FIELD OF THE INVENTION

The present invention relates to a mounting arrangement for singular 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 equipment had been so designed that these accommodate brushless alternators inside them mounted on its transom through a hinge. 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 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 rod type arrangement in order to install V-belts and carry out procedures of belt tensioning. These arrangements require considerable space to mount the alternator and are applicable for certain types of bogies, specially designed to accommodate such type of alternator arrangements.

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.

US2743680, Mounting for generator on railway car truck, teaches a method to mount the alternator beneath the bogie frame. This method is applicable for certain makes and types of bogies which are big in size and are designed for low speed and have larger frames. However such a method is more or less useless for compact high speed bogies.

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 providing a conventional low cost singular brushless alternators on the upper side of the LHB bogie’s crossbeam and design and positioned in such a manner, that it gets accommodated even on space constrained bogie like the LHB; thereby providing more alternator length along its rotational axis and with reduced diameter, enabling it to be accommodated in less vertical space and coupled with the wheel axle pulley through hexagonal V-belts. At least one set of plurality disc brakes of the Bogie could be further removed and /or either replaced with a conventional plurality compact tread brake system so that the axle and the crossbeam of the bogie makes available this space for alternator mounting and thereby providing high output power. 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 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 a singular alternator with one sided pulley firmly mounted on the bogies crossbeam.

It is another object of the invention to increase the length of the alternator along the axis of rotation and decrease the diameter to enable its accommodation in vertically space constrained bogies.

It is another object of the invention to provide a support to its driven pulley with extended alternator shaft on the said pulley and/or at the rear end of the alternator a shaft support bracket with bearing on the other end of the crossbeam to cater for vibrations arising during the high speed operations.

It is another object of the invention to mount the alternators on the top of the bogie’s crossbeam, with appropriately placed mounting brackets to secure the alternator.

A further object of the invention is to provide a belt tensioning arrangement for the alternator by mounting plurality rollers on the plurality belts, placed either on the top surface or on the bottom surface of the hexagonal V-belts, thereby pressing against the said belts and maintaining proper belt tensioning.

A further object of the invention is to provide the tensioning arrangement in such a manner that it could 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.

A further object of the invention is to remove one side disc brake from the LHB bogie, thereby providing additional power and reduced machine diameter yet providing high output power in space constrained bogie.

A further object of the invention is to provide a coach load shedding control and wireless or wired communication in between the alternators power electronics to control the coach load in the events of machine failure, thereby providing passenger comfort.

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 mounting arrangement for singular high power alternator in space constrained bogies of railway vehicles and like transits and methods thereof, comprises; singular brushless alternators on the upper side of the LHB bogie’s crossbeam and design and positioned in such a manner, that it gets accommodated even on space constrained bogie like the LHB; thereby providing more alternator length along its rotational axis and with reduced diameter, enabling it to be accommodated in less vertical space and coupled with the wheel axle pulley through hexagonal V-belts. If pulley and crossbeam side at least one set of plurality disc brakes of the Bogie could be further removed and /or either replaced with a conventional plurality compact tread brake system so that the axle and the crossbeam of the bogie makes available this space for alternator mounting and thereby providing high output power. 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 a singular alternator with one sided pulley is disposed firmly and foot mounted on the bogies crossbeam.

According to another embodiment of the invention the length of the alternator is increased along the axis of rotation and decreased in its diameter to enable its accommodation in a vertically space constrained bogies.

According to another embodiment of the invention a support is disposed to the driven pulley with extended alternator shaft extending from the said pulley along with a removable shaft support brackets with bearing housing suitably mounted to hold the extended shaft on the one end of the crossbeam to cater for vibrations arising during the high speed operations.

According to another embodiment of the invention the alternator is mounted on the top of the bogie’s crossbeam, with appropriately placed mounting brackets welded to the bogies crossbeam in order to secure the alternator.

According to another embodiment of the invention a belt tensioning arrangement for the alternator is disposed 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 of the hexagonal V-belts, thereby firmly adjusted at a desired fixed position, thereby pressing against the said belts and maintaining proper belt tensioning.

According to yet another embodiment of the invention is to provide the tensioning arrangement in such a manner that it could be installed on the inside surface of the said hexagonal V-belts such that the belts are pulled away from the alternators driven pulley and the wheels drive pulley.

According to yet another embodiment of the invention a coach plurality load shedding electronic control and wireless or wired communication in 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 enhanced passenger comfort.

According to yet another embodiment of the invention is to remove and /or replace one side disc brake from the LHB bogie, out of the available four with a conventional compact tread brake system, thereby increasing the length of the alternator and reducing the machine diameter yet providing high output power in space constrained bogie.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 shows a detailed top view of various components of the invention as installed in the bogie.

