Conductor rail

Description

TECHNICAL FIELD OF THE INVENTION

[0001] This invention relates to a conductor rail assembly comprising a construction primarily of aluminum and stainless steel.

BACKGROUND - FIELD OF THE DISCLOSURE

[0002] Conductor rails are used in transit rail transportations systems to transmit electric power to railcars. They can be made of solid steel sections or a combination of aluminum and steel sections to take advantage of aluminum's high electrical conductivity and light weight. The present invention comprises a novel conductor rail construction and method for combining two aluminum sections with a stainless steel section in a conductor rail application.

[0003] Conductor rails (a.k.a power rail or third rail) are used in transit rail transportation systems for transmission of electrical power to rail cars. Original design of conductor rail goes back to Thomas Edison's 1882 patent, U.S. Patent No. 263,132. The evolution of the conductor rail has been dictated by the power requirements of railcars as well as by the needs in improving overall power system safety and efficiency. There are three main types of power rails in common use today across the world. 1) a power rail similar to the one shown in the T. Edison patent made of solid steel; 2) a power rail comprising a steel rail section and two aluminum extruded sections bolted on the web of the steel rail. This design is know as "clad rail" in the industry; and 3) an aluminum rail with stainless steel cap.

[0004] Aluminum has been incorporated in the power rail types 2 and 3 because its conductivity is significantly more than that of steel. Aluminum is the third most conductive metal after silver and copper. It has been proven to be the cost effective option for this application. Adding aluminum to the design increases conductivity which results in decreased power loss during transmission of power over long distances without a substantial increase in cost. Furthermore, aluminum based designs are significantly lighter than their solid steel counterparts. The present invention incorporates two aluminum support sections and a stainless steel cap section. The aluminum support sections are used to give the conductor rail of the present invention its desired shape and conductivity. The stainless steel cap is used as a wear surface. A wear surface is needed to prevent damaging of the conductor rail by collector shoes that extend from rail cars and run on the conductor rail as the train moves.

[0005] DE2219252 discloses a conductor rail assembly comprising a cap which engages first and second support members.

[0006] DE2147956 discloses a conductor rail assembly comprising a cap which engages first and second support members which are bolted together.

BRIEF SUMMARY OF THE INVENTION

[0007] Aspects of the present invention are recited by the appended claims.

[0008] In a first described arrangement, a conductor rail assembly comprises: a cap; a first support member defining a rib; a second support member defining a concavity; wherein portions of each of the first and second support members are friction fit or compression fit within the cap; and wherein the rib of the first support member is disposed with the concavity of the second support member.

[0009] In another described arrangement, a conductor rail assembly has a friction stir weld disposed along a joint between the first and second support members and/or bolts fastening the first and second support members together.

[0010] Another described arrangment, comprises a conductor rail assembly wherein the cap defines a top of the conductor rail assembly and the friction stir weld is disposed on a bottom of the conductor rail assembly.

[0011] Another described arrangment, comprises a conductor rail assembly wherein the first and second support members are aluminum and the cap is stainless steel.

[0012] Another described arrangment, comprises a conductor rail assembly further comprising a copper element disposed between the first and second support members or within or in a conduit defined by one or more of the first and second support members.

[0013] Another described arrangment, comprises a conductor rail assembly further comprising a no-oxide paste disposed between the cap and the support members.

[0014] Another described arrangment, comprises a method for making a conductor rail assembly comprising: rotating first and second elongated support members about respective longitudinal axes so that they can be compression fit within a top cap; depositing a friction stir weld over the joint between the respective bottoms of the first and second elongated support members.

[0015] Another described arrangment, comprises a method for making a conductor rail assembly wherein the first and second support members are aluminum and the cap is stainless steel.

[0016] Another described arrangment, comprises a method for making a conductor rail assembly further comprising: applying a no-oxide paste between the cap and the support members.

