driven permanent magnet alternators.
As the train speeds are increasing day by day the bogies are getting lightweight and compact along with integration of complex stability maintaining mechanisms, leading virtually no space to install alternators as it was done with previous methods. The new high speed LHB bogies also do not offer much space to accommodate for the high power alternators in the range of 25~30KW. Almost all of the above mentioned methods tried by the Indian Railways met with various types of the failures because of the rugged and extremely difficult operating nature of the application.
In the prior arts, the brushless alternators had been mounted underneath bogie frames as transom mount along with tensioning screw type arrangement in order to carry out procedures of belt tensioning. These arrangements require considerable space to mount the alternator and are applicable for certain types of bogies namely ICF bogie of Indian Railways, specially designed to accommodate such type of alternator arrangements.
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There have been proposals for mounting costly permanent magnet alternators employing rare earth magnets due to its smaller size as compared to brushless alternators, however these alternators also require complex electronics and power converters to stabilize output voltage which further increases the pricing to great extent. Also the permanent magnet alternators are dangerous machines with probabilities of catching fire therefore require many safety and fail-safe related features which again increases the machine size. These had been tried by the Indian Railways and these met with failures and have no success till date. More than 15 (fifteen) years had passed and there is no successfully method and product available for electrical power generation for the space constrained LHB bogies till date and the trains are utilizing end on generation also called the power cars with onboard high power diesel generators to power the entire train through electrical connectors. This method occupies two coaches space for the generators, this wastage of space could be made available for the passengers with the utilization of the method suggested by the patent application under consideration. It will ease reservation congestion, reduce the air, noise pollution and earn revenue for the Railways
EP 1 804 363 B1, Axle generator for railway carriages and for un propelled rail-bound vehicles, teaches a method of mounting a permanent magnet alternator on LHB bogie’s axle. This method was also tried in Indian Railways and were discontinued after severe failures.
The problem to be addressed is by mounting existing conventional low cost brushless alternator with driven pulleys at both the ends of its axle, on the upper side of the LHB bogie’s crossbeam with at least one set of the bogies plurality disc brakes removed and / or replaced, exchanged with another kind of efficient and compact brake system known as the tread brakes or use the said different kind of braking system together in permutation and combinations, which do not occupy the bogies axle and the crossbeam
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member; Thereby providing more space on the bogies crossbeam to install the high output alternator along with its dual sided pulleys and axle drive pulleys on the additionally created space without losing the bogies speed and braking potential yet retaining its high speed operation. The space thus made could also accommodate the alternators transom mounting arrangement for high output power similar to the arrangement used in the prior art, but not without the novel suggestion being provided in this application. The bogies H-frame is extended beyond the wheels with cantilever beams firmly welded at the two ends of the LHB bogie H-frame or made as an integral part during its production thus creating an over-hang extending beyond the wheels, this over-hang formed by the two sides of the beams is firmly joined and welded together with a suitable horizontal beam to form a flat base cradle like structure such that the alternator could be mounted as a top foot mounting or bottom transom mount arrangement as per requirements and gain its respective benefits. A plurality load shedding and control electronic equipment interfaced with the plurality power regulator of the coach alternators, suitably communicating via digital or analog means to take actions and adjust, control, isolate the faulty plurality alternator and/ or the coach’s load circuit in the events of failure, thereby providing enhanced passenger comfort. A belt tensioning arrangement for the alternator is disposed by mounting plurality rollers on the plurality belts, placed either on the top surface or on the bottom surface of the hexagonal V-belts. The tensioning arrangement could also be installed on the inside surface of the hexagonal V-belts such that the belts are pressed towards or away from the alternators driven pulley and the wheel’s drive pulley; thereby further facilitating the belt tensioning and alignment in space constrained bogies.
The invention relates more particularly to Fiat type or similar bogies developed and designed by manufacturer ‘Linke Hofmann Busch’ (LHB) and employing a conventional brushless alternator but not by way of limitation, to
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such apparatus and method utilizing other type of alternators and on different manufacturer’s make and type of bogies.