Figure 2 show a detailed side view of various components including the belt tensioning arrangement of the invention 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, 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 bracket 13, to enable the secure mounting of alternator 2, along with the said alternators extended shaft 9, and a shaft support bracket 8, to firmly grip the said alternator on the crossbeam 10, in the events of vibrations. A drive pulley 5, mounted on the bogies axle 4 and coupled via hexagonal V-belts 6, to rotate the alternator 2, driven pulley 12; Thereby generating electrical output for the coach. A belt tensioning arrangement for the alternator 2, is disposed by mounting a plurality tensioning mechanism 433, comprising of plurality rollers 3, on the plurality hexagonal V-belts 6, suitably positioned at a mid-distance or at a convenient location between the said pulleys. The said plurality rollers are suitably placed either on the top surface or on the bottom surface, of the hexagonal V-belts 6, thereby firmly adjusted at a desired fixed position, thereby pressing against the said belts and maintaining proper belt tensioning. Similarly the belt tensioning could also be employed with pulling force, the said plurality rollers 3, could also be installed on the inner surface of the said hexagonal V-belts 6, to apply the pulling force on the plurality hexagonal V-belts 6, thereby adjusting the said rollers at fixed position to facilitate the belt tensioning. A support is disposed to the driven pulley 12, with extended alternator shaft 9, extending from the said pulley along with a removable shaft support brackets 8, with bearing suitably mounted to hold the extended shaft 9, on the one end of the crossbeam 10, to cater for vibrations arising during the high speed operations. 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. Additional power and space could be made with the removal of at least one set of the disc brake system 7, out of the available four disc brake system of the bogie. A disc brake system 7, could be replaced with conventional efficient tread brake system to maintain the desired speed and space a mix of both types of said brake system is not likely to have any consequences on the braking when engineered properly. The removal of the disc brake 7, provides additional space for the placement for the drive pulley 5, thereby increasing the length of the alternator 2, and reducing the machine diameter yet providing high output power in space constrained bogie.

As can be seen in Figure 2, 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 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 2, 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.

I Claim:

1. A mounting arrangement for singular high power alternator in space constrained bogies of railway vehicles and like transits and methods thereof, comprising:

An alternator (2) disposed with foot mounting brackets and plurality holes for screw mounting and firmly fixing the said alternators to the bogie (1) crossbeam (10) mounting brackets (13) which is firmly attached and or welded with the bogies cross beam (10); thereby supporting the said alternator for fixed mounting.

An extended shaft (9) extending from the driven pulley (12) and firmly secured with a shaft support bracket (8) comprising of a bearing housing to hold the said extended shaft; wherein the shaft support bracket (8) is provided with a removable firm support and tied securely to the mounting bracket (13) on the crossbeam (10) and secure, stabilize the alternator (2) from generating excessive vibrations during its operation.

A plurality tensioning mechanism (433), comprising of belt tensioning rollers (43) suitably supported on the bogie crossbeam (46) and / or on the said alternator’s body, with support bracket (45) and adjust screw (44) to maintain desired fixed tensioning on the plurality double sided V-belts (37).

the said plurality belt tensioning rollers (43) could be positioned on the either sides of the double sided V-belts (37) and or on the plurality locations on the surface of the said belts; Thereby maintaining adjustable and fixed tensioning by creating a pushing or a pulling forces on the said belts through said rollers to maintain the required tensioning.

A wiring circuit on the coach disposed with plurality power regulators (15) interfaced with plurality alternators (2) in order to provide regulated output power and voltage, a plurality load shedding control system (16) is disposed which is further interfaced with the said plurality power regulators, 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 enhanced passenger comfort.

2. The device as claimed in any one of the preceding claims, wherein a singular alternator (2) with one sided pulley (12) is disposed firmly with foot mounting arrangement on the bogies crossbeam (10).

3. The device as claimed in any one of the preceding claims, wherein the length of the alternator (2) is increased along the axis of rotation and its diameter is decreased to enable its accommodation in a space constrained bogies (1).

4. The device as claimed in any one of the preceding claims, wherein a support is disposed to the driven pulley (12) with extended alternator shaft (9) extending from the said pulley along with a removable shaft support brackets (8) with appropriate roller bearing and housing suitably mounted to hold the said extended shaft on the one end of the crossbeam (10) to cater for vibrations arising during the high speed operations.

5. The device as claimed in any one of the preceding claims, wherein the alternator (2) is mounted on the top of the bogie’s crossbeam (10), with appropriately placed mounting brackets (13) welded to the said crossbeam in order to firmly secure the alternator (2).

6. The device as claimed in any one of the preceding claims, wherein a belt tensioning arrangement (3) for the alternator (2) is disposed with a tensioning mechanism (433), comprising of plurality rollers (43) 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 of the said hexagonal V-belts, thereby firmly adjusted at a desired fixed position, thereby pressing against the said belts and maintaining proper belt tensioning.

7. The device as claimed in any one of the preceding claims, wherein the said belt tensioning arrangement (3) is disposed in such a manner that it could be installed on the inside surface of the said hexagonal V-belts (37), (6) such that the said belts are pulled away from the alternator’s driven pulley (12) and the wheels drive pulley (5) thereby, maintaining adjusted, fixed, desired belt tensioning force.

8. The device as claimed in any one of the preceding claims, wherein
a coach plurality load shedding electronic control (16) and wireless or wired communication method (17) is disposed in between the plurality alternators (2) on the entire coach and their respective power regulator (15) onboard computers to digitally communicate and suitably adjust, control, isolate the faulty plurality alternator (2) and/ or the coach’s plurality load circuit (166) in the events of failure, thereby providing enhanced passenger comfort, maintaining reliability and redundancy.

9. The device as claimed in any one of the preceding claims, wherein at least one set of plurality disc brakes (7) of the plurality Bogie (1) of the coach is removed and /or either replaced with a conventional plurality compact tread brake system or left vacant so that the axle (4) and the crossbeam (10) of the said plurality bogie makes available this space for the alternator (2) mounting; Thereby making available space for increasing the length of the said alternator and reducing the machine diameter, yet providing high output power in space constrained bogie (1).

10. The device as claimed in any one of the preceding claims, wherein A mounting arrangement for singular 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, of the accompanied drawings.