[0017] Another described arrangment, comprises a method for making a conductor rail assembly further comprising: disposing a copper element (1) between the first and second support members or (2) in a conduit defined by the first and second support members.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] For the present disclosure to be easily understood and readily practiced, the present disclosure will now be described for purposes of illustration and not limitation in connection with the following figures, wherein:

FIG. 1 is a cross-sectional view of a conductor rail according to a preferred embodiment of the present invention;

FIG. 2A is a partially exploded, cross-sectional view of the conductor rail of FIG. 1;

FIG. 2B is another cross-sectional view of the conductor rail of FIG. 1;

FIG. 3A is a partially exploded, top perspective view of the conductor rail of FIG. 1;

FIG. 3B is a top perspective view of the conductor rail of FIG. 1;

FIG. 4 is another top perspective view of the conductor rail of FIG.1; and

FIG. 5 is a bottom perspective view of the conductor rail of FIG. 1;

FIG. 6A is a partially exploded, cross-sectional view of a conductor rail according to another preferred embodiment of the present invention; and

FIG. 6B is cross-sectional view of the conductor rail of FIG. 6A.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S) OF THE INVENTION

[0019] In the following detailed description, reference is made to the accompanying examples and figures that form a part hereof, and in which is shown, by way of illustation, specific embodiments in which the inventive subject matter may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice them, and it is to be understood that other embodiments may be utilized and that structural or logical changes may be made without departing from the scope of the inventive subject matter. Such embodiments of the inventive subject matter may be referred to, individually and/or collectively, herein by the term "invention" merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept if more than one is in fact desclosed.

[0020] The following description is, therefore, not to be taken in a limited sense, and the scope of the inventive subject matter is defined by the appended claims and their equivalents.

[0021] FIGS. 1-5 illustrate a conductor rail 10 according to preferred embodiment of the present invention comprising a cap 12 and first and second support members 14 and 16, respectively. Preferably, cap 12 is made from stainless steel and more preferably, 430 stainless steel or an equivalent thereof. First and second support members 14 and 16 are preferably made from aluminum and more preferably from 6101-T6 electrical grade aluminum or an equivalent thereof.

[0022] First and second support embers 14 and 16, are assembled with cap 12 as shown in FIGS. 2A, 2B, 3A and 3B, by rotating each of the first and second support members 14 and 16, along a respective longitudinal axis so that the respective top portions 22 and 24 fit into cap 12 for assembly. Next, as shown therein, first support member 14 defines a rib 18 running along it longitudinally which fits into a channel, slot or other elongated concavity 20 preferably defined by second support member 16. Such a friction fitting, key-type construction provided by rib 18 and channel 20 may be provided continuously or intermittently along the length of the conductor rail 10.

[0023] After the first and second support members 14 and 16 are fit into the cap 12 with or without any other components as described herein, they are joined together preferably by welding and/or with other fasteners such as huck bolts, and more preferably, by Friction Stir Welding (FSW), along the bottom surfaces of first and second support members 14 and 16, preferably along the joint therebetween and across the entire length of conductor rail 10 creating longitudinal weld 26.

[0024] FIGS. 6A and 6B illustrate another preferred embodiment of a conductor rail 30 according to the present invention comprising a cap 32 and first and second support members 34 and 36, respectively. Preferably, cap 32 is made from stainless steel and more preferably, 430 stainless steel or an equivalent thereof. First and second support members 34 and 36 are preferably made from aluminum and more preferably from 6101-T6 electrical grade aluminum or an equivalent thereof. Conductor rail 30 further comprises an electrical conductivity enhancing element 46 preferably disposed within concave recesses 42 and 44 defined by first and second support members 34 and 36, respectively. Enhancing element 46 preferably is made from copper and, while shown having a circular cross-section, may take any form or shape as required by the design of the conductor rail 30 and/or the overall conductivity level required for the conductor rail 30. First and second support members 34 and 36, are assembled with cap 32 as shown in FIGS. 6A and 6B by rotating each of the first and second support members 34 and 36, along a respective longitudinal axis so that the respective top portions 38 and 40 fit into cap 32 for assembly. Next, as shown therein, first support member 34 defines a rib 31 running along it longitudinally which fits into a channel, slot or other elongated concavity 33 preferably defined by second support member 36. Such a friction fitting, key-type construction provided by rib 31 and channel 33 may be provided continuously or intermittently along the length of the conductor rail 30. In addition, during assembly as shown in FIGS. 6A and 6B, enhancing element 46 is disposed or held between concave recesses 42 and 44 so that after assembly is complete, enhancing element is preferably completely disposed within the conduit 48 formed by concave recesses 42 and 44. After the first and second support members 34 and 36 are fit into the cap 32 with enhancing element 46 disposed within the conduit 48 as described above, they are joined together preferably by welding and/or with other fasteners such as huck bolts, and more preferably, by Friction Stir Welding (FSW) along the bottom surfaces of first and second support members 34 and 36, preferably along the joint therebetween and across the entire length of conductor rail 30 creating longitudinal weld in the same manner as described above with respect to conductor rail 10.