OBJECTS OF THE INVENTION
It is therefore the object of the invention to provide existing high output power single brushless alternator with dual sided pulley of suitable diameter, length and firmly mounted with brackets on the top side and/or the bottom side of the bogies crossbeam as a base or foot mounted method.
It is therefore the object of the invention to provide existing high output single brushless alternator with dual sided pulley of suitable diameter, length and firmly mounted below the bogies crossbeam with existing suspension bracket, hanger pin and cotter arrangement along with existing tensioning device tied and supported firmly on the bogies crossbeam.
It is another object of the invention to provide additional space in the compact bogie on its top surface through the creation of an arc and/or reducing the height of a portion of the beam supporting coach underframe above the alternator and further reinforcing the strength of the said beam with plurality smaller size beams of suitable, alloy, structure and mounted at plurality locations.
It is another object of the invention to provide a single alternator with dual sided pulley arrangement for the space constrained high speed bogie identical to the LHB bogie to cater for vibrations arising during the high speed operations and increase the operating speeds.
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It is yet another object of the invention to provide a belt tensioning device for the single alternator both the driven pulleys by mounting plurality rollers on the plurality hexagonal V-belts, positioned at a mid-distance or at other convenient location in between the said pulleys, placed either on the top surface or on the bottom surface, inner side and/or at the outer side of the hexagonal V-belts, thereby the said rollers pressing and/ or pulling against the said belts and firmly adjusted at a desired fixed position to maintain proper belt tensioning.
It is yet another object of the invention is to remove and /or replace, exchange at-least one side plurality disc brake from the LHB bogie, out of the available four with conventional compact tread brake system or use the said different kind of braking system together in permutation and combinations, thereby providing additional space on the plurality bogies crossbeam and the plurality axle to enable the mounting of the single alternator with dual pulleys without losing the bogies speed and braking potential and yet retaining its high speed operation and also generate high output power in a space constrained bogie.
It is yet another object of the invention to provide an electronic device on coach, plurality load shedding electronic control with wireless or wired communication disposed in between the plurality alternators and their respective power regulator onboard computers to digitally communicate and suitably adjust, control, isolate the faulty plurality alternator and/ or the load
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circuit in the events of failure, thereby providing redundancy and enhanced passenger comfort.
It is yet another object of the invention to dispose plurality cantilever beams firmly supported, welded at the either ends of the LHB bogie H-frame and /or made as an integral part of the said H-frame during its production thus creating an over-hang extending beyond the wheels, the said over-hang thus formed is firmly joined, welded together with a suitable horizontal beam in contiguous manner, thereby forming a cradle like structure to enable the firm base/foot mounting of the single alternator with dual pulleys on the top and / or the bottom surface of the said horizontal beam along with at least one set of plurality disc brakes removed and/or replaced, exchanged with the tread brake system or use the said different kind of braking system together in permutation and combinations yet retaining the bogies braking and speed potential and make available space for the said alternator’s mounting in order to provide means for generating high electrical output power, by driving the said driven pulleys via hexagonal V-belts coupled with the axle’s drive pulley and providing the necessary belt tensioning with a suitable belt tensioning device.
It is yet another object of the invention to dispose independent two/dual alternators firmly foot mounted on the top and / or the bottom surface of the said horizontal beam with their respective pulleys facing each other duly aligned, attached and joined with a common axle and /or with flexible coupling in the center of the said alternators and driving the said pulleys with the aid of drive pulley coupled hexagonal v-belts along with the tensioning device, thereby maintaining redundancy in the system yet generating high output power.
It is yet another object of the invention to dispose said single alternator and /or the dual alternator firmly mounted below the horizontal beam along with
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the existing suspension bracket, hanger pin and cotter arrangement and the existing tensioning device tied and supported firmly on the said horizontal beam, thereby making available space in the space constrained bogie similar to the LHB bogie and facilitating the firm mounting of the said alternators with existing arrangement of mounting.
With the above and other objectives in view, as will hereinafter appear, various embodiments of the present invention are described hereunder.
SUMMARY OF THE INVENTION
According to an embodiment of the invention, a method of mounting a dual pulley high power alternator in space constrained bogies of railway vehicles and like transits and methods thereof, comprises; brushless alternator with driven pulleys at both the ends of its axle, mounted firmly on the upper side of the LHB bogie’s crossbeam with at least one set of the bogies plurality disc brakes removed and / or replaced, exchanged with another kind of efficient and compact brake system known as the tread brakes or use the said different kind of braking system together in permutation and combinations, which do not occupy the bogies axle and the crossbeam member; Thereby providing more space on the bogies crossbeam and its axle and means for installing the existing high output single alternator yet retaining its high speed operation and braking potential. The space thus made available also accommodate the alternators transom mounting like arrangement for high output power. The bogies H-frame is further extended beyond the wheels with cantilever beams firmly welded at the two ends of the LHB bogie H-frame and made as an integral part during its production thus creating an over-hang extending beyond the wheels, at the two ends of the said frame which in turn is firmly joined and welded together with a suitable horizontal beam to form a flat base cradle like structure such that the alternator could be mounted as a top foot mounting or bottom transom mount
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arrangement as per requirements and gain its respective benefits. A plurality load shedding and control electronic equipment interfaced with the plurality power regulator of the coach alternators, suitably communicating via digital or analog means to take actions and adjust, control, isolate the faulty plurality alternator and/ or the coach’s load circuit in the events of failure, thereby providing enhanced passenger comfort. A belt tensioning arrangement for the alternator is disposed by mounting plurality rollers on the plurality belts, placed either on the top surface or on the bottom surface of the hexagonal V-belts. The tensioning arrangement could also be installed on the inside surface of the hexagonal V-belts such that the belts are pressed towards or away from the alternators driven pulley and the wheel’s drive pulley; thereby further facilitating the belt tensioning and alignment in space constrained bogies.
According to another embodiment of the invention an existing high output power single brushless alternator is disposed with dual sided pulley of suitable diameter, length and firmly mounted with brackets on the top side and/or the bottom side of the bogies crossbeam as a base or foot mounted method.
According to another embodiment of the invention the existing high output single brushless alternator with dual sided pulley of suitable diameter, length and firmly mounted below the bogies crossbeam with existing suspension bracket, hanger pin and cotter arrangement along with existing tensioning device tied and supported firmly on the bogies crossbeam.
According to another embodiment of the invention additional space in the compact bogie is provided on the top side of the crossbeam by modifying the coach underframe through the creation of an arc and/or reducing the height
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of a portion of the beam supporting coach underframe above the crossbeam supporting the said alternator and further reinforcing the strength of the said beam with plurality smaller size beams of suitable, alloy, structure and mounted at plurality locations.
According to another embodiment of the invention a single alternator with pulleys at the two ends of its axle is disposed for the space constrained high speed bogie identical to the LHB bogie to cater for vibrations arising during the high speed operations and increase the operating speeds.
According to another embodiment of the invention a belt tensioning device is disposed on the driven pulleys by mounting plurality rollers on the plurality hexagonal V-belts, positioned at a mid-distance or at other convenient location in between the said pulleys, placed either on the top surface or on the bottom surface, inner side and/or at the outer side of the hexagonal V-belts, thereby the said rollers pressing and/ or pulling against the said belts and firmly adjusted at a desired fixed position to maintain proper belt tensioning.
According to yet another embodiment of the invention is to remove and /or replace, exchange at-least one side plurality disc brake from the LHB bogie, out of the available four with conventional compact tread brake system or use the said different kind of braking system together in permutation and combinations, thereby providing additional space on the plurality bogies crossbeam and the plurality axle to enable the mounting of the single alternator with dual pulleys without losing the bogies speed and braking potential and yet retaining its high speed operation and generate high output power in a space constrained bogie along with high speed operation.