[0025] The overall conductivity level of the conductor rail assembly 10 is preferably 1.4 microohm/ft, 2.0 microohm/ft or 4 microohm/ft wherein the cross sectional area and shape of the conductor rail assembly 10 overall and of the first and second support members 14 and 16 may be adjusted to provide the desired conductivity level of the conductor rail assembly 10 overall. The electrical conductivity in the conductor rails 10 and/or 30 of the present invention can be set to any reasonable value by changing the cross sectional area of the components thereof. Using only aluminum and stainless steel in the design will require a change in rail geometry if conductivity needs to be different than the standard value (i.e. 1.4 microohm/ft). However, change in conductivity can also be accomplished by using a third element such as copper, such as in electrical conductivity enhancing element 46, in the design while keeping the geometrical envelope stationary as shown in FIGS. 6A and 6B.

[0026] While not shown, a non-oxide or no-oxide paste (such as the no-oxide paste available from Sanchem, Inc) is preferably applied between the stainless steel and aluminum components, as well as between those components and any other dissimilar metal boundaries such as between the copper or other metallic components employed in the conductor rail assemblies 10 and/or 30 to prevent galvanic corrosion between dissimilar materials.

[0027] In the foregoing Detailed Description, various features are grouped together in a single embodiment to streamline the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment.

Claims

1. A conductor rail assembly (10) comprising:

a cap (12);

a first support member (14) defining a rib (18); and

a second support member (16) defining a concavity (20);

wherein portions of each of the first and second support members (14,16) are friction fit or compression fit within the cap (12); and

wherein the rib (18) of the first support member (14) is disposed within the concavity (20) of the second support member (16), further characterised in that:

the first support member (14) and second support member (16) are joined together along bottom surfaces of the first and second support members (14,16).

2. The conductor rail assembly (10) of claim 1, comprising:

a friction stir weld (26) disposed along a joint between the first and second support members (14,16) and/or bolts fastening the first and second support members (14,16) together.

3. The conductor rail assembly (10) of claim 2, wherein the cap (12) defines a top of the conductor rail assembly (10) and the friction stir weld (26) is disposed on the bottom surfaces of the first and second support members (14,16) of the conductor rail assembly (10).

4. The conductor rail assembly (10) of claim 1 and 3, wherein the first and second support members (14,16) are aluminum and the cap (12) is stainless steel.

5. The conductor rail assembly (10) of claim 1, 3 or 4, further comprising a copper element (46) disposed between the first and second support members (14,16) or within or in a conduit (42,44) defined by one or more of the first and second support members (14,16).

6. The conductor rail assembly (10) of claim 4 or 5, further comprising:

a no-oxide paste disposed between the cap (12) and the support members (14,16).

7. The conductor rail assembly (10) of any preceding claim, wherein the rib (18) and concavity (20) are provided continuously or intermittently along a length of the conductor rail assembly (10).

8. The conductor rail assembly (10) of any preceding claim, wherein the first support member (14) and second support member (16) are joined together along bottom surfaces of the first and second support members (14,16) across an entire length of the conductor rail assembly (10).

9. A method for making a conductor rail assembly (10) comprising:

providing a cap (12);

providing a first support member (14) defining a rib (18);

providing a second support member (16) defining a concavity (20); and

rotating the first and second support members (14,16) about respective longitudinal axes so that they can be compression fit within the cap (12) and the rib (18) is disposed within the concavity (20) of the second support member (16), characterised by:

joining respective bottom surfaces of the first and second support members.