According to yet another embodiment of the invention is to provide an electronic device on coach, plurality load shedding electronic control with
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wireless or wired communication disposed in between the plurality alternators and their respective power regulator onboard computers to digitally communicate and suitably adjust, control, isolate the faulty plurality alternator and/ or the load circuit in the events of failure, thereby providing redundancy and enhanced passenger comfort.
According to yet another embodiment of the invention is to dispose plurality cantilever beams firmly supported, welded at the either ends of the LHB bogie H-frame and /or made as an integral part of the said H-frame during its production thus creating an over-hang extending beyond the wheels, the said over-hang thus formed is firmly joined, welded together with a suitable horizontal beam in contiguous manner, thereby forming a cradle like structure to enable the firm base/foot mounting of the single alternator with dual pulleys on the top and / or the bottom surface of the said horizontal beam along with at least one set of plurality disc brakes removed and/or replaced, exchanged with the tread brake system or use the said different kind of braking system together in permutation and combinations to make available space for the said alternator’s mounting in order to provide means for generating high electrical output power without losing the bogies speed and braking potential and yet retaining its high speed operation, by driving the said driven pulleys via hexagonal V-belts coupled with the axle’s drive pulley and providing the necessary belt tensioning with a suitable belt tensioning device.
According to yet another embodiment of the invention is to dispose independent two/dual alternators firmly foot mounted on the top and / or the bottom surface of the said horizontal beam with their respective pulleys facing each other duly aligned, attached and joined with a common axle and /or with flexible coupling in the center of the said alternators and driving the said pulleys with the aid of drive pulley coupled hexagonal v-belts along with
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the tensioning device, thereby maintaining redundancy in the system yet generating high output power.
According to yet another embodiment of the invention is to dispose the said single alternator with dual pulleys and /or two alternators with pullets joined in the center firmly mounted below the horizontal beam along with the existing suspension bracket, hanger pin and cotter arrangement and the existing tensioning device tied and supported firmly on the said horizontal beam, thereby making available space in the space constrained bogie similar to the LHB bogie and facilitating the firm mounting of the said alternators with existing arrangement of mounting.
According to yet another embodiment of the invention and additional space on the top side of the crossbeam is made further by modifying, elevating the coach underframe and forming a hollow square, slot space along with removing a portion of the beam, supporting coach underframe above the bogie crossbeam, alternators, and its tensioning arrangement and further reinforcing the strength of the said beam with plurality smaller size beams of suitable, alloy, structure mounted at plurality locations away from the alternator arrangement, Thereby creating additional space for accommodating high electrical power output alternator.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 shows a prior art’s detailed top view of various components as installed in the existing ICF bogie.
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Figure 2 shows a detailed top view of various components of the invention as installed in the bogie.
Figure 3 show a detailed side view of various components including the belt tensioning arrangement of the invention as installed in the bogie.
Figure 4 shows a detailed three dimensional (3D) view of the various components of the invention with a cantilever over hang support as installed in the LHB bogie.
Figure 5 show a detailed side view of the various components of the existing Railways tread brake system as installed in the bogie.
For a better understanding of the embodiments of the invention and to show how it may be performed, it will now be described in more detail with reference to the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
The present invention can be better understood by reading the following detailed description of some of the embodiments, with reference made to the accompanying drawings. It will be understood that a particular system embodying the invention is shown by way of illustration only and not as a limitation of invention. The principles and features of this invention may be employed in various numerous embodiments without departing from the scope of the invention. References are made to accompanying drawing in which its novel feature and advantages will be apparent.
As can be seen in Figure 1, depicting prior art’s top view of the existing Indian Railways bogie, it shows the various elements of the existing system
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as installed in the existing ICF bogie. The bogies frame is also called the transom 54, the bottom side of the transom 54, facing the railway lines is provided with a suspension bracket in order to firmly hold the single alternator with pulleys 53, at its each ends. The alternator 50, is designed with a built in mating suspension bracket 52, on its shell with two identical holes suitably placed with the suspension hanger pin 51, to be able to slide and make a lock. The alternators 50, mounting takes place by lifting the said alternator along with its suspension bracket 52, facing towards the transom 54, suspension bracket mating and aligning the respective holes in between the said brackets, thereby enabling the suspension hanger pin 51, to slide in between the said holes and attach the alternator 50, with the ICF bogie. This suspension mounting is not rigid or fixed and enables the alternator 50, to move or swing sideways. The driven pulleys 53, are coupled with the bogie’s axle 56, drive pulley 57, through plurality V-belts 58. The said belts in order to transfer the power require proper tensioning of V-belt 58, which in term is provided by the ICF bogie belt tensioning device 55. The said belt tensioning device are in fact long adjustable spring loaded screws, with one end mounted on the shell of the alternator and the other end to the bogie transom. When the said tensioning device screws are turned, the alternator 50, swings away from the axle 56, thereby pulling the V-belts 58, and hence providing the desired belt tensioning.
As can be seen in Figure 2, top view of the bogie, it shows the various elements of the present invention as installed in the LHB bogie 1. The bogies crossbeam 10, is disposed with mounting brackets 13, to enable the secure mounting of the alternator 2. The drive pulleys 5 and 500, are mounted on the bogies axle 4 and coupled via plurality hexagonal V-belts 6, 12, in order to drive the alternator 2, through driven pulleys 8, 9; Thereby generating electrical power for the coach. A plurality identical belt tensioning device 3, 300, comprising of plurality rollers, positioned on the outer surface of the
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plurality hexagonal V-belts 6, 12, and suitably positioned at a mid-distance or at a convenient location between the said plurality driven and the drive pulleys such that the tensioning device 3, 300, could be adjusted at a desired fixed position through a screw or similar arrangement which creates a push force on the said plurality V-belts 6, thereby maintain desired, proper and fixed belt tensioning. Similarly the belt tensioning could also be employed with a pulling force, the said plurality tensioning device 3, 300 could also be installed on the inner surface of the said plurality hexagonal V-belts 6, 12, in order to apply a pulling force on the plurality hexagonal V-belts 6, 12, thereby adjusting the said rollers at fixed position to facilitate the belt tensioning. The power generated by the alternator 2, is supplied to the coach load 166 through wires 14, and a power regulator 15, regulating the variable generated output voltage to a fixed voltage. The plurality power regulator 15, on the coach is suitably interface with a plurality load shedding controller 16, through communication bus 17, thereby maintaining a wired or wireless digital communication in between the power regulators 15, interfaced onboard computers or micro controllers in order to suitably adjust, control, isolate the faulty plurality alternator 2, and/ or the load circuit 166 in the events of failure, thereby providing enhanced passenger comfort. The additional space for generating high output power and mounting of the alternator 2, is made available to the existing bogie with the removal and /or replacement of at least one set of the disc brake system 7, out of the available four disc brake system of the bogie with conventional efficient tread brake system or use the said different kind of braking system together in permutation and combinations, yet maintaining the desired speed and space. The said plurality disc brake system and the tread brake system could be effectively used together with properly engineered parameters in order to get the desired braking and speed. The removal of the plurality disc brake 7, provides additional space for the disposal of the drive pulley 5, 500, on the axle 4, and the crossbeam 10, thereby facilitating high output power alternator 2, in space constrained bogie.