10. The method for making a conductor rail assembly (10) of claim 9, wherein the first and second support members (14,16) are aluminum and the cap (12) is stainless steel.

11. The method for making a conductor rail assembly (14,16) of claim 9, further comprising:

applying a no-oxide paste between the cap and the first and second support members (14,16); OR

disposing a copper element (46) between the first and second support members (14,16).

12. The method for making a conductor rail assembly (10) of claim 9 or 10, further comprising:

disposing a copper element (46) in a conduit (42,44) defined by the first and second support members (14,16).

13. The method for making a conductor rail assembly of claim 10 further comprising:

disposing a copper element (46) between the first and second support members (14,16).

14. The method for making a conductor rail assembly (10) of claim 9, wherein joining respective bottom surfaces of the first and second support members (14,16) comprises depositing a friction stir weld (46) over the joint between the respective bottoms of the first and second support members (14,16).

15. The method for making a conductor rail assembly (10) of any of claims 9 to 14, wherein joining respective bottom surfaces of the first and second support members comprises joining the bottom surfaces across an entire length of the conductor rail assembly (10).

16. The method for making a conductor rail assembly (10) of any of claims 9 to 15, wherein the rib (18) and concavity (20) are provided continuously or intermittently along a length of the conductor rail assembly (10).

Ansprüche

1. Stromschienenbaugruppe (10) umfassend:

eine Abdeckung (12);

ein erstes Tragelement (14), das eine Rippe (18) definiert; und

ein zweites Tragelement (16), das eine Konkavität (20) definiert;

worin Abschnitte jedes des ersten und zweiten Tragelements (14, 16) eine Reibungspassung oder Kompressionspassung innerhalb der Abdeckung (12) aufweisen; und

worin die Rippe (18) des ersten Tragelements (14) innerhalb der Konkavität (20) des zweiten Tragelements (16) angeordnet ist, ferner dadurch gekennzeichnet, dass:

das erste Tragelement (14) und das zweite Tragelement (16) entlang von unteren Oberflächen des ersten und zweiten Tragelements (14, 16) zusammengefügt sind.

2. Stromschienenbaugruppe (10) nach Anspruch 1, umfassend:

eine Rührreibschweißung (26), die entlang einer Fuge zwischen dem ersten und zweiten Tragelement (14, 16) angeordnet ist, und/oder Schrauben, die das erste und zweite Tragelement (14, 16) miteinander befestigen.

3. Stromschienenbaugruppe (10) nach Anspruch 2, worin die Abdeckung (12) ein Oberteil der Stromschienenbaugruppe (10) definiert und die Rührreibschweißung (26) auf den unteren Oberflächen des ersten und zweiten Tragelements (14, 16) der Stromschienenbaugruppe (10) angeordnet ist.

4. Stromschienenbaugruppe (10) nach Anspruch 1 und 3, worin das erste und zweite Tragelement (14, 16) aus Aluminium bestehen und die Abdeckung (12) aus Edelstahl besteht.

5. Stromschienenbaugruppe (10) nach Anspruch 1, 3 oder 4, ferner umfassend ein Kupferelement (46), das zwischen dem ersten und zweiten Tragelement (14, 16) oder innerhalb oder in einer Leitung (42, 44), die von einem oder mehreren des ersten und zweiten Tragelements (14, 16) definiert ist, angeordnet ist.

6. Stromschienenbaugruppe (10) nach Anspruch 4 oder 5, ferner umfassend:

eine oxidfreie Paste, die zwischen der Abdeckung (12) und den Tragelementen (14, 16) aufgetragen wird.

7. Stromschienenbaugruppe (10) nach irgendeinem vorhergehenden Anspruch, worin die Rippe (18) und Konkavität (20) durchgehend oder intermittierend entlang einer Länge der Stromschienenbaugruppe (10) bereitgestellt sind.