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As can be seen in Figure 3, it shows the various elements of the present invention’s belt tensioning arrangement as seen from the side view of the bogie. The side view of alternator 49, is shown to be mounted on the bogies cross beam 46, along with alternator and the support brackets 47. The bottom side of the bogies cross beam 46, and / or the top side of the said crossbeam or the alternator 49, shell/body is disposed with a plurality tensioning mechanism 433, through tensioning roller support bracket 45, firmly holding the plurality belt tensioning rollers 43, along with a threaded guide and tensioning spring 43. The arrangement is also disposed with a hex bolt type rotatable arrangement 44, at the end to facilitate the forward and backward movement of the plurality belt tensioning rollers 43. The tensioning arrangement could be disposed suitably at any available belt location and other standard arrangement could also be employed to maintain belt tensioning. The existing coach underframe 36, is provided with an existing underframe beam 367, in order to support the load of the coach. The said under frame beam is further modified, through the creation of an arc and/or space in the beam 366, by reducing the height of the portion of the underframe beam 367, supporting the coach load right above the alternator 49, and its related arrangement and further reinforcing the strength of the said beam with plurality smaller size beams of suitable, alloy, structure and mounted at plurality locations.
As can be seen in Figure 4, it shows the various elements of the present invention with a cantilever over hang support. The LHB bogies 91, two ends of the H-frame 106, is securely welded with cantilever beams 94, 95, or even could be made as an integral part of the said H-frame 106, during its production thus creating an over-hang extending beyond the wheels, the said over-hang thus formed is firmly joined, welded together with a suitable horizontal beam 105, in contiguous manner, thereby forming a cradle like
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structure to enable the firm base/foot mounting of the alternators 96, 97, firmly mounted with foot mount 93, on the top and / or the bottom surface of the horizontal beam 105, with their respective driven pulleys 98, facing each other and duly aligned, attached and joined with a common axle and /or with flexible coupling in the center of the said alternators. The said driven pulleys are driven with the aid of drive pulley 102, mounted on the wheel axle 101, and coupled via plurality hexagonal v-belts 99, along with the tensioning device 104, having tensioning rollers 103, disposed in an arrangement where the rollers could be adjusted at fixed position in order to press or pull the said V-belts, thereby maintaining proper belt tensioning in the drive and the dual alternators providing redundancy in the system yet generating high output power without compromising with the speed and the braking potential of the coach and maintaining high speed operation. The horizontal beam 105, has mounts to firmly grip the alternators with dual pulleys on the top and / or the bottom surface of the said horizontal beam along with at least one set of plurality disc brakes 92, removed and/or replaced, exchanged with the tread brake system or use the said different kind of braking system together in permutation and combinations to make available space for the said alternator’s mounting in order to provide means for generating high electrical output power without losing the bogies speed and braking potential and yet retaining its high speed operation, by driving the said driven pulleys via hexagonal V-belts 99, coupled with the axle’s 101, drive pulley 102 and providing the necessary belt tensioning with a suitable belt tensioning device 104. The horizontal beam 105, could be disposed with mounts to firmly hold the alternator 96, 97, with their pulleys 98, mated in the center and /or the existing alternator with two pulleys at its each sides firmly mounted below the horizontal beam 105, along with the earlier stated existing suspension bracket, hanger pin and cotter arrangement and the existing tensioning device tied in fig.1, and supported firmly on the said horizontal beam, thereby making available space in the space constrained bogie similar to the LHB
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bogie and facilitating the firm mounting of the said alternators with the existing arrangement of mounting.
As can be seen in Figure 5, it shows the detailed side view of the various elements of the present invention with the existing Railways tread brake system as installed in the bogie. The tread brake system 110, comprise of a concave shaped brake shoe 108, matched and placed on the circumferential surface of the bogies wheel 107. A suitable lever mechanism 109, actuated with pneumatic or hydraulic system is securely attached to the bogie frame and the actuate-able brake block which is in term firmly tied to the said brake shoe. The pneumatic or hydraulic pressure is applied to the lever mechanism 109, which pushes the brake shoe 108, against the wheel 107, with desired force in-order to provide the desired braking effort.
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I Claim:
1. A method of mounting a dual pulley high power alternator in space constrained bogies of railway vehicles and like transits and methods thereof, comprising:
An existing high output power brushless alternator (2) with common shaft and dual pulleys (8), (9), of suitable diameter, length is disposed with foot mounting brackets and plurality holes for firmly bolting, mounting and fixing the said alternators on the top side and/or the bottom side of the LHB bogie (1) crossbeam (10) with a firmly welded crossbeam mounting brackets (13); Thereby the said duals pulleys reduces vibrations at high speed operation and foot mount supporting the said alternator rigidly and securely in a fixed place; and
An additional space provided on the top side of the crossbeam (366), by modifying the coach underframe (36) through the creation of an arc and/or reducing the height of a portion of the beam (367), supporting coach underframe above the crossbeam (46), supporting the said alternator and further reinforcing the strength of the said beam with plurality smaller size beams of suitable, alloy, structure and mounted at plurality locations.
An at-least one set, out of the available four sets of the plurality disc brake (7), removed and /or replaced, exchanged with a plurality conventional compact tread brake system (110) or use the said different kind of braking system together in permutation and combinations, Thereby providing additional space on the plurality bogies crossbeam (10) and on the plurality axle (4) to enable the mounting of the single alternator (2) with dual driven pulleys (8),(9), along with the drive pulleys(5),(500), without losing the
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bogies speed and braking potential and yet retaining its high speed operation and generate high output power in a space constrained bogie; and
A plurality belt tensioning mechanism (433) and or (55) suitably disposed on the plurality double sided V-belts (37) or the single sided –belts to provide the necessary belt tensioning; and
A wiring circuit on the coach disposed with plurality power regulators (15) interfaced with plurality alternators (2) with plurality load shedding control system (16);
whereby the plurality power regulators onboard microcomputers communicate digitally, analog through wiring or wireless means and suitably adjust, control, isolate the faulty plurality alternator and/ or the load circuit (166) in the events of failure, thereby providing redundancy enhanced passenger comfort and high output power in a space constrained bogie yet maintaining its high speed operation.
2. The device as claimed in any one of the preceding claims, wherein a belt tensioning device (433) is disposed on the driven pulleys (8), (9) by mounting plurality rollers (42) on the plurality hexagonal V-belts (37) positioned at a mid-distance or at other convenient location in between the said pulleys, placed either on the top surface or on the bottom surface, inner side and/or at the outer side of the hexagonal V-belts (37), thereby the said rollers pressing and/ or pulling effort against the said belts could be firmly adjusted at a desired fixed position with a nut (44) to maintain fixed, proper belt tensioning.
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3. The device as claimed in any one of the preceding claims, wherein an electronic device is disposed on the coach, comprising of a plurality load shedding electronic control (16) system having a wireless or wired communication port, link (17) in between the plurality alternators (2) and their respective power regulator (15) onboard computers in order to digitally communicate and suitably adjust, control, isolate the faulty plurality alternator (2) and/ or the plurality coach load circuit (166) in the events of failure, thereby providing redundancy and enhanced passenger comfort.
4. The device as claimed in any one of the preceding claims, wherein a support comprising of plurality cantilever beams (94), (95) is disposed which is firmly supported, welded at the either ends of the LHB bogie (91) H-frame (106) and /or made as an integral part of the said H-frame during its production thus creating an over-hang extending beyond the wheels and the said over-hang thus formed is firmly joined, welded together with a suitable horizontal beam (105) in contiguous manner with the said bogie, thereby forming a cradle like structure to enable the firm base/foot mounting (93) of the alternators.
5. The device as claimed in any one of the preceding claims, wherein the said cradle structure formed by the horizontal beam (105) is disposed with suitable brackets and mounting holes in order to facilitate the firm mounting of said single alternator (2) with dual pulleys (8), (9) on the top and / or the bottom surface of the said horizontal beam along with at least one set of plurality disc brakes (92) removed and/or replaced, exchanged with the tread brake system (110) or use the said different kind of braking system together in permutation and combinations to make available space for the said alternator’s mounting, Thereby providing means for generating high electrical output power without
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losing the bogies speed and braking potential and yet retaining its high speed operation, by driving the said driven pulleys via hexagonal V-belts (6), (12) coupled with the axle’s (4) drive pulley (5), (500) and providing the necessary belt tensioning with a suitable plurality belt tensioning device (433).