8. Stromschienenbaugruppe (10) nach irgendeinem vorhergehenden Anspruch, worin das erste Tragelement (14) und das zweite Tragelement (16) entlang von unteren Oberflächen des ersten und zweiten Tragelements (14, 16) über eine gesamte Länge der Stromschienenbaugruppe (10) zusammengefügt sind.

9. Verfahren zur Herstellung einer Stromschienenbaugruppe (10), umfassend:

Bereitstellen einer Abdeckung (12);

Bereitstellen eines ersten Tragelements (14), das eine Rippe (18) definiert;

Bereitstellen eines zweiten Tragelements (16), das eine Konkavität (20) definiert; und

Drehen des ersten und zweiten Tragelements (14, 16) um jeweilige Längsachsen herum, sodass sie eine Kompressionspassung innerhalb der Abdeckung (12) aufweisen können und die Rippe (18) innerhalb der Konkavität (20) des zweiten Tragelements (16) angeordnet ist, gekennzeichnet durch:

Fügen jeweiliger unterer Oberflächen des ersten und zweiten Tragelements.

10. Verfahren zur Herstellung einer Stromschienenbaugruppe (10) nach Anspruch 9, worin das erste und zweite Tragelement (14, 16) aus Aluminium bestehen und die Abdeckung (12) aus Edelstahl besteht.

11. Verfahren zur Herstellung einer Stromschienenbaugruppe (14, 16) nach Anspruch 9, ferner umfassend:

Auftragen einer oxidfreien Paste zwischen der Abdeckung und dem ersten und zweiten Tragelement (14, 16); ODER

Anordnen eines Kupferelements (46) zwischen dem ersten und zweiten Tragelement (14, 16).

12. Verfahren zur Herstellung einer Stromschienenbaugruppe (10) nach Anspruch 9 oder 10, ferner umfassend:

Anordnen eines Kupferelements (46) in einer Leitung (42, 44), die vom ersten und zweiten Tragelement (14, 16) definiert ist.

13. Verfahren zur Herstellung einer Stromschienenbaugruppe nach Anspruch 10, ferner umfassend:

Anordnen eines Kupferelements (46) zwischen dem ersten und zweiten Tragelement (14, 16).

14. Verfahren zur Herstellung einer Stromschienenbaugruppe (10) nach Anspruch 9, worin das Fügen jeweiliger unterer Oberflächen des ersten und zweiten Tragelements (14, 16) das Aufbringen einer Rührreibschweißung (46) über der Fuge zwischen den jeweiligen Unterseiten des ersten und zweiten Tragelements (14, 16) umfasst.

15. Verfahren zur Herstellung einer Stromschienenbaugruppe (10) nach irgendeinem Anspruch 9 bis 14, worin das Fügen jeweiliger unterer Oberflächen des ersten und zweiten Tragelements das Fügen der unteren Oberflächen über eine gesamte Länge der Stromschienenbaugruppe (10) umfasst.

16. Verfahren zur Herstellung einer Stromschienenbaugruppe (10) nach irgendeinem Anspruch 9 bis 15, worin die Rippe (18) und Konkavität (20) durchgehend oder intermittierend entlang einer Länge der Stromschienenbaugruppe (10) bereitgestellt sind.

Revendications

1. Un ensemble rail conducteur (10) comprenant :

un capuchon (12) ;

un premier élément de support (14) définissant une nervure (18) ; et

un second élément de support (16) définissant une concavité (20) ;

dans lequel des parties de chacun des premier et second éléments de support (14,16) sont à ajustement serré ou à ajustement par compression à l'intérieur le capuchon (12) ; et

dans lequel la nervure (18) du premier élément de support (14) est disposée à l'intérieur de la concavité (20) du second élément de support (16), caractérisé en outre en ce que :

les premier élément de support (14) et second élément de support (16) sont joints ensemble le long des surfaces des premier et second éléments de support (14,16).

2. L'ensemble rail conducteur (10) selon la revendication 1, comprenant :

une soudure par friction-malaxage (26) disposée le long d'une jonction entre les premier et second éléments de support (14,16) et/ou des boulons assujettissant les premier et second éléments de support (14,16) ensemble.

3. L'ensemble rail conducteur (10) selon la revendication 2, dans lequel le capuchon (12) définit une partie supérieure de l'ensemble rail conducteur (10) et la soudure par friction-malaxage (26) est disposée sur les surfaces inférieures des premier et second éléments de support (14,16) de l'ensemble rail conducteur (10).

4. L'ensemble rail conducteur (10) selon la revendication 1 et 3, dans lequel les premier et second éléments de support (14,16) sont en aluminium et le capuchon (12) est en acier inoxydable.

5. L'ensemble rail conducteur (10) selon la revendication 1, 3 ou 4, comprenant en outre un élément en cuivre (46) disposée entre les premier et second éléments de support (14,16) ou à l'intérieur ou dans un conduit (42,44) défini par un ou plusieurs des premier et second éléments de support (14,16).

6. L'ensemble rail conducteur (10) selon la revendication 4 ou 5, comprenant en outre :

une pâte sans oxyde disposée entre le capuchon (12) et les éléments de support (14,16).

7. L'ensemble rail conducteur (10) selon l'une quelconque des revendications précédentes, dans lequel la nervure (18) et la concavité (20) sont fournies de manière continue ou intermittente le long d'une longueur de l'ensemble rail conducteur (10).

8. L'ensemble rail conducteur (10) selon l'une quelconque des revendications précédentes, dans lequel les premier élément de support (14) et second élément de support (16) sont joints ensemble le long des surfaces inférieures des premier et second éléments de support (14,16) sur une longueur totale de l'ensemble rail conducteur (10).

9. Un procédé de fabrication d'un ensemble rail conducteur (10) comprenant :

la fourniture d'un capuchon (12) ;

la fourniture d'un premier élément de support (14) définissant une nervure (18) ;

la fourniture d'un second élément de support (16) définissant une concavité (20) ; et

la rotation des premier et second éléments de support (14,16) autour des axes longitudinaux respectifs de sorte qu'ils puissent être en ajustement par compression à l'intérieur le capuchon (12) et la nervure (18) est disposée à l'intérieur de la concavité (20) du second élément de support (16), caractérisé par :

la jonction des surfaces inférieures respectives des premier et second éléments de support.

10. Le procédé de fabrication d'un ensemble rail conducteur (10) selon la revendication 9, dans lequel les premier et second éléments de support (14,16) sont en aluminium et le capuchon (12) est en acier inoxydable.

11. Le procédé de fabrication d'un ensemble rail conducteur (14,16) selon la revendication 9, comprenant en outre :

l'application d'une pâte sans oxyde entre le capuchon et les premier et second éléments de support (14,16) ; OU

la disposition d'un élément en cuivre (46) entre les premier et second éléments de support (14,16).

12. Le procédé de fabrication d'un ensemble rail conducteur (10) selon la revendication 9 ou 10, comprenant en outre :

la disposition d'un élément en cuivre (46) dans un conduit (42,44) défini par les premier et second éléments de support (14,16).

13. Le procédé de fabrication d'un ensemble rail conducteur selon la revendication 10 comprenant en outre :

la disposition d'un élément en cuivre (46) entre les premier et second éléments de support (14,16).

14. Le procédé de fabrication d'un ensemble rail conducteur (10) selon la revendication 9, dans lequel la jonction des surfaces inférieures respectives des premier et second éléments de support (14,16) comprend le dépôt d'une soudure par friction-malaxage (46) sur la jonction entre les parties inférieures respectives des premier et second éléments de support (14,16).

15. Le procédé de fabrication d'un ensemble rail conducteur (10) selon l'une quelconque des revendications 9 à 14, dans lequel la jonction des surfaces inférieures respectives des premier et second éléments de support comprend la jonction des surfaces inférieures sur une longueur totale de l'ensemble rail conducteur (10).

16. Le procédé de fabrication d'un ensemble rail conducteur (10) selon l'une quelconque des revendications 9 à 15, dans lequel la nervure (18) et la concavité (20) sont fournies de manière continue ou intermittente le long d'une longueur de l'ensemble rail conducteur (10).

Drawing