6. The device as claimed in any one of the preceding claims, wherein the wherein the said cradle structure formed by the horizontal beam (105) could also be disposed with independent two/dual alternators (96), (97) firmly foot mounted (93) on the top and / or the bottom surface of the said horizontal beam (105) with their respective driven pulleys (98) facing each other, duly aligned, attached and joined with a common axle and /or with flexible coupling in the center of the said alternators and driving the said pulleys with the aid of drive pulley (102) coupled hexagonal v-belts (99) along with the tensioning device (104), (433), thereby maintaining redundancy in the system yet generating high output power.
7. The device as claimed in any one of the preceding claims, wherein a single alternator with two pulleys (2) could also be disposed and firmly mounted below the horizontal beam (105) along with the existing suspension bracket (52) hanger pin (51) and cotter arrangement along with existing tensioning device (55) tied and supported firmly on the said horizontal beam(105) with the availability of the created through the removal and/or replacement, exchange of the said brake systems, thereby making available space in the space constrained bogie and facilitating the firm mounting of the said alternators with existing method of arrangement of mounting yet generating high output electrical power.
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8. The device as claimed in any one of the preceding claims, wherein independent two/dual alternators (96), (97) could be disposed with a single shaft and common pulley (98) and firmly mounted below the horizontal beam (105) along with the existing suspension bracket (52), hanger pin (51) and cotter arrangement and the existing tensioning device (55) tied and supported firmly on the said horizontal beam, with the availability of the space created through the removal and/or replacement, exchange of the said brake systems, thereby making available space in the space constrained bogie and facilitating the firm mounting of the said alternators with existing method of arrangement of mounting yet generating high output electrical power.
9. The device as claimed in any one of the preceding claims, wherein the existing high output single brushless alternator (2) with dual sided pulley (8), (9) of suitable diameter, length is firmly mounted below the bogies (1) crossbeam (10) with existing suspension bracket (52), hanger pin (51) and cotter arrangement along with existing tensioning device (55) tied and supported firmly to the bogies crossbeam (10), through the availability of the space created through the removal and/or replacement, exchange of the said brake systems, thereby making available space in the space constrained bogie and facilitating the firm mounting of the said alternators with existing method of arrangement of mounting yet generating high output electrical power.
10. The device as claimed in any one of the preceding claims, wherein additional space on the top side of the crossbeam (366), could be further made available by modifying, elevating (368) the coach underframe (36) and forming a hollow square space and further removing a portion of the beam (367), supporting coach underframe above the crossbeam (46), alternator (49), and its tensioning
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arrangement (433) and further reinforcing the strength of the said beam with plurality smaller size beams of suitable, alloy, structure and mounted at plurality locations away from the alternator arrangement, Thereby creating additional space for accommodating high output electrical power alternator.
11. The device as claimed in any one of the preceding claims, wherein the technology used for the alternators could be existing conventional brushless alternators, conventional brushless electrically excited synchronous generator (EESG), doubly fed induction generator (DFIG), fail-safe type permanent magnet generators, any other superior, efficient and safe technology and /or the ‘high efficiency’ brushless electrically excited synchronous generators by the company Leroy Somer be used in the single alternator (2) and or dual/two alternator arrangement (96), (97) along with their respective efficient power converters, Thereby increasing the efficiency of the power generation system and further saving the energy.
12. The device as claimed in any one of the preceding claims, wherein A method of mounting a dual pulley high power alternator in space constrained bogies of railway vehicles and like transits and methods thereof, substantially as herein described and illustrated in the figure 1, figure 2, figure 3, figure 4, figure 5, of the accompanied drawings.